2004 Kawasaki ZX10R Power Commander Installation Instructions

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Filed Under (Kawasaki) by admin on 08-05-2012

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Remove the main seat and the passenger seat 2. Remove the tail cover by removing the two bolts. 3 Place the Power Commander in the tail section and route the wiring harness on the inside of the tail section towards the front of the bike (Fig. A). 4. Remove the fuel tank. 5. Remove the air box lid by removing the 8 screws around the outer edge (Fig. B). 6. Remove the bolts shown in Fig. C. This will allow you to remove the air box. Fig. A Fig. B Fig. C i212-411 2004-2005 Kawasaki ZX10R – PCIII USB – 2 i212-411 www.powercommander.com Remove these bolts Remove screws Remove bolts 7. Locate the Throttle Position Sensor connector. This connector is located above the left hand side of the engine. This is a white 3 pin connector. Unplug this connector (Fig. D). 8. Plug the white connectors from the PCIII in-line of the stock TPS connector (Fig. E). 9. Locate the fuel rail connector behind the injector bodies (Fig. F). This connector is brown in color

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

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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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SUZUKI GSX-R1300 / HAYABUSA Fuelpak Connectors INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 15-02-2012

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Remove the main seat and passenger seat. 2. Use a prop to hold the tank up in the trunk area. 3. Disconnect the main wiring harness from each of the lower injectors. (Fig 1) 4. Lay the Fuelpak unit in the tail section and route the wire harness down the left side of the motorcycle toward the throttle bodies. 5. Plug the Fuelpak wiring harness in line of the stock wiring harness and injectors. (Fig 2) 6. Locate the throttle position sensor connector on the right hand side of the throttle body. 7. Install the Fuelpak wiring harness TPS connectors in line of the stock wiring harness. (Fig 3) 8. Attach ground wire to the negative side of the battery. 9. Install Fuelpak in the tail section using the supplied velcro. (Fig 4) 10. Bolt the fuel tank back into place. INSTALLATION INSTRUCTIONS FOR P/N 62009 READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION FUEL INJECTION

SUZUKI SV 1000 RADIATOR (COOLING SYSTEM) SERVICE MANUAL

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

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FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR COO NO FAULT C11 Camshaft position sen- sor The signal does not reach ECM for more than 3 sec . after receiving the starter signal . The camshaft position sensor wiring and mechanical parts (Camshaft position sensor, intake cam pin, wiring/coupler con- nection) C12 Crankshaft position sensor The signal does not reach ECM for more than 2 sec . after receiving the starter signal . The crankshaft position sensor wiring and mechanical parts (Crankshaft position sensor, wiring/coupler connection) C13 Intake air pressure sensor The sensor should produce following voltage . (0.50 V < sensor voltage < 4 .85 V) Without the above range, C13 is indicated. Intake air pressure sensor, wiring/coupler connection C14 Throttle position sen- sor The sensor should produce following voltage . (0.20 V < sensor voltage < 4 .80 V) Without the above range, C14 is indicated. Throttle position sensor, wiring/coupler connection C15 Engine coolant temperature sensor The sensor voltage should be the following. (0.15 V <_ sensor voltage < 4 .5 V) Without the above range, C15 is indicated. Engine coolant temperature sensor, wiring/coupler connection C21 Intake air temperature sensor The sensor voltage should be the following. (0.15 V < sensor voltage < 4 .5 V) Without the above range, C21 is indicated. Intake air temperature sensor, wiring/coupler connection C22 Atmospheric pressure sensor The sensor voltage should be the following. (0.50 V < sensor voltage < 4 .5 V) Without the above range, C22 is indicated. Atm. pressure sensor, wiring/coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec . after ignition switch turns ON . (0 .20 V < sensor voltage < 4 .80 V) Without the above value, C23 is indicated. Tip over sensor, wiring/coupler connection C24 or C25 Ignition signalCrankshaft position sensor signal is produced and ECM determines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more. In this case, the code C24 or C25 is indicated. Ignition coil, wiring/coupler connection, power supply from the battery SERVICING INFORMATION 8 .3 C28 Secondary throttle valve actuator No operating voltage is supplied from the ECM, C28 is indicated. STVA can not operate. STVA lead wire/coupler, STVA C29 Secondary throttle valve position sensor The sensor should produce following voltage . (0.10 V < sensor voltage < 4 .90 V) Without the above range, C29 is indicated . Secondary throttle position sensor, wiring/coupler connection C31 Gear position signalGear position signal voltage should be higher than the following for more than 2 seconds. (Gear position switch voltage >_ 0 .6 V) Without the above value, C31 is indicated. Gear position sensor, wiring/coupler connection, gearshift cam, etc. C32 or C33 Fuel injector Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted continuous by 4 times or more. In this case, the code C32 or C33 is indicated. Injector, wiring/coupler connection, power supply to the injector C41 Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF . Fuel pump relay, connecting lead, power source to fuel pump relay C42 Ignition switchIgnition switch signal is not input in the ECM . Ignition switch, lead wire/coupler C44 Heated oxygen sensor (HO2S) [For E-02, 19] During 02 feedback control, 02 sensor voltage is higher or lower than the specification . No signal is detected during engine operation or no electrical power is supplied from the battery . HO2S lead wire/coupler connection Battery voltage supply to the HO2S C49 PAIR control solenoid valve (PAIR valve) When no operating voltage is supplied from the ECM, C49 is indicated. PAIR valve can not operate. PAIR valve lead wire/coupler

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2007 HONDA CRF450X Specifications / PRESS INFORMATION

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Filed Under (Honda) by admin on 18-02-2011

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Specifications CRF450X ED-type Engine Type Liquid-cooled 4-stroke 4-valve SOHC single Displacement 449cm³ Bore x Stroke 96 x 62mm Compression Ratio 12 : 1 Max. Power Output 36.2kW / 7,500min-1 (95/1/EC) Max. Torque 46.8Nm / 7,000min-1 (95/1/EC) Fuel System Carburation 40mm Keihin FCR flat-slide carburettor with throttle position sensor (TPS) Fuel Tank Capacity 8.3 litres Electrical System Ignition System Computer-controlled digital capacitor discharge with electronic advance and lighting coil Starter Electric / Primary kick Drivetrain Transmission 5-speed Primary Reduction 2.739 (63/23) Gear Ratio 1 2.231 (29/13) 2 1.625 (26/16) 3 1.235 (21/17) 4 1.000 (19/19) 5 0.826 (19/23) Final Reduction 3.923 (51/13) Final Drive #520 T-ring sealed chain Frame Type Semi-double cradle; aluminium twin-spar Chassis Dimensions (LxWxH) 2,176 x 825 x 1,254mm Wheelbase 1,478mm Caster Angle 27° 17′ Trail 112.8mm Seat Height 963mm Ground Clearance 348mm Dry Weight 115.7kg Kerb Weight 122.6kg 8/9 Suspension Type Front47mm Showa inverted leading-axle twin-chamber cartridge-type telescopic fork with 16-step adjustable compression and rebound damping; 315mm axle travel RearPro-Link with Showa damper, adjustable low-speed (13- step) & high-speed (3.5-turn) compression and 17-step rebound damping; 315mm axle travel Wheels Type FrontAluminium rim/wire spoke RearAluminium rim/wire spoke Rim Size Front21 x 1.6 Rear18 x 2.15 Tyre Size Front80/100 21 (51M) Rear110/100 18 (62M) Brakes Type Front240 x 3mm hydraulic disc with dual-piston calliper and sintered metal pads Rear240 x 4mm hydraulic disc with single-piston calliper and sintered metal pads

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2011 HONDA CRF250X Specifications

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Filed Under (Honda) by admin on 18-02-2011

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Specifications CRF250X (ED-type) ENGINE Type Liquid-cooled 4-stroke 4-valve SOHC single Displacement 249cm 3 Bore  Stroke 78  52.2mm Compression Ratio 12.9 : 1 Max. Power Output 21.9kW/9,000min -1 (95/1/EC) Max. Torque 24.2kW/8,000min -1 (95/1/EC) FUEL SYSTEM Carburation 37mm Keihin FCR flat slide carburettor with throttle position sensor (TPS) Fuel Tank Capacity 7.3 litres (including 1.6-litre reserve) ELECTRICAL SYSTEM Ignition System Computer-controlled digital capacitor discharge with electronic advance and lighting coil Starter Electric / Primary kick DRIVETRAIN Transmission 5-speed Primary Reduction 3.611 (65/18) Gear Ratios 1 2.384 (31/13) 2 1.750 (28/16) 3 1.333 (28/21) 4 1.041 (25/24) 5 0.814 (22/27) Final Reduction 3.786 (53/14) Final Drive #520 T-ring roller chain FRAME Type Semi-double cradle; aluminium twin-spar CHASSIS Dimensions (LxWxH) 2,174 x 827 x 1,261mm Wheelbase 1,481mm Caster Angle 27˚ 54′ Trail 118mm Seat Height 958mm Press information for 2011 CRF250X 3 EU-EN Ground Clearance 346mm Kerb Weight 115kg SUSPENSION Type Front 47mm inverted Showa leading-axle twin- chamber cartridge-type telescopic fork with 16-step adjustable compression and rebound damping; 280mm axle travel Rear Pro-Link with single Showa damper, adjustable low-speed (13-step) & high-speed (3.5-turn) compression and 17-step rebound damping; 313mm axle travel WHEELS Type Front Aluminium rim/wire spoke Rear Aluminium rim/wire spoke Rim Size Front 21 x 1.60 Rear 18 x 2.15 Tyre Size Front 90/90-21 M/C 54R Rear 120/90-18 M/C 65R BRAKES Type Front 240  3mm hydraulic disc with dual-piston caliper and sintered metal pads Rear 240  4mm hydraulic disc with single-piston caliper and sintered metal pads

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2002 Ducati Monster 620ie Dark SPECIFICATIONS AND PERFORMANCE DATA

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Filed Under (Ducati) by admin on 02-12-2010

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Type: ……………. air-cooled, 90°L-twin Valvetrain: ..desmodromic, two valves per cylinder, shim-on-valve-stem Size: ……………………………………618cc Bore/stroke:……….80.0mm x 61.5mm Comp. ratio: ………………………. 10.7:1 Fueling: ……………………Marelli 5.9 EFI with two 45mm throttle bodies Exhaust:………………………………2-1-2 DRIVE TRAIN Transmission: …………………. 5-speed Final drive: ……..No. 530 O-ring chain, RPM @ 65 mph/redline….4890/9500 DIMENSIONS Wheelbase: ………………………….. 56.7″ Rake/trail……………………..24.0°/3.54″ Ground clearance: ……………………4.4″ Seat height :…………………………..29.9″ GVWR: …………………………….881 lbs. Wet weight: …………………….. 424 lbs. Carrying capacity: ………………457 lbs. SUSPENSION Front: 43mm inverted cartridge forks, non-adjustable, 5.1″ travel Rear: ……..Sachs monoshock damper with progressive rocker linkage, adj. preload and reb. damping, 5.8″ travel BRAKES Front:……single 320mm disc, Brembo four-piston, double-action caliper Rear: …………………………245mm disc, twin-piston, double-action caliper TIRES & WHEELS Front: …….. 120/60ZR17 Dunlop D205 Sportmax on 3.50″ x 17″ wheel Rear:………. 160/60ZR17 Dunlop D205 Sportmax on 4.50″ x 17″ wheel ELECTRICS Battery: …………………………12V, 12AH Ignition: …………..digital-mapped with throttle position sensor Headlight: …………………………55/60W FUEL Tank capacity: ……………………4.0 gal. High/low/avg. mpg: ….47.7/56.0/ 51.9 MISCELLANEOUS Instruments: ………………speedo, tach, odometer, tripmeter, Indicators: …….. hi-beam, t/s, neutral, oil pressure, immobilizer, LCD clock MSRP: ……………………………… $6495 Valve adj. interval: ……………. 6000 mi. Warranty: ….2 years, unlimited miles. Color: …………………………matte black PERFORMANCE Measured top speed……116.0 mph 0-1/4 mile………………12.52 sec. @ 104.24 mph 0-60 mph………………..4.31 sec. 0-100 mph………………12.29 sec. 60-0 mph……………………113.7′ Power to Weight Ratio……..1:7.81 Speed @ 65 mph indicated ….62.5 Low end Mid-range Top end The 620′s motor produces plenty of thrust with a wide, torquey powerband. High-tech fuel injection gives excellent throttle response and delivers terrific gas mileage, too. The 90°V- twin is smooth running and looks good exposed. TEST NOTES PICKS Terrific value for the price, especially for a Ducati Highly tuned engine doesn’t disappoint Light weight and good handling adds up to fun PANS Clutch shudders and grabs when hot Mirrors need to be wider and further forward Matte black everything isn’t particularly flattering

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YAMAHA YZF-R1P/ YZF-R1PC SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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1Fuel pump 2Pressure regulator 3Fuel injector 4Throttle body 5Intake temperature sensor 6Throttle position sensor 7Intake air pressure sensor 8ECU 9Atmospheric pressure sensor 0Coolant temperature sensor ACylinder identification sensor BCrankshaft position sensor ÈFuel system ÉAir system ÊControl system Illustration is for reference only. 1 – 4 GEN INFO FEATURES Fuel control block The fuel control block consists of the following main components: An engine trouble warning light is provided on meter panel. Component Function Control block ECU Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure detection Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throttle angle detection Cylinder identification sensor Reference position detection Crankshaft position sensor Crankshaft position detection and engine RPM detection Speed sensor Speed detection Actuator block Injector Fuel injection Fuel pump Fuel feed Air Induction system, air cut valve Induction of secondary air A. Power supply circuit The power supply circuit obtains power from the battery (12 V) to supply the power (5 V) that is required for operating the ECU. B. Input interface circuits The input interface circuits convert the signals output by all the sensors into digital signals, which can be processed by the CPU, and input them into the CPU. C. CPU (Central Processing Unit) The CPU determines the condition of the sensors in accordance with the level of the signal that is output by the respective sensor. Then, the signals are temporarily stored on the RAM in the CPU. Based on those stored signals and the basic processing program on the ROM, the CPU calculates the fuel injection duration, injection timing, and ignition timing, and then sends control commands to the respective output interface circuits. D. Output interface circuits The output interface circuits convert the control signals output by the CPU into actuating signals for the respective actuators in order to actuate them. They also output commands to the indicator and relay output circuits as needed.

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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