Kawasaki 900 / 1100 Engine Removal and Installation

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Filed Under (Kawasaki) by admin on 01-05-2012

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1.1 (Above) Remove the two retaining straps, disconnect the battery and remove it from the hull. Disconnect the negative (black) cable first, then the positive (red). Step 2 Intake Removal 2.1 (Below) Remove the eight 10mm bolts securing the flame arrestor cover to the base and remove it. 2.2 (Below) Pull out the flame arrestor screens. 2.3 (Below) Remove the six 10mm bolts securing the flame arrestor base and carbs to the manifold and remove the base. 2.4 (Below) Loosen the gas tank cap to relieve pressure. Be sure the fuel switch is turned to the “OFF” position, and be aware of any fuel that may spill from the hoses. Make sure the hull is clear of any gasoline fumes before continuing work, especially with power tools. Remove the pulse lines from the block, and the three oil lines from the carbs. Move the carbs aside in the hull. 2.5 (Below) Remove the 18 10mm nuts from the studs securing the intake manifold to the engine and remove the manifold

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TRIUMPH ROCKET III HEEL / TOE SHIFTER INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 29-01-2011

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1. Loosen the 10mm nuts at the ends of the shifter linkage rod (notice one end is a left hand thread). Remove the 10mm nut from the shifter arm & disengage the linkage. Remove the shifter pivot bolt using a 8mm hex key wrench. Remove the washer on the threaded side of the shifter pivot bolt. 2. Place one of the wave washers supplied onto the pivot bolt. Place a small amount of grease on the shifter pivot bolt shank and the Heel / Toe shifter pivot hole, insert the pivot bolt into the pivot hole of the toe heel shifter. Use a drop of blue loctite on the shifter pivot bolt threads and install the Heel / Toe shifter, tighten the pivot bolt securely. Check to see that the shifter pivots freely. If the side play is excessive (this is a result of variances in manufacturing tolerances of the stock and supplied components) remove the pivot bolt and install the second wave washer supplied. 3. Unscrew the linkage rod and replace it with the longer rod supplied (NOTE the rod has a left hand thread on one end and right hand threads on the other). Insert the shifter linkage stud into the desired hole in the new shifter being sure the flats on the stud engage the slot on the backside of the bolthole. Install the nut and finger-tighten only at this time. 4. While seated on the motorcycle first find the height setting you prefer for the toe shifter. Using one of the three boltholes for the linkage can set this. You can also gain some adjustment by exposing more or less threads of the new longer shifter linkage rod; however be sue that you have a minimum of 4-5 threads still engaged in the linkage ends. After setting the height, tighten all three 10mm nuts (the two at the ends of the linkage rod and the one which attaches the linkage to the toe/heel shifter) securely. After you have the toe shifter adjusted to your liking you can select the heel shifter height by moving the button head cap screw that secures the toe shifter to the heel shifter (Using a 5/32″ hex key wrench) next to the 10mm linkage nut to any of its three holes

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Kawasaki 440/ 550 Engine Removal and Installation

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Filed Under (Kawasaki) by admin on 25-10-2010

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1.1 (Above) Remove the two retaining straps, disconnect the battery and remove it from the hull. Disconnect the negative (black) cable first, then the positive (red). Step 2 Exhaust Removal 2.1 (Below) Remove the exhaust hose from the end of the pipe. Remove the water line from the pipe and the head. 2.2 (Below) Remove the water by-pass line from the pipe. 2.3 (Below) Remove the four 10mm nuts / bolts from the exhaust manifold and bracket. Remove the exhaust pipe from the hull. Step 3 Engine Removal 3.1 (Below) Remove the three 10mm bolts securing the PTO shield and remove it. Remove the two 10mm bolts securing the flywheel electrical wire cap. Open the cap and disconnect the harness. NOTE: DO NOT CUT THE WIRES! 3.2 (Below) Disconnect the starter positive wire at the relay box with a 10mm socket

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