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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.
Are you ready? Where others reach their limits, the Amarok makes its way without compromise. It unites cross-country mobility, flexibility and efficiency like no other pickup: thanks to the optional all-wheel drive, the outstanding off-road safety – thanks to the special off-road ABS and its aligned Electronic Stabilisation Programme – with the broadest load area in its category and, last but not least, thanks to the robust ladder frame chassis, which offers a high level of stability during even the toughest assignments. The Amarok breaks new ground on conventional roads as well: with its high-quality interior and driving characteristics that leave nothing to be desired, it also sets a whole new standard in terms of comfort and dynamics. Exterior. Wheels. Interior. Engines, running gear and transmission. Amarok with BlueMotion Technology. Safety. Comfort. Multimedia. Volkswagen Genuine Accessories. Paint finishes and seat upholstery. 59 Technical data. 61 General information. 1st challenge: You want to get to work on time. Take a short-cut by driving through the river. Please contact your local Volkswagen dealer for details of the standard equipment and optional extras applicable in your country.
Are you ready? Where others reach their limits, the Amarok makes its way without compromise. It unites cross-country mobility, flexibility and efficiency like no other pickup: thanks to the optional all-wheel drive, the outstanding off-road safety – thanks to the special off-road ABS and its aligned Electronic Stabilisation Programme – with the broadest load area in its category, and last but not least, thanks to the robust ladder frame chassis which offers a high level of stability during even the toughest assignments. The Amarok breaks new ground on conventional roads as well: with its high-quality interior and driving characteristics that leave nothing to be desired, it also sets a whole new standard in terms of comfort and dynamics. Exterior and wheels. Interior. Engines, running gear and transmission. Amarok with BlueMotion Technology. Safety and assistance systems. Comfort. Multimedia. Volkswagen Genuine Accessories. Paint finishes and seat upholstery.
Ensure the jack is in sound condition and good working order. Take action for immediate repair or replacement of damaged parts. Use genuine parts only. The use of improper parts may be dangerous and will invalidate the warranty. Locate the jack in a suitable, well lit working area. Keep working area clean and tidy and free from unrelated materials. Use jack on level and solid ground, preferably concrete. Avoid tarmacadam as jack may sink in. Place wedges under wheels of vehicle, but ensure the jack wheels are free to move and that there are no obstructions. Ensure the vehicle handbrake is engaged, engine is switched off and transmission is in gear (or “PARK” if automatic). Ensure minimum distance of 0.5m between vehicle and static objects such as doors, walls, etc., to allow for vehicle tilting. Ensure there are no passengers in the vehicle and that all non-essential persons keep a safe distance whilst the jack is in use. Place jack under lifting points recommended by vehicle manufacturer (see vehicle hand book). Ensure lifting point is stable and centred on saddle. WARNING! When lifting at the jack's maximum rating (2tonne) or close to it, it is recommended that the effort of raising the load shall be reduced by the use of assistance during this operation. ANGER: Use the jack for lifting only, NOT for supporting the lifted load.
HW93776-1 Cummins Engine Stand Adapter For Cummins engines: all NH, NTC, & NTE 855 Series in-line 6 cyl., 378 Series V6, 504, 555 & 903 Series V8, KT 1150 Series in-line 6 Cyl. L10 HW93776 • • • • Complete clearance during 360° rotation Long handle provides easy engine rotation with 95 to 1 gear Floor lock keeps stand from moving during repairs Universal adapter included for use with a wide variety of optional adapters HW93776-3 Mack Diesel Engine Stand Adapter HW93776-2 Detroit Engine Stand Adapter HW93776-4 International Diesel Engine Stand Adapter For Mack engines: 672, 673, 675 & 711. Series in-line 6 cyl. For Detroit engines: 53 Series in-line 6 Cyl., 6V & 8V also 71 series in-line 6 cyl., 6V, 8V & 12V also 92 series 6V & 8V also 8.2 liter V8. For International Harvester engines: DT-466 in-line 6 cyl. DV-550, MV-404, MV-446, V304, V435, V392, 4-152, 4-194, 4-196, 9.0 liter V8, 6.9L (Ford). HW93776-5 Caterpillar Engine Stand Adapter HW93776-6 Allison Transmission Adapter HW93776-7 Small Vehicle Adapter For Caterpillar engines: 1673, 1674, 1693, 3306 & 3406 in-line 6 cyl. also 1100 & 3208 V8 and 3408 V8. All Allison transmissions: AT 500, MT 600, MT 6 speed, VH, VS and V730 Small size vehicle and light truck engine 2,000 Lbs. capacity. Model Capacity HW93776 3 Ton 1-888-332-6419 Overall Dimensions Wheel Diameters Height Width Length Front Rear Rotational clearance from MTG. Head to Ground G.W. 45-3/4″ 46″ 52″ 8″ 5-3/4″ 37-1/2″ to 43-1/4″ 602 Lbs. www.heinwerner-automotive.com
ROTATING ENGINE STANDS 1. Overall visually inspect stand for any signs of wear and fatigue. 2. Lubricate spindles and gear box as referenced in vendor literature if equipped. 3. Inspect anti-rotation locking mechanism if equipped. 4. Install weight equal to engine weight to the engine stand for approximately 2 min. 5. Rotate weight set 360º in both directions if equipped. Operation should be free of binding and/or catching during rotation. 6. Dismantle fixture and visually inspect stand for any signs of wear or failure. Any item, which does not successfully pass the test, is to be rejected and discarded or returned to Tronair for evaluation. Load Cell Data Load Cell Display Cylinder/Pump Eyebolt 2x4 Wood Block Install Weight To Stand 08-2030-0000 AND 08-2034-0000 1. Install engine stand test fixture. 2. Position beam assembly in the center of the engine stand. 3. Tighten beam locks evenly, until the beam assembly is locked in place. 4. Position engine stand over eye hook in floor. Line eye hook directly under pull point of the test fixture. 5. Install 2 x 4 inch block under wheels and lock stand in place. 6. Attach load cell, pull cylinder to eyebolt. 7. Put engine stand through two cycles of loading the engine stand to 3,000 pounds (2,667 psi on gauge). Hold for 30 seconds then release load. 8. Inspect all welds and joints for signs of distortion; if no defects are found, the engine stand is good. 9. If defects are found discard or return to Tronair for evaluation.
Power from transaxle is transferred to driving wheels by 2 axle shafts. Both axle shafts use Constant Velocity (CV) joints at inner and outer ends. CV joints are enclosed in CV boots, and connected by an intermediate shaft. Intermediate shaft is splined on both ends. Retaining rings retain intermediate shaft in the inner and outer CV joints. A retaining ring retains inner CV joint stub in differential side gear. Outer CV joint stub is splined into wheel hub, and secured by a spindle nut. Left axle has a dynamic damper to reduce vibration. The following are possible types of Constant Velocity (CV) joints used on axle shaft: Birfield Joint (BJ), Double Offset Joint (DOJ), Rzeppa Joint (RJ) and Tripod Joint (TJ). Determine type of CV joint used prior to disassembly. See AXLE SHAFT SPECIFICATIONS table under INSTALLATION. Note type of boot and location prior to removal. See BAND & BOOT APPLICATION. Install a NEW retaining ring each time axle shaft is removed from transaxle. Article Text (p. 3) 1992 Mitsubishi Mirage For Dan's Transmission Service 10 Jefferson Place Fort Walton Beach FL 32548 © 1997 Mitchell Repair Information Company, All Rights Reserved. Monday, April 01, 2002 09:00AM
This procedure will require the use of a hand operated vacuum pump with a vacuum gauge. If you do not own one it can often be rented or borrowed from most “big box” parts stores. (Note: 18”HG is the minimum engine vacuum at idle in gear to effectively operate a vacuum booster 1) Remove vacuum hose from check valve on booster. Place hose from vacuum pump onto check valve and draw booster to 20” of vacuum. 2) Let booster sit with vacuum applied for 5 minutes. If vacuum does not stay steady at 20” it is faulty and needs to be replaced. If vacuum does hold steady at 20” proceed to step 3. 3) With 20” of vacuum in booster depress brake pedal once and release it. The booster should transfer some but not the entire vacuum in reserve. Depending on how hard the pedal is depressed it is normal to see 5-10” of vacuum depleted from reserve. The most important thing is to ensure the booster does transfer vacuum but does NOT transfer the entire vacuum in its reserve. If vacuum remains at 20” OR goes to zero the booster is bad and will need to be replaced. If vacuum transfer is within the above parameter proceed to step 4. 4) Once again draw booster down to 20” of vacuum. Go inside car and depress brake pedal and hold down for 30 seconds. You should see the gauge drop slightly and then hold steady. Vacuum should stay steady as long as you are holding the pedal down. If vacuum drops while pedal is being held down the booster is faulty and will need to be replaced.
CONTENTS, PART I - Consists of the bleeding procedure for the Hydraulic Brake Booster only. The Hydraulic Brake Booster works in conjunction with the Power Steering Pump and the Power Steering Gear. CONTENTS, PART II - Consists of bleeding procedure for the Brake System. The Brake System consists of the Master Cylinder and the Wheel Cylinders. The Hydraulic Booster System uses power steering fluid. IMPORTANT! The Brake System uses hydraulic brake fluid. THESE SYSTEMS ARE SEPERATE! USE OF THE WRONG FLUID TYPE WILL CAUSE SEAL DAMAGE TO OCCUR. DO NOT MIX THE TWO SYSTEMS! PART I BLEEDING PROCEDURES FOR THE HYDRAULIC BRAKE BOOSTER 1. Fill power steering pump reservoir with power steering fluid. 2. Start engine and run for approximately two seconds then shut off engine. 3. Check fluid level; add as required. 4. Repeat steps two and three until (power steering reservoir) fluid retains constant level. 5. Raise the front of the vehicle until the height has cleared the tires. 5-a. Run engine at 1000 to 1500rpm. 5-b. Depress brake pedal several times. 5-c. Turn steering right and left, making light contact with wheel stops. 6. Turn the engine off, recheck reservoir fluid, and add if needed. 7. Lower the vehicle and repeat steps 5-a, 5-b, 5-c and 6. 8. If pedal is up and firm, the vehicle is ready for road testing. 9. If reservoir fluid is extremely foamy, let the vehicle stand with engine off for one hour, then recheck. Section I - Trouble Shooting & Guidelines • Page 9 SECTION I - TROUBLE SHOOTING & GUIDELINES PART II - ALL VACUUM UNITS - BLEEDING PROCEDURES IT IS RECOMMENDED THAT ALL BRAKE BLEEDING BE PERFORMED WITH A PRESSURE BLEEDER. IF ONE IS NOT AVAILABLE, USE THE FOLLOWING PROCEDURE:...