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BILLET ALUMINUM DISTRIBUTOR WITH ELECTRONIC ADVANCE AND ADJUSTABLE REV LIMITER FOR 1936-69 HARLEY BIG TWIN MOTORCYCLES INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 25-11-2010

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ELECTRICAL SYSTEM A 12 volt electrical system is required. Check that the charging system is working properly and not producing over 16 volts. DISTRIBUTOR CLAMP A 1966-69 style distributor clamp (original or aftermarket) is required. MODULE This distributor uses an Accel Single/Dual Fire Ignition module part number 35496. See the enclosed form “Instruction Sheet Single/Dual Fire” for instructions on wiring, adjusting the rev limiter and selecting an advance curve. COIL(S) A coil(s) with a total primary resistance of 2 to 4 ohms is recommended. INSTALLATION Step 1 Turn the ignition switch to the off position. Rotate the engine until it is on the compression stroke for the front cylinder. Continue to rotate the engine until the TDC mark is visible through the timing hole. (see repair manual if necessary). Step 2 Remove the existing distributor if still in the engine. Step 3 Remove the two button head screws from the top of the Mallory distributor. Pull the top cover off the distributor. Remove the two hex standoffs and pull the module and upper housing off the distributor base assembly. Adjust the switches on the module for the desired advance curve and rev limit. FORM 1627 07/08 Step 4 Install the distributor base assembly in the engine with the screw holes and shutter wheel positioned as shown in Figures 1 and 2. It may be necessary to pull the distributor out, turn the shaft and reinstall to get the shutter wheel at the approximate angle shown. The slots should be at about the11 o’clock and 7 o’clock positions. The screw holes should be at the 9 o’clock and 3 o’clock positions. Step 5 Install the distributor clamp and tighten the clamp bolt lightly so the distributor can still be rotated. Step 6 Set the upper housing on the base assembly as shown in figure 3. (The upper housing will only install one way because of the locating screw) Rotate the base assembly slightly if necessary so that the slot in the shutter wheel lines up with the slot in the upper housing. Tighten the distributor clamp

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HARLEY DAVIDSON SHIFTER SHAFT COVER WITH INSERT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1 2 4 3 5 6 7 is01872 1. Shifter shaft 2. Inner cover 3. Toe shifter lever 4. Outer cover 5. Set screw (for outer cover) 6. Set screw (for inner cover) 7. Casting Figure 1. Shifter Shaft Covers 1. See Figure 1. Remove the stock heel shift lever and toe shift lever (3) from the gear shifter shaft (1). 2. Install the set screw (6) into the inner gear shifter shaft cover (2). 3. Install inner gear shifter shaft cover with installed set screw over the casting (7) in-board of the shifter shaft (1). 4. Tighten the set screw until light contact is made with the casting. Do not overtighten. 5. Re-install toe shift lever on the gear shifter shaft. Tighten the shifter retaining screw to 18-22 lb-ft (24-30 Nm) . 6. Install the set screw (5) into the outer gear shifter cover (4). 7. Install outer gear shifter shaft cover with installed set screw over the end of the gear shifter shaft (1). 8. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw. SERVICE PARTS

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YAMAHA XV1700 PCR/ XV1700 PCRC OWNER'S MANUAL

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

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High beam indicator light “” 2. Right turn signal indicator light “” 3. Fuel level warning light “” 4. Engine trouble warning light “” 5. Left turn signal indicator light “” 6. Neutral indicator light “” 1. Speedometer INSTRUMENT AND CONTROL FUNCTIONS 3-4 3 EAU04436 Tachometer unit The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. The tachometer unit is equipped with the following: ● an odometer (which shows the total distance traveled) ● two tripmeters (which show the distance traveled since they were last set to zero) ● a fuel reserve tripmeter (which shows the distance traveled since the fuel level warning light came on) ● a meter lighting control ● a clock ● a self diagnosis device NOTE: ● Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons. ● To switch the odometer, the trip- meters and the fuel reserve trip- meter displays between kilometers and miles, press the “SELECT” button for at least two seconds. ECA00123 CAUTION: Do not operate the engine in the tachometer red zone. If operated in the red zone, the tachometer segments will start flashing to notify the rider. Red zone: 5,000 r/min and above 1. Tachometer 2. Clock 3. Odometer/tripmeter/fuel reserve tripmeter 4. “RESET” button 5. “SELECT” button 1. Tachometer red zone
INSTRUMENT AND CONTROL FUNCTIONS 3-5 3 Odometer and tripmeter modes Pushing the “SELECT” button switches the display between the odometer mode”ODO” and the tripmeter modes “TRIP 1″ and “TRIP 2″ in the following order: ODO→ TRIP 1 → TRIP 2 → ODO If the fuel level warning light comes on (see page 3-2), the odometer display will automatically change to the fuel reserve tripmeter mode “TRIP F” and start counting the distance traveled from that point. In that case, pushing the “SELECT” button switches the display between the various tripmeter and odometer modes in the following order: TRIP F → TRIP 1 → TRIP 2 → ODO → TRIP F To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 3mi (5km). Meter lighting control mode 1. Turn the key to “OFF”. 2. Push and hold the “SELECT” but- ton. 3. Turn the key to “ON”, and then after five seconds, release the “SELECT” button. 4. Push the “RESET” button to select the desired brightness. 5. Push the “SELECT” button to set the brightness level. 6. Turn the key to “OFF”. NOTE: When adjusting the meter lighting, the odometer display will indicate the brightness level. Clock mode To set the clock: 1. Push the “SELECT” button and “RESET” button together for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and the minute digits will start flashing. 4. Push the “RESET” button to set the minutes. 5. Push the “SELECT” button and then release it to start the clock. NOTE: ● After setting the clock, be sure to push the “SELECT” button before turning the key to “OFF”, otherwise the clock will not be set. ● To set the clock after the battery has been disconnected, first set the time to 1:00 AM, and then set the clock to the correct time

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Harley-Davidson Motorcycle Services Changeout/ Set Up/ Maintenance/ Repairs

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Filed Under (Harley Davidson) by admin on 28-03-2012

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The Vendor shall use the custom wiring specifications from the current model year Harley-Davidson set ups. One fully outfitted 2005 model is being decommissioned and may be used as a model for 2006 set up. 2. Attach custom tray, rear box, and custom electronics box to rear mount. Rear box should be attached to the rear of the motorcycle using no more than four mounting holes. The rear box shall be adjusted to the officer assigned to the motorcycle by moving it forward or to the rear and by using spacers to elevate the box for saddlebag lid clearance. 3. Install custom brackets for radio, radar/lidar, flashlight and rear box tray. Brackets from changed-out motorcycles can be used on the new motorcycles and vendor shall modify or reinforce to correct metal fatigue as necessary to maintain functionality. 4. Install all components in the rear electronic box to facilitate repairs and maximize available storage space. These components include power source for cell phone, two-way radio, opticom power supply and auxiliary fuse panel. 5. Set handlebars, hand controls and position of rear tour pack to proper height and alignment for assigned rider. 6. A 5-sided box (base and 4 sides) metal frame is included in 2004 models and will be re fabricated into a 3- sided box (base and 2 sides) and painted black by the Vendor to match existing 2005 models. This arrangement shall allow for a full-size closed-face “Syncrotec” helmet to be stored in the rear tour pack in addition to mounted specialized equipment.

HARLEY DAVIDSON GEAR SHIFTER SHAFT COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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Models This kit fits 1982 and later Touring and FL Softail model motorcycles. Kit Contents Table 1. Kit Contents Part Number Description (Quantity) Not Sold Separately Gear shifter shaft cover Not Sold Separately Screw, set There are no Service Parts available with this kit. INSTALLATION 1. Remove the stock heel shift lever from the gear shifter shaft. 2. Install the set screw into the gear shifter shaft cover. 3. Install gear shifter shaft cover with installed set screw over the end of the gear shifter shaft. 4. Tighten the set screw until light contact is made with the shaft groove. 5. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw.

Kawasaki FI Calibration Tool Instruction Manual

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Filed Under (Kawasaki) by admin on 08-02-2011

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System Function Kawasaki FI Calibration Tool (FI Tool) is developed to modify the mapping of the racing machine to gain operating conditions suitable for the course and the rider’s skill. The following are the available setting functions. Table 1 FI Tool Function Model Name Functions Available Setting Range ’04 ZX-10R ’05 ZX-6RR ’05 ZX-10R ’06 ZX-10R ’07 ZX-6R 1) Adjust the injected fuel rate at acceleration -30 % ~ +30 % 〇 〇 〇 〇 〇 2) Adjust the injected fuel rate of No.1 and No.4 cylinder -30 % ~ +30 % 〇 〇 〇 〇 〇 3) Adjust the injected fuel rate of No.2 and No.3 cylinder -30 % ~ +30 % 〇 〇 〇 〇 〇 4) Adjust the injected fuel rate of primary and secondary injector * -30 % ~ +30 % -10 % ~ +10 % — – — 〇 — – — – — 〇 5) Adjust the ignition timing -15°CA~ +5°CA 〇 〇 〇 〇 〇 6) Adjust the sub-throttle opening angle -50 % ~ +50 % -45 % ~ +45 % 〇 — – 〇 〇 — 〇 — – 〇 7) Adjust the exhaust device opening angle -50 % ~ +50 % 〇 — 〇 〇 — 8) Adjust the all injected fuel rates of all cylinders and operating are a simultaneously -30 % ~ +30 % 〇 〇 〇 〇 〇 9) Adjust the value of engine over revolution limiter 0 ~ +300 rpm -1000 ~ +700rpm -1000 ~+1200rpm — – — 〇 — – — 〇 — – — 〇 〇 — – 10) Set the fuel cut or not at deceleration Use or Not Use 〇 〇 〇 〇 〇 11) Set the sub throttle controlled or not Controlled or Full Open Fixed 〇 — – — – 12) Set the exhaust device controlled or not Controlled or Full Open Fixed 〇 〇 〇 〇 〇 13) Set the Auto Shifter Ignition Cut Length Controlled or not, set Ig. Cut Time by gear range — – 〇 〇 〇 14) Set the Pit Road RPM Limit Controlled or not, set Upper Limit RPM by gear range

TRIUMPH 750 BIG BORE CYLINDER AND PISTON SET FOR 650 TWINS INSTALLATION

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Filed Under (Triumph) by admin on 29-10-2010

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Step 1. Unpack your big bore kit and inspect the contents. There should be the following: 1. Cylinder x l 2. piston with wristpin x 2 3. Hepolite piston ring set x l 4. Special big bore head gasket Step 2. Thoroughly wash the cylinder bores with soap and water. Do not use solvent! Dry bores with air or a lint free towel and let completely air dry. This step is most important and will greatly extend the life of the pistons. Step 3. Following the procedure outlined in your service manual, drain the fuel tank, remove the exhaust system, fuel tank and carburetors. Have a catch basin handy to capture any fuel that may spill from the carburetors, as fuel is highly flammable and can be ignited by a dryer pilot light etc. from a long distance. Clean up any spilled fuel immediately and dispose of away from any source of ignition. Store the fuel tank in a well vented area, outdoors is best, in the event your fuel taps should leak. Step 4. Remove the rocker boxes by slacking the 9 head bolts a little at a time in a star pattern. Remove the 6 nuts at the front and back of the head. Remove the 4 corner rocker box bolts. Remove the head bolts and rocker boxes. Remove the push rods. Examine the push rods to insure they are straight and the ends are tight. Replace any suspect push rod. Step 5. Remove the cylinder head. Now would be a good time for guide and valve renewal. This is best left to an expert. More cylinder heads have been ruined by auto machine shops than by hard use. If you do not have a qualified shop in your area please call for a referral. Step 6. Remove the push rod tubes and the cylinder base nuts. Clip rubber bands around the top of the lifters to keep them from dropping into the crankcase. Have a few lint free rags handy. Bring the pistons to the top of the stroke and begin lifting off the cylinder. If the cylinder is hard to lift off, thread a nut on one of the base studs and use a tire lever to pry against the bottom fin close to its base using the stud as a fulcrum. After partially raising the cylinder stuff the crankcase mouth with rags to keep any carbon or broken rings from entering the crankcase. These will remain in place until step 12. Step 7. Leaving the rags in the crankcase remove the wrist pin circlips from the pistons and discard. Heat the piston and gently push the wrist pin out. Do not use force as this can damage the connecting rod or its bearings. Be sure to account for all the clips as one left in the crankcase can do extensive damage. Step 8. Clean all gasket surfaces to remove any traces of the old gaskets. Use Pennatex gasket remover if needed. Be very careful not to scratch the gasket surface or to allow any gasket particles to enter the crankcase. Even a small bit of gasket can stop the oil pump from working! Step 9. Note the direction and location of the lifters. These must be replaced in the same position as when removed. Remove the lifter blocks from the old cylinder. Start by removing the small retaining bolts and washers. The lifter blocks are extremely fragile and are easily broken. They are also very expensive so great care must be taken in this step! Triumph special tool 222-616008 is advisable here. Apply pressure to the center of the block only. Do not press against the tangs that locate the lifter! A tool can be fabricated using two dowels to locate in the lifter holes. Step 10. Clean and examine the lifters and camshaft faces. Clean the lifter blocks and remove the sealing oring under the locating flange. Replace these with the new orings in the gasket set. Apply a smear of gasket sealant to the lifter block oring and press into the new cylinder. Be sure the lifter block is parallel with the bores and the grooved block is on the exhaust side. Apply a small amount of assembly oil to the lifters and replace in the exact position they came from

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Ready to Run 1/ 5-Scale Brushless EP Motorcycle

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

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STABILIZER BAR INSTALLATION 3x8mm BH Screws ASSEMBLE THE BIKE STAND  Slide off the batttery tray door and install four “AA” batteries. Make sure the polarity is correct.  Turn on the transmitter and check the battery light. If the red light glows steadily, the batteries have enough voltage. If the red light blinks, the batteries are low and should be replaced.  Raise the antenna at the top of the transmitter. RED BATTERY LIGHT  The receiver should be factory bound to the transmitter. However, if you ever need to bind, follow these steps: 1. Turn on the transmitter. 2. Turn on the receiver via the switch on the ESC. If the receiver is not bound, the LED light will not be on. 3. Push and hold the bind button on the receiver until the light glows red. 4. Release the bind button. 5. If the binding is successful, the LED will fl ash once and then remain ON. 2. Make sure the collar is mounted on the center of the bar and tight the set screw. 3. Bend the rod and insert the ends into the bike. 4. Secure the bar to the bike using set screws. 1. Slide the metal collar onto the stabilizer bar. 4x4mm Set Screw (use threadlock) 3x3mm Set Screw (use threadlock) 4x4mm Set Screw (use threadlock) 4x4mm Set Screw (use threadlock) 4x4mm Set Screw (use threadlock)

2004 CBR 1000RR CYLINDER HEAD COVER INSTALLATION

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Filed Under (Honda) by admin on 17-12-2011

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COLOR TABLE MARCH, 2004 ©2004 American Honda Motor Co., Inc. 9 When ordering a colored part: 1. Confirm the color code for the required part from the color table according to the part name and color type. 2. Select the corresponding part number from the appropriate PAGE/GRID. 3. Parts marked “X” are unused. 4. “*” = Basic Part Number, no extension (i.e. ZA, ZB). CBR1000RR’04 2004 No. COLOR CODE BASE COLOR NH1 Black NH1 R258B Winning red R258 NH411B Force silver metallic NH411M A R E A DESCRIPTION BASIC PART NO. 1CLIP, PANEL FIXING 91549-MW0-790 ZA ZA ZA 2COWL (UPPER) 64211-MEL-000 ZA ZB ZC 3COWL SET, L. (LOWER) (WL) 64450-MEL-670 ZF ZG ZH 4COWL SET, L. MIDDLE (WL) 64350-MEL-670 ZA ZD ZE 5COWL SET, R. (LOWER) (WL) 64400-MEL-670 ZF ZG ZH 6COWL SET, R. MIDDLE (WL) 64300-MEL-670 ZA ZD ZE 7COWL SET, RR. SEAT (WL) 77210-MEL-010 ZE ZF ZG 8FENDER, FR. 61100-MEL-000 ZA ZC ZB 9FRAME 50100-MEL-670 ZAZAZAA 10 FRAME 50100-MEL-770 ZA ZA ZAAC 11LABEL, COLOR 87565-MEL-000 ZD ZE ZF 12MARK, COWL (LOWER) 64819-MEL-000 ZD ZE ZB 13MARK, L. TOP SHELTER 64852-MEL-000 — ZA ZC 14MARK, L. TOP SHELTER 64856-MEL-000 ZA — — 15MARK, MIDDLE COWL 64811-MEL-000 ZA — — 16MARK, R. TOP SHELTER 64851-MEL-000 — ZA ZC 17MARK, R. TOP SHELTER 64855-MEL-000 ZA — — 18MARK, RR. SEAT COWL 64841-MEL-000 ZA ZB ZD 19MARK, RR. SEAT COWL 64842-MEL-000 ZA ZB ZD 20RAIL ASSY., SEAT 50200-MEL-010 ZA ZA ZA 21SHELTER SET, TOP (WL) 83150-MEL-670 ZA ZD ZE 22STRIPE A, L. MIDDLE COWL 64814-MEL-670 — ZC ZA 23STRIPE A, R. MIDDLE COWL 64813-MEL-670 — ZC ZA 24STRIPE C, L. MIDDLE COWL 64817-MEL-670 — ZA ZB 25STRIPE C, L. MIDDLE COWL 64818-MEL-670 — ZA ZB 26STRIPE, L. TOP SHELTER 64854-MEL-000 — ZB ZB 27STRIPE, R. TOP SHELTER 64853-MEL-000 — ZB ZB 28STRIPE, WINDSCREEN 64805-MEL-000 ZA ZA ZA 29WHEEL SUB-ASSY., FR. 44650-MEL-000 ZA ZA ZA 30WHEEL SUB-ASSY., RR. 42650-MEL-010 ZA ZA ZA 31WINDSCREEN SET 64250-MEL-000 ZA ZA ZA

Edelbrock Nitrous Systems Digital RPM Window Switch USER MANUAL

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Filed Under (Harley Davidson) by admin on 31-10-2010

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Programming the RPM The engine application and rpm activation points are easily selected through push buttons on the LED panel. This Switch can be programmed for a variety of engine and ignitions as shown below. 1-Cylinder This program is used for individual coil per cylinder systems (such as GM LS-1 engines, or ’99-Up Mustangs) 2-Cylinder This is for ignitions with coil packs that fire two cylinders at the same time (waste spark systems) 2-Cyl. Odd Use on coil pack ignitions that are on odd-fire engines such as a Viper V-10 or Harley-Davidson motorcycle. 4-Cylinder Typical 4-cylinder engines with a distributor. 6-Cylinder Typical 6-cylinder engines with a distributor. 6-Cyl. Odd Typical 6-cylinder odd-fire engines with a distributor. 8-Cylinder Typical 8-cylinder engines with a distributor. 1.2 Push Button LED Panel The rpm activation points and cylinder select are programmed through the push buttons on the LED panel (Figure 1) . Press the Mode button, and notice that the indicator point above the On RPM lights. When that point is on, you can scroll the rpm value up or down with the arrows on the left of the panel. Once your On rpm is set, push the Mode button until the Off RPM point lights, then set the off rpm point. Note that if the rpm point is not changed within 2-seconds, the screen returns to the current rpm reading (zero when the engine is not running). After setting the On and Off points, press the Mode button to program the Cylinder Select Valve (default is for 8-cyl.

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