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PRO-CYCLE AND PRO-CYCLE XLT 1,000-Lbs. Capacity Motorcycle Lift

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Filed Under (Tips and Review) by admin on 27-11-2010

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1. Always inspect the lift for freight damage and make note of any damage on the bill of lading. 2. In case of freight damage, call the truck line immediately and report the damage as a freight claim. Final Set-Up for model Pro-Cycle This lift is more than 90% factory pre-assembled. The following steps will guide you through the final set-up. IT WOULD BE EASIER FOR TWO MEN TO COMPLETE FOLLOWING STEPS. 1. Unpack the lift from the shipping skid. With the lift table up side down, connect the air hose to the air cylinder (Part # 26). 2. After tightening the hose to the cylinder, flip the lift over with the table surface up. 5 3. Lift up the table manually to the first lock position to make sure the lift is rising freely. Lubricateing the joints again before use will ensure a better performance of the lift. 4. Connect the other end of the air hose to the foot-operated valve. Then connect the foot- operated valve to 100 PSI air supply. DO NOT USE AIR SUPPLY WITH PRESSURE MORE THAN 100 PSI. 5. Release the safety bar by pushing the handle down. Operate the foot valve by stepping on the footpad forward to raise the lift. The safety bar should engage the ladder automatically while lift is rising. Step on the footpad again to set the pad in middle position to stop the lift when it reaches the desired height. ALWAYS LOWER LIFT IN THE NEAREST LOCKED POSITION BEFORE BEGINNING WORK. NEVER USE THE LIFT UNLESS YOU ARE IN A LOCKED POSITION. The lift should never be left unattended while attached to air pressure. Disconnect the air pressure when lift is not attended by qualified persons. 6. Install the vise using bolts and nuts supplied with the lift (part # 6 to 12). See fig #1. 7. Install the approach ramp by dropping it into the holes punched on the rear edge of the table. The final Set-Up for the Pro-Cycle model is complete

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S&S Connecting Rods Installation Instructions

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Filed Under (S&S) by admin on 29-10-2010

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1. Female rod crankpin end to mainshaft nuts – .030″ minimum clearance recommended. A. Install sprocket shaft and crankpin in driveside flywheel. Snug nuts only. Do not torque to final specs. B. Slide connecting rods and bearings over crankpin. C. Rotate rods on crankpin, and observe clearance between rod and sprocket shaft nut. D. If additional clearance is needed, remove material from sprocket shaft nut. Do not remove material from connecting rod. E. Repeat procedure for camside flywheel and pinion shaft. 2. Female rod crankpin end to inner flywheel rim – .060″ clearance recommended. A. While checking female rod to mainshaft clearance, observe clearance between crankpin end of female rod and rim of both flywheels. B. If additional clearance is required, remove material from flywheel at point of contact. Do not remove material from connecting rod. 3. Wristpin end of both female and male rods to flywheel edge -.060″ minimum clearance recommended. A. While checking female rod to mainshaft clearance, observe clearance between wristpin end of both rods and rim of both flywheels. B. If additional clearance is required, remove material from flywheel at point of contact. Do not remove material from connecting rod. 4. Wristpin end to crankcase and cylinder – .060″ is recommended in these areas. A. With the camside flywheel and rods mocked up, install the assembly in the right crankcase half with pistons (less rings) and cylinders in place. B. Rotate flywheel through one full revolution and check for rod to crankcase and cylinder spigot contact on both the front and rear of each cylinder. C. File or grind crankcase or cylinder spigot as needed to achieve .060″ clearance. Do not remove morematerial than needed. D. Repeat for left crankcase half. NOTE: Whenever clearancing is performed in any of these areas, do not remove any material from the connecting rods as clearancing on the rods may unnecessarily weaken them. Make adjustments to the point of contact on the mainshaft nut, flywheel rim, crankcase, cylinder spigot, etc. Connecting rods weakened by clearancing may fail causing serious engine damage.

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HERO HONDA CD-100 / SS100 / SLEEK / SPLENDOR / PASSION

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Filed Under (Honda) by admin on 14-11-2011

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1500 91255-169-003 30-42-11 FRONT FORK SEAL (S/S) (SLEEK) Improved Quality 200 20 PCS
1500A ————— SET OF 2 PCS FRONT FORK DUST SEAL (S/S) 100 10 PCS 1501 90756-198-000 7-37-7.5 FRONT FORK TRIPLE (COLLER) (CD-100) 200 20 PCS 1502 91202-302-01013.8-24-5 KICK SHAFT 200m20 PCS 1502A 91202-302-010m13.8-24-5+1514 KICK SEAL(SPL.GRADE O.E TYPE) MATERIAL WITH PUCH ROD RUBBER 100 10 PCS 1503 91205-350-000 6-25-6 CLUTCH 200 20 PCS 1504 91202-GK4-722 18.9-30-5 MAGNET
200

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Harley-Davidson Evolution Engines, Hydraulic Lifter Limited Travel Kit Installation Manual

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Filed Under (Harley Davidson) by admin on 23-10-2010

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Remove tappet assemblies from engine being sure that each one is kept with it’soriginal tappet block. NOTE: This procedure is the preferred method of installation. However, kit can be installed without removing lifters from engine. 2. Remove hydraulic piston retaining wire clip from one assembly at a time. Be careful not to bend wire clip during disassembly. 3. Completely disassemble tappet removing all parts. 4. Thoroughly clean all parts including tappet body. Remove any oil which might prevent hydraulic unit from fully collapsing during adjustment. 5. Insert one spacer from S&S HL 2 Tkit in tappet body. 6. Reassemble tappet in reverse order making sure original parts arereturned to their original positions. See Picture1. 7. Replace wire retaining clip in tappet body. 8. Put tappet back in original tappet block. 9. Repeat Steps 2 through 8 for three remaining tappets. 10. Reassemble engine with modified tappets. 11. Adjust pushrods. NOTE – In all cases engine must be cold and lifter must be at lowest point of travel for pushrod adjustment To prevent accidents, remove ground cable from battery. A. Remove spark plugs. B. Bring piston to TDC on compression stroke in cylinder to be adjusted. Normally both tappets will be at their lowest point of travel. C. Extend pushrod adjustment, collapsing lifter until piston assembly is in contact with HL 2 Tspacer and pushrod is tight. If tappets contain oil, as when pushrods are readjusted after engine has been run, or if all oil was not removed during installation, extend pushrod adjustment until valve is open (about five additional turns of adjusting screw). Allow 5 minutes for hydraulic unit to bleed down. If pushrod can be turned with fingers after bleeding down, lifter is not completely collapsed, and this step must be repeated. NOTE – perform this operation on one cylinder at a time. Do not turn engine until pushrod adjustment is complete. Turning engine while valve is held off the seat could result in valve to valve or valve to piston contact and serious valve train damage. D. Loosen pushrod adjustment until pushrod can be rotated with the fingers with slight drag. NOTE – Shortening adjuster an additional six flats or full turn from zero lash often results in quieter pushrod operation. This provides additional travel for the hydraulic piston assembly, which can improve the ability of the hydraulic unit to maintain zerolash under normal operating conditions. E. Tighten lock nut. F. Follow the same procedure for all four push rods. G. Recheck pushrod adjustment after a few hundred miles. NOTES ● It is a good idea to recheck pushrod adjustment in a new engine as valve train may tighten up due to gasket compression and valve seat wear. ● Upon initial start up after modification, HL 2 Tequipped lifters may be somewhat noisy for 10-20 miles. If lifters are still noisy after 20 miles it is recommended that pushrods be adjusted 1⁄2 turnlooser. See step D

YAMAHA PRO-R AIR CLEANER REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 07-01-2012

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STEP 1 Remove the seat, fuel tank, and OEM air cleaner assembly. Disconnect the hoses connected to the air cleaner while leaving them connected to the motorcycle. Save the clamp that secures the air duct to the carburetor and the OEM fasteners used to secure the stock air cleaner assembly to the motorcycle as some will be reused. STEP 2 Remove the carburetor according to the section in your Road Star factory service manual that outlines procedures for carburetor removal, disassembly, reassembly and installation. Now is a good time to proceed with re-jetting the carburetor. We have supplied jets to cover many common configurations. For jet locations and jetting recommendations with various exhaust combinations see Addendum I. Since the OEM screws retaining the float bowl are easily damaged, we have included replacement M4 socket head cap screws to replace them, if necessary. STEP 3 Insert the rubber intake duct into the main support bracket as shown in PIC. 1. The rubber nipple should be pointing toward the longest leg of the bracket. STEP 4 Insert the rubber intake duct into the Pro R-series Hypercharger in the same fashion it was installed in the main support bracket. See PIC.2. You may need to use a screwdriver to help “poke” the flange of the Rubber Intake Boot into position inside the Pro R-series Hypercharger. STEP 5 Line up the three holes in the back plate of the Pro R-series Hypercharger and the three holes in the flange of the rubber intake duct with the three holes in the main support bracket. Insert the three supplied 1/4″-20 x 5/8″ socket head cap screws from inside the Pro R-series Hypercharger and secure on the back side of the main support bracket with the 1/4″-20 thin nylock nuts. You will need to pull back the inner flange of the rubber intake duct to access the holes. Hold the nylock nuts with a 7/16″ wrench as you tighten the socket head cap screws with a 3/16″ hex key. Be careful not to over tighten and cause the rubber intake duct to pucker around the nylock nuts. See PIC.3.

Lilac LS-18 Motorcycle Maintenance Standards

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

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

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HARLEY-DAVIDSON FLH/ FLT MODELS 1985-1996 REAR LOWERING KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-03-2012

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may encounter clearance problems when re-installing the saddlebags. Check for a minimum of 5mm. clearance to prevent damage to the saddlebags. Measure clearance in the recessed area in the “backside” of the saddlebags where the shock sits. Check front, back and side clearance. THE BAGS MUST INSTALL WITHOUT UNDO FORCE. If they don’t, they are hitting the shock and/or shock boot. ****************** Inspect the clearance through the full range of motion of the swing arm ******************* n If more clearance is required, three suggested options are as follows: 1. Place washers between the mounting points where the saddlebags attach to the rails. This will move the bag slightly outward and away from the shock body. NOTE: On saddlebags utilizing DZUS FASTENERS (’85-’92), replace these with bolt/nut combination (as on ’93-’94 years). This will allow you to use washers to gain necessary clearance. 2. Remove or slide off the rubber boot that covers the shock shaft and attaches the body of the shock. The boot can be modified and reattached to the shaft (not the body) and secured with nylon ties and/or removed completely. This should gain you a minimum of 3mm of clearance. 3. Slot and/or space the saddlebag “rail/frame cage” mounting holes to allow the entire frame assembly to be moved out slightly from the shock body. You should use this modification only as a last resort n Lower motorcycle and check preload (shock spring stiffness). Adjustment may be necessary to suit personal preference in ride comfort. Read your Harley-Davidson owners manual for procedure. Test Ride.

YAMAHA YZ250F ALUMINUM PRO SYSTEM INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 20-12-2010

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REMOVING YOUR STOCK SYSTEM 1. Place the machine on a stable work stand. 2. If you are not familiar with removing the original exhaust refer to the owner’s manual before you start work. 3. Always allow your machine to cool down before attempting to remove the exhaust. 4. Remove the two bolts from the right side panel. Then remove the side panel. 5. Loosen the stock mid-pipe clamp, then remove the stand-off bolt and bracket bolt that supports the muffl er. 6. Remove stock muffl er and clamp from the stock head pipe. 7. Remove the stock head pipe at the cylinder head. NOTE: It may be necessary to use a penetrating lubricant on the fl ange nuts. INSTALLING THE NEW ALUMINUM PRO SYSTEM 1. Install Aluminum Pro head pipe onto cylinder head using stock nuts. Leave these fi nger tight for now. 2. Slide mid-pipe onto head pipe. Rotate the mid-pipe slightly to obtain proper alignment with sub-frame mount. 3. Install the OEM bolt through sub-frame into the stand-off mount on mid- pipe (Finger tight). 4. Slide the muffl er onto mid-pipe, align muffl er mount with the stock muffl er mount hole, and install and fi nger tighten the supplied M8x25mm bolt. 5. Once you have the system fully aligned, tighten all the bolts securely to factory specifi cations. NOTE: We recommend starting at the cylinder head and working backwards. 6. Replace the side panel and secure the mounting bolts. BEFORE YOU BEGIN MORE

Harley Davidson 6- SPEED CONVERSION KIT FOR BIG TWIN 5- SPEED TRANSMISSIONS INSTALLATION

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Filed Under (Harley Davidson) by admin on 05-03-2012

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5/16 Bolt hole boss clearance This can easily be checked with the trap door gasket. Put the gasket on the dowel pins. AII material of the boss around the hole that “sticks outside” the gasket (60 degrees forward to 60 degree backwards) must be removed (see figure A). Primary fork clearance Place the gasket on the housing and remove material as indicated for clearing the shifter fork (see figure B). WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® INSTALLATION INSTRUCTIONS FOR 6 SPEED CONVERSION KIT AND 6 SPEED BUILDER KIT speed transmission. Also make sure you have a 1990 or later Factory Service Manual available. Tools The conversion kit should only be used in new or low milage transmissions. If gears or bearings of a used Gear set Removal Refer to the Factory Service Manual Section for Mainshaft and Countershaft removal. When you get to the point of actually sliding the gear set out make sure you properly mark the 5th gear set as described in the Factory Service Manual (for used transmissions only). Further follow the factory removal procedure. Clearance Checks The 6 Speed conversion and builder kit will fit in most OEM or aftermarket transmission housings without may be needed. The following clearances must be checked before assembling the 6 speed transmission. 28-05-2008 We recommend the kits are installed by a qualified mechanic with knowledge of the Harley-Davidson 5 needed are the same as used for a 5 Speed transmission. 5 speed transmission are worn, new ones must be installed, or better, the builder kit should be used. any modification of the housing. However due to casting differences, in some instances some modification
WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® Pillow block clearance (right side) Make sure there is clearance between the pillow block and the housing. Any clearance is O.K. (see figure C). Fork shaft support clearance Again use the gasket as the template and remove the material as indicated (see figure D). Shift drum end play The end play of the shift drum must be checked prior to final installation. Install the shift drum. Measure the end play with feeler gauges at the right pillow block (see figure E). End play should be between .004″ and .010″, some 1/2″ X 7/8″ 0.008″ thick shims are included to adjust the end play

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2000 Celica GTS REPAIR MANUAL CORRECTION: VALVE CLEARANCE ADJUSTMENT

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Filed Under (Toyota Manuals) by admin on 07-06-2011

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Repair Manual corrections have been made to the Valve Clearance Adjustment procedures for the 2000 model year Celica GTS with the 2ZZ–GE engine to allow effective use of the Special Service Tool. For more information on replacement of the SST Swing Arm refer to TSB SS002–00, Valve Clearance Adjusting compressor Swing Arm Retrofit – ’00 Celica GTS

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