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Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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Filed Under (Honda) by admin on 27-12-2011

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

Kawasaki KZ 900/ KZ 1000 Piston Kits Installation Manual

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

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075CC 72MM KZ 900: Resleeving and bore crankcase ROAD 10.5:1 MTC-K1075 KZ 1000: 2mm oversize 2.834 In KZ 1000: Cylinder boring DRAG 12.5:1 MTC-K1075H TURBO 9.0:1 MTC-K1075T 1135CC 74MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1135 KZ 1000: 4mm oversize 2.913 In DRAG 12.5:1 MTC-K1135H TURBO 7.8:1 MTC-K1135T 1197CC 76MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1197 KZ 1000: 6 mm oversize 2.992 In DRAG 12.5:1 MTC-K1197H TURBO 7.8:1 MTC-K1197T 1261CC 78MM Resleeving and bore crankcase ROAD 10.5:1 MTC-K1261 KZ 1000: 8mm oversize 3.070 In DRAG 12.5:1 MTC-K1261H TURBO 7.8:1 MTC-K1261T 1327CC 80MM Big block required bore crankcase ROAD 10.5:1 MTC-K1327 KZ 1000: 10mm oversize 3.149 In DRAG 13.5:1 MTC-K1327H TURBO 7.8:1 MTC-K1327T 1428CC 83MM Big block required bore crankcase ROAD 10.5:1 MTC-K1428 KZ 1000: 13mm oversize 3.267 In DRAG 13.5:1 MTC-K1428H TURBO 7.8:1 MTC-K1428T 1500CC 85MM Big block required bore crankcase DRAG 13.5:1 MTC-K1500H KZ 1000: 15mm oversize 3.346 In TURBO 7.8:1 MTC-K1500T

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1991 Bimota YB10 DYNOJET KIT INSTALLATION MANUAL

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Filed Under (Bimota) by admin on 01-11-2010

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1. Remove the vacuum slide from the carbs. Remove the stock needles & spacers, noting the order of assembly (Fig.A). 2. Install the Dynojet needles on groove #3 , using all stock spacers (Fig. A). Install the Dynojet washer above the E-clip. 3. Replace the stock slide springs with Dynojet slide springs provided. 4. Remove the stock main jets and replace with the Dynojet main jets provided. Use the DJ116 main jets with stock exhaust pipe, or use the DJ120 main jets with aftermarket header or slip-on with high flowing baffles. Use the DJ112 main jets at high altitude. Be sure that the jets you are changing are the main jets. 5. Locate the fuel mixture plug (Fig. B), if you see a screw head, proceed to adjusting procedure. With the plug drill (DD #5/32) provided, carefully drill thru the plug(s). The mixture screw is directly underneath this plug, be ready to pull back on the drill the instant you break thru. Use the screw provided to secure and remove the plug. Carefully turn mixture screw clockwise until seated, then back out 3 turns. 6. Locate the main air correctors (Fig.C). Using the plugs provided (DCO400), plug the main air passage. Place the plug in the carb flat end first.Tap in lightly. Using DT002. STAGE ONE INSTRUCTIONS Fig. B Place E-clip in groove #3 from the top Fig. A Notes: 1. Proper EXUP value adjustment is very important for good midrange performance. 2. If experiencing fueling problems below 4,000 rpm, under full throttle, that the needle can’t fix, try changing fuel level. If you feel it is too rich, lower the fuel level. If you feel it is too lean, raise the fuel leve

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Hot-Start Kit For Yamaha YZ/ WR 400F

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Filed Under (Yamaha) by admin on 16-12-2010

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Blaster Rear Brake Kits 121-01298 • YFS200 Blaster ’88-’98 • This cable will eliminate the stock cable from the handlebar. Cable will go from the rear brake pedal to the caliper. 121-01299 • Same as 121-01298 +4″ • Cable is 4″ longer for extended swingarms. 121-01027 Replacement Ratchet Spark Plug Wrench 121-08147 • Designed specifically to fit where there is limited space • Ratchet mechanism works one way • Fits standard 13/16″ plugs
INDEX PAINT HANDLEBARS STREET LEVERS FORK SEALS CABLES SUSPENSION ELECTRICAL FILTERS BRAKE LINES BRAKES CABLE MAKING SUPPLIES CONTROLS DUAL SPORT MANUALS FSO PRODUCTS EMGO DRIVE DISPLAY JETS BEARINGS EYEWEAR VINTAGE MIRRORS EUROPEAN KICKERS SHIFTERS MISC HARD PARTS SHOP TOOLS CHEMICALS TOOLS R . 03-15-06 21 (626) 792-7384 www.FlandersCompany.com Fax: (626) 792-5341 www.FlandersCo.com Specialty Tools Swingarm Bearing Tool 121-080213 • Designed for installation of the swing arm bearings on late model Japanese motorcycles • Using the correct size insert (various sizes included in kit) and the puller, the mechanic can draw the bearing into the swingarm without beating on it with a hammer Main Jet Wrenches • High-quality die cast construction • 6mm round and hex jets and 8mm round • Cap holds a few spare main jets • Sold each 121-08023 6mm Hex (Fits 6mm hex main jets) 121-08024 8mm Round (Fits 8mm round main jets) 121-08025 6mm Round (Fits 6mm round main and pilot) Allen Extension 121-080184 • 5mm allen on a 6.25″ long, 3⁄8-drive extension for hard-to-reach case bolts • Designed for use with air tools • Great for splitting engine cases

Kawasaki ZX-14 Stage I Turbo Kit INSTALLATION MANUAL

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

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The following items will need to be addressed in order to prepare your ZX14 for the Stage I Turbo kit installation. Please refer to your Kawasaki service manual for further information. q* Remove the following bodywork: Tank front cover Seat Side Fairing Lower Fairing Lower Rear Cowl q* Drain and remove the fuel tank. q* Drain the cooling system into a clean container so that it can be reused. (This is best done from the drain bolt in the water pump housing, open the filler cap to vent while draining.) Remember that coolant is poisonous. Be sure to keep it away from pets and children and store it in a clearly marked and sealed container. q* Remove the radiator.Remove the exhaust system. q* Remove the air box lids and rear inlet tubes. q* Drain the oil and remove the oil filter. q* Remove the crankcase breather line from the frame (left hand side behind the throttle bodies) and plug this inlet with the provided rubber cap and clamp.(photo 2) q* Remove the oil water trap line and install an 8 x 16mm allen bolt and washer. (photo 2) q* Remove the oil sender unit (on oil pan). q* Remove the upper radiator shroud (attached to engine). This will be modified later to accomodate the 2″ air inlet pipe. q* Remove the secondary butterflies. (photo 1) 1. Heat the screws on each plate using a heat gun on medium heat. 2. Remove the screws and plates. (DO NOT OPEN THE THROTTLE DURING REMOVAL!)

KTM 3V TURBO DRIVE MODEL 9808T KNEE FEED Installation and Removal Manual

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Filed Under (KTM) by admin on 28-01-2012

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Gather together the following items that you will need to complete this installation. a) lathe b) 3/8″ electric hand drill c) 9/32″ diameter transfer punch SERVO Turbo Drive Model 9808T Page 2 d) .4375 drill, 3/16″ drill, #7 drill e) 1/4-20 tap f) 3/4″ socket wrench g) set of inch hex wrenches h) clean shop rag Step 2: Clean the power feed mounting area completely. Step 3: Remove the drive clutch nut and the drive clutch from the elevating jack shaft. Step 4: Remove the dial nut, dial, and dial carrier. Keep the dial for reuse later. Step 5: Remove the existing bearing retainer. Keep the screws for reuse later. Step 6: Pull jack shaft out of knee. Hold inboard end up while removing to avoid damage to the pinion gear. Step 7: Press the bearing off the jack shaft. Step 8: Drill and ream the end of the jack shaft .4375″ diameter by 13/16″ deep. The .4375″ dia. must be concentric to the shaft O.D. within .002″ T.I.R. Chamfer 1/32″ x 1/2″ diameter. For best results, machining should be done in a lathe. Step 9: Place the shaft extension #6975 into the end of the jack shaft. Finish drill 3/16″ diameter through the shaft and pin the extension with the 3/16″ diameter x 5/8″ long roll pin. File smooth. Step 10: Reassemble and replace the jack shaft in the machine. Step 11: Replace the existing bearing retainer with #57904 retainer provided. Secure using existing screws. Step 12: Slip spacer #5426 and bearing race #1616 onto the jack shaft. Slide the adaptor #0771 over the bearing race and locate against front of the knee.

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Yamaha V-Star 650 Jet Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 16-01-2012

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Remove the vacuum slide from the carburetor. • Remove the OEM needle and spacer, noting the order of assembly. • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needle. • Reinstall the OEM spacer and washer. • Reinstall the vacuum slide along with the diaphragm spring. • Reattach the diaphragm cover and tighten its screws. Note: Verify that the slide maintains a full range of movement! • Drain the fuel from float bowl and remove the bowl cover. • Remove the new cap head Allen screws in place of the OEM Phillips head screws. • Repeat above steps for other OEM main jet and pilot jet, and replace them with Baron’s main and pilot jets. • Thoroughly clean the inside of the float bowl prior to reinstalling it. • Reassemble the carburetor by reversing the order of previous steps. Use thecarburetor. • Locate the fuel mixture plug on each carburetor; it will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plug for each carburetor. CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and remove the bit the instant you break through the plug. b. Insert a self-tapping sheet metal screw into the drilled hole and remove the plug. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (2) Mikuni main jets, (2) pilot jets, (2) titanium needles, (2) clips, (8) cap head Allen screws Revision 2.0 c. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats, then carefully turn it counter-clockwise 3 turns. Refer to final step for assistance in fine-tuning the setting of the air/fuel adjustment screw. • Reinstall the OEM air filter assembly. • Check all vent lines, fuel lines, and linkage for any obstructions or blockage

Turbo+2 , Roadstar , Quantum Sport , Quantum"GL" , Entourage Owners Manual

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Filed Under (Uncategorized) by admin on 03-12-2010

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tracking Any parting within the tread, sidewall, or inner liner of the tire extending to cord material. CT A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the rim flanges inside the air cavity of the tire. Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel, oil, and coolant, and, if so equipped, air conditioning and additional weight optional engine. Extra load tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire. Groove The space between two adjacent tread ribs. Gross AxleWeight Rating The maximum weight that any axle can support, as published on the Certification /VIN label on the front left side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached to the towing vehicle. Gross Vehicle Weight Rating The maximum weight of the fully loaded trailer, as published on the Certification /VIN label. Actual weight determined by weighing trailer on a public scale, without being attached to the towing vehicle. Hitch Weight The downward force exerted on the hitch ball by the trailer coupler. Innerliner The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire. Innerliner separation The parting of the innerliner from cord material in the carcass. Intended outboard sidewall The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle. Light truck (LT) tire A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. Load rating The maximum load that a tire is rated to carry fora given inflation pressure. Maximum load rating The load rating fora tire at the maximum permissible inflation pressure for that tire. Maximum permissible inflation pressure he maximum cold inflation pressure to which a tire maybe inflated.
-9- Maximum loaded vehicle weight The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight. Measuring rim The rim on which a tire is fitted for physical dimension requirements. Pin Weight The downward force applied to the 5thwheelor gooseneck ball, by the trailer kingpin or gooseneck coupler.

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TOYOTA R150F, R151F ( AX15 ) 5 SP TRANS. TO CHEVY & BUICK ENGINE – TURBO CHARGED

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Filed Under (Toyota Manuals) by admin on 03-06-2011

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This bellhousing is not compatible with transmissions that were previously equipped with diesel engines. The bellhousing design incorporates a special modified clutch release lever and a Toyota Land Cruiser slave cylinder. We have provided slave cylinder mounting on the passenger side of the bellhousing and have incorporated a new push rod location that will provide a quick short travel of the clutch release mechanism. The kit does not include the Toyota Land Cruiser slave cylinder, Part No. 31470-60022. The bellhousing is designed for the 153 tooth flywheel application. If your block is equipped with a 168 tooth flywheel, you will be required to use a high torque starter without a nose cone to fit the bellhousing (P/N 22-0001). The bellhousing is compatible with the Buick flywheel that has 160 teeth. A slight modification may be required in the starter pocket area when using the Buick installation.

PowerMax Turbo System XS21-1200 2000-02 Toyota Celica GT-S Installation Manual

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Filed Under (Toyota Manuals) by admin on 24-05-2011

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Please bear in mind that the conversion from a normally aspirated engine into a turbocharged one is no easy task. This is the reason why we strongly suggest that only experienced professionals install this turbocharger system. In addition, we suggest that this turbocharger system only be installed on engines that are in good condition. Please
inspect the following: 1. Cooling system – make sure that this is within or better than factory specifications.
2. Ignition system – make sure that this is within or better than factory specifications and that the ignition timing is stock. 3. Fuel delivery system – make sure that the fuel pump, fuel filter, and fuel injectors are all working within or better than factory specifications. Also, make sure that the fuel used is at least 91 octane.