service manual for 2013 road glide ultra

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They utilize treaded, knobby or sand paddle type tires mounted to a large travel suspension front and rear that enables the vehicle to travel over very rough terrain and jumps. Racing is held in many parts of the world, with the most well known races happening in the Mexico (Baja) and Africa (i.e. The Paris-Dakar). Not included in the cost are:This is a relative score meant to show overall effort compared to other race vehicle types. A score of 100 would indicate a scratch-built vehicle type that requires a complete ground-up design, a custom fabricated chassis and custom fabricated bodywork. The scale of the transport trailer (if required) The cost of support equipment (as required). This is a relative score meant to show overall racing costs compared to other race vehicle types. A score of 100 would indicate a large trailer is required for the race vehicle and its equpment. A score of 10 or less would indicate the race vehicle is driveable to the track, and carry its own support equipment.These six major areas of the car design work as an integrated unit and the designer must have an understanding of how changes to one area affect the others. Much of the design work is iterative, meaning re-designing areas based on new changes to another area. After the iterations are completed, the design will be complete and optimized. Because of the long suspension travel there can be significant camber change. Some camber may be of benefit in cornering, but excessive camber will likely mean less traction. Body roll may also be an issue if not properly controlled. Springs and dampers (shock absorber) must be matched to the calculated forces. Intake, Cooling and exhaust need to be considered in relation to chassis design, bodywork and aerodynamics. http://www.zuppardo.eu/userfiles/danby-premiere-owners-manual.xml service manual for 2013 road glide ultra, service manual for 2013 road glide ultra harley davidson, service manual for 2013 road glide ultra, service manual for 2013 road glide ultra blue paint jobs, service manual for 2013 road glide ultra classic cvo fairing wiring harness. Wings and other aero devices may be of significant help if the racing takes place on a circuit with high speed corners. A racing seat and harness are also mandatory. Protection for fuel storage, fire protection, and bumpers are recommended if not mandatory in racing. The use of a solid, flat and level build space is important.This will lower the overall cost. Costs for a race quality machine usually include higher quality suspension, engine and safety components. There is however, an equally great satisfaction and sense of accomplishment at being one of the few people in the world who have built their own race car from the ground up! A dirty or gritty working environment will usually translate into parts wearing out sooner. Email address: Visitors who use this website and rely on any information do so at their own risk. This Web site and the attached documents are provided “as is” without warranty of any kind, either express or implied, including, but not limited to, the implied warranties of fitness for a particular purpose. Visitors assume all liability for their use and interpretation of the materials presented, whether those materials be correct or errant. No liability shall be assumed by the web site owner, publisher or related parties for visitor use or misuse of the information contained within this site. No liability shall be assumed by the web site owner, publisher or related parties for information which may be errant or omitted, or the use or misuse of such errant or omitted information by visitors. Trademarks and Names mentioned in this site are the property of their respective owners. See the References page for attribution of sources for site content. Privacy Policy and Terms and Conditions. Just remember the only time you have too much fuel is when you are on fire.After 6 months of planning I built one, then there was 6 months of testing and revising. http://www.tamm.be/_files/danby-premiere-portable-air-conditioner-manual-dpac13009.xml It was a very enjoyable experience for me and I would like to offer some information to help anyone interested in building their own. What kind of Go Kart do you want? 1. Purpose Offroad Good for riding through the woods, snow, mud, etc. Less expensive 2. Number of Passengers Before choosing your location choose how many people you want riding with you. 3. Locomotion Gasoline Most common Affordable Maintenance every 5 to 20 hrs depending on conditions Electric Efficient Batteries are expensive requires knowledge about electronics Diesel Engines are expensive A lot of torque More efficient than Gasoline Hybrid Diesel electric Gasoline electric Or other form of Locomotion 4. Composition What should it be made out of. Wood or Metal? Personally I would prefer to buy metal over wood. I like to have a good sturdy roll cage in case a holy mole moment suddenly arises. I used conduit on my rig, and I never had a problem with the frame. Carefully draw out how the go kart will look. Use advance math to help design it (I know what you are thinking, Do I have Too. At least use basic trigonometry.) Here are some important questions to consider. How is the motor going to be mounted. Where is the throttle going to be mounted. How Wide and how long. What size sprockets do I need. Inspiration for my design Back to the main question of this step, What kind of go kart do you want. That question right there was the biggest one for and the hardest for me. I went through three go kart designs (0.0, 1.0, 2.0) before I ended up where I am at now. I told myself that I wanted an electric go kart that sat one person. Then it evolved into a two person electric go kart. Anyways, I ended up with a two, maybe three, person gasoline go kart. My first and second design was close the cigar car above (my first frame is the last to pics). After a lot of thinking I came to the sudden realization that my first design wasn't going to work. https://www.informaquiz.it/petrgenis1604790/status/flotaganis21052022-1405 Not to long after that, I came to the conclusion that the electric go kart is not for me, so I scrubbed that frame. My current frame reminds me of a sandrail buggy just with a 6hp motor on it. If money is a limiting factor, look around and buy materials when they are affordable. Salvage parts from other things that have been deemed broken; basically recycle parts from stuff that would either end up in a landfill or laying around doing nothing. It is amazing what you can find laying around. Frame Building the frame is really easy, I would say that is the easiest part of the whole project. Just follow you design and measure twice and cut once. If you are using Conduit, you are probably asking, do i have to notch it out or cut shape the conduit to fit over another one. This is what I do, I put the two piece of conduit against each other and I build up the weld. You don't have to do that, but it was easier for me. Rear End Assembly When assembling the rear end, go ahead and slide the bearings on the axle then attach the bearing housing to the bearings. Next you want to measure out where it is going to be fastened too, which should have been noted on your design (mine was seven inches from the bottom of the frame). Tack welded it on the frame and measure again, if the measurement is correct finish welding it and if it is not adjust as necessary. Front End Assembly Most people buy there own parts for the front end, but me being frugal i decided to make my own. Main with odd pieces of steel found at Tractor Supply and Lowe's. So my spindles are custom made, I suggest to buy some because mine are not as perfect as machined ones. I had to use a little bit of Redneck engineering to make them work. When you attaching either your homemade ones or store bought spindles make sure you have extremely goods welds on them. One of my spindles broke off when I hit a bump, so take extra care when welding the front and rear assemblies on the frame. http://jointworkstudio.com/images/casio-ctk-800-service-manual.pdf Add Tip Ask Question Comment Download Step 4: Testing and Revising We all know the that version 1.0 is never perfect, so learn from what happens during the testing phase. Remember this is a homemade vehicle there are going to be problems, a lot of them. That's why we test, revise, and apply then the cycle continues. You are going to have to tinker with it. Anyways, I hope that this instructable inspired you to build your go kart.Share it with us! I Made It! Recommendations Inverse Solar System I wanted to create my own offroad kart and that's defenitely going to be useful. Even though building a kart isn't that simple, you made it very easy to follow. Great work! 0 NeilRG One very important point however if you're welding anything galvanized is to do it with plenty of fresh air because the fumes are toxic. Welding with MIG can be made more difficult outdoors if its windy though because the shielding gas gets blown away. 0 steve DeEarleigh I would love to make this. Do you have any updated pics.I rekon its beut and would love to build one myself.Keep instructing! I absolutely love conduit; it is the most affordable multi-purpose metal out there. 0 tomatoskins I hope to see more great stuff from you in the future. Post Comment Categories Circuits. Please try again.Please try again.Please try again. Please try your request again later. Here is the complete step-by-step practical guide to the equipment and building techniques needed to build a Buggy, as well as sound guidance on the choice of donor car and new components. With this manual in your workshop, you can build any VW-based Dune Buggy avoiding all the common pitfalls and money-sapping mistakes, and end up with a superb, roadworthy multi-purpose vehicle. Then you can start reading Kindle books on your smartphone, tablet, or computer - no Kindle device required. Page 1 of 1 Start over Page 1 of 1 Previous page Next page Register a free business account Who knows, you might be able to build a buggy as good as the one gracing our cover! ? - Full content visible, double tap to read brief content. Videos Help others learn more about this product by uploading a video. Upload video To calculate the overall star rating and percentage breakdown by star, we don’t use a simple average. Instead, our system considers things like how recent a review is and if the reviewer bought the item on Amazon. It also analyzes reviews to verify trustworthiness. Please try again later. Michael F. 5.0 out of 5 stars The illustrations and procedures. The illustrations and procedures were well presented. A somewhat different approach that stimulated thought!I sort of expected to see the authors finished buggy at the end. But No! Dang.However it still is useful.I have never built a buggy and this book pointed me in the right direction to begin.Very through coverage.Not worth the priceAlso, as in my case, at the ripe old age of 63 and having built my first buggy way back in 1974, it a great read also. I bought this with nostalgia in view and enjoyed every page. Thoroughly recommended to all.Last bit puts you off building one. Gives the positives and negatives of building and pit falls involved. Like the author says it is a long term project taking months not weeks. By using our site, you agree to our cookie policy.Learn why people trust wikiHow It is a fun way to cruise around, but building your own vehicle from scratch is challenging unless you have mechanical experience. Most people start with an old Volkswagen Beetle or a building kit for a reliable but relatively inexpensive way to get into building. You have to take apart the car and replace the broken parts, but eventually, you can end up with a drivable dune buggy to take out on the open road. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.The Type 1 is the perfect size and shape for a dune buggy. If you get a good car, most of the important parts are reusable, so you don’t have to purchase or assemble them yourself. In addition to the chassis, you could save the seats, brakes, engine, and other parts.Even if you are able to track one down, it may not be in great condition and could still require a lot of work. Later Beetle models aren’t as easy to convert into a dune buggy. You could work one part at a time if you have the knowledge or take it to a mechanic. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Some companies sell pre-made dune buggies. Pay for a chassis, then fit the fiberglass frame over it to prepare your buggy for the road. The only problem is you still need to hook up parts like the engine and transmission that you buy separately.There are a few companies that sell them. The finished dune buggies are considered street legal in most areas, which makes them much easier to transport. You also have to consider the cost of shipping and your ability to trick the buggy out with the equipment it needs to run. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.The plan is your blueprint showing you how to construct the buggy. However, you still get to devote plenty of time to creating the chassis, selecting and assembling the mechanical parts, and so on.Most builders use MIG welding with a MIG electrical torch, a shielding gas, and a metal wire used to solder steel pipes together. They can point you in the right direction when you’re looking for plans and parts. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.No matter how you get your frame, you are still going to need an engine and other parts. The easiest way to do this is by visiting a site that sells buggy parts. Many companies that sell kits also sell rebuilt Beetle parts, which are very difficult to find new. You then need to figure out how to install each part in your buggy unless you have a mechanic do it.Ask other dune buggy owners where they get their parts. Many people repurpose parts from old cars or appliances like snowmobiles. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Park the Beetle on a flat, level surface, then locate the jack spots behind each wheel. Raise the car up with a jack, then slip the jack stands underneath it to hold it up. You will need to get underneath the car in order to detach the frame. Make sure the car feels stable and doesn’t move when you touch it.Take plenty of time inspecting the car, making sure the jacks are well-positioned and stable. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Start with the car’s engine compartment, which is in the back on a classic Beetle. The battery is underneath the back seat and held down by a bracket you can turn counterclockwise with a socket wrench. Do the same thing with the nuts on the battery terminals to remove the red and black wires connected to them.That includes the brake lights, the oil pressure switch, and the motor. Some of them are hard to spot at first, but you will get another chance at them as you remove each component. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Crawl under the car with a box-end wrench in hand. A classic Beetle has about 22 bolts with 17 mm (0.67 in) and 13 mm (0.51 in) heads around its edges.If someone removed them without replacing them, that makes your job a little easier. Be sure to get new bolts if you need them when you begin putting the dune buggy back together. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Check back inside the car for any bolts holding the components in place. There are usually 4 of them around the fuel tank in the front end, but you may find other ones to take care of. Use your box-end wrench again to remove them.This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.This part gets a little messy, so have some clean storage containers available. Find the fuel line first as it runs from the fuel tank to the chassis. Using a pair of locking pliers, pull the hose free and catch the draining fuel in a container.If you can’t reuse it, take it up to a car repair shop and ask them if they can recycle it for you. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Now you get to start the fun part of pulling all the guts out of the car. Try to remove the engine, the fuel tank, and other parts sitting inside the trunk and hood. Lift them up slowly in case you missed any wires that need to be disconnected first. Set them all aside, since most of them can be reused in your buggy.It’s usually too heavy to move right away, although you could try taking off the doors and hoods by unscrewing them with a Phillips-head screwdriver. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Once you have all the internal parts out, detach any remaining body panels. The frame is like the car’s metal skeleton that all the parts attach to, while the chassis is the base part that rests over the wheels. The framework is too heavy for a single person to lift, so gather 4 of your strongest friends.Many times, you can save both the frame and chassis to form the base structure of the buggy. If the panels won’t come off, lift the frame off the chassis. Otherwise, repurpose the scrap metal for another project. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.If you’re using an old VW, you’re probably working with a lot of rusted parts. Replace anything in bad condition so you can enjoy plenty of safe rides later. Try to get parts that are as similar as possible to the old ones to make the building process simpler. Shop online or take the old parts with you when you go shopping at an auto parts store.Soak them in a penetrating oil like WD-40 to loosen them for removal. Freestyle customizing is possible if you know how to build cars. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.The VW Beetle 4-cylinder, air-cooled engine works well in a dune buggy. It is relatively light, inexpensive, and easy to maintain.You don’t need to worry about cooling fluid or much of anything else that complicates things. The engine stays cool by taking in air as you drive. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Find some space in the battery bracket near the engine. Generally, a dune buggy does well with a 12 or 24-volt battery. Use the old battery in the vehicle for comparison if you still have it.Dune buggies don’t require the strongest batteries, but if you have a choice, get a larger battery to ensure your vehicle has enough power. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.A good suspension system gives you that smooth, relaxing ride even when you’re driving over some bumpy hills. The old shocks are the coiled spring-like pieces underneath your buggy. Use a socket wrench set and penetrating oil to remove them.Consider using a basic system from a VW Beetle and then replacing the individual components as they wear out. This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.Keep your car jacked up and start removing the lug nuts with an appropriately-sized socket wrench. Hang onto the lug nuts unless they’re in bad condition. Then, get some VW Beetle tires as replacements.This image is not licensed under the Creative Commons license applied to text content and some other images posted to the wikiHow website.The easiest way to do this is by purchasing a pre-made fiberglass frame. The underside of the body attaches to the chassis through metal bolts.This is handy since the bolt size you need to use could vary depending on the manufacturer. Can it be sold? Engines from other cars, motorcycles, and even vehicles like snow blowers work well in a buggy. This makes it lighter and less cluttered so it zips along faster. Wear an asbestos-safe respirator mask and keep other people away from the construction area. This article has been viewed 311,864 times.Place the Beetle on jacks in a garage so you can work on it, and remove all of the parts from the car besides the frame, engine, suspension, steering wheel, tires, brakes, and driver's seat. Then, start working on replacing the old parts with the new parts that you bought. When you're finished replacing parts, paint the frame and add extras like lights or a modified engine. For tips on building a dune buggy from a kit, read on! By continuing to use our site, you agree to our cookie policy. Please help us continue to provide you with our trusted how-to guides and videos for free by whitelisting wikiHow on your ad blocker. If you really can’t stand to see another ad again, then please consider supporting our work with a contribution to wikiHow. Learn how to make your own go-kart by reading this article. Photo by Appic on Unsplash A go-kart is a small vehicle with a simple design, a small body build, four wheels, brakes, and an automotive engine. As difficult as it looks, they are somewhat easy to build on your own. It will be a very interesting project for you and your family and friends. You will spend lots of bonding time building something useful together. But before you follow the step-by-step guide below, be warned: Building one requires time, special tools, dedication, and money. Building Your Own Go-Kart Will Also Build Your Sense of Responsibility and Dedication If you're one of those people who really love to assemble things, go ahead and build your own go-kart from scratch. Buy every spare part after hunting for the best price. An alternative to buying your own tools is to have an automotive shop fix the parts as needed. It might be costly, but its a real time-saver. You don't have to clean the mess inherent in fixing your own parts, and you won't make noises that often annoy neighbors. You will need a special place for your project. That place should be dry, roomy, and well lit with a concrete floor. You'll also probably be working on this project for three to six months, so a part of your garage is the obvious choice. Are you really ready to build your own go-kart. Let's start and gather the spare parts you will need. 5 Do-It-Yourself Aspects of Building Your Own Go-Kart Front A-arms assembly Never use welded pieces for the main supporting parts. Use steel clips to keep these pieces from moving while welding. Do not forget to put a washer in between each nut and bolt. Join the ends of steel tubes to avoid warp and wear. Be sure to measure the length and width before welding each piece. Use a pattern to be sure that all curves are equally measured. There are two types of steel for the frame: Pipe (round): Pipe steel on a go-kart looks neat, but it is harder to manipulate and weld together. Put in supports where needed. They also start-up more easily in extremely cold temperatures; they won't freeze because there's no coolant. The downside of air-cooled engines is that they're prone to overheating. Water-cooled Engines Water-cooled engines are heavy-duty and they can keep running without the risk of overheating. But the water system of this type of engine should be properly set up, or your engine could be ruined due to a simple leak. Where can I Source a Go-Kart Engine. Motorcycle engines: Motorcycle engines are the most adaptable and flexible engines for a go-kart. Whether a 2-stroke or a 4-stroke, a motorcycle engine of any size is a very easy fit. They have enough power, even though they're a little bit slow. These engines can produce more torque which can set your vehicle in motion. They are not cheap though, and you need to install a clutch. They have a lot of torque, but they do not perform well during hot weather. It is possible to build a go-kart that uses a small car engine, but you need to set up the original transmission, clutch, and other essential parts to make it run smoothly. With a 10 HP engine, you can create a larger gear ratio, so you will have more torque and your vehicle will be able to climb higher with minimum hassle. Best Practices for Working With Engines You can bring all the tasks that need professional attention to a reputable auto mechanic shop. Never attempt to do something that you do not understand fully. Engine parts that need to be fitted and steel frames to be cut, drilled into, or welded together should be done with some expertise. You just have to make sure that everything is done according to your specifications. If you have a welding machine, a steel-cutting machine, or any other type of machine, and you would like to try your hand on them while building your go-kart, be sure to wear protective clothing and gadgets such as a welding helmet and face mask. You also need to work in a comfortable and well-ventilated area. Go-kart frame—Photo from Flickr Go-Kart Suspension The role of suspension in your vehicle is to make the ride less bumpy during long travels. Some go-karts have shocks installed. But since you're not driving your vehicle over long distances, you might want to skip the installation of any suspension. Eliminating suspension will also save you a lot of money. If you really want a softer ride, you have the option to put in big tires instead. Go-Kart Steering Second to the engine, steering is the most complex part of setting up your vehicle. The main role of steering is to keep all—both rear and front—wheels aligned and neither pushed away or toward each other. A durably constructed steering wheel is absolutely crucial because it gives direction to your vehicle. Steering calls for some expert handling, so have it assembled by your dependable mechanic. Or find and buy a new steering set-up from major parts stores.The spindle is the steering connection to the axle. When you turn the steering wheel, the steering shaft also turns, and the pitman arm attaches to tie rods to push them towards the desired direction. You can find different sizes of wheels that fit the 4.10 x 3.50 from major auto parts suppliers. Best choices: Ribbed tires are more resistant to traction and to wear than the knobby type. This brake pedal can be transformed into a hand brake but can put a lot of pressure on tires. A band brake uses a metal band to squeeze around the outside of a brake drum to stop the motion of the wheels. Drum brakes are better and more durable than band brakes because they don't get wet often. You may use the drive sprocket as a substitute for the brake disc, but it needs to be cleaned often to work properly. Most have bucket seats made of durable plastic or fiberglass. You can use old car-upholstered seats, but they collect dirt and are more difficult to clean. Seat Belts Seat belts are compulsory protective contraptions in every vehicle, even on a small and simple one. Two Types of Seatbelt: 3-point harness: These are cheaper and commonly used. Three-year-old racing belts are less expensive than new versions because they cannot be used by professional racers anymore. A chain and sprocket are popular for the drive assembly because they perform better than the pulley system. They are also simple to set up and a lot cheaper. Large sprockets (or drive sprockets) have better low-end power, while small sprockets (or engine sprockets) give higher top-end speed. Small sprockets tend to weaken the low-end torque of a vehicle. To help improve its poor performance, you might want to add torque converters. A Go-Kart Centrifugal Clutch or Torque Converter. Centrifugal Clutch The centrifugal clutch is the very simple mechanism that transmits the engine's power to the drive wheel. Your other option, which could be more efficient, is the torque converter. Torque Converter Torque converters get more power from the engine to be used while running the go-kart. At low speed, the torque converter automatically shifts to low gear, creating more torque and power. A lower gear ratio means your vehicle can run faster and can climb higher. You might want to consider using a low-cost torque converter to help boost up a low-horsepower engine, rather than buying a much costlier 10 HP engine. Customizations to Your Go-Kart Single-Wheel Drive Go-karts with the single-wheel drive are common choices for the do-it-yourself enthusiasts.