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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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A750 Transmission Solenoid Identification Automatic Transmission/ Transaxle

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Filed Under (Toyota Manuals) by admin on 19-09-2011

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Provided below isachartlisting the Repair Manual name of each solenoid used in the A750 transmission, as well as the part name description provided in the electronic parts catalog. REPAIR MANUAL SOLENOID NAME PARTS CATALOGP ART DESCRIPTION S1 3WayTransmission Solenoid S2 Transmission Solenoid#3 SL1 Clutch Control Solenoid#1 SL2 Clutch Control Solenoid#2 SLT Line Pressure Control Solenoid SLU Lock UpControl Solenoid SR

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery cables, negative (-) battery cable first. 3. Remove seat according to the instructions in the service manual. 4. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 5. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. 2. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. 3. Remove engine from chassis following the instructions in the service manual. 4. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. 5. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). 1. Remove cylinder studs from the engine crankcase. 2. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. 3. Inspect and clean engine case mating surfaces. 4. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. 5. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). 6. See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase

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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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HARLEY DAVIDSON STARTER SOLENOID REPAIR KIT

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Filed Under (Harley Davidson) by admin on 31-10-2010

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1. Remove, but do NOT discard, bolt washer 1 and 4 (fig. 1). 2. Remove, but do NOT discard, nut washer 2 (fig. 1). 3. Remove, but do NOT discard, nut washer 3 from shortest copper bolt on cap (fig. 1). 4. Gently remove solenoid cap. 5. IMPORTANT!: Snip wire 5 as close as possible to large copper bolt (fig. 2). 6. Discard old copper bolt and cap. 7. Replace old plunger 6 with new plunger provided in kit. 8. Guide small bolt 7 through hole in new cap as shown (fig. 3). 9. Solder cut wire 5 to new copper bolt terminal 8CAUTION!: Solder wire to terminal, so as not to interfere with contact of plunger to terminal. 10. Install new cap. 11. Re-assemble nuts, bolts and washers 1 2 3 4 as shown (fig. 1). Replace worn parts with those provided in kit.

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HARLEY DAVIDSON ADVANCED AUDIO CB RADIO KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available from a Harley-Davidson Dealer. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

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2010 Harley-Davidson FLHR Road King front and rear 4-piston braking system Installation

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Filed Under (Harley Davidson) by admin on 31-10-2010

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in Vivid Black with blue and silver pinstripes, six-speed. Air-cooled, Twin Cam 96™ engine with Electronic Sequential Port Fuel Injection (ESPFI), ABS, security system, cast wheels with independent front and rear 4-piston braking system. Motorcycle generously donated by Harley-Davidson Motor Company Police & Fleet Sales. MSRP excludes all taxes title/documentary fees, registration, tags, dealer prep, labor and installation charges, insurance, optional equipment and accessories, certificate of compliance or non-compliance fees, and finance charges. Delivery must be coordinated through Rockville Harley-Davidson by November 30, 2010. Winner is responsible for any applicable fees above. 6,000 tickets printed. Odds of winning are 1:6,000. Ticket holder need not be present to win. Licensed by the D.C. Lottery and Charitable Games Control Board. Must be 18 years or older to win. No substitutes, return for cash, or other models. As per IRS tax code, amounts paid for chances in a raffle do not qualify as a deductible charitable contribution. Taxes on prizes are the responsibility of the winner. Harley-Davidson is proud to be a sponsor of the National Law Enforcement Officers Memorial Fund. Harley-Davidson Motor Company is a prize provider only, and Harley-Davidson, Inc., and Harley-Davidson Motor Company have no responsibility regarding conduct or administration of the raffle.

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SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 10-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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HARLEY DAVIDSON REAR THUNDERSTAR WHEELS INSTALLATION, MAINTENANCE AND CLEANING

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from a Harley-Davidson dealer. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first, following the instructions in the service manual and using the WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle, and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING NOTE This wheel assembly includes plugs that have been installed in the openings between the brake disc mounting holes on one side of the wheel and in the compensator bowl of the 16×5 inch wheel. Missing or damaged plugs can be replaced using Wheel Plug Kit (44459-04) or individual plug (43871-09 – 16×5 inch wheel). Chrome parts must be maintained regularly so they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

HARLEY DAVIDSON REAR ROAD WINDER WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 1 and Service Parts Tables. INSTALLATION 1. Remove existing rear wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Refer to the service manual. NOTES Prior to removing or installing the wheel, the rear brake caliper must be removed. The cotter pin or spring clip for the axle nut must be replaced. They are available for purchase from you dealer. See your dealer for the correct part number for your model motorcycle. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b) 2. See Figure 1. Install valve stem assembly (E) on wheel. Refer to the service manual. 3. Assemble wheel installation kit components, stock brake disc, and sprocket to wheel using the appropriate service parts table. Refer to the service manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. The machined grooves in the hub face indicate the primary bearing side. 4. Install rear wheel (1), stock axle and stock spacers to motorcycle. Refer to the service manual. MAINTENANCE AND CLEANING Chrome parts must be maintained regularly to keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley-Davidson Wheel and Tire Cleaner, applied with Harley Wheel and Spoke Brush. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner. 3. After cleaning and polishing, seal the finish with a good quality sealer, such as Harley Glaze Polish and Sealant

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