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WORKS PERFORMANCE STREET TRACKER SHOCKS FOR BIG DOG MOTORCYCLES

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Filed Under (Tips and Review) by admin on 17-12-2010

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SHOCK REMOVAL AND INSTALLATION– The shocks are fitted with special length spacers to maintain correct alignment between the frame and the swingarm. If the shocks are removed for service or repair, they must be installed in the correct position. Refer to the diagram on the next page for spacer positioning and layout. NOTE: Misalignment between the mounts on the frame and the mounts on the swingarm can cause binding between the shock shaft and shaft bushing. Misalignment of more than 1/4 inch can cause the shocks to bind up and not function properly. If this binding occurs, the shocks will feel overly stiff and harsh. Follow the procedures below to check for misalignment when installing the shocks. NOTE: The shock bushings are designed to have a certain side-to-side “float” to keep them from binding. As a result, do not grind or file the inner or outer edges of the bushings to make them narrower. The amount of “float” in the bushing set is necessary to ensure smooth operation of the damper assembly. If the shock eyes are tightened metal-to-metal (the outer faces of the eyes to the flanges or washers), this will lead to a harsh, stiff or choppy ride and premature seal leakage or damage to the shafts. MULTI-RATE SPRINGS Depending on each application, single or dual-rate springs are available. Dual-rate springs are just that– a spring set with two separate rates. This is done with a short spring stacked on a longer spring. As both springs compress they produce a soft, or initial, rate. The spring set will maintain this initial rate until the short spring stops compressing. At that point, the spring rate “crosses over” to the stiffer, or final, rate. This multi-rate system allows a soft initial rate for comfort on small bumps, but has the capability of soaking up the big pot-holes and other road hazards. PRELOAD ADJUSTMENT— On Works shocks, threaded preload is standard. (See Fig. 2.) This allows the adjustment of the ride height of the motorcycle. The preload is changed by turning a threaded nut down towards the spring (higher ride height) or up away from the spring (lower ride height). The nut is a right-hand thread. It is used primarily to set the ride height for solo riding, but can also be used when

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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 CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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BILLET ALUMINUM DISTRIBUTOR WITH ELECTRONIC ADVANCE AND ADJUSTABLE REV LIMITER FOR 1936-69 HARLEY BIG TWIN MOTORCYCLES INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 25-11-2010

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ELECTRICAL SYSTEM A 12 volt electrical system is required. Check that the charging system is working properly and not producing over 16 volts. DISTRIBUTOR CLAMP A 1966-69 style distributor clamp (original or aftermarket) is required. MODULE This distributor uses an Accel Single/Dual Fire Ignition module part number 35496. See the enclosed form “Instruction Sheet Single/Dual Fire” for instructions on wiring, adjusting the rev limiter and selecting an advance curve. COIL(S) A coil(s) with a total primary resistance of 2 to 4 ohms is recommended. INSTALLATION Step 1 Turn the ignition switch to the off position. Rotate the engine until it is on the compression stroke for the front cylinder. Continue to rotate the engine until the TDC mark is visible through the timing hole. (see repair manual if necessary). Step 2 Remove the existing distributor if still in the engine. Step 3 Remove the two button head screws from the top of the Mallory distributor. Pull the top cover off the distributor. Remove the two hex standoffs and pull the module and upper housing off the distributor base assembly. Adjust the switches on the module for the desired advance curve and rev limit. FORM 1627 07/08 Step 4 Install the distributor base assembly in the engine with the screw holes and shutter wheel positioned as shown in Figures 1 and 2. It may be necessary to pull the distributor out, turn the shaft and reinstall to get the shutter wheel at the approximate angle shown. The slots should be at about the11 o’clock and 7 o’clock positions. The screw holes should be at the 9 o’clock and 3 o’clock positions. Step 5 Install the distributor clamp and tighten the clamp bolt lightly so the distributor can still be rotated. Step 6 Set the upper housing on the base assembly as shown in figure 3. (The upper housing will only install one way because of the locating screw) Rotate the base assembly slightly if necessary so that the slot in the shutter wheel lines up with the slot in the upper housing. Tighten the distributor clamp

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HARLEY DAVIDSON EFI SCREAMIN' EAGLE BIG BORE EFI STAGE 2 KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION Installation of this kit is divided into six steps: 1. Big-Bore Cylinder and Piston Conversion 2. High Performance Camshafts 3. High Performance Clutch Diaphragm Spring 4. High Performance Air Cleaner 5. Calibrate the ECM 6. Exhaust NOTES This Big-Bore Stage 2 kit is intended for High Performance applications only. This engine-related performance part is legal for sale or use in California on pollution-controlled motor vehicles. Engine-related performance parts are intended for the experienced rider only. -J04173 1 of 5 The air cleaner contained in these kits is designed to perform with these kits only. Any other combination of components is not confirmed to be legal for street use. The Product Information Label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the Product Information Label on the right side of the frame, directly beneath the VIN sticker. Do not place the label on motorcycles other than those specified in the Instruction Sheet. Gaskets provided in the 1690 conversion kit eliminate the need for original head gasket O-rings. For this reason, DO NOT install the Original Equipment (OE) O-rings (Part Number 11273) to the top of cylinder dowels, or severe engine damage may occur. Big-Bore Cylinder and Piston Conversion NOTE Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to Section 3, ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL of the applicable Service Manual for instructions. High Performance Camshafts NOTE Installation of this kit requires removal and re-installation of the cam support plate. Refer to Section 3, ENGINE: BOTTOM END Cam Support Plate, Removal and Disassembly/Assembly (Camshaft, Camshaft Bearings) of the applicable Service Manual for instructions. Measuring Piston-to-Valve Clearance After installing non-stock cams, check piston-to-valve clear- ance. 1. Apply 1/8-inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons. 2. Refer to the appropriate Service Manual and assemble the heads and valve train, and tighten cylinder studs to torque specified. 3. Turn engine through two complete revolutions by hand. 4. Remove heads and measure clay at its thinnest point. NOTE Clay must measure 0.080 inch (2.03 mm) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 0.135 inch (3.43 mm). Measuring Valve-to-Valve Clearance NOTE Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents you from bending push rods or valves. 1. Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust evel sensor to the fuel pump with screw (3). Tighten the screw enough to seat the fuel sensor against the mounting tab e. Route fuel level sensor wiring under the fuel hose and connect the fuel level sensor to the low fuel switch connector on the fuel pump module. If necessary use the jumper harness (Figure 4, item 5). f. See Figure 2. Secure the fuel pump wires and con- nectors

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TOYOTA COROLLA 1984-2006 VEHICLE WIRING VEHICLE WIRING REMOVAL

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Filed Under (Toyota Manuals) by admin on 04-10-2011

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IRING INFORMATION: 1984 Toyota Corolla FWD WIRE WIRE COLOR WIRE LOCATION 12V CONSTANT WIRE WHITE OR WHITE/RED Ignition Harness STARTER WIRE BLACK/WHITE Ignition Harness IGNITION WIRE BLACK/YELLOW Ignition Harness SECOND IGNITION WIRE BLACK/ORANGE Ignition Harness ACCESSORY WIRE BLUE/RED Ignition Harness POWER DOOR LOCK (-) BLUE/WHITE Harness In Driver’s Kick Panel POWER DOOR UNLOCK (-) BLUE/RED Harness In Driver’s Kick Panel PARKING LIGHTS (+) DK. GREEN Harness In Driver’s Kick Panel PARKING LIGHTS (-) LT. GREEN Harness At Steering Column HEADLIGHTS (-) RED/WHITE Harness At Steering Column DOOR TRIGGER (-) RED/WHT OR BLK/WHT Harness At Fuse Box TRUNK TRIGGER COMMON WITH DOORS (Hatchback Only) TACHOMETER WIRE BLACK At Ignition Coil BRAKE WIRE (+) GREEN/WHITE Brake Pedal Switch HORN TRIGGER (-) GREEN/RED Steering Column LEFT FRONT WINDOW UP GREEN/BLACK At Driver Window Motor Inside Door LEFT FRONT WINDOW DOWN BLUE/RED At Driver Window Motor Inside Door RIGHT FRONT WINDOW UP GREEN Harness In Driver’s Kick From Driver Door RIGHT FRONT WINDOW DOWN BLUE/WHITE Harness In Driver’s Kick From Driver Door LEFT REAR WINDOW UP RED/BLACK Harness In Driver’s Kick From Driver Door LEFT REAR WINDOW DOWN RED/YELLOW Harness In Driver’s Kick From Driver Door RIGHT REAR WINDOW UP RED/BLUE Harness In Driver’s Kick From Driver Door RIGHT REAR WINDOW DOWN BLUE/BLACK Harness In Driver’s Kick From Driver Doo

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AJS Big-end replacement instructions

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

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Above: Once the first wheel is off, the pin can be removed in the vice using a drift and spacer. Right: Out with the old; in with the new. Big-end track renewal is a two- in-one operation. Left: No wonder the original bearing was making let-me-out noises! New big end assemblies come dipped in a protective plastic coating. Below: A smear of grease stops the new rollers squirting all over the place. Cotton tape holds them tight to the pin, until the big end is in position. Below. Ensure that the new pin is absolutely square before you attempt to press it in. Mating faces must be operating theatre clean. one out of the con-rod as you fit it. A short piece of square-ended pipe makes a spacer, but take great care that the track goes in square. Soft jaws in the vice prevent damage. The new bearing will usually be grease packed, which helps to stick uncaged rollers onto the inner track. Wrap a length of tape around, pulling it out as you drop the big end eye over. Get the rod the right way round! Check the fit, because the con-rod can occasionally squeeze a new outer race so that it nips the rollers. Lapping it in is the cure, but that’s not within the scope of this article. (Universal journalists’ copout). Press up the second flywheel, using a set square to get the alignment about right, and nip up the nut. The scrap box supplied materials for my truing jig. Two pairs of small roller bearings support the mainshafts, and one support post is adjustable to allow for different crank widths and shaft diameters. For ease and accuracy, a dial gauge wins every time, and if you compare it to the cost of employing an expert, you’ll have no difficulty in justifying the expense. Wedge the con-rod between

2004+ Victory motorcycles PGR-1000 SERIES Programmable Gear Readout Installation

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

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1. Turn the key on and make sure the transmission is in neutral and ‘n’ is displayed on the readout. (Please leave the key ‘ON’ for about 5 seconds before continuing) 2. Turn the key off (.1 seconds) and then back on (1 second) again rapidly. The display should show 1 bar. If you wait too long before continuing the readout will exit the setup routine. (If the unit has already been cleared, it will immediately jump to step 6.) 3. Repeat step #2. The display should show 2 bars. 4. Repeat step #2. The display should show 3 bars. 5. Repeat step #2. The display should show 2 bars. 6. Repeat step #2. The display should show ‘n’ with a bar over it. If the display is upside down then kick the transmission out of neutral and the display will invert and show ‘C’. Tach adapter(for open-collector tach signal from ECM w/out pull-up resistor) ( 2004+ Victory motorcycles use this option , most other bikes use application on front page) VSS Notes: The PGR-1000 is designed for motorcycles with an Electronic VSS signal. Most modern motorcycles use a 3-wire hall-effect type speed sensor in the transmission with a power, ground, and a signal wire. The SEN-1019 is available for motorcycles without a factory VSS signal, fabrication will be required for sensor mounting

EDELBROCK NITROUS SYSTEM UNIVERSAL MOTORCYCLE NITROUS SYSTEM

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Filed Under (Suzuki) by admin on 26-11-2010

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Wiring Diagram #1 Wiring Diagram #2 Red Red Red Red Black Black Black Black Black Black Factory Harness to Horn Factory Harness to Horn Horn Horn Nitrous Solenoid Nitrous Solenoid Switch Switch Bottom View Bottom View +12V with Key On From Horn Button (Ground when button is pressed) From Horn Button (Ground when button is pressed) To Nitrous Bottle To Nitrous Bottle To Nitrous Nozzle To Nitrous Nozzle Install Relay for OPTIONAL RPM Activated Switch Here. See Section 7.0 for More Details. Install Relay for OPTIONAL RPM Activated Switch Here. See Section 7.0 for More Details ©2007 Edelbrock Corporation Brochure #63-71940 Catalog #71940 Rev. 2/07 – DC/mc Page 4of 4 To Nitrous Bottle To Nitrous Nozzle Nitrous Solenoid To Starter Solenoid Switch Bottom View Ground Starter Button +12V when Pushed Install Relay for OPTIONAL RPM Activated Switch Here. See Section 7.0 for More Details. Wiring Diagram #3 Starter Button Activation for Suzuki Hayabusa 7.0 – WIRING MSD 8950 RPM SWITCH NOTE – This is a suggested wiring application. There are many ways that the RPMswitch may be installed. The installer needs to set RPMswitch to proper RPM and test operation. Use diagrams on page 3 for relay terminal #30 connection. Nitrous Solenoid To Nitrous Bottle To Nitrous Nozzle RPM ACTIVATED SWITCH 10,000 Desired RPM Chip Here Connect as Outlined in Wiring Diagrams White to 4-Coil Tach Adapter #T-101-MSD Black Battery Ground Yellow – N/C Gray – OFF When Set RPMis Exceeded Connect as Outlined in Wiring Diagrams NOTE – RPM Chips are Ordered Separately Red to Switched +12 Volt Tailight Power or any Other +12 Volt Source with the Key On Note – This Method Will Turn the Nitrous Off When Set RPM has Been Exceeded. 85 87A 30 86 87 A Test Light Can Be Used Here to Check Operation 8.0 – OPTIONAL PRODUCTS FOR EFI MOTORCYCLES A Progressive Timing Retard Controller is available from Schnitz Racing for fuel injected motorcycles. The EFIR Series Timing Retard Controllers can be used with or without a Power Commander installed.

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Motorcycle Safety & Licensing Start Seeing Motorcycles

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Filed Under (Tips and Review) by admin on 10-02-2012

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What All Drivers Should Know • Assume a motorcycle is closer than it looks. Motorcycles look further away than they are and seem to move slower than they really do. • Allow more following distance. Keep three to four seconds behind a motorcycle. Motorcyclists often slow down without using the brakes, thus not activating the brake light. • Make sure the turn signal is for real. Motorcycle turn signals are usually not self-canceling. • Use extra caution with passengers. A passenger complicates a motorcyclist’s task. Balance is more diffi cult. Stopping distance is increased. • Don’t crowd them. Maneuverability is one of a motorcycle’s better characteristics, but only at slower speeds with good road conditions. They can’t always dodge out of the way. Motorcycle Traffi c Laws Motorcyclists have the same rights and the same responsibilities as other drivers in Nevada. There are also some special conditions: • Motorcyclists must wear helmets in Nevada. • Motorcyclists have the right to use a complete traf- fi c lane. Two motorcycles may share a lane if the operators both agree to do so. • Motorcyclists may not pass or ride next to another vehicle in the same travel lane. • Motorcycles may not be driven between vehicles in adjacent lanes even if the vehicles are stopped. Police offi cers are an exception. (NRS Chapter 486) Gonna Ride? Take a Course – Get the License Riding a motorcycle is an enjoyable and challenging pastime. The best thing you can do for your safety and your family is to take a rider education course and get a Class M driver license

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