Harley-Davidson feuling Adjustable Pushrods Installation Instructions

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Filed Under (Harley Davidson) by admin on 22-04-2012

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1. Refer to the proper factory service manual for your model and year of engine, for removal of existing pushrods. 2. The Feuling pushrods are designed with a small adjustment parameter for rigidity creating maximum lift – These are not quick install pushrods and may require the removal of the lifter blocks and or loosing of the breathers/rocker arms supports. When loosening the rocker arm supports always remove the breather bolts first. 3. Clean and inspect each new Feuling pushrod including center oil hole 4. Feuling pushrods are marked Intake and Exhaust. The shorter pushrods are Intake and the longer pushrods Exhaust 5. Feuling recommends using new O-rings and gaskets where applicable to prevent oil leaks
6. Always pump up hydraulic lifters before installing them. Use an oil squirt can to fill the lifter with oil through the feed hole on the side of the lifter, push oil through the feed hole until the air bubbles are gone. If needed work the oil back and forth through the feed hole and pushrod seat with the squirt can. Light weight oil can be helpful. 7. Assemble and adjust one cylinder at a time, the servicing cylinder needs to be on TDC of compression stroke so the cam lobes are at their lowest point 8. Install pushrods into proper locations with the adjusting side of the pushrod down, towards the lifter. Slide the pushrods through the pushrod covers up into the rocker housing and set the pushrod on the seat of the lifter. We recommend filling the pushrods with oil then maneuver the pushrod up into the rocker arm seat. 9. Torque rocker arm housings and breathers to factory torque spec’s 10. See the instructions for your lifters for the proper adjustment. All Feuling hydraulic lifters run best at . 090″ – . 100″ of crush.

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Harley Davidson Big Twin EVO Engines Edelbrock Performer-Plus Camshaft , Performer RPM Camshaft , & Performer RPM Camshaft INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-03-2012

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Disconnect the battery. Secure the motorcycle on a suitable stand with the rear wheel off the ground. Remove components necessary for easy access to rocker covers, pushrod covers, and gear case cover, i.e., exhaust system, gas tank, air cleaner, foot rest, etc. Remove spark plugs. 2. Remove top and middle sections of rocker boxes, then rotate engine so both valves are closed on the cylinder head being worked on (put transmission in high gear and move rear wheel to slowly rotate engine). Remove the two 5/16″ bolts nearest the rocker arm shafts (keep all shafts, rocker arms, and pushrods in order so they can be installed in their original position). Remove the pushrod covers and pushrods. NOTE: The use of adjustable time-saver pushrods will simplify installation. Follow the manufacturer’s recommendations for installation of those parts. 3. It is not necessary to remove the tappet guides if you use a cam installation tool such as Crane #9-0020 to hold the tappets in place during cam installation. If you remove the tappet guides, you must use a tappet block alignment tool such as Crane #9- 0021 to re-install the tappet guides. Tappets can be held up in place during removal of guides by using U-shaped piece of safety wire or paper clip hooked to the tappets. 4. Remove ignition covers on gearcase cover by drilling out rivets to gain access to sensor plate. Remove the inner cover, sensor plate and rotor. NOTE: For re-installation, use new rivets H-D #8699 or drill and tap for 10-32 screws. 5. Remove the gearcase cover screws and remove cover while holding end of cam inward. Now remove the camshaft, spacing washer and thrust plate

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Harley-Davidson Twin Cam Engines Performer RPM Gear Drive Camshaft Kit INSTALLATION PROCEDURE

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Filed Under (Harley Davidson) by admin on 03-03-2012

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1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 INSTALLATION PROCEDURE 1. Disconnect the battery, and remove the fuel tank. 2. On engines with the oil tank above the engine, drain the engine oil. 3. Remove the front exhaust pipe to clear the Cam Housing Cover. 4. Remove the Rocker Covers and remove the four 5/16″ bolts and the two 1/4″ bolts holding the rocker arms in place. With the rocker arms removed, remove the stock pushrods. 5. Remove the push rod tube retaining clips and push rod tubes. 6. At this point, you may remove the lifter covers and take the lifters out, or you can make a lifter holding tool from a binder clip as shown in Figure 1 . 7. On pre-2000 models with a cam position sensor, you may want to remove the inspection cover, unplug the wires, and remove the sensor at this time to ease installation later on. 8. Remove the cam housing cover keeping the bolts in a separate cup. ( Note: Oil will run out of the cam housing.) 9. Using the Chain Tensioner Unloader Tool, unload pressure on the outside chain tensioner, and pin it in place with the retaining pin (See Figure 2) .

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Honda XR600/ XR650L Camshaft Installation and removal Instructions

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Filed Under (Honda) by admin on 05-12-2011

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Remove the tappet covers. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise direction. Position the engine at true top dead center (TDC) using the mark on the flywheel. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Since the rocker arms are located in the valve cover on an XR600, true TDC occurs when the cam lobes are pointed downward when the piston is at TDC. Remove the cylinder head cover. Warning, do not drop the locating dowels into the cam chain cavity. There are two dowels, one on either side of the cover. Remove and discard the gasket. Note the positioning of the cam lobes, this will help during installation of your new Hot Cams camshaft. Note also the location of the sealed bearing on the end of the camshaft and the direction in which it is facing. Loosen the bolts that hold the camshaft sprocket. Remove the lower camshaft sprocket bolt first, it will be necessary to rotate the engine. Rotate the engine back to TDC. Release the spring tension on the cam chain tensioner by lifting the end of the spring out of its hole in the tensioner block. A spring tool is a good method. Be careful not to scar the cylinder head’s gasket surface for the cylinder head cover. Remove the allen bolt that holds the end of the tensioner block shaft
just to the inside of the tensioner block. Note the location of the tensioner block shaft cap ridge. Using a pair of pliers pull the shaft out by grasping the ridge and using a clockwise rotation of the shaft while pulling outward. Pull the tensioner block upwards, out of the cylinder head. Remove the top camshaft sprocket bolt. Pull the sprocket off the camshaft but maintain upward tension, do not allow the chain to sag, it is possible for the chain to “slip” on the bottom sprocket of the crankshaft and change the cam timing. Remove the camshaft. Remove the cam bearings. Set the stock camshaft with the auto-decompression aside. It is not possible to use the auto-
decompression on the Hot Cams so do not attempt to re-install. Use a manual decompression. Install the bearings onto the new Hot Cam

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HARLEY DAVIDSON CHROME BILLET LIFTER-COVER KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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Installation with Stock Pushrods Refer to the service manual for your motorcycle model. Installation with Adjustable Pushrods Lifter-Cover Removal Installing or removing the pushrods with the valve train loaded can result in engine damage. On the cylinder being serviced, always set the lifters to the base circle on the cam before servicing pushrods, lifters, rocker arms, and valves. 1. Set the lifters of the rear cylinder to their lowest point, or base circle, on the cam. Refer to Setting the Lifters to the Base Circle in this instruction sheet. 2. See Figure 1. Insert a screwdriver into the slot on the side of the spring-cap retainer on the pushrod cover. 3. Press the spring-cap and retainer down while pulling outward to remove the spring-cap retainer. 4. See Figure 2. Lift the lower pushrod cover to reveal the lower third of the pushrod. 5. If the engine has stock pushrods installed and you are installing adjustable pushrods with this lifter-cover installation, go to step 6. If the engine already has adjustable pushrods installed and you are installing adjustable pushrods with this lifter-cover installation, go to step 7 6. Use a bolt cutter or similar tool to cut the stock pushrod. Avoid cutting the pushrods with a saw, grinder, or other method that may allow metal debris into the engine. Go to step 8. 7. Loosen the jam nut on each adjustable pushrod and resize each rod to its shortest length. 8. Remove the pushrod covers and pushrods from the engine. 9. Remove the O-rings from the seats in the engine at the top and bottom of the pushrod cover. 10. Remove the four screws fastening the lifter cover to the engine to remove the cover and gasket. 11. Remove old lifter-cover gasket material from the engine, taking care not to allow material to fall into the engine. Continue to Lifter-Cover Installation in this I-Sheet. Lifter-Cover Installation 1. See Figure 3. Verify that the lifter anti-rotation pin is in position. Installing or removing the pushrods with the valve train loaded can result in engine damage. On the cylinder being serviced, always set the lifters to the base circle on the cam before servicing pushrods, lifters, rocker arms, and valves. 2. Verify that the cylinder lifters are set to their lowest point, or base circle, on the cam. Refer to Setting the Lifters to the Base Circle in this instruction sheet. 3. Fasten the new lifter-cover gasket and chrome billet lifter cover to the engine using the chrome screws from this kit. In a cross pattern, torque the lifter-cover screws to 90 – 120 in-lbs (10.2 – 13.6 Nm). 4. See Figure 4. Loosen the jam nut on all of the pushrods and adjust the pushrods to their shortest length. NOTE See Figures 4 and 5. Install the narrow-band pushrods in the cylinder-intake location. Install the wide-band pushrods in the cylinder-exhaust location. 5. Assemble the O-rings (purchased separately) and pushrod covers. 6. Install the pushrods with the pushrod covers. The adjustment-end of the pushrod must be on the lifter

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Moto Guzzi Griso V1100 workshop manual

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Filed Under (Moto Guzzi) by admin on 27-11-2010

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DIMENSIONS Max. length 2260 mm (88.98 in.) Max. width 880 mm (34.64 in.) Max. height 1070 mm (42.12 in.) (excluding the rear/view mirrors) Seat height 800 mm (31.49 in.) Wheelbase 1554 mm (61.18 in.) Minimum ground clearance 185 mm (7.28 in.) Weight in running order 240 kg (529.1 lb) ENGINE Type twin-cylinder, 90° V transversal, 4-stroke engine Number of cylinders two Cylinder arrangement V, 90° Total displacement 1064 cu cm (65 cu in) Bore/stroke 92 x 80 mm (3.6 x 3.1 in). Compression ratio 9.6 : 1 Starting electric Engine idling speed 1100 ± 100 rpm Clutch dry, twin disc Lubricating system System under pressure, adjustment by valves and vane pump Air filter cartridge, dry Cooling system air cooled TIMING SYSTEM Timing diagram: 2 valves, with rods and rocker arms Values with inspection clearance between rocker arms and valve intake 0.10 mm (0.0039 in.) exhaust 0.15 mm (0.0059 in.) CAPACITIES Fuel (reserve included) 17.2 litres Fuel reserve 3.3 litres Engine oil Engine oil and oil filter change 3600 cu. cm (219 cu in) Gearbox fluid 500 cu cm (30.5 cu in) Transmission fluid 380 cu cm (23.2 cu in) Fork oil 520±2.5 cu cm (31.7 ± 1.5 cu in) (per leg) Seats 2 Max. vehicle load 210 kg (462.97 lb) (rider + passenger + luggage) TRANSMISSION SYSTEM primary drive gear, ratio: 24/35 = 1:1.4583 gearbox Mechanic, with 6 speeds, controlled by a pedal on engine left side overall gear ratios: 1st gear 17/38 = 1:2.2353 2nd gear 20/34 = 1:1.7 3rd gear 23/31 = 1:1.3478 4th gear 26/29 = 1:1.1154 5th gear 31/30 = 1:0.9677 6th gear 29/25 = 1:0.8621 final drive with cardan joint ratio 12/44 = 1:3.6667 FUEL SYSTEM Type Electronic injection (Weber – Marelli) with stepper motor Choke Ø 36 mm (1.417 in.) Fuel Premium grade unleaded petrol, minimum octane rating 95 (RON) and 85 (MON). FRAME Type Tube, with double cradle in high-strength steel Steering head angle 26°30′ Trail 108 mm (4.25 in.)

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Indian Rocker Arm End Play Rear Cylinder/ Front Cylinder Installation

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Filed Under (Indian) by admin on 12-11-2010

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Rear Cylinder 1Rotate the engine so that the rear piston is at Top Dead Center (TDC), compression stroke, so no load is on the valves. 2Using a 3/16″ allen wrench, remove the four screws securing the rear cylinder rocker cover. 3Remove the cover and inspect both O-ring seals. Discard if damaged or worn. 4Push both rocker arms towards the valve end support bracket (A) and using a feeler gauge check the gap between the rocker arms and the pushrod end support bracket (B). NOTE: The Rocker arm end play specification should be between 0.003″ to 0.012″. 5 Compare the measurement to the specification an determine whether adjustment is necessary. If the end play is within specification, adjustment will not be required. Refit the rocker cover (instructions 14 to 15) and carry out the same inspection on the front cylinder . If the measurement is outside the specification, adjustment will be required and shimming will be necessary (follow the remainder of these instructions). Adjustment 6Using a 1/4″ allen wrench remove the 4 screws securing the rocker shaft assembly.Refit the LH support bracket and reposition the complete assembly on the rocker base. Make sure that the three dowels are in place and the slots in the rocker shafts are properly aligned with the mounting screw holes in the RH support bracket. 11Clean the threads of the 4 support bracket screws and apply Blue Loctite to the first 4 threads. 12Fit the 1-3/4″ screws into the LH support bracket (A) and the 2″ screws to the RH bracket (B). Torque all screws in cross pattern to 16-20 foot-pounds. CAUTION: The rear piston must be at TDC, compression stroke, when tightening the support bracket screws. 13Re-check the rocker end play to ensure it is within specifica- tion. 13Lubricate the two O-rings with clean engine oil and refit them in the grooves in the rocker base. 14Refit the rocker cover.

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