KTM 250 SX-F & XC-F Piston Kits Installation and Removal Manual

0

Filed Under (KTM) by admin on 28-01-2012

download
Features* Benefits •*Dedicated*forging •*Light*weight,*superior*strength,*optimized*design •*Stock*Compression •*Matches*OEM*compression*ratio •*Dome*design Improved*flame*travel*to*maximize*air/*fuel*burn*efficiency •*Chrome*plated*piston*pin •*Reduced*friction,*improved*scuff*resistance •*Horizontal*slot*pin*oiling .•*Improved*lubrication,*better*pin*oiling,*reduced*friction •*Pressure*seal*groove •*Maximum*ring*seal •*Skirt*coated •*Reduced*friction,*quieter*operation,*improved*scuff*resistance •*Dedicated*rings ……………………………… •*Optimized*for*each*application,*light*weight,*high*perfromance,*better*oil*control •*Experience ……………………………………. •*68*years*as*the*industry*leader*in*forged*piston*technology Piston sold complete*with:*Rings,*piston*pin,*and*circlips. Complete*top*end*kits*sold*complete*with:*Piston,*rings,*piston*pin,*circlips,*and*complete*top*end*gasket*kit

HARLEY DAVIDSON XLH 1200cc BIG BORE KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 06-03-2011

download
Boring and Honing Procedures 1. Check again for burrs on cylinder gasket surfaces and remove burrs before performing Step 2. 2. Install original head and base gaskets, CYLINDER TORQUE PLATES (Part Number 33446-A) and TORQUE BOLTS (Part Number 33446-4). Tighten TORQUE BOLTS following tightening procedure given in the INSTALLATION, CYLINDER HEAD procedure in the ENGINE section of the Service Manual. NOTE Torque plates, properly tightened and installed with gaskets, simulate engine operating conditions. Measurements will vary as much as 0.001 inch without torque plate. 3. The cylinder must be bored with gaskets and torque plates attached. Bore the cylinder to 0.003 inch under the desired finish size. 1 WARNING CAUTION CAUTION 1 WARNING Kit Number 4. Hone the cylinder to its finished size (See Figure 1) using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Honing must be done with torque plates attached. All honing must be done from the bottom (crankcase) end of the cylinder. Work for a 60 degree crosshatch pattern. 5. See Figure 1. After machining and honing, chamfer the bottom edge of the cylinder liner. the chamfer provides a beveled surface for easier installation of the cylinder over the piston rings. Break leading edge of liner to a flat surface. The bottom edge of the liner will be somewhat sharp after machining. This sharp edge could easily be damaged during installation of the cylinder. Piston Installation The 1200cc pistons have an arrow on the top of the piston. This arrow must face the front of the engine when piston is installed. There is no front cylinder piston or rear cylinder piston. New pistons can be installed in either cylinder. Check piston rings for proper side clearance and end gap (See XLH Service Manual). Be sure end gaps of adjacent rings are installed 90 degrees apart. Assembly Follow assembly and torque specifications given in the ENGINE section of the applicable Service Manual. Replace original gaskets, O-rings and seals with new components furnished in kit. NOTE Push rod covers on 1991 and later models are one-piece and the correct O-rings are as follows: Bottom – Part Number 17944-89 Upper – Part Number 11190 Engine Break In For the first 500 miles, to wear-in critical parts, observe these few simple driving rules: During the first 50 miles, keep the engine speed below 2500 RPM in any gear. Up to 500 miles, vary the engine speed, avoiding any steady speed for long distances. Engine speed up to 3000 RPM is permissible in any gear. Avoid fast starts at wide open throttle. Drive slowly until engine warms up. Avoid running the engine at extremely low RPM in higher gears. 2 of 3 -J00001 1200cc CYLINDER FINAL BORE SIZE AFTER HONING STANDARD BORE DIAMETER 3.4980 inch + 0.0002 inch Figure 1. Bottom Edge of Cylinder Liner Chamfer i04852 Break Edge to Flat Surface

Incoming search terms:

Harley-Davidson Big Twin Evolution and Twin Cam Edelbrock/ JE Sport INSTALLATION INSTRUCTIONSsman Pistons

0

Filed Under (Harley Davidson) by admin on 07-02-2011

download
INSTALLATION PROCEDURE Note: All Evolution® “Big Twin” pistons are marked “Front” or “Rear” and come with rings, wrist pins, and locks. • Note: We highly recommend that a dealer or trained mechanic perform the installation of these pistons. Specialized equipment is required for honing and finishing the cylinders to ensure long life of the piston and cylinder assembly. 1. Remove original equipment cylinders from engine. Refer to a shop manual or other reference book for specific steps, if needed. (Note: Care should be taken not to bend the studs or damage the cylinder during removal of the cylinders.) 2. With a small screwdriver, move the wrist pin retainer around to gain access to the tail of the retainer as it lines up with the notch in the bottom of the wrist pin hole. 3. Use a small screwdriver, pick or awl to roll the wrist pin retainer out of its groove. 4. Push wrist pin out and remove piston. 5. Repeat procedure for the other piston. 6. At this point, take cylinders, new pistons, and piston-to-wall clearance specifications to your dealer or machine shop to perform necessary machining operations. • IMPORTANT NOTE (Evolution® and Twin Cam®): The cylinder bore must be machined/honed to provide .0025″ of piston-to-wall clearance. Measure the piston diameter at a point .500″ up from the lower skirt (See Figure 3). 7. Starting with the front cylinder, install new piston rings and one wrist pin retaining clip (Note: Second ring has a dot which must face up when the ring is installed) . 8. Place the piston over the conecting rod, making sure that the intake valve pocket is towards the intake side. (For Evolution ® , see Figure 1. For Twin Cam ® , see Figure 2) . Coat the wrist pin with engine oil and insert it into the piston. Install the second wrist pin retainer into the groove. 9. Lightly coat the piston skirt with engine oil. Place a piston ring compressor over the piston/ring assembly and compress. Place the cylinder over the piston and gently push down until all rings are in the cylinder. Remove the ring compressor, and push the cylinder the rest of the way down. (Note: Be careful not to get oil onto the base gasket.) 10. Place two nuts and washers on opposite corners of the #1 cylinder to hold it down while you repeat the procedure for cylinder #2. 11. Assemble the rest of the engine per factory specifications. Start the engine and let it run at 2000 rpm for about 10 minutes.

Incoming search terms:

POLINI X1 GENERAL INFORMATION AND SPECIFICATIONS

0

Filed Under (Polini) by admin on 02-12-2010

download
Air cleaner – Clean and reoil daily or after each moto to prevent motor failure and reduced performance. Transmission oil – change after every race, or at end of riding day. Chain – check tension and lubricate before every ride, adjust or replace as needed. Reoil after riding in damp conditions. Clutch – disassemble and clean clutch assembly frequently, every 2-3 races at least. Inspect kickstarter gears at this time. Ignition cover – remove cover and wipe dry after each ride or after washing bike to remove condensation. Piston rings – replace as often as every 3-5 races with expert rider, less often with less aggressive riders. Piston, pin, rod bearing & circlips – replace as often as every 8-10 races with expert rider, less often with less aggressive riders. Coolant – change yearly, make sure there is at least a 50/50 mixture of antifreeze if freezing temperatures are possible. Steering bearings – Check daily for looseness or play. Adjust and regrease as needed. Swingarm – Check often for looseness. Regrease several times a year. Replace bushings if any play is evident. Sprockets – check for worn or curved teeth each time chain is adjusted. Chain roller& wear pads – check roller for free rotation when checking chain. Make sure roller is not bent or damaged. Check chain wear strips on swingarm and chain guide frequently. Replace as needed to prevent chain from damaging motorcycle. Spokes – Check after each race or after each day of riding for looseness or damage. Wheels & tires – check wheels after each race for dents, cracks or other damage. Check tires for cuts, damage or wear. Check tire pressure daily and adjust for riding conditions. Shock – Check shaft area daily for signs of oil leakage or damage. Check swingarm and shock bushings for looseness. Forks – Check forks daily for leaking oil or damage to tubes. Make sure forks are not twisted check for smooth operation. Spark plug – check sparkplug color and condition after each race or end of riding day. Adjust jetting to keep plug from fouling or overheating. Silencer – If bike seems to be getting louder, replace packing and decarbonize inner tube. Expansion pipe – check daily for large dents, damage or leakage. Remove carbon from headpipe when pipe is removed. Have large dents fixed, or any dents within 8″ of the cylinder. Replace o-rings on pipe as needed to maintain a good seal. Footpegs – check daily for proper operation, pegs should spring back into place. Make sure pegs are not bent or overly dull. Handlebars – check bars after any crash for bending. Look for cracks near bar clamps. Replace bars that have been straightened more than 2 or three times, or if bar is badly bent. Aweakened bar can snap suddenly causing injury to rider. Throttle – check throttle for proper operation each time before bike is started. Remove and clean inside of grip and bar as needed. Grips – check grips daily for wear or looseness. Replace as needed. Use grip glue & safety wire to help hold grips in position. Calipers & pads – check pad wear and caliper function daily or after each race. Replace pads and clean calipers as needed. Brake lever – check lever daily for damage or wear. Make sure lever is at proper angle for both seated and standing positions. Leave lever clamp loose enough to allow clamp to rotate during crash rather than breaking lever. Check and adjust freeplay as needed. Brake pedal – Check pedal daily for damage and proper freeplay. Adjust rear caliper as needed. Reeds – Remove and inspect reed block during every ring change. Check reeds for signs of wear, fraying and cracking. Make sure reeds sit flat and seal well. Replace at any sign of wear or damage or at least once a year, more often for expert riders. Nuts & bolts – Check all nuts and bolts regularly. Make sure to check engine mounting bolts and swingarm bolt frequently

Incoming search terms:

2005 Honda CRF450R OWNER'S MANUAL AND COMPETITION HANDBOOK

0

Filed Under (Honda) by admin on 02-12-2010

download
Normal Engine Stop 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle (1) 2 – 3 times, and then close it. 4. Depress and hold the engine stop button (2) until the engine stops completely. Failure to close the fuel valve may cause the carburetor to overflow, result in hard starting. Emergency Engine Stop To stop the engine in an emergency, press the engine stop button. Basic Operating Instructions 15 Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: •piston is replaced •piston rings are replaced •cylinder is replaced •crankshaft or crank bearings are replaced Break-in Guidelines 16 Basic Operating Instructions Servicing Your Honda 17 Servicing Your Honda Keeping your CRF well maintained is absolutely essential to your safety. It’s also a good way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To help keep your CRF in good shape, this section includes a Maintenance Schedule for required servicing and step-by-step instructions for specific maintenance tasks. You’ll also find important safety precautions, information on oils, and tips for keeping your Honda looking good. An ICM (Ignition Control Module) system is used on this motorcycle; consequently, routine ignition timing adjustment is unnecessary. If you want to check the ignition timing, refer to the Honda Service Manual (page 156).

Incoming search terms:

YAMAHA VMX12W1 (C) OWNER'S MANUAL

0

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

download
Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. EAU13060 Fuel tank cap To remove the fuel tank cap 1. Push the levers on the left and right side of the rider seat backrest as shown and slide the rider seat backrest forward. 2. Insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed. To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark on the cap facing forward. 2. Turn the key counterclockwise to the original position, and then remove it. 3. Slide the rider seat backrest rearward and push it down. NOTE: The fuel tank cap cannot be installed 1. Brake pedal 1. Opening lever 1. Unlock.
INSTRUMENT AND CONTROL FUNCTIONS 3-7 2 3 4 5 6 7 8 9 unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. WARNING EWA10130 Make sure that the fuel tank cap is properly installed before riding. EAU13211 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. WARNING EWA10880 * Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. * Avoid spilling fuel on the hot en- gine. CAUTION: ECA10070 Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 CAUTION: ECA11400 Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduc