HARLEY DAVIDSON SPORTSTER BRAIDED REAR BRAKE LINE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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This kit fits 1988-2003 XL models. INSTALLATION Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Drain Brake Fluid 1. Remove bleed screw cap on rear brake caliper. 2. Install one end of a length of plastic tubing over caliper bleeder valve. Place free end of the tubing in a suitable container. 3. Open the bleeder valve about one-half turn and pump the brake pedal to drain the brake fluid out of the rear brake system. Do not re-use brake fluid. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) Remove Existing Rear Brake Line 1. Disconnect wiring harness connectors from brake light switch spade terminals. 2. See Figure 1. Remove screws from the three P-clamps and one bracket used to secure brake line to motorcycle. a. Save all screws except bracket screw and save stock P-clamp, located at the right side sprocket cover, for later use. b. Do not mix up the screws. The screws must go back into the same threaded hole in which they were removed. c. Discard remaining two P-clamps. 3. Note brake line routing, then remove existing brake line. NOTE This kit contains clamps to replace the original equipment clamps removed, except for the small clamp on the right side sprocket cover.

KTM Preload Adjuster frontfork Disassembly And assembling

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

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Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 5 Preload Adjuster Frontfork 03/2002 Screw the screw-cap to the right so that the spring washer is turning out of the screw-cap PA. Remove the spring washer. Pay attention to the assembling direction!!! Turn the plastic adjustment tube holder out of the screw-cap. 12_021 12_022 12_023Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 6 Preload Adjuster Frontfork 03/2002 1. Remove the O-ring inside. Unscrew the air release plug. 12_024 12_025 12_026 2. Remove the O-ring.Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 7 Preload Adjuster Frontfork 03/2002 Disassemble the adjusting knob from the screw-cap. Pay attention to the steel balls and spring!!! 12_027 12_028 12_029 Heat the steel nut. Unscrew the nut (size 32) clockwise .Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 8 Preload Adjuster Frontfork 03/2002 The nut. Pay attention to the assembling direction!!! Remove the O-ring. 12_030 12_031 12_032 Push the holder rebound PA out of the screw-cap.Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 9 Preload Adjuster Frontfork 03/2002 – springring – spring washer – O-rings – holder rebound adjustment tube – rebound adjusting knob with steel balls and spring – air release screw with O-ring – nut – holder rebound adjustment cpl. with O-ring – screw-cap PA

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KTM WP FORK 4860 MXMA CLOSED CARTRIDGE REPAIR MANUAL

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

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 22-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork