HARLEY DAVIDSON IRONSIDE BRAKE PEDAL PAD INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. Remove the previously installed brake pedal cover from the foot brake lever. 2. See Figure 1. Obtain the mounting plate (7) from kit. Position the mounting plate over the brake pedal (A) aligning raised area under plate with oval hole in brake pedal. 3. Obtain the offset washer (2) from kit. Position washer under brake pedal and align the “offset” area of the washer so that it covers oval hole in brake pedal. 4. From top of mounting plate, install 5/16 inch flathead screw (1) through mounting plate (7), brake pedal (A) and offset washer (2). 5. From under brake pedal, install acorn nut (3) to secure mounting plate and offset washer to brake pedal. Tighten acorn nut to 25-29 ft-lbs (33-39 Nm). 6. Obtain brake pedal cover (5) and pedal tread (6) from kit. Align and insert tread (6) into the brake pedal cover. 7. From the side, slide the brake pedal cover assembly over the mounting plate (and pedal) and align the two holes in bottom of cover with two holes in mounting plate. 8. Obtain the two 10-24 screws (4) from kit. From under brake pedal (A), install screws through holes in mounting plate (7) and into pedal cover (5). Tighten screws to 20-22 in- lbs (2.2-2.5 Nm)

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HONDA VTX1800 Complete System Installation Instructions

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Filed Under (Uncategorized) by admin on 12-01-2011

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You should have 2 sets on instructions, use the 2 !! -This kit includes 8 brake lines and 1 clutch hose. -1) First of all, remove gas tank and seat. -2) Remove all fluid from motorcycle, bike has 5 bleeding nipples. -3) Understand the complete stock brake system write yourself a few notes about the connections for the front caliper lines, make sure to label all lines as you remove them in case you need to re-install. -4) Set up one of the “T” block on the frame by the gas tank. -5) Remove rear stock line and stock junction block (under seat area) -6) install Galfer rear hose, (Diagram 1 ) and route it as shown in picture, use stock frame clamps to bring rear hose to the Galfer “T”. (See picture on step 4) 7) Remove stock foot brake line. Route line labeled as Diagram #2 from foot master cylinder to 3-way splitter on frame. Foot master cylinder end banjo:

2008 KTM 125 SX, 144 SX, 250 SX OWNER'S MANUAL

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Filed Under (KTM) by admin on 25-11-2010

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Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open it: Press the release button [2] and turn the tank cap in a counterclockwise direction. To close it: Put the tank cap back on and turn in a clockwise direction until the release button snaps into place. Install tank breather hose [3] without kinks. Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor. Choke knob When pulling the choke knob [4] fully towards the top, a bore is opened in the carburetor. Through this bore the engine can take in additional fuel. This results in a rich fuel-air mixture, that is needed for a cold start. When pressing the choke knob downward in the carburetor, the bore is closed again. ON OFF 4 1 2 3 ENGLISH 7 Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work). 1 N 2,3,4,5, (6) 2 3 1 Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs. Turn the screw [1] clockwise to increase damping, turn it counterclockwise to reduce damping during compression. STANDARD ADJUSTMENT: -turn adjusting screw clockwise as far as it will go -turn it back by as many clicks as are specified for the relevant type of fork Typ WP Suspension 14187D01 . . . . .14 clicks Typ WP Suspension 14187D03 . . . . .14 clicks

Ural Motorcycle Repair Manual

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Filed Under (Ural) by admin on 11-11-2010

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FLUID CAPACITIES TOURIST & -10 Models Sportsman Solo Gasoline tank 19 L / 5 Gal 19L / 5 Gal 18.5 L / 4.9 Gal Reserve 2L / 0.5 gal 2L / 0.5 gal 2L- / 0.5 Gal Engine crankcase 2 L / 2 qt. + 3.6 oz. 2.0L / 2.11 qt 2 L / 2 qt. + 3.6 oz. Gearbox 0.9L / 1 qt 0.9L / 1 qt 0.9L / 1 qt Final drive 110 ml / 3.85 oz. 150 ml / 5.25 oz. 110 ml / 3.85 oz. Telescopic Forks (-10 & solo models) N/A on Tourist N/A on Sportsman 135 ml / 4.56 oz. Shock Absorbers 105 ml / 3.55 105 ml / 3.55 oz 105 ml / 3.55 oz
RUNNING GEAR TOURIST / SPORTSMAN SOLO Frame Tubular welded Rear wheel suspension Swing arm with hydraulic spring shock absorbers Sidecar: same as -40 Solo: Lower spring rate Front fork Leading link Telescopic spring Sidecar Cushioned body (on rubber cushions) and wheel on long-lever suspension with hydraulic spring shock absorber N/A Brakes Shoe-type with mechanical drive on front, rear and sidecar wheels, front wheel has dual cams. Tires 4″ x 19″ Front & Side: 22 psi cold Rear: 36 psi cold 3.5″ x 18″ Solo: Front 25 psi cold Rear: 32 psi cold -10′s: Front & side: 25 psi cold Rear: 36 psi cold CLEARANCES mm in Valves with engine cold 0.05 0.002 Between spark plug electrodes 0.50 – 0.65 0.020 – 0.026 Between brake shoes and drum 0.3 – 0.70 0.012 – 0.028 Backlash between tooth faces of bevel gears in final drive 0.1 – 0.3 0.004 Between rotor and ignition pickup 0.3 – 0.4 .012 – .016 FREE TRAVEL / ADJUSTMENTS mm in Hand brake control lever 5 – 8 0.2 – 0.3 Clutch control lever 5 – 8 0.2 – 0.3 Foot brake drive pedal ¼ of full stroke of pedal, 25 – 30 1.0 – 1.2 Toe-in throughout motorcycle center distance (exception: Sportsman 0 ° toe-in) 10 N/A Angle of motorcycle inclination to vertical plane (camber angle of rear wheel) 1° away from sidecar N/A Headlight installation (with motorcycle laden) horizontal (high beam) TORQUE SPECIFICATIONS Metric (in repair manual) US Equivalent Location on Bike 29 to 33 Nm 22 ft/lb. to 30 ft/lb. cylinder heads 22 to 25 kgf-m 175 ft/lb. to 185 ft/lb. fly wheel tightening screws 3.8 to 4.2 kgf-m 30 ft/lb. to 40 ft/lb. cylinder 2.1 to 3.0 kgf-m top 14 ft/lb. to 22 ft/lb. shock absorber 3.6 to 5.0 kgf-m bottom 28 ft/lb. to 36 ft/lb. shock absorber 3.0 to 3.4 kgf-m 22 ft/lb. to 26 ft/lb. bearing nut 3.0 to 3-4 kgf-m 22 ft/lb. to 26 ft/lb. final drive to swing arm bolts 1.6 to 1.8 kgf-m 12 ft/lb. to 14 ft/lb. oil pump bolt .8 to 1.0 kgf-m 5 ft/lb. to 8 ft/lb. engine sump 1.4 to 1.8 kgf-m 10 ft/lb. to 14 ft/lb. final drive case nuts 7 to 9 kgf-m 50 ft/lb. to 66 ft/lb. nut fastening the pinion bearing 2.2 to 2.8 kgf-m 16 ft/lb. to 20 ft/lb. reverse gear brake lever 1.8 to 2.0 kgf-m 14 ft/lb. to 16 ft/lb. generator gear nut 14.0 to 16.8 kgf-m 100 ft/lb to 120 ft/lb steering stem nut CONVERSIONS To convert from mm to in, divide by 25.4 (there are 25.4 mm per inch). To convert from liters to gallons, divide by 3.785 (there are 3.78 liters per gallon). To convert from liters to quarts, multiply by 1.056 (there are 1.056 quarts per liter). To convert from liters to pints, multiply by 2.112 (there are 2.112 pints per liter). To convert from km to miles, multiply by .62 (there is .62 mile per km). To convert from km/hr to mph, multiply by .62. To convert from Newton-meter (Nm) to inch-pound, multiply by 8.86. To convert from cm 3 (cc) to pints, divide by 473 (there are 473 cc per pint). To convert Celsius to Fahrenheit, F° = C° x 1.8 = 32°. To convert Fahrenheit to Celsius,C ° = (F° – 32° ) divided by 1.8

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Yamaha 1100 V-Star Motorcycles Oil Filter Relocation Kit Installation

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Remove the four bolts that attach the right foot peg and foot brake assembly. Disconnect the electrical connection for the brake light. Leave the hose to the brake fluid reservoir connected. 2. Loosen and remove the muffler assembly from the motorcycle. Loosen the manifold nuts for the lower exhaust pipe (front cylinder) and remove it. 3 3. Remove the five bolts that secure the beauty cover to the motor casing and remove the cover. 4. Remove the oil filter cap and the oil filter. Be aware that the bottom bolt hole has an O- ring. Do not lose or damage this O-ring. Remove the two O-rings from the filter cap with an O-ring pick and inspect them. Replace them if there is any damage or signs of wear. 4 5. Lightly grease the O-rings and install them into their respective locations on the filter plate adapter as shown below. 6. Insert the filter plate adapter carefully into the filter housing to prevent damage to the O- rings. 7. Install the bolts for the filter plate adapter. The bottom bolt location of the filter housing requires a different bolt than all the others. This bolt has a larger head and collar diameter. The top rear bolt hole of the filter adapter will now use one of the short 6x20mm bolts removed from the beauty cover. There are two remaining holes on the motor casing left empty from the removal of the beauty cover. Use two of the bolts from the “Yamaha” cap to fill these locations. Use a thread lock compound such as Loctite ® Blue Threadlocker 243. Evenly tighten the bolts on the filter adapter with quarter turns, until tight. Finish tightening the filter plate adaptor bolts to 7.2 ft-lb each. 58. Install the short end of the spud into the remote filter housing. Do not use thread compound for this step. 9. Install the 45° Elbow to the input port of the remote filter housing as shown below. Position the opening of the fitting to face inward and down slightly to the remote filter housing. Install the fixed end of the oil lines to the remote filter housing. Use Teflon tape or some other type of thread compound on all oil line fittings. 10. Install the compression fittings to the filter plate adapter. 11. Route each oil line between the frame and the brake fluid reservoir and slightly thread the swivel from each oil line into place as shown below. Many different configurations for routing oil lines can be used depending on the height and angle chosen for the remote filter housing when mounted on the frame. Before tightening compression fittings, position the remote filter housing on the frame and adjust the routing of the lines to your preference. After choosing a routing option for the oil lines, tighten the compression fitting

2008 KTM 50 SX JUNIOR 50 SX OWNER'S MANUAL

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Filed Under (KTM) by admin on 22-10-2010

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Choke Dell’Orto carburetor PHVA 14 DS (50SXJunior) Choke lever [1] is mounted to the right side of the carburetor. If you move the choke lever up to the stop, a hole is opened in the carburetor through which the engine can draw in additional fuel. This results in a “rich” fuel-air mixture required for a cold start. Moving the choke lever back closes the hole in the carburetor again. Choke Dell’Orto carburetor PHBG 19 BS (50 SX) Choke control knob [2] is mounted to the left side of the carburetor. If you pull the choke control knob up to the stop and turn it 90º, a hole is opened in the carburetor through which the engine can draw additional fuel. This results in a “rich” fuel-air mixture required for a cold start. Turning back the choke control knob returns the knob to the starting position and closes the hole in the carburetor again. Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake lever The foot brake lever is located in front of the right footrest. The basic position can be adjusted to the seating position (see maintenance work). Side stand (50 SXJunior) Use your foot to swing the side stand forwards to the stop. Make sure it rests securely on solid ground.

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