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SUZUKI SV1000 PERIODIC MAINTENANCE

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Filed Under (Suzuki) by admin on 26-02-2011

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MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER I Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months) . • * Remove the seat. (LF6-7) • * Lift and support the feul tank . (C-74-65) • * Remove the air cleaner box cap O. • * Remove the air cleaner element O. • * Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION Always use air pressure on the throttle body side of the air cleaner element . If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element . PERIODIC MAINTENANCE 2-5 2-6PERIODIC MAINTENANCE • * Reinstall the cleaned or new air cleaner element in the reverse order of removal . CAUTION If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug . SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months) . No. 1 (FRONT) SPARK PLUG REMOVAL • * Remove the radiator mounting bolt O. • * Move the radiator forward. • * Remove the spark plug cap O. NOTE: Be careful not to damage the radiator fins . A WARNING The hot radiator and the hot engine can burn you . Wait until the radiator and the engine are cool enough to touch . • * Remove the spark plug with a spark plug wrench. 1 6 I It No. 2 (REAR) SPARK PLUG REMOVAL • * Remove the seat. (r–,-6-7) • * Lift and support the fuel tank . (=4-65) 4-65) • * Disconnect the camshaft position sensor 1O and breather hose (Z. • * Remove the rubber heat shield ® . • * Remove the spark plug cap . • * Remove the spark plug with a spark plug wrench . HEAT RANGE • * Check to see the heat range of the plug . CARBON DEPOSIT •Check to see if there are carbon deposits on the plugs . If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end . SPARK PLUG GAP • * Measure the plug gap with a thickness gauge . If out of specification, adjust it to the following gap . 09900-20803 : Thickness gauge Spark plug gap OA Standard: 0.6 – 0 .7 mm (0.024 -0.028 in) ELECTRODES CONDITION •Check to see the worn or burnt condition of the electrodes . If it is extremely worn or burnt, replace the plug . And also replace the plug if it has a broken insulator, damaged thread . CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result

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SANYANG HD 125/ 200 Specifications And SERVICE MANUAL

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Filed Under (Sym) by admin on 24-11-2010

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heck and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor Fuel supplied tom carburetor sufficient No fuel is supplied to carburetor Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground. Perform cylinder compression pressure test. Check if sparks Weak sparks, no spark at all Low compression pressure or no pressure Re-start by following the starting procedures No ignition There are some signs of ignition, nut engine can not be started Remove the spark plug again and check it. Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit. Then blow the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1. No fuel in fuel tank 2. Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged. 3. Float valve clogged 4. Lines in fuel tank evaporation system clogged 5. Malfunction of fuel pump 6. Loosen or damaged fuel pump vacuum hose 7. Fuel filter clogged 1. Malfunction of spark plug 2. Spark plug foul 3. Malfunction of CDI set 4. Malfunction of AC generator 5. Ignition coil is in open or short circuit 6. Ignition coil leads open or short circuit 7. Malfunction of main switch 1. Piston ring seized 2. Malfunction of cylinder valves 3. Worn cylinder and piston ring 4. Cylinder gasket leak 5. Sand hole in compression parts 1. Malfunction of throttle valve operation 2. Air sucked into intake manifold 3. Incorrect ignition timing 1. Fuel level in carburetor too high 2. Malfunction of throttle valve operation 3. Throttle valve opening too wid

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Honda CG125 Owners Workshop Manual

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

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Clean the air filter Pull off the right-hand side panel and remove the two nuts which secure the air filter cover. Withdraw the cover, checking that the sealing gasket is in good condition, pull out the retaining spring and withdraw the element assembly. Peel off the inner and outer foam sleeves. Wash all components in white spirit (Stoddard solvent) or in warm water and detergent and dry them thoroughly. Soak the foam sleeves in the specified oil, then squeeze them gently (do not wring them out or they will be damaged) to expel all surplus oil. Refit the sleeves to the element frame. On reassembly ensure that all components are correctly fitted so that unfiltered air cannot bypass the element. 2 Check the spark plug Remove the spark plug cap, unscrew the plug and check its condition, comparing it with the photographs on page 65. If it is badly worn or fouled it must be renewed. If it is fit for further service check the gap and reset it if necessary, as described in Chapter 3.8. 3 Check the valve clearances It is important that the correct valve clearance is maintained. A small amount of free play is designed into the valve train to allow for expansion of the various components. If the setting deviates greatly from that specified, a marked drop in performance will be evident. In the case of the clearance becoming too great, it will be found that valve operation will be noisy, and performance will drop off as a result of the valves not opening fully. If on the other hand, the clearance is too small the valves may not close completely. This will not only cause loss of compression, but will also cause the valves to burn out very quickly. In extreme cases, a valve head may strike the piston crown, causing extensive damage to the engine. The clearances should be checked and adjusted with a cold engine. Place the machine on its centre stand and remove the rocker cover, taking care not to damage the 0 ring. Remove the gearchange pedal and the left-hand outer cover to expose the generator rotor. Remove plug and allow old oil to drain Remove the spark plug, then slowly rotate the engine anticlockwise by way of the generator rotor, watching the inlet valve. When it has opened and closed again (sunk down and risen up to its original position), rotate the engine further until the T mark on the rotor periphery aligns exactly with the raised index mark which is positioned between 12 and 1 o’clock (from the crankshaft) on the generator stator. The engine will then be in the correct position for checking the valve clearances, namely at Top Dead Centre (TDC) on the compression stroke; check that there is free play at both rockers. Using a 0.08 mm (0.003 in) feeler gauge, check the clearance between the top of each valve stem and its corresponding rocker. The feeler gauge must be a light sliding fit, with the rocker and valve stem just nipping it. If necessary, slacken the locknut, and turn the small square-headed adjuster to obtain the correct setting. Tighten the locknut, holding the adjuster at the same time to prevent it from moving. Finally, recheck the setting and then repeat the procedure on the other rocker. 4 Check the contact breaker points and ignition timing Note: since the generator stator plate is located by its countersunk retaining screws, the ignition timing can only be altered by opening or closing the contact breaker gap; therefore both operations are described as one. The full procedure is given here for ease of reference, but if the points are found to be in good condition and if the gap has not altered or is within the tolerance, then the ignition timing will be sufficiently accurate and there will be no need to carry out the full check. First remove the gearchange pedal, the left-hand outer cover, the spark plug and the left-hand side panel

Honda VT1100 Shadow Guide Plug Patch Repair Manual

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Filed Under (Honda) by admin on 24-04-2011

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Find the guide plug.bn The guide plug is shown in the shop manual with the engine removed from the frame and the left crankcase cover removed. (You’ll find this illustration in the “ELECTRIC STARTER/STARTER CLUTCH” chapter in the “STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL” section.) It’s a little bit harder to find it on the bike. Start by following the yardstick to see where the guide plug is on my bike. To find it on your bike, lie on the ground (or, preferably a mechanics creeper) next to the bike (without the yardstick) and peek under the shift lever and over the frame There it is, just barely visible from the side of the bike. Here’s what a new one looks like: 2. Clean the guide plug and crankcase. From the front of the bike, clean the guide plug and crankcase with brake cleaner in a VERY focused spray. Let the cleaner evaporate before moving to the next step. Page 4 Rev: Draft 5/20/2007 Page 4 of 5 3. Reposition the guide plug. a. From the side of the bike, use the yardstick (or a long screwdriver if you prefer) to gently push the guide plug back into the crankcase. (Note the JB Weld from the previous patch operation.) b. From the front of the bike, gently push upward on the bottom of the upper tab (as shown below) or the bottom of the forward tab to rotate the guide plug into the proper position while maintaining pressure with the yardstick

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HARLEY DAVIDSON GLOSS BLACK HEAD BOLT COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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This kit fits 1992 and later Evolution 1340 and XL models and 1999 and later Twin Cam-equipped models. INSTALLATION 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) 1. Remove spark plugs. 2. See Figure 1. Install head bolt covers (1), on head bolts (3), secure using setscrew (2) and Allen wrench included with kit. To prevent setscrews from falling into the spark plug holes, start threading the setscrews into the covers before placing them over the head bolts. Position cover on head bolt so that when spark plug is reinstalled setscrew is hidden from view but accessible with Allen wrench. Do not tighten setscrews on high points of bolts. 3. Reinstall spark plugs. Tighten spark plugs to 11-18 ftlbs (15-24 Nm) . If a torque wrench is not available, finger- tighten spark plug and then, using a spark plug wrench, tighten plug an additional 1/4 turn. 4. Readjust setscrew tightness after motor has operated at full operating temperature and then cooled. 2 1 3 is 001586 1. Head bolt cover 2. Setscrew 3. Head bolt Figure 1. Head Bolt Cover Installation

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HONDA CB650/ 750F/ 900F/ 1100F/ GL1100 Spark Unit Set Installation Manual

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Filed Under (Honda) by admin on 05-04-2011

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INSTALLATION INSTRUCTIONS: 1. All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation. 2. Remove the seat and/or petrol tank to gain access to the original spark units (if fitted); these are normally fitted under the seat between the top frame tubing. Each of these units consists of a small alloy metal box with sleeved wires terminated by a small connector (coupler). They also have a mounting tab with a single fixing hole. 3. On four cylinder machines there will be two units, normally mounted back to back; one for cylinders 1&4 and one for cylinders 2&3. 4. For safety, disconnect the battery. 5. Unplug the couplers from each of the units. Undo the fixings and remove the units. 6. Fit the new spark units in the place of the old ones or find a suitable alternative, close to the connectors. Secure the units to the frame or mounting platform using the supplied tie-straps and adhesive mounting base (if required). If required, a thin sheet of rubber or double-sided tape can be used to keep the units in position. Do not completely wrap the units in foam rubber. 7. Push the wiring harness plugs into the new spark unit socket connectors; they will only fit one way. Reconnect the battery. 8. If you are rewiring the machine or do not have the standard wiring harness, the spark unit wire colours & functions are as follows: GREEN Ö GROUND (0 VOLTS) BLACK/WHITE Ö IGNITION SUPPLY (+12 VOLTS) VIA ENGINE STOP SWITCH YELLOW Ö IGNITION COIL OUTPUT (TO COIL —) WHITE Ö PULSE GENERATOR (WHITE RING) BLUE Ö PULSE GENERATOR (UNMARKED) There are two pulse generators, one for cylinders 1&4 and one for cylinders 2&3. The left hand one is normally for cylinders 1&4 (see fig.1). There are two wires of the same colour coming from each pulse generator, one of these wires is normally marked with a white band. The pulse generator wire with the white band connects to the white wire from the corresponding spark unit, the other pulse generator wire connects to the blue wire on the corresponding spark unit. If the white band is missing, this is normally the upper wire coming from the pulse generator. 9. Refit the seat and tank (if removed earlier). 10. Fitting is now complete, although for best results you may wish to verify the ignition timing, see the following guide

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1998-2001 Ducati 996 Power Commander Installation Instructions

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

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1) Lift the rear section. 2) Remove the left hand side fairing. 3) Locate the plug that resides in between the two throttle bodies (Fig. A). This plug has a round, silver retaining ring on the end of it. 4) Unscrew this connector by turning it counter-clockwise. 5) NOTE: You may want to route the wires from the PCIII from the tail section to this area before plugging it in. This will make for a cleaner installation. Plug the female connector from the PCIII into the wiring harness (Fig. B). 6) Plug the male connector from the PCIII into the female connector on the bracket (Fig. C). 7) Route the wires along the frame towards the rear of the bike. Make sure the wires are routed so they do not get pinched. 8) Attach the ground wire from the PCIII to front, left hand, mounting point of the ECU (Fig. D). 9) Attach the PCIII to the top of the ECU using the supplied velcro. (Fig. D). 10) Reinstall the left hand side fairing

2003 DCx65 Owners And Service Manual

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Filed Under (Cobra) by admin on 10-11-2010

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Dimensions Wheelbase 44.75″ (1136 mm) Wheel size 14″ (356 mm) front, 12″ (305 mm) rear Seat height Engine Type 2-stroke, single cylinder, reed valve Cooling system Liquid-cooled Displacement 64.8 cc (3.95 Cubic inches) Bore and stroke 43 mm x 44.6 mm Ignition system Electronic Spark plug Splitfire SF406B Gap 0.023″ – 0.025″ (0.58 – 0.64 mm) Fuel type Sunoco MO2 X or 93 octane pump gasoline OTHER RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2-cycle Race Oil Fuel / oil mix ratios 32:1 to 40:1 Ignition timing 0.050″ Carburetion 28 mm PWK style Main jet 128 Slow (Pilot) jet 38 Jet needle JJH 3rd position from the top Float height 19 mm + 0.5mm (0.75″ + 0.020″) Transmission Speed Six speed Clutch Manual hydraulic Final drive ratio 13/46 T Transmission / clutch oil type 85W 90 Gear Lubricant Quantity 530 ml (18 oz) 6 Chassis Front tire 60/100 x 14 Pressure 10 – 15 psi. Rear tire 80/100 x 12 Pressure 10 – 15 psi. Front fork Cobra USD 35 mm Fork oil type SAE 5 weight Fork oil amount 4 oz (118 ml) Fork oil level Specifications – Torque Values Torque Value ENGINE Fastener ft-lb in-lb Nm Size & Remarks Cylinder head nuts 9.2 110 12 ¼” x 20 Engine oil drain 3 36 4 8 x 1.25 Engine oil fill 2 24 2.7 14 x 1.0 Spark Plug (SP) (SP) (SP) 14 x 1.25 Crank case half 5 60 6.8 6 x 1.0 Crank case cover 5 60 6.8 6 x 1.0 Flywheel rotor nut 40 480 54 10 x 1.25 (G) Clutch hub 40 480 54 10 x 1.25 (G) Units of mm unless otherwise specified (G) denotes the use of wicking / bearing retainer (green) thread locking agent to applied to the mating surfaces of the two components but not the threads. (SP) To apply the proper torque to the spark plug when inserting, one must first screw the spark plug in until the metal gasket ring causes resistance and then turn another 1/8 to ¼ turn.

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HARLEY DAVIDSON SCREAMIN' EAGLE XL1200S RACE IGNITION SYSTEM Installation MANUAL

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Filed Under (Harley Davidson) by admin on 26-12-2010

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Disconnect battery, negative cable first. 2. See Figure 1. Remove seat and locate ignition module. 3. Remove the two nuts that hold the ignition module in place. 4. Unplug the two module connectors and remove module. 5. Plug in new module and secure module in place with nuts removed in step 3. Tighten nuts to 15-21 in-lbs (1.7-2.4 Nm). 6. Disconnect spark plug cables from coil towers, noting their positions for reinstallation on new coil. ® Kit Numbers 32737-98, 32738-98, 32739-98 Figure 1. Ignition Module i01020 1 of 2 NOTE The spark plug cables have numbers printed on them that correspond to numbers adjacent to the coil towers on the coil. 7. See Figure 2. Making note of wiring positions, disconnect primary wire plug from back of coil by gently prying up latch and pulling connector rearward. 8. Remove mounting bolt and remove existing ignition coil. 9. Install new coil with mounting bolt removed in previous step. Tighten bolt to 2-6 ft-lbs (3-8 Nm). 10. Plug in primary wire connector into back of coil. 11. Connect spark plug cables to new ignition coil. 1 WARNING Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 12. Reconnect battery cables, positive cable first. 13. Check engine timing according to procedures in applicable XLH Service Manual.

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BMW PISTONS AND RINGS INSTALLATION INSTRUCTIONS

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

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1. Always clean the grooves before installing rings. Carbon build-up in the groove will lead to ring “bottoming” and can result in engine seizure. 2. Check the fit of rings in the groove. A maximum of .003″ side clearance is allowable. 3. Check the cylinders for taper and out-of-roundness. Any taper of out-of-roundness will have an adverse effect on the performance of an engine. Excessive piston clearance will detract from maximum performance as well. 4. Allow ample ring gap. There is far more danger of ring butting than of an appreciable compression loss through the ring gap. Gaps, if staggered, do not cause any measurable reduction of compression. Compression rings should be fitted with a minimum of .004″ end gap per inch of cylinder deglazing. 5. Always deglaze cylinder walls before installing new rings. A 400 grit stone is recommended for deglazing. 6. All parts should be spotlessly clean before installation. Dirt in any form is the worst enemy of a hi- performance engine. You may wash all parts in hot, soapy water. Ring Gap Installation 1. Do not gap oil control rings. Start with the oil control expander. Expander Ring ends butt together. Do not overlap them. 2. Install oil control rings. Set gap 90 from where expander ring butts together. Gap top oil control ring 180 from lower oil control ring gap. 3. Install 2nd and top ring also with marks up. Stagger gaps

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