connections from flywheel to coil on a 1999 sherco 2 5

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HARLEY DAVIDSON DYNA CHROME COIL COVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Installation 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. 2. Note the position of each spark plug wire in the ignition coil, then disconnect the two wires. 3. If there is an existing coil cover: Remove and discard the coil-cover mounting screws and spacers. Remove and discard the coil cover. If there is not an existing coil cover: Remove and discard the two coil mounting screws. 4. See the Service Parts illustration. Obtain the coil cover bracket (3), two long screws (4) and two spacers (2) from the kit. 5. Insert the screw into one of the holes in the bracket as shown, through a spacer, and into a coil mounting hole. Repeat with the second screw and spacer. 6. Assemble the coil to the electrical caddy with the two screws. Tighten the screws to 50 in-lbs (5.6 Nm). 7. Obtain the new chrome coil cover (1) from the kit. Position the cover over the coil, and fasten to the coil cover bracket with the three chrome screws (6) and washers (7) from the kit. Do not fully tighten the screws at this time. 8. Connect the spark plug wires through the holes in the side of the coil cover onto the correct coil terminals. 9. Adjust the cover to center the spark-plug wire boots in the coil cover holes for best appearance. Tighten the three chrome screws securely 10. Refer to the Service Manual and follow the instructions given to install the maxi-fuse

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CR500R/ 500 AF Hi Power Digital Ignition & Light Coil Installation Instructions

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Filed Under (Honda) by admin on 19-11-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI.b6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator. 10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on
the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 bkg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012”. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012”. Use a good/no good
technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap

HONDA CR 500R/ 500AF Hi Power Digital Ignition AND Light Coil Installation Instructions

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Filed Under (Honda) by admin on 16-12-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI. 6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator.
10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 kg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012″. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012″. Use a good/no good technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap. 15. If the pulser gap needs to be adjusted loosen the pulser mounting bolts adjust the pulser up or down as needed

HARLEY DAVIDSON CHROME SEAT POST REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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REMOVE 2 1 is00000 1. Seat Post 2. Screw Figure 2. Lower Seat Post 1. Refer to Owners Manual to remove the seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery negative cable. 3. On motorcycles equipped with oxygen sensors, disconnect the rear sensor connector. 4. See Figure 2. Remove screw (2) and washer from the lower seat post (1) and discard. -J04294 1 of 2 5. Disconnect spark plug wires and primary wire from ignition coil. 6. See Figure 3. Loosen the bracket screws (1). Remove seat post screw (2) and seat post with ignition coil and cover. 7. See Figure 4. Remove coil cover screw (5) and cover (4) from stock seat post (1). 8. Remove ignition coil screws (3) and coil (2) from seat post. 2 1 is04241 1. Bracket Screws 2. Upper Seat Post Screw Figure 3. Upper Seat Post Fasteners 2 5 1 3 4 is04337 1. Seat Post 2. Ignition Coil 3. Coil Screw 4. Coil Cover 5. Coil Cover Screw Figure 4. Install Ignition Coil to Seat Post INSTALL 1. See Figure 4. Install ignition coil (2) to new seat post using screws (3). Tighten ignition coil screws to 10-15 ft-lbs (13.6-20.3 Nm) . 2. Install coil cover (4) to seat post with screw (5) and tighten to 30-40 in-lbs (3.4-4.5 Nm) . 3. See Figure 1. Place seat post (1) in position and attach lower post with screw (2), washers (3) and dome nut (4). Tighten screw (2) to 10-15 ft-lbs (13.6-20.3 Nm) . 4. See Figure 3. Attach upper seat post with screw (2). Tighten screw (2) to 12-15 ft-lbs (16.2-20.3 Nm) . Tighten bracket screws (1) to 12-15 (16.2-20.3 Nm) . 5. Connect primary wire to ignition coil. 6. Connect spark plug wires to ignition coil. The rear cylinder plug wire attaches to the top coil post. Ensure that spark plug wire boots are fastened securely. 7. Connect rear oxygen sensor connector, if equipped. 8. Reconnect battery negative cable

HI-4 DUAL FIRE MOTORCYCLE IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 09-11-2010

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Turn ignition switch off and disconnect battery ground cable. 2. Refer to Figure 3. Remove OE ignition module and wire harness (items 1-4). You will disconnect two wires at the coil (15), a wire going to the VOES (Vacuum Operated Electrical Switch) (18), a black ground wire at the ignition module, and the 3 pin plug (20) that connects to the sensor plate (11). Refer to shop manual for locations. 3. Remove ignition cover plates and gasket (items 5- 9). This will require drilling out two rivets. The rivets will later be replaced with two supplied self- threading screws. 4. In order to remove the sensor plate cable, the cable plug (20) must be removed first. Use needle nose pliers to pull the terminals out of the plug. Then pull the cable through the exit hole at the bottom of the timing cover. 5. Note location of sensor plate (11). There is a V notch in the sensor plate used for alignment. When you install the HI-4, you should align the V notch in the same location. This should set the timing close enough to start the engine. Remove and save the two standoffs and washers (10). Remove the sensor plate (11). HI-4 INSTALLATION Refer to Figure 4. The HI-4 requires use of the OE timing rotor P/N 32402-83 (used only on 1985 and newer models). If you have an older model or are not sure, check the rotor (9) for the correct part number. For models prior to 1980, use the supplied 10-32 x ¾”bolt and washer to mount the rotor. 1. Install the HI-4 system in place of the OE breaker or sensor plate. Rotate the HI-4 about 90 degrees to give better access to the cable exit hole. Install the HI-4 first, then push the cable through the hole. On some early models it may be necessary to enlarge the wire harness exit hole in the gear cover. Align the V notch on the HI-4 same as the OE plate you removed. Use the OE standoffs to secure the HI-4. You must use lockwashers under the standoffs for proper clearance between the HI-4 and cover plate. Do not fully tighten the standoffs until the timing has been set. 2. Route the HI-4 wire harness along the frame rails up to the coil. Make sure that harness will not be chafed or burned by exhaust heat. Secure harness with tie wraps. Do not install timing cover. HI-4 HOOKUP Crimp terminals and hardware are supplied for your convenience. Use the ring terminals for coil hookup. Use male-female quick disconnects for connections to the tach and vacuum switch (VOES). Tape up any unused wires. 1. Circuit Breaker Cover Screws (2) 2. Circuit Breaker Cover 3. Circuit Breaker Cover Gasket 4. Breaker Plate Screws (2) 5. Breaker Plate Screw Lockwashers & Washers (2 each) 6. Retainer (1971 to early 1972) 7. Circuit Breaker Cam Bolt 8. Breaker Plate Assembly 9. Breaker Cam 10. Advance Assembly 11. Gear Case Cover 11 10 9 8 7 6 5 4 3 2 1 NOTE: Damage will result if the brown tach wire comes in contact with +12V. Figure 1. Harley-Davidson®OE Points System
9000-4002A REV A 3 2/05 1. Identify switched +12 volt wire and tach wire (if equipped) going to the coil. Refer to your service manual, or reconnect the battery and use a test light or voltmeter. The switched +12 volt wire will be hot when the ignition key is turned on. 2. Refer to Figure 5. Connect the HI-4 red wire and switched +12 volt wire to Coil positive. 3. The HI-4 white wire is not used and should be taped. 4. Connect the HI-4 black wire to the Coil negative terminal. 5. Connect the HI-4 green wire to the vacuum switch (Figure 3, item 18), if used. 6. Connect the HI-4 brown wire to the tach wire, if equipped with tach. Tape up if unused. 7. The HI-4 is grounded via the timing housing; a separate ground connection is not required. 8. Reconnect battery ground cable. Verify proper ground connections to the frame and engine. VOES HOOKUP The OE vacuum switch (VOES) is normally an open circuit. Above 3-5 inch-Hg vacuum, the VOES closes and grounds the vacuum input on the OE ignition module. This increases the total advance generated by the OE ignition module. Vacuum advance improves part throttle 17 16 1. Cover Screws (2) 2. Ignition Timer Cover 3. Ignition Module 4. Timer Plate Screws (2) 5. Washers (2) 6. Screws & Washers (2 each) 7. Shield 8. Sensor 9. Trigger Rotor Bolt 10. Timer Plate 11. Trigger Rotor 12. Advance Assembly 13. Gear Case Cover 14. Ignition Coil 15. Spark Plug Wires (2) 16. Ignition Coil Terminal (FX) 17. Ignition Coil Terminal (FL) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 NOTE: Most motorcycle coils do not have terminals marked. Use either terminal for Coil+ (positive) and the other one for Coil- (negative). Warning: The HI-4 (8-1100) Dual Fire ignition will not work with 2 plugs per head, dual coil application. Damage will result if attempted. Use the HI-4 (8-2100) single fire ignition for 2 plugs per head applications

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1999 – 2003 1.25, 2.0, 2.5 and 2.9 Sherco Ignition Timing Removal And Installation Manual

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Filed Under (Sherco) by admin on 20-04-2011

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Remove the gear shift lever bolt by using a 5mm Allen wrench. Insert the wrench through the hole in the skid plate. Holding the gear shifter up in second gear makes it easier to align the wrench into the head of the bolt. Pull the gear shift lever as far as possible towards the chain. (The chain does not have to be removed in order to remove the ignition cover and flywheel) Remove the three ignition cover bolts by using a 4mm Allen wrench. Carefully remove the ignition cover-which requires a little twisting and some outward pressure on the gear shift lever. The shift lever may also have to be pressed down into the first gear position. Inspect the rubber ring gasket for cracks or cuts while the ignition cover is off. Replace if necessary. We recommended applying a ring of high grade silicone sealant to further improve the seal of the rubber ring gasket. Tap a chisel-mark across the flywheel retaining nut and the crankshaft by using a small, sharp chisel. This mark serves as a reference point for retightening the flywheel in its original position during reassembly.

Kawasaki KX 80 1992-ON, KX100 IGNITION STATOR Installation instructions

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

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Take the ignition cover off. Take note of the wire colors of the original stator wires and disconnect them from the wiring loom. Remove the flywheel using a proper puller tool. Remove the baseplate with the original stator. Remove the screws that secure the coil and take the coil off. Cut the original wires close to the original coil. Take a good look at how the wires are connected to the coil. (at which side of the original coil which wire color goes). Connections: Connect the wire colors accord- ing to the drawing. RED and BLACK/RED Connect the old wires up to the new coil. Put the wires in exactly the same place as on the original. Make sure you have good connections here. Use a soldering iron and rosin core solder (the type used in electrical applications). Mount the coil onto the baseplate, fit the screws using locking compound on the threads and TIGHTEN THE SCREWS SECURELY! Refit the stator baseplate. Ensure the wires CANNOT TOUCH THE FLYWHEEL! (especially on the inside of the flywheel) Refit the flywheel. Tighten the bolt to specified torque

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DUCATI CLUTCH INSTALLATION INSTRUCTIONS

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

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When a vehicle is so equipped, the pilot must be replaced. The pilot is located in either the engine’s crankshaft or in the center of the flywheel. To remove a flywheel-fit pilot, remove the flywheel from the engine and drive or press out the pilot from the backside of the flywheel. Press or gently tap new pilot into flywheel after flywheel has been machined (where applicable). For crankshaft-fit pilots, an effective means for removal is to select a drift punch or wooden dowel that fits snugly into the old pilot. Then, pack the old pilot tightly with grease. Using the drift punch (or dowel) and a hammer, drive the grease toward the engine. The grease will not compress and will in turn push the old pilot out of the crankshaft. Install the new pilot carefully using a bearing driver. NOTE: Do not grease new pilots. New pilot bearings come pre-greased (often with special synthetic grease). Bronze pilot bushings have oil in the pores of the material that grease will clog. For bushings, a few drops of 30W oil can be used if desired. PRESSURE PLATE AND DISC Install flywheel (refer to flywheel section above) . Always tighten flywheel to crankshaft bolts in a star pattern to manufacturer’s torque specification. Before installing the disc, make sure that it slides smoothly on the transmission input shaft. Apply a thin coat of high temperature grease (such as wheel bearing grease) to the splines of the input shaft. DO NOT USE ANTI-SEIZE! It does not cling to rotating parts. Slide the disc back and forth on the input shaft and remove any extra grease that squishes out of the splines of the disc. Do not get grease or oil on the disc facing. Any grease or oil on a disc facing can be removed with alcohol or brake cleaner if done quickly. Lay the disc on the flywheel noting the flywheel side of the disc and hold it in place with the alignment tool. Clean the pressure ring of the pressure plate with brake cleaner to remove the rust inhibiting coating. Do not spray the entire pressure plate with brake cleaner as lube for internal parts will be removed. Set the pressure plate on the flywheel dowel pins (if equipped) and hand tighten the hold-down bolts. With hand tools, tighten pressure plate bolts ½ turn at a time in a star pattern until the manufacturer’s torque specification is met. Remove the alignment tool. NOTE: Different brands of the same pressure plate may have a difference in appearance and uninstalled lever height. These are not issues. Appearance can vary greatly and the installed lever height will be the same.

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HARLEY-DAVIDSON 5 Speed Transmissions 1984 – 1999 EVO / 5 Speed & 1999 – 2006 Twin Cam Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-11-2010

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Remove Original Parts From Vehicle. 2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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HARLEY-DAVIDSON 1984 – 1999 Evo/ 5-Speed & 1999 – 2004 Twin Cam Transmissions Installation Instructions

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

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Illustrated Parts List Main Shaft Gear (Small Gear) (1) Special Tools (1 set): • 3/4″ Socket Adapter • Ring-Seat Tool • Spring Tapered Split Ring (2) Counter Shaft Gear (Large Gear) (1) Trap Door Gasket (1) Trap Door (1) .010 Shim /Spacer (20) Delrin Crush Washer (2) Wavy Washer (2) Bearing Lock Nut (2) Nylon Set Screws (4+1 spare) Trap Door Cover Gasket (1) * Not illustrated : Champion Super-lock compound : 0-ring for clutch cable (if needed) : .010″ feeler gauge (3/16″ wide) : Scotch Brite Pad

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