Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

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Wildfire Scooter WF 250CB Owner's Manual

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Filed Under (Uncategorized) by admin on 26-11-2010

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• Check before Riding • Make sure the brakes work properly and adjust if necessary. • Check all nuts and bolts for tightness. • Make sure that the gas tank is full. • Check tire pressure. • Check all gauges. • Check and make sure that all of the lights are working properly, headlight, taillight, turn signal etc. • Check the engine oil. STARTING, RIDING, STOPPING AND PARKING Before starting, put the kickstand up. • Practice in an empty area away from people and vehicles. • Always remember to obey your local and state laws and regulations. • Be sure your bike has fuel and oil. • Be sure the bike is in neutral. • Apply the rear brake. • Turn the key on. • Press the electric start button. • After engine warms up, push the choke 1/4 in then 1/2 in and in 1 minute completely off. • If the engine is warm it should start without choking. • For a cold engine, let the engine idle for 1-3 minutes before driving, then begin to turn the choke off. • Never exceed 4 seconds when engaging the starter. • Release the button immediately after the engine starts. • Do not apply the key while the engine is running, it can cause damage to the starter. • Sit on the bike keeping one foot on the ground for stability, release the clutch by pulling in the lever, shift bike into first gear by using the foot shifter. • Apply the throttle gradually as you release the clutch lever slowly until the clutch engages. • To shift into the next gear release the throttle pull the clutch lever in and shift into the next gear, after you shift, gradually apply the throttle and slowly release the clutch. • Use this sequence when shifting to all gears. • Only put your feet on the ground when coming to a stop. • When coming to a stop decrease your speed by releasing the throttle and applying the brakes and the clutch, if the tire skids release the brake and reapply. • Parking: Put your kick stand down. Park away from pedestrians. NOTE: The muffler and exhaust pipe are h

BMW Motorcycles New Boxer (R 259) Gearbox Repairs Manual

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Filed Under (BMW) by admin on 16-11-2010

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cause: Gears are not correctly and fully engaged. The edges of the shift dogs and shift gears are rounded. Solution: Beginning with the 1997 model year, a modified set of gears has been introduced in production. Service Remedy: Installation of tolerance-optimized gears and shift forks is now possible. Parts: The installation of the optimized parts is to be done in accordance with the listing on the next page, based on the individual gearbox type and nature of complaint . We also recommend installation of the new “clean bearings” where applicable as noted. Clean Bearings: BMW has introduced deep-groove ball bearings which are sealed, therefore the bearings operate in their own lubricant rather than the gearbox lubricant. Clean bearings provide longer life expectancy and on some models provide the opportunity to extend gearbox lubrication intervals without reducing bearing life expectancy. Note: On a gearbox before the introduction of clean bearings, the layshaft roller bearing cannot be replaced with a ball bearing, since the ball bearing’s outer diameter is larger and the layshaft is longer. On the input shaft, we recommend always using the new ball bearing instead of the tapered roller bearing. Caution: New Shimming Procedure!

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New Styles And Features for Ridley's Automatic Motorcycles in 2008

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Filed Under (Ridley) by admin on 15-11-2010

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“Our focus is on delivering a motorcycle that fits the needs of the new market. It seems that so many companies are trying to revamp their line by adding a sixth gear. We’re taking the gears completely out of the equation and letting riders get back to actually riding”, said Clay Ridley about the effort his company has directed towards their new product line. Several new unique features are creating interest among Ridley Riders on the company’s riders forum, one of which is a parking brake. “We take comments from the owners of our motorcycles very, very seriously. Ridley Riders have asked for a parking brake for added security”, commented Jay Ridley, Vice President for the company. Added to the long list of improvements for the new year model is the new “2 Year Plus” factory warranty which offers twenty-five months of factory backed warranty. According to Ridley, this new warranty exceeds coverage provided by most other domestic manufacturer’s. One more reason Ridley believes 2008 will be the company’s best selling year model. With the holiday season fast approaching, Ridley Motorcycle felt the introduction of the new models would have more impact if held back until the middle of November. For Ridley, the holiday season means big business. Several of Ridley’s dealers have reported higher sales in December than in May. The company attributed this to their market which is nearly divided in half among men and women.

2004 King 50 And CM 50 clutch cover alignment and securing technique

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Filed Under (Cobra) by admin on 10-11-2010

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Some 2004 King & CM models have a thicker (brown) clutch cover gasket that requires retightening of the cover bolts several times before they remain tight. Follow this procedure to properly align the kick start gears and clutch cover. You should do this if the kick lever is not engaging properly (high frequency of not engaging the engine when you attempt to kick start the bike) . NOTE : Proper clutch cover torque value is 70 in-lb (7.9 Nm). NOTE : Lay the bike on the left hand side, or drain the clutch lubricant from the bottom end before performing this procedure. Loosen the six clutch cover screws (5mm allen) enough that the clutch cover can be moved by hand. Engage the kick lever with your hand and stroke it half way down and stop holding pressure on the kick lever (see picture)

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