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2003 SUZUKI SV 1000 Service Manual

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Filed Under (Suzuki) by admin on 26-02-2011

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HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : 1. The text of this manual is divided into sections . 2. The section titles are listed in the GROUP INDEX . 3 . Holding the manual as shown at the right will allow you to find the first page of the section easily . 4. The contents are listed on the first page of each section to help you find the item and page you need . COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view . Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided . Example: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 1 OW-40 . If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart . BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result . Do not use any brake fluid taken from old or used or unsealed containers . Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil . GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only . WATER FOR MIXING Use distilled water only . Water other than distilled water can corrode and clog the aluminum radiator . ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze . Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator . LIQUID AMOUNT OF WATER/ENGINE COOLANT

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SUZUKI VX800 ENGINE MANUAL

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

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1. Use only unleaded gasoline of at least 87 pump octane by the F method or 91 octane or higher rated by the Research method. alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6. Failure to follow these guideline could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above COOLANT Use an anti-freeze/coolant compatible with an aluminum radiator, mixed with distrilled water only. WATER FOR MIXING Use distrilled water only. Water other than distrilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/COOLANT The coolant perform as a corrosion and rust inhabit as well as anti-freeze. Therefore, the coolant should be used at all times even though the atomospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI GOLDEN CRUISER 1200NA anti-freeze/coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator

HI-4 DUAL FIRE MOTORCYCLE IGNITION INSTALLATION INSTRUCTIONS

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

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

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Suzuki SV1000 COOLING AND LUBRICATION SYSTEM REPAIR MANUAL

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Filed Under (Suzuki) by admin on 25-02-2011

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At the time of manufacture, the cooling system is filled with a 50 :50 mixture of distilled water and ethylene glycol anti-freeze . This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system from freezing at temperatures above -31 °C (-24 °F) . If the motorcycle is to be exposed to temperatures below -31 °C (-24 °F), this mixing ratio should be increased up to 55 % or 60 % according to the figure. CAUTION • Use a high quality ethylene glycol base anti-freeze, mixed with distilled water . Do not mix an alcohol base anti-freeze and different brands of anti-freeze. • Do not rut in more than 60%anti-freeze or less than 50 %. (Refer to the right figure.) • * Do not use a radiator anti-leak additive. A WARNING COOLING AND LUBRICATION SYSTEM 5-3 20 40 60 80100 0 10 20 30 40 50 60 Density (%) Fig .2 Engine coolant density-boiling point curve • * You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot . After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off . • * The engine must be cool before servicing the cooling system . • * Coolant is farmful; • * If the comes in contact with skin or eyes, flush with water. • * If swallowed accidentally, induce vomiting and call physician immediately . • * Keep it away from children . Anti-freeze density Freezing point 50% -31 °C (-24 °F) 55% -40 °C (-40 °F) 60% -55 °C (-67 °F) 50 % engine coolant including reservoir tank capacity Anti-freeze 1 100 ml (2.3/1 .9 US/Imp-pt) Water 1 100 ml (2.3/1.9 US/Imp.pt) Density (%) Fig.1 Engine coolant density-freezing point curve (°F) (°C) 302 150 (kgf/cm2) 284 140 1.5 c Q 266 130 0.9 0) a) :0 248 120 0.5 0) m Z3 230 110 0 (7 212 100 (F) (C) 32 0 14 -10 -4 -20 C 0 Q -22 -30 O) C N -40 -40 a) a) U- -58 -50 -76 -60 -94 -70 5-4 COOLING AND LUBRICATION SYSTEM COOLING CIRCUIT THERMOSTAT RESERVOIR TANK RADIATOR NO. 1 CYLINDER HEAD NO . 1 CYLINDER NO. 2 CYLINDER NO. 2 CYLINDER HEAD WATER PUMP INSPECTION Before removing the radiator and draining engine coolant, inspect the cooling circuit for tightness. • * Remove the body cowling. (=6-6) • * Remove the radiator cap ® . • * Connect the tester 02 to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • * Give a pressure of about 110 kPa (1.1 kgf/cm 2, 15 .6 psi) and see if the system holds this pressure for 10 seconds. • * If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system. In such a case, inspect the entire system and replace the leaking component or part. A WARNING When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. CAUTION Do not allow the pressure to exceed the radiator cap release pressure, or the radiator can be damaged

2006 King Cobra Service Procedure

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Filed Under (Cobra) by admin on 10-11-2010

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Cobra CX50 SR is a close-tolerance high performance machine and break- in time is very important for maximum life and performance. The CX50 SR can be ridden hard after the first ½ hour break-in time but it is recommended that no adjustments are made to the carburetion or suspension until the full 8 hours of bike break-in has elapsed. Also, after the engine, transmission, and drive train have been broken-in for the full 8 hours, the bike will be faster! Use a fuel / oil mixture of 32:1 for the full 8 hour break-in period. Be sure to use high-octane pump gas, with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil . (Part # MCMUOL02) CAUTION: Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine wear or damage to the machine. Adhering to the following break-in schedule will result in long lasting high performance machine. • Start bike on stand • First 5 minute period, operate the bike on the stand with a combination of idle and high RPM operation. (avoid prolonged high RPM but spin the rear wheel good at least once or twice per minute) • Allow bike to cool • Ride for 15 minutes maximum (avoid prolonged high RPM operation and avoid abusing the clutch with throttle blipping. • Cool and inspect bike for loose fasteners. • Next ½ hour of operation, avoid prolonged operation at Wide Open Throttle. • After 1 hour of operation o Check for loose bolts and nuts on the bike and retighten as necessary (proper toque values are listed under Specifications). o Clean the carburetor bowl. o Change the transmission / clutch lubricant. • After 8 hours of operation o Change the fork oil. o Have a Certified Cobra Mechanic change the shock oil. • Your bike is now ready for the highest level of competition! NOTE: During break-in the bike will likely lose some engine coolant through the radiator overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level will cover the top of the radiator cores. Removing the radiator cap and looking inside is the only way to check the coolant level. 8
Never open the radiator cap of a machine that has a hot or warm engine or one that has recently been ridden. Burning and scalding could occur. CAUTION: It is important that the radiator cap is installed correctly and completely otherwise engine damage could occur. Starting Procedure Before starting the machine inspect the following: • Check for proper tire pressure in both tires. • Observe the chain tension and adjust if necessary. • Observe the coolant level and fill if necessary. • Verify that the chain rollers and sliders do not have improper wear. • Verify that the handlebars are tight. • Check the throttle for smooth operation and that it ‘clacks’ shut properly. • Check for loose bolts and nuts, and re-torque as necessary. • Verify that the air filter is clean and properly saturated with oil. • Insure that the fuel tank contains an adequate volume of fuel / oil mixture to complete the distance required. (High octane pump gas with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil ) • Turn the fuel on by rotating the fuel petcock knob to the vertically downward position (reserve position is horizontally forward) CAUTION: For best results from your Cobra Motorcycle use only the recommended fuels. Testing has shown that most ‘race’ fuels actually degrade performance. Always wear a helmet and other protective riding gear. When your pre-ride inspection is complete the bike may be started. For a cold engine follow this procedure. 1. Place the motorcycle on a stand of sufficient strength that positions the motorcycle in a level upright position with the rear wheel off the ground. 2. Pull up the choke knob and turn it to lock it. 3. Kick start the engine. 4. Rev the engine in short spurts, turning the throttle no more than 1/4 open until the engine will run without the choke.

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Ultima Billet Rear Shocks Installation Instruction Sheet

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Filed Under (Tips and Review) by admin on 30-11-2010

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Unloading the rear suspension Use a jack under a flat part of the motorcycle and lift until the rear tire is barely resting on the surface. This ensures that the shocks are unloaded. They are now ready for removal. Remove the old shocks Refer to the service manual specific to your motorcycle for this process. Unbolt the old shocks. Save the necessary hardware if you have not purchased new hardware. Installation Shocks should be installed with the preload adjuster on top (see Preload Adjustment). With the new shocks in hand; please go over the hardware configuration diagram (Figure 3) to decide which configuration best fits your application. Spacers are included to provide clearance between the shocks and your motorcycle (Figure 4). Typically start on which ever side the final drive is located. This side normally causes the clearance issues. Each eye and each side should be configured the same way. Make sure to use the proper hardware so that the shock- bushings fit the shock-bolts as snugly as possible. Shocks come with a 1/2″ ID bushing installed. This is needed for all applications. An optional bushing is included and should be used in addition when 3/8″ bolts are used instead of the larger 1/2″bolts. Unless new hardware was purchased, you will use the stock bolts from your old shocks to install the new shocks. Use Red Locktite (or equivalent) and use a torque wrench to tighten as follows: Models that use 1/2″ bolts: 65ft-lbs Models that use 3/8″ bolts: 30ft-lbs (Figures 1 & 2) Be sure to check clearance between the shock and the belt-guard. If there is any contact you will need to alter your spacer arrangement to accommodate this. Check tire to fender clearance as well. This clearance will be reduced when lowering shocks are used. Preload Adjustment Your new Ultima Billet Shocks are preload adjustable. Adjustment should be done once the shocks are installed. To adjust use a strap wrench and turn the top part of the shock (Figure 6) clock-wise to tighten or provide more preload (this stiffens the suspension), or counter-clockwise to loosen or subtract preload (this softens the suspension). Hand adjustments may be sufficient on models with smaller spring rates while the strap wrench will be required on the high spring rate shocks. You will see notches (Figure 6) that appear on the shock as the shock is preloaded. These should help you obtain the same preload for both sides of the motorcycle. Both shocks should be adjusted to the same level of preload.

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2007 King 50 Specifications, Owners Parts, Service Tuning

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

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Use a fuel / oil mixture of 32:1 for the full 8 hour break-in period. Be sure to use high-octane pump gas, with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil . (Part # MCMUOL02) CAUTION: Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine wear or damage to the machine. Adhering to the following break-in schedule will result in long lasting high performance machine. • Start bike on stand • First 5 minute period, operate the bike on the stand with a combination of idle and high RPM operation. (avoid prolonged high RPM but spin the rear wheel good at least once or twice per minute) • Allow bike to cool • Ride for 15 minutes maximum (avoid prolonged high RPM operation and avoid abusing the clutch with throttle blipping. • Cool and inspect bike for loose fasteners. • Next ½ hour of operation, avoid prolonged operation at Wide Open Throttle. • After 1 hour of operation o Check for loose bolts and nuts on the bike and retighten as necessary (proper toque values are listed under Specifications). o Clean the carburetor bowl. o Change the transmission / clutch lubricant. • After 8 hours of operation o Change the fork oil. o Have a Certified Cobra Mechanic change the shock oil. • Your bike is now ready for the highest level of competition! NOTE: During break-in the bike will likely lose some engine coolant through the radiator overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level will cover the top of the radiator cores. Removing the radiator cap and looking inside is the only way to check the coolant level. 8 Never open the radiator cap of a machine that has a hot or warm engine or one that has recently been ridden. Burning and scalding could occur. CAUTION: It is important that the radiator cap is installed correctly and completely otherwise engine damage could occur. Starting Procedure Before starting the machine inspect the following: • Check for proper tire pressure in both tires. • Observe the chain tension and adjust if necessary. • Observe the coolant level and fill if necessary. • Verify that the chain rollers and sliders do not have improper wear. • Verify that the handlebars are tight. • Check the throttle for smooth operation and that it ‘clacks’ shut properly. • Check for loose bolts and nuts, and re-torque as necessary. • Verify that the air filter is clean and properly saturated with oil. • Insure that the fuel tank contains an adequate volume of fuel / oil mixture to complete the distance required. (High octane pump gas with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil ) • Turn the fuel on by rotating the fuel petcock knob to the vertically downward position (reserve position is horizontally forward

Triumph Center Mount Oil Pressure Gauge with active oil light Installation

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Filed Under (Triumph) by admin on 29-10-2010

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Remove the two hex head screws and spacers that secure the handlebars. Attach the oil pressure mounting bracket using the bolts removed earlier. It is not necessary to use the spacers as the bracket is the same thickness as the spacers that were removed. Make sure the oil pressure gauge bracket is clamped securely so that the handlebars cannot rotate. This part of the assembly is complete. Do not tighten the fitting mounted on the far side of the Swivel body. This fitting is designed to rotate and is sealed in place with Loctite 242 thread sealant. Over tightening will shear the threads resulting in destruction of the fitting. Remove oil pressure sending unit. Sit the copper crush washer aside for future use. The Swivel and Swivel Adaptor are supplied assembled. Remove the plug from the rear of the Swivel. Slip the crush washer removed earlier over the end of the Adaptor. There is an ‘O’-ring seal between the Adaptor and the Swivel, leaving the two assembled will prevent damage to the seal. Thread the Adaptor, with Swivel still attached, into the port from where the original sending unit was removed. With the use of a 5/32″ Allan wrench, reach inside the Swivel and tighten the Swivel against the Adaptor. Install the original oil pressure sending unit in the top port as shown using the new copper crush washer supplied. Use a wrench on both the Swivel and the original oil pressure sending unit to prevent imparting stress on the Adaptor to Swivel junction. Reinstall the 1/8 NPT plug in the end of the Swivel using with the use of a 3/16″ Allan wrench. Use Loctite 242 or equivalent semi-permanent thread sealant at this junction. Do not over tighten. Use a 3/16″ Allan wrench on the plug and an open end wrench on the Swivel to prevent imparting stress on the Adaptor to Swivel junction. Next, attach one end of the oil pressure line to the swivel fitting (located far side) by pushing the end of the tubing into the hole at the end of the fitting. FYI: these fittings are quick disconnect and self-clinching. They need only to be pushed in to connect. They will not slip out unless the ferrule at the end of the fitting is pushed back away from the tubing as the tubing is pulled from the fitting. Routing: Next, route the other end of the tube up along the frame and in front of the steering head over to the fitting in the gauge body. Avoid the exhaust pipes when routing the tubing. Push the end of the tube into the gauge fitting as was done at the swivel fitting at the other end of the tube. The tubing can be removed and cut to the length required by your routing. Make sure there is enough service loop remaining so

YAMAHA YZF-R125 SPECIFICATIONS AND OWNER'S MANUAL

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

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Fuel tank cap To remove the fuel tank cap 1. Open the fuel tank cap lock cover. 2. Insert the key into the lock and turn it 1/4 turn counterclockwise. The lock will be released and the fuel tank cap can be removed. To install the fuel tank cap 1. Push the fuel tank cap into position with the key inserted in the lock. 2. Turn the key clockwise to the original position, and then remove it. 3. Close the lock cover. NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. WARNING EWA11140 Make sure that the fuel tank cap is properly installed before riding. EAU13211 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. WARNING EWA10880 Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. Avoid spilling fuel on the hot en- gine. 1. Fuel tank cap lock cover 2. Unlock. 1. Fuel tank filler tube 2. Fuel level
INSTRUMENT AND CONTROL FUNCTIONS 3-8 3 CAUTION: ECA10070 Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU43420 CAUTION: ECA11400 Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your Yamaha engine has been designed to use premium unleaded gasoline with a research octane number of 95 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. EAU13442 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system. WARNING EWA10860 The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. CAUTION: ECA10700 The following precautions must be observed to prevent a fire hazard or other damages. Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. Never park the vehicle near possible fire hazards such as grass or other materials that easily burn. Do not allow the engine to idle too long.

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HONDA 420 RANCHER 2×4/4×4 2007-2009 CLUTCH KIT INSTRUCTIONS

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Filed Under (Honda) by admin on 22-12-2011

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Remove key from the ignition switch. Remove the side panels from both sides. Remove both foot wells. 2. Drain coolant. Remove the oil drain plug from the motor; if you carefully drain it into a clean container you should be able to reuse it. 3. Disconnect shift motor (on electric shift models only). Remove coolant hoses. 4. Remove the bolts that mount the front differential to the frame, no other parts need to be removed. Carefully slide the front differential towards the front of the machine; you might need to lift up slightly to get the differential to move. Remove the drive shaft. Remove o-ring on output shaft (on motor). 5. Remove the fuel pump. 6. Loosen the front crankcase cover bolts, keep track of each bolt length and location. Slowly remove the crankcase cover. Carefully watch for o-ring shims and dowel pins that may fall out. 7. Unstake the nut holding the clutch on and remove nut. Using Honda tool #07933-HB3000A thread the large part of the tool into the center of the clutch. Tighten the center bolt on the tool while holding the large part of the tool with a wrench. This will pull the clutch off the machine. Place the clutch on a clean work surface. EPI performance.com
8. Using the c-clamps push down slightly on the outside cover and remove the four e-clips. Keeping track of which way they come off, remove the round metal plates one at a time. This will allow you to see the complete spring. Remove one end of each spring using a spring tool or needle nose pliers and then remove springs. Install the EPI springs by inserting the spring into the outer edge first. Using a spring tool or pliers (45 degree bent pliers work well) pull on the spring and insert the end into the hole. Install the metal plates and the e-clips. If you can’t get the plates to sit flat make sure each clutch arm is flat against the bottom plate of the clutch. Occasionally when you put the springs on, the clutch arms will pop up. Slide the clutch into the machine. The Sprague clutch is marked “outside” when installing make sure this is facing out. Torque clutch nut to 87 ft/lbs. 9. Clean the gasket surface on the motor and on the cover. Put a thin layer of Honda Bond or Yamabond semi-drying liquid gasket (or something similar as long as it is semi-drying) on the crankcase cover. Carefully install crankcase cover, do not force cover on. Torque bolts to 9 ft/lbs. 10. Install the fuel pump. 11. Install the o-ring on the output shaft (on motor) and install the drive shaft. Carefully slide the front differential back into place and mount to the frame. Install the coolant hoses. Refill your engine coolant to the proper level according to your owner’s manual. 12. Install the oil drain plug. Refill your engine to the proper level according to your owner’s manual. You can reuse your oil if it is clean and was drained into a clean container. Only use manufactures recommended oil. 13. Be sure to double check coolant and oil levels and to look for any leaks after the machine has run for a few minutes. 14. Go out and ride your machine. If your performance doesn’t seem right double check to make sure everything has been done properly. 15. EPI is constantly testing our products. Sometimes there is a need to contact the user with new technical information. To ensure that you are receiving this information visit our web site EPIperformance.com to register your clutch kit.

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