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This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle.
Using this repair manual is an inexpensive way to keep your car working properly. You can see on mobile phone, Ipad, Note, Computer… You will be received download link after payment. What customer say about us! Win Thu Manuals are as advertised, and if there is a problem, they will correct it immediately. Darren Milke Jacque D Scot Nikistratos Kanavas Paul Garrison Blacky Dog Ardz New Zealand Grades range from No. For specific applications, manufacturers may recommend water-resistant type grease or one with an additive such as molybdenum disulfide MoS2.
Mineral oil will cause. Brake fluid is the hydraulic fluid used to transmit hydraulic pressure force to the wheel brakes. This classification appears on the fluid container.
Each type of brake fluid has its own definite characteristics. Do not intermix different types of brake fluid as this may cause brake system failure. DOT 5 brake fluid is silicone based and the type required for XL sportsters. Other types are not compatible with DOT 5 brake fluid. When adding brake fluid, only use the fluid recommended by the manufacturer DOT 5. Brake fluid will damage any plastic, painted or plated surface it contacts. Use extreme care when working with brake fluid and remove any spills immediately with soap and water.
Hydraulic brake systems require clean and moisture free brake fluid. Never reuse brake fluid. Keep containers and reservoirs properly sealed. Cleaners, Degreasers and Solvents Many chemicals are available to remove oil, grease and other residue from the motorcycle. Before using cleaning solvents, consider how they will be used and disposed of, particularly if they are not water-soluble. Local ordinances may require special procedures for the disposal of many types of cleaning chemicals.
Refer to Safety and Cleaning Parts in this chapter for more information on their use. Use brake parts cleaner to clean brake system components when contact with petroleum-based products will damage seals. Brake parts cleaner leaves no residue. Use electrical contact cleaner to clean electrical connections and components without leaving any residue. Carburetor cleaner is a powerful solvent used to remove fuel deposits and varnish from fuel system components. Use this cleaner carefully, as it may damage finishes.
Generally, degreasers are strong cleaners used to remove heavy accumulations of grease from engine and frame components.
Most solvents are designed to be used with a parts washing cabinet for individual component cleaning. For safety, use only nonflammable or high flash point solvents. Gasket Sealant Sealants are sometimes used in combination with a gasket or seal and occasionally alone. Use extreme care when choosing a sealant different from the type originally recommended. Choose sealants based on their resistance to heat, various fluids and their sealing capabilities.
One of the most common sealants is RTV, or room temperature vulcanizing sealant. This sealant cures at room temperature over a specific time period. This allows the repositioning of components without damaging gaskets. Moisture in the air causes the RTV sealant to cure.
Always install the tube cap as soon as possible after applying RTV sealant. RTV sealant has a limited shelf life and will not cure properly if the shelf life has expired.
Keep partial tubes sealed and discard them if they have surpassed the expiration date. Applying RTV sealant Clean all old gasket residue from the mating surfaces. Remove all gasket material from blind threaded holes; it can cause inaccurate bolt torque. Spray the mating surfaces with aerosol parts cleaner and then wipe with a lint-free cloth. The area must be clean for the sealant to adhere. Apply RTV sealant in a continuous bead 0.
Circle all the fastener holes unless otherwise specified. Do not allow any sealant to enter these holes. Assemble and tighten the fasteners to the specified torque within the time frame recommended by the RTV sealant manufacturer.
Gasket Remover Aerosol gasket remover can help remove stubborn gaskets. This product can speed up the removal process and prevent damage to the mating surface that may be caused by using a scraping tool. Most of these types of products are very caustic.
Use caution when using these products in areas where plastic components are located. A threadlocking compound is a fluid applied to the threads of fasteners. After tightening the fastener, the fluid dries and becomes a solid filler between the threads. This makes it difficult for the fastener to work loose from vibration, or heat expansion and contraction.
Some threadlocking compounds also provide a seal against fluid leaks. Before applying threadlocking compound, remove any old compound from both thread areas and clean them with aerosol parts cleaner. Use the compound sparingly. Excess fluid can run into adjoining parts. Threadlocking compounds are available in different strengths.
TOOLS Most of the procedures in this manual can be carried out with familiar hand tools and test equipment. Always use the correct tools for the job at hand.
Keep tools organized and clean. Store them in a tool chest with related tools organized together. Quality tools are essential.
The best are constructed of high-strength alloy steel. These tools are light, easy to use and resistant to wear. Their working surface is devoid of sharp edges and the tool is carefully polished. They have an easy-to-clean finish and are comfortable to use. Quality tools are a good investment. If a tool kit is just now being started, consider purchasing a basic tool set from a quality tool supplier. These sets are available in many tool combinations and offer substantial savings when compared to in-.
As work experience grows and tasks become more complicated, specialized tools can be added. In most cases, the tool is described in use. In some cases a substitute tool may work.
However, do not risk injury or damage to the equipment by using the incorrect tool. If the required tools are expensive it may be more cost effective to have the task performed by a dealership or qualified shop. These part numbers are correct at the time of original publication. The publisher cannot guarantee the part numbers or tools listed in this manual will be available in the future.
Screwdrivers Screwdrivers of various lengths and types are mandatory for the simplest tool kit. The two basic types are the. An open-end wrench is fast and works best in areas with limited overhead access. It contacts the fastener at only two points, and is subject to slipping under heavy force, or if the tool or fastener is worn.
A box-end wrench is preferred in most instances, especially when breaking loose and applying the final tightness to a fastener. The combination wrench has a box-end on one end, and an open-end on the other. This combination makes it a very convenient tool. Adjustable Wrenches. These are available in sets that often include an assortment of tip sizes and shaft lengths.
As with all tools, use a screwdriver designed for the job. Make sure the size of the tip conforms to the size and shape of the fastener. Use them only for driving screws. Never use a screwdriver for prying or chiseling metal.
Repair or replace worn or damaged screwdrivers. A worn tip may damage the fastener, making it difficult to remove. An adjustable wrench or Crescent wrench Figure 11 can fit nearly any nut or bolt head that has clear access around its entire perimeter.
Adjustable wrenches are best used as a backup wrench to keep a large nut or bolt from turning while the other end is being loosened or tightened with a box-end or socket wrench. Adjustable wrenches contact the fastener at only two points, which makes them more subject to slipping off the fastener. The fact that one jaw is adjustable and may loosen increases this possibility. Make certain the solid jaw is the one transmitting the force. Socket Wrenches, Ratchets and Handles Sockets that attach to a ratchet handle Figure 12 are available with 6-point A, Figure 13 or point B openings and different drive sizes.
The drive size indicates the size of the square hole that accepts the ratchet handle. The number stamped on the socket is the size of the work area and must match the fastener head. As with wrenches, a 6-point socket provides superior-holding ability, while a point socket needs to be moved only half as far to reposition it on the fastener. Wrenches Open-end, box-end and combination wrenches Figure 10 are available in a variety of types and sizes.
The number stamped on the wrench refers to the distance between the work areas. This size must match the size of the fastener head. The box-end wrench is an excellent tool because it grips the fastener on all sides. This reduces the chance of the tool slipping. The box-end wrench is designed with either a 6- or point opening. For stubborn or damaged fasteners, the 6-point provides superior holding ability by contacting the fastener across a wider area at all six edges.
For general use, the point works well. It allows the wrench. Always wear eye protection when using impact or air tools. Sockets are designated for either hand or impact use. Impact sockets are made of thicker material for more durability. Compare the size and wall thickness of a mm hand socket A, Figure 14 and the mm impact socket B.
Use impact sockets when using an impact driver or air tools. Use hand sockets with hand-driven attachments. Various handles are available for sockets.
The speed handle is used for fast operation. Flexible ratchet heads in. Extension bars allow the socket setup to reach difficult areas. The ratchet is the most versatile. It allows the user to install or remove the nut without removing the socket. Sockets combined with any number of drivers make them undoubtedly the fastest, safest and most convenient tool for fastener removal and installation. An impact driver provides extra force for removing fasteners, by converting the impact of a hammer into a turning motion.
This makes it possible to remove stubborn fasteners without damaging them. Impact drivers and interchangeable bits Figure 15 are available from most tool suppliers. When using a socket with an impact driver make sure the socket is designed for impact use.
Refer to Socket Wrenches, Ratchets and Handles in this section. Allen Wrenches Allen or setscrew wrenches Figure 16 are used on fasteners with hexagonal recesses in the fastener head. These wrenches are available in L-shaped bar, socket and T-handle types. Allen bolts are sometimes called socket bolts.
Torque Wrenches A torque wrench is used with a socket, torque adapter or similar extension to tighten a fastener to a measured torque. The drive size indicates the size of the square drive that accepts the socket, adapter or extension. Common methods of reading the torque value are the deflecting beam, the dial indicator and the audible click Figure When choosing a torque wrench, consider the torque range, drive size and accuracy. The torque specifications in this manual provide an indication of the range required.
A torque wrench is a precision tool that must be properly cared for to remain accurate. Store torque wrenches in cases or separate padded drawers within a toolbox. Torque Adapters Torque adapters or extensions extend or reduce the reach of a torque wrench. The torque adapter shown in Figure 18 is used to tighten a fastener that cannot be reached due to the size of the torque wrench head, drive, and socket. If a torque adapter changes the effective lever length Figure 19 , the torque reading on the wrench will not equal the actual torque applied to the fastener.
It is. When a torque adapter is used at a right angle to the drive head, calibration is not required, since the lever length has not changed. To recalculate a torque reading when using a torque adapter, use the following formula, and refer to Figure TA is the torque specification and the actual amount of torque that will be applied to the fastener. A is the amount that the adapter increases or in some cases reduces the effective lever length as measured along the centerline of the torque wrench Figure L is the lever length of the wrench as measured from the center of the drive to the center of the grip.
The effective lever length is the sum of L and A Figure When using a beam-type wrench, tighten the fastener until the pointer aligns with In this example, although the torque wrench is preset to Pliers Pliers come in a wide range of types and sizes.
Pliers are useful for holding, cutting, bending, and crimping. Do not use them to turn fasteners. Figure 20 and Figure 21 show several types of useful pliers. Each design has a specialized function. Slip-joint pliers are general-purpose pliers used for gripping and bending. Diagonal cutting pliers are needed to cut wire and can be used to remove cotter pins.
Needlenose pliers are used to hold or bend small objects. Locking pliers Figure 21 , sometimes called Vise-Grips, are used to hold objects very tightly. They have many uses ranging from holding two parts together, to gripping the end of a broken stud. Use caution when using locking pliers, as the sharp jaws will damage the objects they hold. Also, the snap ring plier tips may break. Always wear eye protection when using snap ring pliers.
Snap ring pliers are specialized pliers with tips that fit into the ends of snap rings to remove and install them. Snap ring pliers are available with a fixed action either internal or external or convertible one tool works on both internal and external snap rings. They may have fixed tips or interchangeable ones of various sizes and angles. For general use, select a convertible type of pliers with interchangeable tips.
Never use a metal-faced hammer on engine and suspension components, as damage will occur in most cases. Equipment is manufactured to close tolerances, and obtaining consistently accurate measurements is required to determine which components need replacement or further service.
Each type of measuring instrument is designed to measure a dimension with a certain degree of accuracy and within a certain range. When selecting the measuring tool, make sure it is applicable to the task.
Refer to Figure 23 for a comprehensive measuring set. As with all tools, measuring tools provide the best results if cared for properly. Improper use can damage the tool and cause inaccurate results. If any measurement is questionable, verify the measurement using another tool. A standard gauge is usually provided with measuring tools to check accuracy and calibrate the tool if necessary. Precision measurements can vary according to the experience of the person performing the procedure.
Accurate results are only possible if the mechanic possesses a feel for using the tool. Heavy-handed use of measuring tools will produce less accurate results. Hold the tool gently by the fingertips so the point at which the tool contacts the object is easily felt. This feel for the equipment will produce more accurate measurements and reduce the risk of damaging the tool or component. Refer to the following sections for specific measuring tools. Make sure the hammer face is in good condition and the handle is not cracked.
Select the correct hammer for the job and make sure to strike the object squarely. Do not use the handle or the side of the hammer to strike an object. The feeler or thickness gauge Figure 24 is used for measuring the distance between two surfaces. A feeler gauge set consists of an assortment of steel strips of graduated thickness. Each blade is marked with its thickness. Blades can be of various lengths and angles for different procedures.
A common use for a feeler gauge is to measure valve clearance. Wire round type gauges are used to measure spark plug gap. Various types of hammers Figure 22 are available to fit a number of applications. A ball-peen hammer is used to strike another tool, such as a punch or chisel. Soft-faced hammers are required when a metal object must be struck.
Calipers Figure 25 are used for obtaining inside, outside and depth measurements. Although not as precise as a micrometer, they typically allow measurement to within. Most calipers have a range up to mm 6 in. Calipers are available in dial, vernier or digital versions. Dial calipers have a dial readout that provides convenient reading. Vernier calipers have marked scales that must be compared to determine the measurement.
The digital caliper uses a LCD to show the measurement. Properly maintain the measuring surfaces of the caliper. There must not be any dirt or burrs between the tool and the measured object.
Never force the caliper closed around an object; close the caliper around the highest point so it can be removed with a slight drag. Some calipers require calibration. To read a vernier caliper refer to Figure The fixed scale is marked in 1 mm increments.
Ten individual lines on the fixed scale equal 1 cm. The movable scale is marked in 0. To obtain a reading, establish the first number by the location of the 0 line on the movable scale in relation to the first line to the left on the fixed scale. In this example, the number is 10 mm.
To determine the next number, note which of the lines on the movable scale align with a mark on the fixed scale. A number of lines will seem close, but only one will align exactly. In this case, 0. The result of adding 10 mm and 0. Micrometers A micrometer is an instrument designed for linear measurement using the decimal divisions of the inch or meter Figure While there are many types and styles of micrometers, most of the procedures in this manual call for an outside micrometer.
The outside micrometer is used to measure the outside diameter of cylindrical forms and the thickness of materials. The usual sizes Figure 28 are in. Micrometers that cover a wider range of measurements are available. These use a large frame with interchangeable anvils of various lengths. This type of micrometer offers a cost savings; however, its overall size may make it less convenient. Adjustment Before using a micrometer, check its adjustment as follows.
Use it when reading decimals from one-tenth to one one-thousandth of an inch or millimeter. It is not a conversion chart for example: 0.
Clean the anvil and spindle faces. To check a in. Turn the thimble until the spindle contacts the anvil. If the micrometer has a ratchet stop, use it to ensure that the proper amount of pressure is applied. If the adjustment is correct, the 0 mark on the thimble will align exactly with the 0 mark on the sleeve line. If the marks do not align, the micrometer is out of adjustment.
To check a micrometer larger than 1 in. A standard gauge is a steel block, disc or rod that is machined to an exact size. Place the standard gauge between the spindle and anvil, and measure its outside diameter or length. Micrometers are precision instruments. They must be used and maintained with great care. Note the following: 1. Store micrometers in protective cases or separate padded drawers in a toolbox. When in storage, make sure the spindle and anvil faces do not contact each other or another object.
If they do, temperature changes and corrosion may damage the contact faces. Do not clean a micrometer with compressed air. Dirt forced into the tool causes wear. Lubricate micrometers to prevent corrosion. Reading When reading a micrometer, numbers are taken from different scales and added together.
Make sure there is no dirt or burrs between the tool and the measured object. Never force the micrometer closed around an object. Close the micrometer around the highest point so it can be removed with a slight drag. The standard inch micrometer Figure 29 is accurate to one-thousandth of an inch or 0. The sleeve is marked in 0. Every fourth sleeve mark is numbered 1, 2, 3, 4, 5, 6, 7, 8, 9.
These numbers indicate 0. The tapered end of the thimble has twenty-five lines marked around it. Each mark equals 0. One complete turn of the thimble will align its zero mark with the first mark on the sleeve or 0. When reading a standard inch micrometer, perform the following steps while referring to Figure Read the sleeve and find the largest number visible.
Each sleeve number equals 0. Count the number of lines between the numbered sleeve mark and the edge of the thimble. Each sleeve mark equals 0. Read the thimble mark that aligns with the sleeve line. Each thimble mark equals 0. NOTE If a thimble mark does not align exactly with the sleeve line, estimate the amount between the lines or use a vernier inch micrometer. Add the readings from Steps Neither gauge has a scale for direct readings.
An outside micrometer must be used to determine the reading. To use a telescoping gauge, select the correct size gauge for the bore. Compress the movable post and carefully insert the gauge into the bore. Carefully move the gauge in the bore to make sure it is centered. Tighten the knurled end of the gauge to hold the movable post in position. Remove the gauge and measure the length of the posts. Telescoping gauges are typically used to measure cylinder bores. To use a small-hole gauge, select the correct size gauge for the bore.
Carefully insert the gauge into the bore. Tighten the knurled end of the gauge to carefully expand. Do not overtighten the gauge, as there is no built-in release.
Excessive tightening can damage the bore surface and damage the tool. Remove the gauge and measure the outside dimension Figure Small hole gauges are typically used to measure valve guides.
Dial Indicator A dial indicator Figure 34 is a gauge with a dial face and needle used to measure variations in dimensions and. Measuring brake rotor runout is a typical use for a dial indicator. Dial indicators are available in various ranges and graduations and with three basic types of mounting bases: magnetic Figure 34 , clamp, or screw-in stud.
Cylinder Bore Gauge. A cylinder bore gauge is similar to a dial indicator. The gauge set shown in Figure 35 consists of a dial indicator, handle, and different length adapters anvils to fit the gauge to various bore sizes. The bore gauge is used to measure bore size, taper and out-of-round. The gauge adapter is either inserted and held in place or screwed into the spark plug hole to obtain the reading.
Disable the engine so it does not start and hold the throttle. Multimeter A multimeter Figure 37 is an essential tool for electrical system diagnosis. The voltage function indicates the voltage applied or available to various electrical components. The ohmmeter function tests circuits for continuity, or lack of continuity, and measures the resistance of a circuit.
Results may vary if using a meter not recommended by the manufacturer is used. Such requirements are noted when applicable. Ohmmeter analog calibration Each time an analog ohmmeter is used or if the scale is changed, the ohmmeter must be calibrated. Digital ohmmeters do not require calibration. Make sure the meter battery is in good condition. Make sure the meter probes are in good condition. Touch the two probes together and observe the needle location on the ohms scale.
The needle must align with the 0 mark to obtain accurate measurements. If necessary, rotate the meter ohms adjust knob until the needle and 0 mark align. However, an understanding of electrical basics is necessary to perform simple diagnostic tests.
Voltage Voltage is the electrical potential or pressure in an electrical circuit and is expressed in volts. The more pressure voltage in a circuit, the more work that can be performed. Direct current DC voltage means the electricity flows in one direction.
All circuits powered by a battery are DC circuits. Alternating current AC means that the electricity flows in one direction momentarily then switches to the opposite direction. Alternator output is an example of AC voltage. This voltage must be changed or rectified to direct current to operate in a battery powered system.
Measuring voltage Unless otherwise specified, perform all voltage tests with the electrical connectors attached. When measuring voltage, select the meter range that is one scale higher than the expected voltage of the circuit to prevent damage to the meter. To determine the actual voltage in a circuit, use a voltmeter. To simply check if voltage is present, use a test light. When using a test light, either lead can be attached to ground.
Attach the negative meter test lead to a good ground bare metal. Make sure the ground is not insulated with a rubber gasket or grommet. Attach the positive meter test lead to the point being checked for voltage Figure Turn on the ignition switch.
The test light should light or the meter should display a reading. The reading should be within one volt of battery voltage. If the voltage is less, there is a problem in the circuit. Voltage drop test Resistance causes voltage to drop. This resistance can be measured in an active circuit by using a voltmeter to perform a voltage drop test. A voltage drop test compares the difference between the voltage available at the start of a circuit to the voltage at the end of the circuit while the circuit is operational.
If the circuit has no resistance, there will be no voltage drop. The greater the resistance, the greater the voltage drop will be. A voltage drop of one volt or more indicates excessive circuit resistance. Connect the positive meter test lead to the electrical source where electricity is coming from.
Connect the negative meter test lead to the electrical load where electricity is going. See Figure If necessary, activate the component s in the circuit.
A voltage reading of 1 volt or more indicates excessive resistance in the circuit. A reading equal to battery voltage indicates an open circuit. Resistance Resistance is the opposition to the flow of electricity within a circuit or component and is measured in ohms. Resistance causes a reduction in available current and voltage. Resistance is measured in an inactive circuit with an ohmmeter.
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