yamaha grizzly 660 crankcase vent

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Harley Davidson Electra Glides, Ultra Vent (model LV-2,3,4) Installation Manual

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Filed Under (Harley Davidson) by admin on 07-03-2012

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Remove the fairing lower from the engine guard using the procedure provided in your Harley-Davidson user/service manual. Do not remove the glove box from the fairing. Vent Placement, Hole Drilling and Cut-Out: Caution: Place cloth or cushion underneath fairing lower to protect it from getting scratched during the following procedures. LV-2,3,4 Installation Copyright 2003-2004 2 3. Working inside the fairing and using the bottom of the glove box as a guide, position a closed vent parallel to and no more than 1/16″ from the rear edge of the fairing. Position the assembly so that the vent side tabs are no more than 1/8″ below the bottom of the glove box. (You want the vent assembly as close as possible to the glove box but with enough room so that the side tabs do not touch the glove box when the vent is closed! ) Mark the back two holes with a pencil then remove the vent and replace it with the cutting template in the exact same location. See photo to the right to assist in judging the cutting template orientation. 4. Lift out the glove box, steady the template with one hand and using an 11/64″ drill bit carefully drill 1 hole near the back edge of the fairing through the bottom corner hole of the cutting template. Install one screw and nut and tighten slightly to stabilize the template’s location. On the other corner (same edge) , drill the second hole. (You cannot drill the remaining holes from inside the fairing because the front edge of the fairing lower is in the way. ) 5. Remove the screw and nut and re-position the cutting template on the outside of the fairing with the three hole side of the template towards the front of the fairing (away from the edge of the fairing) . Install two screws and nuts into the open holes. Drill the remaining two corner holes and install two screws and nuts. Change drill bit size to 1/8″ to drill the final center latch hole. Next skip down to one of the two following procedures to make the vent opening using either A) Dremel tool/RotoZip router or B) coping saw/frameless hacksaw

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YAMAHA CRANKSHAFT LOWER END REMOVAL AND INSTALLATION TOOLS

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Filed Under (Yamaha) by admin on 08-01-2012

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90 LOWER END REMOVAL & INSTALLATION TOOLS SHOP EQUIPMENT & TOOLS 35-8399 35-8513 35-8516 35-8508 35-8504 35-8507 YAMAHA CRANKSHAFT PROTECTORS Sold each. 35-8504 YM-4063-A, XV750/920 Virago, XT550, YFP350, YFM660R Raptor 35-8399 YM-1382, XT250/XT350, RZ350, YFP350, YFZ350 35-8507 YM-33282, XV500 Virago, XZ550 Vision, XVZ12/13 Venture & Venture Royale, VMX12 V-Max 35-8508 YM-38145, XV750/XV1000 Virago YAMAHA CRANKSHAFT INSTALLATION SET Sold as a set. Consists of the following: Qt1-Installing Pot, Qt1-Pot Spacer, Qt1-Bolt. 35-8509 YU-90050 Crankshaft Installation Set OPTIONAL POT SPACERS 35-8513 YU-90070-A, XV750/920 Virago, XT550, TT600 35-8515 YU-91044, YFM350, SRX600, XT550/600 35-8516 YU-1202, SR500, TT/XT500 CRANKCASE PRESSURE TESTER An accurate method for checking possible air leaks on two-stroke engines. Complete with air pressure gauge, pump-up bulb and all fittings and adapters for single and multi-cylinder two-cycle engines. 35-5962 Crankcase Pressure Tester CRANKSHAFT INSTALLING JIG TOOL Supports and centers crankshaft webs while assembling two-stroke engine cases and rebuilding crankshafts. Prevents rod misalignment. Adjustable tang ends. 35-9804 Crankshaft Installing Jig Tool CRANKCASE SEPARATOR TOOL This tool will work on most two and four stroke engines that have a vertically split crankcase. Moveable fingers allow a multitude of bolt patterns to be used so it will work on a variety of models. Includes 6mm and 8mm mounting bolts, center pulling bolt and a three leg frame that is appropriate for many applications. 35-9642 Crankcase Separator Tool 35-9637 Replacement 6mm and 8mm mounting bolts. Each

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GAS VENT INSTALLATION INSTRUCTIONS

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Filed Under (S&S) by admin on 29-10-2010

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1. Appliances . Carefully review the appliance manufacturer’s installation instructions for positioning the unit, any special venting or connector requirements, and verify that it is a Category I appliance or an appliance that requires the use of Type B gas vent. 2. Placement . The placement of the vent and fittings must be in accordance with Local Codes, as well as accepted venting practices. If more than one appliance is to be connected to one venting system, the common vent must be correctly sized. It is a good idea to make a sketch of the proposed installation, labelling the components you will need. Adjustable Pipe Lengths are available to make up odd lengths. Minimize the number of turns and lateral runs, as the National Fuel Gas Code places limitations on these. A 45° turn is preferable to a 90° turn. The appliance reference material should be consulted at this time, as well as any Local Authority having jurisdiction. In most localities, building permits are required for any new appliances, or modifications to existing venting systems.
3 3. Figures 1 , 2, & 3 show examples of some typical residential installations . 4. Clearance to Combustibles . A 1-inch clearance (air space) to combustible materials must be maintained , when using Simpson Dura-Vent Round B- Vent, regardless of the pipe diameter. 5. Combustion Air . Refer to appliance installation instructions and local building codes to ensure compliance with required volume of combustion air for each appliance installed . 6. Slope . If the venting system contains lateral (horizontal) components, they shall be positioned so they have an upwards slope away from the appliance of not less than 1/4- inch rise per foot of run. (Horizontal vent installed in attics, unconditioned area, or between floors have further restrictions, please consult your local building codes for specific limitations.)

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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YAMAHA TZR50 X-POWER SERVICE MANUAL

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Filed Under (Yamaha) by admin on 19-11-2010

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SPARES 1. Use only original Yamaha/MBK spares for all changes. Use the oils and /or greases recommended by Yamaha/MBK for assembly and adjustments. Other makes may have the same function and appearance but nevertheless be of lower quality. GASKETS, OIL SEALS AND O RINGS 1. When an engine is dismantled, all the gaskets, oil seals and O rings must be replaced. All the surfaces of all the gaskets and the lips of oil seals and O rings must also be cleaned. 2. When assembling, properly lubricate all bearings and matching parts. Apply grease to the lips of oil seals. WASHERS AND LOCKING TABS AND SPLIT PINS 1. All washers/locking tabs (1) and split pins have to be replaced and when locking tabs are removed and replaced they must be folded over the sides of the bolts or nuts, after these have been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearings and oil seals with the makes or manufacturer numbers facing outwards. (This means that the printed letters should be visible). When installing oil seals, apply a thin layer of light lithium grease to the lips. Put plenty of oil on bearings when installing these. 7. Crankcase remover tool Ref. 90890-11030 This tool is used for dismantling the crankshaft or removing the crankcase. 8. Tools for installing the crankshaft. Ref. 90890-01284 These tools are used for installing the cranks- haft. 9. Crankcase installer (Magnetic flywheel side) Ref. 90890-11032 10. Seal installer (Selector axle) Ref. 90890-11033 11. Seal installer (Water pump) Ref. 90890-11034

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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HONDA GL1800 WINDSHIELD VENT INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 04-03-2011

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NOTE: CAUTION is required when drilling and cutting to prevent cracking and scratching the windshield material. A professional glass service is highly recommended for this purpose. Should you attempt to install the windshield vent on your own, follow the instructions below. Add On Inc. will not be held liable or responsible for any damage to the windshield. 1. Place bike on center stand. 2. Cut out the template provided and center on windshield approximately 2 ¾” above the tint line. Tape the template to windshield using masking tape. Use enough masking tape to cover the area to be cut out to prevent scratching. If using a power sabre saw to cut the pattern out, put masking tape on the foot to prevent scratching the windshield. Drill the four corners using a sharp power sabre saw, electric drill (using a 7/16″ drill bit), and or hack saw. 3. Smooth cut edges with sand paper. 3. Install the vent. The two pieces will snap together in the windshield. Use chrome screws provided to secure vent in the windshield.

Yamaha Road Star NEEDLE/ JET KIT INSTALLATION INSTRUCTIONS

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

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1. Remove the vacuum slide from the carburetor. 2. Remove the OEM needle, spacer and washers, noting order of assembly. 3. Counting from the top to the bottom, install the new Baron needle clip on groove #4 for 04-07 models and on groove #5 for 99-03 models of the replacement. NOTE: Baron adjustable needle – The top is the blunt end of the needle. 4. Reinstall the OEM spacer and washers as shown in this diagram. 5. Reinstall the vacuum slide along with the diaphragm spring. 6. Reattach the diaphragm cover back and tighten screws. NOTE: Verify that the slide maintains its full range of movement. 7. Drain the fuel from the float bowl and remove the bowl cover. 8. Remove the OEM main jet and replace it with a Barons genuine Mikuni main jet. Install the correct main jet as indicated in JET SELECTION area above on this page. Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or fitment may be required. Page: 2 BA-2420RD NEEDLE/JET KIT – Yamaha Road Star (99-07) 9. Thoroughly clean the inside of the float bowl prior to reinstalling it. 10. Reassemble the carburetor by reversing the order of step #1 through step #10. Use the new cap head allen screws in place of the OEM phillips head screws. 11. Locate the fuel mixture screw – it will either be a screw head or a brass plug. If it is a screw head, skip to step #11c. 11c. If you see a brass plug with a small hole in the center, proceed as follows: With the drill bit, carefully and slowly drill through the fuel mixture plug. CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and remove the bit the instant you break through the plug. Insert the self-tapping sheet metal screw into the drilled hole and remove the plug. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats, then carefully turn it counter-clockwise 3 1/2 turns. Refer to step #16 for assistance in fine tuning the setting of the air/fuel adjustment screw. 12. Reinstall the carburetor. We strongly suggest that you attach the throttle cables prior to mounting to intake manifold. 13. Reconnect the fuel line, ensuring the clamp is firmly in place. 14. Reinstall all vent hoses and electrical connectors that were previously removed, checking for any obstructions or blockage. 15. Reinstall the OEM air filter assembly or, if you are installing our Big Air Kit (BAK), follow the instructions that accompany that kit, then continue with next step. NOTES: When the BAK is installed, the vent hose that terminated on the rear of the OEM airbox can be relocated in any safe position that does not kink or pinch it. It is important to verify proper throttle operation before starting the engine.

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