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1999-2003 Harley Davidson TC88 Micro Tach TM Tachometer Installation Manual

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Filed Under (Harley Davidson) by admin on 10-03-2012

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Installation of the Speedway Instruments microTach+TM tachometer requires some basic mechanical skills, including removing decorative covers, cutting protective tubing around wires, and using suitcase splice connectors to splice existing wiring harness. These actions may void your warranty, and if done incorrectly may cause damage to your motorcycle. Only you know your capabilities, if you do not feel capable of making modification please have a qualified motorcycle technician install it. Speedway Instruments, LLC is not responsible for damage to your motorcycle due to improper installation. The microTach+ TM tachometer designed for 1999-2003 TC88 Harley Davidson motorcycles is designed to operate when connected to a dedicated Tachometer signal from the Electronic Ignition Controller. It is not intended to run off signals going to the ignition coil unless utilizing a Speedway Instruments Tach Adapter. WARNING: Damage may occur to the microTach+ TM tachometer or your motorcycle if micro Tach+ TM tachometer is connected directly to coil signals, you must use a Speedway Instruments tach Adapter (sold seperately) ! ! 1. Turn ignition off and disconnect Battery. 2. Determine a mounting position. Each motorcycle is unique and the microTach+TM tachometer is small enough to be placed in many different locations to provide an attractive appearance and vital engine status. Possible locations are: a. Front Brake Reservoir

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2004 Harley Davidson Micro Tach Tachometer Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-03-2012

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Tachometer Installation Instructions for 2004+ Harley Davidson Sportster Custom Look for other model instructions online at www.speedwayinstruments.com Introduction: Installation of the Speedway Instruments microTach+ TM tachometer Tachometer requires some basic mechanical skills, including removing decorative covers, cutting protective tubing around wires, and using suitcase splice connectors to splice existing wiring harness. These actions may void your warranty, and if done incorrectly may cause damage to your motorcycle. Only you know your capabilities, if you do not feel capable of making modification please have a qualified motorcycle technician install it. Speedway Instruments, LLC is not responsible for damage to your motorcycle due to improper installation. These instructions utilize a 2004 Harley Davidson XL1200C motorcycle as basis for the all descriptions and pictures. Variations in location, color and procedure may be required for different year and make. Please refer to the Service manual to confirm the proper color and location of wires. Please make sure you have the proper service manual and tools before starting the installation. 1. Turn ignition off and disconnect Battery. 2. Determine a mounting position. Each motorcycle is unique and the microTach+TM tachometer is small enough to be placed in many different locations to provide an attractive appearance and vital engine status. Possible locations are: a. Front Brake Reservior b. Top handle bar clamp

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Harley-Davidson FL Models (1993-2009) HARLEY PASSENGER FLOORBOARD COMFORT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2012

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1. Using your 5/16″ allen wrench, unscrew the Cap head allen bolts attaching the stock passenger floorboard mount to the frame and remove the assembly. You will reinstall this assembly once the mounts have been installed. STOCK MOUNT FEATURES: Notice the floorboard mount has a locating pin that protrudes from the rear surface. This pin is what keeps the mount from swiveling on the frame. The frame has three threaded holes and one unthreaded hole on each side. These holes provide the three different floorboard heights the bike offers stock. HEIGHT POSITIONS: The Comfort Kit mounts provide you the ability to raise the stock floorboards height 1-1/4″ or 2″ higher than the highest stock position. This is accomplished by attaching the mounts to the specific combinations of the threaded holes on the frame. POSITION #1 – Raises the floorboards 2″ by attaching the mounts to the #1 & #2 threaded holes from the top. NOTE: You must use the rectangular spacer block in order to use the 2″ rise position in order to clear the right exhaust pipe. POSITION #2 – Raises the height 1-1/4″ by attaching the mounts to the #2 & #3 thread holes from the top. TILTING: You will notice one threaded and one unthreaded hole towards the top of each mount and directly between these holes is an engraved L & R. These mounts are Left and Right side specific. The locating pin mentioned in the stock mount features paragraph inserts into the unthreaded hole and locks the floorboard into its tilted position.

SUZUKI SV 1000 RADIATOR (COOLING SYSTEM) SERVICE MANUAL

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

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FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR COO NO FAULT C11 Camshaft position sen- sor The signal does not reach ECM for more than 3 sec . after receiving the starter signal . The camshaft position sensor wiring and mechanical parts (Camshaft position sensor, intake cam pin, wiring/coupler con- nection) C12 Crankshaft position sensor The signal does not reach ECM for more than 2 sec . after receiving the starter signal . The crankshaft position sensor wiring and mechanical parts (Crankshaft position sensor, wiring/coupler connection) C13 Intake air pressure sensor The sensor should produce following voltage . (0.50 V < sensor voltage < 4 .85 V) Without the above range, C13 is indicated. Intake air pressure sensor, wiring/coupler connection C14 Throttle position sen- sor The sensor should produce following voltage . (0.20 V < sensor voltage < 4 .80 V) Without the above range, C14 is indicated. Throttle position sensor, wiring/coupler connection C15 Engine coolant temperature sensor The sensor voltage should be the following. (0.15 V <_ sensor voltage < 4 .5 V) Without the above range, C15 is indicated. Engine coolant temperature sensor, wiring/coupler connection C21 Intake air temperature sensor The sensor voltage should be the following. (0.15 V < sensor voltage < 4 .5 V) Without the above range, C21 is indicated. Intake air temperature sensor, wiring/coupler connection C22 Atmospheric pressure sensor The sensor voltage should be the following. (0.50 V < sensor voltage < 4 .5 V) Without the above range, C22 is indicated. Atm. pressure sensor, wiring/coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec . after ignition switch turns ON . (0 .20 V < sensor voltage < 4 .80 V) Without the above value, C23 is indicated. Tip over sensor, wiring/coupler connection C24 or C25 Ignition signalCrankshaft position sensor signal is produced and ECM determines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more. In this case, the code C24 or C25 is indicated. Ignition coil, wiring/coupler connection, power supply from the battery SERVICING INFORMATION 8 .3 C28 Secondary throttle valve actuator No operating voltage is supplied from the ECM, C28 is indicated. STVA can not operate. STVA lead wire/coupler, STVA C29 Secondary throttle valve position sensor The sensor should produce following voltage . (0.10 V < sensor voltage < 4 .90 V) Without the above range, C29 is indicated . Secondary throttle position sensor, wiring/coupler connection C31 Gear position signalGear position signal voltage should be higher than the following for more than 2 seconds. (Gear position switch voltage >_ 0 .6 V) Without the above value, C31 is indicated. Gear position sensor, wiring/coupler connection, gearshift cam, etc. C32 or C33 Fuel injector Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted continuous by 4 times or more. In this case, the code C32 or C33 is indicated. Injector, wiring/coupler connection, power supply to the injector C41 Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF . Fuel pump relay, connecting lead, power source to fuel pump relay C42 Ignition switchIgnition switch signal is not input in the ECM . Ignition switch, lead wire/coupler C44 Heated oxygen sensor (HO2S) [For E-02, 19] During 02 feedback control, 02 sensor voltage is higher or lower than the specification . No signal is detected during engine operation or no electrical power is supplied from the battery . HO2S lead wire/coupler connection Battery voltage supply to the HO2S C49 PAIR control solenoid valve (PAIR valve) When no operating voltage is supplied from the ECM, C49 is indicated. PAIR valve can not operate. PAIR valve lead wire/coupler

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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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1980-2003 HARLEY DAVIDSON BARON TACHOMETER installation manual

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Filed Under (Harley Davidson) by admin on 12-03-2012

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1. Mount new Baron Tach on handlebar in your preferred position. Ideal location is between handlebar risers. If mounted off-center, you can rotate tach face back to vertical (or any position you desire) by first loosening tach unit’s set screw (found either in handlebar area of housing or underside of housing, depending on tach style), then unscrewing tach housing’s bezel, rotating the tach internals, re-installing the bezel and retightening the set screw. 2. Secure handlebar clamp by first tightening the rear, flat side of clamp all the way down, and then tighten the tapered front side of clamp until tach does not rotate. There should be a small gap on the pointed side and no gap on the flat side when the clamp is correctly tightened. 3. Route tach’s wire harness lead under dash for simplest and cleanest installation. 4. Make your wire connections as follows: a. Locate the pink wire under the speedo (sometimes has a plastic bullet end on it). Cut the plastic off and splice the pink wire with the green wire from the tachometer. b. Find the orange wire and attach the tach power wires to it (usually blue & red from tach (incandescent) or red & yellow for single color LED tachs. On 7-color LED models it is red from tach and red from LED controller box) . c. Locate a suitable ground (usually a bare frame bolt) and attach the black wires from the tachometer and the LED controller box (if equipped).

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Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

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2009 Harley-Davidson FLH Series Independent Suspension Trike Conversion Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Important Safety Precautions a. Make sure you have a clear understanding of all basic shop safety practices and that you wear appropriate clothing and use safety equipment. Be especially careful of the following: · Read all directions before you begin, and make sure you have the tools, the parts and the skills required to perform the tasks safely and completely.Harley-Davidson® FLH 2009 & Up Independent Suspension CHAMPION TRIKES Installation Guide Page 5 of 18 Revision 8 · Protect your eyes by using proper safety glasses, goggles or face shields anytime you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. · Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. · Protect yourself and others when you have a vehicle up in the air. Anytime you lift a vehicle, either by hoist or a jack, make sure that it is securely supported. b. Make sure the engine is turned off and battery disconnected before you begin work. · Carbon Monoxide poisoning from exhaust gases: Be sure there is adequate ventilation whenever you run the engine. · Burns from hot parts: Let the engine and exhaust system cool before working on those areas. · Injury from moving parts: If running the engine, keep hands, fingers and clothing away from moving/rotating parts. c. Gasoline vapor and hydrogen gases from batteries are explosive. To reduce the possibility of fire or explosion, be careful when working near gasoline and batteries. d. Use only nonflammable solvent, not gasoline, to clean parts. e. Never drain or store gasoline in an open container. f. Keep all cigarettes, sparks or flame away from the battery and all fuel related parts. 1.6 Specifications Overall Length: 103″ Overall Width: 57.25″ Wheel Base: 53″ Max Load Capacity: 600 Lb Max Tire Size (15″): 205 / 70 / R15 Wheel Size (15″) (4 lug) Offset +35 mm 15x7JJ 4 on 4.5 Tire Pressure: 24-26 PSI Suspension: Double A-arm Independent Rear Differential: Custom-built rear differential utilizing OEM drive belt. Brakes: Original front plus 2 high performance disc brakes at rear. Storage Capacity: 5.75 cubic feet. Two full-face helmets and additional storage. *Champion does not change certain components that will affect EPA, CARB, or any laws that will change the emission characteristics of the motorcycle.

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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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2009 – Current Harley Davidson Trike Conversion Kit INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 27-02-2012

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the ¼ – 20 Phillips head screw and Seat. 6. Disconnect and REMOVE battery. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Remove and save the Passenger Handrail and two ¼ – 20 flanged hex head nuts if equipped. 8. Remove the Saddle Bags. 9. Remove the Right and Left Side Covers. 10. Remove Inner Tour Pak Molded Liner. 11. Disconnect the Tour Pak wiring. 12. Remove four ¼ – 20 HHCS. 13. Remove Tour Pak from Top Support Tube. 14. Remove both saddlebag support rails. 15. Loosen Muffler Clamps on both Mufflers and remove two 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 16. Remove right side rear heat shield. 17. Remove and discard Muffler Support Plates. 18. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip. 19. Remove four frame cover fasteners and the Left and Right Frame Covers. 20. Remove four Tour Pak Support fasteners and the Tour Pak Support.
7 21. Remove four rear fender fasteners and rear fender. 22. Remove four ½ – 13 HHCS and washers. Remove and discard Rear Air Shocks, Air lines and Air Valve bracket. 23. NOTE: NOTE: NOTE: NOTE: If motorcycle is A.B.S. Equipped refer to A.B.S. Installation Instructions. WARNING: WARNING: WARNING: WARNING: If A.B.S. Equipped DO NOT drain brake fluid. 24. Drain all Brake Fluid from the Rear Brake System. 25. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 26. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 27. Remove the Spring Clip and nut from the Rear Axle. 28. Remove Rear Axle and Rear Wheel Spacers. 29. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 30. Remove Rear Brake Caliper. 31. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate. 32. Remove Rear Wheel Assembly. 33. Remove two 3/8 – 16 SHCS. Remove Passenger Footboards.

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