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2009 Harley Davidson Softail POWER COMMANDER V INPUT ACCESSORY INSTALLATION

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Filed Under (Harley Davidson) by admin on 26-02-2012

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1 Remove the seat 2 Uplug the stock wiring harness from the ECM (Fig. A) 3 Remove the 4 nuts that hold the ECM to the bracket and remove the ECM. 4 Remove the bolt that holds the seat strap to the rear fender. 5 Remove the ECM bracket from the fender. Remove one nut at a time or the bracket will fall into the tire. Reinstall the nuts to support the inner fender bracket. Due to the limited amount of room on this bike the seat strap and ECM bracket can NOTbe re-used. 6 Connect the PCVharness in-line of the stock wiring harness and ECM (Fig. B). 7 Place the BLACK PCVto GREYstock connector as close to the fuse box as possible. This connection will NOT lay flat against the frame. 8 Using the supplied velcro secure the ECM to the rear fender. Place the ECM as far down as possible. The upper part of the ECM will just overlap the bolt hole for the seat strap. Make sure to clean both surfaces with the alcohol swab before attaching. If using the Autotune kit offset the ECM about 1″ from center to the right side of the bike. 9 Remove the security module from the top of the battery (Fig. C). This unit slides to the right of the bike.

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Harley-Davidson Electronic Fuel Injection Tuner INSTALLATION Manual

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Filed Under (Harley Davidson) by admin on 14-04-2012

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Harley-Davidson Electronic Sequential Port Fuel Injection System, (ESPFI) This completely new engine management system was released starting with select 2001 model year Softail motorcycles. This system is a speed/density, open loop, sequential port fuel injection design that also controls spark timing and spark intensity. Speed/Density System – When the ECM monitors manifold air pressure, air temperature, throttle position and engine rpm to manage fuel delivery. Open Loop Control – When the ECM monitors sensors positioned on the intake side of the engine and does not monitor the end result of internal combustion at the exhaust. Sequential Port Fuel Injection – When the injector nozzle is positioned in the manifold near the intake valve and is precisely timed to deliver fuel to each cylinder. This ESPFI system is the exclusive design used on 2001 and Later EFI-equipped Softail models, 2002 and Later EFI-equipped Touring models, 2004 and Later Dyna models, and 2004 and later V-Rod models. Current ESPFI Components The following is a list of the major components of Harley-Davidson’s current ESPFI system. It is important to have an understanding of what these components do before learning how the ESPFI system functions. Refer to the appropriate Harley-Davidson Service Manual for the vehicle you are working on for additional information on component design and function and for the physical location and testing procedures for each individual component. ECM – Electronic Control Module – this is the brain of the system that collects input signals from multiple sensors, makes decisions and sends output signals to deliver fuel and spark to the engine. CKP – Crank Position Sensor – this sensor provides input signals to the ECM that indicate engine rpm, (how fast the engine is running in R evolutions P er M inute). The ECM also uses these inputs to determine what stroke the engine is in so it can deliver the fuel and spark at the desired time.

Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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HARLEY DAVIDSON SCREAMIN' EAGLE ELECTRONIC FUEL INJECTION (EFI) STAGE 1 KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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Installation NOTE The installation procedure is divided into three parts: 1) Replacing ECM (1996 and earlier models ONLY) 2) Calibrating the ECM 3) Replacing stock air cleaner with air cleaner from kit. 1) REPLACING ECM (1996 and earlier models ONLY) 1. Refer to the REMOVAL/REPLACEMENT section 9C in the 1995-1996 FLT Service Manual, Part No. 99483- 96A. 2. Install ECM in accordance with the installation procedure given in the Service Manual. 2) CALIBRATING THE ECM Have dealer recalibrate the ECM prior to starting vehicle. NOTE The product information (EO) 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 information label on the right side of the frame directly beneath the VIN sticker. Do not place the label over other product information labels. Do not place the label on motorcycles other than those specified in the instruction sheet. 3) REPLACING STOCK AIR CLEANER Removing Stock Air Cleaner NOTE Refer to the applicable Service Manual and check the warm- slow idle speed adjustment before removing stock backplate. 1. Remove stock backplate following the instructions given in the appropriate Service Manual. 2. See Service Parts Illustration. Retain stock air cleaner cover and buttonhead screw and washer. Installing High Performance Air Cleaner 1. See Service Parts Illustration. Locate banjo bolts (10) included with kit. Place one washer (11) over each banjo bolt. Insert bolts through holes in mounting bracket (15). Place a second washer over each bolt. Place manifold breather (16) over bolts with hose fitting toward rear of motorcycle. Install remaining washers over the ends of bolts

2001-2003 GL1800/ A ECM Replacement/ Cooling System REPAIR PROCEDURES

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

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Install the new ECM, then reinstall the cruise/ reverse control module in the reverse order of removal. NOTE: When you start the vehicle – after completing ALL procedures – the new ECM will require initialization . To initialize the new ECM, perform the following procedure: • Start the bike and allow it to warm up to normal operating temperature and remain at idle for at least 90 seconds . Do not operate the throttle during this time; if you do, the ECU will not initialize properly and the process will need to be repeated. 5. Proceed to the Cylinder Head Inspection section below. Use the Cylinder Head Inspection Kit for the Cylinder Head Inspection procedure. Use the kit for each GL1800/A you inspect. Do NOT dispose of kit items. 1) 19X20 mm cap (2) (cap B) 2) 8X15 mm cap (cap A) 3) Hose plug 4) Bottle/cap w/feed hose 5) Harness clips (10) 6) Harness tape 7) Inspection mirror A limited number of additional Cylinder Head Inspection Kits are available: call TechLine at 800-421-1900, ext. 1 if you need one. Kit contents are NOT available separately as parts. NOTE: • The following late ’03 models do not have to have their cylinder heads inspected: • Perform the following procedure with the engine at room temperature. • Both Left and Right cylinder heads must be inspected. • Use the Cylinder Head Inspection Kit for the following procedure. 1. Remove the front lower fairing. (See S/M, 2-6) 2. Remove and suspend the rear brake reservoir, being careful not to stress the brake hose. (See S/M, 15-A-8) CONNECTOR B (22-GRY) CONNECTOR C (6-BLK) CONNECTOR A (22-BLK) ECM (ENGINE CONTROL MODULE) 1 2 3 4 5 6 7 Late ’03 (Non-ABS): after VIN 1HFSC470*3A204632 Late ’03 (ABS): after VIN 1HFSC474*3A201020 Cylinder Head Inspection Kit Cylinder Head Inspection

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INSTRUCTIONS FOR PROGRAMMING KEYS INTO RE-FLASHED TOYOTA / LEXUS ECM

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Filed Under (Toyota Manuals) by admin on 23-06-2011

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After we re-flash the ECM it will be in “Automatic Registration Mode” when you install it. The ECM is
expecting that when first powered up (by turning on a key) that it will encounter 3 new keys. The first two keys
are internally (inside the ECM) designated as MASTER keys and the 3rd key inserted will be internally
designated as the VALET key. The ECM can be programmed with as few as 1 key. If less than 3 keys are
programmed into the ECM the security light may flash for some time (hours to weeks) until the ECM “learns”
that it is apparently not going to get any more keys.

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2010 Harley Davidson Touring Model Power Commander Installation manual

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Filed Under (Harley Davidson) by admin on 29-02-2012

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1 Remove the stock seat. 2 Unplug the stock wiring harness from the ECM (Fig. A) . 3 Plug the PCV connectors in-line of the stock ECM and wiring harness (Fig.B). 4 Tuck the PCV to wiring harness connection into the opening in front of the battery box (Fig. C). 5 Using the supplied velcro attach the PCV to the top of the ECM (Fig. C) FIG.A FIG.C Remove Ground wire FIG.B PCV connector PCV connector Stk connector Connection 15-011 www.powercommander.com 2010 Harley Davidson Touring PCV – 4 6 Remove the right hand saddlebag and sidecover. 7 Locate the stock O2 sensor connections and unplug both connectors (Fig. D) The stock O2 sensors will NOT be connected to anything at this time. The sensors can be removed from the exhaust if you have a way to plug the hole. Unplugging the sensors does NOT cause an engine light but will cause a historic code in the ECM for non-active O2 sensor. This is not causing any issues with the running of the bike. FIG.D Follow these instructions when using the Auto tune kit – part #AT-100B 1 Remove the left hand side cover. 2 Place the Autotune modules in front of the battery as shown in Figure H. If using velcro make sure the velcro does not cover the designation of the unit on the back (AT #1 or AT#2). The modules are coded to the front and rear cylinders. FIG.E 3 Remove the rubber plug for the diagnostic connector. Plug the lead from the Autotune kit into the stock diagnostic connector (Fig. J).This connection is under the LH sidecover. DO NOT connect to the accessory connection in front of the battery. 4 Reinstall the sidecover. FIG.F 15-011 www.powercommander.com 2010 Harley Davidson Touring PCV – 5 5 Connect the longer harness to the front O2 sensor. Route the harness along the front down tube and along the backbone of the frame to Autotune module AT#1. Wire the harness to the module per Figure G. The harness can be cut to length if desired. 6 Repeat step 4 for the rear cylinder. Wire the harness to Autotune Module AT#2. The harness can be cut to length if desired. If your exhaust does not accept the M18x1.5mm O2 sensor you will need to install the supplied O2 bungs with the Auto tune kit into your exhaust. See Auto tune instructions for more information

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2010 Harley-Davidson FLHR Road King front and rear 4-piston braking system Installation

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Filed Under (Harley Davidson) by admin on 31-10-2010

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in Vivid Black with blue and silver pinstripes, six-speed. Air-cooled, Twin Cam 96™ engine with Electronic Sequential Port Fuel Injection (ESPFI), ABS, security system, cast wheels with independent front and rear 4-piston braking system. Motorcycle generously donated by Harley-Davidson Motor Company Police & Fleet Sales. MSRP excludes all taxes title/documentary fees, registration, tags, dealer prep, labor and installation charges, insurance, optional equipment and accessories, certificate of compliance or non-compliance fees, and finance charges. Delivery must be coordinated through Rockville Harley-Davidson by November 30, 2010. Winner is responsible for any applicable fees above. 6,000 tickets printed. Odds of winning are 1:6,000. Ticket holder need not be present to win. Licensed by the D.C. Lottery and Charitable Games Control Board. Must be 18 years or older to win. No substitutes, return for cash, or other models. As per IRS tax code, amounts paid for chances in a raffle do not qualify as a deductible charitable contribution. Taxes on prizes are the responsibility of the winner. Harley-Davidson is proud to be a sponsor of the National Law Enforcement Officers Memorial Fund. Harley-Davidson Motor Company is a prize provider only, and Harley-Davidson, Inc., and Harley-Davidson Motor Company have no responsibility regarding conduct or administration of the raffle.

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HARLEY DAVIDSON ADVANCED AUDIO CB RADIO KIT INSTALLATION MANUAL

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

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2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available from a Harley-Davidson Dealer. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

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2007 Harley Davidson Sportster 1200 Installation Manual

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Filed Under (Harley Davidson) by admin on 11-04-2012

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1 Remove the stock seat. 2 Unplug the stock wiring harness from the ECM (Fig. A) . 3 Remove the ECM from the tray and remove the tray from the fender. You can reach underneath the fender to gain access to the release tabs for the tray. 4 Install the Dynojet tray into the rear fender . Make sure that all 3 location tabs are underneath the fender. 5 Lay the PCIII in the tray (Fig. B). 6 Install the stock ECM on top of the PCIII making sure that it is secured by the tray locking tabs. 7 Plug the GREYconnector from the PCIII into the ECM. 8 Route the PCIII harness on top of the GREY connector (Fig. C) and route towards the front of the bike. Fig. A Fig. B Fig. C 2007 Harley Davidson Sport ster 1200 – PCIII USB – 2 i817-51 1 www .powercommander .com Unplug Tray 9 Plug the BLACK connector from the PCIII into the stock wiring harness. Secure this connection with one of the supplied zip ties (Fig. D). 10 Run a zip tie behind the wiring harness (Fig. E). 11 Route the stock wiring harness as shown in Fig. E. Due to the lack of room on this bike this step needs to be exact or the install will not fit properly . Make sure that the harness coming from the GREYconnector is flush against the battery box. Acouple inches of this harness will be tucked underneath the frame

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