2003 SUZUKI SV 650 COOLING AND LUBRICATION SYSTEM SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • * Remove the cowling. (SV650S) (C-7–7-6) • * Loosen the radiator cap stop screw 10 . (SV650) • * Remove the radiator cap O2 and connect the radiator tester to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • * Give a pressure of about 120 kPa (1 .2 kgf/cm2,17.0 psi) and see if the system holds this pressure for 10 seconds . • * If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system . In such a case, inspect the entire system and replace the leaking component or part. A WARNING When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. CAUTION Do not allow the pressure to exceed specified pressure, or the radiator can be damaged. COOLING AND LUBRICATION SYSTEM 6-3 6-4COOLING AND LUBRICATION SYSTEM RADIATOR REMOVAL • * Remove the cowling. (SV650S) ( r- 7-7-6) • * Drain engine coolant. (r– 72-20) • * Disconnect the right and left radiator hoses from the radiator. • * Disconnect the siphon hose from the radiator. • * Disconnect the horn lead wires. rI .rr • * Remove the radiator lower mounting bolt. • * Disconnect the cooling fan motor and its thermo-switch lead wire coupler 10. • * Remove the radiator by upper mounting bolt. • * Remove the cooling fan. • * Disconnect the cooling fan thermo-switch. • * Remove the cooling fan thermo-switch. • * Remove the horn. CAUTION When removing the horn, hold the nut by spanner to prevent the horn bracket distortion. COOLING AND LUBRICATION SYSTEM 6-5 INSTALLATION • * Install the cooling fan and horn. 0 Cooling fan/horn mounting bolt: 8 N .m (0.8 kgf-m, 6 .0 Ib-ft) • * Install the cooling fan thermo-switch. ( l”76-9) • * Install the siphon hose to the radiator. • * Install the radiator in the reverse order of removal. • * Route the radiator hoses properly. (=9-22) 9-22) • * Install the drain plug with a new sealing washer and pour engine coolant. (=2-20) • * Bleed air from the cooling circuit. (r– 72-21) • * Install the cowling. (SV650S)

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HONDA VT1100 SHADOW EXHAUST SYSTEM Installation Manual

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Filed Under (Honda) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header nuts from the exhaust port on both front and rear cylinders. The nuts will be reused during installation. 2. Remove the mounting bolts/nuts located below the lower muffler. Carefully remove the entire system and set it aside. Note: The system is heavy so have someone assist you. 3. Remove the muffler mounting bracket from the frame but save the two bolts for reuse. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Remove the bar bracket from the box. Hold the bar bracket in front of you with the four hole bracket positioned to the right hand side and pointing down. Mount one muffler to the bracket on the left hand side of the bar using two of the 5/16″ bolts (supplied) and leave them loose. Be sure the small end of the muffler is pointing to the right hand side. 3. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. 4. Slide a new flange onto each header tube. Note: The two smaller holes in the header flanges are offset from the large hole. If the small holes do not align with studs at the exhaust port, spin the flange on the pipe one half of a turn and try again. Refer to Figure 1. 5. Place the head pipe into the heat shield, unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Wrap the hose clamp around the head tube and give the screw three to four turns, leaving heat shield loose on the head pipe. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike

CSS/ CSR Separator, Recovery Tank, Purge Valve, CYC Timer & Pump INSTALLATION & OPERATION MANUAL

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Filed Under (CSR) by admin on 27-10-2010

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1.*The*CSS/CSR*system*skid*should*be*bolted*to*a*flat*&*level*concrete*foundation*with*suitably*sized*and*quantity*of*anchor*bolts.* The entire system (1″-6″) is on a single skid. For systems 8″ and larger, the separator stands alone on its own 3 legs, while the pump/motor, recovery tank (CSR only), and control panel are on an individual skid. It is therefore incumbent upon the installer to insure*that*the*complete*package*is*bolted*to*a*flat*&*level*concrete*foundation,*to*insure*that*the*”piping*assembly”*is*installed* without any undue stress. 2. Inspect and hydrotest all pipe connections for leaks. *All*flanged*connections*must*have*gaskets,*and*all*threaded*connections*must*have*Teflon*tape*or*anti-seize*coating. 4. Flush all new pipe construction before system operation. In the absence of a pump strainer basket, use a y-strainer with 1/4″ perforated*screen.**The*perforated*screen*must*be*at*least*the*same*size*or*one*pipe*size*larger*than*the*pump*suction.**The* perforated screen will block out larger debris such as welding rods, tools, rugs, gloves, etc. ELECTRICAL 1. Voltage supply to the system must be the same as the voltage indicated on the control panel. 2. Follow the pump operating instructions prior to start-up. 3.*Turn*the*motor*”ON”*and*check*rotation.**Rotation*must*turn*in*the*same*direction*as*the*arrow*located*on*the*pump* casing. If pump is rotating in the opposite direction then reverse L1 and L2 on the incoming power to the panel. Recheck rotation. 4. Starting or in-rush current should not exceed 3 seconds, running current should be equal to or less than nameplate full load amps (FLA). 5. Thermal Overload Setting 5a. Select the Operating Voltage 5b. Multiply Motor Service Factor (SF) by the Full Load Amps (FLA) to get the Service Factor Amps (SFA). 5c. Adjust the Thermal Overload Dial to match SFA Note: Some motors come with SFA written on the nameplate. The majority of our motors come with a 1.15 service factor, but very few come with a 1.25 SF. STARTUP 1. Open system inlet valve 100% and outlet valve 50% (supplied by others). 2.*Suction*line*must*be*flooded. 3. Open separator air vent located near the outlet, (standard on 2″ and larger). 4.*Turn*the*system*”ON.” 5. Purge all the air. 6.*For*HH*&*SP*systems,*open*outlet*valve*until*the*gauge*reads*35psi.*For*LH*systems,*open*outlet*valve*until*a*100%* opening*is*achieved.**If*system*begins*to*vibrate,*then*slightly*close*separator*outlet*until*it*stabilizes

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