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SUZUKI SV1000 PERIODIC MAINTENANCE

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

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MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER I Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months) . • * Remove the seat. (LF6-7) • * Lift and support the feul tank . (C-74-65) • * Remove the air cleaner box cap O. • * Remove the air cleaner element O. • * Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION Always use air pressure on the throttle body side of the air cleaner element . If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element . PERIODIC MAINTENANCE 2-5 2-6PERIODIC MAINTENANCE • * Reinstall the cleaned or new air cleaner element in the reverse order of removal . CAUTION If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug . SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months) . No. 1 (FRONT) SPARK PLUG REMOVAL • * Remove the radiator mounting bolt O. • * Move the radiator forward. • * Remove the spark plug cap O. NOTE: Be careful not to damage the radiator fins . A WARNING The hot radiator and the hot engine can burn you . Wait until the radiator and the engine are cool enough to touch . • * Remove the spark plug with a spark plug wrench. 1 6 I It No. 2 (REAR) SPARK PLUG REMOVAL • * Remove the seat. (r–,-6-7) • * Lift and support the fuel tank . (=4-65) 4-65) • * Disconnect the camshaft position sensor 1O and breather hose (Z. • * Remove the rubber heat shield ® . • * Remove the spark plug cap . • * Remove the spark plug with a spark plug wrench . HEAT RANGE • * Check to see the heat range of the plug . CARBON DEPOSIT •Check to see if there are carbon deposits on the plugs . If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end . SPARK PLUG GAP • * Measure the plug gap with a thickness gauge . If out of specification, adjust it to the following gap . 09900-20803 : Thickness gauge Spark plug gap OA Standard: 0.6 – 0 .7 mm (0.024 -0.028 in) ELECTRODES CONDITION •Check to see the worn or burnt condition of the electrodes . If it is extremely worn or burnt, replace the plug . And also replace the plug if it has a broken insulator, damaged thread . CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result

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Harley-Davidson Camshaft TC, EVO, Shovelhead, XL EVO, Iron Head, XR Specifications

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Filed Under (Harley Davidson) by admin on 02-11-2010

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EVO Black Widow PP8833-2 – 29 55 62 25 264 267 54 103 109 105.8 0.600 0.602 EVO Black Widow PP8826-2 – 27 61 63 29 268 272 56 107 107 107.0 0.602 0.602 EVO Black Widow PP8817-2 – 254 254 0.590 0.590 EVO Carl’s Speed Shop CM4 – 28 44 52 20 252 252 48 98 106 102.0 0.495 0.495 EVO Carl’s Speed Shop CM495F Y 19 47 50 16 246 246 35 104 107 105.5 0.495 0.495 0.179 0.168 EVO Carl’s Speed Shop CM580 – 19 47 50 16 246 246 35 104 107 105.5 0.580 0.580 0.194 0.163 EVO Carl’s Speed Shop CM612 – 36 60 68 28 276 276 64 102 110 106.0 0.612 0.612 0.277 0.235 88 EVO Carl’s Speed Shop CM660 – 38 62 68 28 280 276 66 102 110 106.0 0.660 0.660 0.314 0.277 90 EVO Carl’s Speed Shop CM774 – 284 284 0.784 0.784 0.277 0.236 EVO Carl’s Speed Shop CM780F – 34 70 74 30 284 284 64 108 112 110.0 0.774 0.774 103 EVO Crane EVR0020 – 31 64.5 77 23 275 280 54 107 117 112.0 0.608 0.589 88 EVO Crane Fireball 2000 Y -12 22 20 -10 190 190 -22 107 105 106.0 0.490 0.490 0.026 0.032 EVO Crane Fireball 300 Y 12 34 41 15 226 236 27 101 103 102.0 0.490 0.490 4000 EVO Crane Fireball 310 Y 16 40 43 19 236 242 35 102 102 102.0 0.490 0.490 1500 4500 75 EVO Crane Fireball 316 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 2000 5000 80 EVO Crane Fireball 326 – 24 48 57 25 252 262 49 102 106 104.0 0.490 0.500 2500 5500 EVO Crane H286 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 2000 5000 80 EVO Crane H290 – 17 43 45 23 240 248 40 103 101 102.0 0.581 0.581 1800 5200 EVO Crane H296 – 24 48 57 25 252 262 49 102 106 104.0 0.490 0.500 2500 5500 EVO Crane H304 – 24 50 55 25 254 260 49 103 105 104.0 0.600 0.600 2500 5800 EVO Crane H306 – 28 54 69 23 262 272 51 103 113 108.0 0.500 0.510 0.224 0.195 3000 6000 EVO Crane H310 – 23 63 68 28 266 276 51 110 110 110.0 0.550 0.550 0.229 0.229 3000 6500 88 EVO Crane H314 – 26 54 65 21 260 266 47 104 112 108.0 0.600 0.600 2800 6000 EVO Crane HEV0042 – 27 59 71 23 266 274 50 106 114 110.0 0.600 0.576 0.226 0.194 3000 6000 100 116 EVO Crane HEV0067 – 24 50 56 24 254 260 48 103 106 104.5 0.600 0.530 0.128 0.113 EVO Crane HEV0098 – 36 62 72 34 278 286 70 103 109 106.0 0.650 0.650 0.171 0.156 96 EVO CycleRama CR-E550 – 24 52 53 23 256 256 47 104 105 104.5 0.550 0.530 EVO CycleRama CR-E581 – 22 46 53 23 248 256 45 102 105 103.5 0.581 0.550 EVO CycleRama CR-E600A – 24 50 56 24 254 260 48 103 106 104.5 0.600 0.530 EVO CycleRama CR-E600B – 23 51 54 22 254 256 45 104 106 105.0 0.600 0.550 EVO CycleRama CR-E617 – 22 50 50 22 252 252 44 104 104 104.0 0.617 0.617 EVO CycleRama CR-E630 – 18 60 63 13 258 256 31 111 115 113.0 0.630 0.630 EVO CycleRama CR-E660 – 27 59 71 23 266 274 50 106 114 110.0 0.660 0.660 3500 6500 140 EVO Dave Mackie DM500 Y 22 38 52 12 240 244 34 98 110 104.0 0.500 0.500 0.189 0.138 EVO Dave Mackie DM500X Y 25 40 55 20 245 255 45 98 108 102.5 0.500 0.500 0.208 0.178 EVO Dave Mackie DM530 – 28 42 55 15 250 250 43 97 110 103.5 0.530 0.530 0.221 0.141 EVO Dave Mackie DM580 – 26 42 56 12 248 248 38 98 112 105.0 0.580 0.580 0.227 0.144 113 EVO Dave Mackie DM581 – 26 42 56 12 248 248 38 98 112 105.0 0.580 0.580 0.227 0.144 EVO Dave Mackie DM595 – 21 49 57 14 250 251 35 104 112 107.8 0.595 0.595 0.192 0.150 EVO Dave Mackie DM635 – 20 56 59 18 256 257 38 108 111 109.3 0.635 0.635 0.194 0.176 EVO Edlebrock 1740 Y 19 43 48 24 242 252 43 102 102 102.0 0.490 0.490 0.176 0.203 EVO Edlebrock 1741 – 20 46 52 22 246 254 42 103 105 104.0 0.600 0.600 0.183 0.187 EVO Head Quarters HQ-23 – 19 47 52 24 246 256 43 104 104 104.0 0.600 0.530 EVO Head Quarters HQ-24 Y 20 36 52 19 236 251 39 98 107 102.3 0.500 0.500 EVO Head Quarters HQ-25 – 18 38 42 14 236 236 32 100 104 102.0 0.550 0.550 EVO Head Quarters HQ-26 – 20 54 53 22 254 255 42 107 106 106.3 0.600 0.530 89 EVO Head Quarters HQ-27 – 26 60 70 24 266 274 50 107 113 110.0 0.650 0.575

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SANYANG HD 125/ 200 Specifications And SERVICE MANUAL

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

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heck and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor Fuel supplied tom carburetor sufficient No fuel is supplied to carburetor Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground. Perform cylinder compression pressure test. Check if sparks Weak sparks, no spark at all Low compression pressure or no pressure Re-start by following the starting procedures No ignition There are some signs of ignition, nut engine can not be started Remove the spark plug again and check it. Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit. Then blow the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1. No fuel in fuel tank 2. Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged. 3. Float valve clogged 4. Lines in fuel tank evaporation system clogged 5. Malfunction of fuel pump 6. Loosen or damaged fuel pump vacuum hose 7. Fuel filter clogged 1. Malfunction of spark plug 2. Spark plug foul 3. Malfunction of CDI set 4. Malfunction of AC generator 5. Ignition coil is in open or short circuit 6. Ignition coil leads open or short circuit 7. Malfunction of main switch 1. Piston ring seized 2. Malfunction of cylinder valves 3. Worn cylinder and piston ring 4. Cylinder gasket leak 5. Sand hole in compression parts 1. Malfunction of throttle valve operation 2. Air sucked into intake manifold 3. Incorrect ignition timing 1. Fuel level in carburetor too high 2. Malfunction of throttle valve operation 3. Throttle valve opening too wid

HARLEY DAVIDSON SCREAMIN' EAGLE XL1200S RACE IGNITION SYSTEM Installation MANUAL

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Filed Under (Harley Davidson) by admin on 26-12-2010

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Disconnect battery, negative cable first. 2. See Figure 1. Remove seat and locate ignition module. 3. Remove the two nuts that hold the ignition module in place. 4. Unplug the two module connectors and remove module. 5. Plug in new module and secure module in place with nuts removed in step 3. Tighten nuts to 15-21 in-lbs (1.7-2.4 Nm). 6. Disconnect spark plug cables from coil towers, noting their positions for reinstallation on new coil. ® Kit Numbers 32737-98, 32738-98, 32739-98 Figure 1. Ignition Module i01020 1 of 2 NOTE The spark plug cables have numbers printed on them that correspond to numbers adjacent to the coil towers on the coil. 7. See Figure 2. Making note of wiring positions, disconnect primary wire plug from back of coil by gently prying up latch and pulling connector rearward. 8. Remove mounting bolt and remove existing ignition coil. 9. Install new coil with mounting bolt removed in previous step. Tighten bolt to 2-6 ft-lbs (3-8 Nm). 10. Plug in primary wire connector into back of coil. 11. Connect spark plug cables to new ignition coil. 1 WARNING Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 12. Reconnect battery cables, positive cable first. 13. Check engine timing according to procedures in applicable XLH Service Manual.

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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Honda CG125 Owners Workshop Manual

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

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Clean the air filter Pull off the right-hand side panel and remove the two nuts which secure the air filter cover. Withdraw the cover, checking that the sealing gasket is in good condition, pull out the retaining spring and withdraw the element assembly. Peel off the inner and outer foam sleeves. Wash all components in white spirit (Stoddard solvent) or in warm water and detergent and dry them thoroughly. Soak the foam sleeves in the specified oil, then squeeze them gently (do not wring them out or they will be damaged) to expel all surplus oil. Refit the sleeves to the element frame. On reassembly ensure that all components are correctly fitted so that unfiltered air cannot bypass the element. 2 Check the spark plug Remove the spark plug cap, unscrew the plug and check its condition, comparing it with the photographs on page 65. If it is badly worn or fouled it must be renewed. If it is fit for further service check the gap and reset it if necessary, as described in Chapter 3.8. 3 Check the valve clearances It is important that the correct valve clearance is maintained. A small amount of free play is designed into the valve train to allow for expansion of the various components. If the setting deviates greatly from that specified, a marked drop in performance will be evident. In the case of the clearance becoming too great, it will be found that valve operation will be noisy, and performance will drop off as a result of the valves not opening fully. If on the other hand, the clearance is too small the valves may not close completely. This will not only cause loss of compression, but will also cause the valves to burn out very quickly. In extreme cases, a valve head may strike the piston crown, causing extensive damage to the engine. The clearances should be checked and adjusted with a cold engine. Place the machine on its centre stand and remove the rocker cover, taking care not to damage the 0 ring. Remove the gearchange pedal and the left-hand outer cover to expose the generator rotor. Remove plug and allow old oil to drain Remove the spark plug, then slowly rotate the engine anticlockwise by way of the generator rotor, watching the inlet valve. When it has opened and closed again (sunk down and risen up to its original position), rotate the engine further until the T mark on the rotor periphery aligns exactly with the raised index mark which is positioned between 12 and 1 o’clock (from the crankshaft) on the generator stator. The engine will then be in the correct position for checking the valve clearances, namely at Top Dead Centre (TDC) on the compression stroke; check that there is free play at both rockers. Using a 0.08 mm (0.003 in) feeler gauge, check the clearance between the top of each valve stem and its corresponding rocker. The feeler gauge must be a light sliding fit, with the rocker and valve stem just nipping it. If necessary, slacken the locknut, and turn the small square-headed adjuster to obtain the correct setting. Tighten the locknut, holding the adjuster at the same time to prevent it from moving. Finally, recheck the setting and then repeat the procedure on the other rocker. 4 Check the contact breaker points and ignition timing Note: since the generator stator plate is located by its countersunk retaining screws, the ignition timing can only be altered by opening or closing the contact breaker gap; therefore both operations are described as one. The full procedure is given here for ease of reference, but if the points are found to be in good condition and if the gap has not altered or is within the tolerance, then the ignition timing will be sufficiently accurate and there will be no need to carry out the full check. First remove the gearchange pedal, the left-hand outer cover, the spark plug and the left-hand side panel

Honda VT1100 Shadow Guide Plug Patch Repair Manual

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Filed Under (Honda) by admin on 24-04-2011

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Find the guide plug.bn The guide plug is shown in the shop manual with the engine removed from the frame and the left crankcase cover removed. (You’ll find this illustration in the “ELECTRIC STARTER/STARTER CLUTCH” chapter in the “STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL” section.) It’s a little bit harder to find it on the bike. Start by following the yardstick to see where the guide plug is on my bike. To find it on your bike, lie on the ground (or, preferably a mechanics creeper) next to the bike (without the yardstick) and peek under the shift lever and over the frame There it is, just barely visible from the side of the bike. Here’s what a new one looks like: 2. Clean the guide plug and crankcase. From the front of the bike, clean the guide plug and crankcase with brake cleaner in a VERY focused spray. Let the cleaner evaporate before moving to the next step. Page 4 Rev: Draft 5/20/2007 Page 4 of 5 3. Reposition the guide plug. a. From the side of the bike, use the yardstick (or a long screwdriver if you prefer) to gently push the guide plug back into the crankcase. (Note the JB Weld from the previous patch operation.) b. From the front of the bike, gently push upward on the bottom of the upper tab (as shown below) or the bottom of the forward tab to rotate the guide plug into the proper position while maintaining pressure with the yardstick

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HARLEY DAVIDSON GLOSS BLACK HEAD BOLT COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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This kit fits 1992 and later Evolution 1340 and XL models and 1999 and later Twin Cam-equipped models. INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Remove spark plugs. 2. See Figure 1. Install head bolt covers (1), on head bolts (3), secure using setscrew (2) and Allen wrench included with kit. To prevent setscrews from falling into the spark plug holes, start threading the setscrews into the covers before placing them over the head bolts. Position cover on head bolt so that when spark plug is reinstalled setscrew is hidden from view but accessible with Allen wrench. Do not tighten setscrews on high points of bolts. 3. Reinstall spark plugs. Tighten spark plugs to 11-18 ftlbs (15-24 Nm) . If a torque wrench is not available, finger- tighten spark plug and then, using a spark plug wrench, tighten plug an additional 1/4 turn. 4. Readjust setscrew tightness after motor has operated at full operating temperature and then cooled. 2 1 3 is 001586 1. Head bolt cover 2. Setscrew 3. Head bolt Figure 1. Head Bolt Cover Installation

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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

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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.

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