KTM Front Wheel Bearing Installation Manuals

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

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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.

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KTM Rear Wheel Bearing Installation and REMOVAL

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Filed Under (KTM) by admin on 23-01-2012

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1 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). 2 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. 3 Use a long screwdriver or narrow pry bar and pry the seals out of each side of the wheel (Fig. 3). 4 Using snap ring pliers, remove the bearing retaining snap ring from either the disc or sprocket side of the wheel (Fig. 4). 5 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. 6 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 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)

HARLEY DAVIDSON DYNA GLIDE ADJUSTABLE HIGHWAY PEG MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 04-04-2011

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Installation 1. See Figure 1. Install setscrew (14) into lower hole on frame tube boss (2) leaving .20 in. of setscrew (or three threads) exposed. 2. Place highway peg mounting plate (1) into position. For a lower peg position, place bottom hidden hole in mounting plate over setscrew. For a higher peg position place upper hidden hole in mounting plate over setscrew. Attach mounting plate to frame tube boss using 1 in. long screw (3), lockwasher (4), and flat washer (5) from kit. Tighten screws to 33 ft-lbs. 3. Install footrest support (6) onto highway peg support plate using hex nut (7), lockwasher (8) and flat washer (9) from kit. Tighten nut (7) to 47 ft-lbs. 4. Locate spring washer (10) from kit. While holding spring washer in position on inside of footrest support (with square edge towards motorcycle), position footpeg (not included with this mounting kit) between footrest support mounting tabs, as shown. 5. Insert 1-1/2 in. long screw (12) from kit through footrest support mounting tabs, footpeg, and spring washer. Secure using locknut (13) from kit. 6. Repeat these steps for the other side of vehicle. 1 WARNING These footrest pegs must fold upward and toward the rear at about a 45°angle when retracted. If they do not, peg could contact ground while motorcycle is in a turn, causing loss of control or startling the rider, resulting in possible personal injury. If pegs do not fold up and back at a 45°angle, remove pegs and turn them over so the flat surface is facing forward.

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HARLEY DAVIDSON HEEL RAISER FOOTPEG KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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INSTALLATION 1. Remove the locknuts and screws that hold the existing footpegs in place. If the motorcycle is equipped with a pin and retaining ring, remove them and retain for future use. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs and the spring washers. Save the spring washers for installation. NOTE See Figure 1. When performing the next step, verify that the spring washer is positioned inside of the footpeg support with the square edge (2) towards the inside of the support. 1 3 2 is02094 1. Spring washer 2. Spring washer square edge 3. Footpeg support slot Figure 1. Footpeg Spring Washer Installation 3. See Figure 1. Install the new footpegs in the same manner as the old footpegs were installed. Insert a spring washer (1) and the mount end of the footpeg inside the slots (3) of the footpeg supports. 4. Secure each footpeg and spring washer to the footpeg support with the screw and locknuts or pin and retaining rings removed earlier. Tighten the locknuts to 19 ft-lb (26 Nm) . Footrests must fold up and toward rear of motorcycle if struck. Failure to set footrests to fold up and back could result in death or serious injury. (00366a) Position footpegs so rider can operate foot controls without interference. Failure to have full access to foot controls can cause loss of control, which could result in death or serious injury. (00313a)

HARLEY DAVIDSON SLOTTED CUSTOM FOOTPEG INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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INSTALLATION 1. See Figure 1. Remove locknuts (1) and screws (2) that hold existing footpegs in place. Save hardware for installation of new footpegs. 2. Remove existing footpegs along with spring washers (3). Save spring washers for installation of new footpegs. 3. Install new footpegs in the same manner as old footpegs were installed: •Place a spring washer (3), along with the mount end of the footpeg, inside the slots of the footpeg supports (4). •Make sure the spring washer is positioned inside the footpeg support with the square edge toward the inside of the support. •Secure each footpeg and spring washer with a screw (2) and locknut (1). •Tighten locknuts to 19 ft-lbs (26 Nm) . Footrests must fold up and toward rear of motorcycle if struck. Failure to set footrests to fold up and back could result in death or serious injury. (00366a) 4. For each footpeg, remove the screw (5) and rubber pad (6). Loosen the adjusting screw (7) until the footpeg (8) rotates. Position the footpeg (8) as desired, then tighten the adjusting screw to 19 ft-lbs (26 Nm) . Place the rubber pad (6) on the footpeg and tighten the screw (5)

HARLEY DAVIDSON ENGINE-GUARD FOOTPEG BILLET MOUNTING KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1. See Figure 1. Position a footpeg mount (3) and clamp (1) on the engine guard. Position the footpeg mount (3) to allow the footpegs to fasten on the inboard side of the engine guard. 2. Apply LOCTITE® 243 (blue) to two screws (4). 3. Use the screws from Step 2 to fasten the footpeg mount in a comfortable location on the engine guard. Tighten screws to 14 ft-lbs (19 Nm) . 4. Install a footpeg, sold separately, using the spring washer (2), and bolt and locknut (from kit 94133-01). Position the spring washer inside the footpeg mount with the square edge toward the inside of the mount. Tighten locknut to 19 ft-lbs (26 Nm) . 5. Repeat Steps 1-4 on the other side of the motorcycle. SERVICE PARTS

HARLEY DAVIDSON ADJUSTABLE MALE-MOUNT FOOTPEGS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. Remove the locknuts and screws that hold the existing footpegs in place. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs along with the spring washers. Save the spring washers for later installation. 3. Install the new footpegs in the same manner as the old footpegs were installed. Place a spring washer, along with the mount end of the footpeg, inside the slots of the footpeg supports. Make sure the spring washer is positioned inside the footpeg support with the square edge towards the inside of support as shown at the bottom of Figure 1. 4. Secure each footpeg and spring washer with the screw and locknut removed earlier. Tighten the locknuts to 19 ft-lbs (26 Nm) . 5. For each footpeg, loosen the adjusting screw in the recessed hole until the footpeg rotates. Position the footpeg as desired, then tighten the adjusting screw as follows: For Kits 50133-95, 50134-95 or 50500-03: Tighten to 21 ft-lbs (29 Nm) . For Kit 50474-03: Tighten to 14-16 ft-lbs (19-22 Nm)

HARLEY DAVIDSON BILLET NARROW BAND FOOTPEG KIT INSTALLATION MANUAL

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

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INSTALLATION 1. Remove the locknuts and screws that hold the existing footpegs in place. If your model motorcycle is equipped with a pin and retaining ring, remove them and retain for future use. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs along with the spring washers. Save the spring washers for later installation. NOTE See Figure 1. When performing the next step, ensure that the spring washer is positioned inside of the footpeg support with the square edge (2) towards the inside of the support. 3. See Figure 1. Install the new footpegs in the same manner as the old footpegs were installed. Place a spring washer (1), along with the mount end of the footpeg, inside the slots (3) of the footpeg supports. 4. Secure each footpeg and spring washer with the screw and locknut or pin and retaining ring removed earlier. Tighten the locknuts to 19 ft-lbs (26 Nm)

HARLEY DAVIDSON CUSTOM FOOTPEG KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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INSTALLATION The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE A Service manual for your motorcycle is available at your Harley-Davidson Dealer. 1. See Figure 1. The footpeg shown in Figure 1 is different from the footpeg in the kit, however the installation is identical. Remove the locknuts and screws that hold the existing footpegs in place. Save all hardware for installation of the new footpegs. 2. Remove the existing footpegs along with the spring washers. Save the spring washers for later installation. NOTE When performing Step 3, make sure the spring washer is position inside the footpeg support with the square edge toward the inside of the support as shown in Figure 2. 3. Install the new footpegs in the same manner as the old footpegs were installed. Place a spring washer, along with the mount end of the footpeg, inside the slots of the footpeg supports. 4. Secure each footpeg and spring washer with the screw and locknut removed earlier. Tighten the locknuts to 19 ft-lbs (26 Nm) . Footrests must fold up and toward rear of motorcycle if struck. Failure to set footrests to fold up and back could result in death or serious injury. (00366a) 5. For each footpeg, loosen the adjusting screw in the recessed hole until the footpeg rotates. Position the footpeg as desired, then tighten the adjusting screw to 21 ft-lbs (29 Nm)

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STROKE DOWNHILL MOUNTAIN BIKE SHOCK SPECIFICATIONS

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Filed Under (Tips and Review) by admin on 01-12-2010

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The shock has an adjustable rebound and standard Hi/low compression. The optional independent hi/ low compression adjuster has a low speed brass screw and a seperate blue high speed hex. The rebound adjuster is at the bottom of the shock. The standard setting is 8 clicks out (counter clockwise) from full hard. To increase rebound damping turn the adjuster in (clockwise), this will slow the extension of the shock. To decrease rebound damping turn the adjuster out (counter clockwise) this will quicken the extension of the shock. The standard compression adjuster has a the slotted brass screw on the reservoir. The standard setting is 12 clicks out low/hi speed brass screw(counter clockwise) and 1.75 turns out on the blue hex high speed adjuster from full hard. To increase compression damping turn the adjuster in (clockwise) – this will stiffen the compression of the shock. The low speed compression adjuster will soften small bumps and improve traction. The optional high speed adjuster will firm up the damping for big hits with no loss in small bump compliance, firmer settings will improve pedaling as well, lighter settings will smooth out square edge hits. Spring preload can also be changed to tune the shock to the weight of the rider. The shock spring preload can be varied by tightening or loosening the preload collars. The standard preload is 1.5 turns, (min 1 turn / max 3 turns). The rider sag must be adjusted to 1/3 of the total stroke with the rider sitting on the bike. This is the difference from fully extended position to the rider sitting. The ride height can be raised or lowered ± 5 mm to quicken or slow steering within the range of preload settings

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