Yamaha YZF-R1 and R6 TiForce slip on exhaust system REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 09-01-2012

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1. Remove the fairing lowers. 2. For R1 owners, please remove the existing exhaust system from the EXUP valve rearward (EXUP valve is retained) and set aside. Save the stock exhaust clamp for reuse. For R6 owners, please disconnect the stock S-bend from the rear of the collector and set aside. Save the stock exhaust clamp for reuse (new clamp provided). Save the stock end can mounting bolt for reuse as well. 3. R1 owners only -Inspect the exhaust gasket. Replace if necessary (gasket provided). 4. For R1 owners -Install the S-Bend to the rear of the EXUP valve, make sure the system fits flush. Reuse the stock exhaust clamp to connect the S-bend to the valve. For R6 owners -Install the TiForce S-bend to the rear of the stock head pipes and collector. Make sure the system fits flush and snug. Reuse the stock exhaust clamp or the provided clamp and loosely attach for now. 5. Install the TiForce end can to the S-bend tail pipe. 6. Loosely attach the two rubber bands, stainless steel bands (K), and stay to the end can using the supplied 6mm hardware (H) and the hanger / stay arm (G). See figure 1 for the assembly procedure. 7. R1 owners -Place the bands approximately 180mm from the edge of the end can. See figure 2. R6 owners -Place the bands approximately 195mm from the edge of the end can. See figure 2. 8. R1 owners -Using the stock provided mounting point on the passenger footpeg, use the M10x45mm bolt and hardware to mount the end can loosely, allowing for some adjustment. 9. Carefully align the two stainless bands so that theyare parallel to each other, and spaced properly on the can. Tighten the 6mm hardware (H). Make sure that the rubber pads fully cover the bands (K). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. 10. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire TiForce exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED. 11. Attach the supplied springs to secure the end can to the S-bend pipe using a spring installation tool if available. Make sure the exhaust system is free and clear of the bike. If necessary, adjust for proper clearance. 12. Go back and tighten all fasteners. 13. Check that all fasteners are tightened per specifications, then start the motor and check for exhaust leaks. 14. Reinstall the fairing lowers.

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Bajaj Removing And refitting Automatic Cam Chain Tensioner

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

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1. Remove the 2 Flanged Bolts securing the Tensioner Assembly. 2. Remove Tensioner Assembly from the engine block. 3. Unscrew and remove Lock Bolt. 4. Remove Pushrod, Ball & Retainer, Spring and “O” ring. Clean parts thoroughly and apply grease to the Balls & Retainer. Re-assembly procedure : 1. Place Spring on Pushrod and compress the spring beyond the hole in the Pushrod. 2. Insert a pin or wire into the hole in the Pushrod to hold the Spring in its’ compressed position. 3. Place Balls & Retainer onto Pushrod. 4. Insert Pushrod into the Tensioner body with the small flat on the Pushrod facing, and aligned with, the Locking Bolt hole. 5. Insert the Locking Bolt and tighten it against the small flat on the Pushrod to lock the Pushrod in the compressed position. Remove the pin that’s holding the Spring compressed. 6. Install the Tensioner assembly onto the cylinder block and install and tighten both Flanged Bolts. Be sure that the “O” ring has been installed at the base of the flange. 7.Looosen the Lock Bolt to release the Pushrod, then re-tighten the lock bolt

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