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HSR Carburetor Total Kits Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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Intake Manifold: 1. Install MAP sensor in Mikuni manifold (Twin Cam only). 2. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 3. Attach the rubber flange to the Mikuni manifold with the furnished 5/16″x3/4″ bolts and washers. Choke Cables: Mikuni & Harley-Davidson Route the cable with largest radius bends possible. Check the cable for free-play after installation. If there is no free-play, the engine may run rich and deliver poor performance or low fuel mileage. Harley Cable (Twin Cam Kits: 42-19, 45-4) : 1. Remove the Harley choke cable from the stock carb. 2. Remove the spring and plunger from the cable. 3. Remove the spring and plunger from the Mikuni. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut (See Figure 1). Total Kit Installation Instructions The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during installation will pay off in both short and long term performance and reliability. This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for most applications. However, since Harley-Davidson motors are often highly modified, alternate tuning settings may be required. The Mikuni Tuning Manual helps make jetting alterations and adjustments an easy matter. NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in the state of California, or in any other states and countries where similar laws apply. WARNING NOTE: NOTE: WARNING CAUTION NOTE: NOTE: TK-2 6. Install the new assembly into the Mikuni carburetor. Be careful to only gently tighten the plastic nut. 7. Loosen the knurled plastic friction nut behind the choke knob and check for free-play (see Figure 2). Figure 1: Harley nut with Mikuni spring & plunger Figure 2: Choke cable adjustments Mikuni Cable (Evo Kits: 42-8, 45-2 & 45-3) : 1. Remove nut, spring and plunger from the Mikuni. 2. Install the nut, spring and plunger onto the cable. 3. Install the assembly into the Mikuni HSR carburetor. Be careful to only gently tighten the plastic nut. 4. Check for free-play. Adjust the cable as necessary. An optional choke cable mounting bracket is included in the Evo kits for custom installations. Carburetor Installation: 1. Insert the carb fully into the rubber flange, align with engine and tighten the clamp. 2. Slip the fuel hose onto the carburetor’s fuel fitting and secure with the enclosed hose clamp. NOTE: Some Twin Cam installations may require removal of a small amount of fin material from the cylinders to clear the float bowl. Throttle Cables The HSR carburetor uses stock 1990 and later Harley- Davidson cables. However, if your Harley is fitted with some other carburetor, you may need to purchase a set of cables. See your dealer for the correct cable set. 1. Route the throttle cables with large radius curves and so they do not interfere with other components. 2. Screw the cable adjusters together to make them as short as possible. 3. Connect the “close” cable first (see Figure 3). 4. Install the “open” cable next (see Figure 3). 5. Adjust the opening cable until the slide can be opened fully. Snug the adjuster lock nut. 6. Turn the handlebar to the right and adjust the throttle free-play with the closing cable adjuster to approximately 1/8″ (see Figure 4)

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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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HSR Carburetor Total Kits Installation And Tuning Manual

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Filed Under (Tips and Review) by admin on 31-10-2010

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1. Disconnect the battery ground wire from the battery. 2. Turn the fuel petcock to the “OFF” position. 3. Elevate the rear of the fuel tank for better access to the carburetor area. 4. Remove the coil, horn or other devices on the left hand side of the engine to allow free access to the intake manifold bolts. 5. Remove the complete air cleaner assembly, including the backing plate. 6. Disconnect any vacuum hoses and the fuel hose from the stock carburetor. 7. Disconnect the choke cable from the frame. 8. Remove the stock carburetor. 9. Evo: remove the stock manifold. 10. Twin Cam: unplug MAP sensor, remove manifold and then remove the MAP sensor from the manifold. Installation: Intake Manifold: Twin Cam only: Install MAP sensor in Mikuni manifold. 1. Attach the Mikuni manifold to the engine. Align the manifold before tightening the bolts. The flange surface of the Mikuni manifold should be parallel with the front of the engine’s cam cover. Use a level or angle meter to check this. Tighten the manifold bolts. 2. Attach the rubber flange to the Mikuni manifold with the 5/16″x3/4″ bolts and washers. To ease installation, use liqiud detergent to lubricate the manifold seals. Choke: Evo: We recommend that you use the Mikuni choke cable that is furnished with the carburetor. However, you can use the stock Harley cable (’90-’99 models only) if you follow the Twin Cam choke cable instructions. Twin Cam: 1. Remove the Harley choke cable from the stock carb. 2. Remove the Harley spring and plunger from the Harley choke cable. 3. Remove the Mikuni spring and plunger from the Mikuni carburetor. 5. Install the Mikuni spring and plunger onto the Harley choke cable. Change nothing else; be sure to use the Harley plastic nut, not the Mikuni nut. 6. Install the new assembly into the Mikuni. Be careful to only gently tighten the plastic nut.

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KTM 250/ 300/ 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot. To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the idle adjusting screw. Opening up B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer. Full throttle range D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. mixture too rich: too much fuel in proportion to air mixture too lean: not enough fuel in proportion to air 1 2 OPERATING RANGES OF THE CARBURETOR 2-3C Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB:

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Mikuni HSR 42/ 45 Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at ½ to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle.

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42MM MIKUNI FLATSLIDE CARBURETOR INSTRUCTIONS

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at 1/2 to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle. The output of the OEM fuel pump is too high and will cause fuel overflow in the HSR carb, resulting in a possible dangerous fire hazard

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KTM 60 SX / 65 SX REPAIR MANUAL ENGINE

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

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Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment low altitude or low temperatures  choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer

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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 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 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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