Harley-Davidson FLTR/ FLH/ FLHT/ FLHR EFI models 1995-2001 Variable Pressure Fuel Regulator Intallation manual

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Filed Under (Harley Davidson) by admin on 27-04-2012

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1 . Ensure vehicle runs correctly through all rpm ranges and idles correctly before attempting any work. It is highly recommended that a pressure / flow test be carried out before & after installation of the VariReg to determine fuel system condition . Stock HD 300 kPa / 44 psi, VariReg as delivered 360 kPa / 52 psi Note: In some countries gas stations do not “final filter” the fuel & therefore we recommend that the fuel filter canister be replaced every 15,000 klms (10,000 miles). Restriction of the fuel by way of a blocked or partially blocked filter will result in difficulty in tuning or failure to obtain satisfactory results during tuning. Should you experience difficulties in tuning, see Diagnosing fuel filter and pump faults 2. Remove air filter cover, air filter and backing plate. Check Throttle Position Sensor value at completely closed throttle as best performance will be obtained at the nominated settings. This will require backing off the idle screw and cold start idle actuator and screw adjustment as described in the workshop manual. The original T.P.S. values should be recorded for possible future reference. To set TPS values without the HD breakout box see VariReg TPS Setting for Harley-Davidsons The T.P.S. values must be set to 1995 – 1996 175 mV (+/- 25mV) 1997 – 2001 275 mV (+/- 25mV) Record the original TPS value here. ………………..mV YOU MUST ENSURE THROTTLE PLATES ARE COMPLETELY CLOSED AND NO BINDING EXISTS IN CABLES to obtain the correct value setting. 3. Reset idle screws to approximate previous settings, no need to start the engine. 4. Complete full or partial fuel tank removal as described in workshop manual. 5. Remove stock fuel pressure regulator as described in workshop manual and leave Horn removed from vehicle until after tuning, this will allow ease of access to the regulator

Electronic Gear Actuator Installation Instructions

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Filed Under (Tips and Review) by admin on 31-10-2010

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Fault Finding Mechanical If this is a new installation then there are checks that should be made to ensure that the unit can operate correctly. • Check the gear linkage for free play; this represents an effective loss of stroke. Tighten or replace any ball joints or other linkages as necessary • Check that you have oil in your gearbox, if the level is low the gears will run hot after a short period and become tight. • Check that the clutch is clearing properly, any clutch drag will cause the gears to mesh and prevent you changing gear cleanly. If your installation has been working satisfactorily, but has begun to change erratically check the following: • Ensure that the bearing in the clamp is tight and that there is no wear in it, if there is excessive play then replace the bearing. • If you are using a ball joint to connect to the shift lever check this for wear, replace if necessary. • Check all alignments, in particular if you have clamped onto a tubular frame it is possible that this has moved slightly over time • Check the gear linkage for free play; this represents an effective loss of stroke. Tighten or replace any ball joints or other linkages as necessary – if your linkages are all tight you may still have some play in the gearbox itself. – 3 – When offering up the actuator it must also be borne in mind that the angle between the actuators connecting rod, and the pivot point of the lever should be as near as possible to 90 degrees. This ensures that the effort is equal in both directions. When looking for a suitable mounting location you may be able to pick up on existing bolts, the back-plate on the clamp can be drilled to pick up on these. If there is no convenient mounting point then you will have to make up a transition bracket to get the unit into the correct position. The following photographs show some of the common options. See our web site for a full index of mounting arrangements

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