1997 road king cam sensor

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SUZUKI SV 1000 RADIATOR (COOLING SYSTEM) SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR COO NO FAULT C11 Camshaft position sen- sor The signal does not reach ECM for more than 3 sec . after receiving the starter signal . The camshaft position sensor wiring and mechanical parts (Camshaft position sensor, intake cam pin, wiring/coupler con- nection) C12 Crankshaft position sensor The signal does not reach ECM for more than 2 sec . after receiving the starter signal . The crankshaft position sensor wiring and mechanical parts (Crankshaft position sensor, wiring/coupler connection) C13 Intake air pressure sensor The sensor should produce following voltage . (0.50 V < sensor voltage < 4 .85 V) Without the above range, C13 is indicated. Intake air pressure sensor, wiring/coupler connection C14 Throttle position sen- sor The sensor should produce following voltage . (0.20 V < sensor voltage < 4 .80 V) Without the above range, C14 is indicated. Throttle position sensor, wiring/coupler connection C15 Engine coolant temperature sensor The sensor voltage should be the following. (0.15 V <_ sensor voltage < 4 .5 V) Without the above range, C15 is indicated. Engine coolant temperature sensor, wiring/coupler connection C21 Intake air temperature sensor The sensor voltage should be the following. (0.15 V < sensor voltage < 4 .5 V) Without the above range, C21 is indicated. Intake air temperature sensor, wiring/coupler connection C22 Atmospheric pressure sensor The sensor voltage should be the following. (0.50 V < sensor voltage < 4 .5 V) Without the above range, C22 is indicated. Atm. pressure sensor, wiring/coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec . after ignition switch turns ON . (0 .20 V < sensor voltage < 4 .80 V) Without the above value, C23 is indicated. Tip over sensor, wiring/coupler connection C24 or C25 Ignition signalCrankshaft position sensor signal is produced and ECM determines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more. In this case, the code C24 or C25 is indicated. Ignition coil, wiring/coupler connection, power supply from the battery SERVICING INFORMATION 8 .3 C28 Secondary throttle valve actuator No operating voltage is supplied from the ECM, C28 is indicated. STVA can not operate. STVA lead wire/coupler, STVA C29 Secondary throttle valve position sensor The sensor should produce following voltage . (0.10 V < sensor voltage < 4 .90 V) Without the above range, C29 is indicated . Secondary throttle position sensor, wiring/coupler connection C31 Gear position signalGear position signal voltage should be higher than the following for more than 2 seconds. (Gear position switch voltage >_ 0 .6 V) Without the above value, C31 is indicated. Gear position sensor, wiring/coupler connection, gearshift cam, etc. C32 or C33 Fuel injector Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted continuous by 4 times or more. In this case, the code C32 or C33 is indicated. Injector, wiring/coupler connection, power supply to the injector C41 Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF . Fuel pump relay, connecting lead, power source to fuel pump relay C42 Ignition switchIgnition switch signal is not input in the ECM . Ignition switch, lead wire/coupler C44 Heated oxygen sensor (HO2S) [For E-02, 19] During 02 feedback control, 02 sensor voltage is higher or lower than the specification . No signal is detected during engine operation or no electrical power is supplied from the battery . HO2S lead wire/coupler connection Battery voltage supply to the HO2S C49 PAIR control solenoid valve (PAIR valve) When no operating voltage is supplied from the ECM, C49 is indicated. PAIR valve can not operate. PAIR valve lead wire/coupler

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HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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Harley-Davidson Softail, Touring, Dyna, Sportster and V-Rod, SELF LEARNING MODULE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2012

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STEP 1 – BATTERY CONNECTION Locate the battery and disconnect the negative battery cable. Mount the module in the open area in front of the battery with 2-tie straps or velcro straps, directing the harness from the module towards the 6 o’clock position. STEP 2 – THROTTLE POSITION SENSOR (TPS): Remove the air cleaner assembly and unplug the TPS sensor connector at the TPS sensor. The harness includes (2) TPS connectors which should be routed under the gas tank into the factory wire loom to the TPS sensor. The TPS sensor is located on the left side of the throttle body. Plug the (2) TPS connectors from the module in between the TPS sensor and to the factory TPS connector. STEP 3 – O2 SENSOR: Systems equipped with factory O2 sensors Rear: Unplug the Rear O2 sensor connector from the factory harness, which is located at the Rear exhaust pipe. Route the module’s harness which includes (2) O2 sensor connectors and connect one connector to the Rear O2 sensor and connect the other connector to the main factory O2 sensor connector. Front: Unplug the Front O2 sensor connector from the factory harness, which is located at the Front exhaust pipe. Route the module’s harness which includes (2) O2 sensor connectors, and connect one connector to the Front O2 sensor and connect the other connector to the main factory O2 sensor connector. Systems not equipped with factory O2 sensors NOTE: Many aftermarket exhaust systems are now equipped with plugged O2 sensor bungs which can be removed to accept an aftermarket O2 sensor. Typically these bungs already have a thread size of 18 mm x 1.5 mm. Exhaust systems not equipped with O2 sensor bungs need to have the supplied 18 mm x 1.5 mm thread size bung welded to the exhaust pipe in order to install an O2 sensor. The O2 sensor bung should be installed 3 to 6 inches away from the rear cylinder exhaust port and in front of the exhaust torque tube pipe area. The module prefers to receive information from the O2 sensor from an area that is NOT contaminated from atmospheric air. This air may enter through the tail pipe of an unrestricted or un-baffled exhaust pipe. The bung should not be installed in the “5 to 7 o’clock” area. If mounted in this area the O2 sensor can be damaged. The moisture from the gases exiting from the rear cylinder exhaust port will harm the ceramic shell element of the O2 sensor.

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WEGO II Wide-Band Exhaust Gas Oxygen Sensor Interface Installation Instructions

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Filed Under (Tips and Review) by admin on 27-10-2010

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1. Turn off the ignition switch before proceeding. 2. Select a convenient mounting location for the Bosch sensor. In general, the sensor should be mounted as close to the exhaust valve or exhaust manifold as practical. When choosing a mounting location, allow several inches clearance for the sensor wire harness. The wire harness must exit straight out from the sensor. Do not loop the harness back onto the sensor body. The sensor responds to oxygen pressure. Excessive backpressure will cause a reading error. For turbocharged applications, you must mount the sensor downstream of the turbo. 3. For temporary use during dyno tuning, you can mount the Bosch wide-band sensor in place of one of the original equipment rear oxygen sensors (after the catalytic converter). You can also use a sniffer in the tailpipe. For permanent mounting, an 18 x 1.5 mm weld nut must be welded onto the exhaust pipe. After welding, run an 18 x 1.5 mm tap through the threads. Failure to clean the threads may result in sensor damage. Note that most automotive muffler shops are familiar with oxygen sensor weld nut installation on custom pipes. Do not install the sensor until after the free air calibration procedure described in the following section. Always use an anti-seize lubricant such as Permatex 133A on the sensor threads. 4. Install the WEGO II unit. The WEGO II unit should be mounted where the LCD display will be visible during testing. You can secure the WEGO II unit with Velcro tape strips. 5. Connect the Bosch sensor to the 6 pin mating connector on the WEGO II wire harness. 6. Refer to Figure 1. Connect the black WEGO II wire to frame ground using the supplied ring terminal. Try to use an existing wire harness ground location. Do not extend the WEGO II ground wire or ground the WEGO II to the battery minus terminal or to the engine. 7. Connect the red WEGO II wire to switched +12 volt power. You can usually find switched +12V power at an accessory fuse on the fuse block. You can use the supplied fuse tap and 3/16″ female crimp terminal for this purpose

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WEGO IV Wide-Band Exhaust Gas Oxygen Sensor System Installation Instructions

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Filed Under (Harley Davidson) by admin on 21-04-2012

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1. Turn off the ignition switch before proceeding. 2. Select a convenient mounting location for the Bosch sensor. In general, the sensor should be mounted as close to the exhaust valve or exhaust manifold as practical. When choosing a mounting location, allow several inches clearance for the sensor wire harness. The wire harness must exit straight out from the sensor. Do not loop the harness back onto the sensor body. The sensor responds to oxygen pressure. Excessive backpressure will cause a reading error. For turbocharged applications, you must mount the sensor downstream of the turbo. 3. For temporary use during dyno tuning, you can mount the Bosch wide-band sensor in place of one of the original equipment rear oxygen sensors (after the catalytic converter). You can also use a sniffer in the tailpipe. For permanent mounting, an 18 x 1.5 mm weld nut must be welded onto the exhaust pipe. After welding, run an 18 x 1.5 mm tap through the threads. Failure to clean the threads may result in sensor damage. Note that most automotive muffler shops are familiar with oxygen sensor weld nut installation on custom pipes. Do not install the sensor until after the free air calibration procedure described in the following section. Always use an anti-seize lubricant such as Permatex 133A on the sensor threads. 4. Install the WEGO IV unit where the display will be visible during testing. The unit is not sealed and must be mounted in a dry location away from sources of heat. We recommend underdash mounting or use in a dyno lab environment. The unit is not intended for underhood mounting. The unit can be secured by means of Velcro tape strips. Use nylon tie wraps to secure the wire harness near the unit. 5. Working with clamping terminal blocks . All connections to the WEGO IV terminal block must be clearly identified either by means of distinct wire colors (such as shown in Figure 1) or wire labels. If you use different wire colors, mark up Figure 1 for future reference. All connections can be made with 18-20 AWG wire. Wire should be stripped back

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YAMAHA YZF-R1P/ YZF-R1PC SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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1Fuel pump 2Pressure regulator 3Fuel injector 4Throttle body 5Intake temperature sensor 6Throttle position sensor 7Intake air pressure sensor 8ECU 9Atmospheric pressure sensor 0Coolant temperature sensor ACylinder identification sensor BCrankshaft position sensor ÈFuel system ÉAir system ÊControl system Illustration is for reference only. 1 – 4 GEN INFO FEATURES Fuel control block The fuel control block consists of the following main components: An engine trouble warning light is provided on meter panel. Component Function Control block ECU Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure detection Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throttle angle detection Cylinder identification sensor Reference position detection Crankshaft position sensor Crankshaft position detection and engine RPM detection Speed sensor Speed detection Actuator block Injector Fuel injection Fuel pump Fuel feed Air Induction system, air cut valve Induction of secondary air A. Power supply circuit The power supply circuit obtains power from the battery (12 V) to supply the power (5 V) that is required for operating the ECU. B. Input interface circuits The input interface circuits convert the signals output by all the sensors into digital signals, which can be processed by the CPU, and input them into the CPU. C. CPU (Central Processing Unit) The CPU determines the condition of the sensors in accordance with the level of the signal that is output by the respective sensor. Then, the signals are temporarily stored on the RAM in the CPU. Based on those stored signals and the basic processing program on the ROM, the CPU calculates the fuel injection duration, injection timing, and ignition timing, and then sends control commands to the respective output interface circuits. D. Output interface circuits The output interface circuits convert the control signals output by the CPU into actuating signals for the respective actuators in order to actuate them. They also output commands to the indicator and relay output circuits as needed.

2001-2002 GL1800 A ABS Speed Sensor Wire Clamp Location INSPECTION/ REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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1. If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9*GL1800 #9*0112*2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location*GL1800, ABS Speed Sensor Wire Clamp Location*Motorcycle*1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. 3. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly. Torque the bolts,. Torque: 12 N • m (1.2 kgf • m, 9 lbf • ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly. Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service. AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474*2A100001 – 1HFSC474*2A101643 * = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin.

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Yamaha YZ 250F Camshafts REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 30-12-2011

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Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that hold the intake camshaft cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust cam out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft. Fit the half moon shaped retainers in the grooves of the Hot Cams camshaft bearings to ensure good fit, set retainers aside for the time. Using assembly lube, lube the shim buckets, bearing surfaces for the camshafts in the cylinder head, and pack some in the camshaft bearings. Set the exhaust cam into the cylinder head casting while at the same time fitting the cam chain over the sprocket. Make sure that you keep all the cam chain slack to the back of the engine. The cam chain pulls the camshaft sprockets in a counter clockwise direction and the slack of the chain must be kept on the cam chain tensioner side of the engine. The exhaust cam has two timing marks on it. When correctly installed one mark will be at the 9 o’clock position and the other mark will be at the 12 o’clock position. When correctly timed the mark at 9 o’clock will be aligned with the valve cover gasket surface. Repeat the above process for the intake camshaft. Again, make sure you keep the chain slack to the cam chain tensioner side of the engine. Check to be sure the crankshaft is still at TDC. The intake cam has two timing marks also. One at 12 o’clock and the other at 3 o’clock. When both cams are installed correctly, the valve cover gasket surface will form a straight line through the exhaust timing mark at 9 o’clock and the intake timing mark at 3 o’clock

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HARLEY DAVIDSON HYBRID CAM PLATE AND HIGH FLOW OIL PUMP KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the service manual and follow the instructions to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. Gasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a) NOTES Installing this kit requires removal and installation of the cam support plate. Refer to the service manual for instructions with the following exception pertaining to cam compartment compo- nents: The crank and primary cam sprocket flange bolts are specially hardened, and the flat washers are of a special diameter and have ground surfaces. Use ONLY the parts provided in the Drive Gear Retention Kit (H-D Part Number 25533-99A, sold separately) when installing this kit. -J04804 1 of 7
The cr ank sprocket flange bolts and pr imary cam sproc ket flange bolts ARE NOT interchangeable. 2. Refer to the service manual to remove and discard the crank sprocket flange bolts and primary cam sprocket flange bolts and washers. 3. For 1999 models only: Refer to the service manual to remove and discard the currently installed cam drive sprocket. 4. Refer to the service manual to remove and disassemble the cams from the support plate and oil pump. Discard the support plate and oil pump. 5. For 1999 – 2000 Dyna, 2000 Softail, 1999 – 2000 Touring, and 2001 EFI Touring models only: Inspect the cams, chain, sprockets and chain tensioners for wear, and replace as needed. Refer to the service manual for inspection and replacement procedures. For 2001 – 2005 Dyna, 2001 – 2006 Softail, 2002 – 2006 Touring, and 2001 carbureted Touring models only: Inspect the cams and secondary cam chain for wear, and replace as needed. Refer to the service manual for inspection and replacement procedures. The primary cam chain, primary sprockets and both tensioners will be replaced by new components from the kit. For ALL models and years: Discard the guide, as it will not be used. INSTALLATION 1. ALL models: See Figure 1. Obtain the new Rear Cam Roller Bearing Kit (H-D Part Number 8983) from inside the Cam Service Kit (H-D Part Number 17045-99C, purchased separately), and install as indicated in Step 2. NOTE See Figure 2. If not enough of the splined shaft is exposed to install the sprocket, omit the spacer (4) and proceed to Step 2e. When the bearing inner race is started onto the machined area, remove the flange bolt (5), flat washer (6) and sprocket, then assemble using the spacer (4). Repeat Step 2e to fully install bearing inner race. To center thrust washer, be sure o-ring is installed in relief groove. Damage to bearing cage and engine can occur if thrust washer is not centered. (00473b) 2. See Figure 1. Install the O-ring (5), thrust washer (4) and bearing inner race (3) onto the rear camshaft as follows: a. See Figure 2. To properly locate the thrust washer (2), install the O-ring (3) in the grinding relief groove on the splined end of the rear camshaft between the machined area and the secondary cam sprocket.

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Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

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