Harley-Davidson Softail, Touring, Dyna, Sportster and V-Rod, SELF LEARNING MODULE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2012

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STEP 1 – BATTERY CONNECTION Locate the battery and disconnect the negative battery cable. Mount the module in the open area in front of the battery with 2-tie straps or velcro straps, directing the harness from the module towards the 6 o’clock position. STEP 2 – THROTTLE POSITION SENSOR (TPS): Remove the air cleaner assembly and unplug the TPS sensor connector at the TPS sensor. The harness includes (2) TPS connectors which should be routed under the gas tank into the factory wire loom to the TPS sensor. The TPS sensor is located on the left side of the throttle body. Plug the (2) TPS connectors from the module in between the TPS sensor and to the factory TPS connector. STEP 3 – O2 SENSOR: Systems equipped with factory O2 sensors Rear: Unplug the Rear O2 sensor connector from the factory harness, which is located at the Rear exhaust pipe. Route the module’s harness which includes (2) O2 sensor connectors and connect one connector to the Rear O2 sensor and connect the other connector to the main factory O2 sensor connector. Front: Unplug the Front O2 sensor connector from the factory harness, which is located at the Front exhaust pipe. Route the module’s harness which includes (2) O2 sensor connectors, and connect one connector to the Front O2 sensor and connect the other connector to the main factory O2 sensor connector. Systems not equipped with factory O2 sensors NOTE: Many aftermarket exhaust systems are now equipped with plugged O2 sensor bungs which can be removed to accept an aftermarket O2 sensor. Typically these bungs already have a thread size of 18 mm x 1.5 mm. Exhaust systems not equipped with O2 sensor bungs need to have the supplied 18 mm x 1.5 mm thread size bung welded to the exhaust pipe in order to install an O2 sensor. The O2 sensor bung should be installed 3 to 6 inches away from the rear cylinder exhaust port and in front of the exhaust torque tube pipe area. The module prefers to receive information from the O2 sensor from an area that is NOT contaminated from atmospheric air. This air may enter through the tail pipe of an unrestricted or un-baffled exhaust pipe. The bung should not be installed in the “5 to 7 o’clock” area. If mounted in this area the O2 sensor can be damaged. The moisture from the gases exiting from the rear cylinder exhaust port will harm the ceramic shell element of the O2 sensor.

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1999-2001 Harley-Davidson Twin Cam 88 FI Controller Installation MANUAL

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Filed Under (Harley Davidson) by admin on 25-03-2012

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Remove the seat. Remove or raise the fuel tank. The tank needs to be raised enough to give access to the fuel injectors and TPS wires. Unplug the front injector. On the FI Controller, there are 2 pairs of injector connectors. Plug the pair with the orange wires into the front cylinder injector harness and front cylinder injector. Repeat this using the other connector pair and the rear cylinder injector. Locate the TPS connector behind the throttle body. STEP 1 STEP3 STEP2 Installation Part# DFCH-2 2 Rear Cylinder Injector Front Cylinder Injector TPS Connector STEP 3 STEP 2 STEP1 Unplug the connector from the TPS. Crimp the wire tap onto the wire that is grey with a purple stripe. This wire should be in position “C” on the connector. Plug the grey wire from the FI Controller into the wire tap. Run the wiring harness for the FI Controller from the engine to the seat. Make sure that it will not get damaged when you reinstall the tank. Use one of the wire ties to tie the wires to the frame, away from the cylinder head. Place the FI Controller where you plan on mounting it permanently. In most cases, this will be under the seat. Connect the ground lug (black wire) to a grounding point on the bike. Use the Velcro tape to mount the FI Controller in position. Use alcohol swab to clean mounting surface prior to attaching Velcro. Reinstall fuel tank and seat. STEP 4 STEP 6 STEP 5 STEP4 STEP6 STEP5 Installation Part# DFCH-2 3 FI Controller
For Tech Support: 800.928.3962 Controls The FI Controller is preprogrammed with 4 base fuel curves. The curves are selected using the switch labeled BASE. These curves adjust fuel delivery based on throttle position and RPM, providing the right amount of fuel under all conditions. The 4 fuel curves correspond to varying levels of performance modifications. The levels of modification are broken down into the following groups. Base Curve 1 – Stock or basic modifications. This includes slip on exhausts, intakes, air boxes, and air filters. It will also work for headers or full exhaust systems. Base Curve 2 – Motor upgrades. This includes cams, 95 ci motors. Base Curve 3 – More extensive motor upgrades. This includes 103 ci motors, cams, ported heads

1997-1998 Harley-Davidson Evo FI controller installation manual

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Filed Under (Harley Davidson) by admin on 25-03-2012

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Remove the seat. Remove or raise the fuel tank. The tank needs to be raised enough to give access to the fuel injectors and TPS wires. Unplug the front injector. On the FI Controller, there are 2 pairs of injector connectors. Plug the pair with the orange wires into the front cylinder injector harness and front cylinder injector. Repeat this using the other connector pair and the rear cylinder injector. Locate the TPS connector behind the throttle body. STEP 1 STEP3 STEP2 Installation Part# DFCH-1 2 Rear Cylinder Injector Front Cylinder Injector TPS Connector STEP 3 STEP 2 STEP1 Unplug the connector from the TPS. Crimp the wire tap onto the wire that is grey with a purple stripe. This wire should be in position “C” on the connector. Plug the grey wire from the FI Controller into the wire tap. Run the wiring harness for the FI Controller from the engine to the seat. Make sure that it will not get damaged when you reinstall the tank. Use one of the wire ties to tie the wires to the frame, away from the cylinder head. Place the FI Controller where you plan on mounting it permanently. In most cases, this will be under the seat. Connect the ground lug (black wire) to a grounding point on the bike. Use the Velcro tape to mount the FI Controller in position. Use alcohol swab to clean mounting surface prior to attaching Velcro. Reinstall fuel tank and seat

HARLEY-DAVIDSON DRESSER BIG SHOT DUALS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2012

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1. Remove both left and right saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffl er. Note: On older model Dressers, spread the clamps just enough to remove them. 3. Remove the two 5/16″ bolts that mount the muffl er to the saddlebag supports. Repeat this step on the opposite muffl er. 4. Remove the stock muffl ers with sliding hangers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the muffl er from the head pipe. 5. Remove the right hand fl oor board. 6. Remove both passenger fl oor boards. 7. Loosen the heat shield clamps on both front and rear exhaust pipes. 8. Loosen the rear head pipe clamp located behind the rear cylinder. Remove the section of head pipe connecting the left side muffl er. 9. Remove the clamp holding the front head pipe to the transmission housing. 10. Remove the two mounting nuts from each head pipe, located at the cylinder head. Carefully remove the head pipes and set them aside. 11. Remove the rear cylinder bracket by removing the two starter mounting bolts. Install new mounting bracket (stamped 353-P), and torque to (13-16) ft. lbs. (Figure 1). Make sure the battery ground cable is secure and properly routed. Install mounting post (from stock system) so the nut is accessible from right side of motorcycle and saddle will support underside of exhaust pipe. Note: Pre 1998 dressers do not come with this mounting post. It can be ordered from your local dealer, Harley part number: 65619-98. 12. Carefully remove the exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them

Harley Davidson Touring Bikes TRUMPET INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2012

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COMPRESSOR INSTALLATION TOUR MODELS 1992 -2000 On the Dressers and Tour bikes, remove the seat. If the battery is located underneath the seat, then remove the right saddlebag and right hand side cover. Using a zip tie, mount the compressor to the main wiring harness at the front of the covered area with the compressor air outlet facing down. If the battery is not under the seat and is located beside the right saddlebag, the compressor will be mounted underneath the seat, utilizing a bolt to the frame The air hose routes from the air horns, behind the fuel valve, over the rear cylinder and to the right side cover or underneath the seat. Do not cut hose until you connect it to the compressor. TOUR MODELS 2001 & NEWER On the Dressers and Tour bikes, the compressor will mount under the seat, in the square hole in front of the frame, just in front of the battery. The air output will face left toward the air horns. The hose routes thru a hole at the bottom of the square hole, then to the air horns. WIRING Connect both black wires from the relay to the original horn wires. It does not matter which wire you connect. The fuse wire on the relay will connect to the positive terminal on the battery. Observe negative and positive terminals on compressor. Ground the negative terminal to the battery. The positive terminal connects to red wire on relay. Refer to wiring schematic on the next page

1981-1983 Yamaha Virago 750 & 920 Installation Instructions

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Filed Under (Yamaha) by admin on 11-02-2012

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Start by loosening the rear cylinder down tube bolt located on the top of the old mufflers center collector in front of the rear tire. 2. Remove both of the front cylinder exhaust pipe head nuts and set them to the side for reuse with the MAC exhaust system. 3. Remove the right side passenger’s foot peg. Set the foot peg aside as you will need to reinstall it. 4. Remove the left side passenger’s foot peg. Set this foot peg aside as it will also need to be reinstalled. Note: When you remove this bolt the entire exhaust system will be loose and may fall. You will need to support the old exhaust at this point to keep from injuring yourself. Gently move the old exhaust system side to side to remove it from the rear cylinder down tube. Once the exhaust system is loose from the down tube remove the system from under the Virago. 5. Remove the bolt holding the rear brake pedal in place and remove the brake pedal from the motorcycle. Note: Set both the bolt and the pedal aside for reinstallation. 6. Next loosen the nut on the drivers right foot peg, 1 full turn to start with. Then remove the rear nut on the same foot peg. (Note: The bolt that this nut is on goes completely through the motorcycle. This is the center stand mounting bolt.) Now remove the front nut and set both aside for reuse with the MAC system. 7. Install the center stand stop bracket under the left passenger foot peg. Install this bracket with the 90° bend facing down and towards the rear tire. (Note: Center stand sop bracket in provided in the hardware kit and is approx. 5″ long with a 90° bend in it.) Adjust the bracket by one of the large bolts through the foot peg then through the bracket and then install it into the stock location. Put on one of the washers and a nut and snug up the nut. Lower the center stand until the center stand come in to contact with the bottom of the bracket. Tighten the nut until it will hold the bracket securely. 8. Install the rear down tube clamp onto the rear muffler and install the medium sized nut/bolt/washer onto the clamp just finger tight. 9. Install the (2) small bolts into the channel bracket on the rear muffler. Install the rear mounting bracket onto the two bolts and then install the washers and nuts onto each. Tighten the (2) nuts only slight amount so that you can slide the bracket front to rear to insure that when you install the bracket you position it properly. 10. Slide the rear pipe onto the rear down tube about ¼”to ¾” past the pre-cut slots on the rear muffler pipe. Slightly snug the clamp making sure that the position of the bolt and nut will not interfere with any moving parts. The final position of this bolt can hit the tire if it is not positioned properly. 11. Install the other large bolt into the right passenger and then through the top hole in the rear muffler mounting bracket. Insert the bolt into the stock location and install the washer and the nut. 12. Align the rear muffler and you can then tighten the nuts on the rear muffler mounting bracket, the cylinder down tube and the right side passenger foot peg.
13. Install the front muffler on the rear most mounting bolt of the drivers foot peg and put the stock nut back onto the bolt. Hand tighten the bolt only at this time. Note: Install the nut at this time is only to support the muffler and to insure that the pipe does not fall on the ground while you complete the next step. 14. Lift the front head pipe into position and start the stock nuts onto the studs. It is strongly recommended that you install new exhaust gasket at this time. Note: The new exhaust gaskets are not included in the kit but are available at your local Yamaha Dealer. After gaskets are installed hand tighten the front head pipe. 15. Remove the nut from the drivers foot peg bolt and reinstall the drivers foot peg. Note: Hand tighten only at this time. 16. Finish tightening the nuts on the front head pipes. (Install these nuts according to Yamaha’s Factory specifications.) Once the nuts are tightened on the head pipe you can then tighten the drivers foot peg nuts. 17. Reinstall the rear brake pedal and tighten the bolt that holds it on to factory specifications. 18. Check all of the bolts that you have installed of removed to insure that they are tight. 19. Start the motorcycle and check for any leaks. 20. You are finished with your new MAC Exhaust System.

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Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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Filed Under (Honda) by admin on 27-12-2011

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

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HONDA VTX1800R AND HONDA VTX1800N BIG SHOTS EXHAUST SYSTEM REMOVAL

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Filed Under (Honda) by admin on 17-11-2011

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If motorcycle is oxygen sensor equipped, unscrew the sensors from the stock exhaust system and install them
into the Vance & Hines exhaust system, being sure to install the front cylinder sensor into the lower pipe and
the rear cylinder sensor into the top pipe. Note: Use caution when handling. Do not touch sensor tip area.
2. If motorcycle is not oxygen sensor equipped, install both M12 x 11 plugs and washers (supplied)into the oxygen
sensor bosses. 3. Check condition of stock exhaust gaskets. Replace if damaged or worn. 4. Install and tighten supplied mounting bracket (stamped 345-P) in the original mounting bar location, using one M10 x 35 flange bolt and nut on top (supplied) and one M10 x 20 flange bolt on bottom (supplied) (Figure 2). Note: The bracket mounts behind the top frame mount and in front of the bottom frame mount(Figure 2).5. Install and tighten rectifier using M6x30 flange bolt, nut
and washer combinations (supplied) (Figure 2). 6. Place heat shields on a non-abrasive surface such as a blanket or carpet. Using a felt tip marker mark outside surface of front and rear heat shields with location of the mounting clips welded to the inside

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HARLEY DAVIDSON XLH 1200cc BIG BORE KIT INSTALLATION MANUAL

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

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Boring and Honing Procedures 1. Check again for burrs on cylinder gasket surfaces and remove burrs before performing Step 2. 2. Install original head and base gaskets, CYLINDER TORQUE PLATES (Part Number 33446-A) and TORQUE BOLTS (Part Number 33446-4). Tighten TORQUE BOLTS following tightening procedure given in the INSTALLATION, CYLINDER HEAD procedure in the ENGINE section of the Service Manual. NOTE Torque plates, properly tightened and installed with gaskets, simulate engine operating conditions. Measurements will vary as much as 0.001 inch without torque plate. 3. The cylinder must be bored with gaskets and torque plates attached. Bore the cylinder to 0.003 inch under the desired finish size. 1 WARNING CAUTION CAUTION 1 WARNING Kit Number 4. Hone the cylinder to its finished size (See Figure 1) using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Honing must be done with torque plates attached. All honing must be done from the bottom (crankcase) end of the cylinder. Work for a 60 degree crosshatch pattern. 5. See Figure 1. After machining and honing, chamfer the bottom edge of the cylinder liner. the chamfer provides a beveled surface for easier installation of the cylinder over the piston rings. Break leading edge of liner to a flat surface. The bottom edge of the liner will be somewhat sharp after machining. This sharp edge could easily be damaged during installation of the cylinder. Piston Installation The 1200cc pistons have an arrow on the top of the piston. This arrow must face the front of the engine when piston is installed. There is no front cylinder piston or rear cylinder piston. New pistons can be installed in either cylinder. Check piston rings for proper side clearance and end gap (See XLH Service Manual). Be sure end gaps of adjacent rings are installed 90 degrees apart. Assembly Follow assembly and torque specifications given in the ENGINE section of the applicable Service Manual. Replace original gaskets, O-rings and seals with new components furnished in kit. NOTE Push rod covers on 1991 and later models are one-piece and the correct O-rings are as follows: Bottom – Part Number 17944-89 Upper – Part Number 11190 Engine Break In For the first 500 miles, to wear-in critical parts, observe these few simple driving rules: During the first 50 miles, keep the engine speed below 2500 RPM in any gear. Up to 500 miles, vary the engine speed, avoiding any steady speed for long distances. Engine speed up to 3000 RPM is permissible in any gear. Avoid fast starts at wide open throttle. Drive slowly until engine warms up. Avoid running the engine at extremely low RPM in higher gears. 2 of 3 -J00001 1200cc CYLINDER FINAL BORE SIZE AFTER HONING STANDARD BORE DIAMETER 3.4980 inch + 0.0002 inch Figure 1. Bottom Edge of Cylinder Liner Chamfer i04852 Break Edge to Flat Surface

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HARLEY DAVIDSON CHROME FAN KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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INSTALLATION 1. Refer to Service Manual and remove 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. Horn Relocation NOTE This cooling fan is designed to provide supplemental cooling for motorcycles subjected to long periods of idling/parade duty. The fan is mounted on the left side of the engine in the area where the horn is mounted. The stock horn must be removed. Remove Stock Horn 1. Follow Service Manual instructions to remove stock horn and its bracket. 2. Assemble new horn 69043-96B to bracket 69135-04 using screws 3658 and washers 7069. 3. Remove right front fuel tank TORX® screw. 4. Mount horn at front of fuel tank with TORX screw. Verify there is adequate room between horn bracket and fuel tank to prevent paint damage. Tighten screw to 15-20 ft- lbs (20-27 Nm) . 1 is05140a 1. Horn mounting location Figure 1. Horn Relocation Remove Stock Upper Engine Mounting Bracket 1. Remove screw securing rear of fuel tank and gently raise fuel tank to gain access to upper engine mounting bracket. Place suitable blocking under tank. 2. On 2007 models remove bolt attaching stabilizer link to upper engine mounting bracket. 3. Remove two bolts and washers securing upper engine mounting bracket to front and rear cylinder heads. Retain bolts and washers for attaching new upper engine mounting bracket from kit. 4. Note position of fuel hose. Remove upper engine mounting bracket. 5. Connect horn relocation harness to horn. 6. Route stock horn wires forward towards relocated horn. 7. See Figure 7. Cut ends off stock horn wires and strip wires 3/8 inch. Follow instructions in Service Manual, “SEALED

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