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2006-up Harley-Davidson Single Bore Induction System Installation Instructions

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Filed Under (Harley Davidson) by admin on 10-11-2010

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Remove the stock fuel induction system, including the manifold and disconnecting all wire connections. It is up to the technician as to whether the gas tank should be removed or just raised up in the rear. Picture 1 2- You will need to disassemble the stock induction system to remove the pre-listed parts for re-use. 3- Verify the new manifold size is appropriate for your motorcycle by sliding it in place. Picture 2 Picture 3 4 5- Slide the MAP sensor in place, being sure not to pinch the orange rubber seal—some clean engine oil may make this easier. Install the cable guide and verify it is aligned with the throttle cable actuator. Once alignment is satisfactory, apply Loctite® 222 to the 10-24 x 1/4″ screws and tighten to 18-22 in-lbs. 4- Install the new O-ring into the throttle body. A light film of clean engine oil can be used to help hold the O-ring in place. Align the manifold to the throttle body, use purple 222 Loctite® on the 10-24 x 1″ socket-head assembly screws (with flat washers) and tighten them to 35-40 in-lbs. 6- Using the new S&S® supplied gasket, slide the S&S supplied intake air temperature (IAT) sensor in place. Use Loctite 222 on the T10 Torx button head M3 x .5 x 10mm screws and tighten to 6-8 in-lbs. Picture 4 Picture 5 Picture 6 5 7- For the stock throttle position sensor attach the “C” shaped spacer to the end of the throttle shaft, put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, apply some Loctite® 222 and torque screws to 18-23 in-lbs. 8- Install the new O-ring on the IAC motor. Lubricate the OD of the O-ring with a light film of clean engine oil. Put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, coat the threads with Loctite 222. Install the IAC motor and tighten the screws to 18-23 in-lbs. 9- Partially install the fuel injectors in the fuel rail. Be sure to orient the black O-rings to the rail and align the clocking tabs with their holes. It may be helpful to lubricate the O-rings with clean engine oil. See Picture 9. NOTE : These are special O-rings that seal pressurized gasoline. If you see one with damage or an abrasion—replace it immediately. Picture 7 Picture 8 Picture 9 6 10- Connect the Injectors to the manifold with a light squeezing action. Lubricate the O-rings with clean engine oil. Once in place, use Loctite® 222 on the threads of two 8-32 x 5/8″ slotted panhead screws and tighten to 15-20 in-lbs. 11- Install the backing washer and O-ring on the fuel supply tube. Lubricate the O-ring with clean engine oil. When the tube is in place, position the Y-shaped clip on the fuel rail and tighten the Loctite 222 coated T20 Torx button head M4 x 7 x 12mm screw to 18-23 in-lbs – Gently push the injectors downward toward the manifold to increase clearance for connecting the wire connectors. Cut the existing injector connectors from the motorcycle harness. Slide the sleeveing onto the injector harness. Slide heat shrink tubing on to each wire of the injector harness wires. Crimp the butt splices to the motorcycle harness. Move the heat shrinks over the splices and shrink with a heat gun. Slide the sleeve into place. Picture 10 Picture 11a Picture 11b Picture 12 Picture 12a 7 13- Put the stock manifold flanges on the manifold. YOU MUST USE THE S&S® RUBBER GASKETS ON THEM. Be sure to orient the tapered end towards the manifold and the flat end to the heads. 14- Hold the manifold up in its basic mounting position and connect all of the wiring harness connectors at this time. Install the manifold using the stock mounting flange bolts (from the primary side of the motorcycle) coated with Loctite® 242 and the new S&S cam side screws (1/4″ socket head, 5/16-18 x 3/4″). If a screw longer than 3/4″ is used, damage to the heads will result. Lightly snug all four manifold mounting bolts but DO NOT TIGHTEN AT THIS TIME. Connect the throttle cables and cruise control bracket (if applicable) at this time. NOTE: The Harley-Davidson® service manual for your model motorcycle will be helpful during this step. 15- Install the breather system now. On 4.00-inch bore or smaller engines the breather uses banjo fittings with hollow bolts and connects across the heads to the intake with a T-hose. This hose will need to be trimmed and have spring clamps attached as shown in photo. Torque the hollow bolts to 10-12 ft-lbs. On 41/8-inch bore or larger engines, install the sharp bent hose on the rear head and install the check valve with the white end towards the head. Mount the other hose on the black end of the check valve and connect it to the throttle body using spring clamps to secure the connections. Picture 13 Picture 14 Picture 15 8 16- Once the breathers are secure, install the fuel line per the factory service manual you are working with. Connect the battery and verify the fuel pump turns on to pressurize the system and there are no gas leaks, but DO NOT START THE ENGINE. At this time, PC software may also be used to verify sensor readings and adjust the throttle position sensor voltage if necessary. 17- Install two 242 Loctite® coated pipe plugs (included in kit) in the air cleaner backplate as shown in Picture 16. Torque to 35-45 in-lbs. Also, two pan screws coated with Loctite® 222 must be installed in the backplate in place of the enrichment device. See Picture 16a. Torque them to 12-18 in-lbs. Failure to install these screws could allow dirt and debris into the intake system. 18- Use a new gasket on the backplate and put it in place noting the number of shims required. Once you select the appropriate shims (included) mount the backing plate to the engine but DO NOT INSTALL THE SCREWS YET

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2003-2007 Victory Motorcycles Installation Instructions for S&S Freedom Performance Tuner

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Filed Under (Victory) by admin on 31-10-2010

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Once the download of S&S Freedom Performance Tuner has been installed on your PC, double click the icon on your desk top. Picture 3 illustrates the S&S Freedom Performance Tuner icon. 2- Enter in your Username and Password and click the login button. Your Username and Password for logging in will be the same as your login for Picture 1 Picture 2 Picture 3 3 3 – Once you’re logged onto S&S® Freedom® Performance Tuner, click on the Year and Model of the bike you’re performing the work on in the middle of the page as illustrated in Picture 4. 4 – Click on the Select Vehicle tab at the bottom of the page as illustrated in Picture 5. The tabs on the left side of the page will now be illuminated. Picture 4 Picture 5 4 5- Click on the ECU Reprogramming tab on the left side of the screen as illustrated in Picture 6. 6- In the center of the screen you will now be prompted to enter in customer information, VIN number of the motorcycle you are performing calibration download on, and calibration card number. Select a re-flash file from the drop down list that you want to download into the motorcycle. All the fields must be filled out for you to continue with the download. Picture 7 illustrates the information screen with required fields filled out. Picture 6 Picture 7 5 Note: Due to the limited description space available in the drop down list in S&S® Freedom® Performance Tuner, a detailed list of available calibrations and part numbers can be viewed on the S&S dealer web. Go to ® Calibrations on the left side of the home page. Here you will find a detailed list of calibrations and part numbers for reference only. Picture 8 illustrates the home page and location for the S&S/Victory Calibrations. Picture 9 illustrates the calibrations for reference

S&S Super E and G Series "Shorty" Carburetors REMOVAL, Installation and Jetting Instructions

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Filed Under (S&S) by admin on 29-10-2010

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Remove Old Carburetor WARNINGS ● Gasoline is extremely flammable and explosive under certain conditions. Do not smoke around gasoline. Gasoline fumes are toxic when inhaled. Perform installation in a well ventilated area away from open flames or sparks. Any gasoline leak or spill constitutes a health and fire hazard. ● If motorcycle has been running, wait until engine and exhaust have cooled to avoid getting burned during installation. ● Electrical sparks can ignite explosive gasoline fumes. Failure to disconnect battery while working on motorcycle can also result in inadvertent engagement of starter and personal injury. A. Shut off fuel petcock and disconnect battery. B. Remove air cleaner assembly. Drain fuel from existing carburetor. Remove carburetor, manifold, choke cable and any carburetor mounting hardware NOTE – Removing and tightening hard to reach Allen bolts such as carb-manifold mounting bolts and V2 manifold flange bolts can be greatly simplified by the use of Allen ball-end drivers. These tools are available at most automotive and tool supply houses. See Picture 9. Additionally, Performance Plus of Evansville, Indiana, produces a hex wrench specially modified for accessibility of V 2 manifold bolts. Call 812-963-8854 for further information. As alternative, standard hex wrench can be shortened for convenience. NOTE – Some Buell motorcycles have a breather fitting with 90° elbow on rear head. Due to proximity of frame, elbow must be removed before fitting can be taken off engine. Loosen fitting and rotate to position convenient for cutting elbow. Secure fitting by tightening against cylinder head. Elbow may be inaccessible to hacksaw. In most instances, a die grinder with cutoff wheel will remove elbow with little difficulty. If die grinder is unavailable, grasp elbow firmly with pliers and snap off, then remove fitting. CAUTION – Extreme care must be taken to prevent metal chips from entering engine when elbow is removed. S&S recommends packing breather fitting with gease before removing elbow. Metal chips inside engine will cause extensive damage. Installer bears all responsibility for containment of chips and other debris. Picture 2 Picture 4 Picture 3
5 2. Prepare Air Cleaner Backplate NOTE – Fast idle lever screws, part #11-2384, must not be overtightened. Loctite or other thread locking compound may be used sparingly on threads to prevent screws from vibrating loose. CAUTION – Overtightening fast idle screws may damage backplate. A. All engines except V2s 1. Knuckles & Pans, 1936 to 1965 – Press plugs, part #50-8312, into holes in air cleaner backplate. See Picture 2 . 2. Shovels, 1966 to 1979, and Ironhead (IH) XLs, 1957 to 1979 – Press plug, part #50-8312, into hole in air cleaner backplate. See Picture 3 . 3. Shovels 1980 to 1984 and IH XLs 1980 to 1985 – Screw crankcase breather vent elbow fitting, part #50-8110, into hole in air cleaner backplate and angle downward as shown in Picture 4 . On 1983 and 1984 Shovels press plug, part #50-8312, into other hole on left. 4. Assemble fast idle mechanism as shown in Figure A . B. FL V2s 1984 to 1992 1. Press plug, part #50-8312, into hole on left in air cleaner backplate as shown in Picture 5 . 2. Screw vent hose elbow fitting, part #50-8110, into remaining hole at right. See Picture 5 . 3. Assemble fast idle mechanism as shown in Figure A . C. XL V2s 1986 to 1990 1. Press plug, part #50-8312, into hole on right in air cleaner backplate as shown in Picture 6 . 2. Screw vent hose nipple fitting, part #50-8111, into remaining hole at left. See Picture 6 . Elbow fitting, part #50-8110, supplied in kit may also be used in this location if required. 3. Assemble fast idle mechanism as shown in Figure A . D. FL V2s 1993 and up and XL V2s 1991 and up 1. Press plugs, part #50-8312, into both holes in air cleaner backplate as shown in Picture 7 . 2. Assemble fast idle mechanism as shown in Figure A . E. Buell motorcycles, 1994 and up 1. Assemble fast idle mechanism as shown in Figure A. 3. Throttle Preparation NOTE – Throttle grip assembly must be assembled correctly and work freely to prevent possible sticking during operation. Throttle must snap closed when released. Cable routing must be free of tight bends to minimize friction between cable and housing

KTM KINETO TRACKING MOUNT – MODEL K433 Installation and Removal Manual

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Filed Under (KTM) by admin on 30-01-2012

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the KTM meets the needs of a wide variety of test range and scientific applications:  On-board operator, or remote analog or digital control  Payloads up to 1200 pounds (unmanned) or 600 pounds (manned)  Mission configuration with four (manned) or six (unmanned) payload positions  Complete turnkey systems available  Detailed installation documentation FIELD-PROVEN RUGGED AND RELIABLE The KTM consistently demonstrates its performance and durability:  Weather tight seals designed to withstand harsh range environments  The KTM’s direct drive axis design delivers smooth, jitterfree tracking to ensure precise Time, Space and Position Information (TSPI)  Self-contained and trailer-mounted, the KTM is quickly and easily deployed via highway and unimproved roads to remote tracking sites  Digital Control System (DCS) that guarentees system reliability WHEN THE RANGES REQUIRED PRECISE AND RELIABLE OPTICAL TRACKING MOUNTS, THEY SELECTED THE BRASHEAR KINETO TRACKING MOUNT MORE THAN 150 TIMES. Recognized Standard for Tracking Systems Worldwide THE KTM DIGITAL CONTROL SYSTEM (DCS) INCLUDES:  High speed communication via an Ethernet interface to provide remote operation  Advanced servo loop control to optimize tracking performance  Built-in error correction to ensure precision tracking accuracy  Versatile chassis architecture that accommodates additional PC104 cards suchas an “Automatic Video Tracker” (AVT) to satisfy specific customer requirements and missions

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2003 – 2006 KTM The e-Axle Installation Manuals

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Filed Under (KTM) by admin on 01-02-2012

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Remove the stock wheel spacers from both sides of the wheel hub and install both of the Rekluse wheel spacers. After installing the Rekluse wheel spacers, stow the wheel in a suitable place so that the brake rotor cannot be damaged. See following picture. 5 5. Remove the brake pads by removing the clips and sliding out the pin. See following picture. 6. Remove the leaf spring from the caliper. See following picture. 7. Re-install the brake pads with the included coil spring positioned on the pin between the brake pads. Secure the pin by re-installing the 2 clips. See following picture. Coil Spring on the pin and in between the brake pads 6 8. Coat the center axle in a thin layer of grease to aid in sliding the center axle on and off. Note: Coat the center axle in a thin layer every time it is reinstalled after removing the front wheel for tire maintenance. 9. Position the front wheel back in between the forks so that the brake disk is in place between the brake pads, and so the wheel spacers line up with the hole in the fork fists. 10. Slide the center axle, with 30-mm Bushing attached, through the right-side fork fist and through the wheel spacers in the front hub. Rotate the 30-mm bushing so the set screw is facing up, this will line the “0″ Offset Mark with the fork fist pinch clamp slot. Continue sliding the axle through until the 30-mm bushing is almost flush with the outer edge of the right fork fist. See following picture

KTM EXC Enduro & SX Motocross REPAIR MANUAL

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Filed Under (KTM) by admin on 06-03-2012

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Thanks to a history of competition successes, particularly in off-road racing, KTM motorcycles enjoy a large and loyal following. Established in 1953, KTM (from Kraftfahrzeuge Trunkenpolz Mattighofen where founder, Hans Trunkenpolz, had his engineering works) went through difficult times in the early 1990s. After a takeover, the Austrian company emerged as KTM Sportmotorcycle AG and has gone from strength to strength in recent years. Mainstay of their range are their Enduro and Motocross models, the EXC and SX, and these are covered in the latest new manual from Haynes. Models covered are the 250, 400, 450, 520 and 525 EXC and SX with 4-stroke sohc engines, 2000 to 2007. Information has also been included on the SMR Supermoto versions and MXC/XC derivatives. Haynes Manuals for cars and motorcycles are so popular that 150 million have been sold worldwide. Lay them end-to-end and they would circle the globe at the equator! The new manual begins with essential pre-ride checks, competition prep and routine maintenance tasks before moving on to more major repairs. There are comprehensive, fully illustrated, instructions for overhauling the engine, transmission, brakes, suspension and electrical system. Useful reference pages include colour wiring diagrams, fault-finding charts and a comprehensive section on tools and workshop tips. Because all Haynes Manuals are based on a complete stripdown and rebuild, not only are the procedures written from first-hand experience, but there is information about special tools required for each job, and its complexity, plus Haynes tips for saving time and money. The new Haynes KTM EXC Enduro & SX Motocross Manual is the only complete manual for owners of these motorcycles.

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2005-2007 KTM MOTORCYCLE REPAIR MANUAL

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Filed Under (KTM) by admin on 21-11-2010

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 2 2-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B 2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork Dismounting the fork -Place your motorcycle on a stand. -Notice the position of the front fork in the triple-clamps. NOTE: To remove the front fork. Read your KTM Instruction Manual or Workshop Manual. 3-3 Mounting the fork -Clean the innerside of the triple-clamps with brake cleaner. -Slide both fork legs into the triple-clamps. NOTE: Pay attention to the position of the fork legs. Standard riding height! NOTE: The maximum riding height is the level of the second groove! -Tighten the middle bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the first bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the third bolt of the lower triple clamp to a torque of 17 Nm!

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KTM ATV 525 XC specification

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Filed Under (KTM) by admin on 12-11-2010

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Engine ] Pure power for Enduro enthusiasts. The power of the 525 XC is the indisputable benchmark in the ATV Enduro sector. Its acceleration and top speed cast a shadow over all its predecessors. Variable ignition curves and perfect maintenance features like simple valve play adjustment and the removable clutch cover are even further highlights of the XC engine that make the KTM Enduro quads so superior. First Oil Filling for all KTM Engines. [ CarburEttor ] The Keihin carburettor, which has been proven multiple times in racing, with 39 mm and the Throttle Positioning System guarantees a uniform, forceful power delivery in all speed ranges. It ensures an unrivalled response behavior and perfect service-friendliness at all times. [ StartEr ] Packed in a space-saving manner into the free space behind the cylinder head, the small, light electric starter motor is ready for use. It brings every KTM ATV up to speed reliably and comfortably even when racing becomes hectic. [ rEar SuSPENSIoN ] Premium-quality ÖHLINS suspension components specially designed for tough Enduro use are provided as standard – both at the front and the rear. Easy to adjust, they guarantee optimal tuning for the most varied of terrains. Another highlight: the front and rear spring travel of 275 mm and 272 mm respectively is 100 % trend-setting for an Enduro ATV! [ alumINIum SubFramE ] The rear subframe is made of aluminium and is extremely light and easy to remove. [ FramE ] The lightweight, extremely durable frame sets the benchmark in the quad racing segment and is made of high-strength, powder-coated Chromoly steel. [ haNDlEbar ] An ultra-durable tapered aluminium Magura® handlebar comes standard that is four-position adjustable to suit your preferred ergonomics. Further highlights are the functional and individually adjustable operating levers for brake and hydraulic clutch. In addition, the chassis has an integrated mount for a steering damper – available as a PowerPart accessory. [ CurvED raDIator ] Best cooling by means of its curved shape and the resulting maximized surface area. [ rImS / tIrES ] MAXXIS Razr tyres on light, stable DWT aluminium rims. [ ExhauSt ] The powerful XC silencer is made of light-weight aluminium.

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KTM WP FORK 4860 MXMA CLOSED CARTRIDGE REPAIR MANUAL

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Filed Under (KTM) by admin on 13-02-2011

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 22-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork

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2000-2003 KTM MXC / EXC Dual Sport Kit Installation And Removal Manual

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Filed Under (KTM) by admin on 08-02-2012

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00-’03 KTM 400/450/520/525 EXC & MXC Dual Sport Kit Installation Manual 1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3
4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit uses a hydraulic brake-switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install

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