Filed Under (Harley Davidson) by admin on 06-03-2011
1995 Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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) 1.1995 MODELS, REMOVAL OF ELECTRONIC SPEEDOMETER AND BRACKET 1a. Refer to applicable Service Manual procedure and remove seat. 1b. Refer to applicable Service Manual procedure and remove fuel tank. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 1c. Remove speedometer sensor cable from mounting clips under tank. See Figure 1. The 3-place speedometer sensor connector  is located on the frame beneath the seat. Remove connector from t-stud and disconnect. Cut cable tie holding sensor wires to right rear frame tube. 1d. Refer to applicable Service Manual procedure and remove headlamp, for work clearance. 1e Remove handlebar clamp screws securing speedometer bracket. Remove speedometer, bracket, and harness. 2.1995 MODELS, DISCONNECT MAIN WIRING HARNESS 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 2a. Disconnect the battery, negative cable first. Refer to applicable Service Manual procedure and disconnect main wiring harness 8-place connector [21A, B], at the front of the motorcycle. 3.1995 MODELS, REMOVE SPEEDOMETER LEADS FROM 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 3a. See Figure 2 and Service Manual wiring schematic. Pull the following wires and terminals out of connector [21B]. Wire Color Cavity Number Orange/white 5 White/green 1 Black 2 3b. Remove the large female connector from the fuel gauge black wire. 3c. Slide the wires removed in step 2a out of the plastic conduit covering the wires connected to the 8-place connector. 1 WARNING 1 WARNING 1 WARNING Figure 1. Speedometer Sensor Connection  4973 Speedometer sensor connector  Figure 2. Tachometer/Speedometer Wire Splices and Terminal Connections [21B, A] i00240-.tif Splices 4.1995 MODELS, REMOVE INDICATOR LAMPS FROM BRACKET 4a. Remove the screws that secure the indicator lamps assembly to the speedometer bracket. Retain screws and indicator lamps assembly for installation on speedometer/tachometer bracket later. 5.1995 MODELS, REMOVE SPEEDOMETER FROM BRACKET 5a. Unscrew boot from speedometer reset switch. Remove cover screws and rear cover. 5b. See Figure 3. Note position of rear speedometer gasket and remove it. Push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket. Do not remove front gasket from the speedometer. 6.1995 MODELS, INSTALL SPEEDOMETER IN KIT BRACKET 6a. See Figure 5. Place wires from speedometer through front of left opening in double bracket. Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation. 6b. Insert speedometer into the front of the double bracket. Be sure wire guides are aligned with opening at bottom of bracket. 6c. Place rear gasket in position and align gasket tabs. Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into position at the opposite side. 6d. Add amber bulb assembly from kit to speedometer in order for tachometer and speedometer backlighting to match. 6e. Replace cover and boot from reset switch.
Filed Under (Tips and Review) by admin on 29-11-2010
INSTALLATION ON 2004 MODELS 1. Turn off the ignition switch and disconnect the battery ground cable before proceeding. 2. Refer to Figures 2 and 3 for wiring details. 3. Remove the Gill Module. 4. Cut off the OE 18 terminal AMP connector used with the Gill module. Refer to the terminal list. Crimp new Deutsch terminals on the wires, and install into the 12 terminal Deutsch connector required by the TC88A-IH module. 5. Install the new TC88A-IH module. 6. Reconnect the battery ground cable. INSTALLATION ON 2005 AND LATER MODELS 1. Turn off the ignition switch and disconnect the battery ground cable before proceeding. 2. Refer to Figures 4 and 5 for wiring details. 3. Remove the Gill Module. 4. Cut off the OE 18 terminal AMP connector used with the Gill module. 5. The crankshaft position (CKP), MAP, and engine temperature (ET) sensor share a common ground Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119 TC88A-IH (386) 304-0700 www.daytona-twintec.com 10/2009 Page 2 return. This is not compatible with the TC88A-IH and some rewiring will be required. The temperature sensor is not used, but does not require removal. 6. Trace the BK/GN ground return wires from terminal B of the ET sensor and terminal A of the MAP sensor to where they join the BK/GY ground return wire from the CKP sensor. Cut the ET and MAP sensor ground return wires off at this point. You can tape up the ground return wire from the ET sensor – this wire will not be used. 7. Extend the ground return wire from terminal A of the MAP sensor up to the ignition module, crimp on a Deutsch terminal and install in position 4 on the Deutsch connector. 8. Refer to the terminal list. Crimp new Deutsch terminals on the remaining wires, and install into the 12 terminal Deutsch connector required by the TC88A-IH module. 9. Use a DVM to verify isolation (no continuity) between terminals 4 and 9 on the Deutsch connector. 10. Verify continuity between terminal A at the MAP sensor and terminal 4 on the Deutsch connector. 11. Verify continuity between terminal 2 at the CKP sensor and terminal 9 on the on the Deutsch connector. 12. Install the new TC88A-IH module. 13. Reconnect the battery ground cable. Terminal List for American IronHorse Ignition Conversion TC88A Deutsch Connector OE AMP Connector Signal Wire Color Code 1 2 +12V Power W/R
Filed Under (Harley Davidson) by admin on 27-03-2012
Removing the Cam Chain Drive System. NOTES Changing camshafts and cam drives in the 2006-up Harley-Davidson® Twin Cam 88® engines is different than in pervious engines. Procedures require use • of some special tools. Installation should be done by an experienced mechanic with access to factory service manual and required tools. Tighten all fasteners to the correct specifications and in order described. Always use an accurate torque wench. • Incorrect installation can cause engine damage not covered under warranty. CAUTION Failure to install components correctly can result in sudden engine seizure. Engine seizure may result in serous injury to motorcycle operator, passenger, or others. A- Disconnect the battery ground cable to eliminate potential sparks and inadvertently engagement of the starter while working on the motorcycle. B- Remove spark plugs and pushrod cover clips. Collapse the pushrod covers to expose the pushrods. C- Safely elevate and stabilize the rear of the motorcycle. Place the transmission in high gear. Turn the rear wheel to rotate the engine until both lifters and pushrods for either cylinder are at the lowest point on the camshaft (TDC of compression stroke). Both intake and exhaust pushrods for that cylinder will be under pressure from the valve springs and will rotate with light finger pressure. NOTE: 510G camshafts may use stock style non-adjustable pushrods instead of adjustable pushrods. If installing non-adjustable pushrods, disassemble and assemble rocker boxes per H-D® instructions. All other S&S® gear driven cams require installing adjustable pushrods. As a time-saving measure, the stock pushrods can be removed with bolt cutters. Be sure to head caution and warnings of these instructions. D- Cut the pushrods for the cylinder that is at TDC with the bolt cutter and remove the pushrod covers from the engine. Rotate the engine to place the pushrods for the other cylinder at their lowest point. Cut and remove the remaining pushrods. WARNING CAUTION Cutting pushrods with a saw or cutoff wheel may result in debris entering the engine, causing engine damage not covered under warranty. WARNING Cutting pushrods without releasing spring pressure, by rotating the engine until tappets are at the lowest point of travel can result in bodily injury. E- Remove the pushrod covers and lifters form the crankcase. F- Remove engine cam cover and gasket. Secure lifers with a tool made from a large binder clip
Filed Under (Harley Davidson) by admin on 07-02-2011
INSTALLATION PROCEDURE Note: All Evolution® “Big Twin” pistons are marked “Front” or “Rear” and come with rings, wrist pins, and locks. • Note: We highly recommend that a dealer or trained mechanic perform the installation of these pistons. Specialized equipment is required for honing and finishing the cylinders to ensure long life of the piston and cylinder assembly. 1. Remove original equipment cylinders from engine. Refer to a shop manual or other reference book for specific steps, if needed. (Note: Care should be taken not to bend the studs or damage the cylinder during removal of the cylinders.) 2. With a small screwdriver, move the wrist pin retainer around to gain access to the tail of the retainer as it lines up with the notch in the bottom of the wrist pin hole. 3. Use a small screwdriver, pick or awl to roll the wrist pin retainer out of its groove. 4. Push wrist pin out and remove piston. 5. Repeat procedure for the other piston. 6. At this point, take cylinders, new pistons, and piston-to-wall clearance specifications to your dealer or machine shop to perform necessary machining operations. • IMPORTANT NOTE (Evolution® and Twin Cam®): The cylinder bore must be machined/honed to provide .0025″ of piston-to-wall clearance. Measure the piston diameter at a point .500″ up from the lower skirt (See Figure 3). 7. Starting with the front cylinder, install new piston rings and one wrist pin retaining clip (Note: Second ring has a dot which must face up when the ring is installed) . 8. Place the piston over the conecting rod, making sure that the intake valve pocket is towards the intake side. (For Evolution ® , see Figure 1. For Twin Cam ® , see Figure 2) . Coat the wrist pin with engine oil and insert it into the piston. Install the second wrist pin retainer into the groove. 9. Lightly coat the piston skirt with engine oil. Place a piston ring compressor over the piston/ring assembly and compress. Place the cylinder over the piston and gently push down until all rings are in the cylinder. Remove the ring compressor, and push the cylinder the rest of the way down. (Note: Be careful not to get oil onto the base gasket.) 10. Place two nuts and washers on opposite corners of the #1 cylinder to hold it down while you repeat the procedure for cylinder #2. 11. Assemble the rest of the engine per factory specifications. Start the engine and let it run at 2000 rpm for about 10 minutes.
Filed Under (Harley Davidson) by admin on 25-03-2012
Speed Sensor Installation: The microSpeed™ speedometer can be used with either +12V or +5V hall effect electronic sensors located in transmission. Sensor is not include. If your sensor operates on +5V DC wire speedometer to sensor and power as shown in Figure 2 below. Please note that color of wires from the sensor may vary, check sensor documentation for proper signal connections. For +12V sensor you will not need the Blue wire of the microSpeed™ speedometer. It may be cut short, but make sure that the end is properly protected so that it will not accidentally short to metal on the motorcycle. Use Figure 3 below for wiring a +12V sensor. H-D motorcycles 1999 and earlier used +12V sensors. H-D motorcycles 2000 and later use +5V sensors. Note: H-D OEM sensors require 20Kohm resistor(provided) between Sensor power and Sensor signal as shown. Procedure: 1. Locate wires and determine connection points. Cut wires and techflex to proper lengths. 2. Connect speedometer wires to proper signal wires as shown in diagrams, including 20K ohm resistor if using stock H-D sensor. Use either butt connectors provided or customer supplied connectors. 3. Use electrical tape or Heat Shrink tubing around sensor signal wire, sensor power, and resistor to protect resistor. 4. Proceed to Setup Section below. Setup microSpeed™ Speedometer: 1. Before proceeding review User Guide document for detailed instructions on following procedure. 2. Turn on power to speedometer, display should read “odo” 3. Set initial odometer value 4. Turn off power for 2 seconds; then turn power on again 5. Display should read “F 0″ 6. Enter Configuration and Calibration and set speedometer to proper operating mode. a. Harley English b. Harley Metric c. Standard speed sensor English d. Standard speed sensor Metric 7. Set Fuel miles per tank 8. Set Oil change interval 9. Set Speed adjustment 10. Confirm. 11. Test speed is reporting properly and adjust is necessary