xr650l subframe issues

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Honda XR600/ XR650L Camshaft Installation and removal Instructions

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Filed Under (Honda) by admin on 05-12-2011

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Remove the tappet covers. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise direction. Position the engine at true top dead center (TDC) using the mark on the flywheel. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Since the rocker arms are located in the valve cover on an XR600, true TDC occurs when the cam lobes are pointed downward when the piston is at TDC. Remove the cylinder head cover. Warning, do not drop the locating dowels into the cam chain cavity. There are two dowels, one on either side of the cover. Remove and discard the gasket. Note the positioning of the cam lobes, this will help during installation of your new Hot Cams camshaft. Note also the location of the sealed bearing on the end of the camshaft and the direction in which it is facing. Loosen the bolts that hold the camshaft sprocket. Remove the lower camshaft sprocket bolt first, it will be necessary to rotate the engine. Rotate the engine back to TDC. Release the spring tension on the cam chain tensioner by lifting the end of the spring out of its hole in the tensioner block. A spring tool is a good method. Be careful not to scar the cylinder head’s gasket surface for the cylinder head cover. Remove the allen bolt that holds the end of the tensioner block shaft
just to the inside of the tensioner block. Note the location of the tensioner block shaft cap ridge. Using a pair of pliers pull the shaft out by grasping the ridge and using a clockwise rotation of the shaft while pulling outward. Pull the tensioner block upwards, out of the cylinder head. Remove the top camshaft sprocket bolt. Pull the sprocket off the camshaft but maintain upward tension, do not allow the chain to sag, it is possible for the chain to “slip” on the bottom sprocket of the crankshaft and change the cam timing. Remove the camshaft. Remove the cam bearings. Set the stock camshaft with the auto-decompression aside. It is not possible to use the auto-
decompression on the Hot Cams so do not attempt to re-install. Use a manual decompression. Install the bearings onto the new Hot Cam

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BMW Motorcycles F 650 GS/Dakar Driveability Issues

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

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Concern: Customer complains about hesitation, surging and stalling when the engine is operated at low to medium RPM. Service Measure: In the event of a customer complaint on the above concerns, please check the following points, adjusting to specification as necessary: Fuel pressure: Measure fuel pressure under all operating RPM. If fuel pressure is outside of specification, replace fuel filter with pressure regulator. Recheck fuel pressure, with new components installed, to confirm fuel pressure is to specification. Fuel pressure specification = 3.5+/- 0.2 bar Clutch adjustment: Clutch may not disengage completely with engine cold. Oil in the viscosity range 20W50 may be in use. Insure that the clutch is adjusted correctly and change oil to viscosity range 10W50. Control unit update: Using the BMWMoDiTeC CD 8/x, Update 3, update the programming of the BMS COMPACT control unit. The update of a BMS COMPACT control unit program is not to take place unless a customer has a complaint about hesitation, surging and stalling, these complaints have been verified by the retailer and the service measures covering fuel pressure, clutch adjustment and oil viscosity have been completed. Important Note: Always comply with the instructions, as included with the update CD, for the correct installation of CD 8/x, Update 3. Identification Label: Print a new identification label ( YELLOW for update ) and affix it to the BMS- COMPACT control unit. Please note that it is not permissible to deliver an updated motorcycle to a customer without the correct identification label affixed to the control unit.

HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

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Cobra 2008 CX50SR (King) Ignition System installation Manual

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

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Many 2008 Cobra CX50SR (King) customers are experiencing performance issues with their new motorcycles. These issues include cracking/popping noises, degrading performance, and excessively hot exhaust pipes. These issues have been traced back to manufacturing flaws with the new IDM brand ignition system. Because of the time associated with getting these issues sorted out, Cobra is switching production of the 2008 King over to the PVL brand ignition system (the same design used on 2007 model King motorcycles). Customers with 2008 Kings built prior to this date may exchange it for a PVL system at no cost for the hardware. For existing product in the field, Cobra will not support the IDM system until our supplier has their component functioning properly. To install the PVL system on the 2008 King simply remove the old hardware, and bolt on new (an updated Cobra universal puller will be required to remove the ignition rotor). The timing of the new PVL system will have to be set properly during installation

HONDA 2005 CBR 600 RR FULL S/S EXHAUST HEADER INSTALLATION

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Filed Under (Honda) by admin on 01-12-2011

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Place the motorcycle in a vise or on it’s kick stand and make sure it is safe and secure. NOTE: If reusing the stock midpipe and muffler, skip ahead to step #5. 2) Remove the rider and passenger seats. Unplug the tail light, license plate light, and turn signals wires inside the tail section. 3) Remove the four bolts that secure the tail section to the subframe. Carefully remove the tail section from the subframe. 4) Remove the four bolts that secure the license plate/turn signal mount to the subframe. Remove the mount from the motorcycle. 5) Remove the upper and lower front fairing pieces. 6) Remove the two bolts that attach the right side footpeg assembly to the motorcycle. Disconnect the rear brake light switch and swing the footpeg assembly out of the way. Remove the outer plastic foot guard. Remove the aluminum heat shield from the motorcycle. 7) If equipped, remove the o2 sensor from the stock midpipe assembly.
NOTE: If reusing the stock midpipe and muffler, loosen the midpipe mounting bolts, and loosen the clamp securing the headpipe to midpipe connection. Skip ahead to step #9 8) Remove the midpipe mounting bolt, located on the right side of the subframe. Remove the
muffler mounting bolts. Lower the muffler and remove the rear exhaust section from the midpipe. 9) Remove the eight hex flange nuts securing the header flanges to the cylinder. 10)Remove the bottom header mounting bolt from the midpipe assembly. Remove the complete header from the motorcycle. 11)Remove the hat washer and rubber grommet from the stock midpipe assembly. Install the rubber grommet and hat washer into the hole provided on the Jardine midpipe assembly. 12)Slide the four headpipes into the new collectors. The headpipes are numbered from #1 thru #4, with #1 being the furthest toward the left side of the motorcycle, then work your way to the right. Do not install the provided springs at this time

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KTM EXC 2004-2007 rear fender REMOVAL

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Filed Under (KTM) by admin on 29-01-2012

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Remove lower section of rear fender • Using care not to damage the threads, drill 1/8″ pilot hole up through subframe and rear fender (fig1) • Remove fender, enlarge pilot hole in upper subframe with 1/4″ drill, do not drill out threads- take care not to damage threads in subframe. • Enlarge holes in fender to 5/8″ • Install upper section of rear fender, insert enclosed 5/8″ spacers in fender holes (fig.2) • Install cross brace (bolt holes closer to front of bike) using enclosed M6 X 50mm button head bolt (fig 3) • Re-install lower fender section using original stepped washer with enclosed 6mm nuts (fig 4) • Install side brackets as shown in fig 5 – replace subframe bolts with enclosed flat head bolts at forward mounting points if necessary.

Honda CBR-929RR/ 954RR – Installation Instructions (slip on system)

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Filed Under (Honda) by admin on 03-11-2011

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Remove the lower fairing. Remove the rear turn signals. Remove the existing exhaust system from the HTEV valve rearward, save the mounting bolts for reuse. Save the stock exhaust can mounting bolt and nut for the end can to the passenger footpeg for reuse as well. Install the supplied HTEV joint plate to the rear of HTEV valve (see photo 1) using the stock mounting bolts. Tighten per factory specifications. Install the 2 Y-pipes to the joint plate, but do not install the supplied springs at this time. Install the S-Bend to the two Y-pipes, but do not install the supplied springs at this time. If you plan to keep the passenger footpegs, follow this step, otherwise, skip to step 8. Reassemble the right
passenger footpeg assembly in this order (from the subframe outwards): Spacer A, Stay Arm F, Spacer B, passenger footpeg assembly (from step 7 above). Use the supplied 8x110mm bolts D (2x) to fasten to the subframe (reuse nuts). See figure 3 for details. Proceed to step 8. If you plan to remove the passenger footpeg assemblies, follow this step and ignore step 6 above. Use: Spacer A and place the Stay Arm F against it. Use the supplied 8x50mm bolts E (2x) to fasten to the subframe (reuse nuts). See figure 3 for details, but use only the hardware specified in this step.
Slide the TiForce end can into place. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. See figure 1 for details. Place the bands approximately 120mm from the edge of the end can. See figure 2 for details.

2003 Cannondale E440, C440, X440, S440 Owner's Manual

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

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INSPECTION OF ALUMINUM CHASSIS COMPONENTS The aluminum chassis components of your vehicle have a finite, limited, useful life. The length of that life varies depending on the material used in their manufacture, the amount of use they are subjected to, and the care they receive while in service. Regular inspection by a Cannondale Motorsports Dealer is important. Frame – a main support structure for the engine, various components, and rider. Subframe – adds structural support. Swingarm – a suspension component Use in competitive events, hard and aggressive riding, riding on severe terrain, riding in severe climates, and riding fast can dramatically shorten the life of the aluminum (frame) components. Any one and/or a combination of these conditions may result in an unpredictable failure. We recommend that you carefully inspect your vehicle’s chassis components for cracking, bending, deep scratches and/or other damage before every ride. If you have crashed or rolled your vehicle, there could be damage hidden from your view. DO NOT ride a vehicle with any crack, even a small one. It must be carefully inspected by an authorized Can- nondale Motorsports Dealer before it is operated again. Riding a cracked frame could lead to complete frame failure. If you have any questions, contact your Can- nondale dealer or call 1-800-MOTO-USA. WARNING POTENTIAL HAZARD(S) (1) Riding on a cracked or damaged frame. (2) Attempting to fix a damaged frame. WHAT CAN HAPPEN (1) Riding on a cracked or damaged frame can lead to a complete frame failure. (2) Aluminum frame (and components) are heat treated. Welding, drilling, or modifying the frame, subframe, or swingarm may weaken the component and result in complete failure, leading to a serious accident with subsequent injury or death. HOW TO AVOID THE HAZARD Inspect carefully before riding. Don’t ride on a cracked or damaged frame. Don’t try to repair the frame, subframe, swin- garm, or other components. Have your Cannondale dealer inspect the frame at every visit and at the 25 hour maintenance interval. Call 1-800-MOTO-USA with any questions

KTM ATV 525 XC specification

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

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Engine ] Pure power for Enduro enthusiasts. The power of the 525 XC is the indisputable benchmark in the ATV Enduro sector. Its acceleration and top speed cast a shadow over all its predecessors. Variable ignition curves and perfect maintenance features like simple valve play adjustment and the removable clutch cover are even further highlights of the XC engine that make the KTM Enduro quads so superior. First Oil Filling for all KTM Engines. [ CarburEttor ] The Keihin carburettor, which has been proven multiple times in racing, with 39 mm and the Throttle Positioning System guarantees a uniform, forceful power delivery in all speed ranges. It ensures an unrivalled response behavior and perfect service-friendliness at all times. [ StartEr ] Packed in a space-saving manner into the free space behind the cylinder head, the small, light electric starter motor is ready for use. It brings every KTM ATV up to speed reliably and comfortably even when racing becomes hectic. [ rEar SuSPENSIoN ] Premium-quality ÖHLINS suspension components specially designed for tough Enduro use are provided as standard – both at the front and the rear. Easy to adjust, they guarantee optimal tuning for the most varied of terrains. Another highlight: the front and rear spring travel of 275 mm and 272 mm respectively is 100 % trend-setting for an Enduro ATV! [ alumINIum SubFramE ] The rear subframe is made of aluminium and is extremely light and easy to remove. [ FramE ] The lightweight, extremely durable frame sets the benchmark in the quad racing segment and is made of high-strength, powder-coated Chromoly steel. [ haNDlEbar ] An ultra-durable tapered aluminium Magura® handlebar comes standard that is four-position adjustable to suit your preferred ergonomics. Further highlights are the functional and individually adjustable operating levers for brake and hydraulic clutch. In addition, the chassis has an integrated mount for a steering damper – available as a PowerPart accessory. [ CurvED raDIator ] Best cooling by means of its curved shape and the resulting maximized surface area. [ rImS / tIrES ] MAXXIS Razr tyres on light, stable DWT aluminium rims. [ ExhauSt ] The powerful XC silencer is made of light-weight aluminium.

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TRIUMPH DAYTONA 675 DUAL OUTLET SLIP-ON EXHAUST INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 30-10-2010

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1) Make sure the motorcycle is cool and place securely on a service lift or stand. 2) Lift up on the front of the passenger seat and remove the bolt securing the passenger seat to the subframe. Remove the passenger seat. See Figure #1 3) Using the key, remove the rider seat. 4) Remove the four bolts securing the tail section to the subframe. lift up on the tail section and disconnect the tail light wire. remove the tail section. See Figure #2 PERFORMANCE DELIVERED! TECH: (951)739-5900 PARTS INCLUDED Ref. Part Number Description Qty 1) 00-200-00060 Slip-on S-bend Assembly 1 2) 00-200-00056 Carbon Fiber Dual Outlet Muffler 1 3) 04-24-42866 Supersport Fender Bracket 1 4) 03-46-42004 Muffler Mounting Strap 1 5) 07-27-42005 Muffler Strap Silicone Rubber Sleeve 1 6) 04-18-37594 Muffler Strap Mounting Spacer 2 7) 01-5106100016-SS M6-1.0x16mm Socket Button Head Bolt 4 8) 01-7406100-27 M6-1.0 Hex Flange Nut 2 6) 07-41-35929 Dual Swivel Spring, Long 2 7) 07-38-42063-35 T-Bolt Clamp 1 TOOLS REQUIRED Ref. Description 1) 3/8″ Drive Ratchet 2) 3″ Extension 3) 10mm Socket 4) 12mm Socket 5) 13mm Socket 6) 4mm Allen Socket Ref. Description 7) 5mm Allen Socket 8) 8mm Allen Socket 9) 10mm Wrench 10) 12mm Wrench 11) Torque Wrench 12) Spring Tool or Needlenose Pliers INSTALLATION INSTRUCTIONS FIGURE #1
18-7009-524-02 RT1 DUAL OUTLET SLIP-ON EXHAUST TRIUMPH DAYTONA 675 2006-07 PERFORMANCE DELIVERED! TECH: (951)739-5900 5) Remove the four bolts securing the plastic cover over the stock muffler. Remove the cover. See Figure #3 6) Remove the left and right turn signal mounting bolts. Slide the turn signals/license plate light assembly away from the license plate mount and disconnect all wires. Make note of the right and left turn signal wiring. Set turn signal assembly aside. See Figure #4 7) Remove the four bolts that secure the license plate bracket to the stock muffler. Remove the license plate bracket. See Figure #5 8) Loosen the muffler inlet clamp. See Figure #6 9) Remove and retain the muffler mounting bolt and nut. Remove the muffler assembly from the motorcycle.

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