stator for x1r 135 cc

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Kawasaki KX 80 1992-ON, KX100 IGNITION STATOR Installation instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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Take the ignition cover off. Take note of the wire colors of the original stator wires and disconnect them from the wiring loom. Remove the flywheel using a proper puller tool. Remove the baseplate with the original stator. Remove the screws that secure the coil and take the coil off. Cut the original wires close to the original coil. Take a good look at how the wires are connected to the coil. (at which side of the original coil which wire color goes). Connections: Connect the wire colors accord- ing to the drawing. RED and BLACK/RED Connect the old wires up to the new coil. Put the wires in exactly the same place as on the original. Make sure you have good connections here. Use a soldering iron and rosin core solder (the type used in electrical applications). Mount the coil onto the baseplate, fit the screws using locking compound on the threads and TIGHTEN THE SCREWS SECURELY! Refit the stator baseplate. Ensure the wires CANNOT TOUCH THE FLYWHEEL! (especially on the inside of the flywheel) Refit the flywheel. Tighten the bolt to specified torque

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HARLEY DAVIDSON DYNA STATOR AND ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. 2. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. 3. Remove primary chaincase according to the instructions in the Service Manual. 4. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. 5. Remove the two T-27 TORX screws (2). 6. Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. 7. Disassemble connector [46B] (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. 8. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. 9. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole. 2. See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. 3. Insert wires into connector [46B] (A). 4. Mate connector [46]. See VOLTAGE REGULATOR in Service Manual. is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). 6. Install the rotor (1) on the sprocket shaft. 7. Apply Loctite Threadlocker 262 (red) to sprocket nut threads. Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). 8. Install primary chaincase according to the instructions in the Service Manual. 9. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. 10. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual

Pulsar XR 650R ELECTRIC-START KIT INSTALLATION INSTRUCTIONS

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Filed Under (Pulsar) by admin on 27-10-2010

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1. Remove the seat, fuel tank, side panels, muffler, and headers. 2. Disconnect the stator wires from their corresponding mates underneath the seat (trace the wires up from the left side case.) Un-route the stator wiring so it hangs free from the left side case. 3. Remove the stock shift lever and the left side engine case cover. You do not need to drain the oil from the engine. 4. Unbolt and remove the stator and wiring from the stock cover. Do not cut any wires. 5. The stock pulsar coil (small black box hanging from the stator) will have to be modified slightly to clear the ring gear before installation into the new cover. Remove (file or grind) about .030 inches of material from the base of the pulsar coil so that the base is flush with the face of the rest of the coil as shown in Photos 1 and 2. File Here Photo 2 Make flush with this surface Remove material here Photo 1 6. Install the stator and modified pulsar coil into the new engine case cover as shown in Photo 3. Use the three provided Phillips head bolts, split lock-washers, and plastic cable clamps to secure the wiring as shown. You will need to pull about ½” of extra wire through the grommet (Photo 4) to give you enough wire length for the grommet to sit in its case cutout. To do this, remove the electrical tape from the end of the stator wires and pull each wire individually through the grommet. Neither of the stock metal wire guides will be used when reinstalling the stator into the new case (Photo 5). 5/16″ cable clamps 1/8″ cable clamp Photo 3 Photo 5 Not Used Pull extra wire through grommet Photo 4 7. Remove the stock flywheel nut (An air impact tool works best to remove this nut without turning the motor). Remove the flywheel using the flywheel puller provided. 8. Locate the T and F marks on the stock flywheel (Photo 6). The T mark is used to adjust valve clearances and its location needs to be transferred to the ring gear. Scribe a line in the edge of the flywheel in line with the T mark as shown in Photo 7

HONDA CR 500R/ 500AF Hi Power Digital Ignition AND Light Coil Installation Instructions

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Filed Under (Honda) by admin on 16-12-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI. 6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator.
10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 kg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012″. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012″. Use a good/no good technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap. 15. If the pulser gap needs to be adjusted loosen the pulser mounting bolts adjust the pulser up or down as needed

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CR500R/ 500 AF Hi Power Digital Ignition & Light Coil Installation Instructions

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Filed Under (Honda) by admin on 19-11-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI.b6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator. 10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on
the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 bkg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012”. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012”. Use a good/no good
technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap

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XR 600 Dual Sport Kit Installation Manual

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Filed Under (Pulsar) by admin on 27-10-2010

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1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the side panels, seat, and gas tank. 3. Unplug the headlight and taillight from the stock wiring and remove. 4. Locate the AC voltage regulator mounted on the left side of the frame backbone, (Fig.1) unplug from wiring harness, and remove the regulator. This regulator is located above the air box on ’87 and earlier XR 600′s and 500′s. AC Regulator (Remove) Pulsar Coil Alternator (Stator) Wiring Alternator (Stator) Contains both exciter coil and lighting coils Figure 1: If you are colorblind or even think you might be a little color blind, now is the time to get someone to assist you. Successful installation of the kit requires good color recognition. You want to go riding this weekend, don’t you? 5. A three wire group consisting of a black/red wire, a green wire, and a white/yellow wire (may appear light gray/yellow) are the output leads from the stator. 1990 and earlier models only have two wires coming up from the alternator, a black/red wire and a blue wire. On 1991 – 1999 XR 600′s, unplug the green wire and the white/yellow wire. (This should have already been done 3 when you removed the voltage regulator in Step 4.) On 1990 and earlier XR 600′s see the Stator Modification Instructions enclosed. 6. Temporarily disconnect the black/red wire and remove the rubber boot that shields the wire bundle. Reconnect the black/red wire making sure that it plugs in tightly, as this lead is responsible for powering the bike’s ignition. 7. Voltage Regulator Installation: The voltage regulator/rectifier mounts to the top right rear corner of the air box (Photo 1). Use the template provided to determine the location at which to drill the two 1/4 inch mounting holes in the air box lid. The outside edge of the regulator should be nearly flush with the outside edge of the air box when mounted properly.

URAL Classic Motorcycles SPECIFICATIONS And Owner's Manual

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

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Maximum speed of motorcycle 108 km/h 65mph 119 km/h 70 mph Reference fuel consumption at 85% of 12.5 km/L 29 mpg 14 km/L 32.5 mpg maximum speed Dry mass of motorcycle 700 lb 680 lb. Maximum load-carrying capacity 500 lb. / 485 lb. 400 lb. Noise level below 80db OVERALL DIMENSIONS Length 2500 mm / 8 ft Width 1700 mm / 5 ft 6 in Height 1100 mm / 3 ft 6 in Road Clearance 125 mm / 5 in Seat height 840 mm / 33 in Wheel base 1470 mm / 58 in ENGINE Type 4 stroke, overhead valves, opposed twin-cylinder Displacement 649 cc Cylinder bore 78 mm Piston stroke 68 mm Compression ratio 9.1:1 Rated horsepower 25.8 KW / 35 Hp Rated rotational speed 5600 RPM Rated torque, Nm 45 Nm / 33.2 ft.-lbs. Lubrication system Dual system of forced lubrication and by splashing Lubricant SAE 20W/50 CARBURETOR Carburetor type 32 CVK Keihin Number of carburetors 2 Air cleaner K & N Air filter Fuel 91 octane premium unleaded gasoline PCV Valve Internal Breather
12 ELECTRICAL Ignition system (CDI) Ignition coil 135.AC.B Spark plugs NGK BP7HVX / or equivalent Ignition timing Automatic spark timer Alternator 35 amp / 12 Volt Battery Interstate #YTX20L-BS or equivalent Headlight Sylvania Halogen 6024, 7″ round sealed beam TRANSMISSION Clutch Dry double-disk clutch Gearbox 4 speed gearbox with reverse gear lever GEAR RATIOS I gear 3.6 II gear 2.28 III gear 1.7 IV gear 1.3 Reverse gear 4.2 Speedometer drive ratio 0.4 Deco & BC-65 0.5 Final drive ratio 4.62 FLUID CAPACITIES Tourist, Bavarian Patrol & Deco Fuel tank 5 Gal / 19L 5 Gal / 19L Reserve .5 Gal / 2L .5 Gal / 2L Engine 76 oz / 2.25L 76oz / 2.25 L Transmission 34 oz / 1 L 34oz / 1 L Final drive 3.5 oz / 105 ml 4.5 oz / 135 ml Telescopic Forks N/A on Tourist N/A on Patrol (LC-75 & Deco) 135ml / 4.5 oz Shock Absorbers 105 ml / 3.5 oz 105ml / 3.5 oz

Ural electronic ignition installation Instruction

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

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Section 4: Installation on Motorcycle 4.1 Remove old system. 4.2 Install the ignition coil (135.3705.000) and ignition module base (135.3734.000) with wires positioned toward coil (lightly tighten ignition base screws) . 4.3 Install rotor on the camshaft; note washer positions (see installation figure for specifics) . 4.4 – Position engine at timing position (mark on Dnepr flywheel “P” or see your motorcycle operation manual for specifics however there is mention of “arrow with dot” – Ural? ) . – Position base so the scribed line on the rotor lines up with the center index on the base (index between +10 and -10 marks) . Tighten screws. – Loosen sensor screws and using a feeler gauge, adjust so the rotor and sensor gap equals 0.35 +/- 0.05 mm (note, other manuals mention 0.2 +/- 0.1 mm) . Tighten screws. – If the scribed line is not visible with the engine positioned for timing, rotate the engine 360 degrees (again at the timing position) . 4.5 Connect the wires (КЗ) and (+) from ignition module to the coil. Connect the high voltage leads to the coil. Connect the 12V lead from the switched 12V source to the coil (see installation figures for specifics) . 4.6 Gap sparkplugs 0.8 – 1.0 mm. 4.7 Test ride motorcycle and adjust if necessary; turn ignition module base CW to advance or CCW to retard timing

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2003 URAL Retro Solo Owner's And Repair Manual

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

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SPECIFICATIONS GENERAL Retro Maximum speed of motorcycle 120 km/h 74 mph Reference fuel consumption at 85% of 14 km/L 33 mpg Dry mass of motorcycle 680 lb. Maximum load-carrying capacity 400 lb. Noise level below 80db OVERALL DIMENSIONS Length 2500 mm / 8 ft Width 1700 mm / 5 ft 6 in Height 1100 mm / 3 ft 6 in Road Clearance 125 mm / 5 in Seat height 840 mm / 33 in Wheel base 1470 mm / 58 in ENGINE Type 4 stroke, overhead valves, opposed twin-cylinder Displacement 745 cc Cylinder bore 78 mm Piston stroke 78 mm Compression ratio 9.0 :1 Rated horsepower 33 KW / 44.2 BHp Rated rotational speed 5600 RPM Rated torque 36 ft.-lbs @ 3750 RPM Lubrication system Dual system of forced lubrication and splashing Lubricant SAE 20W/50 CARBURETOR Carburetor type 32 CVK Keihin Number of carburetors 2 Air cleaner Paper Filter Element Lifetime JR Fuel 91 octane premium unleaded gasoline PCV Valve Internal Breather8 ELECTRICAL Ignition system 135.3734.COM-2 (CDI) Ignition coil 135.3705-2 Spark plugs NGK BP7H Ignition timing Automatic spark timer Alternator 35 amp / 12 Volt Battery Interstate #YB18L-A or equivalent Headlight Sylvania Halogen 6024, 7″ round sealed beam TRANSMISSION Clutch Dry double-disk clutch Gearbox 4 speed gearbox with reverse gear lever GEAR RATIOS I gear 3.6 II gear 2.28 III gear 1.56 IV gear 1.19 Reverse gear 4.36

URAL 2004 Model Retro Solo SPECIFICATIONS And Owner's Manual

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

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SPECIFICATIONS GENERAL Retro Maximum speed of motorcycle 120 km/h 74 mph Reference fuel consumption at 85% of 14 km/L 33 mpg Dry mass of motorcycle 680 lb. Maximum load-carrying capacity 400 lb. Noise level below 80db OVERALL DIMENSIONS Length 2500 mm / 8 ft Width 1700 mm / 5 ft 6 in Height 1100 mm / 3 ft 6 in Road Clearance 125 mm / 5 in Seat height 840 mm / 33 in Wheel base 1470 mm / 58 in ENGINE Type 4 stroke, overhead valves, opposed twin-cylinder Displacement 745 cc Cylinder bore 78 mm Piston stroke 78 mm Compression ratio 9.0 :1 Rated horsepower 33 KW / 44.2 BHp Rated rotational speed 5600 RPM Rated torque 36 ft.-lbs @ 3750 RPM Lubrication system Dual system of forced lubrication and splashing Lubricant SAE 20W/50 CARBURETOR Carburetor type 32 CVK Keihin Number of carburetors 2 Air cleaner Paper Filter Element Lifetime JR Fuel 91 octane premium unleaded gasoline PCV Valve Internal Breather 8 ELECTRICAL Ignition system 135.3734.COM-2 (CDI) Ignition coil 135.3705-2 Spark plugs NGK BP7H Ignition timing Automatic spark timer Alternator 35 amp / 12 Volt Battery Interstate #YB18L-A or equivalent Headlight Sylvania Halogen 6024, 7″ round sealed beam TRANSMISSION Clutch Dry double-disk clutch Gearbox 4 speed gearbox with reverse gear lever GEAR RATIOS I gear 3.6 II gear 2.28 III gear 1.56 IV gear 1.19 Reverse gear 4.36 Speedometer drive ratio 0.4 Final drive ratio 3.86 FLUID CAPACITIES Fuel tank 5 Gal / 19L Reserve .5 Gal / 2L Engine 68 oz / 2L Transmission 30.6 oz / .9 L Final drive 3.74 oz / 110 ml Shock Absorbers 3.5 oz / 105 ml RUNNING GEAR FrameTubular welded Rear wheel suspension Swing arms with spring shock absorbers Front fork Telescopic Brakes Hydraulic Disk on front, Hydraulic Drum on rear Tires 110 / 90 – 18″ Front 22 psi cold (1.5 Bar / 150 kPa) Front 22 psi cold Rear 36 psi cold (2.5 Bar / 250 kPa) Rear 36 psi cold

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