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BILLET ALUMINUM DISTRIBUTOR WITH ELECTRONIC ADVANCE AND ADJUSTABLE REV LIMITER FOR 1936-69 HARLEY BIG TWIN MOTORCYCLES INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 25-11-2010

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ELECTRICAL SYSTEM A 12 volt electrical system is required. Check that the charging system is working properly and not producing over 16 volts. DISTRIBUTOR CLAMP A 1966-69 style distributor clamp (original or aftermarket) is required. MODULE This distributor uses an Accel Single/Dual Fire Ignition module part number 35496. See the enclosed form “Instruction Sheet Single/Dual Fire” for instructions on wiring, adjusting the rev limiter and selecting an advance curve. COIL(S) A coil(s) with a total primary resistance of 2 to 4 ohms is recommended. INSTALLATION Step 1 Turn the ignition switch to the off position. Rotate the engine until it is on the compression stroke for the front cylinder. Continue to rotate the engine until the TDC mark is visible through the timing hole. (see repair manual if necessary). Step 2 Remove the existing distributor if still in the engine. Step 3 Remove the two button head screws from the top of the Mallory distributor. Pull the top cover off the distributor. Remove the two hex standoffs and pull the module and upper housing off the distributor base assembly. Adjust the switches on the module for the desired advance curve and rev limit. FORM 1627 07/08 Step 4 Install the distributor base assembly in the engine with the screw holes and shutter wheel positioned as shown in Figures 1 and 2. It may be necessary to pull the distributor out, turn the shaft and reinstall to get the shutter wheel at the approximate angle shown. The slots should be at about the11 o’clock and 7 o’clock positions. The screw holes should be at the 9 o’clock and 3 o’clock positions. Step 5 Install the distributor clamp and tighten the clamp bolt lightly so the distributor can still be rotated. Step 6 Set the upper housing on the base assembly as shown in figure 3. (The upper housing will only install one way because of the locating screw) Rotate the base assembly slightly if necessary so that the slot in the shutter wheel lines up with the slot in the upper housing. Tighten the distributor clamp

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Victory V92SC Sport Cruiser COMFORT SPORT HANDLEBAR REMOVAL AND INSTALLATION

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Filed Under (Victory) by admin on 13-11-2010

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1. Remove wiring harness dart clips. 2. Disconnect clutch switch connector. 3. Remove 2screwsforclutch lever bracket clamp, remove clutch lever bracket from handlebar. 4. Remove screws for left handlebar switch assembly. Disconnect fast idle cable from lever. Remove switch assembly. 5. Grasp left grip end firmly. While twisting grip end back&forth, pull grip end off and discard. 6. Remove left grip by insertingathin screwdriver between the grip and handlebar end. Spray as mall amount of water/soap solution into the area between the grip and handlebar end. Aggressively twist the grip back-and-forth while simultaneously pulling the grip off. 1. Locate accessory handlebar. 2. Clean inside of throttle grip assembly and throttle cable flange grooves. Ill. 1. 3. Clean throttle grip area. Ill. 1. 4. Slide throttle assembly onto right handlebar end (cableshavenot been removed and should still be attached to the throttle tube). 5. Position the handlebar over the top of the triple clamp and reinstall using bolts removed instep 10. of handlebar removal. Torque to 30 ft. lbs. 6. Install right handlebar switch housing onto handlebar. NOTE: Make sure that locating pin of switch assembly aligns with hole in handlebars. 7. Install right handlebar switch housing screws, make sure locating pin properly aligns with hole in handlebar. Tighten screws to specified torque. 8. Install master cylinder and clamp, install screws. 9. Torque screws to specification. 10. Connect front brake switch wiring harness. 11. Install fast idle cable onto fast idle lever. 12. Clean inside of left grip and handlebar grip surfaces

HONDA VFR800, CBR1100XX Blackbird, ST 1300 Sport Brake Lever Part INSTALLATION

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Filed Under (Honda) by admin on 02-11-2011

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Congratulations on your purchase of an ASV C/5 Sport Streetbike lever. The correct installation of control
levers on a sport/street motorcycle is critical. Incorrect installation or the installation of an incorrect part
can result in a malfunction of your clutch and / or front brake system. This lever should be installed by a
certified mechanic; preferably at your local motorcycle dealer service dept. ASV Inventions, Inc. accepts no
liability for malfunctions as a result of incorrect installation or the installation of a part that was not
designed specifically for your motorcycle. Please check the list below to confirm that the correct year, make
and model of your motorcycle is listed. If the correct year, make and model of your motorcycle is not listed
below, then this part is not the correct part for your motorcycle and must not be installed onto your
motorcycle. ASV C/5 Sport front brake lever part number: BRC541 fits only the following motorcycles:
Please disregard any dashes or letters after this part number that are listed on the part number label of
this box that your lever came in, (ex; BRC541-SK) Any dashes or letters following your part number are for
colors and/or length of the lever and do not affect the application of the lever to the bike.

MPS Sport Bike Auto Shift Installation Manuals

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Filed Under (Suzuki) by admin on 21-02-2012

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The first thing to do is remove the seat, fuel tank, and possibly the front fairing if equipped. You will need plenty of room to work. Electrical Connections – You will need to locate and test a few things on your bike before you start wiring. A good ground, an ignition switched 12 volt power source, the horns, and the ignition coils. We have plug n play style harnesses available for some bikes. Check the web site for specific models. Control Box Wiring Coils – Most four cylinder motorcycles use either a individual firing system or a waste spark system. Waste spark is by far the most common. All four cylinder bikes with only two coils use a waste spark system. Most late model four cylinder sport bikes use waste spark systems even though they have four individual coils. Bikes with a waste spark systems will need the 360 calibrated unit. The 360 calibrated Sport Bike Autoshifts are identified by the 360 engraved into the box below the wire lead exit. The P/N for these boxes has the 360 as a suffix. (P/N 1-0299-360) Some of the newest fuel injected bikes (Hayabusa, GSXR1000, ZX12) that have cam sync sensors are individual firing. These bikes will require 720 calibration and will have no outside identifiers and the P/N 1-0299. The Sport Bike Auto Shift has four brown wire leads that are connected to the negative of each individual coil on a four coil system. You will notice that the connector for the four brown wires has a molded in ridge that marks the brown wire that is used as the rpm sensor. This must be connected to the number one cylinder coil negative wire.

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Yamaha XVS 650AN Supplementary Service Manual

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Filed Under (Yamaha) by admin on 15-12-2010

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MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Connecting rod: Oil clearance Color code (corresponding size) 0.031 0.055 mm (0.0012 0.0022 in) Blue Black Brown Green CHASSIS Item Standard Limit Front suspension: Front fork travel Fork spring free length Installed length Spring rate (K1) Stroke (K1) Optional spring Oil capacity Oil level Oil grade 140 mm (5.5 in) 332.5 mm (3.1 in) 287.4 mm (11.3 in) 3.43 N/mm (0.343 kg/mm, 19.2 lb/in) 0 140 mm (0 5.5 in) No 0.507 L (17.4 US oz) 95 mm (3.74 in) Yamaha fork oil 10 WT or equivalent 325.9 mm (12.83 in) Front brake: Type Disc outside diameter thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Single disk 298 5 mm (11.73 0.2 in) 6.0 mm (0.24 in) 6.0 mm (0.24 in) 14.0 mm (0.55 in) 30.2 mm (1.19 in) 33.3 mm (1.31 in) DOT 4 4.5 mm (0.18 in) 0.8 mm (0.03 in) 0.8 mm (0.03 in) Brake lever & brake pedal: Brake lever free play (at pivot) Brake lever free play (at lever end) Brake pedal position Brake pedal free play Clutch lever free play (at pivot) Clutch lever free play (at lever end) 1 2 mm (0.04 0.08 in) 10 15 mm (0.39 0.59 in) 108 mm (4.25 in) 20 30 mm (0.79 1.18 in) 2 3 mm (0.08 0.12 in) 10 15 mm (0.39 0.59 in) -4- MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer 182 222 Ω at 20C (68F)/Gray – Black J4T088/MITSUBISHI (U.S.A) J4T128/MITSUBISHI (CAL) Ignition coil: Model /manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance F6T541/MITSUBISHI 6 mm (0.24 in) 3.6 4.8 Ω at 20C (68F) 10.7 14.5 kΩ at 20C (68F) Voltage regulator: Type Model /manufacturer No load regulated voltage Semi-conductor, short-circuit type SH650C-11/SHINDENGEN 14.1 14.9 V Rectifier: Model /manufacturer Capacity Withstand voltage SH650C-11/SHINDENGEN 18 A 200 V Electric starter system: Type Starter motor: Model /manufacturer I.D. number Output Brush overall length Commutator diameter Mica undercut Starter relay: Model /manufacturer Amperage rating Constant mesh type SM-13/MITSUBA SM-13 0.7 kW 10 mm (0.39 in) 28 mm (1.10 in) 0.7 mm (0.08 in) MS-5F-441/JIDECO 180 A 4 mm (0.16 in) 27 mm (1.06 in) Flasher relay: Type Model /manufacturer Self cancelling device Flasher frequency Wattage Semi transistor type FB257H/DENSO Yes 75 95 cycle/min 27 W 2 + 3.4 W Fuel pump relay: Model /manufacturer G8R-30Y-Q/OMRON

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HARLEY DAVIDSON ROAD KING FAT HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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PREPARATION – ALL MODELS 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. See the service manual and remove the seat and disconnect battery cables or remove the main fuse. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTES Immediately wipe up any brake fluid spills with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spilled D.O.T. 4 brake fluid. 2. See the service manual and drain the brake fluid from the front brake reservoir. ORIGINAL HANDLEBAR REMOVAL NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 1. Using a T-40 TORX® drive head, remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. 2. Carefully make note of the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See FRONT BRAKE MASTER CYLINDER in the service manual. 3. Remove the old brake lines from the motorcycle. 4. Using a T27 TORX drive head, remove the front-brake master cylinder and clutch-lever assemblies (refer to CLUTCH CABLE in the service manual) from the stock handlebar.

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HARLEY DAVIDSON XL BRAIDED FRONT BRAKE LINE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) 1. Drain the brake fluid following the instructions in the service manual. Dispose of waste properly. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Disconnect the battery, negative (-) cable first or remove the main fuse. Follow the instructions in the service manual 3. Remove bolt and two sealing washers to disconnect brake line fitting from master cylinder. Discard sealing washers, but save bolt for installation. 4. Remove bolt and two sealing washers to disconnect brake line fitting from front brake caliper. Discard sealing washers, but save bolt for installation. 5. Carefully make note of brake line routing, then remove existing brake line. NOTE This kit contains clamps and cable straps to either replace the original equipment clamps and cable straps being removed or to add additional brake line support. INSTALLATION Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a) Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 1. Position new sealing washers from kit on each side of hydraulic brake fittings (banjo fittings). Small ID washers are for caliper end, large ID washers are for master cylinder end. 2. Insert bolts (removed earlier) through washers and fittings. 3. Hold new braided brake line in position and install bolts into master cylinder and caliper. Tighten only enough to keep banjo fitting in the same orientation as the stock banjo fitting. 4. Verify there is no twist in the brake line. Adjust brake line if necessary. 5. Install clamps from kit by wrapping clamp around braided brake line at each of the clamp mounting locations. Verify clamps are oriented the same as the stock clamps. Install clamp screws but do not tighten. 6. Check entire length of braided brake line: a. Be sure brake line is not twisted. b. Turn handlebars fully-left and right while checking to make sure brake line does not contact any vehicle components. c. Be sure brake line length between clamps is sufficient. 7. Adjust brake line if necessary. 8. Tighten caliper and master cylinder banjo bolts to 20-25 ft-lbs (27-34 Nm) .

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HARLEY DAVIDSON STREET SLAMMER HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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This kit does not fit models equipped with Hydraulic Clutch Kits, handlebar mounted gauges or the Road Tech® Radio or FLHRS models equipped with an accessory windshield. REMOVAL Preparation – All Models To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 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. See the service manual and remove the seat and disconnect battery cables or remove the main fuse. Save the seat hardware for installation. -J04406 When servicing the fuel system, do not smoke or allo w open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Softail and Dyna models: See the service manual and loosen the fuel tank. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTES Immediately wipe up any brake fluid spills with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spilled DOT 4 brake fluid. 3. See the service manual and drain the brake fluid from the front brake reservoir and brake lines. Handlebar Removal – Dyna and Softail NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 1. Note the front brake line routing and the orientation of the banjo fittings. See the service manual and disconnect and remove the brake line. Save the banjo bolts, but discard the brake line gaskets. 2. Remove the plastic wiring retainer clips that secure the turn signal harnesses to the handlebar, if equipped. 3. Remove the front brake master cylinder and clutch lever assemblies from the handlebar.

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HONDA GL1800 CHROME SPORT SHIFTER INSTALLATION MANUAL

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Filed Under (Honda) by admin on 27-02-2011

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1. Place bike on center stand. 2. Remove the two bolts that hold the stock foot pegs and remove foot peg. 3. Install shifter slot over shifter peg. 4. With the longer bolts supplied, sandwich the Sport Shifter plate between the peg and frame. 5. Screw in bolts and secure tightly. Double check tightness per service manual. 6. Install shifter pegs with hardware provided MOUNTING INSTRUCTIONS FOR 45-1620 GL1800 CHROME SPORT SHIFTER

Moto Guzzi Sport 1100i Owners Manual

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Filed Under (Moto Guzzi) by admin on 29-11-2010

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General features Identification data Instruments and controls Riding your motorcycle Break-in Maintenance and adjustments Wheel removal Service schedule Cleaning – Storing Cleaning the windscreen Lubrication Valve gear WEBER injectionignition system (I.A.W.) Electrical equipment Wiring diagram Illustrations Lubrication Pressure fed by gear pump. Oil filters: wire mesh inside sump and replaceable cartridge filter outside sump. Normal lubrication pressure 3.8Ö 4.2 [5] kg/cm2, pressure valve, thermostat and cooler. Low oil pressure sensor (electrical) on crankcase. Generator/Alternator On front of crankshaft (1 4V – 25A). Ignition “WEBER MARELLI” electronic digital induced discharge, with high efficiency coil. Spark plugs: Spark plug gap: 0,7 mm. SPORT 1100 DAYTONA R NGK BPR 6 ESI NGK DR9 E IMS Starting Electric starter (12V-1,2 kW) with solenoid engagement. Ring gear bolted on flywheel. Starter button (START) on right of handlebars. Driveline data Clutch Twin driven plates, dry type, on flywheel. Hand controlled by lever on left of handlebars. Primary drive By gears. Ratio: 1 to 1.3529 (tooth ratio 17/23). Gearbox 5-speed, with constantly meshed gears with front dog clutch. Incorporated cush drive. Pedal operated on the left side of the motorcycle. Gear ratios: Low gear = 1 to 1,812 (tooth ratio 16/29) 2nd gear = 1 to 1,250 (tooth ratio 20/25) 3rd gear = 1 to 1 (tooth ratio 23/23) 4th gear = 1 to 0,833 (tooth ratio 24/20) 5th gear = 1 to 0,730 (tooth ratio 26/19) Ratio: 1:4,125 (tooth ratio 8/33) Overall gear ratios (Engine-wheel): Low gear = 1 to 10,1150 2nd gear = 1 to 6,9761 3rd gear = I to 5,5809 4th gear = 1 to 4,6507 5th gear = 1 to 4,0783 Frame Rectangular section single-beam in NiCrMo steel. Semisupporting engine base. Suspensions Front: White Power upside-down hydraulic telescopic fork with individually adjustable rebound and compression; Rear: steel swing arm with oval cross section. Single shock absorber White Power with separate adjustment of spring preload and of hydraulic rebound and compression damping. Wheels Light alloy castings with 3 hollow spokes (rear wheel with cush drive unit). Rim sizes: – front: 3,50x 17 MT H2 – rear: 4,50×17 MT H2 Tires -front: 120/70 ZR 17 – rear: 160/70 ZR 17 [160/60 ZR 17] Type: Tubeless Front: two Brembo drilled semi-floating disc brakes in stainless steel for SPORT I 100; [two Brembo drilled floating discs, Racing type for DAYTONA RS] with fixed 4 differential piston calipers. Adjustable manual control lever on the right side of the handle-bar; – disc 320 mm;

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