Throttle Sensor
Always replace the O-ring with new ones. 3-way fuel joint pipe new O-rings 3-way air vent joint pipe new O-rings Air joint rubber pipe Thrust spring No. 4 carburetor synchronization spring
Guzzi V 8 At Race Retro
Race Retro, over 25-27 February, at Stoneleigh Park, Coventry, promises a treat for Italian racing motorcycle enthusiasts, for among the high performance machinery is a legend from the days when technology was seen as an alternative to sheer brute force of big bore displacement - the 500cc Moto Guzzi V8. Owner Giuseppe Todero will be starting up this two-wheeled tour-de-force each day during the show's new-for-2011 Fire Up Paddock, sponsored by Ace Cafe London. Adult ticket prices start from 20...
Stray from the mainstream
Brian Lopes wears Jawbone and Split Jacket, both with Switchlock Technology Brian Lopes wears Jawbone and Split Jacket, both with Switchlock Technology There's nothing standard about Brian Lopes' standards. When the pack zigs, he zags. Then, he rounds the last turn, points it straight downhill and wins handily, again. For Lopes, it's always been that way. In the mountain bike world where most guys will do anything to stay on course, Lopes swerves off the beaten track anytime he gets a chance....
Evaporative Emission Carburetor Air Vent Evap Cav Solenoid Valve Inspection
The EVAP CAV solenoid valve should be inspected if hot restart is difficult. Remove the air cleaner housing page 5-14 . Remove the bolt and solenoid valve stay from the frame. Disconnect the No. 8 and No. 4 hoses. Blow air into the No. 4 hose fitting that goes to the EVAP canister with the ignition switch OFF. Blow air into the No. 8 hose fitting with the ignition switch ON. Air should flow through the EVAP CAV solenoid valve and out the air vent port No. 4 hose fitting that goes to the air...
Discharge Volume Inspection
Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. Raise the fuel tank and support it page 2-3 . Remove the seat cowl page 2-2 . Short the Black white and Black blue terminals at the fuel pump transfer relay with the jumper wire. Disconnect the fuel tube from the 3-way tube joint Hold the a graduated beaker under the fuel...
By Pierre Terblanche
Tiif. Pf.tf.r Williams-df.signf.d Norton Monocoque 750 racer is really special, a project that I can only now truly appreciate after trying to design motorcycles for so long. Here we are not talking about styling but about brilliant engineering product design, an essentially underpowered bike that could win races against bikes with up to 40 hp more because of its advanced conceptual engineering design. The fact that in 1973, Peter Williams managed to create such a competitive bike as rider...
Assembly 1
Install the three collars and starter valve shaft. Install the starter valve assembly into the valve hole. Tighten the starter valve lock nut to the specified torque. TORQUE 2 N-m 0.18 kgf-m, 1.3 Ibf.ft Compress the thrust spring and install the No.3 4 starter valve arm onto the starter valves. Install and tighten the starter valve arm mounting sciews to the specified torque. TORQUE 1 N-m 0.09 kgf-m, 0.7 lbf-ft Install the No.1 2 starter valve arm to the starter valves. Install and tighten the...
Armstrong
If only it were as simple as winning the Tour de France. 2010 is turning into Lance Armstrong's annus horribilis following damaging accusations of doping by his former US Postal team-mate Floyd Landis f Words Lionel Birnte Photos Graham Watson, Press Association, Getty mages ' Lance Armstrong could have been kicking back with a beer and a burrito and playing in the sunshine with his children this summer. Instead, he's spending June scrabbling to muster enough form to be competitive at the Tour...
Camshaft Installation
Remove the ignition pulse generator rotor cover cap. Align, the T mark notch mark with the index mark on the ignition pulse generator rotor cover by turning the crankShaft clockwise. Apply molybdenum disulfide oil a 50 50 mixture of engine oil and molybdenum disulfide grease to the cam shaft journals of the cylider head and camshaft holders. Install each camshaft to the correct side Each camshaft has an identification mark IN is for the intake side and EX is for the exhaust side Install the...
Roundups
Wf.ll awarf. of its aging customer base, Harley-Davidson has been hard at work rolling out new products aimed at attracting a younger demographic. No need to reinvent the wheel, however, as the venerable Sportster has proven to be an ideal platform to deliver hip styling and solid performance at an affordable price. The 1200 Nightster was the first Sportster model in Harley's Dark Custom series, followed a year later by the 883-based Iron, a sim-plistically cool bobber that effectively stripped...
Rider seat
Remove the nuts, and then pull the rider seat up. In addition to the main switch steering lock, there are brackets on the right side of the steering head pipe for locking the steering with a padlock. To do so, turn the handlebar until the holes in the two brackets are aligned, and then lock the steering with a suitable padlock. Make sure that the rider seat is properly secured before riding. Insert the projection on the rear of the rider seat into the seat holder as shown, place the seat in the...
Onroadstrack
The exclusive BrakeTech AXIS series Ductile iron fully-floating disc providet a higher coefficient of friction over conventional stainless steel, with more feel and feedback at the brake lever and the patented AXIS Design floating system provides an interface between earner and disc many times stronger than conventional semi-floating brake roters for reduced wear. A simply tar superior by design with a longer life designed to perform perfectly with your siandard or aftermarket calipers. From...
Grommet
COVER, CRANKCASE L 4X7-15411-00
Oil Viscosities
Change the engine oil with the engine warm and the motorcycle on level ground to assure complete draining. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. Stop the engine and remove the oil filler cap and drain bolt. Remove...
Ktm 690 Duke
f medals were awarded for bravery, this little KTM would have one proudly protruding from its orange chest. It may be a cylinder down on these rivals, but its single piston gets through a titanic amount of work and is only caught lacking at anything above lOOmph. The Duke is part of KTM's royal family - and rightly so. While other manufacturers have gone down the easy route and opted for either more capacity or more cylinders, this lliird generation Duke proves that you need neither to...
Ace Classics Calendar
Naturally enough, seeing as they're pre unit Triumph specialists, the 2011 Ace Classics Calendar has 12 full colour, super glossy-Triumphs on show. The calendar is A3 portrait with an A4 image across the page, with the calendar and the bike details beneath. There are some superb shots, a couple of which are taken at night and there's one taken at Gaydon's Bonneville celebration, with the BBMF Lancaster flying overhead. There's the Ace Classics traditional monochrome shot with red tail light and...
Requisite Service
Side fairing removal instalation page 2-3 Side fairing removal instalation page 2-3 Front turn signal connector 3P mini Align the basses on the headlight case with the grommets. Front turn signal connector 3P mini Instal the right seat rubber with the mark MT4-R facing in. Install the left seat rubber with the mark MT4-L facing in. Install the right plate with the marked side in and each arrow Install the left plate with the marked side out and each arrow Front cowl removal installation page...
Desirability 6
solid. Tile frame is light and purposeful, the swingarm industrially sparse, the can is made stumpy and set low to aid balance, and if there's no need to stop the bike from 170mph I hen why have two calipers As soon as it rolls into this racy setting, the Duke becomes a toy through and through. Even with the strange geometry making the bike feel as if it's already pointing upwards we pointed I he finger at the shock set-up , the bike still pings between turns like a mosquito eying up Al. Gas...
Requisite Service Rxs
- Fuel tank removal installation page 2-11 Installation is in the reverse order of removal Before removing the air cleaner base, disconnect the cylinder head cover breather tube from the air cleaner When installing, align the boss on the front end of the air cleaner base with the hook on the frame. Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area where gasoline is stored can cause a...
Pearls Of
We all think we know a bit when it comes to bikes and we've all read or received some great advice. We spoke to some biking high fliers and asked what's the best piece of advice you were ever given Words Rob Hoytes Pics Graeme Brown, 2 Snap, Jonty Edmunds M The best piece of advice I was ever given was to treat every championship as a series and to not be blinded by individual races. My Dad Keith drummed it into me at a very early age that to win a championship you need to be consistent as well...
Disassembly
Before disassembly, prepare a clean and well lit work place where carburetor components can be laid out neatly and will not get lost. Study the service manual carburetor diagram and familiarize yourself with component locations and the different fuel circuits and their routing through the carburetor. The throttle position sensor is preset at the factory. Prior to disassembly, mark the throttle position sensor's original position with paint or a scribe for accurate reinstallation. Avoid removing...
Charlie Daniels
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Cleather Saddlebag Kit For Sportster Models
These bags match Bar amp Shield Solo Saddle P N 52663-96A and work with Detachable sissy bar sideplates with Docking Hardware Kit P N 90465-98A. Chrome-plated buckles, strap keepers and decorative strap and an inset embroidered Bar amp Shield logo complete the styling. Includes saddlebag supports, die-cast chrome-plated directional relocation kit and all necessary hardware and reflector. 90598-04 Fits '94-later XL models except XL1200S, 883R, and models equipped with rear axle covers, flat lens...
California Chic
In an effort to stay profitable and identifiable, many companies are returning to their roots and going back to what it is they do best. For Loren Kreiss, the managing director of San Diego-based Kreiss Enterprises www.kreiss.com , those origins arc a casual, California elegance. A lot of furniture companies sell something for everyone, he says. We used to do that. But now we've just focused on our look. One of the most popular Kreiss designs is the Medici bed 6,000 to 7,000 , a wrought iron...
Starter Valve Synchronization
Synchronize the starter valve with the engine at the normal operating temperature and with the transmission in neutral. Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change. Support the front end of fuel tank page .1-4 . Remove the No.1 and No.4 vacuum hoses from the air Disconnect the pressure regulator vacuum hoses at Connect the hoses to the vacuum gauge. Disconncct the PAIR air suction hoses from the reed valve covers and plug the cover. Start...
News Torque
ACCORDING to event organisers, competitors in the 2010 Australasian Safari will experience diverse, remote and dramatic terrain when they travel 3600km from Perth through historic gold-fields to Esperance in September. But they won't be taking the usual tourist route. The majority of the Australasian Safari course is off-road, and much on private and Crown land. But at the end of each day, the competitors meet up with their teams and families and camp at overnight stops in local towns. This...
Calibrating The Carburetor Balancer
Disconnect the vacuum hoses for fuel valve and for PAIR valve from carburetors 4 and 3, and install a cap of the proper size to each carburetor's vacuum inlet. Start the engine and let it run at idle until it is warmed up. Remove the vacuum inlet cap from the carburetor for cylinders 1 or 4 . Connect one of the carburetor balancer's rubber hoses to this inlet.
Cylinder Head Disassembly
Remove the spark plugs from the cylinder head. Install the tappet hole protector into the valve lifter bore. Remove the valve spring cotters using the special tools. Valve spring compressor 0 757-U010000 Compressor attachment 07959-KM30101 To prevent loss of tension, do not compress the valve springs more than necessary to remove the cotters. valve springs valve stem seal -spring seats Mark all parts during disassembly so they can be placed back in their original locations.
Map Sensor Removalinstallation
Support the front end of fuel tank paye 3-4 . Disconnect the MAP sensor connector. Disconnect the vacuum hose from the MAP sensor. Remove the air cleaner housing page 5-60 . Remove the screw and MAP sensor from the air cleaner housing. Installation is in the reverse order of removal.
Carburetor Heater Inspection
Remove the carburetor assembly. CI7 4-14 Disconnect the carburetor heater terminal lead wires. Connect the positive terminal of a 12V battery to the terminal of the carburetor heater and the battery negative terminal to the terminal 2 . Check that the heater section is heated in 5 minutes after the battery has been connected. If the carburetor heater is not heated up, replace the carburetor heater with a new one. Do not touch the carburetor heater directly to prevent burn.
Thrashing The 32 Talas
Crank down the fork's TALAS knob to gain access to and remove the fork's Schr der valve cap to add or remove air pressure. It is easy to adjust air pressure with any conven- Gold standard That gold finish on the stanchion tubes Is called Slick Technology, and It fills In microscopic pores that are a common occurrence of any hard-anodlzed aluminum surface. tional suspension pump, and we ran a healthy amount of suspension sag a little over 2 inches on the Pivot Mach 5. It requires a full...
Xlite X802 Marco Melandri Replica
This spangly green colourscheme was clearly thought up before the stealth-black Hayate bike was revealed. But this top-end Nolan X802 lid is a pretty looking thing, with Marco Melandri's trademark hedgehog on the back. The spec is high and includes a tri-composite outer shell that comes in three different sizes to optimise the design for each head size. There's a quick-release, tool-free visor change and removable washable liner. CONTACT www.tranam.co.uk 01425 620580
Air Filter Case And Carburetor
Carburetor manifold clamps 1 Engine idle speed control knob bracket 4 Starter control knob bracket 5 Carburetor joint clamps 6 Cover the carburetor with a rag to prevent dirt or foreign bodies entering.
Checking The Timing Chain Tensioner
timing chain tensioner Cracks damage Replace. Rough movement Replace the timing chain tensioner housing. timing chain tensioner rod Damage wear Replace the defective part -s .
Maintenance And Lubrication Chart 2 1
Introduction Maintenance Interval Charts Periodic Maintenance Emission Control System 2-1 General Maintenance Lubrication Carburetor Air Engine Engine Oil and Oil Filter Clutch Adjustment Cam Chain Adjustment 2-7 Valve Clearance Adjustment 2-7
Requisite Service Erq
Side fairing removal page 2-3 Exhaust system removal installation page 2-10 Installation is in the reverse order of removal. Ignition pulse generator connector 2P mini 3P mini connector oil pressure switch wire neutral swich wire thermo sensor wire Refer to page 7-4 for removal and installation. Install the link with the punch marks on the link and gearshift spincfle. Disconnect the water hoses at the engine side. Install the long one to the left hanger arm and the short one to the right...
Chapter 4 Engine Overhaul
ENGINE LEADS, HOSES AND EXHAUST PIPES 4-1 LEADS AND DRIVE ENGINE INSTALLING THE ENGINE CYLINDER HEAD CAMSHAFTS REMOVING THE CAMSHAFTS 4-9 CHECKING THE CHECKING THE CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES CHECKING THE TIMING CHAIN TENSIONER 4-11 INSTALLING THE CYLINDER REMOVING THE CYLINDER HEAD 4-16 CHECKING THE CYLINDER HEAD 4-16 INSTALLING THE CYLINDER HEAD 4-17 VALVES AND VALVE REMOVING THE VALVES CHECKING THE VALVES AND VALVE GUIDES 4-20 CHECKING THE VALVE CHECKING THE VALVE SPRINGS 4-23...
Ian Bartram Clock
A superbly detailed history of the famous British factory's motorcycles both road and racing . Besides the company's origins and history there arc detailed technical specifications, biographies of key individuals. Chapters include Military Bikes, TT and other Racing Successes, Dirt Track, Clubmans IT, 80 amp 90 Plus, Mark Series, Dragonfly, etc. Mick Walker, 10 Barton Road, Wisbech, Cambridgeshire, PE13 1 LB Tel 01945 461914 Ian Bartram's workshop is a converted garage. At one end there's a...
Motorcycles
T 0845 B44 83601 F 0845 644 8361 I E nfoOTheHogfatherco.jk IW www TheHog1atherco.uk an j rejands Exclusive Harley-Davidson and Big Dog Motorcycles Specialists But all Motorcycles, Trikes and Quads Catered For - Workshop Services, Projects and Repair Centre - Engine Diagnostics and Dyncuet Tuning Centre - Self Ride Harley Hire and Harley Chauffeuring Services - Motorcycle, Scooter, Quad and Accessory Sales Showroom - Earner Segal, Commuter and Back into Biking Centre MAi - otorcycle ccident...
FUEL SYSTEM DFI Fuel Injectors
Check the injector fuel line for leakage as follows OConnect a commercially available vacuum pressure pump A to the nipple of the delivery pipe B with a high-pressure fuel hose C both ends connected with the clamps D as shown. Torque - Fuel Hose Clamp Screws 1.5 N-m 0.15 kgf-m, 13 inlb OApply soap and water solution to the areas E as shown. OWatching the pressure gauge, squeeze the pump lever F , and build up the pressure until the pressure reaches the maximum pressure. Injector Fuel Line...
Throttle Cable Adjustment Major Adjustment
Minor adjustment can be made by the throttle grip side adjuster. Remove the fuel tank. T7 4-3 Loosen the lock nut of the throttle returning cable. Turn the returning cable adjuster 2 to obtain proper cable play. Loosen the lock nut 3 of the throttle pulling cable. Turn the pulling cable adjuster in or out until the throttle cable play of 2.0 - 4.0 mm 0.08 - 0.16 in at the throttle grip is obtained. Tighten the lock nut d securely while holding the adjuster D. While holding the throttle grip at...
Cylinder Head Cover Removal
Air cleaner housing page 5-4 Remove the spark plug caps. Disconnect the crankcase breather tube. Disconnect the PAIR control valve air tube, vacuum tube and remove the PAIR control valve assembly. Remove the SH bolts and PAIR check valve covers from the cylinder head cover. Remove the cylinder head cover bolts and washers. Remove the cylinder head cover rearward. J1' Mill ij illlMliiillliillilM . iMii. W ,1' JP
Advertorial
eight machines together - plus on-site bead blasting, polishing, thread restoration etc. What's more, they manufacture certain parts in stainless or steel when necessary. They also work closely with local painting and powder coating companies, so all aspects of restoration are covered. Proprietor Ged has been working on motorcycle engines for over 25 years, having undertaken full training with a major Lancashire based motorcycle dealer. Despite a full order hook and a busy daily schedule, their...
Carburetor Clamps
Position the carburetor clamps as shown. Carburetor clamp position air cleaner side Carburetor clamp position air cleaner side Carburetor clamp position engine side Carburetor clamp position engine side
Replacing The Rear Brake Pads Note
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 3. Measure brake pad wear limit Out of specification pads as a set. brake pad shims onto the brake pads
Cyberfit Jacket
Italian bike kit firms all have pretty classy design departments. But Spidi has a definite style of its own, with a much more mature, modern, simple feel to many of its products. That's exemplified by something like this Cyberfit jacket, which combines sharp, modish design cues, with sober, classic colour-schemes. It's modern enough to go with a sportsbike. yet makes a sound match for a naked roadster or tourer. Spidi is also right on the cutting-edge in terms of technology. So the Cyberfit is...
Headlight Blub Replacement
1. Disconnect Headlight leads T Keep flammable products or your hands away from the bulb while it is on, it will be hot. Do not touch the bulb until it cools down. 4. Install Bulb new Secure the new bulb with the bulb holder. Avoid touching glass part of bulb. Also keep it free from oil otherwise, transparency of glass, bulb life and illuminous flux will be adversely affected. If oil gets on bulb, clean it with a cloth moistened thoroughly with alcohol or lacquer thinner. ENGINE SIDE COVERS,...
Intercom operation
Provided both the rider and passenger are wearing headsets, they can talk to each other through the intercom at any time. See the Adjusting the intercom volume section. It is dangerous to operate the cassette deck while riding. Never take your hands off the handlebars while riding. Keep the volume at a low enough level to be aware of traffic conditions and ensure safety. To clean the tape head, use a de-magnetizing cleaning cassette, but be sure to turn the volume all the way down to avoid...