Dellorto Motorcycle Carburetor Tuning Guide and INSTALLATION

0

Filed Under (Tips and Review) by admin on 04-02-2012

download
Installation angles The tapered-needle-type Carburetor s with concentric, central float chambers have a horizontal main barrel and can be mounted up to a maximum inclination of 40 degrees from the horizontal (figure 3) . For
applications on motocross and trials engines, etc, this inclination should be 30 degrees or less. fig. 3 2.4 Engine connections The Carburetor is usually connected to the engine with one of the following : Male clamp fixing : the male clamp connection used for the flexible fixing of the Carburetor to the engine is usually recommended on motorcycles for motocross, trials, etc or fitted to engines which run to high rpm or those which produce strong vibrations. fig. 4 Female clamp : the female clip connection and the flange connection, with a rigid fitting to the engine, are usable on road motorcycles or fitted to engines which do not generate very strong vibrations

1996-2004 HONDA XR250R Removing stock carburetor and cables

0

Filed Under (Honda) by admin on 26-11-2011

download
Install the throttle cables into the supplied throttle housing and place onto clean handlebar end. 2. Remove the rubber carburetor alignment tabs from the manifold using a razor blade or sharp cutters. This should be done with the rag left in the manifold. Be very careful not to damage the manifold or your hands while doing this!! 3. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering
adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap. 4. Install provided fuel line onto fuel inlet banjo and secure with pinch clamp. 5. Place Edelbrock carburetor into manifold. Do not tighten clamp yet. 6. Remove the cable bracket end from cable bracket using #2 phillips. 7. Install pull cable (see Figure 2) end into
the 4:00 position of the cable wheel and the return cable into the 1:00 position. Secure cables into cable bracket by replacing end piece and phillips screw. See figure 3.

Incoming search terms:

HONDA AERO 750 CRUZER EXHAUST SYSTEM REMOVAL And INSTALLATION

0

Filed Under (Honda) by admin on 18-11-2011

download
Install mounting bracket (stamped 363-P) in the original muffler mounting position, using two 10mm bolts and
one 10mm nut. (supplied)(Refer to figure 2). 2. Mark outside surface of front and rear heat shields with location of mounting clips that are welded to the inside.(Refer to figure 3).Place each heat shield on a non-abrasive surface such as a blanket or carpet. Position each head pipe/muffler over its respective heat shield. (Refer to figure 4).
3. Feed tail end of each hose clamp through each mounting clip welded to back side of front and rear heat shields. Take note of clamp hex screw head direction. (Clamp head direction is critical for adjustment when system is installed on bike.) Wrap each clamp around back side of head pipe threading tail end into clamp head. (Refer to figure 3 & 4).
4. Install front head pipe/muffler using stock flange nuts. Slide dog bone shaped nutplate (supplied) inside
bracket welded to backside of muffler. Attach muffler to mounting bracket 363-P using (supplied) 5/16” flange
bolts engaging dog bone nutplate. Leave head pipe/muffler assembly loose at this time (Refer to figure 4). Repeat this step with the rear head pipe.5. Align mufflers so they are parallel when viewing from right side of the motorcycle. Tighten 5/16” flange bolts securing upper and lower muffler positions.. Tighten cylinder exhaust port flange nuts securing head pipes to cylinder heads. 7. Adjust heat shields so they meet front of muffler taper. (Refer to figure 6). Tighten all hose clamps securing heat shield locations. NOTE: Heat shields should cover muffler/head pipe weld joint.

HARLEY DAVIDSON LOW REAR SHOCK KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 13-03-2011

download
See Figure 3 and Table 1. INSTALLATION Shock Absorbers Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b) NOTES This procedure requires that both shocks be removed prior to installing the new shock absorbers. You need to place the motorcycle on a center stand with the rear wheel raised off of the ground. The jiffy stand should be able to move through its full range of travel. The exhaust system may interfere when removing and installing the lower right shock mounting hardware. If necessary, see Service Manual and remove the rear exhaust pipe. 2 4 5 7 1 6 3 is05206 1. Lower screw 2. Upper screw 3. Lower washer 4. Upper washer 5. Cover 6. Nut 7. Shock absorber Figure 1. Remove / Install Shock Absorber 1. Block the motorcycle under the frame so that the motorcycle is securely resting upright, the jiffystand may be moved through its full range of travel, and rear wheel is just off the ground. 2. Remove the lower shock mounting screw (1), washer (3) and nut (6) from the shock absorber (7). Save the hardware for reuse. 3. Remove the upper bolt (2), washer (4) and cover (5) and remove the shock absorber. Save the hardware for reuse. 4. Repeat Steps 1 and 2 for opposite side and save the hardware. 5. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the lower mounting bolt, then install bolt, lower washer and nut to the shock. 6. Apply 2-3 drops of LOCTITE 243® (blue) on the threads of the upper mounting bolt, then install the shock cover, upper mounting bolt and washer to the shock. Verify the cutout in shock cover locates properly

Incoming search terms:

HARLEY DAVIDSON SHORT RAIL BACKREST PADS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 08-03-2011

download
These Backrest Pad kits are designed for installation on 1984 and later models equipped with a sissy bar sideplate kit in combination with a Short Rail upright kit, Part No. 52737-94 or 52728-95. The 52513-94 Backrest Pad kit is only for models equipped with Badlander seats and one of the following Mini Rail upright, kits: 52738-94A, 52744-94 or 51512-02. The 52568-01 Backrest Pad Kit is designed for installation on 2001 FXDWG2 model motorcycles and should be used with mini rail upright part number 52744-94 as well as the right and left stock FXDWG Sideplates or an appropriate detachable sideplate kit. The 52901-01 Backrest Pad Kit is designed for installation on 2002 FXDWG3 model motorcycles and should be used with mini rail upright part number 51512-02 as well as the right and left stock FXDWG Sideplates or an appropriate detachable sideplate kit. Kit Contents See Figure 3 and Table 2. There are no Service Parts available with this kit. INSTALLATION NOTE Figures 1 and 2 show pad being mounted on short upright, Part No. 52737-94, before short upright is mounted on side- plates. The pad may be installed before or after short upright is mounted. 1. See Figure 1. Remove protective film from mounting bracket (1) and attach the mounting bracket with the 1/4- 28 x 3/8 in. screw (2) onto short upright, Part No. 52737- 94 or 52728-95; or onto Mini Rail upright, Part No. 52738- 94 or 52744-94. Check that mounting bracket is parallel with upright and tighten screw to 48-60 in-lbs (5.4-6.8 Nm). 2. See Figure 2. Position backrest pad (1) on the upright. Place mounting plate (2) in position and secure with two chrome screws (3) as shown. Tighten screws to 48-60 in- lbs (5.4-6.8 Nm)

HARLEY DAVIDSON SOFTAIL OIL COOLER KIT WITH CHROME OIL COOLER COVER INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 07-03-2011

download
INSTALLATION 1. See Figure 1. Install the oil cooler (2) to the frame with three clamps (4), three socket head screws (1), three nuts (5) and six washers (3) from the kit. Orient the clamps flat side forward and on the forward side of the oil cooler. Tighten the three oil cooler mounting screws to 96-120 in- lbs (10.9-13.5 Nm) . 2. See Figure 2. Remove the spin-on oil filter and oil filter adapter (1) from oil filter mount location. Clean the oil filter mounting area thoroughly. Discard oil filter and adapter. 1 3 4 4 4 3 5 2 is03387 1. Socket head screw (3) 2. Oil cooler 3. Washer (6) 4. Clamp (3) 5. Locknut (3) Figure 1. Oil Cooler Clamp Installation NOTE The oil cooler adapter assembly has two flanges protruding out of the back side. The flanges must be installed toward the oil filter mounting location and through the oil adapter gasket. 3. See Figure 3. From the kit, install the oil cooler adapter gasket (3) onto the oil cooler adapter assembly (1). The oil cooler adapter assembly flanges should be aligned so it is installed into the oil adapter cooler gasket cutout as shown. NOTE Due to the locating flanges, the oil cooler adapter assembly and gasket will only install properly in one position on the oil filter mounting surface. 4. See Figure 3. Install the oil cooler adapter assembly and gasket onto the oil filter mounting surface of the engine with the mounting fitting (2). Ensure adapter locates properly in the mounting surface. Ensure the raised lip of the mounting fitting faces the adapter assembly. Tighten mounting fitting to 12-16 ft-lbs (16.3-21.7 Nm) .NOTE Slide hose clamps from the kit onto the hoses prior to installa- tion. 1 2 is00754 1. Oil filter adapter 2. Oil filter seal surface Figure 2. Stock Filter Mounting Adapter 1 2 3 is00761 1. Oil cooler adapter assembly 2. Mounting fitting 3. Oil cooler adapter gasket Figure 3. Install Oil Adapter 5. See Figure 5. Obtain the left side cooler hose (4) and right side cooler hose (5) from kit. Follow the markings on hoses to connect onto the oil cooler and oil cooler adapter, as shown. 6. Fasten hoses to oil cooler adapter and oil cooler with worm drive clamps (6). Tighten clamps to 8.0 in-lbs (0.9 Nm) . 7. Lubricate a new oil filter’s seal with new engine oil. Thread filter on until seal touches mounting surface, then turn an additional 1/2 to 3/4 turn. NOTE Position the clamps to avoid interference with oil filter installation. Check that hose routing is clear of the oil filter and sharp edges. The hoses must be free of bends or kinks that could obstruct oil flow. 8. Ensure all cables and harnesses are clear of the oil cooler adapter, in order to prevent wear. 9. Thoroughly clean the oil cooler of all dirt, grease and wax with isopropyl alcohol. Use the alcohol to clean the chrome oil cooler cover as needed. Allow to dry. is00745 Figure 4. Apply Sealant Inside Chrome Cover 10. See Figure 4. Apply sealant to the inside of the chrome cover as shown, at the upper and lower corners. NOTES Be careful to avoid getting sealant on the oil cooler cooling fins. Do not operate the motorcycle for 24 hours to allow the sealant to fully cure. 11. Slip the cover over the oil cooler. Remove any excess sealant from the front and back of the oil cooler. Hold the cover firmly in place for one minute. System Flow Test 2005 & Later Models or Models with Later Style Dipsticks Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a) 2004 & Earlier Models

Incoming search terms:

HARLEY DAVIDSON VRSC SADDLEBAG SUPPORT KIT (WIDE TIRE) REMOVAL AND INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 05-03-2011

download
REMOVAL Remove Pillion and Rear Fender NOTE If possible, lift the rear of the motorcycle up so the rear wheel drops to the bottom of shock travel. This will help provide clearance between the rear tire and fender when installing the mounting brackets. 1. Open the rider seat. 2. See Figure 1. Remove rider seat post (1), nut (2), and washer (3) from passenger pillion. Slide grabstrap (4) forward off pillion. Save mounting hardware for kit installation. 3. Push passenger pillion forward to release slot on bottom of pillion from post on fender tongue. 4. See Figure 2. Lift pillion up to remove lanyard (1) from hole in center of passenger pillion (2). Then lift pillion away from motorcycle. 5. Disconnect turn signal and tail light electrical connections from back of rear electrical caddy. Note position for later installation. 6. See Figure 3. Unsnap rear electrical caddy (1) from rear inner fender. 7. Remove and save two fender support bolts (2), washers (3), and grabstrap (4) from rear fender. 1 2 3 4 is03548 1. Rider seat post 2. Nut 3. Washer 4. Grabstrap Figure 1. Passenger Pillion and Mounting 2 1 3 i03571 1. Seat lanyard 2. Hole in pillion 3. Passenger pillion Figure 2. Seat Lanyard and Passenger Pillion 8. Remove four remaining fender support bolts (2) and washers (3) near center of rear fender. 9. Remove rear fender from vehicle. 3 2 4 2 3 2 3 1 is03544 1. Rear electrical caddy 2. Fender support bolt (6) 3. Washer (6) 4. Grabstrap Figure 3. Grabstrap, Rear Electrical Caddy, and Fender INSTALLATION Install Attach/Release Weldment, Rear Fender, and Grabstrap NOTE Apply Loctite 243 (blue) to last four threads of leave-on bracket screws. 1. See Figure 4. Install leave-on bracket (1) to outside surface of inner fender using two button head screws (2) and nuts (3). Tighten screws to 48 Nm (35 ft-lbs). Repeat for opposite side. 2. See Figure 5. Install release/attach weldment (1) to leave- on brackets (2) using two washers (3) and socket head cap screws (4). Tighten screws to 25 Nm (18 ft-lbs). Repeat for opposite side.

HARLEY DAVIDSON XL SOLO CUSTOM SEAT KITS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 02-03-2011

download
INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. 1 2 4 1 3 is03341 1. Stock retention nut and washer 2. Plastic cap 3. Rearward fender hole 4. Center fender hole Figure 1. Retention Nut and Plastic Cap Location 2. For models that had a solo seat: Proceed to Step 3. For models that had a 2-up seat: The retention nut and washer must be moved from the rearward mounting hole to the center fender hole where the rear seat bracket will be attached. Use a cable strap to aid in this step as fol- lows: a. See Figure 1. Remove retention nut from rearward fender hole (3) and plastic cap (2) from center fender hole (4). b. Install plastic cap into the rearward fender hole. c. See Figure 2. Place the retention nut over the cable strap so the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender and through the center fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib of the retention nut seated into the notch in the fender hole, slide the retention washer into place from the rear. This will lock the retention nut in place. 3. Position the solo seat on the motorcycle frame with the mounting bracket at the rear. Bring the seat forward and engage the tab on the seat into the slot at the base of the fuel tank. 4. See Figure 3. Secure the seat to the fender using the knurled knob (3) and neoprene washer (4) from the kit. Install the washer on the knob and tighten the knob securely to the fender seat nut

HARLEY DAVIDSON CHROME INNER PRIMARY COVERS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 23-02-2011

download
INSTALLATION 1 2 3 is06139 Figure 1. Remove Three Original Equipment Screws As Shown 1. See Figure 1. Remove the stock fasteners as shown in Figure 1. Save screw (3) for reuse. 2. Install the stock fastener in the rear inner cover. Place a locating washer over the fastener with the rounded side facing toward the hole in the primary chain case. 3. Slide the rear inner cover into place and loosely secure it with the stock fastener. 1 is06416 1. Acorn nut Figure 2. Fasten Front And Rear Inner Primary Covers Together 4. See Figure 2. Position the front inner cover over the rear inner cover and make sure that the hole in the front cover fits over the threaded stud in the rear cover. Secure the covers together with the acorn nut installed finger tight. 5. See Figure 3 and Table 1. Place the new 4.25 inch (5) and 1-1/2 inch (4) screws in the front inner primary cover. Place locating washers (6) over the fasteners with the rounded side of the washer facing toward the hole in the primary chain case. 6. Tighten all three screws to 108-120 in-lbs (12.2-13.6 Nm) . 7. Tighten the acorn nut. 8. Push the Allen hole plugs (7) into the four exposed screw heads

HARLEY DAVIDSON SCREAMIN' EAGLE VENTILATOR PERFORMANCE AIR CLEANER INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 21-02-2011

download
REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the main fuse. Refer to the service manual. 2. Remove the existing air cleaner backplate. Refer to the service manual. Save the original equipment (OE) button head screw that secures the air cleaner cover. Discard the remaining parts. 3. Remove the fuel tank. Refer to the service manual. 4. See Figure 1. Remove and discard the induction module support bracket. is05912 Figure 1. Remove Induction Module Support Bracket INSTALLATION Air Cleaner Installation Use only supplied air cleaner cover. Use of another air cleaner cover could cause element failure and detachment of the air cleaner cover, which could distract the rider and result in death or serious injury. (00596b) NOTE When servicing the air cleaner, apply Loctite 243 – Blue to the threads of all fasteners. 1. See Figure 3. Install two O-rings (1) from the kit in the grooves around the breather bolt holes on the induction module side of the backplate assembly (2). Install the remaining two O-rings in the grooves in the underside of the heads of the breather bolts (5). 2. Remove the liner from the adhesive backing of the gasket (3). Carefully position the adhesive side of the gasket to the backplate, aligning to the equally spaced screw holes, and press the gasket firmly into place. 3. Insert new breather bolts (5) through the backplate. 4. Apply Loctite 243 – Blue to the breather bolt threads and the mating tapped holes in the cylinder head. 5. Thread the bolts into the cylinder head, but do not tighten. 6. Thread the air cleaner mounting studs (4) all the way through the backplate (2) until the screw threads are captured in the induction module. Do not tighten completely at this time. 7. Alternately tighten the two breather bolts to 120-144 in- lbs (13.6-16.3 Nm) . 8. Tighten the three air cleaner studs to 55-60 in-lbs (6.2- 6.8 Nm) . 9. Install the fuel tank. Air Cleaner Element and Cover Installation