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HARLEY DAVIDSON TOURING LAYBACK LICENSE PLATE MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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This kit fits all 1999 and later FLHR (Road King®) models, FLTR (Road Glide®) and FLHT (Electra Glide® standard) models having license plates measuring a maximum of 7-1/4 x 4-1/4 inches (184 x 108 mm). Also fits 2003 FLHRSEI2 (Screamin’ Eagle® Road King). Does not fit with Detachable Tour-Pak Rack, part number 53276-04. Does not fit 2002 FLHRSEI (Screamin’ Eagle Road King). Kit Contents See Figure 1. INSTALLATION 1. Remove the license plate from the vehicle (if installed). Remove the two hex head bolts holding the original equipment (O.E.) license-plate bracket in place. The bolts and license-plate bracket can be discarded. 2. See Figure 1. Install the new layback license plate holder (1) using the button-head hex socket screws (3) from the kit. Tighten the screws to 19 ft-lbs (25.8 Nm) . 4 1 3 7 5 2 6 is02737 1. License plate holder, layback 2. Foam pad (6) 3. Screw, button head, hex socket (2) 4. License plate frame 5. Set screw, socket head (2) 6. Hex key 7. Reflector assembly, Part Number 59365-07 Figure 1. Layback License Plate Mount Components 3. Position the license plate onto the foam pads (2) of the license plate holder, centering and aligning the plate parallel to the holder edges for best appearance. NOTE Slots in the inside top edge of the license plate frame (4) fit over the two tabs on the top edge of the license plate holder. 4. Hook the top of the license plate frame over the top edge of the holder. Swing the bottom edge of the frame inward, holding the license plate in position against the pads. 5. Use the hex key (6) from the kit to securely fasten the license plate frame to the holder with the two socket head set screws (5)

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HARLEY DAVIDSON DYNA REAR STOP/ TAIL/ TURN SIGNAL RELOCATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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PREPARATION NOTE Position the motorcycle upright using a suitable lift or jack. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow instructions to remove the main fuse. 2. Follow the service manual instructions to remove the seat. 3. Raise the rear of the vehicle to allow access to the underside of the rear fender. LICENSE BRACKET AND ILLUMINATOR REMOVAL For Models WITHOUT a Center Tail Lamp NOTE See Figure 1. The reflector mounting block (2) is held to the fender (1) with double sided tape. Remove with care to avoid scratching paint. 1 3 2 5 4 6 7 is06256 1. Rear fender 2. Rear reflector and mounting block 3. Wire channel (2) 4. License plate bracket mount 5.5/16-18 screw (2) 6. License plate illuminator 7. M4 screw (2) Figure 1. Rear Fender, Models Without Center Tail Lamp 1. Remove the rear reflector and mounting block (2) from the underside of the rear fender (1). 2. Remove the license plate from the vehicle (if installed). Retain the plate and attaching hardware. NOTE Before removing rear wiring, note wire routing. -J04856 1 of 10 3. Remove the rear lamp wiring from behind the wire channels (3) on the underside of the fender. 4. Disconnect the two-way license lamp connector [93] and the four-way right [18] and left [19] stop/tail/turn (STT) lamp connectors from the STT module in the area under the seat. 5. Remove the two 5/16-18 screws (5) retaining the license plate bracket mount assembly (4) to the fender support. 6. Remove the license plate illuminator (6) from the license plate bracket mount assembly. Save the illuminator. The bracket mount (4) and four screws (5, 7) can be discarded. 7. Proceed to License Bracket and Illuminator Assembly . For Models WITH a Center Tail Lamp NOTE On these models, the license plate illuminator is part of the center tail lamp and is not removed. 1. Remove the three screws retaining the license plate bracket to the tail lamp housing. Remove the bracket and set aside for later assembly. 2. Proceed to Rear Lamp Wiring, For Models WITH a Center Tail Lamp and RED Stop/Turn Signals or AMBER Turn Signals . LICENSE BRACKET AND ILLUMINATOR ASSEMBLY For Models WITHOUT a Center Tail Lamp 1. See Figure 7. Get the new license plate bracket (3), illuminator cover (4), spacer (6) and two M4 screws (5) from the kit, and the license plate illuminator (A) removed from the original equipment (OE) license plate bracket. 2. See Figure 2. Assemble the illuminator (1), spacer (2) and cover (3) to the license plate bracket (5) in the sequence shown, and tighten the screws (4) securely. 3. Get the STT relocation weldment (6), two screws (7) and two flat washers (8) from the kit. 4. Apply a few drops of Loctite 271 – Red to the clean screw threads. Assemble the license plate bracket to the weldment as shown, and tighten the screws to 120 in-lbs (13.6 N-m) . NOTE If using a metal tool to install the black nuts, protect the finish with cloth or paper to prevent damage. 5. Loosely install the black painted nuts (9) onto the threaded studs on each side of the STT relocation weldment. 6. Remove the wires and socket terminals from the two-way license plate illuminator socket housing. Set the socket housing aside for later installation

BMW Motorcycles R 850/ R 1100 Series and K 1200 RS – New Clutch and Pressure Plate

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Filed Under (BMW) by admin on 16-11-2010

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Details: All R 850/R 1100 and K 1200 RS models produced from December 1997 have received a new clutch disc, manufactured by VALEO, and a new pressure plate (see applicable part numbers below). Earlier production for both series can be fitted with the new parts. However, due to changes in specifications (a thicker pressure plate, a thinner clutch disc), the new VALEO clutch disc is not compatible with the old pressure plate. In this application, the new clutch disc and pressure plate must be replaced as a pair. Series Production: R 850/R1100 models: Starting with December 1997 production. K 1200 RS: Starting with December 1997 production. Part Number: R 850/R1100 Models: VALEO Clutch Disc: 21 21 2 325 864 Used only in conjunction with Pressure Plate: 21 21 2 325 863 R 850/R1100 models: VALEO Clutch Disc with reduced play on gearbox input shaft (KD – Scheibe): 21 21 2 325 862 Used only in conjunction with Pressure Plate: 21 21 2 325 863 K 1200 RS: VALEO Clutch Disc: 21 21 2 332 973 Used only in conjunction with Pressure Plate: 21 21 2 332 974 Attention: For R 850/R1100 and K 1200 RS models with production dates of 12/97 and later, all clutch parts can be replaced individually, as the new pressure plate will already be installed. On earlier production examples, installing the new VALEO clutch disc without replacing the pressure plate will not allow the clutch to completely disengage.

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HI-4 DUAL FIRE MOTORCYCLE IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 09-11-2010

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Turn ignition switch off and disconnect battery ground cable. 2. Refer to Figure 3. Remove OE ignition module and wire harness (items 1-4). You will disconnect two wires at the coil (15), a wire going to the VOES (Vacuum Operated Electrical Switch) (18), a black ground wire at the ignition module, and the 3 pin plug (20) that connects to the sensor plate (11). Refer to shop manual for locations. 3. Remove ignition cover plates and gasket (items 5- 9). This will require drilling out two rivets. The rivets will later be replaced with two supplied self- threading screws. 4. In order to remove the sensor plate cable, the cable plug (20) must be removed first. Use needle nose pliers to pull the terminals out of the plug. Then pull the cable through the exit hole at the bottom of the timing cover. 5. Note location of sensor plate (11). There is a V notch in the sensor plate used for alignment. When you install the HI-4, you should align the V notch in the same location. This should set the timing close enough to start the engine. Remove and save the two standoffs and washers (10). Remove the sensor plate (11). HI-4 INSTALLATION Refer to Figure 4. The HI-4 requires use of the OE timing rotor P/N 32402-83 (used only on 1985 and newer models). If you have an older model or are not sure, check the rotor (9) for the correct part number. For models prior to 1980, use the supplied 10-32 x ¾”bolt and washer to mount the rotor. 1. Install the HI-4 system in place of the OE breaker or sensor plate. Rotate the HI-4 about 90 degrees to give better access to the cable exit hole. Install the HI-4 first, then push the cable through the hole. On some early models it may be necessary to enlarge the wire harness exit hole in the gear cover. Align the V notch on the HI-4 same as the OE plate you removed. Use the OE standoffs to secure the HI-4. You must use lockwashers under the standoffs for proper clearance between the HI-4 and cover plate. Do not fully tighten the standoffs until the timing has been set. 2. Route the HI-4 wire harness along the frame rails up to the coil. Make sure that harness will not be chafed or burned by exhaust heat. Secure harness with tie wraps. Do not install timing cover. HI-4 HOOKUP Crimp terminals and hardware are supplied for your convenience. Use the ring terminals for coil hookup. Use male-female quick disconnects for connections to the tach and vacuum switch (VOES). Tape up any unused wires. 1. Circuit Breaker Cover Screws (2) 2. Circuit Breaker Cover 3. Circuit Breaker Cover Gasket 4. Breaker Plate Screws (2) 5. Breaker Plate Screw Lockwashers & Washers (2 each) 6. Retainer (1971 to early 1972) 7. Circuit Breaker Cam Bolt 8. Breaker Plate Assembly 9. Breaker Cam 10. Advance Assembly 11. Gear Case Cover 11 10 9 8 7 6 5 4 3 2 1 NOTE: Damage will result if the brown tach wire comes in contact with +12V. Figure 1. Harley-Davidson®OE Points System
9000-4002A REV A 3 2/05 1. Identify switched +12 volt wire and tach wire (if equipped) going to the coil. Refer to your service manual, or reconnect the battery and use a test light or voltmeter. The switched +12 volt wire will be hot when the ignition key is turned on. 2. Refer to Figure 5. Connect the HI-4 red wire and switched +12 volt wire to Coil positive. 3. The HI-4 white wire is not used and should be taped. 4. Connect the HI-4 black wire to the Coil negative terminal. 5. Connect the HI-4 green wire to the vacuum switch (Figure 3, item 18), if used. 6. Connect the HI-4 brown wire to the tach wire, if equipped with tach. Tape up if unused. 7. The HI-4 is grounded via the timing housing; a separate ground connection is not required. 8. Reconnect battery ground cable. Verify proper ground connections to the frame and engine. VOES HOOKUP The OE vacuum switch (VOES) is normally an open circuit. Above 3-5 inch-Hg vacuum, the VOES closes and grounds the vacuum input on the OE ignition module. This increases the total advance generated by the OE ignition module. Vacuum advance improves part throttle 17 16 1. Cover Screws (2) 2. Ignition Timer Cover 3. Ignition Module 4. Timer Plate Screws (2) 5. Washers (2) 6. Screws & Washers (2 each) 7. Shield 8. Sensor 9. Trigger Rotor Bolt 10. Timer Plate 11. Trigger Rotor 12. Advance Assembly 13. Gear Case Cover 14. Ignition Coil 15. Spark Plug Wires (2) 16. Ignition Coil Terminal (FX) 17. Ignition Coil Terminal (FL) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 NOTE: Most motorcycle coils do not have terminals marked. Use either terminal for Coil+ (positive) and the other one for Coil- (negative). Warning: The HI-4 (8-1100) Dual Fire ignition will not work with 2 plugs per head, dual coil application. Damage will result if attempted. Use the HI-4 (8-2100) single fire ignition for 2 plugs per head applications

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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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Harley-Davidson CHAIN DRIVE INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 15-04-2012

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1) Assemble & install the chain tensioner assembly over the primary chain as shown in figure 1. 2) Install the compensator sprocket with extender & spacer (numbers 5, 6, & 7, FIG 2)(#7 is not included in this kit), primary chain, chain tensioner, and clutch basket simultaneously onto the motor drive shaft & transmission main shaft. Rotate the chain drive slightly as needed to allow the splines to line-up. 3) Install the chain tensioner nut loosely on the chain tensioner bolt. 4) Install the sliding cam onto the compensator sprocket, & slide the compensating sprocket cover-assembly (#3) over the cam. 5) Apply 2 drops of Rivera “Red” thread-lock on the threads of the motor drive shaft, & install the motor nut loosely with the fingers at this time. The hex spacer (#7) and spacer (#2) as seen in fig.2 are not provided in Rivera Engineering’s chain drive kit. These components are required with some applications, and can be purchased from your local Harley-Davidson dealer. FIG 2 6) Apply 2 drops of Rivera “red” thread-lock on the threads of the transmission main-shaft and loosely install the clutch hub nut (left hand threads). 7) Place the HD “Primary Drive Locking Tool” HD-41214 on the primary chain as shown in figure XXX and tighten the motor sprocket nut to 150-165 foot-pounds. 8)Turn the locking tool 180 degrees and move it to the clutch sprocket. Tighten the clutch hub nut to 70-80 foot pounds (left- hand thread). Adjust chain tension so that the top strand has 5/8″- to-7/8″ of up and down play (cold drive train). Tighten the center bolt nut to 21-29 foot pounds of torque.

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FXR and Softail TOP FUEL 14MM DRIVE INSTALLATION

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Filed Under (Tips and Review) by admin on 31-10-2010

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1. Install oil line fittings on back side of motor plate, cut hose to make 2 pieces, top fitting is for oil return ( oil out of filter), bottom fitting is for oil feed ( oil into filter). 2. Install motor plate with alternator cover over engine spacer and install the 2 standoffs. Be sure that the motor plate is aligned properly. Fig. 1 Fig. 2 Fig. 3 3. Install threaded oil filter mount on front side of motor plate, grease rubber gasket on oil filter and install hand tight. (Fig. 4 & 5) Install starter pinion gear supplied with kit. (See PG-100 Installation). Fig. 4 1 Fig. 5 Fig. 6 4. The pictures below refer to special bushing enclosed which is used only to install front pulley, it is a tool only and must be removed after front pulley is installed. (Fig. 7) Fig. 7 5. Refer to 3″ Electric Start Installation for FXR #5 & #6 for proper procedure for alignment. 6. For final installation remove pressure plate and clutch pack for easier handling and place belt on both pulleys and with special bushing in place,(#4 above) and install belt drive onto engine and trans shaft simultaneously. (Fig. 8) Fig. 8 7. Make sure writing on belt is facing towards you. (Fig. 9) Fig. 9 VERY IMPORTANT! APPLY RED LOCTITE TO SPLINED HUB OF REAR BASKET BEFORE FINAL INSTALLATION. (Fig. 10) 2 Fig. 10 8. Install engine shaft nut and torque to Harley specifications. An electric impact may be used.

Honda GL1000/1100 starter motor Removal/ Over haul Manual

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Filed Under (Honda) by admin on 08-04-2011

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1. Remove the three long bolts that hold the sections together and separate them. Be careful as there are a series of flat thrust washers on each end of the armature (located in the middle section). 2. The end cap basically performs no function other than to cover the brush plate and commutator area as well as center the armature shaft in a pressed in bushing located in the end of the cap. 3. The drive end contains the reduction gearing and if need be, can be disassembled to replace the bearing. This is extremely unlikely. The shaft should turn freely and normally only requires a cleaning and grease application. If the bearing in fact needs replacing, simply remove the “C” clips on either end, drive out the bearing and reinstall with an appropriate size replacement. Any decent auto parts / industrial supply should be able to supply the correct bearing. 4. Remove the brush plate from the end of the center section by removing the screw at the one brush connection. Before removing the brushes, note that one of them has an insulating sleeve over the braided wire. The replacement must go in the same brush holder. Remove the brushes and replace if necessary and clean the brush plate. ** Brake Cleaner is a good general cleaner for this entire job. 5. Remove the thrust washers from brush plate end of the armature. Count them and ensure they go back on the correct way. 6. The end of the center section that had the drive end on it has a circular plate covering it with a short splined shaft protruding through the plate. Drive the plate out by tapping the opposite end of the section on the shaft – just lightly with a rubber hammer or piece of wood to protect the shaft. Once the plate is out, remove the armature from the section. You will find more thrust washers at this end. Make sure they go back on correctly. 7. In the center of the center section there are four large Philips screws. These hold in the field coils found within the housing. Using an “impact driver”, loosen the four screws that go around the circumference of the center section and remove them. Remove the 10mm nut for the battery connection and the accompanying fiber insulating washers. With the screws and nut removed, the entire field coil assembly should withdraw entirely from the housing. There will be four (4) metal plates that the screws mounted into come falling out. They are easily replaced into the field coils when you slide it back into the housing. Do not be alarmed that you suddenly have four loose metal parts. 8. With everything out of the housing, thoroughly clean everything using the Brake Cleaner. Although the cleaner will dry without leaving a film, it is suggested that the components be dried with compressed air. 9. Get some extremely fine steel wool (“000″ of even “0000″ is better) and gently clean the metal surfaces or bars of the armature and the commutator. Blow with compressed air. 10. Using a volt/ohmeter, test for continuity between pairs of armature bars (the long ones). There should be continuity between the pairs around the entire circumference.

HARLEY-DAVIDSON 1979-Later Big Twin CONVERSION INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2012

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Turn ignition switch to the OFF position. Disconnect the ground cable from the battery. 2) Disconnect the wire at the coil which runs down to the points. Remove the point cover plate. 3) Note the position of the slots in the point plate. When the Mallory UNILITEfi plate is installed, use the position of the slots to approximate the timing. 4) Remove the wire to the points. Remove the O.E. standoffs and washers. Remove the point plate assembly. 5) Remove the O.E. cam sleeve from the advance assembly. Place a small amount of oil on the advance shaft which supported the cam sleeve. 6) Slide the Mallory shutter wheel onto the advance shaft. Make sure the shutter wheel is all the way down into the advance assembly (it will only go one way due to the roll pin in the advance assembly). 7) Install the advance and shutter wheel into the nose cone. Make sure that the pin on the bottom of the advance engages the slot on the end of the camshaft. Apply Loctite to the threads and install the advance bolt. Torque to 25 in.lb. 8) Rotate the shutter wheel by hand (counter-clockwise) and release. It should rotate about 10 degrees and “snap” back when released. 9) Install the two Mallory standoffs. Place Loctite on the threads and torque to 16 in.lb. Do not use any washers with the standoffs. 10) Start the three wires of the Mallory UNILITEfi Module through the hole in the nose cone housing. (The module goes in towards the advance assembly with the flat plate outward). Pull on the three wires to remove any slack and prevent the wires from rubbing on the shutter wheel. 11) Rotate the UNILITEfi plate assembly until the slots in the plate are in the same position as the point plate was. This should make the timing close enough to start the engine. Slide the two Mallory 8-32 sleeve nuts (supplied) through the UNILITEfi plate and onto the male threads of the Mallory standoffs. Tighten the sleeve nuts just enough to prevent the plate from moving. 14) Route the wires from the UNILITEfi Module to the ignition coil, carefully avoiding the exhaust system. Connect the red wire to the positive (+) terminal (12 volts) on the coil. Connect the green wire to the negative (ñ) terminal on the coil (where the point wire was connected). Connect the brown wire to ground. The best place for the brown wire is the negative (ñ) post on the battery, however, any part of the frame or engine which is grounded to the battery will work

DUCATI EVOLUZIONE SLIPPER CLUTCH KIT INSTALLATION INSTRUCTIONS

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

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If installing with Ducati OEM basket you need the washer cod. 0D1SR140C220045 (3mm). – If installing with STM basket (Z12 o Z48) you need the washer cod. 001MG019 (1,5mm). – Insert the correct washer on the gear shaft. – Perform the initial hub group assembly: position the progressive engagement steel plate (003MG015) on the hub (0F3SR140J24001C) , with the step facing up. Be careful to position it correctly into the specific seats, then check that pushing one side, the opposite stand up simultaneously. – Now put the 6 steel balls (001MG025) at the bottom of the grooves using a little bit of grease. Then fix the clutch drum (0F3SR140J24002C) on the clutch hub (0F3SR140J24001C) at rest position, using an M6 screw to help locking the two parts, avoiding in this way any possibility for the steel balls (001MG025) to fall out while inserting the hub pack on the main shaft. – Insert the hub pack on the gear shaft – Insert the clutch discs starting with the sintered one and finishing with the steel guided one; total disc set thickness must be included between 36 and 36,5mm. – Remove the M6 screw from the hub (0F3SR140J24001C). – Put the drum stopper hub (003MG106) on the hub (0F3SR140J24001C). – Verify that the secondary spring support (0F3SR540B140016) is well inserted into its housing on the drum (0F3SR140J24002C). – Insert the secondary spring (0S2085) into its housing on the drum (0F3SR140J24002C). – Mount the pressure plate (003MGP10) on the drum (0F3SR140J24002C) . – Position the Evoluzione spring (0S1090) on the pressure plate (003MGP10), with the convex part facing up (STM logo facing up), making sure previously that the squared section ring (901SE003), which works as primary spring support, is well positioned into the pressure plate itself. – Assemble the complete spring stopper pack: starting from the spring stopper plate (003MG008), with the shaped side facing up as shown in the picture. Insert the ball bearing (003MG007) and finally the spring stopper hub (0F3SR140N220007). Once completed these operations, position the complete spring stopper pack inside the Evoluzione spring (0S1090). – Insert the toothed washer (901RD101) with the convex side facing up, then insert and tighten up the clutch nut (0F30S140C220013); use a dynamometric wrench setting the torque suggested by the bike manufacturer. We suggest to use the specific optional tool (UTL-0020) in order to lock the pressure plate (003MGP10) while performing this operation. – Assemble the complete bearing rest pack: insert the washer (001MG018) in its housing on the bearing rest (0F3SR140N220004). Then put in the same housing the ball bearing and the push rod pin of the original clutch. – Position the complete bearing rest pack in the pressure plate (003MGP10), making sure it fits correctly into the housing grooves. – Manually practise a little pressure on the bearing rest (0F3SR140N220004) in order to release the seat for the tightness circlip (003MG018). – Fit correctly the above mentioned tightness circlip (003MG018). MAKE SURE that it adheres to all the groove perimeter. NB: Once completed the installation, repeatedly operate the clutch lever, checking that the pressure plate performs correctly the opening and closing movements. For a road use of the clutch you have to check clutch plates set every 2000 km. Please verify that the clutch plates set thickness is between 36,5mm and 35,0mm. If it is inferior to 35,0mm please replace a 1,5 steel plate with a 2 mm steel plate. For a racing use of the clutch we suggest to check the clutch plates set thickness frequently. GENERAL SAFETY REGULATIONS – In this sheet are reported the directions to perform correctly the clutch assembly operations. – STM reserves the right – without notice – to introduce any technical change whenever deemed it to be necessary to improve functionality and quality of the products. – Assembly operations must be performed by a skilled technician and must be scrupulously observed. – Before mounting the clutch make a complete inspection of the various parts, in order to verify the possible presence of faults or anomalies on the motorbike. – Make sure that there are no missing/damaged parts in the package . – Some parts of the clutch and its components can have sharp surface: handle with care. – Some components of the clutch, because of their small dimensions can be swallowed: keep away from children. STRADA srl Via Campo Archero 20 10023 Chieri ( TO ) Tel +39 011 9422832 Fax +39 011 9471447 003 MG 018 Tightness circlip

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