Harley-Davidson MSD Pulse Ignition Installation Manual

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Filed Under (Harley Davidson) by admin on 11-03-2012

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PICKUP PLATE INSTALLATION Remove the existing trigger/points plate and rotor, points cam and advance. Refer to the bike’s Service Manual for the proper procedure. EVOLUTION AND LATE MODEL SHOVELHEAD V-TWINS 1. From inside the cam/ignition housing, feed the free end of the MSD pickup harness through the wire access port. Note: The harness includes a heat-resistant acrylic sleeve that fits snugly inside the port opening. Do not pull the sleeve completely through the port. It must be positioned to protect the wires as they pass through the port opening. 2. Mount the MSD pickup plate inside the housing (Figure 1). Note the “adjusting notch” on the edge of the plate. This notch must be located over the series of “steps” inside the housing (about the 7 o’clock position as you face the housing). One of the sensor units will be at approximately 12 o’clock. SPORTSTER MODELS 1. On Sportsters, the wire access port must be enlarged. Use a 9/32″ drill bit to enlarge the wire port. 2. Remove the wire harness clamp of the pickup assembly and route the wires through the port. 3. Mount the MSD pickup plate inside the housing (Figure 2). Note the “adjusting notch on the edge of the plate. This notch must be located over the “cast notch” inside the housing (about the 11 o’clock position as you face the housing). The shorter of the two sensors will be approximately in the 9 o’clock position. 4. Install the hold-down/standoff screws with flat washers until they are snug – do not tighten at this time (Figure 3). 3. Put the MSD rotor in place on the end of the camshaft. The locating pin in the rotor bore must align with the groove in the cam. Do not force the rotor on the camshaft! Push the rotor into place until it is tightly against the end of the cam then snug the retaining screw. 4. Check the distance from the outer surface of the pickup plate to the end of the installed rotor (Figure 4). If necessary, add shims until the measured rotor height is 9/16″ (+/- 1/32″). 5. When the rotor height has been verified, remove the retaining screw, place a drop of Red Loctite on the threads and reinstall the screw to the factory recommended torque

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1994 – 1996 Camry L4 A/C COMPRESSOR KNOCKING NOISE REPAIR

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Filed Under (Toyota Manuals) by admin on 23-10-2011

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Ensure that the A/C system high & low side refrigerant pressures are normal before Procedure proceeding with the following repair procedure. NOTE: For abnormal system pressures, use the diagnostic procedure given in the Repair Manual to determine the problem. 1. Remove the A/C Compressor. 2. Replace the Alternator Adjusting Bar with the new part number. 3. Replace the Magnetic Clutch Rotor with the new part number. 4. Adjust the clearance between the pressure plate and rotor from 0.35 to 0.60 mm (from 0.014 to 0.024 inch). NOTE: Use shims to adjust the clearance according to Repair Manual. 5. Install the A/C Compressor. 6. Adjust the drive belt tension to 121 ft. lbs. otherwise the condition may persist

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HARLEY DAVIDSON FRONT NINE-SPOKE WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-04-2011

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INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN models: Discard moon-style hub cap. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 2. See Figure 1. Install valve stem assembly (D) on wheel. Refer to TIRES in service manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in service manual. NOTES Install the primary bearing first with the WHEEL BEARING REMOVER/INSTALLER, following the service manual instructions. The machined grooves in the hub face indicate the primary bearing side. The front wheel should be installed so that the valve stem is on the right side of the motorcycle. 4. Install wheel assembly parts from the appropriate service parts table for your fitment and stock brake disc(s). Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in service manual. 5. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in kit installation. All other models: Install wheel spacers previously removed. 6. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual. 7. For 2009-Later TLE/U Sidecars: Assemble the sidecar brake disc and hub cap (purchased separately) to the wheel. The brake disc is to be installed on the side of the wheel opposite the valve stem. Install wheel according to the sidecar service manual

HARLEY DAVIDSON FRONT DETONATOR WHEELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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INSTALLATION 1. Remove existing front wheel assembly. Save axle, axle nut, brake disc and wheel spacers for kit installation. Discard moon-style hub cap on FLSTC and FLSTN models. Discard left side spacer on FXSTS models and tapered spacer on FXSTD models. Refer to FRONT WHEEL in Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 2. See Figure 1. Install valve stem assembly (D) on wheel. Refer to TIRES in Service Manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual. NOTE Install primary bearing first using the applicable Service Manual and WHEEL BEARING REMOVER/INSTALLER. Kit 44550-07: The left side of the wheel has a groove machined in the hub to identify it as the disc side for installation, as well as the primary bearing side. The wheel should be installed so that the valve stem is on the right side of the motorcycle. Kits 44660-07 and 44661-07: The wheel should be installed so that the hub markings are on the left side of the motorcycle. An arrow engraved into the rim of 44661-07 indicates the direction of rotation. A groove is machined in the left-side hub face to indicate the primary bearing side. • Dual-disc models: Install the brake discs according to the Service Manual procedures. The Chrome hub cap (2) is not used. • Single-disc models: Install the brake disc according to the Service Manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Kit 44660-07: The gross axle weight rating is unaffected by the installation of this wheel on a vehicle originally equipped with 21-inch wheels. Kit 44661-07: The gross axle weight rating is unaffected by the installation of this wheel on a vehicle originally equipped with 19-inch wheels. Kit 44552-08: The left side of the wheel has a groove machined in the hub to identify it as the left side for installation, as well as the primary bearing side. The wheel should be installed so that the valve stem is on the right side of the motorcycle. Kit 44556-07: The right side of the wheel has a groove machined in the hub to identify it as the right side for installa

HONDA GL1500 FRONT WHEEL INSTALLATION MANUAL

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Filed Under (Honda) by admin on 27-02-2011

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1. Rotor Covers. Tri-chromed ABS rotor covers replace the painted ones. Light weight, beautiful and functional. Include a rear strap and sold in pairs. Also, available are chrome rotor covers with amber strip lights installed. Fits 1988 to 2000. 2. Fork Light Mounts . Specially designed mounts are tri-chromed metal and hold a total of 6 lights. Lights not included. Sold in pairs 3. LED Lighted Rotor Cover Trim Rings . NEW Update your bike with LED lights. Tri-chromed ABS rings include amber or red, blue and amber LED lights. Sold in Pairs 5. 252-216 Rotor cover Plugs. These¾” chromed steel plugs fill the holes on the GL1500 rotor covers. Sold in a 4 pack

Basic Rotor Installation Instructions

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Filed Under (Tips and Review) by admin on 10-01-2011

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1. Take wheel off the bike. 2. Install rotors offset on the wheel. (refer to pictures below) 3. Replace the wheel on the bike keeping the axle, pinch bolts, and caliper bolts loose. 4. Begin to pump the brakes, applying the pads, making contact with the rotors. 5. While maintaining pressure, tighten the axle and all of the bolts. 6. This aligns the wheel, rotor, caliper, and pads to ensure optimum contact between rotor and pad. 7. Check that brake fluid level is not too high after install. 8. Make sure the wheel spins freely. 9. Bed in easily for first 100 miles.

AUTOMOTIVE BRAKE BLEEDING KIT MODEL MV8020 USER'S MANUAL

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Filed Under (Tips and Review) by admin on 25-11-2010

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MOTORCYCLE BLEEDING PROCEDURE Before bleeding the system, ensure that: 1) The brake caliper pistons are free to move within the calipers. 2) The master cylinder piston is free to return to the end of its stroke, and 3) Inspect the line to ensure that all fittings are tight. FRONT BRAKE 1) Pump brake lever to seat caliper pads against rotor. 2) Cover gas tank with plastic protective sheet if using DOT 3 fluid (not necessary if using DOT 5 fluid). 3) Remove master cylinder reservoir cap and fill reservoir. 4) Select the appropriate adapter(s). The L-shaped universal adapters should fit snugly over the brake bleeding fitting in order to seal properly. The tapered adapters fit inside the thru-hole of fitting and will generally seal well when inserted tightly with a pressing and twisting motion. Attach adapter to reservoir hose. 5) Pump several times to create vacuum. Crack bleeder valve with box wrench, extracting fluid into reservoir. (Stop and add fluid when master cylinder begins to get low. Do not allow air to enter line.). At this point, all air should be out of system and line full of fluid. (Note: if air is entering the pump hose from around bleeder fitting, remove bleeder fitting and apply Teflon tape to threaded portion of bleeder screw only. This will prevent air seepage around threads of bleeder screw.) 6) While maintaining vacuum on the pump line, tighten bleeder fitting. 7) Top off reservoir and reinstall cover. Check brake by pumping lever several times. Pedal should have a positive, solid feel. If not, repeat bleeding process as more air may have entered the system. Inspect line to ensure all fittings are tight. If brake still feels slack, consult a service technician.

EVO 3-Phase Charging System Installation And Owner's Manual

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

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install rotor onto sprocket shaft and seat against rotor spacer 9. Install the compensator extension shaft on the sprocket shaft 10. Using your motorcycle’s specific repair manual instructions, check for proper chain alignment. Use OEM-specified shims to bring chain alignment into specification if required. 11. Using your motorcycle’s specific repair manual instructions, install the primary drive and clutch. Assure that all driveline components line up correctly. 12. Apply Loctite Threadlocker #262 (“red”) to the threads of the sprocket nut (also supplied with compensator shaft extension kit). Tighten sprocket nut to 150-165 ft-lbs (203.4-223.7 Nm). 13. Using your motorcycle’s specific repair manual instructions, install the primary cover. 14. Connect the negative battery cable. 2.3 Factory Regulator Removal 1. Disconnect the negative battery cable. 2. Using your motorcycle’s specific repair manual instructions, remove the regulator. Save the factory-supplied hardware. 2.4 3-Phase Regulator Installation 1. Connect the 3-pin stator connector to the regulator. 2. Using the factory-supplied hardware, locate the 3-phase regulator on the mounting bracket and install using the factory-supplied hardware. Tighten to 50-80 in-lbs. 3. Attach the ground wire between the bracket mounting bolt and the bracket. Tighten to 70-100 in-lbs. 4. Trial-fit the long power wire to the motorcycle, and route to the original location of the factory regulator wire on the circuit breaker. 5. Trim any excess wire, and strip 5/16″ of insulation from the end of the wire using a wire stripper. 6. Slip the 1″ length of heat shrink (supplied) onto the wire. 7. Crimp on the (supplied) ring lug to the end of the wire, taking care that a good crimp connection is made.

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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Ural electronic ignition installation Instruction

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Filed Under (Ural) by admin on 02-11-2010

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Section 4: Installation on Motorcycle 4.1 Remove old system. 4.2 Install the ignition coil (135.3705.000) and ignition module base (135.3734.000) with wires positioned toward coil (lightly tighten ignition base screws) . 4.3 Install rotor on the camshaft; note washer positions (see installation figure for specifics) . 4.4 – Position engine at timing position (mark on Dnepr flywheel “P” or see your motorcycle operation manual for specifics however there is mention of “arrow with dot” – Ural? ) . – Position base so the scribed line on the rotor lines up with the center index on the base (index between +10 and -10 marks) . Tighten screws. – Loosen sensor screws and using a feeler gauge, adjust so the rotor and sensor gap equals 0.35 +/- 0.05 mm (note, other manuals mention 0.2 +/- 0.1 mm) . Tighten screws. – If the scribed line is not visible with the engine positioned for timing, rotate the engine 360 degrees (again at the timing position) . 4.5 Connect the wires (КЗ) and (+) from ignition module to the coil. Connect the high voltage leads to the coil. Connect the 12V lead from the switched 12V source to the coil (see installation figures for specifics) . 4.6 Gap sparkplugs 0.8 – 1.0 mm. 4.7 Test ride motorcycle and adjust if necessary; turn ignition module base CW to advance or CCW to retard timing

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