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Harley-Davidson S&S Super E and G Series Shorty Carburetors Installation and Jetting Instructions

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Filed Under (Harley Davidson) by admin on 24-10-2010

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throttle linkage with no cable modification. S&S Super E and G carb kits for 1936 to 1989 Big Twins contain a throttle cable guide (11-2339) designed for butterfly type throttle cables, and kits for 1990 and later Big Twins contain a taller throttle cable guide (11-2338) designed for CV type throttle cables. See Picture 2. The two throttle cable guides are interchangeable on the carburetor body, and can be changed very easily to update older carburetors or to accommodate custom throttle cables which are not stock for a particular year chassis. 1981 to Present Sportster Models Stock Sportster models from 1981 to 1987 have two cable throttle system designed for butterfly type carburetors. Sportsters from 1988 to present have a two cable throttle system designed for use with the stock constant velocity (CV) type carburetor. Since the taller #11-2338 cable guide bracket can not be used on a Sportster chassis due to insufficient frame clearance, throttle cables on Sportsters originally equipped with a CV type carburetor must be changed to butterfly style cables. S&S can supply the correct style throttle cables. See S&S Throttle Cable Application Chart. Picture 2 S&S THROTTLE CABLE APPLICATION CHART Length Total Housing Length Vinyl Housing Part Number Open Side Part Number Close Side Fitment 36″ 32″ #19-0430 #19-0431 For Buell with 7/8″ handlebars 36″ 32″ #19-0432 #19-0433 To ’95 ’81-’85 FX and FL; All ’81-’85 XL (Also pre-’81 w/2-cable throttle housing replaced.) For Buell with 1″ diameter handlebar 36″ 32″ #19-0436 #19-0437 ’96-Up 883-1200 XL 39″ 35″ #19-0434 #19-0435 To ’95 Softail (FXSTC, FXST, FLSTC, FLSTF) ’86-’94 FXR, ’93-’95 Dyna 39″ 35″ #19-0438 #19-0439 ’96-Up Softail (FXSTS, FXSTC, FLSTC, FLSTF) ’96-Up Dyna 42″ 38″ #19-0446 #19-0447 To ’95 custom application 42″ 38″ #19-0440 #19-0441 ’96-Up custom application 48″ 44″ #19-0462 #19-0463 To ’95 All FLT Models 48″ 44″ #19-0464 #19-0465 ’96-Up All FLT Models ” 1996 to Present Buells 1996 and 1997 Buells require special S&S butterfly style throttle cables for Buells, which are compatible with the stock 1996-1997 throttle assembly. 1998 and later carburated Buells require installation of stock 1996 – 97 throttle grip and the special S&S Buell style throttle cables when installing Super E or G carburetors. S&S Throttle Kits S&S throttle kits fit 1″ handlebars and can be used on most chassis. (An adapter sleeve is available for use with earlier, 7 ⁄ 8 ” OEM handlebars originally equipped with internal throttle cable.) Barrel fittings on S&S cables readily “plug in” to S&S Super E, G, and stock H-D 1981-’90 butterfly type carb throttle linkage. Kits include one opening and one closing side cable, left and right grips, and handlebar clamps. Kits with 36″, 39″, 42″, or 48″ length cables are available. Length specified refers to overall cable length. Vinyl covered outer housing is 4″ shorter than overall length

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BMW K 1300 S, K 1300 R and K 1300 GT SPECIFICATION

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Filed Under (BMW) by admin on 17-11-2010

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The K 1300 S with 175 hp, the K 1300 R with 173 hp and the K 1300 GT with 160 hp. The new K bikes feature updated transmission and clutch assembly, plus smoother engine performance and new switchgear. Von Kuenheim continues: “By raising capacity to 1300 cc, our engineers have not only increased output but also torque on all three models. At the same time the driveline was intensively revised from air/fuel mixture formation right through to the exhaust system. In this way we have been able to optimize partial load behavior as well as throttle response. Now the clutch can be operated with even less effort and with greater refinement. Shifting has been improved tangibly due to constructional changes to the gearbox and drive.” BMW is introducing new options for the 2009 as well. The popular Electronic Suspension Adjustment that first appeared on the 2005 K 1200 S has now been updated with even more on-the-fly adjustability and it’s called ESA II. Also new is the quick-shifter option, racing-style gear shift assistant, borrowed from BMW’s race-ready HP2 Sport. Automatic Stability Control (ASC) is also offered as an option on the new K bikes. “Both the K 1300 S and also the R will also have the shift assistant – familiar from the HP2 Sport – available as an option for the first time,” von Kuenheim emphasized. “We have also advanced the chassis. The new lower longitudinal strut is now made of aluminum and is thus considerably lighter. This makes the front wheel guidance response even more sensitive. The result of this comprehensive development work is superior handling, improved rideability and lower fuel consumption. The electronically adjustable suspension – called ESA in short – was launched as a world first on the K 1200 S. Now we are presenting the new, well-proven ESA II as an option for the K Series. Apart from the suspension and damping this unique system also allows the spring rate to be adjusted at the press of a button. The K Series model revision also heralds a new and innovative generation of switches and controls.

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Yamaha V Star 1300 Fuel Injected INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Be sure the main switch is in the off position during the installation process. Failure to do this will cause the “check engine” light to be set. 2. Remove seat exposing the tool tray and battery. 3. Remove the (2) 12mm Hex head bolts securing rear of tank. Prop up the rear of the tank. 4. Locate and unplug the white 4-pin connector under left side of tank as shown in figure 1. 5. Route Fuelpak as shown in figure 2. Plug Fuelpak white connectors to the factory connectors unplugged in step 4. 6. Connect brown and green wires to the negative side of the battery. 7. Route Fuelpak long black wire under right side of tank and down to the horn as shown in figure 3. Disconnect the factory black / white wire from horn. Plug in Fuelpak long black wire to horn and then connect factory black / white wire to terminal on Fuelpak black wire. 8. Locate the throttle position sensor on the throttle body located on right side of the tank. As shown in figure 4, attach T-tap to yellow / black wire on throttle position sensor. Connect Fuelpak violet wire to T-tap. 9. Using supplied Velcro, mount Fuelpak next to tool tray as shown in figure 5. 10. Reinstall tank with (2) 12mm Hex head bolts removed in step 3. 11. You are now ready to set-up your Fuelpak 1. Remove Fuelpak clear case cover by removing all four screws, save hardware . 2. Turn on main power with key, but do not start engine. Fuelpak display should light up, if not, turn power off and verify the connectors are fully seated. 3. Refer to Fuelpak Setting Reference to locate the Setting Values specific to your bike and exhaust system. If you do not find your setting, visit fuelpakfi.com or call tech support at (562) 921-0071. 4. Starting with mode 1 selected, press the value (+) or the value (-) buttons to input the correct value as indicated in your Setting Value. After entering your first value, press the mode select button to move to mode 2 and enter the value. Continue until you have entered the value for each of the first 18 mode positions. Each time the value (+) is pressed, the value increases by one number. Each time the value (-) is pressed, the value decreases by one number. (Please refer to the “How It Works” section directly above if you have questions about this step. 5. As the next procedure, after you have entered in your values for the first 18 modes, press the mode select button to move to mode 19. Fully twist open the throttle and return to idle position to calibrate the Fuelpak to your bike. 6. By pressing the mode select button twice, move to mode 21 and verify that it reads “0″ with the throttle closed, “50″ at approximately half-throttle and “99″ when fully opened; if not, repeat step 5. Do not proceed to step 7 until mode 21 is verified. 7. Enter any other mode values as required for your application. 8. Turn off power. 9. Reinstall clear cover, tuck Fuelpak under seat area and reinstall seat. 10. You are now ready to ride

Toyota 2006-10 Yaris L4-1.5L NTAKE TUBE, THROTTLE BODY AND ENGINE REMOVAL AND INSTALLATION

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Filed Under (Toyota Manuals) by admin on 26-09-2011

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turn the ignition OFF and disconnect the vehicle’s negative battery cable. NOTE: FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS AND NOT USING THE PROVIDED HARDWARE MAY DAMAGE THE INTAKE TUBE, THROTTLE BODY AND ENGINE. 2. Depress the locking tab and remove the mass air sensor connector. Remove the clips that secure the mass air sensor har- ness to the stock air box. 3. Pull the vacuum switching valve and bracket assembly from the stock intake tube. Un-clip the vacuum hose from the stock intake tube. 4. Loosen the spring clamp that secures
the crank case vent tube to the stock intake tube as shown. Remove the crank case vent tube from the stock intake tube. Note: The spring clamp will be re-used. 5. Loosen the hose clamp that secures the stock intake tube to the throttle body as shown. Remove the stock intake tube from the throttle body

2003 SUZUKI SV 650 FUEL SYSTEM AND THROTTLE BODY SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve . The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM . When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impel- ler . This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it . Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port . The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped . Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 -600 kPa (4.5- 6.0 kgf/cm2,64- 85 psi) . Relief valve Brush , ∎ I,’ Check valve Magnet L Armature When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction . This process continuously takes place causing fuel pressure to be built up . The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve . FUEL SYSTEM AND THROTTLE BODY 5- 3 Inlet port I I Impeller 5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve . It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm2,43 psi) to be applied to the injector at all times . When the fuel pressure rises more than 300 kPa (3 .0 kgf/cm2, 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank . 90 Spring 02 Valve FUEL INJECTOR The fuel injector consists of the solenoid coil, plunger, needle valve and filter . It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion . As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized (injection time)

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TERMS AND DEFINITIONS OF FUEL INJECTION MANAGEMENT SYSTEMS

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Filed Under (Tips and Review) by admin on 19-11-2010

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Throttle Body Assembly (TBA) — The throttle body assembly (also called air valve), controls the airflow to the engine through one, two or four butterfly valves and provides valve position feedback via the throttle position sensor. Rotating the throttle lever to open or close the passage into the intake manifold controls the airflow to the engine. The accelerator pedal controls the throttle lever position. Other functions of the throttle body are idle bypass air control via the idle air control valve, coolant heat for avoiding icing conditions, vacuum signals for the ancillaries and the sensors. FUEL INJECTOR — There are basically three approaches in delivering the fuel to the engine: • Above the throttle plate as in throttle body injection • In the intake port toward the intake valves as in multi-port injection or central multi-port injection. • Directly into the combustion chamber as in gasoline direct injection systems (GDI). The fuel injector is continuously supplied with pressurized fuel from the electric fuel pump. The pressure across the metering orifice of the injector is maintained constant by the fuel pressure regulator. The fuel injector is an electromagnetic valve that when driven by the ECU delivers a metered quantity of fuel into the intake manifold (or combustion chamber in the GDI system). The ECU controls the fuel flow by pulse width modulation. The time the injector is driven into an open condition is determined by the following sensor inputs: • Engine RPM • Throttle position (TPS) • Manifold absolute pressure or mass air flow • Engine coolant temperature • Oxygen sensor feedback voltage • Intake air charge temperature • Battery voltage CENTRAL POINT INJECTION SYSTEM (CPI) — Electronic fuel Injection system consisting on a single fuel injector mounted in the throttle body. DIGITAL FUEL INJECTION (DEFI OR DFI) — Electronic fuel injection system controlled by digital microprocessors as opposed to earlier systems that were of analog design. The analog input signals to the microprocessor are converted from analog to digital before being processed.

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1995 – 2004 Toyota Tacoma Body Lift Kit Installation and REMOVAL

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Filed Under (Toyota Manuals) by admin on 24-09-2011

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RADIATOR FAN SHROUD: Only raise body high enough to remove and replace body mounts. Always watch the fan shroud for sufficient clearance when raising the body. 2. Remove the 12mm bolts and nuts from the upper steering coupler on the rack and pinion noting the position of the steering column. Note: do not let the steering column turn, keep the column and rack aligned to its original position, mark if necessary. See figure 2. 3. Loosen body mount bolts on the driver’s side of vehicle and remove bolts from opposite side for positions 1,2 and 3, see Figure 1. Place a 2×4 between the jack and body to pread out load. 4. Raise the body on the driver’s side just far enough to remove mounts. Temporarily prop up the cab between cab and the frame with a wooden 2×4 or spacer. (This is to avoid cab from falling while working on body mounts.) The bolts on the opposite side will help ensure that the body does not shift. Make sure cab doesn’t contact bed when lifting. 5. Remove factory mounts one at a time.
6. Install the new S10321 steel bracket, polyurethane body mounts, and steel sleeves in positions 1, 2 and 3. Refer to the diagrams for positions. NOTE: On 2001 and newer models you will need to invert the #2 position bushings so that the M02787 is on top. 7. Install the supplied aluminum steering coupler with the round bosses pointing down. Note: you may have to loosen the pinch bolt at the top of the steering coupler so that it will slide up enough to install the steering coupler. See figure 2. 8. Lower the driver’s side and START the new bolts into the new mounts. Reconnect the steering coupler with the supplied 5/16” bolts from the top and nuts. DO NOT TIGHTEN!
9. Now remove bolts from passenger side of vehicle and repeat steps 3 through 6. 10. Tighten the steering coupler bolts and nuts to 35ft lbs also tighten the upper steering bolt to 35ft lbs

2004 Honda CRF450R OWNER'S MANUAL

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

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motorcycle can be kickstarted with the transmission in gear by disengaging the clutch before operating the kickstarter. Check the engine oil, transmission oil and coolant levels before starting the engine (page 21, 23, 24). Cold Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. If the temperature is 35°C (95°F) or below, pull the choke knob fully out. 4. If the temperature is below 0°C (32°F), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 5. With the throttle closed, operate the kickstarter starting from the top of the kickstarter stroke, kick through to the bottom with a rapid, continuous motion. (Do not open the throttle, As the carburetor is equipped with an accelerator pump, excessive fuel will be charged into the engine, and the spark plug will be fouled if the throttle is opened and closed repeatedly. Excessive fuel in the engine makes kick- starting difficult.) 6. About a minute after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. (1) FUEL FILL CAP (2) BREATHER TUBE WARNING (1) FUEL VALVE (2) CHOKE KNOB Warm Engine Starting: 1. Turn the fuel valve ON. 2. Shift the transmission into neutral. 3. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever 1. Shift the transmission into neutral. 2. Pull the hot start lever and kick-start the engine. (Do not open the throttle.) 3. As soon as the engine starts, release the hot start lever. Starting the engine excessively charged with fuel by throttle blipping or other reasons: 1. Shift the transmission into neutral. 2. With the throttle fully opened, repeat kickstarter operation approximately 10 times very slowly to discharge excessive fuel from the engine. 3. Pull the hot start lever and kick-start the engine (Do not open the throttle.) 4. As soon as the engine starts, release the hot start lever. Stopping The Engine 1. Shift the transmission into neutral. 2. Turn the fuel valve OFF. 3. Lightly open the throttle 2 – 3 times, and then close it. 4. Depress and hold the engine stop button until the engine stops completely. NOTE: • Failure to close the fuel valve may cause the carburetor to overflow. (1) THROTTLE GRIP (2) ENGINE STOP BUTTON Break-In Procedure Help assure your CRF’s future reliability and performance by paying extra attention to how you ride during the first operating day or 15 miles (25 km). During this period, avoid full-throttle starts and rapid acceleration. This same procedure should be followed each time when: • Piston is replaced • Rings are replaced • Cylinder is replaced • Crankshaft or crank bearing are replaced

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CCS- 100 ELECTRONIC CRUISE CONTROL INSTALLATION MANUAL

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Filed Under (Tips and Review) by admin on 10-11-2010

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UNDER HOOD INSTALLATION Connecting the Cruise Control Cable to the Throttle NOTE: Prior to attaching servo cable to throttle, locate an accessible area to mount the cruise control servo, but do not mount it. Leave the servo in this area (unmounted) and route cable to throttle attachment area. CAUTION: Attach the cruise control cable so that it parallels the existing throttle cable as nearly as possible. Choose a mounting method from the figures below: Attachment area for securing cable Bead Chain Coupling Sleeve (#23) Bead Chain Coupling (#24) 3 BEAD CONNECTOR FIG. 6 FIG. 7 FORD LINKAGE ADAPTOR Rubber Ring WIRE LOOP FOR PULLEY Carburetor Existing Snap-On Throttle Arm On Vehicle FIG. 2 SNAP-ON THROTTLE ARM MOUNT FIG. 3 CLAMP-ON THROTTLE ARM MOUNT Determine a suitable point on the throttle linkage to mount the cable connector. The mounting point chosen should have between 1-1/2″ to 2″ total linkage travel. It must operate smoothly by hand. There should be at least 5 beads between the throttle connector and servo cable end. The cable must pull in a straight line from throttle linkage. Some vehicles that do not have enough total linkage travel have to be connected at the accelerator pedal. The bead chain and servo cable end must be inserted into the bead chain connector. Then the bead chain coupling sleeve must slide over bead chain connector to insure that the end will not hang in the connector. FIG. 1 Cable Bead Chain Eyelet Connector (#25) Pull off Throttle Arm and Insert Bead Chain Connector between it and Carburetor Arm. Be sure additional thickness of adaptor does not bind linkage. 20° Bead Chain Eyelet Connector (#25) Cable Must Be within 20° of same angle as Throttle Rod Throttle Cable Throttle Wire Loop (#29) Barrel Wire Adaptor (#30) WIRE BARREL FOR PULLEY FIG. 5 FIG. 4

HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/ IDLE CABLE KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be placed into the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 4. Remove the right upper and lower switch housing screws INSTALLATION Throttle and Idle Cable Installation 1. See Figure 3. Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar. NOTE The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle control cable. For assembly, apply a drop of light oil on the retaining rings of the crimped inserts. 2. See Figure 7. Push the throttle cable housing and retaining ring into the larger hole of the switch housing, located in front of the tension adjuster screw. 3. Push the idle cable housing and retaining ring into the smaller hole of the switch housing, located behind the tension adjuster screw. 4. Push the throttle and idle control cable housings into the lower switch housing until each snaps into place. NOTE For models not equipped with factory-installed cruise control, if the friction shoe has fallen out or become dislodged, install the shoe with the concave side facing up and position it so the pin hole is over the point of the adjuster screw. 5. Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip until the ferrule notches are at the top. To prevent binding, pull the grip back about 0.12 inch (3.2 mm). 6. See Figure 3. Position the lower switch housing beneath the throttle control grip. Install two brass ferrules (Item 3, Figure 11) from this kit onto cables, seating the ferrules in their respective notches on the throttle control grip. The cables must be captured in the grooves molded into the grip. 7. Position the upper switch housing over the handlebar and lower switch housing. Route the wire harness conduit through the depression at the bottom of the handlebar. 8. Tighten the upper and lower switch housing screws finger- tight. 9. Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket. 10. Align the holes in the handlebar clamp with those in the master cylinder housing and tighten the lower screw and flat washer finger-tight. Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm)

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