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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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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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2004 Kawasaki ZX10R Power Commander Installation Instructions

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Filed Under (Kawasaki) by admin on 08-05-2012

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Remove the main seat and the passenger seat 2. Remove the tail cover by removing the two bolts. 3 Place the Power Commander in the tail section and route the wiring harness on the inside of the tail section towards the front of the bike (Fig. A). 4. Remove the fuel tank. 5. Remove the air box lid by removing the 8 screws around the outer edge (Fig. B). 6. Remove the bolts shown in Fig. C. This will allow you to remove the air box. Fig. A Fig. B Fig. C i212-411 2004-2005 Kawasaki ZX10R – PCIII USB – 2 i212-411 www.powercommander.com Remove these bolts Remove screws Remove bolts 7. Locate the Throttle Position Sensor connector. This connector is located above the left hand side of the engine. This is a white 3 pin connector. Unplug this connector (Fig. D). 8. Plug the white connectors from the PCIII in-line of the stock TPS connector (Fig. E). 9. Locate the fuel rail connector behind the injector bodies (Fig. F). This connector is brown in color

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Kawasaki ZX10R 2008 Frame Slider Installation And Removal Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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installation Steps: 1. Remove right side bolt. Mount right side puck with (99-HB-SH10125060) Socket Cap 10 X 1.25 X 60 Main Engine Stud and torque down. 2. Remove left side mid panel. 3. Locate the left side engine stud and remove bolt. 4. Some photos in this section are used for illustration examples only. It is up to you how you decide to cut your motorcycles bodywork to accept the frame slider there are many different ways customers go through this process. Shogun is not responsible for any part of your motorcycle for any reason. Precisely measure location of cut and if in doubt at any point please call us before the install process has begun. Professional installation is recommended. Always use proper safety measures during the install of this product. Do not try to install this product without proper tools, recently calibrated torque wrench, correct torque specifications from factory service manual, safety goggles and gloves. 5. Body Prep. Use masking tape to completely mask off the area on the body where you will be working. We usually will tape off approximately 6 to 8 inches around the though hole area and any other edges that could get bumped or scratched while working. Tip: In some locations you may want to double up the thickness of the masking take to give extra protection

Kawasaki ZX10R Muffler Bracket Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Remove the 8mm bolt that secures the mounting strap to the muffler. 2. Remove the two 8mm bolts that secure the existing muffler bracket to the bikes sub-frame. 3. Install the new bracket to the sub frame with the 8X20 socket capscrews included in the kit. Place a small amount of Loctite on the threads of the screws before assembly. 4. Mount the lower part of the bracket to the muffler strap with the existing hardware. 5. Adjust the muffler strap as needed and tighten the lower 8mm bolt. 6. Double check all your work before riding.

YAMAHA TW200EU/ EUC SPECIFICATION AND SUPPLEMENTARY SERVICE MANUAL

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Filed Under (Yamaha) by admin on 24-11-2010

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Model code number: TW200EN: 5FY8 TW200ENC: 5FY9 Dimensions: Overall length 2,090 mm (82.3 in) Overall width 820 mm (32.3 in) Overall height 1,120 mm (44.1 in) Seat height 790 mm (31.1 in) Wheelbase 1,325 mm (52.2 in) Minimum ground clearance 265 mm (10.4 in) Engine: Engine type Air cooled 4-stroke, SOHC Cylinder arrangement Forward inclined single cylinder Displacement 196 cm3 (11.96 cu.in) Bore 〈 stroke 67.0 〈 55.7 mm (2.638 〈 2.193 in) Compression ratio 9.5 : 1 Compression pressure (standard) 900 kPa (9 kg/cm2, 128 psi) Starting system Electric starter Carburetor: Type/manufacturer MV28/TEIKEI Spark plug: Type/manufacturer DR8EA (NGK), X24ESR-U (N.D.) Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Chassis: Frame type Diamond Caster angle 25.8° Trail 95 mm (3.74 in) Tire: Type With tube Size (F) 130/80-18 66P TW31 Size (R) 180/80-14M/C 78P TW34 Wear Limit <1.0 mm (0.04 in)> Carburetor: ID mark TW200EN: 5FY10 TW200ENC: 5FY00 Main jet (M.J.) TW200EN: #126 TW200ENC: #128 Main air jet (M.A.J.) 1.2 Jet needle-clip/position (J.N) TW200EN: 5B21-1/1 TW200ENC: 5B21-1/3 Main nozzle (M.N.) 2.600 Pilot jet (P.J.) #31 Pilot air jet (P.A.J.) TW200EN: 0.95 TW200ENC: 1.0 Pilot outlet 0.8 Bypass 0.7 Valve seat (V.S.) 1.6 Starter jet (G.S1.) 0.6 (G.S2.) 0.8 Fuel level (above the line on the float chamber mating surface) (F.L.) 0.5 ~ 1.5 mm (0.02 ~ 0.06 in) Float height 10 ~ 11 mm (0.39 ~ 0.43 in) Engine idling speed 1,300 ~ 1,500 r/min Vacuum pressure at idling speed 29.3 ~ 34.7 kPa (220 ~ 260 mmHg, 8.66 ~ 10.24inHg) or more

2011 HONDA CBF1000/ CBF1000 ABS Specifications

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Filed Under (Honda) by admin on 18-02-2011

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Press information for 2011 CBF1000 / CBF1000 ABS 7 Specifications – CBF1000 (ED-type) ENGINE Type Liquid-cooled 4-stroke DOHC inline-4 Displacement 998cm3 Bore  Stroke 75  56.5mm Compression Ratio 11.2 : 1 Max. Power Output 79kW/9,000r/min -1 (95/1/EC) Max. Torque 96Nm/6,500r/min -1 (95/1/EC) Idling Speed 1,200min -1 Oil Capacity 3.6 litres FUEL SYSTEM Carburation PGM-FI Throttle Bore 36mm Aircleaner Dry, cartridge-type paper filter Fuel Tank Capacity 20 litres Fuel Consumption 18,4 km/l (WMTC Mode #) ELECTRICAL SYSTEM Ignition System Computer-controlled digital transistorised with electronic advance
Press information for 2011 CBF1000 / CBF1000 ABS 8 Ignition Timing 5° BTDC (idle) ~ 45° BTDC (7,500min -1 ) Sparkplug Type IMR8C-9HES Starter Electric Battery Capacity 12V/8.6AH ACG Output 350W/5,000 rpm Headlights 12V, 55W  1 (low) / 55W  1 (high) DRIVETRAIN Clutch Wet, multiplate with coil springs Clutch Operation Hydraulic Transmission Type 6-speed Primary Reduction 1.6 Gear Ratios 1 2.6 2 1.83 3 1.5 4 1.32 5 1.17 6 1.07 Final Reduction 2.687 (43/16) Final Drive #530 O-ring sealed chain FRAME Type Mono-backbone; cast aluminium
Press information for 2011 CBF1000 / CBF1000 ABS 9 CHASSIS Dimensions (LWH) 2,210  780  1,220mm Wheelbase 1,495mm Caster Angle 26° Trail 110mm Turning Radius 2.9m Seat Height 795mm ±15mm Ground Clearance 135mm Kerb Weight *245kg (F: 120kg; R: 125kg) Max. Carrying Capacity 195kg Loaded Weight *440kg SUSPENSION Type Front 41mm free valve-type telescopic fork & adjustable spring; 120mm stroke Rear Gas-charged HMAS damper & adjustable spring and rebound; 120mm axle stroke WHEELS Type Front Hollow-section 6-spoke cast aluminium Rear Hollow-section 6-spoke cast aluminium Rim Size Front 17M/C  MT3.5 Rear 17M/C  MT5
Press information for 2011 CBF1000 / CBF1000 ABS 10 Tyre Size Front 120/70 ZR17M/C (58W) Rear 160/60 ZR17M/C (69W) Tyre Pressure Front 250kPa Rear 290kPa (290kPa with passenger) BRAKES Type Front 296  4.5mm dual hydraulic disc with 2- piston calipers, floating rotors, sintered metal pads (*3-piston calipers and Combined ABS) Rear 240  5.0mm hydraulic disc with 1-piston caliper, sintered metal pads (*and Combined ABS) *C-ABS version All specifications are provisional and subject to change without notice

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2010 HONDA VFR1200F Dual Clutch Transmission Specifications

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Filed Under (Honda) by admin on 18-02-2011

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Specifications VFR1200F Dual Clutch Transmission (ED-type/ F-type) ENGINE Type Liquid-cooled 4-stroke UNICAM 76° V-4 Displacement 1237cc Bore  Stroke 81  60mm Compression Ratio 12:1 Max. Power Output ED: 127kW/10,000min-1 (95/1/EC) F: 83kW/9,500min-1 (95/1/EC) Max. Torque ED: 129Nm/8,750min-1 (95/1/EC) F: 115Nm/4,000min-1 (95/1/EC) Idling Speed 1,150 min-1 Oil Capacity 4.9 litres FUEL SYSTEM Carburation PGM-FI electronic fuel injection Aircleaner Oil-permeated, viscous-type paper filter Fuel Tank Capacity 18.5 litres Fuel Consumption ED/E : 15.9 km/l F : 15.9 km/l (tested in D-Mode) (WMTC mode*) VFR1200F 03/05/10 9 9 ELECTRICAL SYSTEM Ignition System Computer-controlled digital transistorised with electronic advance Ignition Timing 8.4° BTDC (idle speed) Sparkplug Type IMR9E-9HES (NGK); VUH27ES (DENSO) Starter Electric Battery Capacity 12V/11.2Ah (YTZ14S) ACG Output 570W Headlights H7x2 (55Wx2) Tail-light 5Wx2,STOP LIGHT 21W( 21/5W+5Wdual-light) DRIVETRAIN Clutch Wet multi-plate, hydraulic, dual Clutch Operation Hydraulic Transmission Type Constant mesh 6-speed Primary Reduction 1.738 (73/42) Gear Ratios 1 2.4666 (37/15) 2 1.7894 (34/19) 3 1.4090 (31/22) 4 1.1600 (29/25) 5 1.0322 (32/31) 6 0.9393 (31/33) VFR1200F 03/05/10 10 10 Final Reduction 2.7061 Final Drive Shaft FRAME Type Diamond; aluminium twin-spar CHASSIS Dimensions (LWH) 2250  740 1220mm Wheelbase 1,545mm Caster Angle 25.5° Trail 101mm Turning Radius 3.5m Seat Height 815mm Ground Clearance 125mm Kerb Weight 277kg Loaded Weight 473Kg SUSPENSION Type Front 43mm cartridge-type telescopic fork with stepless preload adjustment, 120mm axle travel RearPro-Link with gas-charged damper, VFR1200F 03/05/10 11 11 25-step (*stepless remote-controlled hydraulic) preload and stepless rebound damping adjustment, 130mm axle travel WHEELS Type Front 5-spoke hollow gravity Die-cast aluminium Rear7-spoke gravity Die-cast aluminium Rim Size Front 17M/C  MT3.50 Rear 17M/C  MT6.00 Tyre Size Front 120/70 ZR17M/C (58W) Rear 190/55 ZR17M/C (75W) Tyre Pressure Front 250kPa Rear 290kPa BRAKES Type Front 320mm dual floating hydraulic disc with two 6-piston callipers, C-ABS and sintered metal pads Rear276mm hydraulic disc with 2-piston calliper, C-ABS and sintered metal pads All specifications are provisional and subject to change without notice. * Please note that the figures provided are results obtained by Honda under standardized testing conditions prescribed by WMTC. Tests are conducted on a rolling road using a standard version of the vehicle with only one rider and no additional optional equipment. Actual fuel consumption may vary depending on how you ride, how you maintain your vehicle, weather, road conditions, tire pressure, installation of accessories, cargo, rider and passenger weight, and other factors

2011 HONDA XL1000V Specifications / Press Information

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Filed Under (Honda) by admin on 18-02-2011

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Specifications – XL1000V / XL1000V ABS (ED-type) ENGINE Type Liquid-cooled 4-stroke 8-valve DOHC 90° V- twin Displacement 996cm 3 Bore  Stroke 98  66mm Compression Ratio 9.8 : 1 Max. Power Output 69kW/7,500min -1 (95/1/EC) Max. Torque 98Nm/6,000min -1 (95/1/EC) Idling Speed 1,300min -1 Oil Capacity 4.1 litres FUEL SYSTEM Carburation PGM-FI electronic fuel injection Throttle Bore 42mm Aircleaner Viscous, cartridge-type paper filter Fuel Tank Capacity 25 litres (including 4-litre warning light reserve) ELECTRICAL SYSTEM Ignition System Computer-controlled digital transistorised with electronic advance Ignition Timing 15° BTDC (idle) ~ 55° BTDC (5,100min -1 ) Sparkplug Type IJR8B9 (NGK) Press information for 2011 XL1000V 6 Starter Electric Battery Capacity 12V/18AH ACG Output 434W Headlight 12V 60W  2 (low) / 55W  2 (high) DRIVETRAIN Clutch Wet, multiplate with coil springs Clutch Operation Mechanical; cable-actuated Transmission Type 6-speed Primary Reduction 1.682 (44/74) Gear Ratios 1 2.571 (14/36) 2 1.684 (19/32) 3 1.292 (24/31) 4 1.100 (30/33) 5 0.969 (32/31) 6 0.853 (34/29) Final Reduction 2.938 (16/47) Final Drive O-ring sealed chain FRAME Type Steel tube CHASSIS DIMENSIONS Dimensions (LWH) 2,300  930  1,465mm Wheelbase 1,560mm Caster Angle 27° 30′ Press information for 2011 XL1000V 7 Trail 110mm Turning Radius 2.58m Seat Height 838mm Ground Clearance 181mm Kerb Weight 268.7kg (F: 126.3kg; R: 142.4kg) *276.7kg (F: 130kg; R: 146.7kg) Max. Carrying Capacity 201kg Loaded Weight 469.7 kg *477.7 kg SUSPENSION Front 43mm telescopic fork, 155mm axle travel Rear Pro-Link damper, 145mm axle travel WHEELS Type Front Hollow-section triple-spoke cast aluminium Rear Hollow-section triple-spoke cast aluminium Rim Size Front 19M/C  MT2.50 Rear 17M/C  MT4.00 Tyre Size Front 110/80 R19M/C (59H) Rear 150/70 R17M/C (69H) Tyre Pressure Front 250kPa Rear 250kPa (with passenger: 280kPa) Press information for 2011 XL1000V 8 BRAKES Front 296  4.5mm dual hydraulic disc with Combined 3-piston calipers (*ABS) and sintered metal pads Rear 256  5mm hydraulic disc with Combined 3- piston caliper (*ABS) and sintered metal pads * Combined-ABS version All specifications are provisional and subject to change without notice

2011 HONDA NT700V Specifications/ Press Information

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Filed Under (Honda) by admin on 18-02-2011

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Press information for 2011 NT700V 5 Specifications – NT700V (ED-type) ENGINE Type Liquid-cooled 4-stroke 8-valve SOHC 52° V- twin Displacement 680cm 3 Bore  Stroke 81  66mm Compression Ratio 10 : 1 Max. Power Output 48.3kW/8,000min -1 (95/1/EC) Max. Torque 66.2Nm/6,500min -1 (95/1/EC) Idling Speed 1,200min -1 Oil Capacity 3.2 litres FUEL SYSTEM Carburation PGM-FI electronic fuel injection Throttle Bore 40mm Aircleaner Dry, cartridge-type paper filter Fuel Tank Capacity 19.7 litres (including 3.5-litre reserve) Fuel consumption 20.1 km/l (WMTC Mode #) ELECTRICAL SYSTEM Ignition System Digital transistorised with electronic advance Ignition Timing 10° BTDC (idle) ~ 45° BTDC (8,900min -1 ) Sparkplug Type CPR8EA-9 (NGK) Starter Electric Press information for 2011 NT700V 6 Battery Capacity 12V/11.2AH ACG Output 438W Headlight 12V; 55W  1 (low) / 55W  1 (high) DRIVETRAIN Clutch Wet, multiplate with coil springs Clutch Operation Mechanical; cable-actuated Transmission Type 5-speed Primary Reduction 1.763 (67/38) Gear Ratios 1 2.571 (36/14) 2 1.688 (27/16) 3 1.300 (26/20) 4 1.084 (29/27) 5 0.923 (24/26) Final Reduction 3.091 (34/11) Final Drive Enclosed shaft FRAME Type Diamond; steel twin-spar CHASSIS Dimensions (LWH) 2,218  810  1,320mm (Raised windscreen: 1,491mm) Wheelbase 1,476mm Caster Angle 28° 50′ Trail 115mm
Press information for 2011 NT700V 7 Turning Radius 3.2m Seat Height 805mm Ground Clearance 156mm Kerb Weight 254kg (F: 112kg; R: 142kg) *257kg (F: 113kg; R: 144kg) Max. Carrying Capacity 197kg Loaded Weight 451kg *454kg SUSPENSION Type Front 41mm telescopic fork, 115mm axle travel Rear Single damper with adjustable preload, 122.5mm axle travel WHEELS Type Front S-section triple-spoke cast aluminium Rear S-section triple-spoke cast aluminium Rim Size Front 17  MT3.5 Rear 17  MT4.5 Tyre Size Front 120/70 ZR17 (58W) Rear 150/70 ZR17 (69W) Tyre Pressure Front 250kPa Rear 290kPa (290kPa with passenger) BRAKES Type Front 296  4.5mm dual hydraulic disc with Combined 3-piston calipers and sintered metal pads Press information for 2011 NT700V 8 Rear 276  6mm hydraulic disc with dual-piston caliper and sintered metal pads (*and Combined ABS) *Combined-ABS version

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