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2004 KTM 950 ADVENTURE REPAIR MANUAL

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Filed Under (KTM) by admin on 23-11-2010

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Intake system Fresh air is drawn into the filter box through the intake snorkel 1 , past the carburetors 2 and through the air filter 3 . The cleaned air is conducted to the combustion chamber through the carburetors and intake ports. 1 2 2 3 2-4 Repair manual KTM LC8 Art.-Nr . 3.206.016-E Secondary air system The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the emissions. A line leads from the filter box 1 to the control valve 2 which opens as soon as the throttle valves 3 are opened. The line continues to the reed valves 4 in the cylinder heads which are actuated by the pressure pulsation in the exhaust system. As a result, cleansed fresh air arrives in the exhaust port. The oxygen content in the air and the high exhaust gas temperature cause the emissions to oxidize. If the throttle valves are closed and the engine goes into an overrun condition, the underpressure in the intake port will rise and the control valve will close. This prevents exhaust backfire (combustion of the unburned fuel/air mixture). 1 2 3 3 4 4 4 2-5 Closed thermostat The thermostat is closed if the temperature of the cooling liquid drops below 75°C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 and the thermostat 2 . Open thermostat The thermostat 3 opens at 75°C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 , the aluminum cooler 4 and the thermostat. The pressure in the cooling system (max. 1.4 bar) is regulated by a valve in the radiator cap 5 . The cooling liquid level in the compensating tank 6 must be between the MIN and MAX marks when the engine is cold. The fan 7 switches on at 102°C.

2007 – 2009 KAWASAKI Z 1000 RACING AND EVOLUTION EXHAUST SYSTEM

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

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The Akrapovic RACING OPEN & EVOLUTION OPEN line is the highest level of Akrapovic exhaust systems and with hexagonal shaped muffler fits perfectly with the aggressive character of the ‘Z’. The conical tubing with interference crossover tubes between the header tubes work exceptionally well. With the Akrapovic exhaust system you will get massive power boost, more torque, a sportier sound and an even more aggressive top- level look on this muscular roadster. You can choose between classy titanium or carbon- fiber mufflers that stand out through their excellent quality. The systems are available in open version only. Besides great power and torque, you will also save in overall weight, as the Akrapovic system weighs 10.21 kg (RACING) or 11.5 kg (EVOLUTION) less than the stock assembly. PERFORMANCE Measurements of the Akrapovic RACING OPEN & EVOLUTION OPEN system on the Ka- wasaki Z 1000: The power curve shows a huge increase over the stock performance figures. It is much more linear, which means the engine is pulling strong and consistently right from the lowest rpm to the highest part of the overrev range. We measured a maximum increased power of 10.0 HP at 10270 rpm. The same goes for torque, which is also increased through entire rpm range. The drop-outs in the stock curve are filled and like the power curve, there is a major increase from 4000 rpm on. CONFIGURATION The configuration of the Akrapovic RACING OPEN & EVOLUTION OPEN system for the Z 1000 is 4-2-1, made of conical stainless steel or titanium tubes. The system includes interference crossover tubes between the header tubes, giving the Kawasaki increased performance characteristics. The muffler is available with either a titanium or carbon-fiber outer sleeve, attached to the motorcycle with an Akrapovic carbon-fiber muffler clamp. The individual elements of the system – header tubes, collector, link pipe and muffler – are connected with sleeve joints, secured with silicon-shielded springs.

2004 Honda CRF450R OWNER'S MANUAL

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Filed Under (Honda) by admin on 21-11-2010

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motorcycle can be kickstarted with the transmission in gear by disengaging the clutch before operating the kickstarter. Check the engine oil, transmission oil and coolant levels before starting the engine (page 21, 23, 24). Cold Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. If the temperature is 35°C (95°F) or below, pull the choke knob fully out. 4. If the temperature is below 0°C (32°F), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 5. With the throttle closed, operate the kickstarter starting from the top of the kickstarter stroke, kick through to the bottom with a rapid, continuous motion. (Do not open the throttle, As the carburetor is equipped with an accelerator pump, excessive fuel will be charged into the engine, and the spark plug will be fouled if the throttle is opened and closed repeatedly. Excessive fuel in the engine makes kick- starting difficult.) 6. About a minute after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. (1) FUEL FILL CAP (2) BREATHER TUBE WARNING (1) FUEL VALVE (2) CHOKE KNOB Warm Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever 1. Shift the transmission into neutral. 2. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 3. As soon as the engine starts, release the hot start lever. Starting the engine excessively charged with fuel by throttle blipping or other reasons: 1. Shift the transmission into neutral. 2. With the throttle fully opened, repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine. 3. Pull the hot start lever and kick-start the engine (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever. Stopping The Engine 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle 2 – 3 times, and then close it. 4. Depress and hold the engine stop button until the engine stops completely. NOTE: • Failure to close the fuel valve may cause the carburetor to overflow. (1) THROTTLE GRIP (2) ENGINE STOP BUTTON Break-In Procedure Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: • Piston is replaced • Rings are replaced • Cylinder is replaced • Crankshaft or crank bearing are replaced

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HOVELHEAD & IRONHEADXL 42mm Mikuni Carburetor And Manifold Kit INSTALLATION Instructions

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Filed Under (Tips and Review) by admin on 31-10-2010

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THROTTLE CABLE ADJUSTMENT A) Rotate the throttle grip to the full open position, look into the throttle bore and see if the throttle valve (slide) opens completely. If the throttle valve does not open completely unscrew the adjuster on the opening cable until it does. This adjustment should be made carefully to assure maximum carburetor performance. After adjustment tighten the adjuster jam nut. B) After adjusting the open cable, adjust throttle freeplay with the closing (idle) cable to approximately 1/8″ an indicated in the following illustration. note It is very important to adjust the cables in the preceding described manner to ensure that the idle cable operates correctly for safety. It must close the throttle completely 2 PLEASE NOTE USE CAUTION PLEASE NOTE SAFETY WARNING pull open cable pull close cable SHOVELHEAD/IRONHEAD XL Installation Instructions Check and make sure that the throttle cables are routed properly by rechecking the throttle play as the handlebars are turned from side-to-side; the amount play should remain consistent. C) After the throttle cables have been adjusted, make sure that all the lock nuts are securely tightened. 5. AIR CLEANER A) The air filter bracket is attached to the crankcase with 1 long bolt, and a bracket-spacer. Removed the crankcase nut located between the tappet blocks & replace it with the enclosed bracket spacer; tighten the spacer securely. B) Remove the stud protectors from the K&N filter and place the two backing plates on the studs. Now slip the the filter onto the carburetor. C) Attach the 2 long brackets to the air filter studs with the enclosed nuts & flat washers, and to the bracket spacer with the enclosed bolt using the lock washers, and flat washers. When the carburetor and air cleaner are properly aligned, securely tighten all of the mounting hardware including the intake manifold clamps. In some cases it may be necessary to bend the brackets slightly to arrive at the correct fit. D) Use the enclosed hose clamps to secure the fuel hose to the petcock, and the HSR carburetor. The screw clamp goes on the petcock end and the spring clamp attaches to the carburetor end. E) Attach the chrome air filter cover with the enclosed socket head screw. 7. CHOKE CABLE INSTALLATION A) Attach the Mikuni choke cable bracket to the original choke cable bracket on the air cleaner stud with the enclose hardware as illustrated

Harley-Davidson BIG-TWIN 8mm BELT DRIVES (OPEN OR CLOSED) INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 16-04-2012

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INSTALLATION : The spacer behind the front pulley should be removed prior to installing the belt drive. This spacer may or may not be required to correctly align the pulleys. If a spacer is needed for alignment, various sizes are available from your local Primo Belt Drives dealer (part number PX-1 =package of 6 various sizes). With all supporting components installed, install front pulley, lubricate and reinstall the clutch hub. Loop the belt around the front and rear pulleys, and gently push into place. Use the washer and nut supplied with the kit on the front motor shaft, (always use an impact wrench on splined shaft motors) tighten to 80-100 foot pounds of torque. After installing and adjusting clutch, track the belt by turning the pulleys. If needed us a straight edge between the front and rear pulleys to check alignment. Improper alignment of the pulleys will result in reduced belt life. Spacing the motor pulley outward will cause the belt to track towards the outer primary cover. If spaced too far out the belt will rub on the inside of the clutch shell. ENCLOSED INSTALLATIONS: The same disassembly is required, with the exception of the clutch hub and inner primary. We recommend using our PC-1000-Acomplete clutch assembly. Loop the belt around both pulleys to insure that you have the proper belt for your pulleys, then gently push the unit into place. Use the washer and nut supplied with the kit on the motor shaft. Torque the motor nut to 80-100 foot pounds . Adjust the clutch & check belt / pulley alignment. Before installing the primary cover be sure that everything inside clears both the outer and inner covers. In some cases a small amount of metal may need to be removed from one or more of the bosses on the inner or outer primary covers

2007 – 2009 APRILIA RSV MILLE EVOLUTION OPEN EXHAUST SYSTEM

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Filed Under (Aprilia) by admin on 06-11-2010

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Measurements of the Akrapovic EVOLUTION street legal system on the APRILIA RSV MILLE (with muffler insert): Power & Torque: the Akrapovic exhaust system increase the responsiveness of the Aprilia and fill out the power and torque curves. The increase in power and torque starts already at around 3000 rpm and leads all the way to the top of the rpm range. At 10300 rpm we measured a massive 129.1 HP on rear wheel and max. increase of power 9.4 HP at 10550 rpm. CONFIGURATION The Racing and Evolution systems differ only in the selection of tubing materials. The Racing is made of stainless steel, and the Evolution is made of titanium. Both systems have conical tubes, collectors, and a link pipe. All of the system components are attached with sleeve joints secured with silicon-shielded springs. The header tubes come with interference crossover tubes, and the systems also include a fitting for attaching a lambda sensor. The HEXAGONAL muffler is definitely the most eye- catching element of the system. It is made of a titanium inlet cap and perforated inner sleeve, while the outlet cap is made of carbon fiber. The outer sleeve is available in titanium or carbon fiber. The muffler is attached to the frame using an Akrapovic carbon fiber clamp. PERFORMANCE stock AKRAPOVIC max. increased power max. rear wheel power HP / rpm (measured on Dynojet ATV) 122.1 / 9740 129.1 / 10300 9.4 / 10550 interference crossover tubes YES (in collector) lambda sensor YES header tube inner sleeves – header tube flanges S.S LASER CUT header tubes – collector connection SLEEVE JOINT + SILICON SHIELDED SPRINGS collector / header tube – link pipe connection SLEEVE JOINT + SILICON SHIELDED SPRINGS link pipe – muffler connection SLEEVE JOINT + SILICON SHIELDED SPRINGS muffler inlet cap /outlet cap Ti / Carb.-fiber muffler metal interior TITANIUM muffler outer sleeve Ti / Carb.-fiber muffler clamp CARBON-FIBER muffler bracket Carb.-fiber (OPTIONAL) muffler insert EU YES heat shield YES (stock) US – catalytic converter YES (2x) CONFIGURA- TION CONFIGURATION header tubes collector link pipe material S.S. (begining) S.S. / TI (header tube) S.S. / TI STAINLESS STEEL / TITANIUM tube shape CONICAL CONICAL CONICAL Technical specifications of Akrapovic exhaust systems and related products subject to change without notice. ADDITIONAL DATA weight comparison (kg) stock AKRAPOVIC difference 12.57 S.S. link pipe TITANIUM link pipe stock – S.S. stock – titanium – 5.52

2004 Honda CRF450R OWNER’S MANUAL

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Filed Under (Honda) by admin on 23-04-2011

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FUEL Fuel tank capacity: 2.0 US gal (7.4 liter, 1.6 lmp gal) To open the fuel fill cap, pull the breather tube out of thesteering stem nut. Then turn the fuel fill cap ounterclockwise. • Use automobile gasoline with a pump octane number of 92 or higher. If “knocking” or “pinging” oc- curs, try a different brand of gasoline or a higher octane grade. • Gasoline is extremely flammable and is explosive under certain conditions. Perform this operation in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refueled. 1.OPERATING INSTRUCTIONS WARNING BASIC OPERATION Starting The Engine • Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas thatcan cause loss of consciousness and lead to death. • Attempting to start the engine with the transmis- sion in gear and clutch engaged may result in in- jury or damage. NOTE: • This motorcycle can be kickstarted with the transmission in gear by disengaging the clutch before operating the kickstarter. Check the engine oil, transmission oil and coolant levels before starting the engine (page 21, 23, 24). Cold Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. If the temperature is 35°C (95°F) or below, pull the choke knob fully out. 4. If the temperature is below 0°C (32°F), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 5. With the throttle closed, operate the kickstarter starting from the top of the kickstarter stroke, kick through to the bottom with a rapid, continuous motion. (Do not open the throttle, As the carburetor is equipped with an accelerator pump, excessive fuel will be charged into the engine, and the spark plug will be fouled if the throttle is opened and closed repeatedly. Excessive fuel in the engine makes kick starting difficult.) 6. About a minute after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. (1) FUEL FILL CAP (2) BREATHER TUBE WARNING (1) FUEL VALVE (2) CHOKE KNOB Warm Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever.

HARLEY DAVIDSON ADVANCED AUDIO REAR SPEAKER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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This kit fits 2006 and later FLHT (Electra Glide®), FLHTC (Electra Glide Classic), FLHX (Street GlideTM) and FLTR (Road Glide®) model motorcycles. INSTALLATION 1. Have a Harley-Davidson dealer perform the speaker software flash to the previously installed AM/ FM/ CD Radio. 2. Refer to the Service Manual and follow the instructions given to remove the seat and the left-side saddlebag. The right-side saddlebag does not need to be removed, but you may choose to do so in order to prevent damage during the installation of this kit. 3. Follow the instructions in the Service Manual to remove the maxi-fuse. NOTE The Tour-Pak does not have to be removed from the vehicle to perform this installation. 4. Open the Tour-Pak lid and remove all items from the Tour- Pak base. 5. Models with rubber mat: Remove the mat. Models with molded liner: Open the map pocket and remove the acorn nuts with flat washers. Remove the map pocket and liner. 6. Obtain the left-side (3) and right-side (4) drilling templates from the kit. is 00439 Figure 1. Template Positioning (Right Side Shown) 7. See Figure 1. Position the the right-side template flat onto the right front corner of the Tour-Pak. a. Fit the notched corner on the left side of the template to the Tour-Pak latch. b. Align the top of the template just under the top edge of the Tour-Pak. c. Apply tape to the locations indicated on the template to hold the template in place

CSS/ CSR Separator, Recovery Tank, Purge Valve, CYC Timer & Pump INSTALLATION & OPERATION MANUAL

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Filed Under (CSR) by admin on 27-10-2010

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1.*The*CSS/CSR*system*skid*should*be*bolted*to*a*flat*&*level*concrete*foundation*with*suitably*sized*and*quantity*of*anchor*bolts.* The entire system (1″-6″) is on a single skid. For systems 8″ and larger, the separator stands alone on its own 3 legs, while the pump/motor, recovery tank (CSR only), and control panel are on an individual skid. It is therefore incumbent upon the installer to insure*that*the*complete*package*is*bolted*to*a*flat*&*level*concrete*foundation,*to*insure*that*the*”piping*assembly”*is*installed* without any undue stress. 2. Inspect and hydrotest all pipe connections for leaks. *All*flanged*connections*must*have*gaskets,*and*all*threaded*connections*must*have*Teflon*tape*or*anti-seize*coating. 4. Flush all new pipe construction before system operation. In the absence of a pump strainer basket, use a y-strainer with 1/4″ perforated*screen.**The*perforated*screen*must*be*at*least*the*same*size*or*one*pipe*size*larger*than*the*pump*suction.**The* perforated screen will block out larger debris such as welding rods, tools, rugs, gloves, etc. ELECTRICAL 1. Voltage supply to the system must be the same as the voltage indicated on the control panel. 2. Follow the pump operating instructions prior to start-up. 3.*Turn*the*motor*”ON”*and*check*rotation.**Rotation*must*turn*in*the*same*direction*as*the*arrow*located*on*the*pump* casing. If pump is rotating in the opposite direction then reverse L1 and L2 on the incoming power to the panel. Recheck rotation. 4. Starting or in-rush current should not exceed 3 seconds, running current should be equal to or less than nameplate full load amps (FLA). 5. Thermal Overload Setting 5a. Select the Operating Voltage 5b. Multiply Motor Service Factor (SF) by the Full Load Amps (FLA) to get the Service Factor Amps (SFA). 5c. Adjust the Thermal Overload Dial to match SFA Note: Some motors come with SFA written on the nameplate. The majority of our motors come with a 1.15 service factor, but very few come with a 1.25 SF. STARTUP 1. Open system inlet valve 100% and outlet valve 50% (supplied by others). 2.*Suction*line*must*be*flooded. 3. Open separator air vent located near the outlet, (standard on 2″ and larger). 4.*Turn*the*system*”ON.” 5. Purge all the air. 6.*For*HH*&*SP*systems,*open*outlet*valve*until*the*gauge*reads*35psi.*For*LH*systems,*open*outlet*valve*until*a*100%* opening*is*achieved.**If*system*begins*to*vibrate,*then*slightly*close*separator*outlet*until*it*stabilizes

KTM 250/ 300/ 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot. To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the idle adjusting screw. 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. Full throttle range D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. mixture too rich: too much fuel in proportion to air mixture too lean: not enough fuel in proportion to air 1 2 OPERATING RANGES OF THE CARBURETOR 2-3C Carburetor adjustment Basic information on 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 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of 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:

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