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Honda CARBURETOR ADJUSTMENT TOOLS

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Filed Under (Honda) by admin on 17-12-2011

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K&L CARBURETOR ADJUSTMENT WRENCHES These tools use tough and accurate bevel gear actuation instead of cable for professional use. The aluminum handle includes index marks for accurate tuning. Sold each. Three types available: 35-9653 Slot-type Pilot Screw Adjustment Wrench for Kawasaki/Suzuki/Yamaha 35-9658 Slot-type Pilot Screw Adjustment Wrench with longer tip for Kawasaki/Suzuki/Yamaha 35-9650 D-type Keihin Pilot Screw Adjustment Wrench for Honda 90-DEGREE 1/4″ HEX DRIVER This gear driven, 1/4″ hex driver set is made of high-grade aluminum and stainless steel. Strongest tool of it’s type on the market. Designed for use on hard-to-reach pilot air screws on inline fours. Can be used with any 1/4″ or 6mm hex bits. 35-7820 90-Degree 1/4″ Hex Driver Set: Includes straight slot, phillips, d-shape pilot screw bit, 6mm hex jet bit & 1/4″ – hex – 1/4″ drive bit. FCR CARB TOOL Set includes three bits – 6mm hex for main jets, long reach straight slot for pilot jets and 3mm allen for float bowl removal. Longer bits make this set ideal for reaching into recessed cavities when adjusting Keihin FCR carburetors. Sold as a set. 35-7978 FCR Carb Tool 12″ DRILL BIT For removal of carburetor plug. (mixture screw plug) 1/8″ bit x 12 inch length. 35-1186 YM-33217-16 JET DRIVER 35-2270 Perfect for removal of jets from small recessed passages

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YAMAHA WR450F (S) 2-TRAC SPECIFICATIONS/ SUPPLEMENTARY OWNER’S SERVICE MANUAL

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Filed Under (Yamaha) by admin on 26-04-2011

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CABLE ROUTING DIAGRAM STEERING DAMPER ADJUSTMENT 19 Damping sweep controls Damping sweep ontrols 5 are located on each side off the damper body. Damping is in position 2, (12 o´clock), when delivered from Yamaha. This setting is fitted for enduro, motocross and off-road riding. WARNING Always ensure that valve setting is within the permitted ranges. NOTE: Both damping sweep controls must always be set in identical positions. Always use positions according to the clock. Suitable starting position: Motocross pos. 1 or 2 Enduro pos. 2 or 3 Off-Road pos. 2, 3 or 4 Technical data External measures 70x70x35 mm Seals Low friction type Oil Öhlins part no. 01306-01 Maintenance and inspection The steering damper is a precision instrument, with extremely fine tolerances. It is therefore essential that it is maintained in a correct manner. Maintenance and service should be carried out by an authorised service center. NOTE: After washing the motorcycle wipe clean and spray with all-round oil. Never subject to direct high-pressure cleaning since water may otherwise penetrate the damper. Ensure that there is no leakage of fluid and that there is no visible damage to the housing and mounts FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT The rebound adjuster is located at the top of the fork leg. 1. Adjust: • Rebound damping force By turning the adjuster. Stiffer → Increase the rebound damping force. (Turn the adjuster in.) Softer → Decrease the rebound damping force. (Turn the adjuster out.) Extent of adjustment: Maximum Minimum Fully turned in 20 clicks out position (from maximum position) • STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 14 clicks out Do not force the adjuster past the minimum  or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same set- ting. Uneven adjustment can cause poor handling and loss of stability

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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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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Harley-Davidson Softail, Touring, Dyna, Sportster and V-Rod, SELF LEARNING MODULE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2012

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STEP 1 – BATTERY CONNECTION Locate the battery and disconnect the negative battery cable. Mount the module in the open area in front of the battery with 2-tie straps or velcro straps, directing the harness from the module towards the 6 o’clock position. STEP 2 – THROTTLE POSITION SENSOR (TPS): Remove the air cleaner assembly and unplug the TPS sensor connector at the TPS sensor. The harness includes (2) TPS connectors which should be routed under the gas tank into the factory wire loom to the TPS sensor. The TPS sensor is located on the left side of the throttle body. Plug the (2) TPS connectors from the module in between the TPS sensor and to the factory TPS connector. STEP 3 – O2 SENSOR: Systems equipped with factory O2 sensors Rear: Unplug the Rear O2 sensor connector from the factory harness, which is located at the Rear exhaust pipe. Route the module’s harness which includes (2) O2 sensor connectors and connect one connector to the Rear O2 sensor and connect the other connector to the main factory O2 sensor connector. Front: Unplug the Front O2 sensor connector from the factory harness, which is located at the Front exhaust pipe. Route the module’s harness which includes (2) O2 sensor connectors, and connect one connector to the Front O2 sensor and connect the other connector to the main factory O2 sensor connector. Systems not equipped with factory O2 sensors NOTE: Many aftermarket exhaust systems are now equipped with plugged O2 sensor bungs which can be removed to accept an aftermarket O2 sensor. Typically these bungs already have a thread size of 18 mm x 1.5 mm. Exhaust systems not equipped with O2 sensor bungs need to have the supplied 18 mm x 1.5 mm thread size bung welded to the exhaust pipe in order to install an O2 sensor. The O2 sensor bung should be installed 3 to 6 inches away from the rear cylinder exhaust port and in front of the exhaust torque tube pipe area. The module prefers to receive information from the O2 sensor from an area that is NOT contaminated from atmospheric air. This air may enter through the tail pipe of an unrestricted or un-baffled exhaust pipe. The bung should not be installed in the “5 to 7 o’clock” area. If mounted in this area the O2 sensor can be damaged. The moisture from the gases exiting from the rear cylinder exhaust port will harm the ceramic shell element of the O2 sensor.

1996 YAMAHA TDM 850 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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Model: TDM850 Model code: 4TX2 5AR1 (CH,A) Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,200 mm 790 mm 1,285 mm 805 mm 1,475 mm 165 mm 2,900 mm Radiator: Radiator capacity (including all routes) 1.7 L Tire: Type Size front rear Manufacturer front rear Type front rear Tubeless 110/80 ZR18 150/70 ZR17 BRIDGESTONE*/PIRELLI/MICHELIN BRIDGESTONE*/PIRELLI/MICHELIN BT54F/MTR03/MACADAM 90X BT54R/MTR04/MACADAM 90X *In Austria and Switzerland only Bridgestone tires are equipped on this mode. MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) Advancer type 10 at 1,150 r/min TPS and electrical type Voltage regulator: Type Model /manufacturer No load regulated voltage Semi conductor-short circuit type SH650A-12/SHINDENGEN 14.1 14.9 V Electric fan: Model /manufacturer NAAF20/NIPPONDEN SO CARBURETION CARBURETOR FUEL LEVEL ADJUSTMENT 1. Measure: Fuel level a Fuel level: 15.8 16.8 mm (below the MIKUNI mark) Out of specification Adjust. Adjust the float level by slightly bending the float tang 1. Fuel level measurement and adjustment steps: Place the motorcycle on a level surface. Use a garage jack under the engine to ensure that the carburetors are positioned vertically. Connect the fuel level gauge 2 to the drain pipe. MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) Advancer type 10 at 1,150 r/min TPS and electrical type Voltage regulator: Type Model /manufacturer No load regulated voltage Semi conductor-short circuit type SH650A-12/SHINDENGEN 14.1 14.9 V Electric fan: Model /manufacturer NAAF20/NIPPONDEN SO

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ATK 50MX INSTALLATION AND ADJUSTMENT TIPS

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Filed Under (Atk) by admin on 01-11-2010

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PRELOAD ADJUSTMENT— On some Works shocks a threaded preload is standard. This allows the adjustment of the ride height of the motorcycle. The preload is changed by turning a threaded nut down towards the spring (higher ride height) or up away from the spring (lower ride height). The nut is a right-hand thread. CHECKING RIDE HEIGHT— 1. With the bike unloaded on the side stand and the shock fully extended, have an assistant measure from a point at the axle (center point) to a point on the frame, fender or bodywork directly above it. Record this measurement. 2. With the bike off the stand and the rider in the seat, bounce on the suspension and let the bike settle. Have the assistant measure from the same two points. Subtract the second measurement from the first. HM CRX50 / BAJA & ATK 50MX INSTALLATION AND ADJUSTMENT TIPS Continued on next page. #HM50 – 5/27/99 #HM50 – 5/27/99 To Front Valve Mounting channel Spacer Flange Shock eye Top View of Shock Mount Fig. 1 Top view of upper shock mount. The flange on the shock bushing must face toward the spacer. The valve should point toward the front of the bike Fig. 1 Top view of upper shock mount. The flange on the shock bushing must face toward the spacer. The valve should point toward the front of the bike 3. The amount of settle, or “sag” is a function of the wheel travel. It should only be between 1/4 and 1/3 of the total travel. 4. If the difference is less than the minimum, reduce the spring preload. Measure the distance again starting with Step 2. Adjust again if necessary. 5. If the difference is more than the maximum, increase the spring preload. Measure the distance again starting with Step 2. Adjust again if necessary. Note: If the ride height is too low, the shock will bottom unnecessarily, resulting in a harsh ride. If the ride height is too high, the shock will “top out” too easily when rebounding from a bump or under hard deceleration. NITROGEN PRESSURES IN EMULSION SHOCKS CAUTION: The pressure in these shocks cannot successfully be checked. Concerns with the gauge volume and the gas volume in the shock body create a situation where you cannot accurately determine what pressure was in the shock. In addition when the pressure is lowered (i.e. checking the pressure) the gas and some of the shock oil escapes into the gauge. It is possible to lose a large percentage of the shock oil by depressing the core of a charged shock to the atmosphere. Please note that in order to check the pressure, some of the gas must escape and fill the gauge assembly. The volume of the gas pocket is about half the size of your thumb, so a very small volume change results in a large pressure drop. Because the gauges’ volumes vary, it is not possible to deduce the actual pressure in the shock prior to attaching the gauge. Therefore it is imperative that any attempt to check pressure be accompanied by the capability of refilling the shock. In other words: If you don’t have a nitrogen source handy, don’t check the pressure! PRESSURIZING EMULSION SHOCKS The pressure setting for Works gas shocks is 250 p.s.i. of dry nitrogen. To pressurize a shock with some residual pressure in it, bring the gauge manifold up to 250 p.s.i. and depress the core with the T-handle. This will either equalize the pressure or refill the shock without transferring oil from the shock into the gauge assembly. The best gauges for this purpose screw on to the valve and incorporate a T-handled core depressor to isolate the shock from the gauge. This allows a leak-free separation once the desired pressure is reached. For simplified operation, an extra valve is provided for the filling apparatus, allowing pressure adjustment with the gauge in place. Works offers a suitable gauge and filling manifold. Most motorcycle shops that deal with dirt bikes can pressurize the shock

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2005 Yamaha Royal Star Tour Deluxe speedo Healer Installation Manual

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Filed Under (Yamaha) by admin on 09-11-2010

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The speed sensor is on the left side (looking from the back towards the front of the motorcycle). Just FYI, here is the speed sensor coming off of the drive shaft behind the left saddlebag. The speed sensor connection for the Speedo Healer is behind this red cover. Take off the seat. There are two screws. One pointed out by the arrow and one on the opposite side. Also, remove the screw on the red cover. After removing the screw on the red cover, remove the cover by pulling it straight away from the bike. It is held on by 2 rubber grommets. The arrow points to the speed sensor coupler. Pull the connection apart. There is a little tab holding the connector together that will need to be depressed in order to get it apart.Hook the SH harness into the appropriate connectors. It only goes one way. The Yamaha plug and go kit works perfectly with no splicing required. Here is a close-up of the connection. Run the cable up under the bar towards the battery and hook the wires up to the Speedo Healer unit. The speedo healer fits nicely right behind the battery. You can barely see it next to the intercom. Note, none of the wires in this example have been secured yet. Put the red cover back on. Figure out the error that needs to be adjusted and make the adjustments to the Speed Healer per their instructions. Put the seat back on and you’re good to go. Be sure to verify that your adjustment was correct before believing your speedometer to be accurate. With the right adjustment, it will be, but don’t wait for a cop to tell you that you miscalculated! The electronic cruise control was not affected by the installation of this unit. I ended up setting mine to -7.5% after chasing my wife’s ’03 Vue for a couple of times. I ended up reading 59mph to her 60mph (previously it read 65mph to her 60mph) which is right where I wanted it since her speedometer reads a little fast, too. My back tire is about halfway worn. Your adjustment may vary

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Yamaha Royalstar Royal Star Tour Deluxe Speedo Healer Installation

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Filed Under (Yamaha) by admin on 07-01-2012

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he speed sensor is on the left side (looking from the back towards the front of the motorcycle). Just FYI, here is the speed sensor coming off of the drive shaft behind the left saddlebag. – 7/2 -The speed sensor connection for the Speedo Healer is behind this red cover. Take off the seat. There are two screws. One pointed out by the arrow and one on the opposite side. Also, remove the screw on the red cover. After removing the screw on the red cover, remove the cover by pulling it straight away from the bike. It is held on by 2 rubber grommets. – 7/3 -The arrow points to the speed sensor coupler. Pull the connection apart. There is a little tab holding the connector together that will need to be depressed in order to get it apart. – 7/4 -Hook the SH harness into the appropriate connectors. It only goes one way. The Yamaha plug and go kit works perfectly with no splicing required. Here is a close-up of the connection. – 7/5 -Run the cable up under the bar towards the battery and hook the wires up to the Speedo Healer unit. – 76 -The speedo healer fits nicely right behind the battery. You can barely see it next to the intercom. Note, none of the wires in this example have been secured yet. Put the red cover back on. Figure out the error that needs to be adjusted and make the adjustments to the Speed Healer per their instructions. Put the seat back on and you’re good to go. Be sure to verify that your adjustment was correct before believing your speedometer to be accurate. With the right adjustment, it will be, but don’t wait for a cop to tell you that you miscalculated! The electronic cruise control was not affected by the installation of this unit. I ended up setting mine to -7.5% after chasing my wife’s ’03 Vue for a couple of times. I ended up reading 59mph to her 60mph (previously it read 65mph to her 60mph) which is right where I wanted it since her speedometer reads a little fast, too. My back tire is about halfway worn. Your adjustment may vary

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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