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Honda VT1100 Shadow Guide Plug Patch Repair Manual

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Filed Under (Honda) by admin on 24-04-2011

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Find the guide plug.bn The guide plug is shown in the shop manual with the engine removed from the frame and the left crankcase cover removed. (You’ll find this illustration in the “ELECTRIC STARTER/STARTER CLUTCH” chapter in the “STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL” section.) It’s a little bit harder to find it on the bike. Start by following the yardstick to see where the guide plug is on my bike. To find it on your bike, lie on the ground (or, preferably a mechanics creeper) next to the bike (without the yardstick) and peek under the shift lever and over the frame There it is, just barely visible from the side of the bike. Here’s what a new one looks like: 2. Clean the guide plug and crankcase. From the front of the bike, clean the guide plug and crankcase with brake cleaner in a VERY focused spray. Let the cleaner evaporate before moving to the next step. Page 4 Rev: Draft 5/20/2007 Page 4 of 5 3. Reposition the guide plug. a. From the side of the bike, use the yardstick (or a long screwdriver if you prefer) to gently push the guide plug back into the crankcase. (Note the JB Weld from the previous patch operation.) b. From the front of the bike, gently push upward on the bottom of the upper tab (as shown below) or the bottom of the forward tab to rotate the guide plug into the proper position while maintaining pressure with the yardstick

CYLINDER HEAD REPAIR MANUAL

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Filed Under (Tips and Review) by admin on 28-10-2010

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ADJUSTABLE CYLINDER HEAD STAND Head can be rotated 360 degrees. Stays in any position using a simple locking mechanism. Use on twin or four cylinder heads. Shipping weight: 14 lbs. Adjustable length-10-1/2″ to 20-1/2″ long x 14″ width x 10-3/4″ high. 35-8602 Cylinder Head Stand VALVE GUIDE DRIVERS Use for removal and installation of valve guides into cylinder head. Available in the following sizes: 35-8418 4.5mm YM-4116 35-8416 6mm YM-4064-A 35-8417 5mm YM-4097 35-8414 7mm YM-1225-A 35-8408 5.5mm YM-1122 35-8413 8mm YM-1200 VALVE GUIDE DRIVER SET (REMOVE & REPLACE) Designed for speed and accuracy, this eleven piece set provides the right tool for the job. Driver set includes two valve guide drivers (5.5mm and 6.6mm), four valve guide installers, one cutter, three cutter pilots (5.5mm, 6.6mm, and 7.7mm) and one tap handle extension bar. 35-9445 Valve Guide Driver Set YAMAHA VALVE GUIDE INSTALLERS These installers are used for installation of Yamaha shoulder less valve guides to a specific depth into the cylinder head. To use, position onto the valve guide and drive into the cylinder head until installer makes contact with cylinder head surface. Note: Must use with Valve Guide Driver. Available in the following sizes: 35-8439 4.5mm YM-4117 35-8437 5.0mm YM-4098 35-8419 5.5mm YM-4015 35-8435 6mm YM-4065-A 35-8423 7mm YM-4017 VALVE GUIDE REAMERS Reaming valve guides after installation assures a proper valve stem to valve guide fit. Available in the following sizes: 35-3829 4.5mm YM-4118 35-3851 7mm YM-1227 35-3836 5.5mm YM-1196 35-3852 8mm YM-1211 35-3847 6mm YM-4066 CLOVER VALVE LAPPING COMPOUND KIT The world famous green can with the four leaf clover. For seating valves, mating gears, and sharpening. Sold as a kit with coarse 120 grit (roughing) and 280 fine grit (finishing). 35-0309 Clover Valve Lapping Compound VALVE LAPPING TOOL The ultimate vacuum stick for insuring perfect surfaces on valves and valve seats. Interchangeable cups make unit suitable for use with virtually any size valve. Set includes vacuum stick, 3/4″ and 1/4″ diameter rubber cups. 35-8998 Valve Lapping Too

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MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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1999 – 2005 Aprilia Falco SL 1000 Scottoiler Installation Guide

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

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Locate the vacuum – There is a rubber bung over a spigot on the inlet tract. Remove this bung and then press the Damper Elbow, part number 4, onto the spigot. For further information see our easy step installation guide – Vacuum Connectors, General . See third picture The RMV can be mounted under the seat. The more vertical the RMV the better and remember to avoid exhaust and engine components. For further information, see our easy step installation guide – RMV Positions, General. See picture bottom left The Dispenser Assembly can be routed along the Swingarm using Dispenser Mounting Sleeves & Glue and secured to the paddock stand bobbin mount using a cut down Dispenser Plate & Clip, parts 19 & 20. For further information see our easy step installation guide – Dispenser Assemblies, General . The nib should feed the rear sprocket between the 6 & 7 o’clock positions, with the cut face facing outwards. Note: Picture shows a similar Swingarm Once fitted, fill and prime the system and set the adjuster knob to ‘prime’. Start the engine and turn the adjuster knob until a flow of between 1 and 2 drops per minute is achieved. Check the condition of your chain after a ride, and then adjust as required

2000 – 2005 Celica REAR DISC BRAKE PAD INSTALLATION

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Filed Under (Toyota Manuals) by admin on 27-10-2011

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A. Install the two brake pads with the anti-squeal shims to the brake caliper. B. Install the two (2) guide pins to fix the brake pads. 2. Install spring No. 1. A. Hook the spring upper portion to guide pin No. 1. Spring No. 1 B. Hook the spring lower portion to the center hole of the brake pad. 3. Install spring No. 2. A. Hook the spring upper portion to guide pin No. 1 Secure the guide pins with the retaining clip. A. Insert the retaining clip end into the hole of guide pin No. 1. B. Insert the other clip end into the hole of guide pin No. 2. NOTE: The retaining clip should be fully inserted into guide pin No. 1 and No. 2. If NOT, the guide pins will come off and the brake caliper will be damaged

Harley-Davidson Valves, Guides And Seats Installation

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Filed Under (Harley Davidson) by admin on 31-10-2010

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1: Clean carbon from old guide O.D. before removal. 2: Guide to head press fit .0015″ / .002″ (head smaller than guide). 3: Heat head to approximately 200° – 250° F. 4: Install the guide at room temperature (Head hot & Guide at room temperature). 5: Let head cool to room temperature before final sizing of the bore. 6: Determine desired clearance valve to guide. Recommended clearance Shovel Head with cast iron guides Intake .001″ – .0015″ Exhaust .0015″ – .002″ (Ampco-45 add .001″) 7: Select the correct plug gage by adding the valve stem diameter and clearance desired for the finish diameter. 8: Select a plug gage .0005″ under finish size for the other end of the handle. 9: Finish hone the bore to size, check the size as you hone with the -.0005″ under size pin gage, finish hone to size with the finish plug gage pin. 10: Cut or Grind the seats, lap the valves to seats and check valve seat concentricity before assembling valve springs. 11: Use a good assembly lube, S’NS works great. 12: Use valve stem seals. Factory OE seals will stay tight with guide top size +.005″ to -.015″ from published size. 13: After the head is assembled and still on the bench check for any leakage valve to seat

Ducati 900ss Scottoiler Installation Guide

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Filed Under (Ducati) by admin on 25-10-2010

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Locate the vacuum – There is a vacuum point on the inlet tract, as shown below left. Remove the screw and replace with the M5 Brass Spigot from the Scottoiler kit, using some RTV Silicon Sealant on the threads to ensure an airtight seal. Then press the Damper Elbow, part number 4, onto the spigot. The Dispenser Assembly, shown bottom left, is routed along the underside of the Swingarm using Dispenser Mounting Sleeves, Cable Ties & Glue. Note: an epoxy resin (eg. Araldite) is req’d to bond the sleeves to the Swingarm. For further information see our easy step installation guide – ‘Dispenser Assemblies, General’ . The nib should feed the sprocket between the 6 & 7 o’clock positions, with the cut face facing outwards. The Dual Injector (sold separately) is shown below. The RMV can be mounted on the frame, where indicated by the arrows in the third picture. The more vertical the RMV the better and remember to avoid exhaust and engine components. For further information, see our easy step installation guide – ‘RMV Positions, General’

Toyota 1/ 2JZE Fitting Guide

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Filed Under (Toyota Manuals) by admin on 20-06-2011

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When installed correctly your VEMS ECU will provide you with long trouble-free
service. Please take time to read this guide, and pay special attention to the section
on Ground Wires. If you have any problems understanding any of the information
here, please contact your VEMS Reseller.
The information contained here should be sufficient to install and run your pre-
configured VEMS and wiring loom. It is designed to compliment the VEMS User
Guide which you should take time to read and refer to as you progress through the
installation and calibration of your VEMS

2006 RIDGELINE MOTORCYCLE WHEEL GUIDE INSTALLATION And REMOVAL

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Filed Under (Honda) by admin on 17-11-2011

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Customer Information: The information in this installation instruction is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your vehicle. These procedures
should not be attempted by “do-it-yourselfers.” NOTE: • Be careful not to damage the body finish. • Determine the location of the wheel guide. One or more wheel guides can be installed in three different locations. 1. Remove the left front upper tie-down hook (two torx bolts). Remove the right front upper tie-down hook (two torx bolts). While wearing eye protection, enlarge the eight holes to 9 mm from the outer surface side of the front bed panel. Remove all burrs from the edges of the holes with a file.

Honda Goldwing GL1800 Independent Rear Suspension Trike Conversion Installation Guide

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Filed Under (Honda) by admin on 17-02-2011

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Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. □ Seat (to be re-installed without modification) □ Left and right side covers (to be re-installed without modification) □ Battery and battery box (to be re-installed without modification) □ Left and right saddle bags □ Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) □ Trunk (to be re-installed without modification) □ Left and right passenger foot rests (to be re-installed without modification) □ Left and right foot rest under covers (to be modified and re-installed) □ Left and right rear crash bars □ Saddle bag trunk stay (to be modified and re-installed) □ Left and right mufflers (Mufflers only, do not remove decorative covers) . Retain OEM muffler rubber mounting bushings and flanged spacers for re-installation of the mufflers. □ Rear wheel □ Left and right pivot bolt covers (to be re-installed without modification) □ Reverse resistor (to be relocated) □ Swing Arm and Driveshaft IMPORTANT : Carry out brake system modifications (See Section 5) prior to removing Swing Arm. Evacuating all the brake fluid from the system will prevent brake fluid spills when the OEM swing arm is removed. Note : Upper bolt of mono shock can be removed without removing the fuel tank. □ Rear Shock and Hydraulics. Unscrew angle sensor from OEM shock and secure to frame with cable tie. □ Shock arm and shock link Note : You may need to cut out the bolt that attaches the shock link to the frame