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Installation Instructions for CRF 150R and KX450F Steahly Flywheel Weight Warning: Improper instalation of this flywheel weight could result in engine damage or a serious crash. If you do not have the tools or the mechanical abilities take it to a professional. 1. Drain the engine oil or turn off the gas and lay the bike on its side. 2. Remove the shift lever. 3. Remove the ignition cover. Take care not to tear the gasket or have a new gasket on hand. Be carefull that you don’t lose the two dowel pins that are between the cover and the engine case. 4. Remove the flywheel nut. Use an air impact wrench or figure out a way to keep the flywheel from rotating while you remove the nut. A strap wrench or an automotive oil filter wrench may work as a holding tool or try putting the bike in high gear and holding the rear brake on. 5. Pull off the stock flywheel with the proper flywheel puller that has a crank end protection cap. Steahly part number E-63. Do not attempt removal with out the correct puller. Do not use claw type pullers. 6. Fit the flywheel weight on to the stock flywheel. Line up the two threaded holes in the weight with two holes in the stock flywheel. 7. Clean the threads of the two special bolts with contact cleaner. Put a big drop of red Loctite or other high strength thread locker on the threads of the 2 bolts. Install the two special bolts as shown in the picture and torque to 12 foot pounds. 8. Unless you plan to take the weight on and off a lot we highly recommend using a center punch and a hammer to flare out the threads at the end of the bolt (see pictures below). This will reduce the possibility of the bolt coming loose. 9. Clean up the flywheel and weight and remove any metal stuck to the magnets. 10. Install the flywheel with weight back onto the tapered crank shaft end making sure the key ways are lined up. Torque the stock nut to 42 ft- lbs.
[b] If clutch contact face is scored or worn, the flywheel may be refaced. [c] If clutch contact face is cracked, the flywheel must be replaced. NOTE: Do not remove more than 0.508 mm (0.020 in.) material from the flywheel. Maintain all of the radii when resurfacing. 2. Inspect the ring gear. [a] Check ring gear for excessively worn or damaged gear teeth. [b] If damaged gear teeth are detected, replace the ring gear. Refer to Section 1.15.3. 3. Inspect crankshaft and flywheel contact surface. [a] Check the butt end of the crankshaft and flywheel contact surface for fretting, brinelling, or burrs. See Figure 1-212. [b] Lightly stone the contact surface to remove any fretting, brinelling, or burrs. Figure 1-212 1.14.3 Crankshaft and Flywheel Mating Surfaces Installation of Flywheel Install the flywheel as follows: 1. Install two flywheel guide studs, J 36235, into two of the tapped holes in the crankshaft at the 3 and 9 o’clock position. 2. Attach the flywheel lifting tool and, using a chain hoist, position the flywheel in the flywheel housing. Align the flywheel bolt holes with the crankshaft bolt holes. All information subject to change without notice. (Rev. 2004) 6SE50 0403 Copyright © 2004 DETROIT DIESEL CORPORATION From Bulletin 2-50-04 1-261 1.14 FLYWHEEL NOTICE: A new scuff plate must be used whenever the flywheel is removed. Failure to replace the scuff plate may cause the flywheel bolts to loosen, even when torqued correctly. 3. Using a new scuff plate, install two bolts with International Compound #2® (or equivalent) through the plate 180 from each other. 4. Install the flywheel lock, J 36375–A. See Figure 1-195. 5. Remove the flywheel lifting tool and guide studs. 6. Apply International Compound #2® (or equivalent) to the threads and to the bolt head contact area (underside) of the remaining bolts. The bolt threads must be completely filled with International Compound #2® (or equivalent). Any excess must be wiped off. See Figure 1-213.
New flanged multi-point socket head bolts have been released to prevent the MBE 900 pilot bearing from walking out of the flywheel housing. The new bolts will replace two flywheel bolts, located 180 degrees from one another. KIT CONTENTS The MBE 900 Pilot Bearing Bolt Service Kit P/N: A9269900105, consists of the following parts, listed in Table 1: Part No. A9269900005 18SP666 Table 1 Qty. 2 1 Description Flanged Multi-point Socket Head Bolts Installation Instructions MBE 900 Pilot Bearing Retaining Bolt Service Kit (P/N: A9269900105) INSTALLATION PROCEDURE Use the following procedure to install the new flanged multi-point socket bolts: 1. Shut off engine and apply the parking brake, chock the wheels, disconnect vehicle battery power, and perform any other applicable safety steps. 2. Remove the transmission. 3. Remove clutch from flywheel. 4. Pull the crankshaft position sensor out of the flywheel housing about 8 mm (0.32 in.). 5. Remove the end cover from the flywheel housing and install the engine barring tool (J-46392). Tighten the bolts on the barring device to 25 N·m (18 lb·ft). Insert the locking pin to block the device and prevent it from rotating. 6. Using J-46385, the flywheel and main pulley socket tool, remove two flywheel multi-point socket head bolts from the flywheel, 180 degrees apart. See Figure 1.
The major cause of clutch failure is excessive heat. Excessive heat generated between the flywheel, driven discs, intermediate plate and pressure plate can cause the metal to flow and the material to be destroyed. If this occurs, the clutch can burst which can cause property damage, serious bodily injury or death. In order to prevent clutch failure resulting from excessive heat: 1. Do not exceed recommended vehicle loads. 2. The clutch should only be used for the recommended applications. 3. Drivers should be properly trained in starting, shifting and operation of the clutch. 4. Drivers should report erratic clutch operation as soon as possible to permit maintenance personnel to inspect, adjust or lubricate as required. 5. The removal and installation procedure described for each component may vary for your vehicle. For Solo and Heavy-Duty ECA clutches only, install shipping bolts before removing clutch assembly from the flywheel. IMPORTANT For service information and assistance, call the Roadranger Help Desk at 1-800-826-HELP (4357) (Mexico: 01-800-826HELP (4357). You may also find more information about Eaton Clutches at www.Roadranger.com. Mechanics must be familiar with proper clutch adjustment, linkage adjustment, lubrication and other maintenance troubleshooting procedures outlined in the Failure Analysis Guide. Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton Corporation makes no warranty, expressed or implied, based on the information provided.
The crankshaft is precision-forged with seven main bearings and eight custom-forged counter weights, and a vibration damper at the front end. For an exploded view of the crankshaft, main bearings, and main bearing caps, see Figure 1-42. 1. Crankshaft 5. Lower Bearing Shell (center) 2. Upper Bearing Shell(s) 6. Main Bearing Cap(s) 3. Upper Bearing Shell (center) 7. Main Bearing Cap (center) 4. Lower Bearing Shell(s) 8. Main Bearing Cap Bolt Figure 1-42 Crankshaft, Main Bearings, and Main Bearing Caps All information subject to change without notice. (Rev. 3/04) 6SE412 0403 Copyright © 2006 DETROIT DIESEL CORPORATION From Bulletin 1–MBE4000–06 1-57 1.9 CRANKSHAFT ASSEMBLY 1.9.1 Crankshaft Removal Remove the crankshaft as follows: FALLING ENGINE To avoid injury from a falling engine, an adequate lifting device with a spreader bar and sling should be used to lift the engine. The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets. To ensure proper weight distribution, all provided lifter brackets must be used. NOTICE: A spreader bar must be used at all times in conjunction with the front and rear lifter brackets to lift the EGR engine to ensure that no engine damage will result. The brackets are designed to lift vertically. 1. Remove the engine from the vehicle.
This paper examines the complex, often misunderstood, relationship between al-Qaeda, the Taliban and the various militant groups found in FATA (the Federally Administered Tribal Areas) in Pakistan, including the TTP (Tehrik-i-Taliban Pakistan). Much of what is commonly assumed about the Taliban, the TTP and al-Qaeda is based on misinformation, misunderstanding or a misrepresentation of historical events. The Taliban and alQaeda can in many ways be seen as sharing common values, although their ultimate goals remain very different. The Taliban were not part of the mujahedeen fighting against the Soviets in Afghanistan, and emerged only in 1994. Al-Qaeda, for all the conspiracy, did not receive money from the CIA during the 1980s, and was only officially formed as an organisation in 1988. The creation of the TTP in 2007 is another matter, and was created as an umbrella organisation for various Pakistani militant groups, and maintains close ties with al-Qaeda. However, the Pakistani Taliban is not the same Taliban as the one formed in 1994, and although it swears its loyalty to Mullah Omar, its goals differ from that of the Afghani Taliban. We can speak of al-Qaeda and the Taliban in two broad strokes – pre 9/11 and post 9/11. The attacks on the Twin Towers and the Pentagon (as well as the failed attack on Washington DC with the hijacked flight 93), was the culmination of al-Qaeda as a tightly knit, hierarchical organisation. The subsequent “War on Terror” and the invasion of Afghanistan in October 2001 destroyed much of its organisational capacity; it also left the Taliban severely weakened. However, they both regrouped in the FATA region over a period of years, and al-Qaeda spread its ideology throughout northern Pakistan, coalescing with militant groups and local warlords. Before 9/11, al-Qaeda and the Taliban were very much two different organisations; today, it is not so simple, and in 2010, General David Petreus claimed that there is “a symbiotic relationship between all of these different organizations: al-Qaeda, the Pakistani Taliban, the Afghan Taliban ... They support each other, they coordinate with each other, sometimes they compete with each other, [and] sometimes they even fight each other.” (cfr, 2010, http://www.cfr.org).
Al Qaeda (AQ) has evolved into a significantly different terrorist organization than the one that perpetrated the September 11, 2001, attacks. At the time, Al Qaeda was composed mostly of a core cadre of veterans of the Afghan insurgency against the Soviet Union, with a centralized leadership structure made up mostly of Egyptians. Most of the organization’s plots either emanated from the top or were approved by the leadership. Some analysts describe pre-9/11 Al Qaeda as akin to a corporation, with Osama Bin Laden acting as an agile Chief Executive Officer issuing orders and soliciting ideas from subordinates. Some would argue that the Al Qaeda of that period no longer exists. Out of necessity, due to pressures from the security community, in the ensuing years it has transformed into a diffuse global network and philosophical movement composed of dispersed nodes with varying degrees of independence. The core leadership, headed by Bin Laden and Ayman al-Zawahiri, is thought to live in the mountainous tribal belt of northwest Pakistan bordering Afghanistan, where it continues to train operatives, recruit, and disseminate propaganda. But Al Qaeda franchises or affiliated groups active in countries such as Yemen and Somalia now represent critical power centers in the larger movement. Some affiliates receive money, training, and weapons; others look to the core leadership in Pakistan for strategic guidance, theological justification, and a larger narrative of global struggle.
Department of History, American University in Cairo, Cairo, Egypt This article examines the nature of religious terrorism, principally with reference to al-Qaeda. It argues that a distinction must be made between the ultimate aims and the immediate objectives of ‘religious’ terrorists, and that while the ultimate aims will be religiously formulated, the immediate objectives will often be found to be almost purely political. This distinction is illustrated with reference to such premodern religious terrorists as the Assassins and Zealots. Immediate objectives, are for many purposes more important than ultimate aims. Although the immediate objectives of al-Qaeda on 9=11 cannot be established with certainty, it is highly probably that the intention was to provoke a response from the US that would have a radicalizing impact on al-Qaeda’s constituency. Reference to public opinion in the Middle East, especially in Egypt, shows that this is indeed what has happened. Such an impact is a purely political objective, familiar to historians of terrorism from at least the time of Errico Malatesta and the ‘propaganda of the deed’ in the 1870s. While no direct link between Malatesta and al-Qaeda exists, al-Qaeda was certainly in contact with contemporary theories that Malatesta would have recognized, and seems to have applied them. Even though its immediate objectives are political rather than religious, al-Qaeda is a distinctively Islamic group. Not only is its chosen constituency a confessional one, but al-Qaeda also uses—and when necessary adapts—well-known Islamic religious concepts to motivate its operatives, ranging from conceptions of duty to conceptions of ascetic devotion. This is demonstrated with reference to the ‘Last Night’ document of 9=11. The conclusion is that terrorism which can be understood in political terms is susceptible to political remedies.