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HARLEY DAVIDSON SOFTAIL FRONT SPOILER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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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 2 and Table 1. INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8. 1. Two-pin voltage regulator connector (2007 only) Voltage regulator 2. 9. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. 3. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. 11. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. 5. Crank position sensor connector (2007 only) Voltage regulator caddy 6. 13. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1. Original Equipment Voltage Regulator  NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. 4. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10). 5. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. 6. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. 7. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine. 8. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors. 9. For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. a. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. b. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.

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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 DYNA VOLTAGE REGULATOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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INSTALLATION 1. Remove and discard the original voltage regulator mounting screws. 2. See Figure 1. Place a chrome washer (4) onto each of the button head screws (5) from the kit. Insert the screws into the mounting holes in the new voltage regulator cover (1). Place first a spacer (2), then a Nylon washer (3) over the screw threads on the inside of the cover. 3. Fasten the cover through the voltage regulator into the motorcycle frame. Tighten to 60-80 in-lbs (6.8-9.0 Nm) . SERVICE PARTS 5 3 4 5 1 4 2 2 is01725 Figure 1. Voltage Regulator Cover Components Table 1. Service Parts: Voltage Regulator Cover Components Part Number Description (Quantity) Item Not Sold Separately Regulator cover 1 Not Sold Separately Spacer, 1.0 inch (25 mm) long (2) 2 62917-01 Washer, Nylon (2) 3 Not Sold Separately Washer, Chrome (2) 4 Not Sold Separately Screw, button head, hex socket 1/4-20 x 2-1/4 inch long (2

XR 600 Dual Sport Kit Installation Manual

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Filed Under (Pulsar) by admin on 27-10-2010

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1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the side panels, seat, and gas tank. 3. Unplug the headlight and taillight from the stock wiring and remove. 4. Locate the AC voltage regulator mounted on the left side of the frame backbone, (Fig.1) unplug from wiring harness, and remove the regulator. This regulator is located above the air box on ’87 and earlier XR 600′s and 500′s. AC Regulator (Remove) Pulsar Coil Alternator (Stator) Wiring Alternator (Stator) Contains both exciter coil and lighting coils Figure 1: If you are colorblind or even think you might be a little color blind, now is the time to get someone to assist you. Successful installation of the kit requires good color recognition. You want to go riding this weekend, don’t you? 5. A three wire group consisting of a black/red wire, a green wire, and a white/yellow wire (may appear light gray/yellow) are the output leads from the stator. 1990 and earlier models only have two wires coming up from the alternator, a black/red wire and a blue wire. On 1991 – 1999 XR 600′s, unplug the green wire and the white/yellow wire. (This should have already been done 3 when you removed the voltage regulator in Step 4.) On 1990 and earlier XR 600′s see the Stator Modification Instructions enclosed. 6. Temporarily disconnect the black/red wire and remove the rubber boot that shields the wire bundle. Reconnect the black/red wire making sure that it plugs in tightly, as this lead is responsible for powering the bike’s ignition. 7. Voltage Regulator Installation: The voltage regulator/rectifier mounts to the top right rear corner of the air box (Photo 1). Use the template provided to determine the location at which to drill the two 1/4 inch mounting holes in the air box lid. The outside edge of the regulator should be nearly flush with the outside edge of the air box when mounted properly.

2006 Saturn ION Window Regulator Replacement – Front Door

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Filed Under (Uncategorized) by admin on 30-10-2011

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regulator. Refer to Water Deflector Replacement – Front Door (See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ComponentsWater Deflector Replacement – Front Door) . Disengage the door glass to the regulator sash channel clips (2). Separate the door glass from the sash channel (1). 6. Push the window to the up position and tape in place. 7. Loosen the power window regulator bolts. Remove the rear regulator bolt. 8. Lift the window regulator, disengaging the loosened bolts from the door. 9. Disconnect the regulator electrical connector. 10. Remove the power window regulator from the door. Installation Procedure

1996 YAMAHA TDM 850 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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Model: TDM850 Model code: 4TX2 5AR1 (CH,A) Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,200 mm 790 mm 1,285 mm 805 mm 1,475 mm 165 mm 2,900 mm Radiator: Radiator capacity (including all routes) 1.7 L Tire: Type Size front rear Manufacturer front rear Type front rear Tubeless 110/80 ZR18 150/70 ZR17 BRIDGESTONE*/PIRELLI/MICHELIN BRIDGESTONE*/PIRELLI/MICHELIN BT54F/MTR03/MACADAM 90X BT54R/MTR04/MACADAM 90X *In Austria and Switzerland only Bridgestone tires are equipped on this mode. MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) Advancer type 10 at 1,150 r/min TPS and electrical type Voltage regulator: Type Model /manufacturer No load regulated voltage Semi conductor-short circuit type SH650A-12/SHINDENGEN 14.1 14.9 V Electric fan: Model /manufacturer NAAF20/NIPPONDEN SO CARBURETION CARBURETOR FUEL LEVEL ADJUSTMENT 1. Measure: Fuel level a Fuel level: 15.8 16.8 mm (below the MIKUNI mark) Out of specification Adjust. Adjust the float level by slightly bending the float tang 1. Fuel level measurement and adjustment steps: Place the motorcycle on a level surface. Use a garage jack under the engine to ensure that the carburetors are positioned vertically. Connect the fuel level gauge 2 to the drain pipe. MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) Advancer type 10 at 1,150 r/min TPS and electrical type Voltage regulator: Type Model /manufacturer No load regulated voltage Semi conductor-short circuit type SH650A-12/SHINDENGEN 14.1 14.9 V Electric fan: Model /manufacturer NAAF20/NIPPONDEN SO

HARLEY DAVIDSON DYNA STATOR AND ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. 2. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. 3. Remove primary chaincase according to the instructions in the Service Manual. 4. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. 5. Remove the two T-27 TORX screws (2). 6. Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. 7. Disassemble connector [46B] (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. 8. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. 9. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole. 2. See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. 3. Insert wires into connector [46B] (A). 4. Mate connector [46]. See VOLTAGE REGULATOR in Service Manual. is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). 6. Install the rotor (1) on the sprocket shaft. 7. Apply Loctite Threadlocker 262 (red) to sprocket nut threads. Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). 8. Install primary chaincase according to the instructions in the Service Manual. 9. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. 10. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual

HONDA 1100 ACE, AERO AND SABRE CENTERSTAND INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 27-12-2010

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Relocation of Regulator. Laying under the right side of the motorcycle, locate the voltage regulator. (finned aluminum box-approximately 3″x 4″) Note: See photo #1 – regulator already relocated. Remove the (2) 10 mm bolts attaching the regulator to the frame. Attach the bracket supplied to the regulator as shown. Using the original bolts, attach the regulator and bracket assembly to the frame as shown in photo #1 using the two 10 mm bolts supplied. Clamping Centerstand to Frame . Notice the centerstand is shipped with (2) white plastic washers. Note: See photo #2-A These are in place to overcome the spring tension or lock the stand in place and allow you to pivot the lower stand down partially to make installation easier. Pivot the upper stand about half way from the retracted to the extended (down) position. Note: This will require some force. If the stand will not stay in the position you can further tighten the two 9/16″ pivot nuts. Remove the bolts from the four band clamps. Wrap the (2) small clamps around the small upper frame tube and start the bolts so that the bolt will be at the bottom of the tube and the wrench head facing towards the rear of the motorcycle. Note: See photo #2. Center the stand on the frame from side to side so as to gain even clearance between the feet on the centerstand and the rear tire when the stand is in the retracted position. Holding the larger cradle up against the frame, tighten the (2) small clamps enough to hold the centerstand in place. Install one of the large clamps as shown in photo #3-A. Install the 2nd large clamp as shown in photo #2-C. Again retract the stand and check that the feet have even amounts of space from the side of the rear tire. Tighten the flour clamps securely 5-7 ft. lbs. Next remove the (2) 9/16″ pivot nuts and the white plastic washers as shown in photo #2-A. Re-install and tighten the 9/16″ pivot nuts securely 8-12 ft lbs. With the stand in the retracted position-adjust the stop bolt and lock nut, see photo #3-B, so that the stand is parallel with the ground and does not come in contact with any parts of the motorcycle. Using your new centerstand . To put the motorcycle up onto the centerstand, hold the left handle bar and saddlebag guard rail or grab under the bottom of the seat. Using the ball of your right foot, lower the stand to the ground. Rock the motorcycle from side to side slightly until you feel both feet of the stand touching the ground. Now put all of your weight onto the centerstand pedal (stand on it). Pull up and back on the grab rail or seat using a rocking motion to rock the motorcycle up onto the stand. Remember it is a matter of using your body weight and leverage not lifting!

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Harley-Davidson FLTR/ FLH/ FLHT/ FLHR EFI models 1995-2001 Variable Pressure Fuel Regulator Intallation manual

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Filed Under (Harley Davidson) by admin on 27-04-2012

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1 . Ensure vehicle runs correctly through all rpm ranges and idles correctly before attempting any work. It is highly recommended that a pressure / flow test be carried out before & after installation of the VariReg to determine fuel system condition . Stock HD 300 kPa / 44 psi, VariReg as delivered 360 kPa / 52 psi Note: In some countries gas stations do not “final filter” the fuel & therefore we recommend that the fuel filter canister be replaced every 15,000 klms (10,000 miles). Restriction of the fuel by way of a blocked or partially blocked filter will result in difficulty in tuning or failure to obtain satisfactory results during tuning. Should you experience difficulties in tuning, see Diagnosing fuel filter and pump faults 2. Remove air filter cover, air filter and backing plate. Check Throttle Position Sensor value at completely closed throttle as best performance will be obtained at the nominated settings. This will require backing off the idle screw and cold start idle actuator and screw adjustment as described in the workshop manual. The original T.P.S. values should be recorded for possible future reference. To set TPS values without the HD breakout box see VariReg TPS Setting for Harley-Davidsons The T.P.S. values must be set to 1995 – 1996 175 mV (+/- 25mV) 1997 – 2001 275 mV (+/- 25mV) Record the original TPS value here. ………………..mV YOU MUST ENSURE THROTTLE PLATES ARE COMPLETELY CLOSED AND NO BINDING EXISTS IN CABLES to obtain the correct value setting. 3. Reset idle screws to approximate previous settings, no need to start the engine. 4. Complete full or partial fuel tank removal as described in workshop manual. 5. Remove stock fuel pressure regulator as described in workshop manual and leave Horn removed from vehicle until after tuning, this will allow ease of access to the regulator

HIGH POWER MOTORCYCLE IGNITION CONTROLLER Specification

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Filed Under (Tips and Review) by admin on 12-11-2010

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Product Overview Instruction FM2981 is an electrical ignition IC for large power motorcycle. It has the features of high reliability and convenience, simple peripheral circuit. Feature ã Operating Voltage Range: 5V to 20 V ã Excellent temperature characteristic ã High voltage protection ã Operating Temperature Range: -10 to ℃+80 ℃ ã DIP package, 24 pin Pin Function Pin Function Pin Function 1 External charge capacitor 13 Ground 2 Reference voltage 14 External resistor and capacitor 3 External capacitor 15 Output 4 Reference voltage 16 High voltage protection 5 Reference voltage 17 Ground 6 External charge capacitor 18 Test 7 Current source output 19 Input 8 External resistor 20 NC 9 External resistor 21 Power 10 External resistor 22 External capacitor 11 External resistor 23 External capacitor 12 Ground

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