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1984-1999 Harley-Davidson Evolution Engines Replacement Cylinder Heads Installation Instructions

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Filed Under (Harley Davidson) by admin on 28-10-2010

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Installation of an S&S Super Stock cylinder head kit is easy and can be performed by any Harley-Davidson®repair shop equipped to do engine overhauls. No special tools other than those used in normal overhaul repair work are required. Read instructions thoroughly before starting work. When they are completely understood proceed with installation. 1. Remove Components and Inspect Parts Follow procedures outlined in appropriate Harley-Davidson® service manual to prepare motorcycle for top end service. NOTE: Disconnect batteryand drain all gasoline from gas tanks beforedoing any work. Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks. A. Remove gas tanks and all other parts required to perform top end service. B. Remove carburetor, rocker covers, pushrods and pushrod tube assemblies, cylinder heads and cylinders. Also remove piston rings from piston. Do not remove pistons. NOTE: Be careful not to introduce any dirt or other foreign material into crankcase during disassembly of engine. Metal filings, dirtand any other foreign contamination in engine may cause premature wear and/or irreversible damage to bearings and other internal engine components. C. Thoroughly clean and inspect all parts that are to be reused. Any parts that show signs of wear or damage should be replaced. WARNING CAUTION 2. Check Piston Alignment in Cylinder Bore The purpose of this procedure is to check for and correct possible piston misalignment in the cylinder bore. During normal manufacturing, engine components such as crankcases, cylinders, and connecting rods can be machined to dimensions within factory specifications but on the extreme ends of the tolerance range. Sometimes these components when combined together form an assembly that is borderline or actually “out of print”. The worst result isthat the pistons can run cocked in the cylinder bores causing the connecting rods to thrust to the sides exerting unnecessary stress on the pistons, rings, rod bearings and other related parts. This procedure is not the same as blue printing, but it provides almost the same result. We feel that not enough emphasis is given to checking the piston alignment in the cylinder bore.

Installation Instructions Fuel Control For BMW Oil heads

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Filed Under (BMW) by admin on 26-10-2010

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Removethechrome right air filter cover. Release the brake fluid reservoir from its mount. Follow the oxygen sensor lead from the exhaust to the connector. It is mounted to the back of the brake fluid reservoir mounting bracket with cable ties. Cut the cable ties to release the connector from the bracket. Gently pull the connector apart. Insert the male O2 connector from the R259 into the oxygen sensor lead. Connect the female side of the R259sO2 connector to the bike’swiringharness side. Make sure both sets of connectors are fully seated. Cable tie the sensor lead connector back to the bracket and tuck the other O2 connector under the front of theairhorn. -Depressthe retaining bail on the right fuel injector connector and gently pull off the connector. Install this connector on the male R259 injector lead. Install the remaining R259 connector on the right injector. -Connecttheground lead by removing the allen screw (5mmhex) that secures theairboxtothe frame. Place the screw through the lug on the ground lead and reinstall and tighten the screw. Go to section 3 and verify power-up. Tuck the wiring below and behind theairhornand cable tie as necessary. Using the supplied velcro, attach the controller box to the top of theairhorn. Reinstall the brake fluid reservoir in its mount and reinstall the side-cover. Seethe Techlusionwebsite for more detail. Installation R850, R1100, R1150, R1100S -Refertothe appropriate BMW service guides and remove the fuel tank. On some models it maybe possible to have an assistant lift the tank up and to the left to expose the oxygen sensor connector, without fully disconnecting the tank. Locate the oxygen sensor connector by following the lead from the exhaust system. It will be cable tied to the right frame backbone. Cut the retaining cable ties and pull the connector away from the frame. Open the connector and insert the male R259 O2 connector into the oxygen sensor lead, and the female to the bike’swiringharness. Cable tie these back to the right frame backbone. -Routethe R259 wiring harness down the right frame, in-between the battery tray and the rear fuel tank mount. Using the supplied velcro attach the R259 to theairboxlid. Locate the lead on the right fuel injector, and while depressing the locking bail on the connector, gently pull the leadoff. Install this lead on the R259 male injector connector; install the remaining connector on R259 harness to the right injector. Make sure all of the connectors are fully seated. Cable tie any excess wiring away from the fuel lines and throttle mechanism. -Connecttheground lead to the battery negative terminal or an alternate good ground

HARLEY DAVIDSON TIMER COVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 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) NOTE For kits 32972-04A, 32924-04A, 32675-04A, and 32923-04A, refer to step 1 and 2 for installation instructions. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. See Figure 2. Remove and discard the original screws and timer cover. 2. Place new timer cover (1) in position and secure with chrome screws (2). NOTE For kits 32584-88TA, 32668-98A, and 32571-98A, refer to steps 3 through 8. 3. Use a 3/8 in. drill bit and drill the heads off the original timer cover rivets. Remove original timer cover. NOTE If the inner timer cover has been riveted in place and access to the cam position sensor is required, use a left hand drill and carefully remove the rivet heads. If a right hand drill is used, the sensor plate screw heads could break off when trying to remove the rivet. NOTE To make the cam position sensor tamper proof, follow steps 4 through 6. If the cam position sensor is not required to be tamper proof, skip steps 4 through 6. 4. Remove and discard inner cover retaining screws. Leave gasket (if used) and inner cover in position. 5. See Figure 1. Place washers (4) over rivets (3) and place rivets into inner cover holes so the backs of the rivets go into the sensor plate screws’ tapped holes. 6. Use a standard rivet tool and install rivets, securing inner cover to sensor plate screws. 7. Use the self-tapping screw (5) to cut threads into the remaining inner cover holes. Discard screw after use. 8. Place new timer cover (1) in position over inner cover (A) and secure with chrome screws (2). NOTE For kit 32581-90TB, refer to steps 9 and 10. 9. Use 3/8 in. drill bit and drill the heads off the timer cover rivets. Remove original timer cover. 10. Place new timer cover in position and secure with chrome screws (Part Number 9462) from kit

HARLEY DAVIDSON EFI SCREAMIN’ EAGLE BIG BORE EFI STAGE 2 KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION Installation of this kit is divided into six steps: 1. Big-Bore Cylinder and Piston Conversion 2. High Performance Camshafts 3. High Performance Clutch Diaphragm Spring 4. High Performance Air Cleaner 5. Calibrate the ECM 6. Exhaust NOTES This Big-Bore Stage 2 kit is intended for High Performance applications only. This engine-related performance part is legal for sale or use in California on pollution-controlled motor vehicles. Engine-related performance parts are intended for the experienced rider only. -J04173 1 of 5 The air cleaner contained in these kits is designed to perform with these kits only. Any other combination of components is not confirmed to be legal for street use. The Product Information Label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the Product Information Label on the right side of the frame, directly beneath the VIN sticker. Do not place the label on motorcycles other than those specified in the Instruction Sheet. Gaskets provided in the 1690 conversion kit eliminate the need for original head gasket O-rings. For this reason, DO NOT install the Original Equipment (OE) O-rings (Part Number 11273) to the top of cylinder dowels, or severe engine damage may occur. Big-Bore Cylinder and Piston Conversion NOTE Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to Section 3, ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL of the applicable Service Manual for instructions. High Performance Camshafts NOTE Installation of this kit requires removal and re-installation of the cam support plate. Refer to Section 3, ENGINE: BOTTOM END Cam Support Plate, Removal and Disassembly/Assembly (Camshaft, Camshaft Bearings) of the applicable Service Manual for instructions. Measuring Piston-to-Valve Clearance After installing non-stock cams, check piston-to-valve clear- ance. 1. Apply 1/8-inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons. 2. Refer to the appropriate Service Manual and assemble the heads and valve train, and tighten cylinder studs to torque specified. 3. Turn engine through two complete revolutions by hand. 4. Remove heads and measure clay at its thinnest point. NOTE Clay must measure 0.080 inch (2.03 mm) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 0.135 inch (3.43 mm). Measuring Valve-to-Valve Clearance NOTE Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents you from bending push rods or valves. 1. Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust evel sensor to the fuel pump with screw (3). Tighten the screw enough to seat the fuel sensor against the mounting tab e. Route fuel level sensor wiring under the fuel hose and connect the fuel level sensor to the low fuel switch connector on the fuel pump module. If necessary use the jumper harness (Figure 4, item 5). f. See Figure 2. Secure the fuel pump wires and con- nectors

2004 KTM 950 ADVENTURE REPAIR MANUAL

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Filed Under (KTM) by admin on 23-11-2010

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Intake system Fresh air is drawn into the filter box through the intake snorkel 1 , past the carburetors 2 and through the air filter 3 . The cleaned air is conducted to the combustion chamber through the carburetors and intake ports. 1 2 2 3 2-4 Repair manual KTM LC8 Art.-Nr . 3.206.016-E Secondary air system The secondary air system supplies fresh air to the emissions in the exhaust port, resulting in the afterburning (oxidation) of the emissions. A line leads from the filter box 1 to the control valve 2 which opens as soon as the throttle valves 3 are opened. The line continues to the reed valves 4 in the cylinder heads which are actuated by the pressure pulsation in the exhaust system. As a result, cleansed fresh air arrives in the exhaust port. The oxygen content in the air and the high exhaust gas temperature cause the emissions to oxidize. If the throttle valves are closed and the engine goes into an overrun condition, the underpressure in the intake port will rise and the control valve will close. This prevents exhaust backfire (combustion of the unburned fuel/air mixture). 1 2 3 3 4 4 4 2-5 Closed thermostat The thermostat is closed if the temperature of the cooling liquid drops below 75°C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 and the thermostat 2 . Open thermostat The thermostat 3 opens at 75°C. The water pump 1 pumps the cooling liquid through the cylinder and cylinder heads 2 , the aluminum cooler 4 and the thermostat. The pressure in the cooling system (max. 1.4 bar) is regulated by a valve in the radiator cap 5 . The cooling liquid level in the compensating tank 6 must be between the MIN and MAX marks when the engine is cold. The fan 7 switches on at 102°C.

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