Auto Manual Resource: February 2009

240 Suzuki Hayabusa Swingarm Installation Instructions

Notes on fitting wide wheel and tire
• An advanced degree of mechanical skill is required to properly install this kit. If after reading these instructions you have any doubts, we strongly recommend that you have a professional install it for you. If you install the kit yourself, we recommend that you also use the applicable shop manual for your motorcycle. This kit involves significant alterations of your motorcycle and may void your factory warranty.
• Whenever installing wheels and tires that are wider than original equipment, please ensure that there will be sufficient clearance throughout the suspension range in the frame, swingarm, fender and that there is no interference with the belt, chain , brake caliper, or exhaust system.
• Motorcycles can be dangerous if not properly maintained and ridden safely. RC Components has no control over the usage of any of its parts. RC Components expects its customers to exercise good judgment as to the proper selection, installation, use, and maintenance of any parts. RC Components assumes no responsibility for damage or injury of any kind because of the misuse or improper application of any parts in any way by any person. RC Components expects the end user to exercise good judgment.
• Before installing this kit, read through these directions completely. This will familiarize you with the way in which the parts fit together and the tools needed to complete the job.
• Before performing any installation steps, disconnect the motorcycle’s battery to eliminate any possibility of electrical damage or personal injury due to a short circuit.

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Suzuki Hayabusa Gear position indicator Geartronics GPI-4 Fitting instructions

The gear indicator comes configured for use with the OEM Suzuki gear position sensor, and is fitted with standard connectors to plug directly into the Suzuki wiring harness. The unit also features the so-called ‘TRE’ modification, which is designed to defeat the gear dependent mapping strategy of the Suzuki ECU. Please refer to the bottom of this document for a description of the TRE function.

Installation
A reasonably competent amateur mechanic, using only basic hand tools, should be capable of fitting the Geartronics indicator in less than 1 hour.
Step 1.
Remove the screw at each side of the seat and remove the riders seat. Remove the 2 screws in front of the fuel tank. Lift the front of the tank and support at approximately 45° to gain access behind the engine.
Step 2.
Remove all screws securing the left hand lower fairing and carefully remove the panel to expose the bike frame. Note that there are 2 different sizes of screws! Remove the single screw & clip securing the insert panel located to the left of the instrument cluster. The centre of the clip should be pushed in, allowing the outer part to be pulled out.
Step 3.
Locate the gear position sensor connectors with reference to the photo below.

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Suzuki Swift S Manual Road Test

The original Suzuki Swift was launched in Australia in 1984, and with a zippy 1.3 litre engine, good build quality and attractive pricing, soon became a favourite with consumers. Owners that have kept Swift’s long term have also been rewarded with class leading reliability, and there plenty of originals still on the road today.

The new model was previewed at the Sydney Motor Show, in 2004 and released in February 2005. Developed in Europe, Suzuki believe the new Swift will have wide international appeal., it’s available as a five door in Australia, with a 1.5 litre engine with a choice of either manual or automatic transmission It replaces the Suzuki Ignis in the Suzuki model line up.

ERGONOMICS
Sitting behind the wheel for the first time the driving position feels quite high, the nose of the Swift drops away sharply from the front screen, so the high position helps in parking. Dash design is simple and straight forward, a large speedometer is in the centre of the dash with the tacho positioned to its left. Two smaller dials for fuel and temperature are either side, all the instruments are easy to read. Audio controls are in the leather bound steering wheel, the main controls for the audio system and air-conditioning are positioned centrally in the dash and are easy to use and operate first up. The clutch pedal sits higher in relationship to the brake pedal and as well the clutch take up is towards the end of its travel, making it awkward to operate.

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Radical SR3 Owners Manual

Before taking to the track, it is important that you carry out a thorough spanner check, paying particular attention to all hoses, connections and suspension fixings, brake bias etc..

Check all fluid levels
The oil level on cars fitted with the standard wet sump should be no lower than three quarters up the sight-glass, with the car on level ground and the motor warm and running. The sump is baffled and the oil takes some time to settle.

For cars fitted with a dry sump system the oil level must be maintained just above the top baffle in the oil tank (100mm down from the top of the tank). This measurement should be taken when the engine is warm and running. The sight glass in the side of the engine should be ignored.

Only use Radical recommended oil, i.e. Silkolene Pro 4 synthetic based racing oil which is formulated to run in the integral gearbox and clutch as well as the engine (see running in)

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Suzuki 03-04 GSX-R1000 TiForce exhaust system

Thank you for selecting and purchasing a TiForce exhaust system for your ’ 03-‘04 GSX-R1000. TiForce is the world’s finest titanium exhaust system available today. Please read the following instructions and materials to fully familiarize you with new exhaust system before getting started.

Before Installation
Make sure to detach the connector of the exhaust device
Coat joints on all parts with liquid gasket
Check all accessories have been included
Detach the battery for your safety
For detach and attaching the parts, please refer the service manual
1. Detach the seat, battery, under cowling, tail winker and passenger foot peg.
2. Use standard rod to lift the fuel tank and detach the connector of the exhaust devise servomotor.
(Failure to detach the connector and turn on the main switch, serious damage may occur to the servomotor.)(*See Photo. 1) Detach the standard silencer and wire for the device.
3. Release the coolant and detach the oil cooler.
Detach the standard exhaust pipes after free the oil cooler.
4. Attach an enclosed exhaust pipe to the engine and tighten enough to keep from slipping out of place. (Cylinder number is 1,2,3 and 4 from the engine right side)
*Suggest using new gasket in order to prevent leaking the exhaust.
*Use the standard flange nut and tighten by hand.
5. Attach the joint pipe followed by the tail pipe. Jiggle it and attach the springs.
*Make sure to push into the joint pipe from the right body side to the oil pan. Failure to push into the joint pipe may touch the under cowling.
6. Attach the enclosed silencer stay using by Collar A and Bolt (M8-50mm) to the position of the passengers foot peg of the silencer side. (See Fig. 1)
*For the passenger foot peg users, use collar B and Bolt (M8-110mm).
7. Push silencer into the tail pipe, put the springs, silencer rubber band, band and silencer stay. (Make sure to use rubbered springs to the upper side of the silencer joint.) (M6 x 20mm x 2, M6 nut x 2, M6 washer x 4) (See Fig. 2)
8. Attach the silencer stay enough to keep from loosening using the enclosed bolt (M8-20mm), M8 nut and washer to the silencer stay B assembled in step 6. (See Fig. 1)
9. Check the exhaust pipe, joint pipe and tail pipe not to contact to any one another in any way. And tighten all.
10. Reinstall the battery, radiator and oil cooler. Put coolant and leak the air. (For leaking the air, please refer the service manual.)
11. Check all bots and nuts are tight; start the engine and check for exhaust leak.
12. Attached the enclosed winker to the seat cowling. (Wire by the electronic tap.)
13. Put the heat-resistant tape on both of the closest place to the front pipe #1 (where is the pipe bulge outside) and the joint pipe of the under cowling back side in order to prevent melting the cowling from the pipe heat. (*See Photos.4 and 5)

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Suzuki introduces an all new lightweight 25PS (18.4kW) Four-Stroke Outboard

Suzuki engineers have designed an all-new light weight 25PS (18.4kW) 4-stroke outboard that weighs just 69kg (152lbs.)*. Its lighter weight and economical operation make it ideal for boaters and fishermen who need a powerful compact outboard. In addition, this new 4-stroke fully complies with 2006 EPA and forthcoming EURO 1 standards (EU Directive 2003/44/EC), and carries the California Air Resources Board (CARB) 3-star Ultra-Low emissions rating.

V-Twin Powerhead
This new 25PS (18.4kW) model is the first Suzuki 4-stroke outboard to feature a V-Twin powerhead. The 70º v-bank angle is wide enough to minimize vibration without the use of a counterbalance system, and narrow enough to provide a compact profile on the transom.

The V-twin layout also moves the center of gravity forward, compared to an inline powerhead. This allows for better balance on the transom, and makes the engine easier to tilt. Since engines in this category typically are tilted by hand, a little bit of help is a big advantage. Twin cylinders, each displacing 269cm 3 (total displacement is 538cm 3) combined with 2 overhead valves per cylinder, produce maximum power at 5,000 rpm. The engine uses a single carburetor for easy maintenance and lighter weight. Aluminum block and aluminum connecting rods contribute to the lightweight design.

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SUZUKI INTRUDER 1500 LC REMOVAL & INSTALLATION OF BOTH WHEELS

The following is the experience I gained in removing my wheels to have new tires fitted on Jan/Feb 2004, I must point out, that I will not be resposible for any accidents to any person/persons, or damage to equipment or property by using my suggestions. Note : The Intruder 1500 LC is a very heavy motorcycle, & all precautions must be taken to do this job safely, by using proper load tested restrainers, proper lifting equipment & the proper tools. A lot of my success was gained by Wes’s guide at :- http://www.intruder1500.com/reartire.shtml

I used my motorcycle bike lift to take the total weight of the bike to a height approx. 22″ from the tip of the fender to the floor, this height may need to be increased later depending on the size of the tires on the wheels to be installed. I then removed the windshield in order to provide access to the triple tree area for installation of the two front safety straps to my storage shed roof trusses, which have been reinforced to take the weight, just in case things go wrong.

I had a total of (7) adjustable load tested nylon straps securing the bike while lifting it to this height, (4) straps were used to hold bike from the roof truss of my storage shed, (2) were secured near the triple tree area to take the weight of the front end, just in case something terrible should occur, these straps will have to be tightened as bike is jacked up.

The other (2) straps secured on the frame tube section below the driver seat (Driver Seat has to be removed for this) these straps will also have to be tightened as the bike is being jacked up.

I used (2) more straps to secure the handlebars from swinging during the lifting, caution: as these are attached to to base of the bike lift, they have to be constantly slackened off until the working height is achieved, otherwise damage to the handlebars can occur. Another strap was put across the frame & secured also to the bike lift caution : this also requires slackening during lifting until desired working height is achieved, this strap will reduce the probability of the bike sliding left or right or tipping during work on the bike.

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SUZUKI 800 VOLUSIA Adaptor Kit Installation Instructions

Congratulations on your purchase of the SUZUKI 800 VOLUSIA Adaptor Kit. We’re sure you’ll be pleased with the new level of performance you’ll experience. This kit should be installed on bikes with After Market Exhaust Pipes only and jetted, (not included). We recommend that an experienced mechanic perform this conversion. Use the appropriate Suzuki service manual for reference to complete jetting of carbs. Remember, gasoline is extremely flammable and can be explosive under certain conditions. Work in a well- ventilated area and clean up any spills immediately. Check for leaks before riding.

1) Remove Seat – 6mm allen head
2) Remove Dash 1 - 3mm allen and 2 - 4mm allen heads.
3) Remove Tank 1 - 12mm socket at the rear of the tank.
4) Remove the chrome cosmetic cover on the left side of the bike – 2 8mm socket heads. Disconnect the 2 vacuum lines from the tank and fuel line.
5) Pop the idle adjustment out of the bracket and lift at the rear of the tank. Unplug the one white electrical plug.
6) Remove the stock air box 2 – 4mm allen heads at the top of the air box. Loosen the hose clamp and pull out from the bottom of the air box and remove.
7) Remove the stock air box hanger bracket 3 – 10mm bolts.
8 )Jetting can now be done.
9) Plug the pair valve hose with the supplied red plug – It is the large 5/8 hose going to the vacuum canister on the left hand side of the bike.
10) Place the provided O-Ring in the grove at the top oval opening.

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SUZUKI TIS 2 Web User Guide

The Techline Information System (TIS 2 Web) User’s Guide provides a comprehensive overview of TIS 2 Web software including Tech2 View, Software Download, Snapshot Upload / Display and Service Programming System (SPS). This TIS2 Web software is available from the Web site (TIS 2 Web) provided by GM Service and Parts Operations via Suzuki Service Protocol Site (http://portal.suzukibitstop.com). ASMC (American Suzuki Motor Corporation) and its affiliated dealers only can obtain it from Suzuki Pit Stop (http://www.suzukipitstop.com) as well.

Everything contained in this manual is based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced, stored in any retrieval system, or transmitted in any form by any means, including but not limited to electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Suzuki Motor Corporation. This includes all text, tables, illustrations, and charts.

To obtain assistance with the TIS 2 Web application distributors and dealers should use the following process based on their location.

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2000 Chevrolet Camaro TRANSMISSION SERVICING - M/T

SERVICE INTERVALS
Metro
Replace transaxle fluid every 12,000 miles under short trip driving conditions. Under long trip driving conditions, change fluid every 30,000 miles.
Prizm
Under normal driving conditions, no fluid changes are necessary. Under severe driving conditions, change fluid every 30,000 miles or 24 months.

All Other Models
Fluid replacement is not required. Check fluid level at each
engine oil change.

CHECKING FLUID LEVEL Saturn (MP2 & MP3) Park vehicle on level surface. Check fluid level when cold. Fluid should be at FULL mark on dipstick. Drain plug is below dipstick tube.
CAUTION: On Camaro and Firebird T5 (M49) 5-speed transmission, DO NOT mistake reverse shift lever pivot bolt (located on left side of transmission case) with filler plug. Drain and fill plugs are located on right side of transmission case. If reverse pivot bolt is loosened, return spring may fall into case, causing a 2nd gear rattle.

All Other Models
Check lubricant level at fill plug hole on side of transmission. Lubricant should be level with bottom of fill plug hole. Add lubricant as necessary. Install fill plug and tighten to specification. See TORQUE SPECIFICATIONS

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BBR’s KLX/DRZ110 Billet Aluminum Brake Pedal

Since installation of this kit is beyond the control of BBR Motorsports, Inc, we cannot accept responsibility for misuse or improper installation. This kit is intended only for use on off-road motorcycles. These instructions are intended only as a supplement to the proper Kawasaki/Suzuki service manual. If the installation of this product is beyond your technical abilities please refer to a qualified service technician.

1. Place bike on stand and remove stock brake pedal (10mm bolt), brake pedal rod, and kickstarter.
2. Replace the lower rear motormount bolt’s nut with the special nut included in this kit (torque to 40 ft. lbs).
3. Install the brake rod into the BBR brake pedal and reinstall the cotter pin.
4. Hook brake pedal spring on the brake pedal. Install the stock o-rings in the BBR pedal.
5. Install the brake pedal (tighten 10mm bolt to 79 in lbs). Be sure to hook the return spring on the frame.

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Kawasaki/Suzuki Techlusion Electronic Jet Kit

Thank you for choosing the Techlusion Electronic Jet Kit, the TFI. The TFI is usable for sequential fuel injection 2 cylinder Kawasaki, Suzuki motorcycles **.
** Kawasaki: 2006-07 Ninja 650R/ 2006-07 VN900/ 2004-07 VN2000
Suzuki:
2002-07 DL650, DL1000/ 2003-07 SV650, SV1000/ 1998-2003 TL1000/ 2006-07 M109R

Photo installs for many applications are available at www.dobeckperformance.com in the support forum.

This product is a great fit for stock bikes with exhaust and intake mods. It is also capable of handling the fuel needs of big bore kits, light cams, and a variety of head porting.

This is an Electronic Jet Kit. Like jet kits in the past, the more you modify, the more responsibility you take in getting your fuel curve right. Going to www.dobeckperformance.com will help you obtain better high horsepower tuning.

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Suzuki MightyBoy history

Suzuki Have a long history of producing small motor vehicles. It all started in 1955 with the Suzulight series of Kei class cars. The Suzulight looked similar to a Moris / Leyland Mini-minor, only the performance was nowhere near as good, considering it was fitted with a 359cc 2-stroke, Air cooled engine.

Now, getting to the inception of the MightyBoy takes us to the late 70’s, and the introduction of the Suzuki Fronte 2nd generation 2-door fastback coupe.

The engine fitted to these vehicles was an in-line, 3 cylinder 543cc, OHC, water cooled engine, transversely mounted, driving the front wheels through a 4 speed manual or 2 speed automatic gearbox. In 1983, a turbo was added to this engine.

1983 brings us to the year the first model Suzuki MightyBoy was released in Japan. Based on the principles and regulations of the Japanese keijidōsha class of vehicles, the MightyBoy is a coupe utility variation of the 2nd generation, 2-door fastback Suzuki Cervo. Released in 1983, it was equipped with an 534 cc SOHC 3 cylinder transverse-mounted engine (F5A), however unlike its cousin the Cervo, no turbo was available. Driving the front wheels through a 4-speed manual or optional 2-speed automatic gearbox, the F5A motor delivered 19 kW of power at the flywheel.

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Suzuki VZR 1800 Services Manual Corrections - Valve Spring Specifications and Cluth Washer

This bulletin contains service manual correction information for the VZR1800. Please change the valve spring specifications in your dealership service manual based upon the information provided below. Insert a copy of each of the attached pages with clutch washer information into your dealership service manual at the appropriate page.

REAR CAM CHAIN TENSION ADJUSTER
• Unlock the ratchet / and insert the special tool. y 09917-62430: Chain tensioner lock tool
• Remove the rear cam chain tensioner No. 1 assy 0.
• Remove the cam chain guide No. 1 1 and rear cam chain tension adjuster No. 1 2.

REAR CAM CHAIN IDLER SPROCKET
• Remove the idler shaft /.
• Disengage the cam chain No. 1 0 from the rear cam chain idler sprocket 1

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Suzuki CAT1 User Guide

The Suzuki CAT1 consists of the following main components;
• Installed CAT1 main unit
• 2 x remote transmitters
• Installed protecting switch
• Installed system fuse and spare fuse
• LED system indicator

Be sure that you know:
1. Where the system fuse is, and where the spare fuse is located. If the fuse fails, the system will not allow the motorcycle to start.
2. Set your PIN override. This will enable you to disarm the system and still start your motorcycle if the remote transmitter is lost or does not function (see Section 16).

The CAT1 will monitor;
1. The motorcycle battery and associated motorcycle wiring. If the battery is disconnected or the ignition is switched on the alarm will trigger. The CAT1 also monitors the state of the motorcycle battery for ‘sleep’ purposes.
2. The ignition circuit. If the ignition is switched on while the CAT1 is protecting the system it will trigger an alarm. Also, the CAT1 Uses the ignition to enter diagnostic and service mode.
3. Nudge and movement, with a liquid filled, state-of-the-art sensor.
4. An anti-tamper switch will cause the alarm to trigger if an attempt is made to gain unauthorised access to the CAT1 system.

The CAT1 also;
1. Has a ‘fully armed’ mode (see section 1)
2. Has a ‘Convenience’ mode (see section 2)
3. Has a service/valet mode (see section 3)
4. Has a diagnostic mode (see section 4)
5. Has 14 different siren tones (see section 5)
6. Can have the audible warning of arming/disarming removed (see section 6)
7. Can activate all four indicators in a Hazard warning mode (see section 7)
8. Can be programmed to arm in ‘Full’ mode (without movement/nudge sensing) (see section 1)
9. Can be programmed to have the nudge sensing removed
10. Can be programmed to act as an indicator or warning system when riding the motorcycle (see section 9)
11. Will tell you if it senses excess voltage when the engine is running (see section 10)
12. Will tell you if the remote transmitter batteries are becoming discharged (see section 11)
13. Has a useful torch in the remote transmitter (see section 12)
14. Has an ignition key conversion feature in the remote transmitter (see section 13)
15. Will tell you if the alarm has triggered in your absence (see section 14)
16. Has a user-selectable PIN override number (see section 16)

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LMF-400 Multi-function Gauge Installation and Operation Instructions

This gauge will only work with a NMEA 2000 network. It MUST be connected to a NMEA 2000 network or it WILL NOT function. When properly installed, the LMF-400 will display information from a variety of Lowrance Electronic Probe (EP) sensors and other NMEA 2000 devices connected to the network.

All Lowrance NMEA 2000 capable devices are either NMEA 2000 certified or certification is pending. See our web site, www.lowrance.com, for the latest product information. To get started with your Lowrance gauge, read Section 2: Installation. After you have read those instructions, install the gauge and any EP sensors you may have purchased, then read the rest of this manual.

Each sensor comes with its own installation instruction sheet, but this manual describes how the gauge operates with each sensor and how to configure and calibrate the sensors. Your gauge packaging also includes the NMEA 2000 Networks General Information. It contains instructions for creating or expanding a NMEA 2000 network.

LowranceNET teams up the powerful NMEA 2000 network standard with a fast-growing, cutting-edge family of Lowrance Electronic Probe Sensors. The product line includes the EP-10 Fuel Flow, EP-15 Fluid Level, Suzuki Engine interface, EP-25 Speed, EP-35 Temp, EP-45 Pressure sensors and EP-50 Storage device. And what’s more exciting, there are others on the way. Be sure to log on to our website, www.lowrance.com, from time to time for the latest developments, including updated operation manuals, instruction sheets and software you can download free of charge. When you are ready to expand your network, see the accessory ordering information on the back cover of this manual.

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1980 Suzuki GS850GT Stator Replacement

Let’s begin by disconnecting the positive terminal of the battery (or removing the battery altogether) and draining the oil. I happened to need an oil/filter change at the same time I was replacing my stator so the timing worked nicely. Some riders will just lean their bikes to the right, against something stable, so that when the left crankcase cover is removed no oil will drain out. Here is the left crankcase cover gasket. I’m holding it upside down, sorry. This is part number 477686-001.

(Before we go much farther, let me apologize for the filthy condition of my bike. I’ve been a little neglectful lately. But now that she’s running better I’ll get her cleaned up.) Moving on…

Remove the left crankcase cover bolts (below). My bike still has the original phillips head bolts. They need a few taps from my impact driver to loosen them up. If I would’ve planned ahead they would be replaced with new hex head bolts. But alas, that will have to wait. In the picture below, the cover is loose and hanging. At this point you may wish to just cut the stator wires but I chose to pull everything out intact.

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Suzuki VZR1800 Supplemental Service Manual Information

This bulletin contains additional technical and service information for the VZR1800K7. Please place a copy of this bulletin with your dealership’s VZR1800 Service Manual.

SUBJECT: SUPPLEMENTAL SERVICE MANUAL INFORMATION
MODEL: VZR1800K7
REFERENCE: VZR1800 SERVICE MANUAL (P/N 99500-39290-03E)

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SUZUKI / GSX-R600/750 / 2006-2007 Carbon Fiber / Aluminum 6061 Installation Instructions

1 After bike is cool make sure the bike is secured before beginning the installation.
2 Remove the right side lower fairing bolts and pull the fairing out from the push pin/rubber connector.
3 Fully loosen the muffler clamp from the header collector.
4 Remove the 3 muffler mounting bolts (2 on the right side, 1 on the left side).
5 Carefully remove the stock muffler and place in a safe location.
6 Apply a small amount of high temperature silicone (such as Permatex Ultra Black) to the inside of the exhaust inlet. Attach the LOR exhaust canister to the slip-on tube adapter with the spring tabs aligned (make sure your hands are protected with a pair of gloves in case the tubes slip). You may have to squeeze the mid- pipe adapter tube to fit into the exhaust inlet as the mandrel bends may become slightly out of round due to a cut near the bend (the tube will take form once connected). Slide the canister all the way until the slip-on adapter seats fully against the exhaust inlet. Wipe off any excess silicone. Place each spring over the exhaust side spring tabs and use the spring tool to pull the springs over the adapter spring tabs. Both springs must be secured for proper installation.
7 Apply a small amount of high temperature silicone sealer (such as Permatex Ultra Black) to the inside (inlet side) of the slip-on adapter. Slide the low profile barrel clamp over the LevelOne Adapter pipe. Slide the slip-on adapter pipe over the stock header collector. Do not fully tighten the barrel clamp.
8 Place the round canister clamp with the rubber gasket over the rear of the exhaust and slide to the angle bracket clamp location (Follow the instructions for the hanger conversion located at the end of this manual). Follow the clamp setup (shown in figure 1a or 2a) based on your sleeve type. Do not fully tighten as you will need to adjust the system for a perfect fit.

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Chevrolet Tracker Suzuki Sidekick/Vitara Years 99-2004 Hardtop Installation Instruction

Refer to your Owner’s Manual for instructions on lowering and removing the canvas top. ALL hardware for your soft top should be removed. This includes the trim around the body. Some of the screws from the Canvas Top Hardware will be used in the Hardtop installation, so keep them available.

Front Lid Installation
STEP 1: Place the Front Lid in position over the Driver and Front Passenger seats.
STEP 2: Take the 2 Curved Joint Brackets (BRK-10) and place them on the bolt threads extending from the Fiberglass Lid, and hold them in place with 2 Speed Knobs (SKB-1).
STEP 3: After the Lid is in position, hook and close the front of the lid with the Windshield Cam Locks (It may be necessary to loosen the front factory cam locks with a Phillips head screwdriver for additional adjustment in some cases), and then tighten the Speed Knobs and Rear Brackets into place, so that the Curved Joint Brackets (BRK-10) tighten against the cross bar of the vehicle. (Diagram B)

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BMW CS1000 Fault Code Scanner Instructions

Insert the OB15-9 memory cartridge into the base of the scanner. Make sure the arrow on the cartridge is facing up as it is inserted. Push the cartridge until the cartridge snaps completely. Be sure to insert the memory cartridge into the scanner before powering-up the scanner.

Refer to the diagnostic cable page of this manual to determine vehicle cable requirements. Connect the diagnostic cable specified to the scanner and to the vehicle Diagnostic Connector.

Before using the CS1000 to read the DME, perform a “PEDAL TEST” on the vehicle to determine if the On-Board computer is working properly. This is for model years 1988- 1994.

Read Fault Codes
Press the READ key to begin to read the fault codes for the system selected. The screen will begin to flash the scan symbol and will display the systemtype number or “U” code (refer to the “U” code list on page 10)

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BMW D7 Workshop Manual

A four-stroke diesel engine with direct injection and open-circuit cooling system. The Neoprene impeller of the coolant pump is driven directly from the crankshaft. Electric starter and flywheel alternator are standard equipment. The injection system is fitted with automatic bleeding.

This workshop manual describes complete procedures for dismantling, overhaul and assembly of the BMW D7 marine engine. If only part of the procedure is to be carried out (e.g. small repairs or replacement of gaskets, oilseals) the remainder can be ignored. The relevant technical data is provided with each section. General specifications are found on page iii.

Assembly is generally a reversal of removal procedure. Special attention, however, should be paid to “notes on assembly”. Checking and adjustment procedures, where applicable, are to be found at the end of the relevant section.

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Rebuilding your Transmission

If you still have transmission in your Samurai, chances are very good that it makes a little noise in at least one of the forward gears… You have a few choices. You can try and find a dealer money. Our kit was purchased from Petroworks.

Everything starts with simply draining the oil. Check the oil as it comes out for metal shavings or flakes. Large metal chunks could be a bad thing depending on where they came from. If the shifter locator pi has broken off in the past it will eventually end up down here in the bottom of the case. If it got wedged in the gearing on the way down, then you may have more to replace than you planned on.

Next it’s time to go inside to check out the condition of the components. To do that you can start at the back and remove all the bolts holding the tail housing to the main section. Don’t forget to remove the reverse shift rim bolt. You can see the arrow pointing at it in the photo on the left. When you remove it you will notice that it looks pretty unique… Don’t lose it, we will talk more about this later. Separate the tail shaft housing (extension case) from the main section and turn it up on end. Here you see the tail shaft seal. You should take this time to replace it and then clean out the case. Then set it aside for later.

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Suzuki LTR 450 Fuelpak Fuel Management System

Fuelpak maps for the LTR450 were created with a White Brothers Power Pro performance module installed. The included Power Pro unit must be used in conjunction with the Fuelpak for proper function. Failure to do so will result in poor performance and may cause engine damage.

1. Be sure that key is in the off position, then remove seat.
2. Referring to figure 1, remove (4) push pins and (1) 10mm bolt. Repeat for opposite side. Push pins that are accessible from the back can be popped out by pushing on the pin from the back side. Push pins with flanged pin heads can be gently pried up with a slotted screwdriver.
3. Remove fuel cap and tank cover. Reinstall fuel cap.
4. Clean Fuelpak mounting location with alcohol and allow to dry. Referring to figure 2, mount Fuelpak as shown with supplied Velcro. Route harness as shown, between airbox and subframe, and underneath subframe cross brace.Gently pull up and out on subframe side cover and attach harness to subframe with included zip ties. Ensure that harness is not running over black rubber strip behind airbox.
5. Remove TPS plug and install TPS T-tap to yellow wire as shown in figure 3. It may be helpful to use a slotted screwdriver to gently disengage the TPS plug lock tab. Plug purple wire into T-tap (use dielectric grease). Reinstall TPS plug.
6. Route ground wire to the left of the throttle body and in front of the fuel pump. Referring to figure 4, remove (1) 8mm bolt on fuel hose bracket, add Fuelpak ground terminal, and reinstall.

Get pdf Suzuki LTR 450 Fuelpak Fuel Management System

Pioneer Xmp3 Owners Manual

The XMp3: Record What You Love, Listen When You Want!™
Live or recorded XM content at your fingertips. Spin the wheel to quickly tune to your favorite XM channels.
Have to step away for a few minutes? Pause and replay up to 30 minutes of XM programming.
Record up to 5 channels simultaneously, so you’ll always have something to listen to. Schedule a recording time, or let the XMp3 radio learn your listening habits and automatically record your favorite channels for you.
Find out what’s playing now or in the future with XM’s programming guide.
TuneSelect and GameSelect find your favorite artists or sports events on any XM channel.
Upload MP3 files, WMA tracks, and Audible.com books from your PC. Manage your collection and playlists with the XM2go Music Manager software.
Store MP3 or WMA files on a removable microSD memory card (sold separately)

XM is America’s number one satellite radio company. Broadcasting live daily from studios in Washington, DC, New York City, Chicago, the Country Music Hall of Fame in Nashville, Toronto, and Montreal, XM’s 2008 lineup includes more than 170 digital channels of choice from coast to coast: commercial-free music, premier sports, news, talk radio, comedy, children’s and entertainment programming; and the most advanced traffic and weather information.

XM, the leader in satellite-delivered entertainment and data services for the automobile market through partnerships with General Motors, Honda, Hyundai, Nissan, Porsche, Subaru, Suzuki, and Toyota, is available in 140 different vehicle models for 2008. XM’s industry-leading products are available at consumer electronics retailers nationwide. For more information about XM hardware, programming, and partnerships, please visit http://www.xmradio.com.

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1996-1999 E36 Supercharger With C38 Blower Instructions

Operating Instructions for AA supercharged cars
Always allow your engine and supercharger to warm up for at least one minute before placing the car in gear. In colder weather (below 50 degrees Fahrenheit), we recommend at least two-to-three minutes of warm-up time.

Always use the best fuel (93 octane) available. If 91 octane is the only available fuel, add an octane booster if you detect any knocking. Active Autowerke calibrates the software to operate on 91 octane, but some cars may experience slight knocking or detonation. Excessive knocking will damage the motor, so pay close attention to any hint of knocking.

On Steptronic or automatic transmission models, we recommend that thetransmission be set in “Sport” mode when the car is driven hard. This will allow the transmission to shift more quickly to prevent any excess slippage. Additionally, after driving hard in an automatic-equipped car, you should allow the car to cool off for at least one minute before shutting off the motor. This will allow your transmission fluid to cool off. It is also a good idea to follow this procedure in order for the supercharger to cool off properly.

It is also recommended that you check the supercharger oil level in the reservoir at least once a month. The level should read at the lower dipstick mark with the engine running in neutral or Park. Following these recommendations will ensure that your supercharger provides many miles of thrilling driving enjoyment.

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SECONS SDI Diagnostics Interface Installation and Operation Manual

Never run diagnostics software for different brand on your vehicle (e.g. running Ford diagnostic software on a Mercedes-Benz car). This may cause major damage to your SDI interface and such action voids your warranty.

The SDI Interface is designed for 12-volts only vehicles. Although the SDI Interface contains protection circuits, please verify if the OBD2 connector is properly connected and no pins are short-circuited to battery before performing diagnosis. Never try to disassemble the SDI Interface. It does not contain any user serviceable parts. Removing SDI Interface cover voids your warranty.

Drivers have to be installed before the SDI interface is first time plugged to your computer. Launch dpinst.exe from the installation CD-ROM. The following screen shoud display: Click on Next button. Windows XP and later will display warning about driver’s signature. Don’t care about it, our drivers are fully tested to work on Windows 2000 and later.

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E36 BMW M3 H&R COILOVER INSTALLATION

In the fall of 1999 I had the pleasure of purchasing a 97 BMW M3. I had always been in awe of the car after hearing many publications rave about its handling prowess and silky smooth drivetrain. I never imagined that I would own a car of this caliber, but that all changed when I made one fatal mistake. I allowed a dealer to hand me the keys for a test drive. Actually, I didn’t want to drive the car, but a friend I had along with me, without my prior knowledge, asked that I be allowed to drive the car. End of story. I now drive an Alpine White M3 and can’t wait to make that last payment.

I quickly realized that the M3 was much more car than I would probably ever be driver. Although I enjoy autocrossing and various other driving events, the M3 has made me realize how far I have to go in the driving skills department. Things happen in a hurry for the uninitiated. I have driven many high powered sports cars, but none have ever moved me or involved me like the M3. I can’t see ever being without one again.

Upon purchase, my car had just over 30,000 pampered miles. Not a scratch inside or out. This was my first BMW and I was pretty unfamiliar with them in general. After joining the E36M3 digest, I learned much, and unavoidably changed much on the car. Hence this write-up.

Through talking to others, it became apparent that the stock suspension on an E36 M3 is generally shot at around 30,000 miles. Pretty disappointing in a $40,000 car, but somewhat common none the less. Lets just look at it as an “opportunity.”

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Suzuki FOUR-STROKE / Electronic Fuel Injection

The engine is designed from the ground up, specifically for outboard use, by Suzuki engineers who draw on decades of knowledge gained through the manufacture of not only outboards, but also technologically-advanced motorcycles and automobiles.The product of their labors is an all-new 3.6-liter DOHC, 24-valve V6 engine that holds some of our most advanced and innovative ideas to date. Upon its base we have created three configurations, each of which is designed to deliver the ultimate in power and performance.

The flagship DF250 is the industry’s first 250PS (184kW) V6 four-stroke outboard and Suzuki’s most powerful outboard built to date. Its 3614cm displacement is of course, our largest to date, and the largest to date in the industry as well. Producing 69PS (51kW) per liter it holds the greatest power to displacement ratio and the greatest power to weight ratio the industry has ever seen in the four-stroke category. It is also the lightest outboard motor in its class. Delivering 225PS (165kW) of power in the DF225 and 200PS (147kW) in the DF200, the engine provides both of these outboards with the largest displacement in their respective categories while its narrow profile makes them, like the DF250, the lightest and most compact outboards in their class.

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2004 Vengeance Motorcycle Owners Manual

Your new Vengeance Motorcycle is designed and manufactured to be the finest in the American V-twin industry. We have prepared a simple and understandable guide for your motorcycle’s care and operation and recommend that you follow the instructions carefully for maximum performance, vehicle safety, and enhanced personal motorcycling pleasure. You should become thoroughly acquainted with your manual before riding your Vengeance Motorcycle.

This Owner’s Manual provides instructions for the care and maintenance of minor service items that can be performed by you, the owner. Maintenance and repair procedures that involve major components such as engine, transmission, brakes, and electrical, etc. are also addressed in this manual, but it is recommended (and in some instances required) that the motorcycle be serviced by an authorized Vengeance Motorcycle Service Center. Specific procedures require the skills of a qualified, skilled technician and the use of special tools and equipment.

This manual also serves as a central location to maintain all data and records pertinent to your motorcycle. Should you ever decide to sell your motorcycle, the manual is designed to be forwarded to its new owner in order to provide its history along with necessary support information to continue its proper care and maintenance.

Driver and passenger safety is our top priority at Vengeance, and as an active member of the Motorcycle Safety Foundation, we have included help on how to ride safely as well as respond to potential riding hazards. Additionally, we have reprinted the MSF’s booklet “You and Your Motorcycle – Riding Tips” which includes insights from seasoned riders and included it in this book. Please pay particular attention to the break-in procedures. Followed correctly, these procedures will ensure peak vehicle performance over a longer period of time.

The information in this manual is based on the most recent production information available at the time of printing and was created for the entire Vengeance Motorcycle model line. Specific features vary among models, and some of the equipment mentioned may not be on your motorcycle. Vengeance Performance Products, LLC reserves the right to make changes on its motorcycles without notice or obligation.

This manuals including:
• Vengeance Warrior
• Vengeance Raider
• Vengeance Vertebreaker
• Vengeance Striker
• Vengeance Vendetta
• Vengeance Vindicator

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Direction on how to install E-Open in to a BMW Z4

Please note the following:
1) This is for information ONLY; you take full responsibility for what you do. If you blow up your car, do not come yelling at me.
2) I did this install on a US spec 2005 BMW Z4. I do NOT know if it will work on BMW’s from other countries.
3) This install did NOT work because my Z4 already had an auto top down feature from BMW that is conflicting with the E-Open.

In order to get this to work in my car I have to find out how to disable the internal remote top down feature. The unit was removed from my old 2003 Z4 and it worked just fine. All of the connections are the same.

The car: If your car was made 4/04 or later, you will have problems. The car already has an Auto-Top down feature.
Look on the inside of the driver’s side door to find out when your car was manufactured:
The E-Open: Here are some images of the E-Open. Just to make sure your are installing the same model
Installation: Open the ashtray and pull it and the lighter out.
You should see one screw in the middle. Un screw it. Then carefully pull the ash tray Up and towards the stick sift. ( look at later images to get an idea of how its shaped )

Get pdf Direction on how to install E-Open in to a BMW Z4

SUZUKI SV1000S Service Manual

This manual contains an introductory description on the SUZUKI SV1000S and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included.

Read the GENERL INFORMTION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service .

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.
* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

Get pdf SUZUKI SV1000S Service Manual

BMW D7 Owners Manual

This manual was written on your behalf in an effort to help you enjoy your new BMW Marine Engine to the maximum. No marine engine, be it the best in the world, will perform at it’s best during a long life, without proper care and maintenance. Please read this manual carefully before you set out on the first trip with your new BMW Marine Engine.

For the practical boat owner, some maintenance procedures are described in this manual. Next to some jobs, you will find this marking which indicates that the work will require special tools as well as certain special knowledge. It is, therefore, recommended that your authorized BMW Marine Dealer complete these operations.

The BMW D7 is a single-cylinder, four-stroke, direct-injection diesel engine. The engine is equipped with a raw-water cooling system, fed by an impeller type pump driven by the crankshaft. Electrical starting and charging systems are standard as is an automatic air bleeder device in the fuel system.

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Add-On Vehicle Belts, Buckles, and Clips

Many older vehicles (made before the 1996 model year) from certain manufacturers have safety belts in the front seat that are not designed to anchor child safety seats tightly. Some have buckles anchored very far forward. Many have automatic (passive) front safety belts either attached to the door of the vehicle or moving on a track above the door. Some have separate lap belts that do not lock tightly around child safety seats. Special parts may be ordered from the vehicle manufacturer to solve some of these problems.

Children should be buckled up in the back seat, if possible. However, it may be necessary to place a child safety seat in the front if all rear seating positions are in use by other children or the child safety seat cannot be firmly attached in the rear. Some manufacturers of cars with automatic belts have provided special child seat buckles or belts for anchoring a child safety seat tightly in the front seat, if necessary.

The parts listed below should ONLY be used when installing a child safety seat in one of these specific vehicles, not for restraining an older child or adult passenger. Order them from your local dealership. Dealer parts departments may not be familiar with these parts, as they are not ordered frequently. Manufacturer customer service numbers are included, in case you wish to inquire further.

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2000-LATER Suzuki DRZ400/400S INSTRUCTION SUPPLEMENT

Removing stock carburetor and cables
1. Remove seat and gas tank. Make sure fuel petcock is in “off” position.
2. Remove throttle cables and throttle housing.
3. Remove voltage regulator from left side of frame to allow carb to come out.
4. Remove stock carburetor.
5. Unplug TPS (throttle position sensor) and tape end off coming from bike.
6. Stuff a dry, clean rag into the intake manifold to keep debris from entering engine.
7. Remove engine breather lines along with plastic canister on right side of bike.

Installing the Edelbrock Carburetor and Throttle Cables
1. Install the provided throttle cables into throttle housing supplied in kit and place onto clean handle bar.
2. Remove the rubber carburetor alignment tabs from the manifold using a razor blade or sharp cutters. This should be done with the rag left in the manifold. Be very careful not to damage the manifold or your hands while doing this!!
3. Install new manifold or air boot at this time to manufacturers recommendations. NOTE: If installing onto an “S” model, you will need to reuse one of the clamps off of the stock manifold. You will reuse the clamp that holds the manifold to the head.
4. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap.
5. Install provided fuel line onto fuel inlet banjo and secure with pinch clamp.
6. If installing carb onto an “S” model, remove vacuum cap and install stock vacuum line to operate petcock. See figure 2. If vacuum line is not installed, the petcock will have too be run in the “PRIME” position.

Get pdf 2000-LATER Suzuki DRZ400/400S INSTRUCTION SUPPLEMENT

T-Engine Vendor Code System

The T-Engine Project has been established to offer an open, real-time standardized development environment with the aim of achieving a ubiquitous computing environment where everything has a computer incorporated in it and is connected to a network. T-Engine is trying to offer an efficient development environment for the development of portable information devices, home electronic appliances and other network devices in a short period of time.

T-Engine employs network security architecture called eTRON whose architecture is intended to prevent tapping, falsification, and disguise of malicious users so that electronic information can be safely delivered to the other party through insecure network channels.

To support efficient development, T-Engine standardizes hardware (T-Engine board) and realtime kernel (T-Kernel), and especially encourages distribution of middleware. T-Engine is also aimed at smoothing cooperation among semiconductor makers, hardware makers, software makers and system manufacturers, encouraging mutual business dealings, reducing development time and cost, thus enabling high value added product offerings in a short period of time. The combination of advanced semiconductors, implementation and software technologies in T-Engine makes it suitable and unrivaled for the development of advanced application products.

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BMW 545i Sedan Manual

We should have known that it would happen eventually. Last year, the vaunted BMW 5-series didn’t win a comparison test and finally fell off of our 10Best list. That the 5-series we’d grown so familiar with was still winning our enthusiast hearts after more than five years (what seems an eternity in the modern car biz), speaks volumes of praise. But, the 2003 5-series finally took the fall, taking second place to the newly designed Mercedes-Benz E-class.

Though it might have been time for a change, we were nonetheless nervous about the fate of one of our favorite luxury-sports sedans. After all, we’d heard that the all-new 2004 model would get the unnecessarily complicated iDrive information and entertainment system from the 7-series. Just as distressing, we knew that the new car would have the ominous-sounding “active front steering,” bigger dimensions, and styling that would mimic the sometimes awkward-looking 7-series.

Well, all of these things came true in the form of the 2004 5-series, and - you know what? - we still like the thing. We’re still going to have to get used to the curious slab-sided styling, but the increased dimensions (1.3 inches of height, 1.8-inches of width, and 2.3 inches of wheelbase) provide for more rear-seat room - something the outgoing car badly needed. And, through the generous use of aluminum, the 2004 5-series is actually lighter than the outgoing car, despite its increased girth. And, the iDrive knob, which is camped out on the center console (behind the shifter), operates fewer functions than in the 7-series and is, therefore, marginally easier to figure out.

It turns out the active steering is available only on Sport-package-equipped models and actually works well. At low speeds the steering ratio is a quick 10:1 to impart a feeling of nimbleness, whereas at high speeds a much slower 18:1 ratio is used to make the car feel less nervous. The transitions from quick to slow are nearly imperceptible. All of the engine choices have appeared before. The base motor is the 2.5-liter inline six in the 525i. The upgrade, in the 530i model, is the familiar 3.0-liter six. New for 2004 is the availability of the 7-series’ 325-hp 4.4-liter V-8 in place of the 290-hp unit of last year. All are available with a choice of three six-speed transmissions: stick, sequential manual, and conventional automatic. We’ll have to wait at least another year for the next M5, rumored to be powered by a 500-horsepower V-10.

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Suzuki VZR1800 Additional service manual information - Clutch cable play adjustment procedure modification

This bulletin is to inform you of a modification to the clutch cable play adjustment procedure. Due to the high engine torque and heavy vehicle weight of the VZR1800, correct clutch cable play adjustment is important to prevent clutch slippage, particularly under heavy load. Inspect and adjust the clutch cable play during pre-delivery inspection and periodic maintenance using the following procedure. Insert a copy of each of the attached pages in your dealership’s VZR1800 Service Manual at the appropriate page.

RADIATOR HOSES
• Remove the fuel tank. (96-3)
• Remove the frame head covers, radiator covers and radiator bottom cover. (99-6)
• Check to see the radiator hoses for crack, damage or engine coolant leakage.
• If any defects are found, replace the radiator hoses with new ones.
CLUTCH CABLE PLAY
• Remove the secondary gear case cover /.
• Remove the clutch cable holder 0 with the clutch cable.
• Inspect the clutch release arm play ?.
: Clutch release arm play ?: STD: 8.0 mm (0.31 in)
LIMIT: 4.0 mm (0.16 in)
• If the clutch release arm play ? less than the specification, adjust the clutch release screw as follows.
* Drain engine oil.
* Remove the muffler.

Get pdf Suzuki VZR1800 Additional service manual information - Clutch cable play adjustment procedure modification
* Remove the clutch cover.

2002 Nissan Sentra SE-R GReddy E-Manage Install

Here are the pictures of the Main Unit and of the Ignition and Injector Harnesses. I will add the GReddy E-O1 and the pressure sensor later. The Main unit is pretty small. This should allow me to easily fit the unit into the glove box for easy access.

With the Injector harness, I will be able to add to the pulse width on the injector pulse, if I run out of room on the stock MAF. In addition, the harness adds the ability to control two additional injectors or other devices. I am going to use the two additional injector outputs to control 1) a two-step rev limiter and 2) my water injection.

With the Ignition harness, I will be able to control my timing. It will allow me to either advance or retard my timing, as I need. When I add the E-O1 with it’s boost sensor, I can retard timing with boost. So I will be able to keep stock timing with normal driving, and the timing will retard up to 6* when I hit full boost. This should allow very good drivability when the car is not boosting

There is very little prep work you have to do to the harnesses before you start to work on the car. If you buy both the Ignition and the Injector harnesses, they come to you disassembled. You have to determine which wires you need and insert them into the correct slot in the plug. On the Ignition harness, we need eight out of the twelve wires provided. The colors that we would use are Blue/White and Blue/Black (Coil #1), Orange/White and Orange/Black (Coil #2), Yellow/White and Yellow/Black (Coil #3), and Purple/White and Purple/Black (Coil #4). The wires that I DID NOT use were Pink/White, Pink/Black, Light Blue/White, and Light Blue/Black. I simply pulled these wires out of the sheathing and saved them. There wires are used on cars with more than four coils. Here is a picture of the assembled Ignition Harness.

Get pdf 2002 Nissan Sentra SE-R GReddy E-Manage Install

Development of the High Speed 2ZZ-GE Engine

The 1ZZ-FE, base engine to the 2ZZ-GE, was designed with the following targets.
1. To reduce exhaust emissions and improve fuel economy without extra systems. (i.e. direct injection)
2. To make compact and lightweight

The 2ZZ-GE was designed with the following additional targets.
1. Provide high speed performance
2. Retain low speed flexibility
3. Maintain same bore pitch as base engine
4. This was to keep the same outer dimensions
5. Maintain same emission standard as base engine Target TLEV
6. Achieve best power to weight ratio in the field

HIGH SPEED PERFORMANCE AND LOW SPEED TORQUE
The 2ZZ-GE adopted a Variable Valve Timing and Lift system called VVTL-i. The system changes valve timing over the entire speed range in accordance to engine speed and load. This feature is also used in the base engine. VVTLi also changes valve lift and event angles at 6000rpm from low to high. Table 2 shows the changes in valve timing and lift.

VVTi mechanism allows the valve timing of the intake cam to be changed continuously in the range shown. VVTL-i MECHANISM – The valve timing change mechanism of the VVTL-i system, VVT-i, has already been introduced in other papers. Figure 3 shows the schematic drawing of the lift change mechanism of the VVTL-i. Figure 4 shows the detail of the mechanism set inside the rocker arm.

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BMW Clamping Adapters 3, 7 & 8 User Manuals

BMW 3 Series (with side jack lifting holes) Clamping Setup
1. Remove conventional clamp jaws.
2. Attach BMW clamping adapter (518315), 1/4 inch spacer (532196) and outer pin support (518313) to pinchweld clamps as shown.
3, Remove plugs in bottom of rocker panels and jacking holes.
4. Lower vehicle onto supports while guiding outer support pins (618302) into jacking holes.
5. Tighten thumbscrew to hold pin in place.
NOTE: Use support bolt holes on clamping adapter

BMW 7 Series Clamping Setup
1. Remove conventional clamp jaws.
2. Attach BMW clamping adapter (518315) with flat (514189) between adapter and front stand.
3. Attach outer pin support (518313) with 1/4 inch and 1/8 inch spacers (532195 and 532196) between outer support and front stand.
4. Attach BMW clamping adapter (518315) to rear stand.
5. Attach outer pin support (518313) with 1/4 inch spacer (532196) between outer support and rear stand.
6. Remove plugs in bottom of rocker panels and jacking holes.
7. Lower vehicle onto adapters while guiding outer support pins (618302) into jacking holes.
8. Add round 1/4 inch spacer (092432) between rocker panel jacking holes and outer sup- port.
9. Add round 1/8 inch spacer (092441) as needed.
10. Tighten thumbscrew to hold pin in place.
NOTE: Use lower center bolt holes on clamping adapter

Get pdf BMW Clamping Adapters 3, 7 & 8 User Manuals

Suzuki Samurai Standard Seat Cover Installation Instructions

This product is designed to enhance the appearance of the vehicle and to shield the occupants from ordinary weather conditions. Do not rely in any way on the components of this product to contain occupants within the vehicle, or to protect against injury or death in the event of an accident. This product will not protect the occupants from falling objects. Never operate vehicle in excess of manufacturer’s specifications.

Step One
Refer to your Owner’s Manual for instructions to remove the headrest. Orient the Seat Cover with the quilting toward the front of the seat. Slip the opening in the cover over the seat back and pull the cover down to the seat bottom. Make sure that the security cord on the bottom of the cover goes around and under the outside of the plastic cover of the seat recliner mechanism and tuck the fabric under the mechanism cover.

Step Two
Locate the flap sewn to the inside of the cover at the corner between the seat back and the seat bottom. Tuck the flap between the seat back and the seat bottom.

Step Three
Slide the cover over the seat bottom with the opening in the side of the cover over the seat back release lever. Release the seat back and tilt the seat forward. Unhook the security cord and thread it through the end of the flap. Hook the ends of the cord together. If necessary for a smooth fit, tighten the cord by tying a knot and tuck in any loose fabric.

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2003-2006 Suzuki SV1000S Heli Installation Instructions

Heli Bars are designed to safely increase your riding comfort, however it is imperative that these instructions be followed to ensure correct installation. Failure to follow these instructions could result in improper installation and create a dangerous control situation.

Installation is simply a reversal of the disassembly process.
* We recommend changing one bar at a time. *
1.) Remove both left and right damper weights. Note the locations of all cables, hydraulic lines and wire looms. On the right bar, the throttle cables run under the front brake reservoir. Make a note of this, as is can be confusing during reassembly. Take a digital photo or video for reference.
2.) Remove top triple clamp. (the steering stem nut is 32 mm)
3.) Remove the front brake reservoir from the right handlebar. Leave the bracket attached to the reservoir, as it will be used to remount to the Heli Bar in the same location.
4.) On the right side, assemble the controls onto the Heli Bar and slide down on the fork tube low enough so they don’t interfere with the top triple clamp when it’s reinstalled. Tighten the clamp screws enough so the bar does not move.
5.) Assemble the left side controls on the left Heli Bar and slide down on left fork tube as per above.
6.) Reassemble the top triple clamp. To make this easier, put the machine in 1st gear. Standing in front of the machine, put one of your shins against the front wheel and apply a bit of rearward force to the front end. This will help take the bind out of the front end and help the triple clamp slide down over the steering stem. Torque the steering stem nut and the two fork tube pinch bolts to the factory specs.

Get pdf 2003-2006 Suzuki SV1000S Heli Installation Instructions

Hyundai Tuscon Engine & Suspension Removal & Replacement Allowances

There have been some changes to time allowances for engine and suspension assemblies on recently scheduled vehicles. Previous schedules have shown separate remove and replace allowances for engines and suspension assemblies of approximately 8.00 to 9.50 hours depending on make and model. When formulated, these allowances reflected a component assembly of the motor, suspension and engine compartment hardware.

A consideration of vehicle design for many new models is modular component assembly. This is revellent to 2 areas of the engine compartment. This is specific to front wheel drive vehicles and is detailed below.
1. Engine and suspension assemblies mounted on a modular cradle and installed into the car from underneath as a single unit – Diagram 1.
2. Wiring harnesses are designed to be disconnected at a junction which could be either the fuse box or the ECU through the firewall. This allows the harness to stay with the engine assembly - Photo 2. As shown on an AH Holden Astra, the engine compartment has 3 individual wiring harnesses which unclip from the lower fuse box casing.

Future schedules will consider the above when the time allowances are being formulated.

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2003- LATER Suzuki LTZ400 and Kawasaki KFX400 INSTRUCTION SUPPLEMENT

Removing stock carburetor and cables.
1. Remove seat, front fenders and gas tank. Make sure fuel petcock is in “ON” or “RES” position. If it is in the “PRI” position it will allow fuel through it.
2. Remove throttle cable, (and housing if installing a twist kit) from throttle housing. Pay close attention to routing when removing cable as the new cables will need too be routed the same.
3. Disconnect choke cable from stock carburetor before disconnecting it from handle bar and remove.
4. Remove stock carburetor.
5. Stuff a dry, clean rag into the intake manifold to keep debris from entering engine.
6. Remove stock rear head stay from frame and head.
7. Remove plastic vent box from right side of frame along with hoses.

Installing the Edelbrock Carburetor and Throttle Cables
1. Install new rear head stay. NOTE: Start four frame bolts before inserting larger bolt through stay and cylinder head. It is recommended blue Loctite or equivalent be used on frame bolts. Tighten frame bolts first, then head bolt.
2. Install large clear hose to upper, rear pointing barb (hose comes from air boot) on plastic breather box and secure with clamps.
3. Remove the rubber carburetor alignment tabs from the manifold using a razor blade or side cutters. Be careful not to damage manifold or fingers during this procedure!!
4. Install the throttle cable into the stock throttle housing. If using a twist kit, install cables into supplied throttle housing supplied with kit and place onto clean handlebar end.
5. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap.
6. Install supplied fuel line onto carburetor and secure with pinch clamp.
7. Install supplied vacuum line onto brass carburetor vacuum fitting. See Figure 1. The vacuum fitting will have a black vinyl cap on it from the factory.

Get pdf 2003- LATER Suzuki LTZ400 and Kawasaki KFX400 INSTRUCTION SUPPLEMENT

Suzuki Grand Vitara Lightbar Roof Rack Mount Installation Guide

This mounting clamp will mount to your Grand Vitara’s roof rack using the supplied mounting hardware. The lightbars mounting foot will mount to the bracket. It is recommended that two people do the installation as you will need to adjust both sides of the brackets and feet once it is on the vehicle.

1. First mount the two mounting feet onto the lightbar as shown in the instructions included with the lightbar. Do not fully tighten the mounting hardware as it will need to be adjusted once it is on the vehicle. You will also need to remove the two outer rubber pads and their guide darts from both feet to accomodate the bracket.
2. Mount the supplied gaskets to both the clamp(s) and bracket(s). The gasket should be applied to the side of the bracket that comes in contact with the vehicle as shown above.
3. Mount both brackets to the roof rack as shown and secure them loosely enough so they slide back and forth so you can adjust them later. The brackets should be mounted as far forward (toward the front of the vehicle) as possible, but not past the seam on the roof rack. Also be sure that the brackets are both mounted the same distance from the front of the vehicle.
4. Now take the lightbar (with both mounting feet loosely mounted to it) and place it onto the brackets so the bolt head on the bracket goes through the hole in the mounting foot that you removed the guide darts from.
5. Adjust both the brackets and mounting feet to the desired mounting position (refer to the manual that comes with the lightbar for any warnings on positioning the lightbar) then secure the mounting feet to the lightbar.
6. Adjust the two brackets so they are in the desired mounting position and tighten the brackets mounting hardware to secure them to the roof rack. IMPORTANT: Be sure to tighten the bracket mounting hardware enough to secure the brackets firmly, but be careful not to over tighten and damage the roof rack.

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Synthetic Manual Transmission & Transaxle Gear Lube

AMSOIL Synthetic Manual Transmission and Transaxle Gear Lube (MTG) is a premium blend of the finest synthetic base oils and advanced, high-performance additives. It is formulated specifically for maximum protection in the most demanding manual transmission and transaxle applications where an extreme-pressure GL-4 gear lube is specified, including those where high-horsepower/high-torque engines and towing or heavy loads increase transmission stress.

AMSOIL MTG prevents the thinning effects of mechanical shear. It maintains its viscosity and superior film strength for consistent, long-lasting wear protection. MTG excels in hot and cold temperature extremes that exceed the limits of conventional mineral oils. It protects against rust, keeps seals soft for long life, and is compatible with brass synchros for smooth synchromesh shift quality. Ideal for NV-4500 Transmissions

MTG is a thermally stable, extreme-pressure formulation that resists heat, oxidation, acid build-up and varnish. It is the ideal gear lube for high-temperature applications, including the New Venture NV-4500 transmission, which retains heat due to its cast iron housing and is often subjected to heavy loads and high torque from turbo-diesel engines.

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BMW Sirius Receiver Installation Guide

This is BMW Sirius receiver installation guide for BMW X5 (E53) with navigation. This installation guide is intended to supplement the BMW Installation Instructions to help you with the installation of the BMW Sirius Receiver for X5 (E53) with Navigation. I opted for the Terk SIR3 Low-Profile Magnetic Mount antenna and mounted it in the spoiler. As a result, this guide will not cover the installation of the BMW Sirius Satellite Antenna and you should follow the instructions supplied with the BMW Sirius Satellite Antenna Kit if you decide to go that route. I found no signal loss or weak reception with the antenna being in the spoiler and would strongly recommend if you want to be stealth and do not like the obtrusive shape of the BMW Sirius antenna on your roof.

You could also try to mount the BMW Sirius Satellite Antenna in the spoiler, but it is too big to fit in there. I attempted to remove the antenna cover to make room, but could not pull back the weather stripping to expose the torx screws. Pictures of the BMW Sirius Satellite Antenna are attached in the last section to show you more details.

Cost wise, the Terk SIR3 and SIR-SP splitter cost about $65 plus sales tax and can be purchased from Best Buy, Circuit City, Crutchfield, Sound Advice, or your local audio shops. The BMW Satellite Roof Antenna is retailed at $125.00 and can be purchased for as little as $93.60 from Pacific BMW, Circle BMW, or Crevier BMW.

It takes me about 3 hours to complete the project, and the bulk of time was spent on mounting the Terk SIR3 antenna on the spoiler and fishing the antenna lead through the rubber grommets (about 1 and ½ hours!). But I also wanted to take my time and do it right, especially not rushing through the procedures and kink or crimp the antenna leads.

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Suzuki VZR1800 Oil Level Inspection And Oil Change Procedure

Suzuki has received reports of overfilled engine oil at initial delivery. The VZR1800K6 uses the Suzuki Advanced Sump System (SASS). The system uses the transmission chamber as an oil tank in this semi-dry sump engine design. Following the proper oil level inspection procedure during Pre-delivery inspection and oil changes is critical to ensure the correct engine oil level. Overfilling the oil sump may cause excess oil to enter the air cleaner housing, contaminating the filter causing poor performance and possible oil leakage. Please instruct your customers in the proper method of checking and filling the oil level.

Oil Level Inspection
Warm up the engine for 15 minutes to move all oil from the crankshaft area to the sump (transmission) area. Stop the engine and wait 3 minutes. Remove and wipe the dipstick. Insert the dipstick- do not thread it in. Read the dipstick and adjust the oil level between the F and L marks as needed.

Running the engine can be done on the sidestand or upright, but the oil level must be checked with the motorcycle in the vertical position. Warm-up for less than 15 minutes will give a false low oil level reading indicating more oil should be added (overfilled). Stopping the engine for 3 minutes stabilizes the oil level. Too little time may indicate a low oil level. If the engine is left to cool, the oil level will read low and the process must be repeated.

Oil Change Procedure
Follow the Periodic Maintenance Chart in the service manual for changing the oil at the prescribed intervals. Warm-up the engine for 15 minutes to move all oil from the crank- shaft area to the sump (transmission) area. With the motorcycle in the vertical position remove both oil drain plugs, one for the engine, one for the sump (transmission)

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1993 Suzuki Swift Adjustments

Swift DOHC uses hydraulic lifters. No adjustments are required.
Samurai & Sidekick
1) Remove valve cover. Rotate engine until zero degree (TDC) timing mark of timing belt cover is in line with timing mark on crankshaft pulley. See Fig. 1.
2) Ensure cylinder No. 1 is at TDC on compression stroke. Remove distributor cap. On Samurai and Sidekick (TBI), ensure rotor is pointed upward at distributor hold-down bolt and to No. 1 terminal of distributor cap. On Sidekick (MPI), ensure rotor is at about 1 o’clock position and pointed to No. 1 terminal of distributor cap. If rotor is not as described, rotate crankshaft 360 degrees.
3) Measure valve clearance between adjustment screw and valve stem using shim thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1and 3. See VALVE CLEARANCE SPECIFICATIONS table.
4) Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4.
5) Adjust valves by loosening lock nut and turning adjusting screw until clearance is as specified. After adjusting clearance, tighten adjusting screw lock nut to 11.0-13.5 ft. lbs. (15-18 N.m) for Samurai or 90-108 INCH lbs. (10-13 N.m) on Sidekick. On all models, recheck clearance.

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MCS 245 MotorVac CarbonClean Fuel System Cleaner Operator Manual

The MotorVac CarbonClean System is a self-contained cleaning system, designed to connect to any gasoline engine. Once the unit is connected, it temporarily replaces the regular fuel supply with a mixture of gasoline and the specially formulated MotorVac CarbonClean Detergent and Top Engine Cleaner.

With the engine idling, the unit pumps the gasoline/detergent mixture through the engine’s fuel system. As the mixture passes through the fuel loop, it loosens and dissolves accumulated deposits, which then pass harmlessly out through the exhaust system or are removed by the unit’s fuel filter. Removing contaminants from the combustion chamber creates a more even burn of fuel, which improves horsepower, increases fuel economy, and reduces exhaust emissions. It is recommended that you perform the fuel system cleaning procedure on a vehicle every 12,000 miles to obtain the highest fuel system efficiency.

Please study this Operators Manual to become thoroughly familiar with the MotorVac CarbonClean System before using it.

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BMW 7 Interface (E65/E66) Installation / Connection Manual

The step for this BMW E65/66 Interface Installation Manual:
Caution before working
1. Before installation, be sure to key off and wait more than 5 minutes for complete discharge of electricity
2. Don’t turn on the ignition during connectors are disconnected, because if you turn on the ignition with disconnected connectors, ECU falsely recognize status of car as an error and display error code on monitor
3. Be sure to use the tools of proper size and usage.
4. Don’t try to dissemble and assemble by force
5. Use proper tape or soft fabric to protect car from scratch or damage
6. Be sure to use power line from cigar lighter. In the case that you cannot use power line from cigar lighter, be sure to use a relay to protect interface from electric shock.

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SUZUKI M50 & C50 BOULEVARD THUNDER Air Filter Kit

We’re sure you’ll be pleased with the new level of performance you’ll experience. This kit should be installed on bikes with After Market Exhaust Pipes only and jetted, (not included). We recommend that an experienced mechanic perform this conversion. Use the appropriate Suzuki service manual for reference to complete jetting of carbs. Remember, gasoline is extremely flammable and can be explosive under certain conditions. Work in a well-ventilated area and clean up any spills immediately. Check for leaks before riding.

Read First
1) Remove the stock air box 2 – 4mm allen heads at the top of the air box. Loosen the hose clamp and pull out from the bottom of the air box and remove.
2) Unplug the electrical sensor and fresh air hose from the back of the air cleaner
3) Remove the stock air box mounting bracket 3 – 10mm bolts

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BMW 740i/iL Trunk Shock Replacement Procedure

Vehicle: 1997 740iL, however, I think this applies to all 95-01.
Symptom: trunk may not stay fully open or may free fall when closing. In my case, the trunk would free fall closed and unless I was holding it carefully, it would slam shut.
The procedure took only about 30 minutes and was very easy. The outcome was excellent making the project well worth it and highly recommended.

Procedure:
1. It is best to remove and replace one shock and then move to the other side. Without any shock the trunk will easily fall on your head. To be safe, you may want to prop the trunk lid so it cannot fall on your head. When I had one shock removed, the wind did blow the lid down on my head!
2. Begin with the driver side shock. I recommend this because it is slightly easier since the wiring/harness does not come into play.
3. First, remove the c-clip of the upper mount, but do not disconnect the shock from the pivot mount yet. Here is picture with c-clip already removed. Another tip, I suggest replacing since cheap, but regardless, when you attempt to remove try to cover the clip with a rag so it doesn’t go flying. Mine disappeared out in the yard somewhere.
4. The next step is to remove the lower mounting clip. This is accomplished by using a screwdriver to push the clip downward and off the shock.
5. Now the driver side shock can be removed. Simply pull the lower part straight out and pull the upper mount off the pivot shaft. Again, be careful here that the trunk stays up and not on your skull.
6. Next install the new drivers side trunk shock. But first clean off the upper mount shaft and the lower ball joint. It really isn’t necessary to grease these connections because the new shock comes with grease already in the part.

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Brake Fluid Exchanger BFX-1 Operator Manual

Verify that the Brake System does not have any malfunctions. If the system is found to be malfunctioning verify that the malfunction will not interfere with the exchange process. Perform all necessary repairs prior to exchanging.
1. Verify that the vehicle engine is off.
2. Verify new and used fluid tank levels. Add new fluid or empty used as required.
3. Verify that all Switches and Attention Lights on the BFX control panel are OFF.
4. Connect red (positive) clamp on power cable to red (positive) terminal on vehicle battery.
Connect the black (negative) clamp to a good ground. A good ground can be located by following the negative cable from the battery to where it is connected to the chassis.
5. Remove master cylinder cover and inspect the master cylinder for damage. Repair any damage found before continuing.
6. Turn on EMPTY MASTER CYLINDER switch and use the Vacuum Hose to remove all of the fluid from the master cylinder.
7. Turn off EMPTY MASTER CYLINDER switch when master cylinder is empty and return Vacuum Hose to Parking Stud.
Note: Failure to park Vacuum Hose on Parking Stud will result in minimum to no vacuum at bleeder hoses.
8. Connect Fill Gun to Fill Hose. Turn on FILL MASTER CYLINDER switch and squeeze trigger on Fill Gun to dispense fluid until master cylinder level is at the fill/max mark. Turn off FILL MASTER CYLINDER and disconnect Fill Gun from the Fill Hose.
Note: To avoid fluid discharge from Fill Gun do not squeeze trigger after disconnecting from Fill Hose.
9. Connect Master Cylinder Adapter

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2007 Suzuki RM-Z/RM Specifications

It is simple, really. You want to win races. When you are not at the race track, it is all you can think about. When you are at the track, it consumes every moment. The desire to win, it is ingrained early on and cultivated through competition. You know what you want, so why not give yourself the best chance to feed your desire for winning with a Suzuki motocrosser?

Suzuki RM and RM-Z motocrossers inspire confidence in riders. That is what Suzuki engineers strive hard for each model year. These are people who have dedicated themselves to making sure you have the perfect bike for winning. Engineered with passion. Engineered by experience.

This year is no different. Based on feedback from multi-time AMA champion –and 2006 AMA Supercross Champion — Ricky Carmichael, countless other test riders and racers just like you, Suzuki brings an all-new, Suzuki-engineered RM-Z250 to the showroom floor. These engineers, testers and this champion ensure you have the winning balance of power and handling.

Whether that balance lay in a bike with a compact and powerful two-stroke powerplant, or a bike with a high-tech and high-revving four-stroke, Suzuki absolutely has you covered. No matter your taste in powerplant, your riding skill or your class at the track, you can choose from the RM-Z450 or all-new RM-Z250 four-stroke or the RM250, RM125, RM85 and RM85L two-strokes. Suzuki is the first manufacturer to win the prestigious AMA Supercross crown on two- and four-stroke machines

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BMW MINI Quick Fit Rallye 4 Harnessbelts Installation & Operating Instructions

This SCHROTH asm harnessbelt is only suitable for adults on front outboard seating positions. SCHROTH asm harnessbelts are not intended or suited for use by children under 12 years of age, or persons who weigh less than 88 lbs (40 kg) or those who are less than 4′11″ tall (1.50 meters), regardless of age. Such persons will not be adequately protected by the harness system and may receive more severe injury than would otherwise be expected.

SCHROTH U.S. model harnessbelts have been tested in accordance with performance parameters of Federal Motor Vehicle Safety Standard 209 with the exception of Paragraph S 4.6 (full scale impact testing as described in FMVSS 208). FMVSS 209 deals with lap and three point restraints and does not expressly refer to harness belts. SCHROTH has nevertheless applied the performance criteria specified in FMVSS 209 to the system to the extent applicable.

Always leave original equipment seat belts in place and available for use. We strongly recommend that you leave in place all MINI factory provided 3-point restraint systems originally supplied for the front and rear seating positions of your vehicle when you install the SCHROTH asm harnessbelt. Removal of original equipment restraint systems may also violate applicable State or Federal law.

To carry rear seat passengers, you must use your standard 3-point factory provided front seat belts. To use the factory installed seat belts after a SCHROTH MINI Rallye 4 belt has been installed you must first release (un-clip) all four points of the SCHROTH belt and remove it.

Leaving original equipment restraint systems in place and fully functional will enable you to choose either the SCHROTH Rallye 4 OR the vehicle’s standard seat belts when it is necessary to transport passengers in any of the rear seats or when either harness belt is not suited for use by the driver or front seat passenger.

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OBD II Code Reader Owners Manual

This Code Reader and manual are designed for use both by consumers with little or no experience in retrieving codes, or by experienced technicians desiring a more in-depth explanation of OBD II system basics.

If you are having problems with your vehicle and only want to know if any Diagnostic Trouble Codes are present in the vehicle’s computer system, go directly to paragraph 4.2 and follow the simple directions to retrieve the codes. The codes retrieved, and their definitions, will give you valuable information and a starting point from which to proceed to the next step.

Once the codes have been retrieved, you can choose to:
• Take your vehicle to an Automotive Service Center for repair: Take your vehicle, a copy of the completed Preliminary Vehicle Diagnosis Worksheet (see page 1-5) and codes retrieved to your technician for evaluation. This will demonstrate to your technician that you are an informed motorist and will also assist him in pinpointing the location of the problem.
• Attempt to fix the problem yourself: If you choose to fix the problem yourself, read and follow all of the manual’s recommendations and procedures.

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