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Lilac LS-18 Motorcycle Maintenance Standards

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Filed Under (Lilac) by admin on 25-11-2010

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

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ATK 50MX INSTALLATION AND ADJUSTMENT TIPS

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Filed Under (Atk) by admin on 01-11-2010

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PRELOAD ADJUSTMENT— On some Works shocks a threaded preload is standard. This allows the adjustment of the ride height of the motorcycle. The preload is changed by turning a threaded nut down towards the spring (higher ride height) or up away from the spring (lower ride height). The nut is a right-hand thread. CHECKING RIDE HEIGHT— 1. With the bike unloaded on the side stand and the shock fully extended, have an assistant measure from a point at the axle (center point) to a point on the frame, fender or bodywork directly above it. Record this measurement. 2. With the bike off the stand and the rider in the seat, bounce on the suspension and let the bike settle. Have the assistant measure from the same two points. Subtract the second measurement from the first. HM CRX50 / BAJA & ATK 50MX INSTALLATION AND ADJUSTMENT TIPS Continued on next page. #HM50 – 5/27/99 #HM50 – 5/27/99 To Front Valve Mounting channel Spacer Flange Shock eye Top View of Shock Mount Fig. 1 Top view of upper shock mount. The flange on the shock bushing must face toward the spacer. The valve should point toward the front of the bike Fig. 1 Top view of upper shock mount. The flange on the shock bushing must face toward the spacer. The valve should point toward the front of the bike 3. The amount of settle, or “sag” is a function of the wheel travel. It should only be between 1/4 and 1/3 of the total travel. 4. If the difference is less than the minimum, reduce the spring preload. Measure the distance again starting with Step 2. Adjust again if necessary. 5. If the difference is more than the maximum, increase the spring preload. Measure the distance again starting with Step 2. Adjust again if necessary. Note: If the ride height is too low, the shock will bottom unnecessarily, resulting in a harsh ride. If the ride height is too high, the shock will “top out” too easily when rebounding from a bump or under hard deceleration. NITROGEN PRESSURES IN EMULSION SHOCKS CAUTION: The pressure in these shocks cannot successfully be checked. Concerns with the gauge volume and the gas volume in the shock body create a situation where you cannot accurately determine what pressure was in the shock. In addition when the pressure is lowered (i.e. checking the pressure) the gas and some of the shock oil escapes into the gauge. It is possible to lose a large percentage of the shock oil by depressing the core of a charged shock to the atmosphere. Please note that in order to check the pressure, some of the gas must escape and fill the gauge assembly. The volume of the gas pocket is about half the size of your thumb, so a very small volume change results in a large pressure drop. Because the gauges’ volumes vary, it is not possible to deduce the actual pressure in the shock prior to attaching the gauge. Therefore it is imperative that any attempt to check pressure be accompanied by the capability of refilling the shock. In other words: If you don’t have a nitrogen source handy, don’t check the pressure! PRESSURIZING EMULSION SHOCKS The pressure setting for Works gas shocks is 250 p.s.i. of dry nitrogen. To pressurize a shock with some residual pressure in it, bring the gauge manifold up to 250 p.s.i. and depress the core with the T-handle. This will either equalize the pressure or refill the shock without transferring oil from the shock into the gauge assembly. The best gauges for this purpose screw on to the valve and incorporate a T-handled core depressor to isolate the shock from the gauge. This allows a leak-free separation once the desired pressure is reached. For simplified operation, an extra valve is provided for the filling apparatus, allowing pressure adjustment with the gauge in place. Works offers a suitable gauge and filling manifold. Most motorcycle shops that deal with dirt bikes can pressurize the shock

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Vespa GTS Super Specification

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Filed Under (Vespa) by admin on 11-11-2010

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Gts super 300 ie Gts super 125 ie s 125cc s 50cc Gts 250 ie Gts 125cc LX 125cc LX 50cc 2 stroke Engine Single-cylinder, catalised, QUASAR 4 stroke, 4 valve electronic injection Single-cylinder LEADER 4 stroke with electronic injection Single-cylinder LEADER 4 stroke Single-cylinder HI-PER 2 stroke Single-cylinder, catalised, QUASAR 4 stroke, 4 valve electronic injection Single-cylinder, catalised, LEADER 4 stroke, 4 valve Single-cylinder LEADER 4 stroke Single-cylinder HI-PER 2 stroke Capacity 278cc 124cc 124cc 50cc 249cc 124cc 124cc 49cc Power 16.4 kW / 7500 rpm 10.5 Kw / 9500 rpm 7.65 Kw / 8250 rpm 3.2 Kw / 7500 rpm 15.7 Kw / 8500 rpm 7.65 Kw / 8250 rpm 7.65 Kw / 8250 rpm 2.5 Kw / 8500 rpm Max Torque 22Nm / 6500 rpm 12 Nm / 8000rpm 9.6 Nm / 7250 rpm 4.4 Nm / 6500 rpm 20.1 Nm / 6500 rpm 9.6 Nm / 7250 rpm 9.6 Nm / 7250 rpm 3.3 Nm / 6500 rpm Cooling Liquid Liquid Forced Air Forced Air Liquid Liquid Forced Air Forced Air Starter Electric Electric Electric and kick starter Electric and kick starter Electric Electric Electric and kick starter Electric and kick starter Transmission Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Automatic twist and go Front Suspension Single arm, dual chamber hydraulic shock absorber with coaxial spring Single arm link with coil spring and double hydraulic shock absorber Single arm link with coil spring and double hydraulic shock absorber Single arm link with coil spring and double hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Single sided trailing link with hydraulic shock absorber Rear Suspension Two dual effect shock absorbers with adjustable preload Coil spring and double hydraulic shock absorber Coil spring and double hydraulic shock absorber Coil spring and double hydraulic shock absorber Twin hydraulic shock absorbers with preload adjuster Twin hydraulic shock absorbers with preload adjuster Hydraulic shock absorbers with preload adjuster Hydraulic shock absorber Front Brake ø 220mm disc brake 220mm disc brake ø 200mm disc brake ø 200mm disc brake ø 220mm disc brake ø 220mm disc brake ø 200mm disc brake ø 200mm disc brake Rear Brake ø 220mm disc brake 220mm disc brake ø 110mm drum brake ø 110mm drum brake ø 220mm disc brake ø 220mm disc brake ø 110mm drum brake ø 110mm drum brake Front Tyre Tubeless 120/70-12″ Tubeless 120/70 – 12″ Tubeless 110/70 – 11″ Tubeless 110/70 – 11″ Tubeless 120/70-12″ Tubeless 120/70-12″ Tubeless 110/70 – 11″ Tubeless 110/70-11″ Rear Tyre Tubeless 130/70-12″ Tubeless 130/70 – 12″ Tubeless 120/70 – 10″ Tubeless 120/70 – 10″ Tubeless 130/70-12″ Tubeless 130/70-12″ Tubeless 120/70 – 10″ Tubeless 120/70-10″ Running weight 158kg 158kg 114kg 96kg 151kg 145kg 114kg 96kg Length/Width/Height 2230mm / 755mm / 1170mm 1930mm / 755mm / 1930mm 1770mm / 740mm / 1140mm 1755mm / 740mm / 1140mm 1930mm / 755mm / 1170 mm 1940mm / 755mm / 1180 mm 1770mm / 740mm / 1140mm 1755mm / 740mm / 1140mm Fuel Tank Capacity 9 litres 9 litres 8.5 litres 8.5 litres 9.2 litres 10 litres 8.5 litres 8.5 litres Emmissions Euro 3 Euro 3 Euro 3 Euro 2 Euro 3 Euro 3 Euro 3 Euro 2 Colours Rosso Dragon Nero Lucido Montebianco Rosso Dragon Nero Lucido Montebianco Taormina Nero Lucido Montebianco Taormina Nero Lucido Montebianco Marrone Terra Di Toscana Bronzo Perseo Nero Vulcano Blu Midnight

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HARLEY DAVIDSON LOW REAR SHOCK KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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See Figure 3 and Table 1. INSTALLATION Shock Absorbers Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) NOTES This procedure requires that both shocks be removed prior to installing the new shock absorbers. You need to place the motorcycle on a center stand with the rear wheel raised off of the ground. The jiffy stand should be able to move through its full range of travel. The exhaust system may interfere when removing and installing the lower right shock mounting hardware. If necessary, see Service Manual and remove the rear exhaust pipe. 2 4 5 7 1 6 3 is05206 1. Lower screw 2. Upper screw 3. Lower washer 4. Upper washer 5. Cover 6. Nut 7. Shock absorber Figure 1. Remove / Install Shock Absorber 1. Block the motorcycle under the frame so that the motorcycle is securely resting upright, the jiffystand may be moved through its full range of travel, and rear wheel is just off the ground. 2. Remove the lower shock mounting screw (1), washer (3) and nut (6) from the shock absorber (7). Save the hardware for reuse. 3. Remove the upper bolt (2), washer (4) and cover (5) and remove the shock absorber. Save the hardware for reuse. 4. Repeat Steps 1 and 2 for opposite side and save the hardware. 5. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the lower mounting bolt, then install bolt, lower washer and nut to the shock. 6. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the upper mounting bolt, then install the shock cover, upper mounting bolt and washer to the shock. Verify the cutout in shock cover locates properly

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Honda ST 1300 Series Single Shock Supplement

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Filed Under (Honda) by admin on 13-02-2011

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Check the orientation of the adjuster on the shock body – looking at the top of the shock, the hydraulic line port should be165 degrees (clockwise) from the nitrogen pressure valve (see figure 2) . If it is not properly oriented, you will need to reposition it. To do this, hold the upper shock eye securely in a vice and carefully rotate the Remote Adjustable Pre-Load adjuster the desired direction. This may be somewhat difficult due to spring tension, and may require slight loosening of the locking ring. Also, the spring, shaft, and lower mount may rotate while repositioning the adjuster. This is OK, just be sure to realign it with the upper mount (also be sure the rebound adjuster on the lower mount is properly oriented as noted below). Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the same path as the stock line was routed to the same location. n Do not loosen or attempt to rotate the line between the shock and the adjuster. n Make sure the shock rebound adjustment is facing the right side of the motorcycle and the pressure valve is facing up and towards the rear (figure 3) . n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket adapter using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80- 90 in/lbs (9-10 N-m). Then mount the bracket and adjuster to the bike in the same location as the stock preload adjuster using the supplied M6-1.0X20mm SHCS fasteners & nuts, and torque them to 80-90 in/lbs (9-10 N-m) (figure 4 & 5) . n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources.

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KTM Enduro Engineering Shock Spring Removal And Installation Instructions

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Filed Under (KTM) by admin on 12-11-2010

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1 Place motorcycle on a stand so that the rear wheel is off the ground. 2 Remove the upper shock bolt. (Figure 1) 3 Remove the lower shock bolt. (Figure 2) 4 Remove the shock from the motorcycle by sliding it down and out the right rear side of the bike. (Figure 3) 5 Place the shock upside down in a vice with soft jaws. Loosen the retaining ring lock screw with a 4mm Allen wrench. (Figure 4) 6 Using EE KTM shock wrench #22-300 (Figure 5), loosen the retaining collar enough to provide ¾ clearance between the bottom of the spring and the spring retaining collar. (Figure 6) 7 Push the spring retaining collar down to access the retaining clip. (Figure 7) 8 Remove the retaining clip. 9 Remove the spring retaining collar by sliding it up and off of the shock clevis. (Figure 8) 10 Slide the shock spring up and off of the shock. 11 Slide the new spring onto the shock. It should be sitting on the adjusting collar. 12 Re-install the spring retaining collar by sliding it over the clevis far enough to allow the retaining clip to be installed. 13 Install the retaining clip. Make sure that it is fully seated in the groove. 14 Slide the spring retaining collar up until it bottoms out on the retaining clip. 15 Tighten the spring adjusting collar until the bottom of the spring contacts the spring retaining collar. Turn the spring adjusting collar a couple more turns to put a small amount of pre-load on the spring. 16 Remove the shock from the vice and re-install it on the bike by reversing removal steps. Make sure to torque the upper and lower shock bolts to the manufacturer’s torque spec. 17 Set static and race sag as specified in your owner’s manual. Remember to torque the adjusting collar lock screw to manufacturer’s specification

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HARLEY-DAVIDSON SOFTAIL MODELS STEALTH AIR SHOCK MOUNTING

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Filed Under (Harley Davidson) by admin on 16-12-2010

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INSTALLATION 1. Remove the seat, inner fender, and ignition coil cover. Removing the rear wheel assembly is recommended for ease of installation, but not absolutely necessary. Remove the nut cup and outer grommet on each of the Works shocks. If you intend to leave the ride height at stock height for road riding, position the inner nut cup SHOC KS SHOC KS WORKS PERFORMANCE PRODUCTS, INC. 21045 Osborne St., Canoga Park, CA 91304 818.701.1010 fax 818.701.9043 STEALTH AIR SHOCK MOUNTING FOR HARLEY-DAVIDSON SOFTAIL MODELS 2000-ON #HDAIR-00 – 02/15/2006 WARNING! THESE SHOCKS MUST ONLY BE USED WITH STOCK SWINGARMS AND ON STOCK FRAMES WITH THE STOCK BOTTOMING BUMPERS ON THE CHASSIS TO LIMIT THE TRAVEL OF THE SHOCKS. AFTERMARKET SWINGARMS, OR MODIFIED SWINGARMS THAT DO NOT HAVE THE UPPER BRACE THAT ACTS AGAINST THE BOTTOMING BUMPERS CANNOT BE USED WITH THESE SHOCKS. INCREASING THE TRAVEL BY ELIMINATING THE BUMP STOPS OR A NON-STANDARD SWINGARM DESIGN WILL ALLOW THE TIRE TO MAKE CONTACT WITH THE FENDER OR OTHER CHASSIS COMPONENTS, AND CAN DAMAGE THE SHOCKS. 19. Lock Washers 20. Long Bolts (2) 21. Short Bolts (2) 13. Din Plug Screw 14. Din Plug Gasket 15. Cap 16. Eye Spacers (4) 17. Cotter Pins (2) 18. Switch Bracket 7. Compressor Bracket 8. Harness 9. Fuse Block 10. Din Connector 11. Solenoid 12. Hose 1. Damper Shock 2. Air Spring Shock 3. Nut Cup 4. Grommet 5. Hose 6. Compressor 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 14 18 19 20 21 Fig. 1–Nomenclature on the damper shock up against the ring nut. The shocks are now ready to install. 2. Place the motorcycle on a suitable frame stand allowing unrestricted access to the shocks. 3. Place a small screw jack under the swing arm to support the weight as well as allow you to position the swing arm correctly to line up the shock mounting bolts. Remove stock shocks. 4. Install the left side (damping) shock with the stock mounting bolt. Make sure that the bolt threads and threaded portions of the frame are free of oil and grease. Grease the shoulders of the bolts and use thread lock compounds on the threads. Discard the stock shock washers on both shocks. Do not use any washers- -including the stock washers on these bolts. Use only the spacers included. The 3/16-inch wide spacers are used on each side of the shock eye. Do not “double-up” the spacers together on either side of the shock eye, as this will cause misalignment of the shocks which can lead to premature wear or damage to the shocks. 5. Put the supplied spacers on each side of the eye. The shoulder of the bolt must protrude a small amount through the shock eyes in order to allow the shock to pivot freely. This is extremely important. With the shocks fully tightened, the spacers should be free to rotate with finger pressure. If the washer is used or a non-stock bolt is used, the bolts will work loose or break because the shocks are in a bind.

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Honda Goldwing GL1800 Solid Rear Axle Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Specifications Overall Width: 57.75″ Overall Length: 108″ Overall Length w/EZ-Steer 109.5 Wheel Base: 71″ Extended 4.5″ At Rear Axel Wheel Base w/EZ Steer 72.5″ Load Capacity: 500 Lb Tire Size: 205 / 70 / R15 Wheel Size (15″) Offset +35 mm 15x7JJ 4×4.5 Tire Pressure 20 PSI Suspension: “Zero-Flex” Internal Swing Arm utilizing 3 shocks, OEM shock absorber plus 2 coil over shock absorbers. Rear Differential: Champion Lightweight rear axle / differential assembly. Gear Ratio 2.93:1 gear ratio Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 6.75 cubic feet. 3 full-face helmets and additional storage. Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 7 of 28 Revision 10 4 Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. • Seat (to be re-installed without modification) • Left and right side covers (to be re-installed without modification) • Battery and battery box (to be re-installed without modification) • Left and right saddle bags • Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) • Trunk (to be re-installed without modification) • Left and right passenger foot rests (to be re-installed without modification) • Left and right foot rest under covers (to be modified and re-installed) • Left and right rear crash bars • Saddle bag trunk stay (to be modified and re-installed) • Left and right mufflers (Mufflers only, do not remove decorative covers) • Rear wheel • Left and right pivot bolt covers (to be re-installed without modification) • Reverse resistor (to be relocated) • Swing Arm – Note : Carry out brake system modifications (Section 5) prior to removing Swing Arm. • Note : Upper bolt of mono shock can be removed without removing the fuel tank. • Note : Do not remove actuator hose from actuator pump or shock absorber. Dismounting shock actuator pump will allow more movement of shock absorber when removing swing arm.Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 8 of 28 Revision 10 5 Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm. From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Sidecars Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Sidecars Trike Conversion Kit.

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BMW K-SERIES (INCLUDING PARALEVER) SHOCK MOUNTING INSTRUCTIONS

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Filed Under (BMW) by admin on 16-11-2010

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1. The shock mounts with the hose towards the rear of the machine, with the shock body at the top and the shaft pointing downward. 2. Take the inside half of the bushing set on the shock eye (at the shaft end) and place it on the mounting post on the drive hub. 3. Insert the body eye into the mounting channel on the frame. In some cases the channel may have to be spread slightly to fit the bushing set. NOTE; Do not try to install the shock with only half of the bushings, as this will lead to poor performance and premature seal leakage. For the same reasons, do not grind or file the inner or outer edges of the bushings to make them narrower. The amount of “float” in the bushing set is necessary to ensure smooth operation of the damper assembly. 4. Slide the shaft end of the shock over the mounting post. If it does not easily align with the bushing in place, the eye (and shaft and spring, etc.) can be rotated to fit. 5. Install the outer shock eye bushing and follow with the washer and nut. Install the upper shock mounting bolt and nut finger tight. 6. Position the reservoir under the frame rail below the seat. It will fit neatly between– and inside– of the stock luggage rack mounts. Let the reservoir dangle and put the hose clamps loosely in position over the frame tube. NOTE: The reservoir should be mounted so that the hose has a slight curve in it. This will allow a certain amount of movement at the shock body without putting pressure on the hose fittings at the shock. 6. Position the reservoir inside the hose clamps with the rubber stand-off pads between the reservoir and the frame. The hose clamps should be fitted on either side of the Allen bolt that attaches the tail section to the frame. They can placed at any point along the O.D. of the reservoir, but about 1/2″ from each end is typical. The stand-off pads should be at the same location on the reservoir as the clamps. Tighten the clamps snugly. Do not over-tighten the clamps, as this can cause them to break during temperature extremes. 7. Sparingly apply a thread locking compound to the threads on the shock mounting fasteners and tighten them to 28 to 32 lbs/ft. Over-tightening the fasteners can damage the bushings and cause

Honda CBR 900 RR Öhlins shock absorber kit Mounting instructions

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Filed Under (Honda) by admin on 14-12-2010

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Put the motorcycle on a stand so the rear wheel is clear of the ground. Make sure it’s steadily fixed so it will not fall over. 2 Remove the seat (2 screws from below) and loosen the six screws (four rear and two front) holding the fuel tank. The tank side covers must be loosened as well. 5 Remove the lower shock absorber mounting bolt from the triangle link. 6 Lower the shock absorber and turn it slightly so that it is possible to remove the horizontal attachment bolt. 7 Lift the rear end of the motorcycle enough to make removal of the shock absorber rearwards possible. 8 Attach the Öhlins shock absorber in reverse or- der. 9 Mount the upper and lower shock absorber bolts. 10 Attach the pre-load adjuster to the rear foot rest bracket on the right side of the motorcycle

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