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HARLEY-DAVIDSON 5 and 6 Speed OEM Transmissions ReverseGear User Operating Instructions

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Filed Under (Harley Davidson) by admin on 16-02-2011

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A. It is good practice to first engage first gear to stop the gearbox from spinning (This will prevent the “grinding” noise when reverse gear is engaged) and then place the bike in neutral and immediately engage reverse. If Reverse Gear still “grinds” after the above procedure – check the clutch adjustment to ensure the clutch is not dragging and causing the gearbox shafts to spin. B. Do not let the bike “free wheel” backwards while in reverse gear and the clutch engaged or disengaged (i.e. when rolling down a slope when in reverse) – The reverse gear will automatically try to disengage and will result in a “grinding” sound. To prevent this – Always stop immediately after the reverse action is completed. WARNING! Reverse gear is intended for light duty use only – like slowly backing in/out of parking spaces etc. Do not drive for long periods in reverse. WARNING! Do not attempt to engage reverse while the motorcycle is up on a lift stand. Maintenance Check transmission fluid levels regularly and fill with Manufacturer’s suggested lubricants. Warranty One year on reverse gear parts only. Champion will not warranty the Reverse Gear if it is deemed to be “abused” by the user like: – Engaging First Gear while the Reverse Gear is still engaged and/or – Over powering the Reverse Gear by revving and dropping the clutch and/or – For an Installation Error (not following the installation instructions exactly). Any attempt to modify this product without written permission from the manufacturer will void the warranty and may cause damage to vehicle and injury to persons.

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2002 GL 1800 Reverse Cable Inspection/ Adjustment PROCEDURE

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Filed Under (Honda) by admin on 29-01-2011

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INSPECTION/ADJUSTMENT PROCEDURE 1. Remove the right engine side cover (see S/M Page 2-4). 2. Check the cable clearance on the N (neutral) and R (reverse) cables. Note: It is not necessary to remove the center inner fairing or inspect the reverse shift actuator. . 6. Push the reverse shift switch to “OFF” and turn off the ignition. 7. Tighten the reverse cable lock nuts. 8. Reinstall the right engine side cover. PARTS INFORMATION No parts are required for this procedure. WARRANTY INFORMATION Normal warranty. After completion of the inspection/adjustment, submit one claim per VIN using the following information only: Template #: GL#5 Flat Rate Time = 0.3 hours The reverse cable lock nuts may not have been properly tightened on some GL1800 units. We have developed a procedure to inspect and adjust any affected units. Please follow the INSPECTION/ ADJUSTMENT procedures included in this Service Bulletin. AFFECTED UNITS 2002 GL1800 units with VIN range: 1HFSC470*2A102303 through 1HFSC470*2A102622 * indicates check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection.

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Harley-Davidson Motorcycle Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-10-2010

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2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 Figure 2. Exposed Shoulders Mark shifter fork rod flush with case Remove Spacers Vehicle Transmission Counter Shaft Main Shaft Front of Motorcycle Figure 1
Reverse Gear Installation Instructions For EVO / 5 Speed and Twin Cam Harley-Davidson® Motorcycle Page 3 of 6 Revision 7 © 2007 Champion Motorcycle Accessories International, Inc. dba Champion Sidecars 11841 Monarch Street Garden Grove, CA 92841 (800) 875-0949 (714) 847-0949 www.championsidecars.com www.championtrikes.com Figure 6 CAUTION: Do not pull the shifter fork rod out of the transmission more than 1/4″. If you pull the shifter fork rod out too far, it will be difficult to realign it with the internal shifter fork. 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

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Front BrakeNoise in Reverse

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Filed Under (Toyota Manuals) by admin on 23-10-2011

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2007-2008 FJ Cruiser Drive Type(s): 4WD VDS(s): BU11F 2007-2008 FJ Cruiser Drive Type(s): 2WD VDS(s): ZU11F Introduction Some customers ma yexperiencefront brake noise when driving the vehicle in reverse and applying the brake pedal. The noise will typically occur when backing out ofaparkingspace after the vehicle has been stopped f or an extended period of time. Updated front brake rotors and brake pad shim grease are now available to improve this condition. Use the following repair procedures to address customer concerns. Production Change Information This TSBappliesto vehicles produced BEFORE the Production Change Effective VINs shown below

Harley-Davidson Six Speed Transmissions Reverse Gear Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the exhaust pipe support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.8 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.9 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Installation 3.1 Reinstall exhaust pipe support bracket with the supplied two 5/16-18 x 1 3/4″ long hex head bolts and the ¼” thick spacer between engine and bracket. Figure 1 3.2 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.3 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 2 3.4 Install the supplied plug into the main shaft hole. To be removed later. 3.5 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 3 3.6 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.7 Remove torque wrench from special tool. Do not remove special tool from small gear

Ignition Upgrade Module for 2004-up Carbureted Harley Davidson Motorcycles Owner's Manual

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Filed Under (Harley Davidson) by admin on 25-11-2010

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1. Disconnect the negative battery cable. 2. Grasp the sides of the electrical caddy (located next the ignition coil) and pull outward to remove. 3. Remove the relay and fuse panels from the electrical caddy. a. Insert a small screwdriver into the slot under each fuse and relay panel. b. Using a screwdriver, disengage the panel from the electrical caddy. 4. Disconnect the main fuse connector from the electrical caddy a. Remove the main fuse from the connector b. Insert small screwdrivers into the slots on each side of the main fuse c. Depress the tabs of the main fuse connector to disengage it from the electrical caddy
Thunder Heart Performance Corp. 615-672-8811 www.thunder-heart.com 2 EI5075.doc 5. Depress the tab located on the electrical caddy securing the TSM/TSSM. Pull it from the electrical caddy. Disconnect the TSM/TSSM connector. 6. Slide the data link connector towards the front of the motorcycle to disengage it from the electrical caddy. 7. Disconnect the ignition control module connector. 8. Disconnect the ignition coil connector and spark plug cables from the coil. 9. Remove the electrical caddy fasteners (3 total). 10. Remove the wiring from the electrical caddy. 11. Remove the fasteners securing the factory ignition control module from the electrical caddy. 12. Installation of the Digital Ignition Module is the reverse of removal. 2.2 Touring Models 1. Disconnect the negative battery cable. 2. Remove the right saddlebag. 3. Gently pull the side cover from the frame downtubes (no tools required). 4. Depress the external latches and use a rocking motion to remove the electrical connector from the ignition control module. 5. Remove the two socket screws to detach the ignition control module from the electrical bracket. 6. To install the Digital Ignition Module, install and tighten the socket screws to 50-60 in-lbs . The remainder of installation is the reverse of removal. 2.3 Softail Models 1. Remove the seat. 2. Disconnect the negative battery cable. 3. Remove the two screws to free the ignition control module from the mounting bracket. 4. Depress the external latches and use a rocking motion to remove the electrical connector from the ignition control module. 5. To install the Digital Ignition Module, install and tighten the socket screws to 15-21 in-lbs . The remainder of installation is the reverse of removal

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URAL TOURIST / SPORTS Repair Manual

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Filed Under (Ural) by admin on 18-11-2010

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Maximum speed of motorcycle 108 km/h / 65 mph *119km/h / 74 mph 122 km/h / 77 mph Reference fuel consumption at 85% of maximum speed 12.5 km/l / 29 mpg 14 km/l / 32.5 mpg 16.7 km/l / 39 mpg Dry mass of motorcycle 700 lb. / *680 lb. 460 lb. Maximum load-carrying capacity 500 lb/485 lb/*400 lb 330 lb. Noise level below 80db OVERALL DIMENSIONS OF MOTORCYCLE Length 2500 mm / 8 ft 2200 mm / 7 ft Width 1700 mm / 5 ft 6 in 850 mm / 2 ft 8 in Height 1100 mm / 3 ft 6 in 1060 mm / 3 ft 8 in Road Clearance 125 mm / 5 in Seat height 840 mm / 33 in 810 mm / 32 in Wheel base 1470 mm / 55 in ENGINE Type 4 stroke, overhead valves, opposed twin-cylinder Displacement 649 cc Cylinder bore 78 mm / 3.07 in Piston stroke 68 mm / 2.68 in Compression ratio 8.5 Rated horsepower 35 Rated rotational speed 5600 RPM Rated torque, Nm 45 Nm / 398.7 in-pound Ignition system Contactless with electronic ignition timing Lubrication system Dual system of forced lubrication and by splashing Lubricant SAE 20W/50 (see Owner’s Manual Maintenance Section) CARBURETOR Carburetor type Keihin Seiki 32 CVK Number of carburetors 2 Air cleaner Pleated Paper Filter Fuel 91 octane premium unleaded gasoline PCV Valve Internal Breather ELECTRICAL EQUIPMENT Ignition system 12 V Ignition coil B204 Spark plugs NGK BP7HS or NDW20FP-1 Ignition timing Automatic spark timer Power supplies Alternator Storage battery (Russian supplied with new motorcycle) Recommended replacement: Interstate #12N9-4B-1 Voltage regulator (electronic) Internal to Alternator Horn C205B Headlight URAL  part no. UA-TB6014-017 Sylvania Incandescent 6014, 7″ round sealed beam TRANSMISSION Clutch Dry double-disk clutch Gearbox 4 speed box with reverse gear (no reverse for solo model) and gear shifting foot pedal GEAR RATIOS TOURIST / SPORTSMAN / UTILITY SOLO/CRUISER I gear 3.6 3.6 II gear 2.28 2.28 III gear 1.7 1.7 IV gear 1.3 1.3 Reverse gear 4.2 N/A on Solo 4.2 on -10 mdls Speedometer drive ratio 0.4 0.5 Final drive Pair of bevel gears with propeller shaft Final drive ratio 4.62 3.89 FLUID CAPACITIES TOURIST & -10 Models Sportsman Solo Gasoline tank 19 L / 5 Gal 19L / 5 Gal 18.5 L / 4.9 Gal Reserve 2L / 0.5 gal 2L / 0.5 gal 2L- / 0.5 Gal Engine crankcase 2 L / 2 qt. + 3.6 oz. 2.0L / 2.11 qt 2 L / 2 qt. + 3.6 oz. Gearbox 0.9L / 1 qt 0.9L / 1 qt 0.9L / 1 qt Final drive 110 ml / 3.85 oz. 150 ml / 5.25 oz. 110 ml / 3.85 oz. Telescopic Forks (-10 & solo models) N/A on Tourist N/A on Sportsman 135 ml / 4.56 oz. Shock Absorbers 105 ml / 3.55 105 ml / 3.55 oz 105 ml / 3.55 oz

2003 Model Ural Gear Up, Patrol, Tourist Owners Manual

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Filed Under (Ural) by admin on 02-11-2010

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19 Kick lever Is designed to start the engine. On pressing the lever the crankshaft of the engine is actuated through the gearbox. The lever is returned to its initial position by the spring inside the gearbox. Gear shift foot pedal Is a two-arm type. When the front arm is depressed, shifting from higher to lower gear takes place. When the rear arm is depressed, shifting from lower to higher gear takes place. Since the heel-toe shift lever is short-coupled, you will find it easier to shift into a higher gear if you do not use your heel to shift, rather the ball of your foot. The neutral position is fixed between the 1st and 2nd gears. It is important to shift smoothly with a constant force and not to kick the gear shift pedal. Serious damage may result to the shifting mechanism if the gear shift pedal is kicked, rather than pushed. IMPORTANT! The green pilot lamp will illuminate when either the transmission is in neutral or when the reverse gear is engaged (see “Starting the Engine”). Turn indicator pilot lamp indicates that the turn signals are activated. Alternator fault indicator lamp , indicates that the charging system is malfunctioning and needs immediate attention. Gearbox neutral and reverse gear engagement , indicates that the gearbox is either in neutral or in reverse. Head lamp high beam indicator , indicates that the headlight high beam is activated. Speedometer is on the dash board, with trip and total odometer. The trip odometer is reset to zero by rotating knob (Fig.1, # 3) counterclockwise. Note that the odometer reads in kilometers not miles.

BMW K 1100 LT/ RS Repair Manual

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

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Renewing fuel filter Inspection III • If necessary, reduce fuel level with pump until filter is clear. • Loosen hose clip (1) and shift towards filter. • Detach line and remove filter together with line from the fuel tank. • Change fuel filter. L Note: Note direction of fuel flow on filter. • Reconnect line to pump. • Install in the reverse order of removal. L Note: Gasket (2) must not close off the overflow hole. Ensure recesses (arrows) in gasket are fitted in correct position. Cleaning inductive pulse generator at rear wheel drive Inspections I, III, IV • Release securing screw (1). • If necessary lever out inductive pulse generator and clean with rag. X Tightening torque: Inductive pulse generator at rear wheel……. 2.5 Nm LT000070 1 2 LT000080 1
00.14 Checking brake pads, brake discs for wear and renewing if necessary Inspection II, III Front wheel brake • Remove rear section of mudguard. • Remove brake caliper. L Note: It is not necessary to release the brake line at the brake caliper if only the brake pads are to be changed. • Drive out retaining pin (1). • Remove brake pads by pulling in downward direction. e Caution: The brake pad thickness (arrows) must not drop below the minimum specified value. Change pads only as complete sets. Min. pad thickness on carrier plate….1.5 mm (0.06 in) • Install in the reverse order of removal. L Note: Before installing the brake caliper, completely press back pistons with resetting tool (1), BMW No. 341500 . • Measure thickness of brake disc with a microm- eter. Wear limit…………………………………………….4.5 mm Rear wheel brake • Lever off cap from brake caliper. • Remove brake caliper. • Drive out retaining pins (1) from wheel side. • Remove brake pads by pulling upward. • Install in the reverse order of removal.

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