1994-1998 HONDA RVF400RR Racing Kit INSTALLATION

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Filed Under (Honda) by admin on 01-12-2011

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(1)Fuel High Octane white gasoline (2)Engine Oil Recommended Oil: HONDA Ultra-GP (for four-cycle Motorbike) SAE20W-50 or 10W-40
Full Capacity: 3.0Liter (5.28pt) Oil Exchange: 2.5Liter (4.4pt) Filter Exchange: 2.4Liter (4.224pt) (3)Spark Plug NGK R 847-10(11)(4)Cooling Water Highly recommend checking the water level on each ignition/riding. Ingredient: Tapped water or Drinking water I. Unscrew a radiator cap. Apply water up to limb of intake. II. Hold steering and heave the body two or three times to let air out. III.Add water if necessary. IV. Screw the cap tighten.V. Start Engine then check water level again. Add water if necessary. < Notes for racing condition> • Keep your attention when you re-check the water level since the water would spill out of intake. Also cover the body with wastes. • Drain cooling water in a catch-tank before riding. • Drain whole water in a radiator after riding. It avoids corrosion or clog of components. • It is admitted adding coolant in winter season. Handle carefully when you apply them. It makes the circuit slippery if it drops or spilled.

2003 SUZUKI SV 650 COOLING AND LUBRICATION SYSTEM SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • * Remove the cowling. (SV650S) (C-7–7-6) • * Loosen the radiator cap stop screw 10 . (SV650) • * Remove the radiator cap O2 and connect the radiator tester to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • * Give a pressure of about 120 kPa (1 .2 kgf/cm2,17.0 psi) and see if the system holds this pressure for 10 seconds . • * If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system . In such a case, inspect the entire system and replace the leaking component or part. A WARNING When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. CAUTION Do not allow the pressure to exceed specified pressure, or the radiator can be damaged. COOLING AND LUBRICATION SYSTEM 6-3 6-4COOLING AND LUBRICATION SYSTEM RADIATOR REMOVAL • * Remove the cowling. (SV650S) ( r- 7-7-6) • * Drain engine coolant. (r– 72-20) • * Disconnect the right and left radiator hoses from the radiator. • * Disconnect the siphon hose from the radiator. • * Disconnect the horn lead wires. rI .rr • * Remove the radiator lower mounting bolt. • * Disconnect the cooling fan motor and its thermo-switch lead wire coupler 10. • * Remove the radiator by upper mounting bolt. • * Remove the cooling fan. • * Disconnect the cooling fan thermo-switch. • * Remove the cooling fan thermo-switch. • * Remove the horn. CAUTION When removing the horn, hold the nut by spanner to prevent the horn bracket distortion. COOLING AND LUBRICATION SYSTEM 6-5 INSTALLATION • * Install the cooling fan and horn. 0 Cooling fan/horn mounting bolt: 8 N .m (0.8 kgf-m, 6 .0 Ib-ft) • * Install the cooling fan thermo-switch. ( l”76-9) • * Install the siphon hose to the radiator. • * Install the radiator in the reverse order of removal. • * Route the radiator hoses properly. (=9-22) 9-22) • * Install the drain plug with a new sealing washer and pour engine coolant. (=2-20) • * Bleed air from the cooling circuit. (r– 72-21) • * Install the cowling. (SV650S)

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2007 King 50 Specifications, Owners Parts, Service Tuning

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Filed Under (Cobra) by admin on 03-12-2010

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Use a fuel / oil mixture of 32:1 for the full 8 hour break-in period. Be sure to use high-octane pump gas, with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil . (Part # MCMUOL02) CAUTION: Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine wear or damage to the machine. Adhering to the following break-in schedule will result in long lasting high performance machine. • Start bike on stand • First 5 minute period, operate the bike on the stand with a combination of idle and high RPM operation. (avoid prolonged high RPM but spin the rear wheel good at least once or twice per minute) • Allow bike to cool • Ride for 15 minutes maximum (avoid prolonged high RPM operation and avoid abusing the clutch with throttle blipping. • Cool and inspect bike for loose fasteners. • Next ½ hour of operation, avoid prolonged operation at Wide Open Throttle. • After 1 hour of operation o Check for loose bolts and nuts on the bike and retighten as necessary (proper toque values are listed under Specifications). o Clean the carburetor bowl. o Change the transmission / clutch lubricant. • After 8 hours of operation o Change the fork oil. o Have a Certified Cobra Mechanic change the shock oil. • Your bike is now ready for the highest level of competition! NOTE: During break-in the bike will likely lose some engine coolant through the radiator overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level will cover the top of the radiator cores. Removing the radiator cap and looking inside is the only way to check the coolant level. 8 Never open the radiator cap of a machine that has a hot or warm engine or one that has recently been ridden. Burning and scalding could occur. CAUTION: It is important that the radiator cap is installed correctly and completely otherwise engine damage could occur. Starting Procedure Before starting the machine inspect the following: • Check for proper tire pressure in both tires. • Observe the chain tension and adjust if necessary. • Observe the coolant level and fill if necessary. • Verify that the chain rollers and sliders do not have improper wear. • Verify that the handlebars are tight. • Check the throttle for smooth operation and that it ‘clacks’ shut properly. • Check for loose bolts and nuts, and re-torque as necessary. • Verify that the air filter is clean and properly saturated with oil. • Insure that the fuel tank contains an adequate volume of fuel / oil mixture to complete the distance required. (High octane pump gas with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil ) • Turn the fuel on by rotating the fuel petcock knob to the vertically downward position (reserve position is horizontally forward

YAMAHA FZS 600 SERVICE MANUAL

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

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CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Check: all connections Loose connection Connect properly. If the pin 2 on the terminal is flattened, bend in up. 4. Connect: lead coupler connector Make sure that all connections are tight. 5. Check: continuity (with a pocket tester) Pocket tester 90590-03112 If there is no continuity, clean the termi- nals. When checking the wire harness, perform steps 1 to 3. As a quick remedy, use a contact revitaliz- er available at most part stores.
1-5 GEN INFO SPECIAL TOOLS 1 2 1 2 1 2 1 EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Tool name/Usage Illustration 90890-01268 Ring nut wrench This tool is used to loosen and tighten the steering ringnut. 90890-01304 Piston pin puller This tool is used to remove the piston pin. 90890-01460 -01326 Damper rod holder T-handle These tool ar used for holding the damper rod when removing or installing the damper rod. 90890-01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber. 90890-01325 -01352 Radiator cap tester Adaptor These tools are used for checking the cooling system. 90890-01362 -01382 Flywheel puller Crank shaft protector These tools are used for removing the rotor and starter clutch. 90890-01367 -01381 Fork seal driver weight Fork seal driver attachment (ø41 mm) These tools are used when installing the forkseal.

2004 KTM 950 ADVENTURE REPAIR MANUAL

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Filed Under (KTM) by admin on 23-11-2010

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Intake system Fresh air is drawn into the filter box through the intake snorkel 1 , past the carburetors 2 and through the air filter 3 . The cleaned air is conducted to the combustion chamber through the carburetors and intake ports. 1 2 2 3 2-4 Repair manual KTM LC8 Art.-Nr . 3.206.016-E Secondary air system The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the emissions. A line leads from the filter box 1 to the control valve 2 which opens as soon as the throttle valves 3 are opened. The line continues to the reed valves 4 in the cylinder heads which are actuated by the pressure pulsation in the exhaust system. As a result, cleansed fresh air arrives in the exhaust port. The oxygen content in the air and the high exhaust gas temperature cause the emissions to oxidize. If the throttle valves are closed and the engine goes into an overrun condition, the underpressure in the intake port will rise and the control valve will close. This prevents exhaust backfire (combustion of the unburned fuel/air mixture). 1 2 3 3 4 4 4 2-5 Closed thermostat The thermostat is closed if the temperature of the cooling liquid drops below 75°C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 and the thermostat 2 . Open thermostat The thermostat 3 opens at 75°C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 , the aluminum cooler 4 and the thermostat. The pressure in the cooling system (max. 1.4 bar) is regulated by a valve in the radiator cap 5 . The cooling liquid level in the compensating tank 6 must be between the MIN and MAX marks when the engine is cold. The fan 7 switches on at 102°C.

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Cobra TSB2108 JR And OI Radiator Cap Installation Manual

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

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Cobra will send a spacer (ECMU0555) to all OI / JR customers with silver radiators. Assembly instructions are listed below. If the customer is uncomfortable with the installation process, they may send the cap to their dealer or back to the factory for installation. Spacer installation 1. Start the process by removing the rubber gasket. Stretch it to elongate the center hole (yes it will stretch a long way). 2. Once the gasket is stretched sufficiently, pull it back over the center crown to remove. 3. With the rubber gasket removed, place the spacer centered crown on the cap. 4. With the spacer in place, lightly pry up the center crown with a small screwdriver . 5. With the center lifted, stretch the gasket and work it’s hole around the center crown. 6. When completed it should look like this.