what is the best carburetor to replace on a 1983 yamaha it 490

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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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YAMAHA V-Star 1100 Carburetor Bowl Screw Repair and Removal After Stripping and Pilot Cap Removal

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Filed Under (Yamaha) by admin on 19-01-2012

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When I first started working on bike many years ago, I learned the danger of stripping the heads of Philips screws when removing or installing them on motorcycles. I remember the two worst screws were the casing side-cover aluminum screws and carburetor bowl screws. I think I tried every method of screw removal after they were stripped. Vice grips, better tipped screwdriver, hammer, drill, and other tools were used. One way I learned to remove stripped screws is to re-make the Philips head into a flathead screw. Cutting a slot in the top of the screw and then use a flat-head screwdriver to remove the screw. On some parts this technique can work, other parts and screws it may not. The Philips screws on the bottom of the V-Star carburetor bowls are VERY prone to stripping. In fact, I will not start a carburetor cleaning without new hex head screws to replace the original Philips bowl screws. Replace the bowl screws for yourself if you keep the bike, or for the next rider that will appreciate the hex-head screws when they clean the carburetors. Not many other parts on a V-Star have screws that are prone to stripping. This documentation is to help riders with motorcycle maintenance. Some riders will find themselves with the problem of removing stripped screws. A carburetor cleaning can quickly double in time when you realize the hardest part of the job is removing bowl screws after they strip. And then realizing you do not have the replacement hex-head screws available and must now go to the hardware store.

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YAMAHA RAPTOR 350 Removing stock carburetor and cables

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Filed Under (Yamaha) by admin on 18-01-2012

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remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Stuff a clean, dry rag into manifold to keep debris out of motor. 4. Remove stock air box. 5. Remove choke cable from handlebars. 6. Remove carb vent line from bike. Carburetor installation 1. Carefully trim the rubber alignment tab off of the face of the manifold with a razor blade or side cutters. 2. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap. 3. Attach fuel line to carburetor and secure with clamp. 4. Install remote idle cable into tab on top of carburetor. See main manual for this step. NOTE: Nut must be removed from cable before installation 5. Place carburetor into manifold

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Harley-Davidson Camshaft TC, EVO, Shovelhead, XL EVO, Iron Head, XR Specifications

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Filed Under (Harley Davidson) by admin on 02-11-2010

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EVO Black Widow PP8833-2 – 29 55 62 25 264 267 54 103 109 105.8 0.600 0.602 EVO Black Widow PP8826-2 – 27 61 63 29 268 272 56 107 107 107.0 0.602 0.602 EVO Black Widow PP8817-2 – 254 254 0.590 0.590 EVO Carl’s Speed Shop CM4 – 28 44 52 20 252 252 48 98 106 102.0 0.495 0.495 EVO Carl’s Speed Shop CM495F Y 19 47 50 16 246 246 35 104 107 105.5 0.495 0.495 0.179 0.168 EVO Carl’s Speed Shop CM580 – 19 47 50 16 246 246 35 104 107 105.5 0.580 0.580 0.194 0.163 EVO Carl’s Speed Shop CM612 – 36 60 68 28 276 276 64 102 110 106.0 0.612 0.612 0.277 0.235 88 EVO Carl’s Speed Shop CM660 – 38 62 68 28 280 276 66 102 110 106.0 0.660 0.660 0.314 0.277 90 EVO Carl’s Speed Shop CM774 – 284 284 0.784 0.784 0.277 0.236 EVO Carl’s Speed Shop CM780F – 34 70 74 30 284 284 64 108 112 110.0 0.774 0.774 103 EVO Crane EVR0020 – 31 64.5 77 23 275 280 54 107 117 112.0 0.608 0.589 88 EVO Crane Fireball 2000 Y -12 22 20 -10 190 190 -22 107 105 106.0 0.490 0.490 0.026 0.032 EVO Crane Fireball 300 Y 12 34 41 15 226 236 27 101 103 102.0 0.490 0.490 4000 EVO Crane Fireball 310 Y 16 40 43 19 236 242 35 102 102 102.0 0.490 0.490 1500 4500 75 EVO Crane Fireball 316 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 2000 5000 80 EVO Crane Fireball 326 – 24 48 57 25 252 262 49 102 106 104.0 0.490 0.500 2500 5500 EVO Crane H286 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 2000 5000 80 EVO Crane H290 – 17 43 45 23 240 248 40 103 101 102.0 0.581 0.581 1800 5200 EVO Crane H296 – 24 48 57 25 252 262 49 102 106 104.0 0.490 0.500 2500 5500 EVO Crane H304 – 24 50 55 25 254 260 49 103 105 104.0 0.600 0.600 2500 5800 EVO Crane H306 – 28 54 69 23 262 272 51 103 113 108.0 0.500 0.510 0.224 0.195 3000 6000 EVO Crane H310 – 23 63 68 28 266 276 51 110 110 110.0 0.550 0.550 0.229 0.229 3000 6500 88 EVO Crane H314 – 26 54 65 21 260 266 47 104 112 108.0 0.600 0.600 2800 6000 EVO Crane HEV0042 – 27 59 71 23 266 274 50 106 114 110.0 0.600 0.576 0.226 0.194 3000 6000 100 116 EVO Crane HEV0067 – 24 50 56 24 254 260 48 103 106 104.5 0.600 0.530 0.128 0.113 EVO Crane HEV0098 – 36 62 72 34 278 286 70 103 109 106.0 0.650 0.650 0.171 0.156 96 EVO CycleRama CR-E550 – 24 52 53 23 256 256 47 104 105 104.5 0.550 0.530 EVO CycleRama CR-E581 – 22 46 53 23 248 256 45 102 105 103.5 0.581 0.550 EVO CycleRama CR-E600A – 24 50 56 24 254 260 48 103 106 104.5 0.600 0.530 EVO CycleRama CR-E600B – 23 51 54 22 254 256 45 104 106 105.0 0.600 0.550 EVO CycleRama CR-E617 – 22 50 50 22 252 252 44 104 104 104.0 0.617 0.617 EVO CycleRama CR-E630 – 18 60 63 13 258 256 31 111 115 113.0 0.630 0.630 EVO CycleRama CR-E660 – 27 59 71 23 266 274 50 106 114 110.0 0.660 0.660 3500 6500 140 EVO Dave Mackie DM500 Y 22 38 52 12 240 244 34 98 110 104.0 0.500 0.500 0.189 0.138 EVO Dave Mackie DM500X Y 25 40 55 20 245 255 45 98 108 102.5 0.500 0.500 0.208 0.178 EVO Dave Mackie DM530 – 28 42 55 15 250 250 43 97 110 103.5 0.530 0.530 0.221 0.141 EVO Dave Mackie DM580 – 26 42 56 12 248 248 38 98 112 105.0 0.580 0.580 0.227 0.144 113 EVO Dave Mackie DM581 – 26 42 56 12 248 248 38 98 112 105.0 0.580 0.580 0.227 0.144 EVO Dave Mackie DM595 – 21 49 57 14 250 251 35 104 112 107.8 0.595 0.595 0.192 0.150 EVO Dave Mackie DM635 – 20 56 59 18 256 257 38 108 111 109.3 0.635 0.635 0.194 0.176 EVO Edlebrock 1740 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 0.176 0.203 EVO Edlebrock 1741 – 20 46 52 22 246 254 42 103 105 104.0 0.600 0.600 0.183 0.187 EVO Head Quarters HQ-23 – 19 47 52 24 246 256 43 104 104 104.0 0.600 0.530 EVO Head Quarters HQ-24 Y 20 36 52 19 236 251 39 98 107 102.3 0.500 0.500 EVO Head Quarters HQ-25 – 18 38 42 14 236 236 32 100 104 102.0 0.550 0.550 EVO Head Quarters HQ-26 – 20 54 53 22 254 255 42 107 106 106.3 0.600 0.530 89 EVO Head Quarters HQ-27 – 26 60 70 24 266 274 50 107 113 110.0 0.650 0.575

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KTM 60 SX / 65 SX REPAIR MANUAL ENGINE

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Filed Under (KTM) by admin on 12-11-2010

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Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment low altitude or low temperatures  choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer

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HSR Carburetor Total Kits Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

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BMW F 650 GS Repair Manual And Maintenance schedule

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Filed Under (BMW) by admin on 19-11-2010

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Replace oil in telescopic forks Check the coolant and restore to correct level if necessary *) Replace the coolant (every 2 years) every 2years Check valve clearances, adjust if necessary Replace the spark plug Drain the outlet hose from the air filter box Replace intake air filter If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every 10,000 km (6,000 miles); check every 3,000 km (1,800 miles) Replace fuel filter (every 20,000 km/12,000 miles) 20,000 km Check clutch play, adjust if necessary Check wheel spoke tension and tighten if necessary more frequently if motorcycle is ridden in severe off-road conditions Examine brake pads and discs for wear, replace if necessary *) more frequently if motorcycle is ridden in severe off-road conditions Check brake fluid level at front and rear and top up if necessary *) Check for operation of brake system and freedom from leaks; repair/replace if necessary *) Replace the brake fluid at least once a year Replace the primary front/rear brake master cylinder cup (every 40,000 km/24,000 miles on a motorcycle with ABS ) 40,000 km Check wheel bearings and replace if necessary *) Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *) more frequently if motorcycle is ridden in severe off-road conditions Check chain tension and adjust if necessary *) Check battery acid level, add distilled water if necessary more frequently if motorcycle is ridden in severe off-road conditions Clean and grease the battery terminals, if necessary Check steering head bearings and adjust *) or replace if necessary *) Grease the side and main stands Grease the brake pedal Check bolts and nuts on engine mountings, frame connections, exhaust system mountings, swinging fork pivot, suspension levers, brake pedal, main and side stands and quick-release axles for tightness Final inspection with road safety and functional check

1981-1983 Yamaha Virago 750 & 920 Installation Instructions

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Filed Under (Yamaha) by admin on 11-02-2012

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Start by loosening the rear cylinder down tube bolt located on the top of the old mufflers center collector in front of the rear tire. 2. Remove both of the front cylinder exhaust pipe head nuts and set them to the side for reuse with the MAC exhaust system. 3. Remove the right side passenger’s foot peg. Set the foot peg aside as you will need to reinstall it. 4. Remove the left side passenger’s foot peg. Set this foot peg aside as it will also need to be reinstalled. Note: When you remove this bolt the entire exhaust system will be loose and may fall. You will need to support the old exhaust at this point to keep from injuring yourself. Gently move the old exhaust system side to side to remove it from the rear cylinder down tube. Once the exhaust system is loose from the down tube remove the system from under the Virago. 5. Remove the bolt holding the rear brake pedal in place and remove the brake pedal from the motorcycle. Note: Set both the bolt and the pedal aside for reinstallation. 6. Next loosen the nut on the drivers right foot peg, 1 full turn to start with. Then remove the rear nut on the same foot peg. (Note: The bolt that this nut is on goes completely through the motorcycle. This is the center stand mounting bolt.) Now remove the front nut and set both aside for reuse with the MAC system. 7. Install the center stand stop bracket under the left passenger foot peg. Install this bracket with the 90° bend facing down and towards the rear tire. (Note: Center stand sop bracket in provided in the hardware kit and is approx. 5″ long with a 90° bend in it.) Adjust the bracket by one of the large bolts through the foot peg then through the bracket and then install it into the stock location. Put on one of the washers and a nut and snug up the nut. Lower the center stand until the center stand come in to contact with the bottom of the bracket. Tighten the nut until it will hold the bracket securely. 8. Install the rear down tube clamp onto the rear muffler and install the medium sized nut/bolt/washer onto the clamp just finger tight. 9. Install the (2) small bolts into the channel bracket on the rear muffler. Install the rear mounting bracket onto the two bolts and then install the washers and nuts onto each. Tighten the (2) nuts only slight amount so that you can slide the bracket front to rear to insure that when you install the bracket you position it properly. 10. Slide the rear pipe onto the rear down tube about ¼”to ¾” past the pre-cut slots on the rear muffler pipe. Slightly snug the clamp making sure that the position of the bolt and nut will not interfere with any moving parts. The final position of this bolt can hit the tire if it is not positioned properly. 11. Install the other large bolt into the right passenger and then through the top hole in the rear muffler mounting bracket. Insert the bolt into the stock location and install the washer and the nut. 12. Align the rear muffler and you can then tighten the nuts on the rear muffler mounting bracket, the cylinder down tube and the right side passenger foot peg.
13. Install the front muffler on the rear most mounting bolt of the drivers foot peg and put the stock nut back onto the bolt. Hand tighten the bolt only at this time. Note: Install the nut at this time is only to support the muffler and to insure that the pipe does not fall on the ground while you complete the next step. 14. Lift the front head pipe into position and start the stock nuts onto the studs. It is strongly recommended that you install new exhaust gasket at this time. Note: The new exhaust gaskets are not included in the kit but are available at your local Yamaha Dealer. After gaskets are installed hand tighten the front head pipe. 15. Remove the nut from the drivers foot peg bolt and reinstall the drivers foot peg. Note: Hand tighten only at this time. 16. Finish tightening the nuts on the front head pipes. (Install these nuts according to Yamaha’s Factory specifications.) Once the nuts are tightened on the head pipe you can then tighten the drivers foot peg nuts. 17. Reinstall the rear brake pedal and tighten the bolt that holds it on to factory specifications. 18. Check all of the bolts that you have installed of removed to insure that they are tight. 19. Start the motorcycle and check for any leaks. 20. You are finished with your new MAC Exhaust System.

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HARLEY DAVIDSON BIG TWIN SPIGET MOUNT CARBURETOR INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 26-03-2012

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A. BEFORE INSTALLATION OF YOUR NEW ZENITH CARBURETOR, NSPECT THE RUBBER MANIFOLD SEAL FOR NICKS,CRACKS, OR DEBRIS. APPLYING A LIGHT FILM OF PETROLEUM BASED LUBRICANT AROUND THE INSIDE LIP OF THE RUBBER SEAL WILL ALLOW THE CARBURETOR TO SLIP INTO PLACE EASIER. B. BEFORE ACTUAL INSTALLATION OF UNIT INTO MANIFOLD, THROTTLE CABLES SHOULD BE HOOKED TO THETHROTTLEWHEEL.MAKESURETHATTHE PULL CABLE IS LOCATEDPROPERLY TO OPEN THE THROTTLE PLATE (IN SOME APPLICATIONS THROTTLE CABLE SLACK MAY NEED TO BE ADJUSTED FOR PROPER HOOKUP AND OPERATION) SEE FIG. #1 C. AFTER THROTTLE CABLES ARE PROPERLY HOOKED UP,UNITCAN BE INSERTED INTO MANIFOLD. MAKE SURE THAT UNIT IS FULLY SEATED. WITH CARBURETOR SEATED INTO MANIFOLD AND FUEL LINE HOOKED UP TO FUEL INLET, INSTALL CHOKE CABLE AND HOOK TO CHOKE LEVER. PLACE AIR INTAKE GASKET ON END OF CARBURETOR, NEXT PLACE INTAKE ADAPTOR OVER INTAKE GASKET. SEE FIG#2 ZENITH MOD.16P12 SPIGET MOUNT CARBURETOR -HARLEY DAVIDSON ™ BIG TWIN INSTALLATION INSTRUCTIONS FIG. # 1 FIG. # 2 D. WITH ADAPTOR IN PLACE, LOCATE THE STOCK AIR BOX OVER THE ADAPTOR, UTILIZING THE STOCK AIR BOX GASKET (THERESHOULDBENO GAPS BETWEEN ADAPTOR, AIRBOX OR CARBURETOR WHEN PROPERLY INSTALLED) STAND-OFF SPACERS PROVIDED ARE TOBEPLACEDBETWEENAIR BOX& ENGINE HEADS BEFORE INSTALLING THE VENT/RETAINING BOLTS. FOR EVALUATION ENGINES STOCK VENT BOLTS CAN BE USED WITH LARGERI.D. SPACER PROVIDED. SEE FIG#3 E. WITH AIR BOXSECURELY IN PLACE, INSTALL THE AIR FILTER COVER RETAINING BRACKET AND FILTER USING THE STOCKBOLTS, AND REPLACE AIR FILTER COVER AND SECURE WITH STOCK BOLT. SEE FIG#4 F. AFTER INSTALLATION IS COMPLETE AND FUEL FLOW HAS BEEN RE-ESTABLISHED, CHECK FOR ANY LEAKS BEFORE STARTING ENGINE. H. AFTER STARTING ENGINE, SOME ADJUSTMENTS OF IDLE AND MAIN JET MAYBE REQUIRED FOR PROPER OPERATION. AFTER ADJUSTMENTS HAVE BEEN MADE AND WITH ENGINEAT IDLE, TURN WHEEL FULLYTOLEFTANDRIGHT.ANYCHANGEIN IDLE SPEED INDICATES THROTTLE CABLES ARE TOO TIGHT AND MORE SLACK MUST BE PROVIDED.

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How To Adjust the Accelerator Pump On the 40mm Mikuni Carburetor

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Filed Under (Yamaha) by admin on 21-01-2012

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1) The “blue” colored screw in the image is the duration adjustment screw. Underneath the head of the screw is a lock nut and the bracket arm that the screw is threaded into. To decrease the amount of fuel squirted the adjustment screw is turned “clockwise” or in. To increase the amount of fuel squirted the adjustment screw is turned “counter clockwise” or out. To get the max, amount of decrease remove the screw and take the lock nut off of the screw. Then replace the screw into the cam arm, then replace the lock nut underneath the arm on the screw. this gives you another 3/32″ of an inch in which the screw can be screwed in.
2) Turn the adjustment screw fully clockwise or IN. Start your engine, Blip your throttle open, if the engine stutters, (hesitates), it is not getting enough fuel so turn the screw counter clockwise to increase the amount of fuel squirted from the accelerator pump into the carburetor. Keep blipping the throttle and adjusting the screw till the carburetor starts to cough. Stop here and turn the screw back in till the coughing stops. Tighten down the lock nut. This should give you the best throttle response with the least amount of coughing and backfiring out the carburetor. Timing Adjustment Screw This is the “Green” colored screw just above the Blue duration adjustment screw. The” Mucker” said it best,,,,, This upper screw adjusts the “timing” of the squirt. By altering it’s setting, you can advance or delay the onset of the fuel squirt. But probably, it won’t have to be touched

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