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Suzuki SV1000 COOLING AND LUBRICATION SYSTEM REPAIR MANUAL

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

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

YAMAHA MOTOR CORPORATION, U.S.A. STREET & ENDURO MOTORCYCLE LIMITED WARRANTY

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Filed Under (Yamaha) by admin on 27-12-2011

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GENERALEXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual. 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. Areasonable dealer imposed fee may be charged for the inspection. In no case will warranty be extended beyond the original period. EMISSIONS CONTROLSYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater, that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

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Aprilia RXV 450 – 550 MAINTENANCE MANUAL

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

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DIMENSIONS Max. length 2240 mm (88.19 in.) Max. width 830 mm (32.68 in.) Max. height (front fairing included) 1250 mm (49.21 in.) Seat height 950 mm (37.40 in) Wheelbase 1485 mm (58.46 in.) Minimum ground clearance 320 mm (12.60 in.) Dry weight 123 kg (271.12 lb) ENGINE Model (RXV 450) 45RX Model (RXV 550) 55RX Type twin-cylinder, 4-stroke with 4 valves per cylinder, single overhead camshaft Number of cylinders 2 Total displacement (RXV 450) 449 cu. cm (27.40 cu in). Total displacement (RXV 550) 553 cu. cm (33.75 cu in). Bore/stroke (RXV 450) 76 mm x 49.5 mm (2.99 in x 1.95 in) Bore/stroke (RXV 550) 80 mm x 55.0 mm (3.15 in x 2.16 in) Compression ratio (RXV 450) 13 ± 0.5 Compression ratio (RXV 550) 12.5 ± 0.5 Starting electric Engine idling rpm 1800 ÷ 2000 rpm Clutch Multiplate in oil bath. Lubricating system Double separate lubrication with external reservoir Air filter with dry filter cartridge Cooling system liquid-cooled TRANSMISSION Type mechanical, 5 gears with foot control on the left side of the engine CAPACITIES Fuel (including reserve) 7.5 l (1.98 gal) Fuel reserve 2.2 l (0.58 gal) Engine oil 1.3 l (0.34 gal) Fork oil 100 mm (3.94 in.) of air (per leg, measured without spring and compressed rod) Coolant 1.1 l (0.29 gal) (50% water + 50% coolant with ethylene glycol) Seat 1 GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio 1st 22/56 = 1: 2.545 12/31 = 1: 2.583 15/48 = 1: 3.200 1 : 21.042 2nd 13/25 = 1: 1.923 1 : 15.664 3rd 15/23 = 1: 1.533 1 : 12.489 4th 19/24 = 1: 1.263 1 : 10.288 5th 21/22 = 1: 1.047 1 : 8.533 DRIVE CHAIN Type with master link

YAMAHA YZF-R1R/ YZF-R1RC OWNER'S MANUAL

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

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1. Right turn signal indicator light “” 2. Fuel level warning light “” 3. Oil level warning light “” 4. Neutral indicator light “” 5. Engine trouble warning light “” 6. High beam indicator light “” 7. Left turn signal indicator light “”
INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU04895 Oil level warning light “” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The oil level warning light will flash ten times, then go off for 2.5seconds. If this occurs, have a Yamaha dealer check the motor- cycle. EAU00061 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU04896 Engine trouble warning light “” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. (See page 3-7 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. EAU00063 High beam indicator light “” This indicator light comes on when the high beam of the headlight is switched on

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YAMAHA Installing the Motorcycle Enhancements Remote Oil Filter

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Filed Under (Yamaha) by admin on 17-01-2012

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In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual. The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3. Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4. Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine. There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine
There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p

YAMAHA V-Star 1100 Motorcycle Enhancements Remote Oil Filter Installation Manual

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

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Removing Your Old Filter and Beauty Cover In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual. The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3. Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4. Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine. There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p. The bottommost bolt on the beauty cover will likely leak some oil when you remove it – it holds on the inner oil filter cover. Once you remove the beauty cover, you can remove the oil filter cover, and the oil filter Keep these two “O” rings, you’ll need them for the remote kit Old oil filter. Toss it away; you’ll never need one again! Throw away the old filter, and carefully remove the orange and black “O” rings from the filter cover (see picture above). These two “O” rings will go on the new engine cap in the same order as on the old filter cover. “O” ring for bottom bolt. When the beauty cover and filter cover are removed, be sure not to lose the tiny “O” ring that the bottom bolt goes through. Preparing the Remote Oil Filter Kit Remove the orange and black “O” rings from the stock filter cover plate, and place them on the Remote Oil Filter Kit engine cap – black on the inside, orange on the outside – just like on the stock filter cover.

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SUZUKI VX800 ENGINE MANUAL

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

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

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2003 SUZUKI SV 1000 Service Manual

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

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

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YAMAHA YZ MOTOCROSS ENGINE specification

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Filed Under (Yamaha) by admin on 13-11-2010

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YZ450F Engine Reshaped intake ports The YZ450F’s innovative 5-valve cylinder head design is one of the most sophisticated in the category, and plays a vital role in enabling this high-tech MX bike maintain its well-documented superiority on the race track. For 2008 the combustion efficiency of this advanced cylinder head is further improved with the introduction of reshaped intake ports which enhance the bike’s low to mid-range performance. New exhaust camshaft profile Yamaha Motor Europe N.V. Page 5 of 33
In order to optimise the significant performance gains of the new intake port design, the latest YZ450F’s 5-valve cylinder head is equipped with new camshafts featuring reshaped Yamaha Motor Europe N.V. Page 6 of 33
profiles. The inlet valve timing has been adjusted, the overlap is modified and exhaust lift is revised to create an idealised balance of intake and exhaust operations for increased combustion efficiency and improved performance in the important low to mid-range zone. Reduced piston clearance The YZ450F powerplant is already one of the most advanced 4-stroke engine designs in the MX world, featuring cutting-edge technology which gives it a real advantage. Extensive use of lightweight materials has enabled Yamaha to create a light, compact and high-revving engine which produces a remarkably wide band of hard hitting power – and for 2008 our engineers have further reduced cylinder/piston tolerances of the 95mm diameter piston in order to enhance the overall package. These reductions may only be measurable in terms of microns, yet the differences are most definitely tangible, and include increased torque output, smoother running and quieter operation. New 94dB silencer Complying with the new FIM94dB(A) regulations is a new stainless steel silencer which maintains the machine’s strong low to mid-range power output, while reducing overall noise.

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Yamaha YZF-R1 Undertail Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 11-01-2012

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Carefully remove the tail section body work. Save all bolts, washers and plastic rivets for re-installation of tail. Disconnect and remove the brake light (with all mounting grommets and washers), license plate and turn signals, key lock (with clip) and move all wiring out of the cutting areas. Remove the two bolts at the rear end of the stock fender (inside glove box) to allow the end to hang down for cutting. 2) Using a “Dremel” tool or cutting disc (this can also be done using a sharp edged knife, but is not recommended), remove the plastic shown in the photos above and below. Be sure to take your time cutting, so that you don’t cut away any more plastic than necessary. 3) Now relocate the rear mounting holes for the glove box 1.25″ lower in the tray to raise it up in the subframe as shown. Yamaha YZF-R1 Undertail Kit (2000-01, Available in: Yamaha Red, Yamaha Blue) Need Help? If you need additional help with the installation of the undertail, go to www.hotbodiesracing.com and look for the “FAQs” link at the bottom of the home page. Most of your general questions can be answered on those pages. This installation does require a basic mechanical aptitude, if in doubt, contact your local motorcycle shop and have a professional mechanic perform the installation, 3 hours is the average installation time. * After this modification your undertail is not returnable. Paint is not war- rantied against paint chips, flaking or scratches from installation or rocks being thrown from tire into the tray. 5) *Install license plate brackets to back side of license plate as shown. Now hold license plate in desired location on undertail, carefully mark and drill holes, install using the two (2) sets of allen bolts and lock nuts