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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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

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REMOVAL 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) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

HARLEY DAVIDSON XL PREMIUM OIL COOLER KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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

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1. Refer to Owners Manual to drain engine oil and remove oil filter. 2. See Figure 1. Remove oil feed hose (1) from oil pump. 3. Remove oil feed hose fitting from engine crankcase. Discard oil feed hose. INSTALLATION 1. See Figure 2 and Table 1. Apply Hylomar Gasket and Thread Sealant to threads of fitting (1) and install fitting to oil pump. 2. Apply Hylomar Gasket and Thread Sealant to threads of fitting (1) and install fitting to crankcase. 3. Tighten fittings to 55-65 in-lbs (6.2-7.4 Nm) . 1 2 3 1 is04015 1. Fitting 2. Oil Hose Cooler Supply 3. Oil Hose Cooler Return Figure 2. Oil Hose Cooler Return and Supply Assmeblies 4. Loosely install oil cooler return hose assembly (3) to crankcase fitting. 5. Loosely install oil cooler supply hose assembly (2) to oil pump fitting. 6. See Figure 3 for proper oil hose routing. The oil supply hose (1) should be the upper hose and the oil return hose (2) the lower hose 1 2 is04018 1. Oil Supply Hose 2. Oil Return Hose Figure 3. Oil Cooler Hose Routing 7. Remove two existing clips holding the clutch cable and wire harness from the left frame downtube. 8. See Figure 4 and Table 1. Position oil cooler clamps (7) in approximately the same position as the clips that were removed from the frame downtube. 9. Loosely attach oil cooler (4) to the clamps (7) using screws (9) and nuts (8). 10. Attach oil return hose (3) to the inboard connection of oil cooler (4) with worm clamp (5).

BUELL ACCESSORY GAS CAP KIT INSTALLATION MANUAL

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Filed Under (Buell) by admin on 29-03-2011

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Installation NOTE When performing the following Steps, use the Fuel Tank Vent Valve Installation Kit (Part Number 91432-96Y). This kit consists of: * Fuel Tank Vent Valve Installation Aid * Fuel Tank Vent Valve Fitting Socket To protect against shock and accidental start-up of vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 1. Disconnect battery cables, negative cable first. An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank. Use extreme caution when servicing fuel tanks. Gasoline is extremely flammable and highly explosive. Do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components. Inadequate safety precautions could result in death or serious injury. 2. Remove gas cap. 3. Carbureted Models: Drain fuel tank. Disconnect hose clamp and fuel supply hose from fuel supply valve and drain fuel into suitable, clean container. See applicable Service Manual, Section 4 for complete, detailed procedure. Fuel Injected Models: Relieve pressure from fuel system. See applicable Service Manual, Section 4 for complete, detailed procedure. Drain fuel tank. a. Using suitable external fuel pump, such as a Gas Caddy, pump fuel from tank and into a suitable, clean container. b. See instructions for external fuel pump for correct use. 4. See Figure 1. Cut cable tie securing vent hose to fitting and remove vent hose from fuel tank. Even with the fuel tank completely drained, a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed. Thoroughly wipe up any fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury. 5. If the fuel supply valve requires cleaning or repair, refer to applicable Service Manual, Section 4, for complete, detailed procedures. 6. See Figure 1. Remove the fuel filler cap and O-ring. 7. Remove the eight self-tapping screws from fuel clamp flange and remove fuel cap flange

HARLEY DAVIDSON MINI-TACH WITH SHIFT LIGHT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION Preparation For EFI models: To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) Follow the instructions found in the Service Manual to purge the fuel supply of high pressure gasoline and remove the fuel supply line. For ALL models, WITH Maxi-Fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the Maxi-Fuse. For ALL models, WITHOUT Maxi-Fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. -J04106 Gasoline can drain fr om the carb uretor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a) 2. For carbureted models: Turn the fuel supply valve to OFF. Remove the fuel line from the valve. 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) 3. For ALL models: Follow the instructions in the Service Manual to remove the instrument console from the fuel tank. 4. See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 5. For all models EXCEPT FLHR or 1986 and later FL Softail models with Chrome Headlight Nacelle Kit (Part Number 67907-96): Follow the instructions in the Service Manual to remove the headlamp housing. For FLHR models, or Softail models WITH the Nacelle Kit: Follow the instructions in the Service Manual and the mini-tach bracket kit (purchased separately) to remove the handlebar shroud. Mini-Tach Bracket Installation 6. For all models except FLHR: Install the mini-tach bracket components per the instructions in that kit. For FLHR models: Follow the instructions in the Service Manual and the mini-tach bracket kit to install the handlebar shroud and bracket components. 7. See Figure 7. Select the rubber isolation gasket (1) from this kit.

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HARLEY DAVIDSON BRAIDED STAINLESS STEEL FUEL CROSSOVER LINE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 11-02-2011

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INSTALLATION, CARBURETED MODELS Models WITH maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. Models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. ALL carbureted models 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) 2. See FUEL SUPPLY VALVE FILTER: CARBURETED in the Service Manual. a. Turn the fuel supply valve to the OFF (horizontal) position. b. Follow the instructions to disconnect the fuel hose from the fuel supply valve outlet nipple. Drain the fuel from the fuel tank into an adequately sized, approved gasoline container using a vacuum pump (Plastic Mity-Vac hand pump or equivalent). c. Re-install the fuel hose to the fuel supply valve with a new fuel hose clamp (Part Number 10014), purchased separately. d. Proceed to Step

Honda GL1000/1100 starter motor Removal/ Over haul Manual

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Filed Under (Honda) by admin on 08-04-2011

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1. Remove the three long bolts that hold the sections together and separate them. Be careful as there are a series of flat thrust washers on each end of the armature (located in the middle section). 2. The end cap basically performs no function other than to cover the brush plate and commutator area as well as center the armature shaft in a pressed in bushing located in the end of the cap. 3. The drive end contains the reduction gearing and if need be, can be disassembled to replace the bearing. This is extremely unlikely. The shaft should turn freely and normally only requires a cleaning and grease application. If the bearing in fact needs replacing, simply remove the “C” clips on either end, drive out the bearing and reinstall with an appropriate size replacement. Any decent auto parts / industrial supply should be able to supply the correct bearing. 4. Remove the brush plate from the end of the center section by removing the screw at the one brush connection. Before removing the brushes, note that one of them has an insulating sleeve over the braided wire. The replacement must go in the same brush holder. Remove the brushes and replace if necessary and clean the brush plate. ** Brake Cleaner is a good general cleaner for this entire job. 5. Remove the thrust washers from brush plate end of the armature. Count them and ensure they go back on the correct way. 6. The end of the center section that had the drive end on it has a circular plate covering it with a short splined shaft protruding through the plate. Drive the plate out by tapping the opposite end of the section on the shaft – just lightly with a rubber hammer or piece of wood to protect the shaft. Once the plate is out, remove the armature from the section. You will find more thrust washers at this end. Make sure they go back on correctly. 7. In the center of the center section there are four large Philips screws. These hold in the field coils found within the housing. Using an “impact driver”, loosen the four screws that go around the circumference of the center section and remove them. Remove the 10mm nut for the battery connection and the accompanying fiber insulating washers. With the screws and nut removed, the entire field coil assembly should withdraw entirely from the housing. There will be four (4) metal plates that the screws mounted into come falling out. They are easily replaced into the field coils when you slide it back into the housing. Do not be alarmed that you suddenly have four loose metal parts. 8. With everything out of the housing, thoroughly clean everything using the Brake Cleaner. Although the cleaner will dry without leaving a film, it is suggested that the components be dried with compressed air. 9. Get some extremely fine steel wool (“000″ of even “0000″ is better) and gently clean the metal surfaces or bars of the armature and the commutator. Blow with compressed air. 10. Using a volt/ohmeter, test for continuity between pairs of armature bars (the long ones). There should be continuity between the pairs around the entire circumference.

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Victory Motorcycles Lloydz Motorworkz Billet Air Cleaner Kit Installation Instructions

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

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1 – Disconnect the negative battery cable from the motorcycle and route it away from any metal parts in the area. 2 – Remove the seat and gas tank from the Victory® motorcycle following your Victory service manual for the specific model you are performing the work on. Key switch Cover and Coil Mounting Bracket Removal 1 – Remove the ignition key switch cover by pulling outward on it. picture 2 below illustrates the key switch cover. 2 – Remove the four socket head cap screws from the ignition and coil mounting bracket that holds the bracket to the front and rear heads. picture 3 below points out the location of the four socket head cap screws. 3 – With the bracket free from the front and rear head unplug the spark plug wires at the coil. 4 – Disconnect the coil and ignition switch at the connectors freeing them from the primary wiring harness. Idle Air Control Hoses and throttle position s ensor Removal 1 – Disconnect the Throttle Position Sensor (TPS) at the connector leaving the TPS attached to the throttle body. picture 4 next page points out the TPS connector. 2 – Remove the Idle Air Control (IAC) supply hose from the air box. Note: Leave the 1.500″ rubber hose attached to the hard plastic IAC supply hose. Picture 4 points out the IAC air supply hose and the 1.500″ rubber hose. 3 – Remove the front Idle Air Control (IAC) air delivery hose from the rubber 90° fitting that leads into the front intake bore on the throttle body. Leave the 90° rubber fitting attached to the throttle body. picture 4 points out the IAC front delivery hose. 4 – Remove the rear IAC air delivery hose from the rubber “T” fitting that leads into the rear intake bore on the throttle body. Leave the rubber “T” fitting attached to the throttle body. picture 4 points out the IAC rear delivery hose

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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YAMAHA YZF-R1P/ YZF-R1PC SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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1Fuel pump 2Pressure regulator 3Fuel injector 4Throttle body 5Intake temperature sensor 6Throttle position sensor 7Intake air pressure sensor 8ECU 9Atmospheric pressure sensor 0Coolant temperature sensor ACylinder identification sensor BCrankshaft position sensor ÈFuel system ÉAir system ÊControl system Illustration is for reference only. 1 – 4 GEN INFO FEATURES Fuel control block The fuel control block consists of the following main components: An engine trouble warning light is provided on meter panel. Component Function Control block ECU Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure detection Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throttle angle detection Cylinder identification sensor Reference position detection Crankshaft position sensor Crankshaft position detection and engine RPM detection Speed sensor Speed detection Actuator block Injector Fuel injection Fuel pump Fuel feed Air Induction system, air cut valve Induction of secondary air A. Power supply circuit The power supply circuit obtains power from the battery (12 V) to supply the power (5 V) that is required for operating the ECU. B. Input interface circuits The input interface circuits convert the signals output by all the sensors into digital signals, which can be processed by the CPU, and input them into the CPU. C. CPU (Central Processing Unit) The CPU determines the condition of the sensors in accordance with the level of the signal that is output by the respective sensor. Then, the signals are temporarily stored on the RAM in the CPU. Based on those stored signals and the basic processing program on the ROM, the CPU calculates the fuel injection duration, injection timing, and ignition timing, and then sends control commands to the respective output interface circuits. D. Output interface circuits The output interface circuits convert the control signals output by the CPU into actuating signals for the respective actuators in order to actuate them. They also output commands to the indicator and relay output circuits as needed.

Installation Instructions S&S Billet Air Cleaner Kit for Victory Motorcycles

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

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1 – Disconnect the negative battery cable from the motorcycle and route it away from any metal parts in the area. 2 – Remove the seat and gas tank from the Victory motorcycle following your Victory service manual for the specifi c model you are performing the work on. Picture 1 WARNING 3 Key Switch Cover and Coil Mounting Bracket Removal 1 – Remove the ignition key switch cover by pulling outward on it. Picture 2 illustrates the key switch cover. 2 – Remove the four socket head cap screws from the ignition and coil mounting bracket that holds the bracket to the front and rear heads. Picture 3 points out the location of the four socket head cap screws. 3 – With the bracket free from the front and rear head unplug the spark plug wires at the coil. 4 – Disconnect the coil and ignition switch at the connectors freeing them from the primary wiring harness. Idle Air Control Hoses and Throttle Position Sensor Removal 1 – Disconnect the Throttle Position Sensor (TPS) at the connector leaving the TPS attached to the throttle body. Picture 4 points out the TPS connector. 2 – Remove the Idle Air Control (IAC) supply hose from the air box. Note: Leave the 1.500″ rubber hose attached to the hard plastic IAC supply hose. Picture 4 points out the IAC air supply hose and the 1.500″ rubber hose. 3 – Remove the front Idle Air Control (IAC) air delivery hose from the rubber 90° fitting that leads into the front intake bore on the throttle body. Leave the 90° rubber fitting attached to the throttle body. Picture 4 points out the IAC front delivery hose. 4 – Remove the rear IAC air delivery hose from the rubber “T” fitting that leads into the rear intake bore on the throttle body. Leave the rubber “T” fitting attached to the throttle body. Picture 4 points out the IAC rear delivery hose