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MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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SUSPENSION SERVICE TOOLS/ FORK DAMPER ROD BLEED TOOL

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Filed Under (Tips and Review) by admin on 30-11-2010

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33 SHOP EQUIPMENT & TOOLS SUSPENSION SERVICE TOOLS K&L FORK TUBE U-BLOCKS Precision machined from billet aluminum, these quality three piece sets are a handy, accurate and safe way to straighten and check fork tubes. 35-9411 36mm (for 33 thru 36mm tubes) 35-9412 40mm (for 37 thru 40mm tubes) 35-9413 43mm (for 41 thru 43mm tubes) 35-9414 46mm (for 44 thru 46mm tubes) 35-1964 35-8579 35-7995 DAMPER ROD HOLDERS Holds damper rod when disassembling forks. 35-8578 Yamaha front forks, 43mm Kayaba YZ125/250 (1988) YZ490 (88-90) 35-8579 Yamaha YZ125/250 with UD(upside down) forks FORK DAMPER ROD TOOLS Sold each. 35-7995 Combination Fork Damper Tool Designed to hold the damper rod during assembly & disassembly of Honda XR400′s or Suzuki DR-Z400S. One end features spanner type prongs for the XR400 and the other a 27mm hex for Suzuki. 35-1964 Combination Damper Rod Fork Tool Designed for assembly and disassembly of most inverted Kayaba and Showa 41mm, 43mm, 46, and 47mm forks. Use one end for Kayaba forks and the other for Showa forks. (not required for 91-92 Honda CR models) ROD HOLDER Double sided damper rod holder. Works on Kayaba U.D (upside down) 41mm forks. 35-8580 Yamaha YZ125/250Amodels (89-90) FRONT FORK CAP SOCKET Designed to remove and install Yamaha front fork caps with female hex head. Sold each. 35-8571 14mm female socket 35-8573 19mm female socket FORK DAMPER ROD HOLDERS Holds damper rod when disassembling and assembling front forks. 35-8576 Use for Yamaha 43mm Kayaba forks, 30mm hex YZ125 (84-87), YZ250 (81-87) IT250 (1983) YZ490 (82-87) 35-8577 Use for Yamaha 38mm Kayaba forks, 24mm hex YZ125 (81-83), IT175 (82-83), IT250 (81-82) YZ250 (77-80), YZ400 (77-79), IT465 (81-82) FORK CAP WRENCH Designed to remove the front fork caps on late model Honda CR’s and Suzuki RM’s. Can also be used for adjusting compression. One end of wrench is 49mm, the other is 50mm. Sold each. 35-7803 Fork Cap Wrench 35-8576 35-8577 35-8571 35-8573 6 Point Hex 35-8578

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DUCATI TITANIUM EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Ducati) by admin on 26-10-2010

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BILLET BRAKE RADIAL MOUNTS Moto Corse brake radial mounts are crafted by precision machine tools as shown, the caliper mount is “box” type precision tooled from single ERGAL 7075 solid piece. The result: performance, reduced weight, quality and beauty unmatched by none used extensively in moto gp as standard technology Moto Corse delivers moto gp technology for the ultimate performance. The kit is available for caliper with bolt distance 108mm or 100mm and includes all the parts to assemble it on the bike. 102143002 102143003 102143005 102143006 102143008 102143009 102143011 raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO racing calipers screW Distance 108MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO racing calipers screW Distance 108MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr OHlins rOaD &tracK Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM raDial MOunt Kit FOr sHOWa Ø 43 FrOnt FOrKs FOr breMbO street calipers screW Distance 100MM Ducati 999s/999r/749r Ducati 748r/996sps/996r/998r/998 eF Ducati 748r/996sps/996r/998r/998 eF Ducati 999s/999r/749/r Ducati 749/749s/999 748/998 – MOnster 1000/s4/s2r Ducati MultistraDa 1000D

HONDA 2008 CRF 450 F SLIP-ON EXHAUST SYSTEM REPAIR MANUALS

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Filed Under (Honda) by admin on 25-12-2011

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The Akrapovic Slip-On system is designed for recreational Honda CRF 450 enthusiasts. It delivers an excellent combination of quality, performance, visual enhancement, easy installation and affordability. The Akrapovic Slip-On is designed for two markets; in the US it is available with an approved spark arrester, and for the EU and other non-US markets it comes with a noise damper. PERFORMANCE Measurements of the Akrapovic SLIP-ON system on the HONDA CRF 450 R (with muffler insert): Power & Torque: Up to 5600 rpm the Akrapovic Slip-On essentially follows the stock power and torque curves. It shows its true colors above that range, where it delivers significant increases to both power and torque. Max. increased power of 2.8 HP was measured at 6600 rpm. At the top of the rpm range the Akrapovic curves again follow the stock power and torque curves. CONFIGURATION The system is composed of a flared stainless steel link pipe which is welded to the muffler. It is attached to the stock header assembly with a sleeve joint secured with a metal clamp. The muffler is the offroad design with a titanium outer sleeve, and stainless steel inlet cap, outlet cap and inner perforation. The muffler is attached to the frame using an Akrapovic carbon-fiber clamp. In the US the system is available with an approved spark arrester, and for the EU and other non-US markets it comes with a standard noise damper

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TOYOTA SUPRA 1990 REPAIR MANUAL COOLING SYSTEM LUBRICATION SYSTEM

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Filed Under (Uncategorized) by admin on 22-05-2011

This manual contains maintenance and repair procedures for the 1990 TOYOTA SUPRA.
Applicable model: MA7O series 4 The manual is divided into 24 sections and 4 appendixes with
a thumb index for each section at the edge of the pages. Please note that the publications below have also been prepared as relevant service manuals to the components and systems in this vehicle.
Manual Name I Pub. No. ‘ 1990 Toyota Supra Electrical Wiring EWDO72U
Diagram Manual ‘ Toyota Supra Collision Damaged Body BRMOOSE Repair Manual ° Toyota Supra Collision Damaged Body BRMOOQE Repair Manual Supplement ° 1990 Model New Car Features NCFO59U
All information in this manual is based on the latest product in- formation at the time of publication. However, specifications and procedures are subject to change without notice.

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2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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KTM 250-525 SX, MXC, EXC RACING ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 07-02-2012

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TM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. T he respective headings can be entered in the list of contents. Remove page (s) Replace by page (s) Insert page (s) after page 2-1 / 2-7 2-1C 2-7C to 2-9C 3-1 3-1C 4-1 to 4-14 4-1C to 4-13C 5-1 / 5-3 5-1C / 5-3C 5-6 to 5-8 5-6C to 5-8C 5-12 to 5-26 5-12C to 5-27C 6-1 / 6-4 6-1C / 6-4C 6-7 to 6-16 6-7C to 6-17C 7-1 to 7-2 7-1C to 7-2C 7-7 to 7-11 7-7C to 7-11C 8-1 to 8-13 8-1C to 8-21C 9-1 9-1C 9-10 to 9-13 9-10C to 9-16C 10-1 10-1C 10-8C to 10-11C 11-1 11-1C 11-11C to 11-13C
Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E EXPLANATION – UPDATING Edition 01/2003 3.205.85-ERepair Manual 400/520 SX, MXC, EXC RACING Basic version Model year 2000 (Engine number with first digit “0″) 2/2000 3.210.01-EUpdating of Rep.Manual 3.205.85-E Model year 2001 (Engine number with first digit “1″) 1/2001 3.210.44-EUpdating of Rep.Manual 3.205.85-E Model year 2002 (Engine number with first digit “2″)

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TOYOTA L, 2L ENGINE REPAIR MANUAL FOR 2L-T ENGINE DESTINATIONS FUEL SYSTEM

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Filed Under (Toyota Manuals) by admin on 21-05-2011

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INSUFFICIENT TURBOCHARGING PRESSURE Check turbocharging pressure (See page EM-6). If not within the  standard shown below, begin diagnosis from item 2. Standard pressure: 0.41 – 0.54 kg/cm2 (5.8 – 7.7 psi, 40 – 53 kPal RESTRICTED INTAKE AIR SYSTEM Check intake air system, and repair or replace parts as necessary. (See page EM-6)
3. LEAK IN INTAKE AIR SYSTEM Check intake air system, and repair or replace parts as necessary. (See page EM-6)
4. RESTRICTED EXHAUST SYSTEM Check exhaust system, and repair or replace parts as necessary, (See page EM-6)
5. LEAK IN EXHAUST SYSTEM Check exhaust system, and repair or replace

KTM 250 – 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 04-02-2012

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KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents.

TOYOTA PREVENTION AND REPAIR OF ACID RAIN DAMAGE ( REVISED)

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Filed Under (Toyota Manuals) by admin on 12-10-2011

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it is the responsibility of the dealer to protect and maintain the quality of the vehicle’s finish after receipt at the dealership. Frequent vehicle washing, up to 4 times weekly during high heat and humidity periods, should be performed to minimize the potential for paint damage due to acid rain exposure. This is especially important in areas known for high frequency and concentration of acid rain and industrial fallout. INSPECTION AND REPAIR: Acid rain damage can frequently be identified on vehicles by the presence of visible spots on the paint surface which resemble hard water stains. Unlike water spots, however, acid rain damage cannot be removed by polishing or buffing only. Because acid rain can etch and soften the paint, normal polishing or buffing repair procedures should not be attempted, as this will result in visible depressions in the paint surface. CORRECTIVE ACTION: The repair of acid rain damaged paint surfaces varies depending on how deep the acid has penetrated. Superficial damage can usually be removed by color-sanding and polishing. If the damage extends to a depth greater than 1/2 mil of the clearcoat on a pearl or metallic color, or more than 1 mil of a solid color, sanding and repainting may be necessary. Unfortunately, there is no simple method of determining the actual extent of the acid penetration other than color sanding a representative affected area until there is no visible etching or depressions and then measuring the amount of paint removed with a magnetic type paint film thickness gauge

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