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Harley-Davidson S&S Super E and G Series Shorty Carburetors Installation and Jetting Instructions

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Filed Under (Harley Davidson) by admin on 24-10-2010

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throttle linkage with no cable modification. S&S Super E and G carb kits for 1936 to 1989 Big Twins contain a throttle cable guide (11-2339) designed for butterfly type throttle cables, and kits for 1990 and later Big Twins contain a taller throttle cable guide (11-2338) designed for CV type throttle cables. See Picture 2. The two throttle cable guides are interchangeable on the carburetor body, and can be changed very easily to update older carburetors or to accommodate custom throttle cables which are not stock for a particular year chassis. 1981 to Present Sportster Models Stock Sportster models from 1981 to 1987 have two cable throttle system designed for butterfly type carburetors. Sportsters from 1988 to present have a two cable throttle system designed for use with the stock constant velocity (CV) type carburetor. Since the taller #11-2338 cable guide bracket can not be used on a Sportster chassis due to insufficient frame clearance, throttle cables on Sportsters originally equipped with a CV type carburetor must be changed to butterfly style cables. S&S can supply the correct style throttle cables. See S&S Throttle Cable Application Chart. Picture 2 S&S THROTTLE CABLE APPLICATION CHART Length Total Housing Length Vinyl Housing Part Number Open Side Part Number Close Side Fitment 36″ 32″ #19-0430 #19-0431 For Buell with 7/8″ handlebars 36″ 32″ #19-0432 #19-0433 To ’95 ’81-’85 FX and FL; All ’81-’85 XL (Also pre-’81 w/2-cable throttle housing replaced.) For Buell with 1″ diameter handlebar 36″ 32″ #19-0436 #19-0437 ’96-Up 883-1200 XL 39″ 35″ #19-0434 #19-0435 To ’95 Softail (FXSTC, FXST, FLSTC, FLSTF) ’86-’94 FXR, ’93-’95 Dyna 39″ 35″ #19-0438 #19-0439 ’96-Up Softail (FXSTS, FXSTC, FLSTC, FLSTF) ’96-Up Dyna 42″ 38″ #19-0446 #19-0447 To ’95 custom application 42″ 38″ #19-0440 #19-0441 ’96-Up custom application 48″ 44″ #19-0462 #19-0463 To ’95 All FLT Models 48″ 44″ #19-0464 #19-0465 ’96-Up All FLT Models ” 1996 to Present Buells 1996 and 1997 Buells require special S&S butterfly style throttle cables for Buells, which are compatible with the stock 1996-1997 throttle assembly. 1998 and later carburated Buells require installation of stock 1996 – 97 throttle grip and the special S&S Buell style throttle cables when installing Super E or G carburetors. S&S Throttle Kits S&S throttle kits fit 1″ handlebars and can be used on most chassis. (An adapter sleeve is available for use with earlier, 7 ⁄ 8 ” OEM handlebars originally equipped with internal throttle cable.) Barrel fittings on S&S cables readily “plug in” to S&S Super E, G, and stock H-D 1981-’90 butterfly type carb throttle linkage. Kits include one opening and one closing side cable, left and right grips, and handlebar clamps. Kits with 36″, 39″, 42″, or 48″ length cables are available. Length specified refers to overall cable length. Vinyl covered outer housing is 4″ shorter than overall length

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YAMAHA XVS 650AK Supplementary Service Manual

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Filed Under (Yamaha) by admin on 18-11-2010

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Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,450 mm (96.5 in) 930 mm (36.6 in) 1,105 mm (43.5 in) 710 mm (28.0 in) 1,625 mm (64.0 in) 145 mm (57.1 in) 3,400 mm (133.9 in) Basic weight: With oil and a full fuel tank 247 kg (544.5 lb) Bulb wattage quantity: Headlight Tail/brake light Front turn signal/position light Rear turn signal light Meter light Neutral indicator light High beam indicator light Turn indicator light Engine indicator light 12 V 60 W/55 W 1 12 V 8 W/27 W 1 12 V 27 W/8 W 2 12 V 27 W 2 12 V 1.7 W 1 12 V 1.7 W 1 12 V 1.7 W 1 12 V 1.7 W 1 12 V 1.7 W 1 ENGINE Item Standard Limit Connecting rod: Oil clearance Color code (corresponding size) 0.031 0.055 mm (0.0012 0.0022 in) Blue Black Brown Green CHASSIS Item Standard Limit Front suspension: Front fork travel Fork spring free length Installed length Spring rate (K1) Stroke (K1) Optional spring Oil capacity Oil level Oil grade 140 mm (5.5 in) 332.5 mm (3.1 in) 287.4 mm (11.3 in) 3.43 N/mm (0.343 kg/mm, 19.2 lb/in) 0 140 mm (0 5.5 in) No 0.507 L (17.4 US oz) 95 mm (3.74 in) Yamaha fork oil 10 WT or equivalent 325.9 mm (12.83 in) Front brake: Type Disc outside diameter thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Single disk 298 5 mm (11.73 0.2 in) 6.0 mm (0.24 in) 6.0 mm (0.24 in) 14.0 mm (0.55 in) 30.2 mm (1.19 in) 33.3 mm (1.31 in) DOT 4 4.5 mm (0.18 in) 0.8 mm (0.03 in) 0.8 mm (0.03 in) Brake lever & brake pedal: Brake lever free play (at pivot) Brake lever free play (at lever end) Brake pedal position Brake pedal free play Clutch lever free play (at pivot) Clutch lever free play (at lever end) 1 2 mm (0.04 0.08 in) 10 15 mm (0.39 0.59 in) 108 mm (4.25 in) 20 30 mm (0.79 1.18 in) 2 3 mm (0.08 0.12 in) 10 15 mm (0.39 0.59 in)

TOYOTA SPECIALTY AND REPLACEMENT PARTS

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Filed Under (Toyota Manuals) by admin on 30-09-2011

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73-3844 Replaces: 3977775, 3078511 CLIP -HOOD INSULATION Head Dia.: 2″ Length: 3/4″ G.M. ’64/ UNIT PACKAGE 100 79-5126 Replaces: 20064875 CLIP -HOOD INSULATION Head Dia.: 1 21/32″ Length: 3/4″ G.M. ’78/ UNIT PACKAGE 50 79-5127 Replaces: 20030401 CLIP -HOOD INSULATION Head Dia.: 1 3/8″ Length: 1″ G.M. ’80/ UNIT PACKAGE 50 79-5100 Replaces: 388908-S RETAINER -HOOD INSULATION Head Dia.: 1-3/4″ Ford ’80/ UNIT PACKAGE 100 74-3945 Replaces: 385330-S, 6003351 FASTENER -HOOD INSULATION Ford & Chrysler Products ’73/ AMC 4005513 ’76 UNIT PACKAGE 100 92-7067 Replaces: 15678493, 21039141 RETAINER -HOOD INSULATION Head Dia.: 1-9/16″ Length: 1/2″, Hole: 1/4″ Plastic Saturn ’91/ UNIT PACKAGE 25 67-3119 Replaces: 389809, C6GY-16776-A CLIP -HOOD INSULATION RETAINER 1-1/2″ x 1-1/2″ Plastic G.M., Ford Products UNIT PACKAGE 50 72-3718 Replaces: 389089 FASTENER -HOOD INSULATION 2″ x 2″ Plastic G.M. Cars UNIT PACKAGE 50 99-8032 Replaces: 385595-S, 386553-S RETAINER -HOOD INSULATION Plastic Formerly 74-3944 For Heavier Type Insulation Head: 1-3/16 Ford ’74/ UNIT PACKAGE 50 95-7382 Replaces: N-803613-S RETAINER -HOOD INSULATION Hole: 1/4″, Head: 1-3/4″ Stem Length: 7/8″ Plastic Ford Explorer ’91/, Taurus, Sable, Mustang, Continental ’92/ UNIT PACKAGE 50 95-7369 Replaces: W700671-S300 RETAINER -HOOD INSULATION Head Dia.: 25MM, Hole: 8MM Black Plastic Ford Contour & Mercury Mystique ’95/ UNIT PACKAGE 15 96-7577 Replaces: 01644290, 15678979, 01553-0075U RETAINER -SPEAKER, DOOR SILL, BUMPER, HOOD INSULATOR Black Plastic Hole: M6, Barb Length: 12MM Head Dia.: 11MM, O/L: 19MM G.M. Various Models ’86/, Nissan Altima & Maxima 2002/

HONDA FURY FRONT HEADPIPE W/HEATSHIELD, REAR HEADPIPE / MUFFLER W/HEATSHIELD INSTALLATION MANUAL

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

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Remove your stock exhaust system and stock exhaust mount. Save the (4) acorn nuts that attach the headpipes to the cylinders for later use during installation. 2. Install exhaust mounting bracket onto outside of frame, where stock mounting bolts were removed, by inserting the supplied M10 x 70 mm bolt into the top mounting hole and the shorter M10 x 45 mm into the lower and thru the frame, see Figure 1. Start threading the supplied M10 Nylock nut onto lower and upper bolts but DO NOT FULLY TIGHTEN. 3. Loosen the right footpeg/floorboard assembly to help provide installation clearance for the front headpipe. 4. Slide the supplied exhaust flange over the front headpipe and bolt to cylinder using stock hardware from Step 1. DO NOT TIGHTEN at this time. 5. Place the supplied 27-61msc clamp onto the lower muffler slip collar then slide the rear headpipe / muffler assembly onto the front headpipe and into the rear exhaust port. Bolt rear headpipe to the rear cylinder using the stock acorn nuts from Step 1. See Figure 2 for clamp orientation. 6. Bolt the muffler assembly to the mounting bracket using the supplied 5/16 bolts. DO NOT TIGHTEN . 7. Make sure the front headpipe is inserted properly into the rear assembly and make sure the pipes are parallel with each other. Fully tighten the exhaust bracket to the frame first, then the front and rear cylinder acorn nuts attaching the exhaust flanges, then the muffler to the exhaust bracket. Then tighten the 27-61msc clamp last. (NOTE: If the muffler clamp is slid past the slots on the slip collar the clamp will not tighten properly.) 8. Unscrew the remaining hose clamps and feed the tail end of the clamp through the clips on the inside of the heatshields, the larger clamps go to the rear of the heatshields where they will rest on the muffler bodies, smaller ones to the front for the headpipes. The screw end of the hose clamp should be accessible for tightening but not visible when heatshields are mounted to the pipes, see Figure 3. 9. To install the front heatshield, first slide the rear portion of the heatshield over the muffler, continue to slowly slide it forward pushing the front of the shield gently into place between the frame and motor (Hint: Spread the hose clamps apart slightly to make it easier to slide them over the muffler assembly and headpipes). Make sure the muffler clamp doesn’t interfere with the heatshields and is aligned as shown in Figure 2. Snug the heatshield clamps but DO NOT TIGHTEN . 10. Install the rear heatshield in the same manor as the front heatshield. Tighten all hose clamps.

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1985-1990 Kawasaki 454LTD EN450 Specifications

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Filed Under (Kawasaki) by admin on 05-11-2010

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Minimum Turning Radius 2.5 m (98.43 in) Braking Distance 12.5 m from 50 km/h (41 ft from 31 mph) DIMENSIONS Overall Length 2,205 mm (86.81 in) Overall Width 820 mm (32.3 in) Overall Height 1,220 mm (48.03 in) Wheelbase 1,485 mm (58.46 in) Road Clearance 130 mm (5.12 in) Dry Weight 180 kg (397 lbs) / 180.5 (398 lbs) ENGINE Type DOHC, 2-cylinder, 4-stroke, liquid-cooled Displacement 454 mL (27.7 cu in) Bore & Stroke 72.5 x 55.0 mm (2.85 x 2.17 in) Compression Ratio 10.7 : 1 Starting System Electric Starter Cylinder Numbering Method Left to Right, 1-2 Firing Order 1-2 Carburetors Keihin CVK34 x2 Ignition System Battery and coil (transistorized ignition) Ignition Timing (Electronically advanced) 10° BTDC @ 1,200 r/min (rpm) – 37.5° BTDC @ 10,000 r/min (rpm) Spark Plugs NGK D9EA or ND X27ES-U NGK DR8ES or ND X27ESR-U Lubrication System Forced lubrication (wet sump) Engine Oil SE or SF class SAE 10W40, 10W50, 20W40, or 20W50 Engine Oil Capacity 3.4 L (3.6 US qt) Coolant Capacity 1.4 L (1.5 US qt) Kawasaki 1985-90 454LTD EN450 Specifications Page 2 of 2 TRANSMISSION Transmission Type 6-speed, constant mesh, return shift Clutch Type Wet, multi disc Driving System Belt Drive Primary Reduction Ratio 2.952 (62/21) Final Reduction Ratio 2.720 (68/25) Overall Drive Ratio 6.840 (Top gear) Gear Ratio: 1st 2.571 (36/14) 2nd 1.777 (32/18) 3rd 1.380 (29/21) 4th 1.125 (27/24) 5th 0.961 (25/26) 6th 0.851 (23/27) FRAME Castor 31.5° Trail 139 mm (5.47 in) Tire Size Front: 100/90-19 57S Rear: 140/90-15 70S Fuel Tank Capacity 11 L (2.9 US gal) ELECTRICAL EQUIPMENT Battery 12 V 12 AH Headlight 12 V 60/55 W Tail/Brake Light 12 V 8/27 W x2

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2011 Ninja ZX-10R Review And SPECIFICATIONS

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Filed Under (Kawasaki) by admin on 13-12-2010

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1. Big Piston Fork (BPF) and Öhlins Steering Damper Throwing out the anchors at track speed demands a fork that remains composed under pressure. The fully adjustable new Big Piston Fork (BPF) does just that by significantly reducing damping pressure while maintaining consistent damping force. The standard Öhlins Steering Damper is likewise adjustable to help you dial in the steering damping level you need. 2. Horizontal Back-Link Rear Suspension New rear suspension positions the shock and its linkage above the swingarm, leaving room beneath the bike for a larger exhaust pre-chamber. The move helps centralize mass for better transitional cornering response, while also improving overall suspension action and road holding. The piggyback-reservoir shock is fully adjustable, including both low- and high-speed compression-damping circuits. 3. Adjustable Footpegs Adapting the ZX-10R for a day at the track or a long street ride is easy, thanks to its new adjustable footpegs. Raise the footpegs to improve your cornering clearance on the track, or lower them for a more relaxed riding position on the street or highway. The total range of adjustment is 15mm. 1. 2. 3. SPECIFICATIONS Engine Four-stroke, liquid-cooled, DOHC, four valves per cylinder, inline-four Displacement 998cc Bore X Stroke 76.0 x 55.0 mm Compression Ratio 13.0:1 Fuel System DFI® with four 47mm Keihin throttle bodies with oval sub-throttles, two injectors per cylinder Ignition TCBI with digital advance and Sport-Kawasaki Traction Control (S-KTRC) Transmission Six-speed Final Drive Chain Rake/Trail 25.0deg / 4.33 in. Front Tire Size 120/70 ZR17 Rear Tire Size 190/55 ZR17 Wheelbase 56.1 in. Front Suspension / Wheel Travel 43mm inverted Big Piston Fork (BPF) with DLC coating, adjustable rebound and compression damping, spring preload adjustability / 4.7 in. Rear Suspension / Wheel Travel Horizontal Back-link with gas-charged shock and top-out spring, stepless, dual-range (low-/high- speed) compression damping, stepless rebound damping, fully adjustable spring preload / 4.9 in. Front Brakes Kawasaki Intelligent anti-lock Braking (KIBS), dual semi-floating 310mm petal discs with dual four-piston radial-mount calipers Rear Brakes KIBS-controlled, single 220mm petal disc with aluminum single-piston caliper Fuel Capacity 4.5 gal. Seat Height 32.0 in. Curb Weight TBD Overall Length 81.7 in. Overall Width 28.2 in. Overall Height 43.9 in. Color Choices Lime Green / Ebony, Ebony / Flat Ebony Warranty 12 Months Good Times™ Protection Plan 12, 24, 36, 48 months PERFORMANCE PARTS Kawasaki offers a full line of performance parts for your new motorcycle. COVER Constructed of water-resistant polyester and a unique shielded vent system that allows built-up moisture to vent. Reinforced grommet at the bottom hem allows the cover to be locked to the bike for added security. Heat resistant panels in the exhaust area. Oversized fit allows for easy installation and removal.

Honda Goldwing GL1800 Solid Rear Axle Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Specifications Overall Width: 57.75″ Overall Length: 108″ Overall Length w/EZ-Steer 109.5 Wheel Base: 71″ Extended 4.5″ At Rear Axel Wheel Base w/EZ Steer 72.5″ Load Capacity: 500 Lb Tire Size: 205 / 70 / R15 Wheel Size (15″) Offset +35 mm 15x7JJ 4×4.5 Tire Pressure 20 PSI Suspension: “Zero-Flex” Internal Swing Arm utilizing 3 shocks, OEM shock absorber plus 2 coil over shock absorbers. Rear Differential: Champion Lightweight rear axle / differential assembly. Gear Ratio 2.93:1 gear ratio Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 6.75 cubic feet. 3 full-face helmets and additional storage. Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 7 of 28 Revision 10 4 Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. • Seat (to be re-installed without modification) • Left and right side covers (to be re-installed without modification) • Battery and battery box (to be re-installed without modification) • Left and right saddle bags • Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) • Trunk (to be re-installed without modification) • Left and right passenger foot rests (to be re-installed without modification) • Left and right foot rest under covers (to be modified and re-installed) • Left and right rear crash bars • Saddle bag trunk stay (to be modified and re-installed) • Left and right mufflers (Mufflers only, do not remove decorative covers) • Rear wheel • Left and right pivot bolt covers (to be re-installed without modification) • Reverse resistor (to be relocated) • Swing Arm – Note : Carry out brake system modifications (Section 5) prior to removing Swing Arm. • Note : Upper bolt of mono shock can be removed without removing the fuel tank. • Note : Do not remove actuator hose from actuator pump or shock absorber. Dismounting shock actuator pump will allow more movement of shock absorber when removing swing arm.Trike Conversion Installation Kit Honda Goldwing GL1800 Champion Trikes Page 8 of 28 Revision 10 5 Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm. From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Sidecars Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Sidecars Trike Conversion Kit.

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Honda VTX 1800 Motorcycles ALL Models (Excluding C Model) Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 17-02-2011

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Specifications Overall width 55.5 in. Overall length 108.06 in. Overall length w/ EZ-Steer 111.75 in. Wheelbase 72.44 in. Wheelbase w/ EZ-Steer 76.125 in. Load capacity 640 lbs. Brakes High-performance rear disc Tires 205/70R-15 Turning Radius 12.3 ft. Wheels Offset +35 mm 15x7JJ 4×4.5 Tire Pressure 20-25 psi · Suspension: “Zero-Flex” swing arm and two new (replacement) Progressive coil-over shocks. · Rear Differential: Champion Left Hand Drive Light Weight Rear Differential Assembly. · Brakes: Original front plus 2 high performance disc brakes at rear. · Storage Capacity: 6.75 cubic feet – 3 full-face helmets and additional over wheel storage. 2 Removal of Original Parts Secure and raise the motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. · Rider’s Seat (to be re-installed without modification) . · Passenger Seat and mounts (to be reinstalled without modification) . NOTE: OEM front and rear seat mounting bolts to be retained and reused. · Left and right passenger foot rests and mounts (to be reinstalled with modification) . · Mufflers (to be re-installed and relocated with minor modification) . · Rear Fender (complete w/ sub frame and all attaching parts) . · Swing Arm, Drive Shaft and Rear Wheel (complete w/ brake line and all attaching parts) . Core Return There are NO core return parts for this model. Installation of Champion Trike Conversion Kit 3.1 Modify Frame and Passenger Footrests. a. Use 17/64″ drill and drill through frame from inside out using passenger footrest mount holes as guide. b. Enlarge the passenger footrest mounting holes on the left and right side of the frame to 27/64″. c. Enlarge the holes in the left and right passenger footrest mounting plates to 27/64″. d. Clean area of all debris. 3.2 Relocate Regulator a. Install supplied “Z” bracket to the regulator as shown using the supplied hardware. b. Attach regulator to frame using the supplied hardware. c. Tie hoses down to avoid contact with the swing arm. Qty Description 1 ¼-20×2 hex head bolt 1 ¼-20×1-1/4 hex head bolt 6 ¼-20 Nyloc nut 10 1/4- SAE flat washer 4 as spacers 3.3 Hose Stay a. For models that have a recover tank below the swing-arm, a holder has been included keep the hose connected to the water pump away from the champion swing-arm. b. Remove the hose from the top of the recovery tank. c. Push the water pump hose forward against transmission. d. Secure hose with supplied stay as shown using existing bolt. Ensure that hose is not being crushed. Bend stay if necessary. e. Reconnect hose to recovery tank

HARLEY-DAVIDSON SPORTSTER MID-LENGTH INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-04-2012

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1. Find and unplug the O² sensor wires from the wiring harness and remove the ZIPSTRIP holding front O² sensor wires to the frame. Feed the end of the wire through the frame so they are free from the motorcycle. Note: pay attention to wire routing for re-installation. 2. Loosen the heat shield clamps on both the front and rear head pipe to gain easier access to the mounting nuts. 3. Remove the two head pipe mounting nuts from the flange at the heads. 4. Remove the clamp bolts that mounts the rear head pipe to the belt drive cover bracket. 5. Remove the two bolts from each muffler body where they attach to the stock mounting bracket. Carefully remove the exhaust system from the motorcycle and set aside. 6. Using a 7/8″ wrench, carefully remove the O² sensors from the stock head pipes and save for re-use on your RUSH system. 7. Remove the drive belt cover and remove the bracket off the rear cover bolt, bracket will not be re-used. 8. Loosen the brake rod at the rear eyelet using a T-30 torx socket. 9. Remove the three mounting bolts and washers attaching the exhaust mounting bracket. 10. If equipped with mid-controls, remove right side foot peg before installing your new RUSH system.

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HONDA 2002-2004 GL1800/A Linked Braking System (LBS) Proportional Control Valve (PCV) Leakage

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

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1. Pump the rear brake pedal four times. •If the brake pedal feels spongy, bleed the brake system per the Service Manual. After verifying proper brake system operation, proceed to step 2 below. •If the brake pedal does not feel spongy, proceed to step 2 below. 2. Place the motorcycle on its side stand, with the handlebars in the full left position . Lock the handlebars. 3. Place a scissor jack directly under the left front brake caliper as shown in the illustration. To avoid damage to the caliper, place a protective piece of rubber (such as a piece of inner tube) between the caliper and the jack. Wind up the jack until the front wheel is approximately 15 mm off the ground. 4. Measure the distance from the secondary master cylinder piston mounting bolt to the edge of the secondary master cylinder body (rod length of the secondary master cylinder). Record this measurement . • If the measured length is 30.3 mm, replace the PCV per the Service Manual. (This length indicates the unit’s secondary master cylinder is fully stroked, which means there is no hydraulic brake pressure acting on the PCV.) After replacing the PCV, proceed to the IDENTIFICATION section of this Service Bulletin. •If the measured length is longer than 30.3 mm , proceed to step 5 below. • INSPECTION/REPAIR PROCEDURE Record this measurement. Pump the rear brake pedal four times.
GL1800/A #16 ©2005 American Honda Motor Co., Inc. – All Rights Reserved 3 of 6 FEBRUARY 2005 5. Wait 30 minutes. Do not disturb the motorcycle in any way during this time. 6. Measure the distance again from the secondary master cylinder piston mounting bolt to the edge of the secondary master cylinder body (rod length of the secondary master cylinder). •If the measurement has decreased more than 1 mm from the measurement you recorded, proceed to step 7 below. •If the measurement is within 1 mm of the measurement you recorded, the PCV is OK. Proceed to the IDENTIFICATION section of this Service Bulletin. 7. Check the PCV for leakage. • If the PCV is leaking , replace the PCV per the Service Manual. After replacing the PCV, proceed to the IDENTIFICATION section of this Service Bulletin. • If the PCV is not leaking , you must diagnose the brake system problem before proceeding. After you have diagnosed and repaired the brake system, proceed to the IDENTIFICATION section of this Service Bulletin. NOTE: Any brake system problem not related to the PCV that is found while performing this Service Bulletin is not covered by this Safety Recall. If the motorcycle’s original factory warranty is still in effect or under HPP, file a normal warranty claim. If the unit is outside its factory warranty period or HPP coverage, contact TechLine for goodwill consideration. 8. Verify proper front and rear brake operation by pumping the front brake lever and rear brake pedal before riding the motorcycle

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