baja 90cc torque spec

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2008 FLT Police Models Service Manual Supplement

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Filed Under (Harley Davidson) by admin on 25-11-2010

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ITEM SERVICED 14-21 ft-lbs (19.0-28.5 Nm) Drain plug torque Engine oil and filter 4 qt. (3.8 L) Oil capacity Hand tighten 1/2-3/4 turn after gasket contact Filter 63798-99A Chrome filter part number 63731-99A Black filter part number FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity Primary chain lubricant Wet: 38 oz. (1124 ml) Dry: 45 oz. (1331 ml) 14-21 ft-lbs (19.0-28.5 Nm) Primary chaincase drain plug torque 1/2-1 turn Adjuster screw free play Clutch adjustment 72-120 in-lbs (8.1-13.6 Nm) Adjuster screw locknut torque 1/16-1/8 in. (1.6-3.2 mm) Free play at hand lever 84-108 in-lbs (9.5-12.2 Nm) Clutch inspection cover torque Dipstick at FULL with motorcycle on jiffy stand and filler plug resting on threads. Lubricant level Transmission lubricant FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity 32 oz (0.95 liters) 14-21 ft-lbs (19.0-28.5 Nm) Transmission drain plug torque 25-75 in-lbs (2.8-8.5 Nm) Transmission filler plug/dipstick torque Front: 36 psi (248 kPA) Pressure: solo rider Tire pressure and wear Rear: 36-40 psi (248-276 kPA) Replace if less than 1/32 in. (0.8 mm) of tread pattern Wear 55 in-lbs (6.2 Nm) minimum Spoke nipple torque Wheel spokes 99953-99A (12 oz.) D.O.T. 4 hydraulic brake fluid part number Brake fluid level Front: 0.20 in. (5.0 mm) Fluid level (from top of master cylinder reservoir) Rear: 0.26 in. (6.5 mm) Front: 7-10 in-lbs (0.8-1.1 Nm) Master cylinder reservoir cover screw torque Rear: 12-15 in-lbs (1.4-1.7 Nm) 0.016 in. (0.4 mm) Minimum brake pad thickness Brake pads and discs 75-102 in-lbs (8.5.-11.5 Nm) Brake caliper pad pin torque Front: 0.18 in. (4.5 mm) Minimum brake disc thickness Rear: 0.25 in. (6.3 mm) 0.008 in. (0.2 mm) Maximum brake disc lateral runout (warpage) 10 lb. (4.5 kg) Upward force applied at midpoint of bottom belt strand Drive belt deflection 3/8-7/16 in. (9.5-11.1 mm) FLHTP 1/4-5/16 in. (6.4-7.9 mm) FLHP/FLHPE 40-60 in-lbs (4.5-6.8 Nm) Air cleaner cover bracket screw torque Air cleaner 36-60 in-lbs (4.1-6.8 Nm) Air cleaner cover screw torque LOCTITE MEDIUM STRENGTH THREADLOCKER 243 (BLUE) Air cleaner cover screw Threadlocker Part No. 99642-97 (6 ml) LUBIT-8 SUPER OIL, Part No. 94968-85TV (1/4 fl. oz.) Lubricant part number Clutch cable 35-45 in-lbs (4.0-5.1 Nm) Handlebar switch housing screw torque

HARLEY DAVIDSON XLH 1200cc BIG BORE KIT INSTALLATION MANUAL

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

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Boring and Honing Procedures 1. Check again for burrs on cylinder gasket surfaces and remove burrs before performing Step 2. 2. Install original head and base gaskets, CYLINDER TORQUE PLATES (Part Number 33446-A) and TORQUE BOLTS (Part Number 33446-4). Tighten TORQUE BOLTS following tightening procedure given in the INSTALLATION, CYLINDER HEAD procedure in the ENGINE section of the Service Manual. NOTE Torque plates, properly tightened and installed with gaskets, simulate engine operating conditions. Measurements will vary as much as 0.001 inch without torque plate. 3. The cylinder must be bored with gaskets and torque plates attached. Bore the cylinder to 0.003 inch under the desired finish size. 1 WARNING CAUTION CAUTION 1 WARNING Kit Number 4. Hone the cylinder to its finished size (See Figure 1) using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Honing must be done with torque plates attached. All honing must be done from the bottom (crankcase) end of the cylinder. Work for a 60 degree crosshatch pattern. 5. See Figure 1. After machining and honing, chamfer the bottom edge of the cylinder liner. the chamfer provides a beveled surface for easier installation of the cylinder over the piston rings. Break leading edge of liner to a flat surface. The bottom edge of the liner will be somewhat sharp after machining. This sharp edge could easily be damaged during installation of the cylinder. Piston Installation The 1200cc pistons have an arrow on the top of the piston. This arrow must face the front of the engine when piston is installed. There is no front cylinder piston or rear cylinder piston. New pistons can be installed in either cylinder. Check piston rings for proper side clearance and end gap (See XLH Service Manual). Be sure end gaps of adjacent rings are installed 90 degrees apart. Assembly Follow assembly and torque specifications given in the ENGINE section of the applicable Service Manual. Replace original gaskets, O-rings and seals with new components furnished in kit. NOTE Push rod covers on 1991 and later models are one-piece and the correct O-rings are as follows: Bottom – Part Number 17944-89 Upper – Part Number 11190 Engine Break In For the first 500 miles, to wear-in critical parts, observe these few simple driving rules: During the first 50 miles, keep the engine speed below 2500 RPM in any gear. Up to 500 miles, vary the engine speed, avoiding any steady speed for long distances. Engine speed up to 3000 RPM is permissible in any gear. Avoid fast starts at wide open throttle. Drive slowly until engine warms up. Avoid running the engine at extremely low RPM in higher gears. 2 of 3 -J00001 1200cc CYLINDER FINAL BORE SIZE AFTER HONING STANDARD BORE DIAMETER 3.4980 inch + 0.0002 inch Figure 1. Bottom Edge of Cylinder Liner Chamfer i04852 Break Edge to Flat Surface

YAMAHA YZF-R1P YZF-R1PC ASSEMBLY MANUAL

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Filed Under (Yamaha) by admin on 26-02-2011

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PREPARATION To assemble the motorcycle correctly, supplies and working space are required. Supplies oils, greases, shop rags. Workshop The workshop where the motorcycle is assembled should be clean and large. The floor should be level. Self-protection Protect your eyes with suitable safety spectacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Product hands and feet by wearing safety gloves or doing. SYMBOLS USED ON CRATE CARTON Contents of the transport package are fragile therefore it shall be handled with care. Indicates correct upright position of the transport package. Transport package shall be kept away from rain. Insertion of the lift arm from this side is prohibited. Lift arm inserting position. -1- UNPACKING 1. Remove the frame cover 1. NOTE: To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the bolts 2 (upper bracket). 3. Remove the bolt 3 (front tire). 4. Remove the packing frames 4 (upward and sideways). NOTE: Remove the bolts while holding frame. NOTE: Before starting the assembly, check for damaged or missing parts. The parts are contained in the cartan and the motorcycle for damage, scratches and other defects. -2- PARTS LOCATION 1 Carton box -3- 1 Carton box Screw, washer and special nuts (windscreen) Bolt (front master cylinder) Bolt (handle crown and handlebar) Nut (rear view mirror) Nut (front reflector) Front reflector Vinyl bag 1 Plugs (handle crown) Owner’s manual Rear view mirrors Windscreen – -5- 1. Handlebar 1 2 3 4 5 6 1 1 1 1 2 1 Reservoir tank (brake) Hexagon socket bolt Crown nut Hexagon socket bolt Cap Hexagon socket bolt * V * V V * d = 6 (0.24), r= 12 (0.47) d = 6 (0.24), r= 25 (0.98) d = 8 (0.31), r= 30 (1.18) 2. Front reflector A: Tighten the crown nut to specified torque. Tightening torque: 115 Nm (11.5 m • kg, 85.0 ft • lb) B: Tighten the bolt to specified torque. Tightening torque: 13 Nm (1.3 m • kg, 9.4 ft • lb) C: Tighten the bolt to specified torque. Tightening torque: 13 Nm (1.3 m • kg, 4.4 ft • lb) A: Tighten the screws to specified torque. Tightening torque: 40 Nm (4.0 m • kg, 29 ft • lb) 1 2 3 4 5 2 2 2 4 4 Reflector bracket Reflector Nut Washer Caliper bolt * V V * * d = 5 (0.20) d = 10 (0.39) d = 10 (0.39), r= 30 (1.18) 3. Clutch cable 1 Clutch cable 1 * A: Check the clutch lever for smooth action. CAUTION: Proper cable routing is essential to assure safe motorcycle operation. Refer to “CABLE ROUTING

Harley Davidson 2004-Up Sportster EZ-Steer Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Installation Notes • Remove front fender, wheel, brake caliper, and fork tubes. • Remove all components attached to stock triple clamps, then the triple clamps themselves. • Remove upper and lower bearings including race. • Install new steering stem bearing races into neck. • Install new upper steering stem bearing with seal into neck. • Install Top and Bottom triple clamps into neck and snug steering stem bolt with washer. • Remove fork tube cap from both forks. • Install fork extensions with o-ring into fork tubes and tighten until fully seated. • Install fork tube caps with o-rings and tighten (see torque table). • Slide fork tubes into triple clamps until the top of each tube cap extends 0.42-0.50 in. above top surface of upper triple clamp. • Tighten 3/8-16 x 1.5″ bolts on upper triple clamp (see torque table). • Tighten steering stem bolt (see torque table). • Tighten pinch bolts on lower triple clamp (see torque table). • Install front wheel assembly and front brake caliper. • Install front fender. Item # Part Description Torque Spec (Lb. Ft.) – Fork Tube Cap 22-58 8 Bolt, Steering Stem, SP 30-35 11 3/8 – 16 X 1.5″ Socket Head Cap Screw 30-35 EZ-Steer Maintenance The bearings in your EZ-Steer rake kit are normal wear items, not subject to replacement under Champion’s one year Limited Warranty for the product. Failure to follow your motorcycle manufacturer’s recommendations for periodic OEM triple-tree maintenance will accelerate the wear on these bearings. Checking/adjustment of the steering stem nut torque with the front end lifted, in accordance with your motorcycle manufacturer’s recommendations, is important to reliable bearing service. Windshield Notes Please note that this EZ-Steer kit accommodates all known windshield types with the exception of a minor modification to Quick Release Compact Windshield, example part no. 58063-04. You will need to oblong the lower bolt holes as shown in figure

2006 DUCATI 996 HORSEPOWER & TORQUE BAR GRAPH installation

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Filed Under (Ducati) by admin on 26-10-2010

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BLUE BEFORE MTECH RED AFTER INSTALLATION OF MTECH MAXIMUM HORSEPOWER INCREASED FROM 106.7 TO 109.2 TORQUE CURVE SHOWS AN INCREASE EVEN THIS HIGHLY SOPHISTICATED ENGINE’S HORSEPOWER IMPROVED WITH THE MTECH FUEL SAVER TORQUE CURVE IS MUCH SMOOTHER AT LOW SPEED

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