HARLEY DAVIDSON EFI INTAKE MANIFOLD COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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INSTALLATION 1. See Figure 1. Remove screw (A) that holds the air cleaner cover (B) and seal (C). 2. Remove three T27 TORX® screws (D) to release the cover bracket (E) from the filter element (F). 3. Remove the filter element, pulling the two breather tubes (G) from hole on the inboard side of element. 4. Remove the two breather tubes (G) from the fittings on the two cylinder head breather bolts (I). 5. Remove the two breather bolts (I) and O-ring seals (K) from the air cleaner backplate (J) with a 7/16 inch deepwell socket. 6. Remove the backplate and gasket (H) from the injection module. 7. Aligning the flat edge of a new cover gasket (2) with the backplate molded tab, install a gasket (2), chrome cover (1) and second gasket, in order, on the air cleaner back- plate. 8. Install the breather bolts through the air cleaner backplate. Re-install O-ring seals onto each breather bolt. Install a washer (3) from the kit on each breather bolt. Apply Loctite 243 to the breather bolts and align holes in the backplate with the holes in the cylinder heads and install the breather bolts. Use a 7/16 inch deepwell socket and alternately tighten the breather bolts to 120-144 in-lbs (13.6-16.3 Nm) . 9. Slide gasket over the sleeve on the inboard side of filter element. 10. Install breather tubes about 1/4 inch (6.4 mm) into holes on inboard side of filter element. 11. Install breather tubes onto fittings of two cylinder head breather bolts. NOTE Air cleaner mounting without installation of the breather tubes allows crankcase vapors to be vented into atmosphere in violation of legal emissions standards. 12. Place the filter element onto backplate, with the flat side down, so that the hole on the inboard side of element fits over the molded boss in the backplate. 13. Align holes in cover bracket with those in filter element and start three screws. Stamp on cover bracket points downwards. Use a T27 TORX drive head, alternately tighten screws to 20-40 in-lbs (2.3-4.5 Nm) . 14. Make sure that the rubber seal is proper seated around perimeter of air cleaner cover and place cover on back- plate. 15. Fit the air cleaner cover onto backplate. Apply Loctite 243 to the threads of air cleaner cover screw. Install screw through cover and tighten to 36-60 in-lbs (4.1-6.8 Nm)

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HARLEY DAVIDSON SCREAMIN' EAGLE BILLET CAM SUPPORT PLATE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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REMOVAL NOTE For removal, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the Maxi® fuse. 2. Remove the cam cover and gasket. 3. Remove and discard the crank and primary cam sprocket flange bolts and washers. 4. Release the oil pump, and remove the cam support plate and cams. Disassemble the cams from the support plate and discard the support plate. 5. Inspect cams, chain, sprockets, oil pump, chain tensioners and guide for wear and replace as needed. Refer to the Service Manual for inspection and replacement proce- dures. -J04503 INSTALLATION NOTES For installation, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. See Figure 1. When installing Screamin’ Eagle camshaft kits, install the O-ring included in this kit over the splined shaft of the rear camshaft as shown. 1. Using the Camshaft Assembly Tool (HD-47956) and assemble the camshafts, chains and tensioners to the billet cam support plate. 2. Install the cam support plate assembly into the crankcase. 3. Using the Crankshaft/Camshaft Locking Tool (HD-47941), install cam sprockets, chain and tensioner. 4. Install cam cover and gasket. 5. Install Maxi fuse.

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

HARLEY DAVIDSON AIR CLEANER COVER MEDALLION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION NOTE All kits except number 29795-02, 29833-06, 29888-06, 29898- 06, and 29929-07 will need to install the medallion onto the insert. Kits 29795-02, 29833-06 and 29888-06 skip to Step 4. 1. See Figure 1. Clean mounting area on insert (2) thoroughly with rubbing alcohol and allow to dry. 2. Remove backing from medallion (3). 3. Carefully place medallion (3) in center of mounting area pressing firmly to activate adhesive. NOTE The medallion will be secure upon contact. Adhesive cures completely in 24 hours. 4. See Figure 1. Carefully press the insert (2)(with medallion installed) and o-ring (1) into the air cleaner cover as shown. SERVICE PARTS 2 A 3 1 is 01866 Figure 1. Service Parts: Air Cleaner Cover Medallion Kit Table 2. Service Parts: Air Cleaner Cover Medallion Kit Part Number Description (Quantity) Item 27226-00 O-ring 1 Not Sold Separately Insert 2 Not Sold Separately Medallion (all kits except 29795- 02, 29833-06, 29888-06, 29898- 06, 29929-07) 3 Items mentioned in text, but not included in kit. Part of Air Cleaner Cover Kit 29745-00A, sold sepa- ratel

KTM 4357/ 4860 MX Multi Adjuster WP Suspension manual Disassembly And Assembling

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Filed Under (KTM) by admin on 13-02-2011

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Disassembly forkleg 12_062 12_079Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 5 Frontfork 4357/4860 MXMA 02/2002 Clamp the forkleg (axle-clamp) in the vice and let the outer-tube down. Pull the spring downwards… …and place open-end spanner (size 22) on the hydraulic stop. Unscrew the screw-cap. 12_067 12_068 12_069 12_072Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 6 Frontfork 4357/4860 MXMA 02/2002 Remove the screw-cap from the piston- rod. 12_070 Remove the preload spacers. 12_074 Pull the spring downwards and remove the spanner. 12_075Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 7 Frontfork 4357/4860 MXMA 02/2002 Remove the spring. 12_076 Remove the adjustment tube with the O-ring. 12_089
Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 8 Frontfork 4357/4860 MXMA 02/2002 Clamp the axle-clamp in the vice so that the forkleg is at an angle of ±45 degrees. 12_095 Unscrew the compression holder out of the axle-clamp. (size 19) (when the cartridge is rotating with the holder, bend the piston- rod a little bit to the side) 12_096 Drain the oil out the forkleg. 12_094 Product Exploded View Disassembly & Assembling Workshop manual 4357 / 4860 MXMA 9 Frontfork 4357/4860 MXMA 02/2002 Remove holder compression. Caution: oil iscoming out the cartridge. Disassemble the cartridge out the forkleg. 12_097 12_098 12_099 Disassemble the dust-wiper

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HARLEY DAVIDSON LCD OIL TEMPERATURE/ LEVEL DIPSTICK INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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LCD DIPSTICK INSTALLATION 1. Remove the original equipment (OE) dipstick from the filler neck. 2. Non-threaded Dipsticks: Lightly oil the O-ring on the new LCD dipstick. Orient the dipstick so that the display window is horizontal and readable from left to right, with the Bar and Shield logo to the left (towards the rear of the motorcycle). Push the dipstick straight into the filler neck until it seats. 3. For threaded dipsticks: Lightly oil O-ring and screw into the transmission like OE dipstick. If the orientation of the display is unsatisfactory when fully seated, refer to Adjusting the Display Angle later in these instructions. NOTE To be sure of correct readings, the dipstick MUST seat firmly against the flange. LCD DIPSTICK USE AND CARE Removing the Dipstick The dipstick assembly must be removed from the filler neck to add oil or to service the internal battery. Displaying the Oil Temperature and Level See Figure 1. Press and release the rubber button on the front face to display the temperature of the oil in the oil tank in degrees Fahrenheit (°F), and the oil level. The display will automatically shut off after approximately ten seconds. Do not overfill oil tank. Doing so can result in oil carryover to the air cleaner leading to equipment damage and/or equipment malfunction. (00190a) NOTES Oil level cannot be accurately measured: • on a cold engine • with the motorcycle upright • with the engine running NOTE Oil level on 2000 through 2004 Softail models with the original dipstick is checked with the motorcycle standing upright (not leaning on the jiffy stand). THIS IS NOT THE CASE with the LCD oil temperature/level dipstick. For all 2000 and later Softail models, oil level inspection must be done with the motorcycle LEANING ON the jiffy stand, on level ground. For pre-ride oil level inspection: With the motorcycle on level ground, RESTING ON the jiffy stand : •The oil level should be as indicated in Figure 1, display 4 through 8 (bars showing oil level, and “COLD OIL” message followed by flashing oil temperature) when the engine is cold. DO NOT ADD OIL to bring the level to the FULL mark on the dipstick of a COLD engine. •If the oil level indicates as in display 9 (animated level bars, followed by an “888 NO SENSOR” code), the wires inside the dipstick may be disconnected or damaged. Refer to Replacing the Battery later in these instructions to separate the dipstick upper and lower assemblies. If the small plug next to the battery has become dislodged from the receptacle, plug it in. If a visible wire is damaged, a repair can be attempted. If no damage is visible, the dipstick is damaged internally and should be replaced. For oil level inspection at operating temperature: Ride the motorcycle until the engine is at normal operating temperature. Idle for 1-2 minutes with the motorcycle on level ground, RESTING ON the jiffy stand (except Softails) , turn the engine OFF.

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HARLEY DAVIDSON FL SOFTAIL PROFILE LOW FRONT SUSPENSION KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-11-2010

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Fork Spring Removal 1. Elevate and support the vehicle so the front tire is off the floor and the forks are fully extended. 4 9 3 1 10 11 2 5 6 7 8 is04004 1. Slider tube cap 2. Spacer washer 3. Oil seal 4. Clamp bolt and washer 5. Fork tube plug 6. O-ring 7. Fork spring 8. Tight-wound end of spring 9. Fork slider tube 10. Fork slider 11. Drain screw and washer Figure 1. Front Fork NOTE Remove the brake caliper from the fork slider. DO NOT remove the brake line from the caliper. 2. Remove the front wheel. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual. 3. Remove the front fender. See FRONT FENDER in the Service Manual. 4. See Figure 1. Remove the slider tube cap (1), spacer (2) and oil seal (3) from the top of one fork side. Save the cap and spacer. The oil seal can be discarded. 5. Loosen the clamp bolt (4) and pull the fork from the brackets. 6. Repeat Steps 4 and 5 for the other fork side. -J00280 1 of 4 Wear saf ety glasses or gog gles when ser vicing f ork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) NOTE Be careful not to damage the O-ring. 7. See Figure 1. Remove the fork tube plug (5) and O-ring (6). Pull the spring (7) out of the slider tube (9). Remove the drain screw and washer (11), and drain the fork. Reinstall the drain screw and washer, and tighten to 52-78 in-lbs (5.9-8.9 Nm). 8. Repeat Step 7 for the other fork side. NOTE The Profile® Low Front Suspension Kit requires a different amount of H-D TYPE E FORK OIL than is listed in the Service Manual. NOTE Measure the oil level from the top of the fork tube with the fork spring removed and the fork fully compressed. 9. See FRONT FORK OIL in the Service Manual, but substitute the measures below. Fill the forks with Harley- Davidson TYPE E FORK OIL: • 1986 through 1999 models: •11.7 oz (345 cc) of oil, or •5.2 inch (132 mm) from top of oil level to top of tube. • 2000 and later models: •13.4 oz (396 cc) of oil, or •4.1 inch (104 mm) from top of oil level to top of tube. Fork Spring Installation 1. Insert a new Profile Low spring (7) from the kit into each slider tube (9), with the tight-wound portion (8) toward the bottom of the fork slider. NOTE Be careful not to damage the O-ring. 2. Install the fork tube plug (5) and O-ring (6) assembly into the slider tube and tighten securely. Be sure that one flat on each fork tube plug faces toward the inside of the fork. 3. Insert both fork side assemblies up through the slider covers, the fork stem and bracket, and the upper bracket. 4. Obtain two new oil seals (3), H-D Part Number 45733-48, and the spacer washers (2) and slider tube caps (1) saved earlier. Place an oil seal, followed by a spacer washer, onto each fork tube plug. 5. Insert the threads of a slider tube cap through each washer and seal, and into the fork tube plugs. Tighten to 40-60 ft- lbs (54.2-81.3 Nm). 6. Tighten the fork stem bracket clamp bolts (4) to 30-35 ft- lbs (40.7-47.5 Nm). 7. Install the front fender. See FRONT FENDER in the Service Manual. Install the front wheel and brake caliper. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual. Jiffy Stand Removal/Installation 1. Move the jiffy stand to the retracted (up) position. Wear safety glasses or goggles when removing or installing spring. Spring tension can cause spring, attached components and/or hand tools to fly out which could result in death or serious injury. (00477c) 2. See Figure 3. Unfasten the jiffy stand leg spring (A) from the vehicle. Remove the hex bolt (B), lock washer (C), flat washer (D) and leg stop (E) from the threaded end of the jiffy stand leg. Discard the jiffy stand leg, but retain all other components. 3. Clean and inspect the jiffy stand attaching parts and mounting bracket for wear or damage. If parts replacement is necessary, refer to the Jiffy Stand section of your Service Manual for replacement procedures

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Aprilia ntic 500 Change

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Filed Under (Aprilia) by admin on 07-11-2010

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Time and Ease: Easy­ Under 30 Minutes Tools/Supplies: Ratchet w/sockets or wrenches, oil, oil pan, oil filter, rags, funnel Step 1: Put scooter on center stand and allow the engine to cool. Step 2: Unscrew and extract the cap­dipstick (1) . Step 3: Unscrew and remove the engine oil filter (3) . Step 4: Unscrew and remove the oil drain plug (4) . Allow the oil to drain completely. Step 5: Install a new oil filter (3) , being careful to lubricate the O­ring on the filter with oil. Step 6: Tighten the engine oil drain plug (4) . Step 7: Fill through the filling hole (2) with approximately 1.7 L of 5W­40 Synthetic or other that exceeds API ST Specifications. Step 8: Tighten the oil level dipstick (1) . Step 9: Start the engine and let run for a few minutes, Shut it off and let it cool. Check the engine oil level again using the dipstick (1) , and top it off if necessary, without ever exceeding the “MAX” level.

KTM 250F Timing Chain Tensioner Installation Instructions

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Filed Under (KTM) by admin on 19-10-2010

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1) Remove OEM Tensioner: On some models including the 250F motors, it may be necessary to put the engine at TDC before proceeding. Check your manual. This is not the case on the 450 and 530 single cam motors. • Remove the outer cover plug. • Remove the large cover with copper washer. • Using needle nose pliers grab the end of the OEM tensioner and pull it outward. Be careful not to damage the aluminum port or face. • If the O-ring did not come out with the tensioner, carefully reach into the port and remove it without pushing it further into the engine. 2) Install new Tensioner: • To prepare the new tensioner, set the spring aside. Put the new tensioner in the collapsed position. (They are packaged and shipped in the collapsed position.) If you have extended it, rotate the assembly until the “top” on the piston is facing up. Then a light tap from the bottom will release the ratchet. This will now allow the plunger to be retracted to about 1- 13/16″ (46mm). • Install the O-ring over the tensioner body, keeping it outboard of the ridge as shown. • Slide the tensioner assembly with O-ring (without the spring), into the engine port. The end (with the hex-head spring hole) should only protrude from the engine about 1/32″ (.75mm). • Install the cover and tighten. The copper washer should be tight. • Insert the spring through the cover port. As it is slowly inserted, you may hear clicks as it pushes the plunger inward while ratcheting. • Install and tighten the plug against the spring. Note: some 250F engines have a one piece cap. Slide the spring into the tensioner far enough to hold it, then capture it with the cap and tighten. • Start the engine and carefully check for oil leaks. Adjustment will occur internally as it is needed. No further maintenance of the tensioner is required

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