Filed Under (Yamaha) by admin on 08-11-2010
1. Remove seat and disconnect battery. Remove fuel tank along with both left and right side battery covers, and remove air box from carburetor (all per Yamaha standard shop manual procedures). 2. Remove chrome plastic cover over fuel pump and disconnect choke cable/knob from lower pump bracket. Remove pump-to-carb fuel line from fuel pump. Disconnect fuel pumps electrical lead connector. 3. Remove two (2) hex-head pump mounting bracket bolts and remove pump assembly from motorcycle. Slide fuel pump up and off bracket mounting posts (Caution: excess fuel may drain from pump and/or fuel lines and fuel filter!). Remove heat shield. Remove remaining fuel line from pump. Pull all fuel lines from filter and remove steel springs and hose clamps from these lines (these will be reused on the kits fuel lines). With a sharp knife or box cutter, trim off the top portion of the fuel pumps rubber isolation/mount system per Photo A. Next cut pumps wiring harness approximately half way between connector and pump. Strip the insulation from the ends of these wires as well as from the supplied Baron harness extension wires. Using the supplied electrical butt connectors, crimp Baron harness extensions red wire to pumps black-w/blue-strip wire, and Baron harness extensions black wire to pumps black wire. Repeat this process on other side of wire harness extension with pumps connector. Now, referring to Photo B, you will need to cut off the square tube that runs along the side of the fuel pump with a hack saw. Cut down toward pump body in a straight cut, then cut tube off by cutting along the body. This will allow you to twist pump in the rubber mount so the curved spigot is facing up (clockwise approx 1/4 turn). 4. Remove pump-to-carb fuel line from carb and separate electrical wires from this line. Remove this fuel line from engine. Re-route choke cable to right side of engine (toward carb) and rotate it up and over rear cylinder head back toward left side of bike. Mount new Baron choke bracket to the choke cable and tighten plastic nut. New choke bracket will mount to rear fuel tank mounting location (Photo C). 5. 99~03 models – Remove electrical relay bracket (found under the right side cover) from the bike and slide each relay off of this bracket. Install fuel pump onto new Baron Fuel Pump Bracket and install bracket in the same location as the stock bracket you just removed, using stock mounting hardware. Refer to Photo F for proper installation. 6. 04~07 models Remove electrical relays from stock bracket and remove relays from rubber holder. Cut rubber holder per Photo E and replace one of the relays into the rubber and install on to new Baron bracket. The second relay will be placed to the right of the tool bag under the seat and secured with the provided two-sided tape pad. Reconnect plugs to the relays. (Photo F)
Filed Under (Suzuki) by admin on 26-02-2011
FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve . The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM . When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impel- ler . This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it . Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port . The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped . Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 -600 kPa (4.5- 6.0 kgf/cm2,64- 85 psi) . Relief valve Brush , ∎ I,’ Check valve Magnet L Armature When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction . This process continuously takes place causing fuel pressure to be built up . The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve . FUEL SYSTEM AND THROTTLE BODY 5- 3 Inlet port I I Impeller 5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve . It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm2,43 psi) to be applied to the injector at all times . When the fuel pressure rises more than 300 kPa (3 .0 kgf/cm2, 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank . 90 Spring 02 Valve FUEL INJECTOR The fuel injector consists of the solenoid coil, plunger, needle valve and filter . It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion . As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized (injection time)
Filed Under (Harley Davidson) by admin on 09-03-2012
1. Open or remove seat according to the instructions in the Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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) 2. Disconnect battery cables, negative (-) cable first. 3. Remove left and right-hand switch housing assemblies. Refer to HANDLEBAR SWITCHES in Service Manual. NOTE It is not necessary to disconnect the switch wiring to replace the switch caps. 4. Remove individual switches from switch housing. Refer to SWITCH REPAIR/REPLACEMENT in Service Manual. INSTALLATION Upper Housing Switches 1. For HORN and START switch caps, release torsion spring leg from hole in switch cap tab. Take note of how the spring is installed. The other leg of the spring can remain in the switch bracket hole. 2. See Figure 1 and Figure 5. Carefully pry stock black switch cap up off the splined actuator shaft (2) on left side of switch. -J02633 1 of 5 5 2 1 1 3 4 is 01405 1. Switch cap installed correctly 2. Switch cap removal from splined shaft 3. Switch cap removal from pivot pin 4. Switch cap installation onto pivot pin 5. Switch cap installation onto spined shaft Figure 1. Switch Cap Removal and Replacement 3. Pry the switch cap up and away from pivot pin (3) on right side of switch, and remove cap. NOTE Use the clear protective cover film to protect the chrome surface of the switch caps during installation. Remove the film after the installation is complete. 4. See Figure 5. Select proper chrome replacement switch cap from kit. 5. See Figure 1. Place cap onto switch, angling the hole on right side over pivot pin (4) on switch. 6. Carefully press switch cap down onto splined actuator shaft (5), rocking and moving the cap until shaft snaps into place in splined hole. 7. For HORN and START switch caps, insert torsion spring leg into hole in switch cap tab. 8. Toggle switch back and forth, checking for proper opera- tion. Turn Signal Switches 1. See Figure 1 and Figure 5. Carefully pry stock black switch cap up off the splined actuator shaft (2) on switch. 2. Pry the switch cap up and away from pivot pin (3) on switch, and remove cap. 3. Select proper chrome replacement switch cap from kit. Peel a clear protective installation cover from the sheet and place it over the surface of the cap. 4. See Figure 1. Place cap onto switch, angling the hole on top over pivot pin (4) on switch. 5. Carefully press switch cap onto splined actuator shaft (5), rocking and moving the cap until shaft snaps into place in splined hole. 6. Toggle switch back and forth, checking for proper opera- tion.
Filed Under (Harley Davidson) by admin on 30-03-2012
1. Remove seat. 1 WARNING 1 WARNING To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) 2. Purge the fuel supply line of high pressure gasoline. a. See Figure 4-36. Disconnect the fuel pump fuse from the main wiring harness. b. Start the engine and allow the vehicle to run. c. When the engine stalls, operate the starter for 3 seconds to remove any remaining fuel from the fuel lines. 1 WARNING 1 WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect negative battery cable. 4. Remove instrument console. a. All but FXSTD, see Figure 4-37. Remove acorn nut and washer on instrument console to separate console from fuel tank. b. For FXSTD, see 8.26 INSTRUMENT CONSOLE: FXSTD. 5. Disconnect console wiring. Figure 4-36. Fuel Pump Fuse: View From Top Figure 4-37. Acorn Nut And Washer: All But FXSTD s0660x8xx 7526
4-28 2007 Softail: Fuel System HOME 1 WARNING 1 WARNING Gasoline can drain from the crossover line when disconnected from fuel tank. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00259a) 6. Drain fuel tank. a. Obtain a short section of hose (5/16 inch I.D.). Insert bolt in one end of hose and install hose clamp to ensure that end is securely plugged. b. See Figure 4-38. Cut clamp (1) from one end of crossover hose (2). Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gasoline from free end of crossover hose into suitable container. 7. See Figure 4-39. Unplug fuel pump module connector (3) . 8. Remove top plate screws (2) and discard. 9. See Figure 4-40. Pull top plate (2) out of fuel tank enough to expose fuel hose and clamp (1). CAUTION Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even the smallest hole can cause a reduction in fuel pressure. 10. Cut clamp and remove hose from regulator housing fit- ting.
Filed Under (Yamaha) by admin on 20-11-2010
CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760