Yamaha YZ400/426F Camshafts REMOVAL AND INSTALLATION MANUAL

0

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

download
Cleanliness is always a good place to start. Make sure the motorcycle is cleaned thoroughly before you start. It would be advisable to use an engine degreaser on the frame and the engine. This will ensure a clean engine during the assembly process and less of a chance of thread damage and/or dirt contamination in the engine during reassembly. And as always, replace any fiber-based gasket that was moved in any way, i.e.: cam chain tensioner. You will need basic hand tools and a torque wrench, machine towels (rags), some cleaning solvent, and a cam chain tensioner gasket. And the Hot Cams’ Degree Wheel Kit if you so desire. We will start by removing the tank and seat, top engine mount, and the cam cover. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise (CCW) direction. Position the engine on top dead center (TDC) using the mark on the flywheel or better yet a degree wheel using a positive stop. Be sure to notice that the intake valves were the last to move, this will ensure the engine of being on “true” TDC. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the Page 1
beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Note the positioning of the cam lobes (their included angle will be close to 170 degrees), this will help during the installation of your new Hot Cams camshafts Remove the cap bolt on the end of the cam chain tensioner block, be aware of the copper washer. Release the spring tension on the cam chain tensioner by turning the flat blade screw slot inside the adjuster block in a clockwise (CW) direction; it will lock in the retracted position. Remove the two 8mm headed bolts that hold the cam chain tensioner to the cylinder block. Remove and discard the gasket. Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that secure the intake cam cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust camshaft out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft

Incoming search terms:

Yamaha YZ 250F Camshafts REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Yamaha) by admin on 30-12-2011

download
Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that hold the intake camshaft cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust cam out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft. Fit the half moon shaped retainers in the grooves of the Hot Cams camshaft bearings to ensure good fit, set retainers aside for the time. Using assembly lube, lube the shim buckets, bearing surfaces for the camshafts in the cylinder head, and pack some in the camshaft bearings. Set the exhaust cam into the cylinder head casting while at the same time fitting the cam chain over the sprocket. Make sure that you keep all the cam chain slack to the back of the engine. The cam chain pulls the camshaft sprockets in a counter clockwise direction and the slack of the chain must be kept on the cam chain tensioner side of the engine. The exhaust cam has two timing marks on it. When correctly installed one mark will be at the 9 o’clock position and the other mark will be at the 12 o’clock position. When correctly timed the mark at 9 o’clock will be aligned with the valve cover gasket surface. Repeat the above process for the intake camshaft. Again, make sure you keep the chain slack to the cam chain tensioner side of the engine. Check to be sure the crankshaft is still at TDC. The intake cam has two timing marks also. One at 12 o’clock and the other at 3 o’clock. When both cams are installed correctly, the valve cover gasket surface will form a straight line through the exhaust timing mark at 9 o’clock and the intake timing mark at 3 o’clock

Incoming search terms:

1999 – 2003 1.25, 2.0, 2.5 and 2.9 Sherco Ignition Timing Removal And Installation Manual

0

Filed Under (Sherco) by admin on 20-04-2011

download
Remove the gear shift lever bolt by using a 5mm Allen wrench. Insert the wrench through the hole in the skid plate. Holding the gear shifter up in second gear makes it easier to align the wrench into the head of the bolt. Pull the gear shift lever as far as possible towards the chain. (The chain does not have to be removed in order to remove the ignition cover and flywheel) Remove the three ignition cover bolts by using a 4mm Allen wrench. Carefully remove the ignition cover-which requires a little twisting and some outward pressure on the gear shift lever. The shift lever may also have to be pressed down into the first gear position. Inspect the rubber ring gasket for cracks or cuts while the ignition cover is off. Replace if necessary. We recommended applying a ring of high grade silicone sealant to further improve the seal of the rubber ring gasket. Tap a chisel-mark across the flywheel retaining nut and the crankshaft by using a small, sharp chisel. This mark serves as a reference point for retightening the flywheel in its original position during reassembly.

HARLEY DAVIDSON SCREAMIN' EAGLE BILLET CAM SUPPORT PLATE REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 01-03-2011

download
REMOVAL NOTE For removal, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the Maxi® fuse. 2. Remove the cam cover and gasket. 3. Remove and discard the crank and primary cam sprocket flange bolts and washers. 4. Release the oil pump, and remove the cam support plate and cams. Disassemble the cams from the support plate and discard the support plate. 5. Inspect cams, chain, sprockets, oil pump, chain tensioners and guide for wear and replace as needed. Refer to the Service Manual for inspection and replacement proce- dures. -J04503 INSTALLATION NOTES For installation, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. See Figure 1. When installing Screamin’ Eagle camshaft kits, install the O-ring included in this kit over the splined shaft of the rear camshaft as shown. 1. Using the Camshaft Assembly Tool (HD-47956) and assemble the camshafts, chains and tensioners to the billet cam support plate. 2. Install the cam support plate assembly into the crankcase. 3. Using the Crankshaft/Camshaft Locking Tool (HD-47941), install cam sprockets, chain and tensioner. 4. Install cam cover and gasket. 5. Install Maxi fuse.

Incoming search terms:

HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 19-02-2011

download
REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

HARLEY DAVIDSON FLHT OIL PRESSURE AND AIR TEMPERATURE GAUGE KIT INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 08-02-2011

download
INSTALLATION Oil Pressure Sending Unit To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. 1 2 3 4 is04574 1. Oil pressure sending unit 2. Cam position sensor 3. Crank position sensor 4. Main harness to ECM Figure 1. Electrical Bracket: 2000-2001 Fuel Injected Models (Magnetti-Marelli) 1 2 3 is04575 1. Oil pressure sending unit 2. Crankshaft position sensor 3. P&A siren kit Figure 2. Electrical Bracket (ECM Removed) 2002-2003 Fuel Injected Models (Delphi) -J01875 1 of 4 NOTE For 2002 to 2003 models: See Figure 2. Remove the two screws securing the ECM and remove the ECM to access the electrical bracket. 2. For 2004 and later models: Proceed to the Gauges section. For 2000 to 2003 models: See Figure 1, Figure 2 and Figure 3 for the applicable model and locate the sensor harness connector (2-piece mini-Deutsch® connector). 3 2 4 1 is04576 1. Ignition harness 2. Cam position sensor 3. Oil pressure sending unit 4. Crankshaft position sensor Figure 3. Ignition Module – Carbureted Models 3. Locate the oil pressure sending unit at the front right side of the crankcase and pull wire socket from terminal of the oil pressure sending unit. 4. Carefully draw the conduit and the pin side of mini-Deutsch connector forward and then up between the rear brake master cylinder reservoir and the frame downtube to area of the rear brake pedal. 5. See Figure 4. Remove the secondary locking wedge (3) from the pin side of the connector with a needle nose pliers. 1 3 2 is04577 1. Pin 2. Wire seal 3. Locking wedge Figure 4. Deutsch Connector Pin Side (2-pin connector shown) 6. Gently depress terminal latches inside pin housing and back out the pin in chamber #1 through the hole in wire seal. 7. Pull the oil sending unit wire through conduit and remove wire. Note the routing of the wire. 8. See Figure 9. Route the jumper (6) pins through the conduit from the kit in the same direction as the original wire noted in Step 7. Use cable straps to secure to the wire bundle. 9. See Figure 5. Locate pin chambers #1 and #2 on pin side of connector. Insert brown/green jumper pin into chamber #2 and feed until it clicks into place. Verify that pin will not back out of the chamber by giving a slight tug on the wire to confirm that it is locked

Incoming search terms:

2003 CM50 Owners And Service Manual

0

Filed Under (Cobra) by admin on 01-12-2010

download
Fastener ft-lb in-lb Nm Size & Remarks Cylinder head nuts 9.2 110 12 ¼” Crankcase bolts 6.6 80 9 6 x 1.0 Spark plug (SP) (SP) (SP) 14 x 1.25 Stator bolts 2.1 25 2.8 #8 Stator cover bolts 1.7 20 2.3 #8 Clutch cover bolts 5.8 70 7.9 6 mm Clutch 40 480 54 10*** Engine mount bolts 22 265 30 8 mm Swingarm Pivot 21 250 28 14 mm Intake manifold bolts 4.6 55 6.2 6 mm Ignition rotor nut 40 480 54 10 mm** Rear Sprocket Bolts 18 216 24 7 mm Rear shock mounts 40 480 54 10 x 1.5 Rear Axle Bolt 25 300 34 12 mm ** Use green (wicking / bearing retainer) thread locker, with primer, on the flywheel / crankshaft taper but none on the threads. *** Use green (wicking / bearing retainer) thread locker, with primer, on the crankshaft / clutch taper but use red (high strength) thread locker, with primer, on the nut. (SP) To apply the proper torque to the spark plug when inserting, one must first screw the spark plug in until the metal gasket ring causes resistance and then turn another 1/8 to ¼ turn. 7 Optional Components • Carburetor jets • Sprockets o Front o Rear • Seat with lower seat height, 22″ (559 mm), # TCHO0001 • Suspension Springs Weight of Rider (lb) Fork Spring Shock Spring Less than 38 (light) KCMZ0012A SCMU0321 (yellow, 320 lb/in) 38 – 45 (std) KCMZ0012 SCMU1360 (red, 260 lb/in) 46 to 55 (stiff) KCMZ0012B SCMU1380 (white, 380 lb/in) Extra stiff SCMU1400 (silver, 400 lb/in) • Suspension Valving Damping Rate Fork Valving Compression (right) Fork Valving Rebound (left) Shock Valving (kit) Soft (fast) KCMZ0033A KCMZ0032A SCMU0318A Standard KCMZ0033 KCMZ0032 SCMU031

Twin Tec Installation Instructions for TC88A-IH Ignition

0

Filed Under (Tips and Review) by admin on 29-11-2010

download
INSTALLATION ON 2004 MODELS 1. Turn off the ignition switch and disconnect the battery ground cable before proceeding. 2. Refer to Figures 2 and 3 for wiring details. 3. Remove the Gill Module. 4. Cut off the OE 18 terminal AMP connector used with the Gill module. Refer to the terminal list. Crimp new Deutsch terminals on the wires, and install into the 12 terminal Deutsch connector required by the TC88A-IH module. 5. Install the new TC88A-IH module. 6. Reconnect the battery ground cable. INSTALLATION ON 2005 AND LATER MODELS 1. Turn off the ignition switch and disconnect the battery ground cable before proceeding. 2. Refer to Figures 4 and 5 for wiring details. 3. Remove the Gill Module. 4. Cut off the OE 18 terminal AMP connector used with the Gill module. 5. The crankshaft position (CKP), MAP, and engine temperature (ET) sensor share a common ground Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119 TC88A-IH (386) 304-0700 www.daytona-twintec.com 10/2009 Page 2 return. This is not compatible with the TC88A-IH and some rewiring will be required. The temperature sensor is not used, but does not require removal. 6. Trace the BK/GN ground return wires from terminal B of the ET sensor and terminal A of the MAP sensor to where they join the BK/GY ground return wire from the CKP sensor. Cut the ET and MAP sensor ground return wires off at this point. You can tape up the ground return wire from the ET sensor – this wire will not be used. 7. Extend the ground return wire from terminal A of the MAP sensor up to the ignition module, crimp on a Deutsch terminal and install in position 4 on the Deutsch connector. 8. Refer to the terminal list. Crimp new Deutsch terminals on the remaining wires, and install into the 12 terminal Deutsch connector required by the TC88A-IH module. 9. Use a DVM to verify isolation (no continuity) between terminals 4 and 9 on the Deutsch connector. 10. Verify continuity between terminal A at the MAP sensor and terminal 4 on the Deutsch connector. 11. Verify continuity between terminal 2 at the CKP sensor and terminal 9 on the on the Deutsch connector. 12. Install the new TC88A-IH module. 13. Reconnect the battery ground cable. Terminal List for American IronHorse Ignition Conversion TC88A Deutsch Connector OE AMP Connector Signal Wire Color Code 1 2 +12V Power W/R

Incoming search terms:

ENGINE ASSEMBLY MANUAL 450i, ENGINE REPAIR STAND – 450i

0

Filed Under (Tips and Review) by admin on 28-11-2010

download
INSTALLING THE CLUTCH : æ Install the bronze bushing, the clutch basket, the spacer washer and the clutch hub. Install the conical washer, apply thread locking material to the threads and install the nut. Use tool #R447 to hold the assembly and tighten the nut to 150 Nm . æ Soak the friction discs in engine oil prior to installation. Alternatively install a friction disc followed by a metal disc until they are all installed, the last disc to be installed will be a friction disc. Install the clutch actuating rod, the clutch lifter piece, the needle thrust bearing and the thrust washer. Install the pressure plate, the six springs, the six washers and the six screws. Tighten the screws to 11 Nm . Tool #R447
Page 8 sur 26 æ Install the two locating dowels, install a new gasket, and note that Sherco uses a special gasket with an integrated silicone bead. Do not use gasket sealer on the mating surfaces as the sealer could plug the oil passages. Install the clutch cover and tighten the twelve screws to 11 Nm . o INSTALLING THE CAM CHAIN DRIVE GEAR ON THE LEFT HAND SIDE OF THE CRANKSHAFT: æ Using a thermal heat gun, heat the cam chain drive gear to ≈ 100°C , install the gear on the LH side of the crankshaft after installing the key, install the circlip. Use care to avoid damage to the end of the crankshaft. Page 9 sur 26 o INSTALLATION OF THE CYLINDER : æ Use a sharp chisel to remove any of the metal gasket that protrudes above the cylinder mounting surface.

YAMAHA TZR50 X-POWER SERVICE MANUAL

0

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

download
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

Incoming search terms: