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TVS – 811 Series Trap Valve Station Installation, Operation and Maintenance Instructions

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

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In a piston valve, the control of stem and seat leakage is obtained by tightness of the valve sealing rings to the body and valve plug. The bonnet compresses the valve sealing rings against the body and the valve plug. Flexible disc springs automatically assure a tight seal by exerting pressure on the valve sealing rings, keeping them compressed. Opening and Closing the TVS Isolation Valves The isolation valve begins to stop flow when the valve plug enters the lower valve sealing ring. When the isolation valve is completely closed, the valve plug is in contact with the full height of the valve sealing rings, ensuring the best possible seal. In fact, there is no advantage to be gained in torqueing the valve closed. Armstrong recommends that after closing the isolation valves completely, the handwheel should be turned back one half turn. This makes it easy to re-open the valve by avoiding metal to metal seizure. Troubleshooting – Isolation Valves A piston valve will retain its leak tightness for several years without maintenance. In severe service, such as rapid heating and cooling, some field maintenance may be required. Depending on the problem, these simple steps may help: ! ! ! ! ! Isolation Valve leaks, when the valve is closed . First, Check to make sure the valve is actually closed . Check to see if bonnet is seated on the body, if not, tighten the bonnet nuts until the bonnet seats. This recompresses the valve sealing rings against the body and the valve plug. If valve continues to leak, replace the isolation valve assembly

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Lilac LS-18 Motorcycle Maintenance Standards

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

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

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1998 YAMAHA YZF-R6 SERVICE MANUAL

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

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Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Intake camshaft lobe dimensions Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions Measurement A Measurement B Measurement C Max. camshaft runout Chain drive (right) 23.000 23.021 mm 22.967 22.980 mm 0.020 0.054 mm 33.05 33.15 mm 25.14 25.24 mm 7.81 8.01 mm 32.55 32.65 mm 25.07 25.17 mm 7.38 7.58 mm 0.08 mm 33.0 mm 25.09 mm 32.50 mm 25.02 mm 0.06 mm
2-5 ENGINE SPECIFICATIONS SPEC Head Diameter Face Width Seat Width Margin Thickness Item Standard Limit Timing chain Model/number of links Tensioning system RH2015/120 Automatic Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions 0.11 0.20 mm 0.21 0.30 mm Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 24.9 25.1 mm 21.9 22.1 mm 1.14 1.98 mm 1.14 1.98 mm 0.9 1.1 mm 0.9 1.1 mm 0.6 0.8 mm 0.6 0.8 mm 3.975 3.990 mm 3.960 3.975 mm 4.000 4.012 mm 4.000 4.012 mm 0.010 0.037 mm 0.025 0.052 mm 0.9 1.1 mm 0.9 1.1 mm 1.6 mm 1.6 mm 0.5 mm 0.5 mm 3.950 mm 3.935 mm 4.042 mm 4.042 mm 0.08 mm 0.1 mm 0.04 mm 1.6 mm 1.6 mm
2-6 ENGINE SPECIFICATIONS SPEC Item Standard Limit Valve springs Free length Intake (inner) (outer) Exhaust Installed length (valve closed) Intake (inner) (outer) Exhaust Compressed spring force (installed) Intake (inner) (outer) Exhaust Spring tilt Intake (inner) (outer) Exhaust Winding direction (top view) Intake Exhaust 37.0 mm 38.4 mm 41.7 mm 30.0 mm 32.5 mm 36.1 mm 69 79 N (7.0 8.0 kgf) 114 132 N (11.6 13.4 kgf) 160 184 N (16.3 18.7 kgf) Clockwise Clockwise 35 mm 36.5 mm 39.5 mm 2.5/1.6 mm 2.5/1.7 mm 2.5/1.8 mm Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max. taper Max. out-of-round Forward-inclined, parallel 4-cylinder 65.5 45.5 mm 12.4 : 1 65.50 65.51 mm 0.05 mm 0.05 mm

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CYLINDER HEAD REPAIR MANUAL

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Filed Under (Tips and Review) by admin on 28-10-2010

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ADJUSTABLE CYLINDER HEAD STAND Head can be rotated 360 degrees. Stays in any position using a simple locking mechanism. Use on twin or four cylinder heads. Shipping weight: 14 lbs. Adjustable length-10-1/2″ to 20-1/2″ long x 14″ width x 10-3/4″ high. 35-8602 Cylinder Head Stand VALVE GUIDE DRIVERS Use for removal and installation of valve guides into cylinder head. Available in the following sizes: 35-8418 4.5mm YM-4116 35-8416 6mm YM-4064-A 35-8417 5mm YM-4097 35-8414 7mm YM-1225-A 35-8408 5.5mm YM-1122 35-8413 8mm YM-1200 VALVE GUIDE DRIVER SET (REMOVE & REPLACE) Designed for speed and accuracy, this eleven piece set provides the right tool for the job. Driver set includes two valve guide drivers (5.5mm and 6.6mm), four valve guide installers, one cutter, three cutter pilots (5.5mm, 6.6mm, and 7.7mm) and one tap handle extension bar. 35-9445 Valve Guide Driver Set YAMAHA VALVE GUIDE INSTALLERS These installers are used for installation of Yamaha shoulder less valve guides to a specific depth into the cylinder head. To use, position onto the valve guide and drive into the cylinder head until installer makes contact with cylinder head surface. Note: Must use with Valve Guide Driver. Available in the following sizes: 35-8439 4.5mm YM-4117 35-8437 5.0mm YM-4098 35-8419 5.5mm YM-4015 35-8435 6mm YM-4065-A 35-8423 7mm YM-4017 VALVE GUIDE REAMERS Reaming valve guides after installation assures a proper valve stem to valve guide fit. Available in the following sizes: 35-3829 4.5mm YM-4118 35-3851 7mm YM-1227 35-3836 5.5mm YM-1196 35-3852 8mm YM-1211 35-3847 6mm YM-4066 CLOVER VALVE LAPPING COMPOUND KIT The world famous green can with the four leaf clover. For seating valves, mating gears, and sharpening. Sold as a kit with coarse 120 grit (roughing) and 280 fine grit (finishing). 35-0309 Clover Valve Lapping Compound VALVE LAPPING TOOL The ultimate vacuum stick for insuring perfect surfaces on valves and valve seats. Interchangeable cups make unit suitable for use with virtually any size valve. Set includes vacuum stick, 3/4″ and 1/4″ diameter rubber cups. 35-8998 Valve Lapping Too

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Kawasaki Ninja 250 FAQ

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Filed Under (Kawasaki) by admin on 15-11-2010

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Am I too small for this motorcycle? Duke – Sun May 14 17:38:31 2000 I’m only about 5’2″ and don’t have a problem, even though I can only touch the ground with the ends of my toes. Once you get a feel for the balance of the bike it’s not hard to keep everything upright. Only place I have trouble is pushing the bike backwards in a parking lot. Usually I just walk the bike (beside it) to where I can get on and get going. How does the EX500 compare to the EX250? Craig M. – Mon May 22 10:23:29 2000 I have both the EX250 and the EX500; both are Y2K models. The 250 is a screamer that performs well and can easily get me into trouble. My only complaints about the 250 are the excessive nose dive when getting on the front brake hard and the skittishness of the rear during high speed cornering. Both are easily corrected with suspension adjustments, I’ve just been too lazy to get the parts and do the work. A bit more wind protection would be great too. The 500 addresses these problems, the diving of the front end (to a degree); the rear’s skittishness and the wind protection. A plus for the 500 is the greater torque and power off the line; it pulls stronger (in my opinion) and will get you into illegal speed territory just a bit quicker than the 250. With greater weight, is has more stability in high speed and windy situations. Insurance is just about the same for both, with the 250 getting the nod for gas mileage. Service requirements are almost identical for both as well, being that they’re both parallel twins, the technology is the virtually the same. The downfalls of the 500: $2K more than the 250 (can do a lot to the 250 with that kind of money); buzzy mirrors, barely useful; heavier weight to have to push around the garage; lesser gas mileage (55-60 MPG; 250 pushes 70 MPG easily); engine is worse than a nervous dog shaking around at idle and at speed (here the 250 is far superior and much smoother). In my opinion, the 500 is a better suited for a larger rider, from a comfort standpoint. I feel I can stretch out a bit more on it than the 250 (I’m 5′ 9″, 160 lbs). The 250′s brakes are better tuned than the 500 and the shifter is much smoother. That may be due to the 3,500 mile difference between the two bikes. Bottom line, both bikes are great, the 250 is now my wife’s ride (mainly) and the 500′s mine (unless she steals the keys away). In time, I’ll make the adjustments to the 250; she doesn’t push it like I do.

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S&S Connecting Rods Installation Instructions

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Filed Under (S&S) by admin on 29-10-2010

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1. Female rod crankpin end to mainshaft nuts – .030″ minimum clearance recommended. A. Install sprocket shaft and crankpin in driveside flywheel. Snug nuts only. Do not torque to final specs. B. Slide connecting rods and bearings over crankpin. C. Rotate rods on crankpin, and observe clearance between rod and sprocket shaft nut. D. If additional clearance is needed, remove material from sprocket shaft nut. Do not remove material from connecting rod. E. Repeat procedure for camside flywheel and pinion shaft. 2. Female rod crankpin end to inner flywheel rim – .060″ clearance recommended. A. While checking female rod to mainshaft clearance, observe clearance between crankpin end of female rod and rim of both flywheels. B. If additional clearance is required, remove material from flywheel at point of contact. Do not remove material from connecting rod. 3. Wristpin end of both female and male rods to flywheel edge -.060″ minimum clearance recommended. A. While checking female rod to mainshaft clearance, observe clearance between wristpin end of both rods and rim of both flywheels. B. If additional clearance is required, remove material from flywheel at point of contact. Do not remove material from connecting rod. 4. Wristpin end to crankcase and cylinder – .060″ is recommended in these areas. A. With the camside flywheel and rods mocked up, install the assembly in the right crankcase half with pistons (less rings) and cylinders in place. B. Rotate flywheel through one full revolution and check for rod to crankcase and cylinder spigot contact on both the front and rear of each cylinder. C. File or grind crankcase or cylinder spigot as needed to achieve .060″ clearance. Do not remove morematerial than needed. D. Repeat for left crankcase half. NOTE: Whenever clearancing is performed in any of these areas, do not remove any material from the connecting rods as clearancing on the rods may unnecessarily weaken them. Make adjustments to the point of contact on the mainshaft nut, flywheel rim, crankcase, cylinder spigot, etc. Connecting rods weakened by clearancing may fail causing serious engine damage.

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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

2008 KTM 250 SX-F 250 XC-F, XCF-W 250 EXC-F, EXC-F SIX DAYS INSTALLATION MANUAL

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Filed Under (KTM) by admin on 22-10-2010

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Hand brake lever The hand brake lever [1] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [A] can be used to change the basic position of the hand brake lever (see “Maintenance”). 1 A Short circuit button The short circuit button [2] turns off the engine. When pressing this button, the ignition circuit is short-circuited. 2 Headlamp switch (XCF-W) In this model the headlamp is switched on with the pull switch [5] . 5 Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right
OPERATION INSTRUMENTS » ENGLISH 7 1 2 3 4 5 Starter button Pushing the red starter button [1] will actuate the E-starter. Emergency OFF switch (EXC-F Australia) The red emergency-OFF switch [2] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [3] will actuate the E-starter. Indicator lamps The green control lamp [4] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [5] lights up when the high beam is on. TEST All of the display segments briefly light up for the display function test. Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor. The display lights up when the engine is running. The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor. The button is used to change between display modes. The + and – buttons are used to control various functions

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2001 – 2002 GL1800/ GL1800A Rear Tire Inspection

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Filed Under (Honda) by admin on 27-11-2010

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1. Inspect the motorcycle for a punch mark as described in Identification on page 2. If a punch mark is present no further action is necessary, return the unit to the customer. 2. Qualify the unit/customer as follows: •Is the tire on the motorcycle the original factory installed tire? •Is the air pressure loss more than three psi per month? Note: Refer to page 145 in the Owner’s Manual. “Even tires that are in good condition may lose one to two psi per month if not checked and adjusted regularly” . If the GL1800 meets the above qualifications, proceed with the repair procedure. 3. Place the motorcycle on a lift and secure it on the centerstand. 4. Remove the rear wheel as described on page 14-9 of the Service Manual. 5. Starting at the valve stem/balance mark area, carefully remove the rear tire from the wheel. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. 6. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 2001 – 2002 GL1800/GL1800A Rear Tire Inspection GL1800 #6 OCTOBER 2001 MTB 9430 (0109) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-ityourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800/GL1800A Rear Tire Inspection 0110 GL1800 #6*GL1800 #6*0110*2001-2002 GL1800/GL1800A Rear Tire Inspection*GL1800/GL1800A, Rear Tire Inspection, Bead, Tread*Motorcycle*1800 2 of 4 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #6 OCTOBER 2001 Inside BeadInjury Outside BeadInjury Outside BeadInjury 7. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 8. If there is no evidence of bead damage, re-install the tire on the rim. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Be sure to align the balance dot with the valve stem. Inflate the tire to 41 psi. Install the wheel assembly on the motorcycle and proceed to the Identification and then to the Warranty section. 9. If any damage or injury is present replace the tire and valve stem. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Balance the new tire as necessary

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Honda CB 750 SOHC 8v Performance and Racing Camshafts Installation

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Filed Under (Honda) by admin on 18-11-2011

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Upon installation of your WEB-CAM camshaft, check the following. These operations are very important to engine
life, please follow instructions! If your cam is described as a bolt-in in the WEB-CAM catalog, you may skip 1-5
below. Check piston to valve clearance. Provide the necessary clearance by removing material from the piston Minimum .050″ intake, .080″ exhaust.1. Check valve to valve clearance. It may be necessary to remove material from the valves or sink valve seat height in head. 2. Check the valve spring retainer to valve guide clearance at maximum lift. Remove material from the top,of valve guides to provide a minimum of .030″ clearance. 3. Check for valve spring coil bind at maximum valve lift. Clearance at every coil should be at least .015″4. Be certain that cam and/or rocker arms rotate
freely in head or block. Remove material from head,block, or rocker arms where necessary.5. Engine and cam life depend on proper installation. New or reground followers should be used when installing WEB-CAM profiles. Apply the provided
assembly lube to cam lobe and follower surfaces

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