KTM 3V TURBO DRIVE MODEL 9808T KNEE FEED Installation and Removal Manual

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

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Gather together the following items that you will need to complete this installation. a) lathe b) 3/8″ electric hand drill c) 9/32″ diameter transfer punch SERVO Turbo Drive Model 9808T Page 2 d) .4375 drill, 3/16″ drill, #7 drill e) 1/4-20 tap f) 3/4″ socket wrench g) set of inch hex wrenches h) clean shop rag Step 2: Clean the power feed mounting area completely. Step 3: Remove the drive clutch nut and the drive clutch from the elevating jack shaft. Step 4: Remove the dial nut, dial, and dial carrier. Keep the dial for reuse later. Step 5: Remove the existing bearing retainer. Keep the screws for reuse later. Step 6: Pull jack shaft out of knee. Hold inboard end up while removing to avoid damage to the pinion gear. Step 7: Press the bearing off the jack shaft. Step 8: Drill and ream the end of the jack shaft .4375″ diameter by 13/16″ deep. The .4375″ dia. must be concentric to the shaft O.D. within .002″ T.I.R. Chamfer 1/32″ x 1/2″ diameter. For best results, machining should be done in a lathe. Step 9: Place the shaft extension #6975 into the end of the jack shaft. Finish drill 3/16″ diameter through the shaft and pin the extension with the 3/16″ diameter x 5/8″ long roll pin. File smooth. Step 10: Reassemble and replace the jack shaft in the machine. Step 11: Replace the existing bearing retainer with #57904 retainer provided. Secure using existing screws. Step 12: Slip spacer #5426 and bearing race #1616 onto the jack shaft. Slide the adaptor #0771 over the bearing race and locate against front of the knee.

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HARLEY DAVIDSON 45-AMP. UPGRADE ALTERNATOR ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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This 45-amp Rotor Kit is designed for installation on 1999 and later FLHT, FLHTC, FLHR, FLHRI, FLHRCI and FLTR Model Motorcycles. Existing Rotor Removal 1. Remove seat and disconnect battery terminals, negative cable first. 2. Follow instructions in applicable Service Manual and remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly. 3. Remove the alternator rotor spacer, if present. Installation The laminated high-output rotor in this kit contains magnets that are considerably more powerful than those used in most previous rotors. The ROTOR REMOVER/INSTALLER and SHAFT PROTECTOR SLEEVE (HD-41771) must be used to prevent parts damage during rotor removal and installation. 1. See Figure 1. Verify threads are clean and thread the Shaft Protector and Rotor Remover/Installer, if removed. NOTE The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to ensure that the rotor is properly centered. 2. Turn thumbscrews of Rotor Remover/Installer into threaded holes in rotor face. CAUTION 1 WARNING 1 WARNING 1 WARNING Kit Number 29999-97B Figure 1. Install Shaft Protector and Rotor Installer Engine Sprocket Shaft 1. Make Sure Threads are Clean 2. Install shaft protector sleeve. Shaft protector sleeve 3. Install Rotor Remover/Installer i04153 Handle Thumbscrew Forcing screw . Center ball on forcing screw in recess at end of engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator. 4. Loosen thumbscrews and remove Rotor Remover/Installer. Remove Shaft Protector Sleeve. 5. Install the shaft extension on engine sprocket shaft. No alternator rotor spacer is necessary). 6. Follow instructions in applicable Service Manual and install the clutch assembly, primary chain and shaft extension as a single assembly. 7. Apply two drops of Red LOCTITE®262 to threads of clutch nut and engine sprocket nut. Tighten nuts as fol- lows: Clutch nut- (left hand threads), 70-80 ft-lbs (94.9-105.5 Nm) Engine sprocket nut- 150-165 ft-lbs (203-223 Nm). 8. Follow instructions in Service Manual and install the Primary Chaincase Cover using new gasket from kit, if necessary.

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