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KTM 4357/ 4860 MX Multi Adjuster WP Suspension manual Disassembly And Assembling

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Filed Under (KTM) by admin on 13-02-2011

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Disassembly forkleg 12_062 12_079Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 5 Frontfork 4357/4860 MXMA 02/2002 Clamp the forkleg (axle-clamp) in the vice and let the outer-tube down. Pull the spring downwards… …and place open-end spanner (size 22) on the hydraulic stop. Unscrew the screw-cap. 12_067 12_068 12_069 12_072Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 6 Frontfork 4357/4860 MXMA 02/2002 Remove the screw-cap from the piston- rod. 12_070 Remove the preload spacers. 12_074 Pull the spring downwards and remove the spanner. 12_075Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 7 Frontfork 4357/4860 MXMA 02/2002 Remove the spring. 12_076 Remove the adjustment tube with the O-ring. 12_089
Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 8 Frontfork 4357/4860 MXMA 02/2002 Clamp the axle-clamp in the vice so that the forkleg is at an angle of ±45 degrees. 12_095 Unscrew the compression holder out of the axle-clamp. (size 19) (when the cartridge is rotating with the holder, bend the piston- rod a little bit to the side) 12_096 Drain the oil out the forkleg. 12_094 Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 9 Frontfork 4357/4860 MXMA 02/2002 Remove holder compression. Caution: oil iscoming out the cartridge. Disassemble the cartridge out the forkleg. 12_097 12_098 12_099 Disassemble the dust-wiper

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Suspension Basics for BMW Motorcycles

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Filed Under (BMW) by admin on 30-11-2010

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tires: Tires are the first part of any suspension system. The design of the tire and even the pressure you run can have a profound affect on the way your motorcycle handles. Stiff, low profile tires will give a sharper feel to the bike, as will higher tire pressures. Those of us who ride our GS’s off the road will decrease the tire pressure to about 50% of the street spec when we are in the dirt. The tire then becomes a very active part of the suspension, but will wallow like an old pig if not re-inflated when pressed back into pavement duty. It still surprises me when we have a customer complain that his BMW needs new shocks when they come in with nearly flat tires. It is possible that the best dollars-per- unit improvement you can make to your BMW may be in keeping the tires inflated. Chassis: There is not much that we can do about the chassis design, unless we are Troy the Welder, but it is a fact that different frames and swing arms flex differently and therefore are part of the suspension. On the Airheads, we often braced various parts of the frame and swing arms, resulting in improved handling that even mere mortals could appreciate. On the latest BMW’s it would take the likes of a Valentino Rossi to even notice if the parts were stiffened. Stiffer is not always better. One of the Japanese racing bike manufactures controls the stiffness of the frame in various areas to allow some flex for better handling. So, Mr. Rossi might not even like it if Troy stiffened his new BMW. Springs: Springs control the ride height of the motorcycle and the ability to allow for different loads. On most BMW’s there is a way to adjust the spring preload to some extent so that the ride can be optimized for a light rider or two-up operation with luggage. Dampers: Dampers control the speed and frequency at which the suspension operates by changing the kinetic (moving) energy to thermal (heat) energy. Without the damper, the suspension would oscillate as each movement occurred, resulting in decreased vehicle control. Dampers on BMW’s fall into two main groups. On airheads, older K bikes, F and G models, and the R1200 HP-2, the front dampers are integrated into the forks. On the rear of the above mentioned -3 – models, and on both ends of all the rest of the bikes, there is a more common shock absorber, around which the spring is located. The HP-2 uses an air spring and air dampened rear shock. Seat: OK, folks, this is here for my old buddy Jeff. We know that a seat isn’t part of suspension, but a bad one sure can make you miserable. We have sent dozens of seats to our friend Mike Harris for inexpensive mods that might improve your riding enjoyment more than any suspension changes you could make! Let us know if we can help you with this most important item

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KTM WP FORK 4860 MXMA CLOSED CARTRIDGE REPAIR MANUAL

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Filed Under (KTM) by admin on 13-02-2011

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 22-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork

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HARLEY DAVIDSON TOURING SUSPENSION AIR PUMP KIT OPERATION/ INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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OPERATION 1. Remove cap from air suspension air valve and connect pump by threading the air valve adapter (1) on the pump as shown in Figure 1. When adapter is threaded properly, the current air pressure in the system will be indicated on the gauge of the pump. Do not exceed maximum air pressure for rear suspension. Air components fill rapidly. Therefore, use low air line pressure. Failure to do so may result in possible damage to components. (00165a) NOTES See the motorcycle’s Owner’s Manual or, if installed, the air suspension lowering kit’s instruction sheet for the recommended air pressures. Using pressures outside the recommended loading range will result in a reduction of available suspension travel and reduced rider comfort. 2. To increase pressure, operate the air pump handle (4) until the desired pressure is indicated on gauge (2). Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) NOTE The pressure release button is designed to release pressure slowly. If the button is completely or rapidly depressed, no air will be released. For the best results, depress the pressure release button slowly and only partially. 3. To decrease pressure, slowly depress the pressure release button (3) on the pump until desired pressure is indicated on gauge (2)

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HARLEY DAVIDSON PREMIUM SUSPENSION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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REMOVAL Front Fork Assembly 1. Refer to the XR model section of the service manual and remove the front forks. INSTALLATION Front Fork Assembly 1. Install front forks from kit to motorcycle according to service manual instructions but do not tighten the fork bracket pinch screws at this time. 2. See Figure 1. Measure the distance from the top of upper fork bracket to top of fork assembly. Both sides must be exactly the same and measure 0.388-0.468 inch (9.85- 11.89 mm) above the top fork bracket. Align the adjustment screws inline with the handlebars (see Figure 5). is06083a Figure 1. Fork Installation Height Measurement. NOTE If new pinch screws are not readily available, use a wire grinder wheel to remove all remaining lock patch from original pinch screws, wash screws in clean solvent and dry thoroughly. Apply two drops of LOCTITE® 262 to the first 1/4 in. (6.35 mm) of the end threads. 3. Install pinch screws to upper and lower fork brackets. 4. Verify fork tube installation measurement is 0.388-0.468 inch (9.85-11.89 mm). 5. Tighten pinch screws to 30-35 ft-lbs ( (40.7-47.5 Nm)) See Figure 2. The top edge of reflector should be 1-1/2 inches (38.10 mm) below the lower edge of the bottom fork clamp. 6. Remove the adhesive backing. Place reflector in position and press reflector firmly into place to activate the adhesive. Repeat for reflector on opposite fork. REMOVAL OEM Rear Shock Absorbers 1. Refer to the XR model section of the service manual and remove the rear shock absorbers. INSTALLATION Rear Shock Absorbers 1. See Figure 3. Install the rear shock absorbers according to service manual instructions. The shocks are installed with the external gas reservoir to the rear of the shock absorbers and the thick side of the grommet installed to the frame rail mounts. is06142 Figure 3. Install Thick Side Of Grommet To Frame Rail SUSPENSION ADJUSTMENTS Front Fork Suspension Adjustment Whenever a wheel is installed and before moving the motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00284a) Adjust both forks equally. Improper fork adjustment can lead to loss of control, which could result in death or serious injury. (00124c) Compression and rebound adjusting valves may be damaged if too much force is used at either end of the adjustment range. (00237a) NOTES Damping is set at the factory for the average solo rider under normal riding conditions. The rider may make adjustments to compensate for individual riding styles and varying road conditions. Evaluating and changing the rebound and compression damping is a very subjective process with many variables and should be approached carefully. The front and rear preload setting will need to be adjusted for the rider’s weight and cargo. This adjustment should be made before the motorcycle is ridden any distance and after changing the overall vehicle weight (adding saddlebags, etc.). If the preload adjustment is correct, and you have the rebound and compression damping set at the factory recommended points, the motorcycle should handle and ride properly. Changes in the load carried requires changes in the preload setting(s). Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload. Increasing the load carried requires adding more preload. The following tools are needed to make suspension adjust- ments. • 5 mm hex key (front fork preload adjustment tool). • Spanner wrench with extension handle (shock absorber preload adjustment). • Screw driver (front fork damping adjustment). 1. Front fork preload adjustment: a. See Figure 4 and Table 1. Using the 5 mm hex key, turn the preload adjuster counterclockwise until it stops. This is the minimum preload setting. b. Turn the preload adjuster clockwise the recommended amount specified for the rider weight

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HONDA GOLD WING GL1800 Independent Suspension Owner's Maintenance Notes

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

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1. Tire Pressure and Rotation : Keep the nominal tire pressure at about 23-27psig. It is not necessary to periodically rotate the trike tires unless you experience unusual tire wear. 2. Bearing Lubrication . Your Swing Arm and wheel bearings are sealed and do not require greasing. However, should you experience unusual wheel bearing noise you should take your trike to a Champion Trike Dealer or to your motorcycle mechanic for a checkup. 3. Body Lubrication . There are no grease fittings on the trike body and no required body lubrication points. 4. Rear end lubrication . Your differential comes filled with SAE 85W140 API GL-6 gear oil. You should not have to top-off the differential unless you experience axle seal or pinion seal leaks. If you want to check the oil level, do so by removing the fill plug on the top of the differential housing (Remove seat) and by using a suitable measuring device, the oil level should be 5 1/4″ inch down from the top of the differential housing. Refill as necessary. Change the differential oil every 30,000 – 35,000 miles by draining it and refill with 2 quarts of above gear oil.. 5. Brakes . Check your front and rear brake system fluid levels every 3,000 miles and top-off as necessary. Inspect brake pads every 10,000 miles and replace as necessary. Rear brake pads are Volkswagen Part # D101P. 6. Drive Train . The rear driveshaft U-joint and slip yoke spline are fitted with grease fittings, pump the fittings with wheel-bearing, graphite or high-pressure grease every 3,000 to 5,000 miles. The front u-joint does not have grease fittings. 7. Suspension System : The suspension is a Double A-arm Independent suspension with a standard single setting anti-roll bar or an optional Variable Sway Control (VSC) which can be adjustment for optimal ride, handling characteristics and performance. The A- arms are equiped with bushings that does not require servicing. The suspension system is designed to give you the best ride with a load of no more than 600 pounds (passengers plus cargo plus trailer tongue weight): 8. EZ-Steer (rake kit) : If your trike is equipped with Champion’s EZ-Steer, the bearings are a wear item. You should follow your motorcycle manufacturer’s recommended front-end triple-tree maintenance requirements. Generally these call for an initial service at 1,000 miles followed by periodic maintenance at 10,000 mile intervals

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HARLEY DAVIDSON LOW-PROFILE REAR TOURING SUSPENSION KIT Installation

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Filed Under (Harley Davidson) by admin on 30-11-2010

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1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. 2. Raise the rear end of the motorcycle so that the rear wheel is just off the ground. Support the motorcycle with suitable blocking under the frame. NOTE Retain the original fasteners for installation of new shocks. 3. Remove the saddlebags from the motorcycle. See the Touring model’s Owner’s Manual for saddlebag removal. 4. Fasten the air pump, part number 54630-03A to the rear air-suspension adjustment valve on the motorcycle. See the Touring model’s owner’s manual for valve location. Add 3-5 psi to clear the line but do NOT exceed 50 psi. 5. Using the pressure-relief valve located below the gauge on the pump, release the air pressure from the rear sus- pension. Failure to relieve air pressure from the rear suspension could cause injury during shock-absorber removal. Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak on to the rear wheel, tire, and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) 6. See Figure 1 and Figure 2. Remove the air hoses from the shock absorber air-hose fittings. NOTE Press the plastic collar down on the air-hose fitting to remove and install the air hose. 7. Remove the air hose fittings from the shock absorbers. Save the fittings for installation on the new shocks. NOTE Air-suspension shock absorbers are oil filled and must be kept upright at all times to prevent oil leakage. 8. Remove the lower mounting bolts and washers from the shock absorbers

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HARLEY DAVIDSON SPORTSTER LOW REAR SUSPENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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INSTALLATION NOTE Internal shock absorber components are not repairable beyond the Service Parts listed on this instruction sheet. Consult your Harley-Davidson dealer if further service is required. The installation procedures for this kit are the same as the original equipment (OE) installation procedures in the Service Manual. Refer to the appropriate Service Manual for the rear suspension system removal and installation procedures. The OE hardware will be re-used in the kit installation. Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) SHOCK PRELOAD (SPRING) ADJUSTMENT Refer to the appropriate Service Manual for spring adjustment. Spanner wrench (94700-52L) is required for spring adjustment. SERVICE PARTS 1 is04854 Figure 1. Service Parts: Sportster Low Rear Suspension Kit Table 1. Service Parts: Sportster Low Rear Suspension Kit Part Number Description (Quantity) Item 54734-04 Rear shock (2)

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Kawasaki Vulcan Front Suspension Lowering Kit Installation manual

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Filed Under (Kawasaki) by admin on 27-02-2011

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INSTALLATION 1. This lowering method requires replacement of the front spring spacers. This is a simple task, and is completely reversible. First, raise the front tire off of the ground before you begin. Raise the motorcycle so no weight is applied to the front wheel. 2. Cover the gas tank with a thick towel to prevent scratching. Don’t omit this…you’ll be sorry if you do! 3. If the handlebar risers are OEM (stock), loosen the handlebars in their clamps and lift them from the risers, carefully placing them on the gas tank on a thick towel to prevent scratching. This will allow room for the spring spacers to be removed from the front forks. 4. Using a small knife blade, sharp screw driver, etc. in the pinch grove on each side of the triple clamp, gently pry upwards and pop the chromed plastic covers off. These are the covers on the top of the front forks, covering the spring retainers. Below these chrome caps, you’ll find a gold anodized metal plug with a small counter bore in the center. This is the part used to retain the springs within the front fork tubes. Using an extension bar, large Phillips screwdriver, etc., press down a bit in the counter bored area of the plug to take the pressure off of the small internal “C” ring. While this “gold” colored plug is depressed, remove the internal C-ring. The C-ring is made of small diameter wire. Once the C-ring is removed, slowly release the pressure on the plug and it’ll push itself out of the top of the shock. The picture below is of the upper fork leg with the gold retaining plug removed. 5. Stick a finger into the fork tube, and slide the OEM tubular spacer up and out of the fork tube. 6. The picture below illustrates the use of a Scootworks lowering spacer with the fork spring. On the right hand end of the you’ll see a Scootworks lowering spacer. The fork spring stays in the front fork, and you’ll drop in the spacer with the desired amount of lowering. The approximate amount of lowering is marked on each Scootworks spacer. 7. Select the spacers for the desired amount of lowering. The longest spacers supplied are marked as [1] and will lower the front suspension 1″. The spacers of middle length are marked as [2] and will lower the front suspension by 2″. The shortest spacers supplied in the kit are marked as [3] and will lower the front suspension by 3″. Omission of the spacers completely will lower the front suspension by approximately 4″. 8. Install the selected spacers in the fork tubes, on top of the internal fork spring. Place the gold anodized metal plugs on top of the spacers and press them back into the fork tube. Be sure to turn the metal plug so the side with the counter bore is facing outwards. Reinstall the C-rings, and gently lower the front end back to the ground. Make sure the C-rings seat themselves in their respective grooves when the weight of the bike is placed back on the front end. Re-install the chrome caps.

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HARLEY DAVIDSON TOURING LOW PROFILE REAR SUSPENSION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION 1. Refer to the Service Manual and follow the instructions given to remove the seat. Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) 2. Disconnect the battery cables, negative cable first or remove the main fuse if equipped. 3. Raise the rear end of the motorcycle so that the rear wheel is just off the ground. Support the motorcycle with suitable blocking under the frame. NOTE Retain the original fasteners for installation of new shocks. 4. Remove the saddlebags from the motorcycle. See the Touring model’s Owner’s Manual for saddlebag removal. 5. Fasten the air pump, part number 54630-03A to the rear air suspension adjustment valve on the motorcycle. See the Touring model’s owner’s manual for valve location. Add 3-5 psi to clear the line but do NOT exceed 50 psi. 6. Using the pressure relief valve located below the gauge on the pump, release the air pressure from the rear sus- pension. Use caution when bleeding air from the suspension. Moisture combined with lubricant may leak onto the rear wheel, tire and/or brake components and adversely affect traction, which could result in death or serious injury. (00084a) 7. See Figure 1 and Figure 2. Remove the air hoses from the shock absorber air hose fittings

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