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HARLEY DAVIDSON DYNA CHROME COIL COVER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Installation 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. 2. Note the position of each spark plug wire in the ignition coil, then disconnect the two wires. 3. If there is an existing coil cover: Remove and discard the coil-cover mounting screws and spacers. Remove and discard the coil cover. If there is not an existing coil cover: Remove and discard the two coil mounting screws. 4. See the Service Parts illustration. Obtain the coil cover bracket (3), two long screws (4) and two spacers (2) from the kit. 5. Insert the screw into one of the holes in the bracket as shown, through a spacer, and into a coil mounting hole. Repeat with the second screw and spacer. 6. Assemble the coil to the electrical caddy with the two screws. Tighten the screws to 50 in-lbs (5.6 Nm). 7. Obtain the new chrome coil cover (1) from the kit. Position the cover over the coil, and fasten to the coil cover bracket with the three chrome screws (6) and washers (7) from the kit. Do not fully tighten the screws at this time. 8. Connect the spark plug wires through the holes in the side of the coil cover onto the correct coil terminals. 9. Adjust the cover to center the spark-plug wire boots in the coil cover holes for best appearance. Tighten the three chrome screws securely 10. Refer to the Service Manual and follow the instructions given to install the maxi-fuse

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2008 KTM Model Engine Oil Recommendation Chart

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Filed Under (KTM) by admin on 24-11-2010

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2008 Model Type Recommended Engine Oil Type Quantity SPORTMINICYCLES AC 50 SX MINI Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L SPORTMINICYCLES LC 50 SX JUNIOR Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 50 SX Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 65 SX Motorex Top Speed 4T 15W50 0.5L SX 2 STROKE 85 SX Motorex Top Speed 4T 15W50 0.5 L 105 SX Motorex Top Speed 4T 15W50 0.5 L 125 SX Motorex Top Speed 4T 15W50 0.7 L 144 SX Motorex Top Speed 4T 15W50 0.7 L 250 SX Motorex Top Speed 4T 15W50 0.7 L SX 4 STROKE 250 SX-F Motorex Power Synt 4T 10W50 1.1 L 450 SX-F Motorex Power Synt 4T 10W50 1.35 L 505 SX-F Motorex Power Synt 4T 10W50 1.35 L CROSS COUNTRY 2 STROKE 65 XC Motorex Top Speed 4T 15W50 0.5L 85 XC Motorex Top Speed 4T 15W50 0.5L 105 XC Motorex Top Speed 4T 15W50 0.5 L 200 XC Motorex Top Speed 4T 15W50 0.7 L
200 XC-W Motorex Top Speed 4T 15W50 0.7 L 250 XC Motorex Top Speed 4T 15W50 0.7 L 250 XC-W (e) Motorex Top Speed 4T 15W50 0.7 L 300 XC Motorex Top Speed 4T 15W50 0.7 L 300 XC-W (e) Motorex Top Speed 4T 15W50 0.7 L CROSS COUNTRY 4 STROKE 250 XC-F Motorex Power Synt 4T 10W50 1.1 L 250 XC-F-W Motorex Power Synt 4T 10W50 1.1 L 450 XC-F Motorex Power Synt 4T 10W50 1.35 L 450 XC-W (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L 505 XC-F Motorex Power Synt 4T 10W50 1.35 L 530 XC-W (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L ENDURO RACING 450 EXC (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L 530 EXC (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L SUPERMOTO LC4 690 Supermoto Motorex Power Synt 4T 10W60 Approx. 2.0 L SPORT ATV 450 XC Motorex Power Synt 4T 10W50 2.0 L 525 XC Motorex Power Synt 4T 10W50 2.0 L LC8 950 Super Enduro (R) Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure Orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure Black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure S Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Super Duke Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Super Duke R Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L

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HARLEY DAVIDSON CHROME SEAT POST REMOVAL AND INSTALLATION INSTRUCTIONS

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

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REMOVE 2 1 is00000 1. Seat Post 2. Screw Figure 2. Lower Seat Post 1. Refer to Owners Manual to remove the seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery negative cable. 3. On motorcycles equipped with oxygen sensors, disconnect the rear sensor connector. 4. See Figure 2. Remove screw (2) and washer from the lower seat post (1) and discard. -J04294 1 of 2 5. Disconnect spark plug wires and primary wire from ignition coil. 6. See Figure 3. Loosen the bracket screws (1). Remove seat post screw (2) and seat post with ignition coil and cover. 7. See Figure 4. Remove coil cover screw (5) and cover (4) from stock seat post (1). 8. Remove ignition coil screws (3) and coil (2) from seat post. 2 1 is04241 1. Bracket Screws 2. Upper Seat Post Screw Figure 3. Upper Seat Post Fasteners 2 5 1 3 4 is04337 1. Seat Post 2. Ignition Coil 3. Coil Screw 4. Coil Cover 5. Coil Cover Screw Figure 4. Install Ignition Coil to Seat Post INSTALL 1. See Figure 4. Install ignition coil (2) to new seat post using screws (3). Tighten ignition coil screws to 10-15 ft-lbs (13.6-20.3 Nm) . 2. Install coil cover (4) to seat post with screw (5) and tighten to 30-40 in-lbs (3.4-4.5 Nm) . 3. See Figure 1. Place seat post (1) in position and attach lower post with screw (2), washers (3) and dome nut (4). Tighten screw (2) to 10-15 ft-lbs (13.6-20.3 Nm) . 4. See Figure 3. Attach upper seat post with screw (2). Tighten screw (2) to 12-15 ft-lbs (16.2-20.3 Nm) . Tighten bracket screws (1) to 12-15 (16.2-20.3 Nm) . 5. Connect primary wire to ignition coil. 6. Connect spark plug wires to ignition coil. The rear cylinder plug wire attaches to the top coil post. Ensure that spark plug wire boots are fastened securely. 7. Connect rear oxygen sensor connector, if equipped. 8. Reconnect battery negative cable

2006 Model Engine Oil Recommendation Chart

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

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2006 Model Type Recommended Engine Oil Type Quantity SPORTMINICYCLES AC 50 MINI ADVENTURE Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 50 SENIOR ADVENTURE Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L SPORTMINICYCLES LC 50 SX JUNIOR Motorex Top Speed 4T 15W50 0.15-0.2 L 50 SX Motorex Top Speed 4T 15W50 0.15-0.2 L 65 SX Motorex Top Speed 4T 15W50 0.3L SX 2 STROKE 85 SX Motorex Top Speed 4T 15W50 0.5 L 105 SX Motorex Top Speed 4T 15W50 0.5 L 125 SX Motorex Top Speed 4T 15W50 0.7 L 250 SX Motorex Top Speed 4T 15W50 0.7 L SX 4 STROKE 250 SX-F Motorex Power Synt 4T 10W50 1.1 L 450 SX Motorex Power Synt 4T 10W50 1.25 L 525 SX Motorex Power Synt 4T 10W50 1.25 L CROSS COUNTRY 2 STROKE 200 XC Motorex Top Speed 4T 15W50 0.7 L 200 XC-W Motorex Top Speed 4T 15W50 0.7 L 250 XC Motorex Top Speed 4T 15W50 0.7 L 250 XC-W Motorex Top Speed 4T 15W50 0.7 L 300 XC Motorex Top Speed 4T 15W50 0.7 L 300 XC-W Motorex Top Speed 4T 15W50 0.7 L CROSS COUNTRY 4 STROKE 450 XC Motorex Power Synt 4T 10W50 1.25 L 525 XC Motorex Power Synt 4T 10W50 1.25 L ENDURO RACING 400 EXC Motorex Power Synt 4T 10W50 1.25 L 450 EXC Motorex Power Synt 4T 10W50 1.25 L 525 EXC Motorex Power Synt 4T 10W50 1.25 L ADVENTURE LC8 950 Adventure orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Adventure black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Adventure S Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L SUPERMOTO RACING 450 SMR Motorex Power Synt 4T 10W50 1.25 L 560 SMR Motorex Power Synt 4T 10W50 1.25 L SUPERMOTO LC4 625 SMC Motorex Power Synt 4T 10W50 Approx. 2.1 SUPERMOTO LC8 950 Supermoto orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Supermoto black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L

CR500R/ 500 AF Hi Power Digital Ignition & Light Coil Installation Instructions

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Filed Under (Honda) by admin on 19-11-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI.b6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator. 10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on
the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 bkg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012”. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012”. Use a good/no good
technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap

HONDA CR 500R/ 500AF Hi Power Digital Ignition AND Light Coil Installation Instructions

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Filed Under (Honda) by admin on 16-12-2011

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Place the motorcycle on a secure stand. 2.Remove the fuel tank and radiator shrouds. 3.Remove the front number plate if CDI unit is located behind number plate. 4.Remove CDI Ground from coil. 5. Remove Old CDI. 6. Remove ignition cover. 7. Use an electric, pneumatic impact to remove flywheel nut. 8. Use flywheel puller to remove flywheel. Thread the flywheel puller into the flywheel by turning the puller counter clockwise (left hand thread). Turn flywheel puller center nut clockwise with an impact set to low to remove flywheel. 9. Remove 2 bolts that secure the stator.
10. Remove stator. 11. Install new stator by aligning the index mark on the lower stator plate with the index mark on the left crankcase. 12.Install and tighten stator bolts to 9 ft-lbs. (1.2 kg-m). 13. Install new flywheel and tighten flywheel nut to 40ft-lb (5.5 kg-m). 14. The pulser gap is preset to .012″. If you have trouble starting you bike after installation confirm the gap between the pulser and the ignition trigger on the flywheel is .012″. Use a good/no good technique when checking and adjusting the gap. The largest feeler that will fit without forcing the feeler into the gap is the current gap. 15. If the pulser gap needs to be adjusted loosen the pulser mounting bolts adjust the pulser up or down as needed

HI-4 DUAL FIRE MOTORCYCLE IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 09-11-2010

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Turn ignition switch off and disconnect battery ground cable. 2. Refer to Figure 3. Remove OE ignition module and wire harness (items 1-4). You will disconnect two wires at the coil (15), a wire going to the VOES (Vacuum Operated Electrical Switch) (18), a black ground wire at the ignition module, and the 3 pin plug (20) that connects to the sensor plate (11). Refer to shop manual for locations. 3. Remove ignition cover plates and gasket (items 5- 9). This will require drilling out two rivets. The rivets will later be replaced with two supplied self- threading screws. 4. In order to remove the sensor plate cable, the cable plug (20) must be removed first. Use needle nose pliers to pull the terminals out of the plug. Then pull the cable through the exit hole at the bottom of the timing cover. 5. Note location of sensor plate (11). There is a V notch in the sensor plate used for alignment. When you install the HI-4, you should align the V notch in the same location. This should set the timing close enough to start the engine. Remove and save the two standoffs and washers (10). Remove the sensor plate (11). HI-4 INSTALLATION Refer to Figure 4. The HI-4 requires use of the OE timing rotor P/N 32402-83 (used only on 1985 and newer models). If you have an older model or are not sure, check the rotor (9) for the correct part number. For models prior to 1980, use the supplied 10-32 x ¾”bolt and washer to mount the rotor. 1. Install the HI-4 system in place of the OE breaker or sensor plate. Rotate the HI-4 about 90 degrees to give better access to the cable exit hole. Install the HI-4 first, then push the cable through the hole. On some early models it may be necessary to enlarge the wire harness exit hole in the gear cover. Align the V notch on the HI-4 same as the OE plate you removed. Use the OE standoffs to secure the HI-4. You must use lockwashers under the standoffs for proper clearance between the HI-4 and cover plate. Do not fully tighten the standoffs until the timing has been set. 2. Route the HI-4 wire harness along the frame rails up to the coil. Make sure that harness will not be chafed or burned by exhaust heat. Secure harness with tie wraps. Do not install timing cover. HI-4 HOOKUP Crimp terminals and hardware are supplied for your convenience. Use the ring terminals for coil hookup. Use male-female quick disconnects for connections to the tach and vacuum switch (VOES). Tape up any unused wires. 1. Circuit Breaker Cover Screws (2) 2. Circuit Breaker Cover 3. Circuit Breaker Cover Gasket 4. Breaker Plate Screws (2) 5. Breaker Plate Screw Lockwashers & Washers (2 each) 6. Retainer (1971 to early 1972) 7. Circuit Breaker Cam Bolt 8. Breaker Plate Assembly 9. Breaker Cam 10. Advance Assembly 11. Gear Case Cover 11 10 9 8 7 6 5 4 3 2 1 NOTE: Damage will result if the brown tach wire comes in contact with +12V. Figure 1. Harley-Davidson®OE Points System
9000-4002A REV A 3 2/05 1. Identify switched +12 volt wire and tach wire (if equipped) going to the coil. Refer to your service manual, or reconnect the battery and use a test light or voltmeter. The switched +12 volt wire will be hot when the ignition key is turned on. 2. Refer to Figure 5. Connect the HI-4 red wire and switched +12 volt wire to Coil positive. 3. The HI-4 white wire is not used and should be taped. 4. Connect the HI-4 black wire to the Coil negative terminal. 5. Connect the HI-4 green wire to the vacuum switch (Figure 3, item 18), if used. 6. Connect the HI-4 brown wire to the tach wire, if equipped with tach. Tape up if unused. 7. The HI-4 is grounded via the timing housing; a separate ground connection is not required. 8. Reconnect battery ground cable. Verify proper ground connections to the frame and engine. VOES HOOKUP The OE vacuum switch (VOES) is normally an open circuit. Above 3-5 inch-Hg vacuum, the VOES closes and grounds the vacuum input on the OE ignition module. This increases the total advance generated by the OE ignition module. Vacuum advance improves part throttle 17 16 1. Cover Screws (2) 2. Ignition Timer Cover 3. Ignition Module 4. Timer Plate Screws (2) 5. Washers (2) 6. Screws & Washers (2 each) 7. Shield 8. Sensor 9. Trigger Rotor Bolt 10. Timer Plate 11. Trigger Rotor 12. Advance Assembly 13. Gear Case Cover 14. Ignition Coil 15. Spark Plug Wires (2) 16. Ignition Coil Terminal (FX) 17. Ignition Coil Terminal (FL) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 NOTE: Most motorcycle coils do not have terminals marked. Use either terminal for Coil+ (positive) and the other one for Coil- (negative). Warning: The HI-4 (8-1100) Dual Fire ignition will not work with 2 plugs per head, dual coil application. Damage will result if attempted. Use the HI-4 (8-2100) single fire ignition for 2 plugs per head applications

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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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Toyota and Lexus Clogged Power Steering Reservoir Filter

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Filed Under (Toyota Manuals) by admin on 02-10-2011

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Clogged Power Steering Reservoir Filter – Toyota & Lexus Toyota and Lexus vehicles with power steering. Noise coming from the power steering pump or reduced assist from the power steering system. Noise or reduced assist may be caused by restriction in the power steering fluid reservoir. Most Toyota/Lexus-style reservoirs have a filter screen at the bottom. Over a period of time this filter could get clogged causing the restriction of fluid. Replace any hose that shows signs of cracking or internal deterioration. Thoroughly flush the power steering system; then remove the reservoir for cleaning as follows: 1. Clean the exterior and interior of reservoir with new power steering fluid or suitable solvent. 2. Blow off the filter screen using pressurized air until restriction or clog is removed. 3. Using a flashlight, check to make sure that the filter screen is free of debris. Note: Contamination may be an indication of internal breakdown of hoses, which must be replaced before operating the vehicle. Failure to replace bad hoses could damage both the pump and steering unit. 4. Reinstall reservoir, referring to the service manual for tightening specs and bleeding procedures.

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Harley Davidson Power Pod Switch Housing Throttle Bracket Installation Instructions

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Filed Under (Harley Davidson) by admin on 19-03-2012

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Attach the “Y” bracket to the Power Pod by using the two Power Pod socket head screws that come in your parts kit. (This bracket may already be attached from the factory. ) 2) Remove the two screws on the Right Hand switch housing on your Harley Davidson motorcycle and reinstall them through the two “Y” bracket open holes and back into the switch housing holes. Tighten snugly. In this mounting position, the heads of the two socket head screws holding the “Y” bracket to the Power Pod should be touching the handlebar; this is necessary as it grounds the unit for proper operation. If the unit is not grounded properly, it will not operate. 3) Run the Power Pod’s 60″ power cord to your battery. Make sure as you hide the cord on the way to the battery, that your handlebars turn freely and that the cord does not come in contact with hot engine parts that may melt the wire over time. 4) At some point, before reaching the battery, attach (using the two butt connectors) the in-line fuse holder. TIP: Keeping the in-line fuse holder in an easy to access place (like under a side panel etc) rather than under the seat, may help you service the fuse easier in case of a blown fuse. In most cases, it’s easier to pull a side panel off than it is to remove a seat! 5) Attach the Power Pod lead wire (with in-line fuse now already attached) directly to the battery for power at anytime without using the key. The hot lead can also be run to the fuse box which will require using the ignition switch to “Accessory” or “ON” in some cases. TIP : Always use the in-line fuse for safety. 6) Insert the 20 amp fuse into the in-line fuse holder. Strap down with zip-ties any loose wires and you’re done!

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