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 oil filter cooler installation instructions

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Filed Under (Harley Davidson) by admin on 10-04-2012

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2000 cH ROME 99 – 07 SOFTAIL MODELS #2001 CHROME 99 – 07 DYNA MODELS #2002 CHROME 99 – 07 FLT MODELS, flht, flhr, fltr #2005 black CHROME 99 – 07 SOFTAIL MODELS #2006 BLACK CHROME 99 – 07 DYNA MODELS #2007 black CHROME 99 – 07 FLT MODELS, flht, flhr, fltr #2020 REPLACEMENT OIL FILTER #’S: 2000, 2001, 2002, 2005, 2006, 2007 1. See Figure 1 to verify all Feuling components and the proper mounting bracket for your model 2. Wash, clean and inspect all new Feuling hardware, Including – off-set sandwich oil filter adapter, filter cooler housing and oil lines, use compressed air to blow dry the oil lines, fittings, threads and bolt holes. Use a tap and die if needed to clean threads. (On installation use lubrication on all fasteners and fittings) 3. Refer to the proper service manual for your model motorcycle & engine, for removal of engine oil and spin-on oil filter. Dispose of these items properly. 4. Clean engine case oil filter spigot and sealing surface thoroughly. 5. Install the clean Feuling off set oil filter sandwich adapter; both O-ring and gasket need to be assembled dry. 6. First install the inside half of the off-set oil filter adapter, O-ring side towards engine case filter mount. We recommend using a dab loctite on the 1″ lock nut. (See figure 2) It is recommend to mock up the sandwich adapter before torquing nuts and bolts to obtain desired orientation and proper clearance to engine case and frame rails. 7. Install the fittings and oil lines onto the outer half of sandwich adapter torque fittings to proper specs using thread sealant on the 1/8 NPT threads and engine oil on the -4 AN oil line fittings. 8. Complete installation of sandwich adapter, including the inner gasket. Finger tight the allen head bolts in an alternating sequence on both sides before final torque. Re-Torque the allen head bolts after the first heat cycle after installation and during every oil change.

HARLEY DAVIDSON BRAIDED OIL HOSES INSTALLATION MANUAL

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

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery negative cable. 2. Drain engine oil according to Service Manual instructions. 3. Removing the rear exhaust pipe may aid in giving access to the oil lines and fittings. If necessary, remove the rear exhaust pipe according to Service Manual instructions. 4. See Figure 5 and Figure 1 for description and location of the three oil hoses that are replaced with the braided hoses in this kit. Remove the original equipment oil feed, return and vent lines. 5. See Figure 2. Remove and discard the original hex threaded quick disconnect fittings (1), (2) and (3) at the engine for each of the hoses removed in Step 4. To remove the fittings, turn the hex in a counterclockwise direction until free. 6. See Figure 5. Install the threaded adapter from the kit onto the corresponding oil line. The adapters for the return and vent lines are the same size. The adapter for the feed line is larger in size. Coat the male threads of the adapters with Loctite 565 thread sealant. NOTE Be sure to install hoses on the correct fittings. If you mix up the hoses, you will change the direction of the engine oil flow, causing severe engine damage. 2 3 1 is04165 1. Oil Return Hose 2. Oil Feed Hose 3. Oil Vent Hose Figure 1. Installed Oil Hoses

HARLEY DAVIDSON SOFTAIL TRANSMISSION TOP-COVER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION – TOP COVER 1. See Figure 3. Remove and retain the stock screw (J) from the top of the transmission upper cover (I). 2. Ease the left side of the cover through the right side of the engine. You may need to angle the transmission cover slightly as you work it into position. 3. Fasten the weld-nut end of the top-cover bracket (2) to the top cover (4) using the screw (3) from the kit. Torque the screw to 6.6 – 9 ft-lbs (8.9 – 12.2 Nm). 4. Fasten the top of the top-cover bracket (2) to the left side of the transmission upper cover using the screw (J) removed in step 1. Torque the screw to 8 – 10 ft-lbs (10.8 – 13.5 Nm). 5. Install the Softail transmission-interface cover (D). Go to the next section in this instruction sheet. NOTE Save the washer (1) from this kit for transmission-interface cover installation. INSTALLATION – INTERFACE COVER 1. See Figure 1. Remove the screw (1) from interface cover at location 1. Keep the screw for installation. 2. Loosen the screw (2) at location 2 approximately three turns. 3. See Figure 2. Position the slotted hole (1) on the interface- cover mounting bracket (2) behind the washer at location 2. 4. Install the screw (4) from Step 1 through the mounting hole on the bracket and into location 1. Tighten the screw to 7 – 9 ft-lbs (9.5 – 12 Nm). 5. Tighten the screw (3) in location 2 to 13-16 ft-lbs (17.6 – 21.7 Nm). 6. See Figure 3. Place the interface cover (D) in position on the motorcycle. Spread the oil-line grommet (E) to wrap around the oil lines, then re-position the grommet in the interface cover. The edge of the interface cover must overlap the top of the top cover

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BMW Motorcycle R1100 RT R1100 RS R850/ 1100 GS R850/ 1100R Repair Manual

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Filed Under (BMW) by admin on 18-11-2010

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Engine Connection Nm Nm Oil filter Oil filter 11 11 Oil drain plug 32 32 Oil pump Mesh filter basket to engine block 9 9 Oil pump cover 9 9 Pressure relief valve 35 35 Oil pressure switch 30 30 Oil cooler Oil cooler pipe to engine block 10 10 Cooling oil line – banjo screw 25 25 Cooling oil line – banjo screw with oil vent valve 25 25 Oil lines to oil cooler 25 – Oil cooler to holder 9 9 Oil cooler return line to engine block 35 35 Oil cooler feed line to frame 20 20 Oil cooler feed line to engine block 25 25 Screw-in union for oil cooler connection at engine block 35 35 Clean threads and apply Loctite 603 to inner and outer threads and in the contact face area Oil cooler hose at oil thermostat – 40 Cylinders Tightening sequence M 8 screw 20 20 M 6 screw 9 9 Chain guide rail pivot screw 18 18 Timing chain Chain tensioner 32 32 Connecting rod Big end cap Joint torque 20 20 Additional wrench angle 80° Crankcase Tightening sequence: M 10 screw (oiled) 45 45 M 8 screw (oiled) 20 20 M 6 screw Engine electrical system Connection Nm Nm Starter motor to engine 20 20 Starter cover to gearbox housing 7 – Positive lead to starter motor 10 10 Alternator to alternator support cover 20 20 Tensioning and retaining strap at alternator 20 20 Spacer at alternator 20 20 Positive lead to alternator 15 15 Belt pulley at alternator 50 50 Belt pulley to crankshaft 50 50 Poly-V belt preload 8 8 Spark plug 20 20 13 Fuel preparation and control Temperature sensor on engine block 25 25 16 Fuel tank and lines Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6 18 Exhaust system Muffler to footrest 35 35 Manifold to cylinder head (with strap) 22 22 (with jacket pipe) 18 18 Muffler to support plate for center stand 20 20 Clip on muffler 50 50 Grease clamping face with Never Seez Oxygen sensor (lambda probe) to muffler 55 55 Grease with Never Seez

1937-1984 Big Twins BRUTE II EXTREME BELT DRIVES INSTALLATION INSTRUCTIONS

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

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Remove the outer primary cover. Remove the front pulley, chain, compensator & chain adjuster Remove oil lines to primary and plug or clamp to prevent leakage. Cut the chain oiler hose 3 inches from the oil pump and permanently plug. All belts must be run dry without lubrication of any kind. Therefore, remove all oil from inside the primary covers. The spacer behind the front pulley should be removed prior to installing the belt drive. This spacer may or may not be required to correctly align the pulleys. If a spacer is needed for alignment, various sizes are available from your local Primo Belt Drives dealer (part number PX-1 =package of 6 various sizes). Install the front pulley supplied in the kit. Loop the belt around both pulleys to insure that you have the proper belt for your pulleys, then gently push the unit into place. Use the supplied washer & nut on the motor shaft. Torque the motor nut to 80-100 foot pounds. If installing a PC-1000-Aremove the clutch hub & clutch basket. On tapered shaft models check the fit on the shaft & the fit of the keyway in the hub. Install the key in the mainshaft, making sure it is firmly seated (use of super glue or threadlock in the keyway is helpful to keep the key from sliding out of the keyway during clutch installation). Tighten the clutch hub nut(left-hand thread) to 60-90 foot pounds. 1 After installing and adjusting clutch, track the belt by turning the pulleys. If needed use a straight edge between the front and rear pulleys to check alignment. Improper alignment of the pulleys will result in reduced belt life. Spacing the motor pulley outward will cause the belt to track towards the outer primary cover. If spaced too far out the belt will rub on the inside of the clutch shell. Before installing the primary cover be sure that everything inside clears both the outer and inner covers. In some cases a small amount of metal may need to be removed from one or more of the bosses on the inner or outer primary cover.

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