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2003 SUZUKI SV 650 FUEL SYSTEM AND THROTTLE BODY SERVICE MANUAL

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

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FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve . The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM . When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impel- ler . This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it . Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port . The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped . Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 -600 kPa (4.5- 6.0 kgf/cm2,64- 85 psi) . Relief valve Brush , ∎ I,’ Check valve Magnet L Armature When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction . This process continuously takes place causing fuel pressure to be built up . The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve . FUEL SYSTEM AND THROTTLE BODY 5- 3 Inlet port I I Impeller 5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve . It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm2,43 psi) to be applied to the injector at all times . When the fuel pressure rises more than 300 kPa (3 .0 kgf/cm2, 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank . 90 Spring 02 Valve FUEL INJECTOR The fuel injector consists of the solenoid coil, plunger, needle valve and filter . It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion . As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized (injection time)

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HARLEY DAVIDSON FUEL LEVEL SENDER ADAPTER BRACKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Remove the currently installed fuel tank from the vehicle. Follow the instructions for the correct model vehicle under FUEL TANK: EFI, REMOVAL in the Service Manual. 3. See FUEL PUMP/FUEL GAUGE SENDING UNIT, REMOVAL in the Service Manual for instructions to: a. Unplug the fuel pump module connector. b. Remove and discard the top plate screws. c. Remove the top plate, fuel pump and fuel level sender (fuel gauge sending unit) from the tank. NOTE Take care to avoid bending the fuel level sender float rod. A bent float rod will lead to erroneous gauge readings. 2 6 1 3 4 7 9 8 5 is05284 1. Fuel level sender 2. Electrical grounding tab 3. Fuel level sender lock tab 4. Adapter bracket 5. Slot (2) 6. Terminal strip insert 7. Sender to adapter lock tab 8. Slider 9. Adapter to tank lock tab Figure 1. Fuel Level Sender Assembly to Adapter – 4. See Figure 1. Clean the electrical grounding tab (2) on the back of the fuel level sender if necessary. The tab must make firm contact with the terminal strip insert (6) in the adapter bracket. Slide the original equipment (O.E.) fuel level sender (1) into the slots (5) in the new adapter bracket (4) as shown until the lock tabs (3 and 7) snap into place. Make sure the wire is not pinched between the adapter and sender. 5. See FUEL SUPPLY CHECK VALVE/TUBE in the Service Manual. Remove the check valve/quick-connect fitting assembly from the old fuel tank, and assemble to the new tank, using a new O-ring (purchased separately). 6. Fit the slider (8) on the adapter bracket into the fuel level sender mounting channel inside the tank, and push down until the lock tab (9) snaps into place. Make sure the sender and adapter wires are not pinched between the adapter and the fuel tank tunnel, and remain accessible through the fuel tank top opening. 7. See Figure 2. Obtain the assembly of the top plate (1), regulator (2) and fuel filter (3) removed from the old fuel tank, and the stainless steel screw (8) and nut (9) provided in this kit.

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

BUELL ACCESSORY GAS CAP KIT INSTALLATION MANUAL

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Filed Under (Buell) by admin on 29-03-2011

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Installation NOTE When performing the following Steps, use the Fuel Tank Vent Valve Installation Kit (Part Number 91432-96Y). This kit consists of: * Fuel Tank Vent Valve Installation Aid * Fuel Tank Vent Valve Fitting Socket To protect against shock and accidental start-up of vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 1. Disconnect battery cables, negative cable first. An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank. Use extreme caution when servicing fuel tanks. Gasoline is extremely flammable and highly explosive. Do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components. Inadequate safety precautions could result in death or serious injury. 2. Remove gas cap. 3. Carbureted Models: Drain fuel tank. Disconnect hose clamp and fuel supply hose from fuel supply valve and drain fuel into suitable, clean container. See applicable Service Manual, Section 4 for complete, detailed procedure. Fuel Injected Models: Relieve pressure from fuel system. See applicable Service Manual, Section 4 for complete, detailed procedure. Drain fuel tank. a. Using suitable external fuel pump, such as a Gas Caddy, pump fuel from tank and into a suitable, clean container. b. See instructions for external fuel pump for correct use. 4. See Figure 1. Cut cable tie securing vent hose to fitting and remove vent hose from fuel tank. Even with the fuel tank completely drained, a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed. Thoroughly wipe up any fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury. 5. If the fuel supply valve requires cleaning or repair, refer to applicable Service Manual, Section 4, for complete, detailed procedures. 6. See Figure 1. Remove the fuel filler cap and O-ring. 7. Remove the eight self-tapping screws from fuel clamp flange and remove fuel cap flange

SUZUKI GSX-R1000 SERVICE MANUAL

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Filed Under (Suzuki) by admin on 12-11-2010

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Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. 5. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft) ! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. ! Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.

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MIKUNI VM CARBURETOR SUPER TUNING

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Filed Under (Mikuni) by admin on 31-10-2010

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This manual is intended as a guide for users of Mikuni carburetors who want to learn the adjusting method to the best performance from our products. In motorcycles, special tuning of the engine is now considereda routine practice. The arrows that appear in the drawings in this text show the direction in which air, fuel and an air-fuel mixture flows, respectively. ¢JAir Fuel “Mixture Mounting angle fore and aft inclination of the carb should not exceed approx Function of a carburetor The function of a carburetor is to produce combustible air-fuel mixture, by breaking fuel into tiny particles (in the form of vapor) and by mixing the fuel with air in a proper ratio, and to deliver the mixture to the engine. A proper ratio (mixture ratio or air-fuel ratio) means an ideal air-fuel mixture that can burn without leaving an excess of fuel or air, Whether the proper mixture ratio is maintained or not holds the key to the efficient engine operation, 2. Air-fuel mixture required by the engine (Fig. 1) The ratio of a mixture of fuel and air is called the mixture ratio or the air-fuel ratio and is generally expressed by the weight proportion. Theoretically, the amount of air required for complete combustion of 1 gram of fuel under normal conditions is

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HARLEY DAVIDSON MINI-TACH WITH SHIFT LIGHT INSTALLATION MANUAL

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

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INSTALLATION Preparation For EFI models: To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) Follow the instructions found in the Service Manual to purge the fuel supply of high pressure gasoline and remove the fuel supply line. For ALL models, WITH Maxi-Fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the Maxi-Fuse. For ALL models, WITHOUT Maxi-Fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. -J04106 Gasoline can drain fr om the carb uretor 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) 2. For carbureted models: Turn the fuel supply valve to OFF. Remove the fuel line from the valve. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 3. For ALL models: Follow the instructions in the Service Manual to remove the instrument console from the fuel tank. 4. See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 5. For all models EXCEPT FLHR or 1986 and later FL Softail models with Chrome Headlight Nacelle Kit (Part Number 67907-96): Follow the instructions in the Service Manual to remove the headlamp housing. For FLHR models, or Softail models WITH the Nacelle Kit: Follow the instructions in the Service Manual and the mini-tach bracket kit (purchased separately) to remove the handlebar shroud. Mini-Tach Bracket Installation 6. For all models except FLHR: Install the mini-tach bracket components per the instructions in that kit. For FLHR models: Follow the instructions in the Service Manual and the mini-tach bracket kit to install the handlebar shroud and bracket components. 7. See Figure 7. Select the rubber isolation gasket (1) from this kit.

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YAMAHA Road Star Fuel Pump Relocation Kit INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Remove seat and disconnect battery. Remove fuel tank along with both left and right side battery covers, and remove air box from carburetor (all per Yamaha standard shop manual procedures). 2. Remove chrome plastic cover over fuel pump and disconnect choke cable/knob from lower pump bracket. Remove pump-to-carb fuel line from fuel pump. Disconnect fuel pumps electrical lead connector. 3. Remove two (2) hex-head pump mounting bracket bolts and remove pump assembly from motorcycle. Slide fuel pump up and off bracket mounting posts (Caution: excess fuel may drain from pump and/or fuel lines and fuel filter!). Remove heat shield. Remove remaining fuel line from pump. Pull all fuel lines from filter and remove steel springs and hose clamps from these lines (these will be reused on the kits fuel lines). With a sharp knife or box cutter, trim off the top portion of the fuel pumps rubber isolation/mount system per Photo A. Next cut pumps wiring harness approximately half way between connector and pump. Strip the insulation from the ends of these wires as well as from the supplied Baron harness extension wires. Using the supplied electrical butt connectors, crimp Baron harness extensions red wire to pumps black-w/blue-strip wire, and Baron harness extensions black wire to pumps black wire. Repeat this process on other side of wire harness extension with pumps connector. Now, referring to Photo B, you will need to cut off the square tube that runs along the side of the fuel pump with a hack saw. Cut down toward pump body in a straight cut, then cut tube off by cutting along the body. This will allow you to twist pump in the rubber mount so the curved spigot is facing up (clockwise approx 1/4 turn). 4. Remove pump-to-carb fuel line from carb and separate electrical wires from this line. Remove this fuel line from engine. Re-route choke cable to right side of engine (toward carb) and rotate it up and over rear cylinder head back toward left side of bike. Mount new Baron choke bracket to the choke cable and tighten plastic nut. New choke bracket will mount to rear fuel tank mounting location (Photo C). 5. 99~03 models – Remove electrical relay bracket (found under the right side cover) from the bike and slide each relay off of this bracket. Install fuel pump onto new Baron Fuel Pump Bracket and install bracket in the same location as the stock bracket you just removed, using stock mounting hardware. Refer to Photo F for proper installation. 6. 04~07 models Remove electrical relays from stock bracket and remove relays from rubber holder. Cut rubber holder per Photo E and replace one of the relays into the rubber and install on to new Baron bracket. The second relay will be placed to the right of the tool bag under the seat and secured with the provided two-sided tape pad. Reconnect plugs to the relays. (Photo F)

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2009 Kawasaki ULTRA 250X/ 260X FUEL INJECTION CONTROLLERS And REGULATORS INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 25-10-2010

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The R&D high performance Air Filter Kit will improve acceleration and top speed performance by increasing air flow and reducing air temperatures that enter directly into the Ultra 250X’s air plenum box area. The O.E.M. air plenum box on the Ultra 250X is a great design that will flow plenty of air. However, the air that feeds the plenum box is heated by the engine. R&D has created an easy to install “flat filter” that installs directly in place of the large center access inspection cover located directly under the main glove box. The R&D Flat Air Filter insert will allow unrestricted fresh and cool air to enter the air plenum box area which will add power you can feel and a nice high performance tone. The R&D Performance Filter Kit also features two filters, one for each of the surge and blowoff protections valves. The O.E.M. surge valve recycles compressed hot air back into the air box plenum at idle and under deceleration conditions. The R&D surge and blowoff valve filter kit removes the air recycling hoses which will keep the hot air from entering the air plenum box reducing the engines intake air temperatures. The R&D Ultra 250X Air Filter Kit offers great performance tips on how to remove the restrictive air vent hoses which will further reduce the under seat ambient air temperatures. The R&D Filter system does not remove or alter the O.E.M. plenum box in any way, therefore there are no questions to be answered regarding water ingestion

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Carbureted vs. Fuel Injected Systems

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Filed Under (Tips and Review) by admin on 25-10-2010

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fuel injection (FI) systems have been around since the 1950′s and became widely used in cars during the 80′s. By the 1990′s all cars sold in the United States were equipped with FI systems, and though motorcycle manufacturers have included FI systems with some models as early as 1982, it isn’t until recently that the industry has seen wide spread use of FI. Since a lot of people come into my shop with questions about FI, I thought I would point out some of the differences between FI and carbureted systems as well as the benefits and disadvantages of both. A carbureted system is a mechanical system using air pressure to control the flow of fuel through the system. There are three basic parts in a carburetor, the throttle valve, the venturi and the float bowl. The throttle valve controls the amount of air that flows into the throat of the carburetor also known as the venturi which is simply a tapered hole through the carburetor body. As the venturi narrows, air moving through it is forced to speed up creating low pressure inside the carburetor. In a siphoning effect as the air tries to equalize the pressure, fuel is drawn in from the float bowl mixing with the air before entering the engine. The wider open the throttle valve, the more air will flow, drawing more fuel. A number of circuits are built into the carburetor in order to control the amount of air/fuel being drawn into the engine. In this context a circuit refers to a fuel passageway as opposed to an electrical circuit. In fact, nothing electrical controls fuel delivery in a carbureted system, it is all based on fluid flow, vacuum and hydraulics. The different circuits represent various throttle positions such as idle, partially open and fully open, and each of these circuits can be tuned to modify the efficiency of fuel delivery to the system. Fuel injection (FI) systems, on the other hand, rely on an electronic fuel pump to deliver fuel. The fuel pump delivers fuel at around 50psi as opposed to carbureted systems at normal atmospheric pressure of about 15psi. When the fuel reaches the injectors, the higher pressure allows much finer atomization (creating mist) of the fuel. The injectors then spray the atomized fuel into the intake manifold in a uniform conical pattern. The uniform pattern and fine atomization of the fuel spray increase the efficiency in which it is burned

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