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BMW MOTO-1 diagnostic scanner user manual

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Filed Under (BMW) by admin on 24-11-2010

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1. When testing the motorcycle ECU with the diagnostic scanner, it displays “Communication failure!” what is the problem? How to deal with it? This problem is caused by the reasons as below: 1.1 The ECU model of diagnostic program you choose is different from the ECU model of motorcycle. Some motorcycles are modified. At this time, you can check the detailed model of the ECU, and choose the actual model from the “ECU MODEL” menu to test. 1.2 The ignition switch hasn’t turned on to the “ON” position. 1.3 The cable between the diagnostic scanner and the diagnostic connector of motorcycle isn’t connected reliable. 2. After electrifying the diagnostic instrument, press the switch of the mainframe, it displays white screen or black screen. What is the problem? How to deal with it? 2.1 Maybe you adjusted the adjustable knob of the mainframe by accident to lead the white screen or black screen of the mainframe. After starting up normally, adjust the offside adjustable knob on the top of the mainframe screen to make the mainframe display normally. 2.2 Check the power supply voltage of the diagnostic scanner is normal or not.

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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

1999 YAMAHA YZF-R6 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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ENGINE SPECIFICATIONS/ELECTRICAL SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons Oil ring Dimensions (B T) End gap (installed) 1.5 2.0 mm 0.10 0.35 mm Crankshaft Crankshaft-journal-to-crankshaft- journal-bearing clearance 0.028 0.052 mm Carburetors ID mark Jet needle Pilot screw turns out 5EB1 #1, 4: N7RA #2, 3: N7SA 1-1/2 2 ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition system Ignition timing 10 BTDC at 1300 r/min Ignition coils Primary coil resistance Secondary coil resistance 0.204 0.276 Ω 8.5 11.5 Ω Oil level switch model (manufacturer) 5EB (DENSO) Fuel pump relay model (manufacturer) Resistance G8R-30Y-M (OMRON) 162 198 Ω -3- TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Item Thread size Tightening torque Remarks Nm mkg Engine mounting adjusting bolts Rear shock absorber and frame Pivot shaft adjust bolt M10 7 40 5 0.7 4.0 0.5 -4- CABLE ROUTING SPEC 1 Throttle cables 2 Clutch cable 3 Left handlebar switch lead 4 Starter cable 5 Main switch lead 6 Front brake hose 7 Right handlebar switch lead AInstall the headlight relays onto the headlight housing bridge. BRoute the headlight lead through the plastic guide. CRoute the headlight lead through the headlight bracket right side, and connect relay. DDon’t kink. EPut coupler into stay. FMake sure the connector is out off the bottom end of front cowling. GRoute the right handlebar switch lead in front of the front fork inner tube. HRoute the throttle cables between the brake hose and right handlebar switch lead. IRoute the wire harness through under the left handlebar switch lead and starter cable. JFasten the left handlebar switch lead to the front fork with a plastic locking tie and cut the end of locking tie. KFasten the throttle cables and starter cable with a band. EB206000 CABLE ROUTING -5- CABLE ROUTING SPEC LLocate the end of band to for ward. Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie. Cut the end of locking tie. And then, route the horn lead under the brake hose and clamp it to the under cover

BMW R259 Installation Instructions Fuel Control For BMWOilheads

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

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Installation R1200 C -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. -Re-install the fuel tank. Make sure the fuel lines are connected and their routing is correct. Insure that both throttle cables are correctly seated in their adjusters on the throttle bodies, and that nothing interferes with the throttle mechanisms on either throttle body. Turn the key on and allow the fuel system to pressurize. CHECK FOR ANY FUEL LEAKS and repair as necessary. Go to section 3 to verify power-up. Re-install any other bodywork removed. Seethe Techlusionwebsite for more detail.

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2000 YAMAHA YZF-R1 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 27-11-2010

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CABLE ROUTING SPEC AProperly insert the meter assembly coupler and rubber boot into the meter assembly. BRoute the meter assembly lead through the left side of the headlight housing. CThe speedometer lead with not be tighten. DInstall the headlight relays onto the headlight housing bridge. EConnect to the right front turn signal connectors. FRoute the turn signal leads upper the headlight housing boss. 1 Clutch cable 2 Left handlebar switch lead 3 Starter cable 4 Main switch lead 5 Steering cover EB206000 CABLE ROUTING -21- NRoute the thermo switch/temperature sender sub- wire harness to the outside of the radiator cap. ORoute the right handlebar switch lead behind the throttle cables. Do not cross the throttle cables and the right handlebar switch lead. PRoute the right handlebar switch lead in front of the throttle cables. GFasten the headlight lead with a plastic clamp at white tape mark. HFasten the wire harness to the headlight housing boss with a plastic locking tie. IRoute the headlight lead through the plastic guide. JRoute the throttle cable to the front side of the brake hose. KRoute the clutch cable behind the front fork leg. LMake sure that the horn leads face out. MRoute the throttle cables and right handlebar switch lead between the lower bracket and steering cover. CABLE ROUTING SPEC -22- CRoute the rollover-valve-to-fuel-tank hose to the inside of the fuel hose (California only). DRoute the coolant reservoir breather hose over the timing chain tensioner. EInsert the plastic clip through the hole in the plastic frame panel and then fasten the wire harness and coolant reservoir breather hose with it. FRoute the clutch cable between the radiator bracket and frame and in front of the thermostat assembly breather hose. GRoute the clutch cable to the inside of the radiator inlet hose. HInsert the plastic clamp into the hole in the coolant reservoir’s tab

DIAGNOSTIC TESTER CONTROLLER AREA NETWORK (CAN) INTERFACE MODULE

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Filed Under (Toyota Manuals) by admin on 30-10-2011

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Remove the original DLC3 Cable and store it in the Diagnostic Tester storage case. 2. Connect the CAN Interface Module to the DLC Cable. 3. Use the Diagnostic Tester with the CAN Module installed for all DLC3/J1962 based vehicle communication. 4. If you experience problems with the Diagnostic Tester or CAN Interface Module, please contact Toyota Special Service Tool Customer Support at 1-800-933-8335. NOTE: There is no need to remove the CAN Interface Module when working with non-CAN systems or older software versions (Version 10.1a or earlier). The Diagnostic Tester will communicate with all DLC3/J1962 based systems with the CAN Interface Module installed. For DLC1 and DLC2 communication you must continue to use the Vehicle Interface Module (VIM)

Yamaha TW200N/ TW200NC SPECIFICATIONS AND SUPPLEMENTARY SERVICE MANUAL

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Filed Under (Yamaha) by admin on 26-04-2011

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GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts CABLE ROUTING 1 Throttle cable 2 Front brake light switch lead 3 Right handlebar switch lead 4 Clutch cable 5 Left handlebar switch lead 6 Clutch switch lead 7 Front turn signal/position light lead (left) 8 Main switch lead 9 Indicator lights lead 0  Speedometer cable A Meter light lead B Headlight coupler C Wire harness D Front turn signal/position light lead (right) E Brake hose ب Fasten the brake hose with a plastic locking tie to the brake hose grommet. ة Fasten the wire harness with a plastic locking tie PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and abjustments.If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM

YAMAHA YZF-R6R/ YZF-R6SR/ YZF-R6RC/ YZF-R6SRC SERVICE MANUAL

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Filed Under (Yamaha) by admin on 26-04-2011

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CABLE ROUTING SPEC A Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables. B Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward. C Pass the clutch cable through the guide. D Plastic locking tie shall be positioned at 10 mm (0.39 in.) below from the upper bracket. E Clamp the left handlebar switch lead to the front fork with the plastic locking tie and cut the tip of the tie. Clamp it to the protector section Set in the coupler between the head light’s hollow section and the duct. J Install the relay to the rib of the head light. (Location for the left and right relays is alternative.) K To the wire harness L To the front turn signal light (right) M Set the sub wire harness in the joint. N Do not catch the sub wire harness when the duct is assembled. O To the front turn signal light (left) P Point the tip of the plastic locking tie to the front side of the vehicle. Cut the tip leaving 2 X 10 mm (0.08 X 0.39 in). Q Point the tip of the plastic locking tie under the under bracket and rear side of the vehicle. Cut the tip leaving 2 X 10 mm (0.08 X 0.39 in) A Pass the main switch lead under the left handlebar switch lead and then to the right side of the vehicle. B Pass the throttle stop cable by the left side of the side stand switch lead, oil level switch lead, A.C. magneto lead and then to the right side of the vehicle. C Pass the fuel tank drain hose and fuel tank breather hose inside of the reservoir tank breather hose, reservoir tank hose and wire harness and then route it by the out side of the starter motor lead. D Pass the coolant reservoir tank hose outside of the fuel tank drain hose and fuel tank breather hose. E Pass the fuel tank drain hose, fuel tank breather hose through the clamp of the coolant reservoir tank

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HARLEY DAVIDSON TOUR-PAK RACK LIGHT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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INSTALLATION 1. Remove all contents from Tour-Pak®. 2. For easier installation, remove Tour-Pak rack, if installed, by removing cap screw, washers and mounting pads. 3. See Figure 1. Remove rubber plug from bottom rear rail on left side of rack. 4. See Figure 2. Use line wire feeder in kit to thread through left rear rack foot and out through the back opening of rail. 5. Attach light harness wires to line wire feeder loop. 6. Carefully pull line wire feeder and light harness wires through rack mounting foot. 7. See Figure 5 and Table 1. Apply foam pads (5) to top surface of light. 8. Secure light (1) to rack with socket head screws (4) and washers (6). 1 is05242 1. Plug Figure 1. Left Side Rack Plug 1 is05244 1. Line wire feeder Figure 2. Thread Wires Through Rack 9. Position rack/light assembly to Tour-Pak lid and route wires through lid, washer and hollow mounting bolt. 10. Attach rack/light assembly to Tour-Pak using instructions and hardware provided with rack except for use of hollow bolt from Step 9. 11. Remove Tour-Pak liner. 12. Thread wires through black vinyl conduit. 13. Ultra Classic models: Follow Steps 14 through 2114. Locate and disconnect three pin AMP connector for Tour- Pak lights. 15. See Figure 3. Attach the Y-harness (2) to the three pin male connector (1) of Tour-Pak harness. 16. Route light wires from back of Tour-Pak along left side to front. Secure conduit with adhesive clips provided in kit. 17. Trim length of light wires and conduit to reach Y-harness. 18. Refer to the Service Manual electrical appendix to install terminal pins (8) to rack light wires and install terminals to three pin housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead 19. Connect rack light to remaining Y-harness connector. 20. Replace Tour-Pak liner. 21. Check operation of Tour-Pak tail and stop light functions before operating motorcycle. 22. Classic models: See Figure 4. If necessary, drill hole in lower left bottom of Tour-Pak and install grommet. Route rack light wires through grommet. 23. Refer to the Service Manual electrical appendix to install terminal receptacle (8) to rack light wires and install terminals to three pin receptacle housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead NOTE To prevent corrosion, fill the cavities of the connectors with dielectric grease (included in kit) prior to making connections. As an additional precaution against moisture seepage into the Tour-Pak, apply silicone sealant (not included in kit) to the entrance of the light harness wire tunnel. See figure 2 for location reference. 24. Connect rack light to male connector of two connector wire harness (12) and connect to accessory connector under seat. 25. Replace Tour-Pak liner. 26. Check operation of Tour-Pak tail and stop light functions before operating motorcycle

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SUZUKI MOTORCYCLES Gsxr 600, Gsxr 750, Gsxr 1000 teak the lead

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

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The launch of the sixth generation of Gsxr marked a shift in Suzuki’s emphasis on two fronts. One, the Gsxr 1000 now took the upper hand in the development stakes. Historically, the Gsxr 750 led the march-arriving first, gaining the most recent technology, absorbing the lion’s share of corporate pride-but by 2003 the Gsxr 1000 was in the lead. Two, the Gsxr 1000 represents another, more subtle shift for Suzuki engineering, in which the designers-the lucky guys who get to clothe these amazing machines-have more freedom of expression. With this generation, the designs turned edgier, sharper, more aggressive looking than ever. What’s more, the Gsxr 1000 K3 would be the proving ground for a host of changes brought to the Gsxr 600 and Gsxr 750 for 2004. In fact, nearly every upgrade to the smaller bikes appeared on the Gsxr 1000 a year before. But the real impetus for driving the Gsxr 1000 to the head of development and, indeed, shortening its development cycle was competition both on the track and in the showroom. For the track, it was understood that Superbike racing would revert to allowing 1000 cc four-cylinder bikes in place of the 750s that had been the limit since 1982. In 2002, Yoshimura and Mat Mladin barely lost the AMA Superbike crown to Nicky Hayden aboard the Honda RC5!. But it would be the RC’s swan song of competitiveness with the change to 1000 cc fours. To keep speeds in check, the AMA Superbike rules would require 1000 cc fours to have some additional limitations compared to the twins and triples. For example, “Cylinder heads may be ported and machined, but altering of valve angles will not be permitted; aftermarket valves, springs, retainers, and other valve-train components will be permitted; valves must be stock size and same basic material as original equipment; aftermarket camshafts will be permitted, but earn lift and resulting valve lift must be no greater than stock. “In addition, the “stock crankshaft must be retained, The only allowable modifications are balancing, polishing of bearing surfaces and attachment of accessory drives. Homologated transmission gear sets (one optional set of ratios per approved model) will be permitted. Optional sets will be price-controlled and must be available to any legitimate AMA Superbike competitor. Homologated fuel-injection throttle-body assemblies (one optional type per approved model) and aftermarket airboxes will be permitted. Modifications to throttle bodies will not be permitted. Optional throttle bodies will be price-controlled and must be available to any legitimate AMA Superbike competitor.” The thinking was simple: keep the liter bikes from sucking through massive throttle bodies, and the horsepower might not (and, it was hoped, would not) go through the roof. In preparation for racing, Suzuki moto wanted to make a host of small changes to the Gsxr 1000, but its motivation was also to keep the bike at the forefront of open-class street bikes. Suzuki engineers knew that Honda and Kawasaki were readying all-new models-the CBR 954 RR and the ZX 9 R had long since been vanquished-and rumor had it that Yamaha was ready with yet another push with the R1.It was the right time to make alterations to the Gsxr 1000. Heading the list was, as one might expect, a revised engine.

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