HARLEY-DAVIDSON TOURING TRUE DUAL INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 08-04-2012

download
1. Remove both saddlebags and side covers from the motorcycle 2. Remove seat and place it away from the work area; disconnect battery. 3. Cover the primary housing, transmission top, and end cover near the head pipe to prevent damage. 4. Remove the bolt for the passenger floorboard that attaches it to the frame. 5. Remove the right side rider floorboard and support brackets. Loosen muffler clamps; remove the support bolts located at the rear upper portion of the mufflers. Remove mufflers from the head pipes. Unscrew clamps on the factory heat shields, and remove heat shields from the head pipes. 6. Unplug both O² sensors. Cut and remove the ZIPSTRIP that holds the front O² sensor wire to the frame. Loosen clamp on the rear exhaust pipe; remove the left side pipe, while leaving the split pipe in place. 7. Loosen clamp on crossover pipe and remove leaving right side exhaust intact. 8. Remove nuts on the flanges located at the cylinder heads. Remove the right side pipe as one unit. 9. Use snap ring pliers to carefully remove the circlips on each pipe inlet; remove

KTM Front Wheel Bearing Installation Manuals

0

Filed Under (KTM) by admin on 31-01-2012

download
1 Place motorcycle on a stand so that the front wheel is off the ground. 2 Using a 27mm socket remove the front axle nut. Using a 10mm socket, loosen the four front axle pinch bolts. Slide front axle out of forks and remove front wheel. 3 Insert a long punch (with a good square edge) into the center of the aluminum wheel bearing spacers and push up against the inner edge of the spacer on the opposite side of the wheel (Fig. 1). Using a hammer, tap the punch around the entire circumference of the spacer until it completely slides out of the bearing (Fig. 2). Turn the wheel over and remove the other spacer in the same way. 4 Use a long screwdriver or narrow pry bar and pry the seals out of each side of the wheel (Fig. 3). 5 Using snap ring pliers, remove the bearing retaining snap ring from the brake rotor side of the wheel. (Fig. 4) NOTE: 2003 – CURRENT MODELS USING # 16-092 KIT DO NOT USE THIS SNAP RING. 6 Insert a long punch (with a good square edge) into the center of the wheel bearing, and push up against the inner edge of the bearing on the opposite side of the wheel. Using a hammer, tap the punch around the entire circumference of the bearing until it completely slides out of the hub. Turn the wheel over and remove the other bearing in the same way. NOTE: It may be necessary to tap on the punch sideways at first to knock the center aluminum sleeve off center so that you are able to get the punch on the edge of the bearing. 7 Clean areas where bearings will be inserted back into hub and apply a thin coat of grease around the machined hub surface. Tap the bearing on the snap ring (if used, either side if not) side of the hub into the machined hub surface, making sure to keep it square with the hub as it goes in and only tap on the outer race of the bearing. Once you get the bearing flush with the outer edge of the hub, use a socket or piece of pipe that is just smaller than the outside diameter of the bearing to finish tapping the bearing into the hub. (Fig. 5) 8 Install the bearing retainer snap ring (if used) into the groove machined in the hub, and then tap the seal in place over the snap ring with the spring on the seal in towards the center of the wheel. Tap in the aluminum spacer in the center of the seal.

Incoming search terms:

HARLEY DAVIDSON HANDLEBAR RESERVOIR COVER SET INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 13-02-2011

download
Kit 46098-98 fits the following models with single-disc front brake. •1996 through 2003 XL (Sportster®) models •1996 and later Dyna models •1996 and later Softail® models Kit 46099-98 fits the following models with dual-disc front brake. •1996 through 2003 XL (Sportster) models •1996 and later Dyna models •1996 and later Softail models •1996 and later FL Touring models INSTALLATION Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged. 1. Adjust the clutch cable for maximum free play. With snap ring pliers, remove and retain the external snap ring from the bottom of the clutch lever pivot pin. Remove the pivot pin, clutch lever, clutch cable and rear-view mirror from the clutch bracket. NOTE Apply anti-seize (10) (Harley-Davidson part number 98960-97) from the kit to all screw threads prior to installation. 2. See Figure 1. Install the new chrome clutch bracket (1) using a clamp half (2), washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). -J01271 1 is01004 Figure 2. Clutch Cable Adjustment 3. Re-install the clutch cable and clutch lever, mirror and pivot pin and snap ring. See Figure 2. Re-adjust the clutch cable so there is a 1/16-1/8 inch (1.6-3.1 mm) gap between the clutch cable ferrule and the end of the clutch bracket (1). 4. Remove the original clamp half from the front brake master cylinder assembly. 5. See Figure 1. Install the new chrome clamp half (2) on the front brake master cylinder assembly using washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). 6. Remove the two screws retaining the brake master cylinder reservoir cover. See Figure 3. Replace with the two standoff studs (1) in the kit. Tighten to 6-8 in-lbs (0.7-0.9 Nm)

Ridley TRANSMISSION BELT REMOVAL AND INSTALLATION

0

Filed Under (Ridley) by admin on 01-11-2010

download
1.Remove the transmission cover and inspect the belt for wear, damage, or breaks. 2.Fraying on sides of belt is considered normal. 3.To replace the belt, remove the clutches and remove the old belt. Install new belt onto clutches and simultaneously install the clutches. Refer to “Clutches” for more detailed information. CLUTCHES: Tools Needed for Service: Transmission Removal A1.) Remove the bolts holding on the transmission cover with a 6mm Allen Wrench and remove the cover away from the motorcycle. Refer to bolt #11 in Figure 3. •6mm Allen Wrench •Torque Wrench •5/16 Allen Wrench •1-1/8″ Socket Wrench •Chisel •Hammer Figure 3
A2.) Bend the tab on the driven washer with a chisel. Remove both the bolt and nut holding the clutches onto the transmission as well as the washers. Refer to numbers 5,6,8 and 9 in Figure 3. Number 9 is for the drive and number 6 is for the driven. Use a 5/16 Allen for the bolt and a 1-1/8 socket wrench for the nut. A3.) Remove the drive and driven at the same time. Remove the belt from the clutches. Refer to number 3 in Figure 3. Drive Clutch Service B1.) Remove the clutch cover by bending down the tabs and removing the bolts. Refer to Figure 4. B2.) Remove the snap ring using a pair of snap-ring pliers. See Figure 5. *NOTE: Make sure to use caution when removing the snap ring. The snap ring can “spring” off during removal and can cause damage to the eyes if not careful.

Incoming search terms: