Harley-Davidson Twin Cam Engines Cam Chain Drive System Installation and removal MANUAL

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Filed Under (Harley Davidson) by admin on 27-03-2012

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Removing the Cam Chain Drive System. NOTES Changing camshafts and cam drives in the 2006-up Harley-Davidson® Twin Cam 88® engines is different than in pervious engines. Procedures require use • of some special tools. Installation should be done by an experienced mechanic with access to factory service manual and required tools. Tighten all fasteners to the correct specifications and in order described. Always use an accurate torque wench. • Incorrect installation can cause engine damage not covered under warranty. CAUTION Failure to install components correctly can result in sudden engine seizure. Engine seizure may result in serous injury to motorcycle operator, passenger, or others. A- Disconnect the battery ground cable to eliminate potential sparks and inadvertently engagement of the starter while working on the motorcycle. B- Remove spark plugs and pushrod cover clips. Collapse the pushrod covers to expose the pushrods. C- Safely elevate and stabilize the rear of the motorcycle. Place the transmission in high gear. Turn the rear wheel to rotate the engine until both lifters and pushrods for either cylinder are at the lowest point on the camshaft (TDC of compression stroke). Both intake and exhaust pushrods for that cylinder will be under pressure from the valve springs and will rotate with light finger pressure. NOTE: 510G camshafts may use stock style non-adjustable pushrods instead of adjustable pushrods. If installing non-adjustable pushrods, disassemble and assemble rocker boxes per H-D® instructions. All other S&S® gear driven cams require installing adjustable pushrods. As a time-saving measure, the stock pushrods can be removed with bolt cutters. Be sure to head caution and warnings of these instructions. D- Cut the pushrods for the cylinder that is at TDC with the bolt cutter and remove the pushrod covers from the engine. Rotate the engine to place the pushrods for the other cylinder at their lowest point. Cut and remove the remaining pushrods. WARNING CAUTION Cutting pushrods with a saw or cutoff wheel may result in debris entering the engine, causing engine damage not covered under warranty. WARNING Cutting pushrods without releasing spring pressure, by rotating the engine until tappets are at the lowest point of travel can result in bodily injury. E- Remove the pushrod covers and lifters form the crankcase. F- Remove engine cam cover and gasket. Secure lifers with a tool made from a large binder clip

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TOYOTA TACOMA (ALL 4WD, 2WD PRERUNNER, & 2WD TRD MODELS) 3" SUSPENSION LIFT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 27-09-2011

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Before Starting Installation 1. Carefully read all warnings and instructions completely before beginning. 2. Verify all parts have been received in this kit by checking the parts list at the end of this document. 3. Only install this kit on the vehicle for which it is specified. If anytime during the installation you encounter something different from what is outlined in the instructions, call technical support at (928) 636-3175. 4. Special tools needed: a. Coil spring compressor 5. Park vehicle on a clean, dry, flat, level surface and block tires so vehicle cannot roll in either direction. Ride Height 1. Measure ride height with the vehicle supporting its own weight on level ground. To settle the suspension, the vehicle should be driven forward at least 10 feet immediately prior to taking these measurements. Ride height is the measurement from the NOTE Kit parts are prefaced by the word kit and appear in bold print. NOTE Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the factory service manual. When re-assembling the vehicle it is recommended by the vehicle manufacturer that certain fasteners are replaced in order to maintain proper retention characteristics. This system may not include all replacement hardware as recommended by the factory service manual. Additional replacement hardware should be obtained prior to installation of this system to meet the requirements of the factory service manual

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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.

YAMAHA YW50X SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EAS00022 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.
1-3 GEN INFO IMPORTANT INFORMATION EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. 1 Oil seal c C Do not spin the bearing with compressed air because this will damage the bearing surfaces. 1 Bearing

Power Trak Installation Instructions

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Filed Under (Tips and Review) by admin on 14-11-2010

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Warnings and considerations: 1. Disclaimer Disclaimer Disclaimer Disclaimer – These instructions assume a level of understanding of motorcycle repair and maintenance beyond that of a “beginner” and/or “novice” and California Sidecar cannot be liable for an installer’s failure to understand or follow these instructions as written. Likewise, California Sidecar cannot be responsible if any of the steps are omitted or shortcuts are taken, or parts other than those supplied by California Sidecar are used. 2. “WARNINGS WARNINGS WARNINGS WARNINGS” are all printed in bold type and capitalized. They mean to use extreme care in a given step so as not to damage the part, motorcycle, and/or yourself. 3. Always Always Always Always wear safety glasses when using hand and/or power tools. 4. When working in and around the fuel system, always always always always work in a well-ventilated area, free from sparks and open flames. 5. All directional references to the “right side” and the “left side” are as you were seated on the motorcycle. 6. All directional references to “forward” mean to the front of the motorcycle while “back” means the rear of the motorcycle unless otherwise stated. 7. Warning: Warning: Warning: Warning: The fork spring cap is under spring pressure; use care when removing it. Specifications: Specifications: Specifications: Specifications: 1. Torque bearing adjustment nut to 30 Ft-Lbs. 2. Finger tighten bearing adjustment jam nut. 3. Torque steering stem nut to 80 Ft-Lbs. 4. Grease for bearings; Multi-Purpose grease.
3 Special tools: Special tools: Special tools: Special tools: 1. Bearing adjustment nut socket. 2. Honda Bearing Installation/Removal tool 3. (refer to p. 13 – 41 in Honda Service Manual)

1984-1999 Harley-Davidson Evolution Engines Replacement Cylinder Heads Installation Instructions

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Filed Under (Harley Davidson) by admin on 28-10-2010

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Installation of an S&S Super Stock cylinder head kit is easy and can be performed by any Harley-Davidson®repair shop equipped to do engine overhauls. No special tools other than those used in normal overhaul repair work are required. Read instructions thoroughly before starting work. When they are completely understood proceed with installation. 1. Remove Components and Inspect Parts Follow procedures outlined in appropriate Harley-Davidson® service manual to prepare motorcycle for top end service. NOTE: Disconnect batteryand drain all gasoline from gas tanks beforedoing any work. Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks. A. Remove gas tanks and all other parts required to perform top end service. B. Remove carburetor, rocker covers, pushrods and pushrod tube assemblies, cylinder heads and cylinders. Also remove piston rings from piston. Do not remove pistons. NOTE: Be careful not to introduce any dirt or other foreign material into crankcase during disassembly of engine. Metal filings, dirtand any other foreign contamination in engine may cause premature wear and/or irreversible damage to bearings and other internal engine components. C. Thoroughly clean and inspect all parts that are to be reused. Any parts that show signs of wear or damage should be replaced. WARNING CAUTION 2. Check Piston Alignment in Cylinder Bore The purpose of this procedure is to check for and correct possible piston misalignment in the cylinder bore. During normal manufacturing, engine components such as crankcases, cylinders, and connecting rods can be machined to dimensions within factory specifications but on the extreme ends of the tolerance range. Sometimes these components when combined together form an assembly that is borderline or actually “out of print”. The worst result isthat the pistons can run cocked in the cylinder bores causing the connecting rods to thrust to the sides exerting unnecessary stress on the pistons, rings, rod bearings and other related parts. This procedure is not the same as blue printing, but it provides almost the same result. We feel that not enough emphasis is given to checking the piston alignment in the cylinder bore.

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