Kawasaki 900 / 1100 Engine Removal and Installation

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Filed Under (Kawasaki) by admin on 01-05-2012

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1.1 (Above) Remove the two retaining straps, disconnect the battery and remove it from the hull. Disconnect the negative (black) cable first, then the positive (red). Step 2 Intake Removal 2.1 (Below) Remove the eight 10mm bolts securing the flame arrestor cover to the base and remove it. 2.2 (Below) Pull out the flame arrestor screens. 2.3 (Below) Remove the six 10mm bolts securing the flame arrestor base and carbs to the manifold and remove the base. 2.4 (Below) Loosen the gas tank cap to relieve pressure. Be sure the fuel switch is turned to the “OFF” position, and be aware of any fuel that may spill from the hoses. Make sure the hull is clear of any gasoline fumes before continuing work, especially with power tools. Remove the pulse lines from the block, and the three oil lines from the carbs. Move the carbs aside in the hull. 2.5 (Below) Remove the 18 10mm nuts from the studs securing the intake manifold to the engine and remove the manifold

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Harley-Davidson Evolution Engines S&S Billet Rocker Cover Assemblies Installation Instructions

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Filed Under (Harley Davidson) by admin on 30-10-2010

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1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas tanks, and all parts required to access original rocker covers. Remove top and center sections of rocker housings. Refer to authorized Harley-Davidson®Service Manual as necessary. Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding. Gasoline is toxic if fumes are inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and perform installation in a well ventilated area away from sparks and open flame. 2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson®Service Manual as necessary, remove rocker assemblies, pushrods and lower rocker cover from front cylinder head. NOTE: Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake, and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris. Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty. 3. Inspect S&S rocker cover assemblies. Remove rough or sharp edges from plain (unchromed) assemblies. Clean all metal parts with solvent. Dry with compressed air and remove any solvent residue with clean, lint free cloth. 3 CAUTION WARNING WARNING CAUTION 4. Install umbrella valves in rocker cover bases. See Picture 1. Valves go in vent ports nearest intake manifold on both front and rear rocker cover bases.

S&S Super E and G Series "Shorty" Carburetors REMOVAL, Installation and Jetting Instructions

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Filed Under (S&S) by admin on 29-10-2010

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Remove Old Carburetor WARNINGS ● Gasoline is extremely flammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic when inhaled. Perform installation in a well ventilated area away from open flames or sparks. Any gasoline leak or spill constitutes a health and fire hazard. ● If motorcycle has been running, wait until engine and exhaust have cooled to avoid getting burned during installation. ● Electrical sparks can ignite explosive gasoline fumes. Failure to disconnect battery while working on motorcycle can also result in inadvertent engagement of starter and personal injury. A. Shut off fuel petcock and disconnect battery. B. Remove air cleaner assembly. Drain fuel from existing carburetor. Remove carburetor, manifold, choke cable and any carburetor mounting hardware NOTE – Removing and tightening hard to reach Allen bolts such as carb-manifold mounting bolts and V2 manifold flange bolts can be greatly simplified by the use of Allen ball-end drivers. These tools are available at most automotive and tool supply houses. See Picture 9. Additionally, Performance Plus of Evansville, Indiana, produces a hex wrench specially modified for accessibility of V 2 manifold bolts. Call 812-963-8854 for further information. As alternative, standard hex wrench can be shortened for convenience. NOTE – Some Buell motorcycles have a breather fitting with 90° elbow on rear head. Due to proximity of frame, elbow must be removed before fitting can be taken off engine. Loosen fitting and rotate to position convenient for cutting elbow. Secure fitting by tightening against cylinder head. Elbow may be inaccessible to hacksaw. In most instances, a die grinder with cutoff wheel will remove elbow with little difficulty. If die grinder is unavailable, grasp elbow firmly with pliers and snap off, then remove fitting. CAUTION – Extreme care must be taken to prevent metal chips from entering engine when elbow is removed. S&S recommends packing breather fitting with gease before removing elbow. Metal chips inside engine will cause extensive damage. Installer bears all responsibility for containment of chips and other debris. Picture 2 Picture 4 Picture 3
5 2. Prepare Air Cleaner Backplate NOTE – Fast idle lever screws, part #11-2384, must not be overtightened. Loctite or other thread locking compound may be used sparingly on threads to prevent screws from vibrating loose. CAUTION – Overtightening fast idle screws may damage backplate. A. All engines except V2s 1. Knuckles & Pans, 1936 to 1965 – Press plugs, part #50-8312, into holes in air cleaner backplate. See Picture 2 . 2. Shovels, 1966 to 1979, and Ironhead (IH) XLs, 1957 to 1979 – Press plug, part #50-8312, into hole in air cleaner backplate. See Picture 3 . 3. Shovels 1980 to 1984 and IH XLs 1980 to 1985 – Screw crankcase breather vent elbow fitting, part #50-8110, into hole in air cleaner backplate and angle downward as shown in Picture 4 . On 1983 and 1984 Shovels press plug, part #50-8312, into other hole on left. 4. Assemble fast idle mechanism as shown in Figure A . B. FL V2s 1984 to 1992 1. Press plug, part #50-8312, into hole on left in air cleaner backplate as shown in Picture 5 . 2. Screw vent hose elbow fitting, part #50-8110, into remaining hole at right. See Picture 5 . 3. Assemble fast idle mechanism as shown in Figure A . C. XL V2s 1986 to 1990 1. Press plug, part #50-8312, into hole on right in air cleaner backplate as shown in Picture 6 . 2. Screw vent hose nipple fitting, part #50-8111, into remaining hole at left. See Picture 6 . Elbow fitting, part #50-8110, supplied in kit may also be used in this location if required. 3. Assemble fast idle mechanism as shown in Figure A . D. FL V2s 1993 and up and XL V2s 1991 and up 1. Press plugs, part #50-8312, into both holes in air cleaner backplate as shown in Picture 7 . 2. Assemble fast idle mechanism as shown in Figure A . E. Buell motorcycles, 1994 and up 1. Assemble fast idle mechanism as shown in Figure A. 3. Throttle Preparation NOTE – Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation. Throttle must snap closed when released. Cable routing must be free of tight bends to minimize friction between cable and housing

Harley-Davidson Style Rocker Cover Assemblies installation Instructions

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Filed Under (Harley Davidson) by admin on 27-10-2010

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Installation 1. Wash motorcycle, taking care to remove sand and other abrasive debris from engine and area of frame around engine. Remove battery, gas tanks, and all parts required to access original rocker covers. Remove top and center sections of OEM rocker housings. Refer to authorized Harley-Davidson Service Manual as necessary. WARNING – Sparks from motorcycle electrical system can ignite gasoline fumes. To prevent sparks as well as prevent electric starter from becoming engaged inadvertently and causing personal injury, disconnect battery and remove from motorcycle before proceeding. WARNING – Gasoline is toxic when fumes inhaled, extremely flammable, and explosive under certain conditions. Do not smoke around gasoline, and perform installation in a well ventilated area away from sparks and open flame. 2. Remove pushrod cover retainer clips for front cylinder and collapse covers. Remove sparkplugs and rotate engine to place pushrods at lowest point on cam with front piston at TDC on compression stroke. Referring to Harley-Davidson Service Manual as necessary, remove rocker assemblies, pushrods and lower rocker cover from front cylinder head.
3 Picture 3 Picture 4 Right Left Rocker shaft reliefs must align with these holes. NOTE – Observe correct location of pushrods. S&S pushrod kits have longest pushrod for front exhaust, next longest for rear exhaust, shortest for rear intake, and remaining one for front intake. Remove all traces of old rocker housing gaskets from cylinder head, taking care to contain debris. CAUTION – Debris such as gasket material can interfere with oil circulation resulting in engine damage not covered under warranty. 3. Inspect S&S rocker cover assemblies. Remove rough or sharp edges from plain (unchromed) assemblies. Clean all metal parts with solvent. Dry with compressed air and remove any solvent residue with clean, lint free cloth. 4. Install umbrella valves in rocker cover bases. See Picture 1. Valves go in vent ports nearest intake manifold on both front and rear rocker cover bases.

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