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Harley Davidson Big Twin EVO Engines Edelbrock Performer-Plus Camshaft , Performer RPM Camshaft , & Performer RPM Camshaft INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-03-2012

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Disconnect the battery. Secure the motorcycle on a suitable stand with the rear wheel off the ground. Remove components necessary for easy access to rocker covers, pushrod covers, and gear case cover, i.e., exhaust system, gas tank, air cleaner, foot rest, etc. Remove spark plugs. 2. Remove top and middle sections of rocker boxes, then rotate engine so both valves are closed on the cylinder head being worked on (put transmission in high gear and move rear wheel to slowly rotate engine). Remove the two 5/16″ bolts nearest the rocker arm shafts (keep all shafts, rocker arms, and pushrods in order so they can be installed in their original position). Remove the pushrod covers and pushrods. NOTE: The use of adjustable time-saver pushrods will simplify installation. Follow the manufacturer’s recommendations for installation of those parts. 3. It is not necessary to remove the tappet guides if you use a cam installation tool such as Crane #9-0020 to hold the tappets in place during cam installation. If you remove the tappet guides, you must use a tappet block alignment tool such as Crane #9- 0021 to re-install the tappet guides. Tappets can be held up in place during removal of guides by using U-shaped piece of safety wire or paper clip hooked to the tappets. 4. Remove ignition covers on gearcase cover by drilling out rivets to gain access to sensor plate. Remove the inner cover, sensor plate and rotor. NOTE: For re-installation, use new rivets H-D #8699 or drill and tap for 10-32 screws. 5. Remove the gearcase cover screws and remove cover while holding end of cam inward. Now remove the camshaft, spacing washer and thrust plate

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Honda XR600/ XR650L Camshaft Installation and removal Instructions

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Filed Under (Honda) by admin on 05-12-2011

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Remove the tappet covers. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise direction. Position the engine at true top dead center (TDC) using the mark on the flywheel. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Since the rocker arms are located in the valve cover on an XR600, true TDC occurs when the cam lobes are pointed downward when the piston is at TDC. Remove the cylinder head cover. Warning, do not drop the locating dowels into the cam chain cavity. There are two dowels, one on either side of the cover. Remove and discard the gasket. Note the positioning of the cam lobes, this will help during installation of your new Hot Cams camshaft. Note also the location of the sealed bearing on the end of the camshaft and the direction in which it is facing. Loosen the bolts that hold the camshaft sprocket. Remove the lower camshaft sprocket bolt first, it will be necessary to rotate the engine. Rotate the engine back to TDC. Release the spring tension on the cam chain tensioner by lifting the end of the spring out of its hole in the tensioner block. A spring tool is a good method. Be careful not to scar the cylinder head’s gasket surface for the cylinder head cover. Remove the allen bolt that holds the end of the tensioner block shaft
just to the inside of the tensioner block. Note the location of the tensioner block shaft cap ridge. Using a pair of pliers pull the shaft out by grasping the ridge and using a clockwise rotation of the shaft while pulling outward. Pull the tensioner block upwards, out of the cylinder head. Remove the top camshaft sprocket bolt. Pull the sprocket off the camshaft but maintain upward tension, do not allow the chain to sag, it is possible for the chain to “slip” on the bottom sprocket of the crankshaft and change the cam timing. Remove the camshaft. Remove the cam bearings. Set the stock camshaft with the auto-decompression aside. It is not possible to use the auto-
decompression on the Hot Cams so do not attempt to re-install. Use a manual decompression. Install the bearings onto the new Hot Cam

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Kawasaki KVF650/ 700, KSV 700 Camshaft Installation Instructions

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Filed Under (Kawasaki) by admin on 29-04-2012

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Liberally apply assembly lube to every surface of the camshaft. Install the camshaft into the cylinder head (the lobes should be pointed down) and align the decompressor shaft dowels with the weight arms. Install one of the camshaft sprocket holder bolts and tighten to less than finger tight, you should be able to move the camshaft very slightly back and forth, roll the crank over until the other bolt hole is exposed and insert the sprocket bolt and tighten to less than finger tight. Install the cam chain tensioner assembly, do not install the spring, spring dowel, washer, and bolt. Using the spring from the cam chain tensioner very slowly push the tensioner shaft in until the cam chain slack has just been taken out, this is witnessed by the very slight lifting of the opposite end of the cam out of the cylinder head cam journal, do not over tighten the cam chain at this point, if you do, remove the tensioner assembly and retract the plunger again and start over. (If it stays too tight it will stretch the cam chain prematurely and cause cam sprocket damage when the engine is assembled) Roll the camshaft toward the back of the machine (clockwise) loading the sprocket bolts against the back of the sprocket bolt holes, while holding the camshaft in that direction, tighten the sprocket mounting bolt to 14 ft/lb of torque. Rotate the engine in the opposite direction that you rotated it earlier and align the TDC mark, tighten the other sprocket-mounting bolt to 14 ft/lb of torque. Verify the cam timing and crankshaft TDC marks are in alignment

2008 FLT Police Models Service Manual Supplement

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

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ITEM SERVICED 14-21 ft-lbs (19.0-28.5 Nm) Drain plug torque Engine oil and filter 4 qt. (3.8 L) Oil capacity Hand tighten 1/2-3/4 turn after gasket contact Filter 63798-99A Chrome filter part number 63731-99A Black filter part number FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity Primary chain lubricant Wet: 38 oz. (1124 ml) Dry: 45 oz. (1331 ml) 14-21 ft-lbs (19.0-28.5 Nm) Primary chaincase drain plug torque 1/2-1 turn Adjuster screw free play Clutch adjustment 72-120 in-lbs (8.1-13.6 Nm) Adjuster screw locknut torque 1/16-1/8 in. (1.6-3.2 mm) Free play at hand lever 84-108 in-lbs (9.5-12.2 Nm) Clutch inspection cover torque Dipstick at FULL with motorcycle on jiffy stand and filler plug resting on threads. Lubricant level Transmission lubricant FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity 32 oz (0.95 liters) 14-21 ft-lbs (19.0-28.5 Nm) Transmission drain plug torque 25-75 in-lbs (2.8-8.5 Nm) Transmission filler plug/dipstick torque Front: 36 psi (248 kPA) Pressure: solo rider Tire pressure and wear Rear: 36-40 psi (248-276 kPA) Replace if less than 1/32 in. (0.8 mm) of tread pattern Wear 55 in-lbs (6.2 Nm) minimum Spoke nipple torque Wheel spokes 99953-99A (12 oz.) D.O.T. 4 hydraulic brake fluid part number Brake fluid level Front: 0.20 in. (5.0 mm) Fluid level (from top of master cylinder reservoir) Rear: 0.26 in. (6.5 mm) Front: 7-10 in-lbs (0.8-1.1 Nm) Master cylinder reservoir cover screw torque Rear: 12-15 in-lbs (1.4-1.7 Nm) 0.016 in. (0.4 mm) Minimum brake pad thickness Brake pads and discs 75-102 in-lbs (8.5.-11.5 Nm) Brake caliper pad pin torque Front: 0.18 in. (4.5 mm) Minimum brake disc thickness Rear: 0.25 in. (6.3 mm) 0.008 in. (0.2 mm) Maximum brake disc lateral runout (warpage) 10 lb. (4.5 kg) Upward force applied at midpoint of bottom belt strand Drive belt deflection 3/8-7/16 in. (9.5-11.1 mm) FLHTP 1/4-5/16 in. (6.4-7.9 mm) FLHP/FLHPE 40-60 in-lbs (4.5-6.8 Nm) Air cleaner cover bracket screw torque Air cleaner 36-60 in-lbs (4.1-6.8 Nm) Air cleaner cover screw torque LOCTITE MEDIUM STRENGTH THREADLOCKER 243 (BLUE) Air cleaner cover screw Threadlocker Part No. 99642-97 (6 ml) LUBIT-8 SUPER OIL, Part No. 94968-85TV (1/4 fl. oz.) Lubricant part number Clutch cable 35-45 in-lbs (4.0-5.1 Nm) Handlebar switch housing screw torque

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2009 Daytona 675 Motorcycle Race Kit Manual

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Filed Under (Triumph) by admin on 29-10-2010

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1. Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual. 2. Position a piece of solder (with a diameter approximately 1.3 mm) on the four squish surfaces of each piston. Position the solder in line with the corresponding squish surfaces on the cylinder head and hold in place with a small amount of grease. 3. Refit the cylinder head with the head gasket. 4. Slowly turn the engine over, by hand, to compress the solder to the same height as the squish clearance. 5. Remove the cylinder head and head gasket. 6. Measure the compressed thickness of the solder. The squish clearance must be a minimum of 0.65 mm. If the thickness of the solder is less than 0.65 mm repeat steps 2 to 6 with a thicker head gasket until the squish clearance is at an acceptable level. NOTE •In some cases, it may be necessary to use a standard cylinder head gasket to achieve the correct squish clearance. 7. Fit the chosen cylinder head gasket following the procedures detailed in the Daytona 675 service manual. Warning Running the engine at less than the minimum recommended squish height can lead to the pistons contacting the cylinder head, causing major engine damage. This could cause loss of motorcycle control and an accident. Triumph Designs Ltd 2009. Camshaft, Valve Spring & Camshaft Sprocket Kits Parts Supplied Camshaft, Inlet – A9618055 Camshaft, Exhaust – A9618056 Valve Spring Kit – A9618086 Camshaft Sprocket Kit – A9618095 Warning The Race Kit camshaft, valve Spring and camshaft sprockets must be fitted as a complete set. If they are not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident. Caution The use of The Race Kit camshaft, valve Spring and camshaft sprockets detailed below will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required. Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage.

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Yamaha YZ 250F Camshafts REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 30-12-2011

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Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that hold the intake camshaft cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust cam out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft. Fit the half moon shaped retainers in the grooves of the Hot Cams camshaft bearings to ensure good fit, set retainers aside for the time. Using assembly lube, lube the shim buckets, bearing surfaces for the camshafts in the cylinder head, and pack some in the camshaft bearings. Set the exhaust cam into the cylinder head casting while at the same time fitting the cam chain over the sprocket. Make sure that you keep all the cam chain slack to the back of the engine. The cam chain pulls the camshaft sprockets in a counter clockwise direction and the slack of the chain must be kept on the cam chain tensioner side of the engine. The exhaust cam has two timing marks on it. When correctly installed one mark will be at the 9 o’clock position and the other mark will be at the 12 o’clock position. When correctly timed the mark at 9 o’clock will be aligned with the valve cover gasket surface. Repeat the above process for the intake camshaft. Again, make sure you keep the chain slack to the cam chain tensioner side of the engine. Check to be sure the crankshaft is still at TDC. The intake cam has two timing marks also. One at 12 o’clock and the other at 3 o’clock. When both cams are installed correctly, the valve cover gasket surface will form a straight line through the exhaust timing mark at 9 o’clock and the intake timing mark at 3 o’clock

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HARLEY DAVIDSON XLH 1200cc BIG BORE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Boring and Honing Procedures 1. Check again for burrs on cylinder gasket surfaces and remove burrs before performing Step 2. 2. Install original head and base gaskets, CYLINDER TORQUE PLATES (Part Number 33446-A) and TORQUE BOLTS (Part Number 33446-4). Tighten TORQUE BOLTS following tightening procedure given in the INSTALLATION, CYLINDER HEAD procedure in the ENGINE section of the Service Manual. NOTE Torque plates, properly tightened and installed with gaskets, simulate engine operating conditions. Measurements will vary as much as 0.001 inch without torque plate. 3. The cylinder must be bored with gaskets and torque plates attached. Bore the cylinder to 0.003 inch under the desired finish size. 1 WARNING CAUTION CAUTION 1 WARNING Kit Number 4. Hone the cylinder to its finished size (See Figure 1) using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Honing must be done with torque plates attached. All honing must be done from the bottom (crankcase) end of the cylinder. Work for a 60 degree crosshatch pattern. 5. See Figure 1. After machining and honing, chamfer the bottom edge of the cylinder liner. the chamfer provides a beveled surface for easier installation of the cylinder over the piston rings. Break leading edge of liner to a flat surface. The bottom edge of the liner will be somewhat sharp after machining. This sharp edge could easily be damaged during installation of the cylinder. Piston Installation The 1200cc pistons have an arrow on the top of the piston. This arrow must face the front of the engine when piston is installed. There is no front cylinder piston or rear cylinder piston. New pistons can be installed in either cylinder. Check piston rings for proper side clearance and end gap (See XLH Service Manual). Be sure end gaps of adjacent rings are installed 90 degrees apart. Assembly Follow assembly and torque specifications given in the ENGINE section of the applicable Service Manual. Replace original gaskets, O-rings and seals with new components furnished in kit. NOTE Push rod covers on 1991 and later models are one-piece and the correct O-rings are as follows: Bottom – Part Number 17944-89 Upper – Part Number 11190 Engine Break In For the first 500 miles, to wear-in critical parts, observe these few simple driving rules: During the first 50 miles, keep the engine speed below 2500 RPM in any gear. Up to 500 miles, vary the engine speed, avoiding any steady speed for long distances. Engine speed up to 3000 RPM is permissible in any gear. Avoid fast starts at wide open throttle. Drive slowly until engine warms up. Avoid running the engine at extremely low RPM in higher gears. 2 of 3 -J00001 1200cc CYLINDER FINAL BORE SIZE AFTER HONING STANDARD BORE DIAMETER 3.4980 inch + 0.0002 inch Figure 1. Bottom Edge of Cylinder Liner Chamfer i04852 Break Edge to Flat Surface

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YAMAHA YZF-R1P YZF-R1PC ASSEMBLY MANUAL

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

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PREPARATION To assemble the motorcycle correctly, supplies and working space are required. Supplies oils, greases, shop rags. Workshop The workshop where the motorcycle is assembled should be clean and large. The floor should be level. Self-protection Protect your eyes with suitable safety spectacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Product hands and feet by wearing safety gloves or doing. SYMBOLS USED ON CRATE CARTON Contents of the transport package are fragile therefore it shall be handled with care. Indicates correct upright position of the transport package. Transport package shall be kept away from rain. Insertion of the lift arm from this side is prohibited. Lift arm inserting position. -1- UNPACKING 1. Remove the frame cover 1. NOTE: To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the bolts 2 (upper bracket). 3. Remove the bolt 3 (front tire). 4. Remove the packing frames 4 (upward and sideways). NOTE: Remove the bolts while holding frame. NOTE: Before starting the assembly, check for damaged or missing parts. The parts are contained in the cartan and the motorcycle for damage, scratches and other defects. -2- PARTS LOCATION 1 Carton box -3- 1 Carton box Screw, washer and special nuts (windscreen) Bolt (front master cylinder) Bolt (handle crown and handlebar) Nut (rear view mirror) Nut (front reflector) Front reflector Vinyl bag 1 Plugs (handle crown) Owner’s manual Rear view mirrors Windscreen – -5- 1. Handlebar 1 2 3 4 5 6 1 1 1 1 2 1 Reservoir tank (brake) Hexagon socket bolt Crown nut Hexagon socket bolt Cap Hexagon socket bolt * V * V V * d = 6 (0.24), r= 12 (0.47) d = 6 (0.24), r= 25 (0.98) d = 8 (0.31), r= 30 (1.18) 2. Front reflector A: Tighten the crown nut to specified torque. Tightening torque: 115 Nm (11.5 m • kg, 85.0 ft • lb) B: Tighten the bolt to specified torque. Tightening torque: 13 Nm (1.3 m • kg, 9.4 ft • lb) C: Tighten the bolt to specified torque. Tightening torque: 13 Nm (1.3 m • kg, 4.4 ft • lb) A: Tighten the screws to specified torque. Tightening torque: 40 Nm (4.0 m • kg, 29 ft • lb) 1 2 3 4 5 2 2 2 4 4 Reflector bracket Reflector Nut Washer Caliper bolt * V V * * d = 5 (0.20) d = 10 (0.39) d = 10 (0.39), r= 30 (1.18) 3. Clutch cable 1 Clutch cable 1 * A: Check the clutch lever for smooth action. CAUTION: Proper cable routing is essential to assure safe motorcycle operation. Refer to “CABLE ROUTING

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Honda CRF/ TRX 450R Camshaft Installation

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

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Break-in of this camshaft is important and you should adhere to all of the following instructions. It is also very important to use plenty of engine assembly lubricant, recommended is Coastal Engine Assembly Lube or Clevite 77, both are available from most automotive supply companies. We recommend you change the engine oil before the initial start-up of the engine after the assembly. Then change the oil again after the break-in of the cams to remove the excess
phosphate from the coated cams. These steps will help ensure that the camshaft breaks-in properly and that you have a long lasting product. Using full synthetic engine oil during break-in is not recommended but, is OK to use after the one-hour break-in period is over. Following a regular maintenance schedule is the best way to ensure durability and performance over the long run. Cleanliness is always a good place to start. Make sure the motorcycle is cleaned thoroughly before you start. It would be advisable to use an engine degreaser on the frame and the engine. Remove the fuel tank and thoroughly clean the inside of the frame rails, around the carburetor, and behind the radiators. Be sure to remove the ignition coil assembly and using high-pressure air, clean the spark plug hole out before the plug is removed. This will ensure a clean engine during the assembly process and less of a chance of thread damage and/or dirt contamination in the engine during reassembly

Yamaha YZ250F 2001-2080 Wiseco High Performance Camshaft INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 15-01-2012

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Wiseco’s new Camshafts are made from premium materials, state-of-the-art forgings, machined to exact tolerances, and specifically engineered for high performance and maximum durability. Brought to you by one of the most trusted names in the industry… Wiseco. Wiseco Cam- blue OEM Cam- red Wiseco’s new high-performance camshafts for the Yamaha YZ250F produce 3% horsepower and 3% torque gain over the stock OEM camshaft across the entire RPM range.

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