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Suzuki GSX-R 1000 AFR Tuner INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 20-02-2012

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The installation of the AFR Tuner should be done by experienced technicians only. Always disconnect the battery from the motorcycle before making any modification to the wiring harness. Remove the negative terminal from the battery before starting the installation work. The quality of the installation work greatly affects the reliability of the AFR Tuner and the motorcycle. Work precisely and very carefully when modifying the wiring harness of the vehicle. Always double check that the wire you are about to cut or tap into is the correct one. The ECM or the AFR Tuner can be destroyed by a faulty installation. 3.2. Installing the AFR Tuner to the wiring harness 3.2.1. Main cable The AFR Tuner connects to the motorcycle through its Main connector . Figure 2 shows the wiring diagram and the necessary modifications, which needs to be made when installing the unit into the fuel injection system of the motorcycle. Information about the ECM terminal numbers and wire colors for some popular motorcycles can be found in Chapter 6 . The best location for installing the AFR Tuner main unit is at the passenger seat area of the motorcycle mounted in the trunk space or on the subframe under the fairing, as this place provides protection from engine heat and the weather. Electrical contact between the metal casing of the AFR Tuner and the rear subframe must be prevented by using insulating material, such as the included self adhesive velcro strips. If necessary use some cable ties to secure the unit in place. The installation of the AFR Tuner into the wiring harness involves tapping into some wires and cutting others while connecting the two ends to the AFR Tuner. The harness modifications are best done near the ECM, since most of the wires can be found there. Part of the wiring modifications are related to connecting the AFR Tuner in-line between the ECM and the fuel injectors. In such cases when the motorcycle is equipped with primary and secondary injectors the AFR Tuner has to be installed on the primary injectors, which operate under all engine conditions. Correct grounding of the AFR Tuner is very important for electrical noise reduction. The above mentioned insulation of the metal case from the motorcycle frame is necessary for the same reason, which is to avoid the forming of a ground loop. An even more important requirement is the correct connection of the three ground wires of the AFR Tuner. As shown on Figure 2 , these three wires must be led out separately to the ECM and connected together at same point where the ECM ground wire is tapped into. This point should be as close to the ECM terminal as possible. For best quality of the electrical contacts all connections should be done by soldering and covering the exposed part of the wire with heat shrink tubing. For reliability reasons do not use clip on type wire taps

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 110 (1800 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery cables, negative (-) battery cable first. 3. Remove seat according to the instructions in the service manual. 4. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 5. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. 2. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. 3. Remove engine from chassis following the instructions in the service manual. 4. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. 5. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). 1. Remove cylinder studs from the engine crankcase. 2. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. 3. Inspect and clean engine case mating surfaces. 4. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. 5. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). 6. See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase

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KTM 990 SUPER DUKE 950 SUPERMOTO 950 SUPER ENDURO REPAIR MANUAL

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Filed Under (KTM) by admin on 22-11-2010

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Adjusting the position of the compression and rebound damping Rebound damping: -Turn in the adjusting screw 1 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, low speed: -Turn in the adjusting screw 2 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Compression damping, high speed: -Turn in the adjusting screw 3 in a clockwise direction all the way to the stop. -Turn back the respective number of clicks in a counterclockwise direction. Adjusting the spring preload NOTE: the spring preload is the difference between the unloaded and preloaded length of the spring. -Tighten the adjusting nut 4 with the special tool T106 until you have the prescribed spring preload. -Tighten the lock screw on the adjusting nut Disassembling the shock absorber -Write down the spring preload. -Write down the rebound and compression damping settings, counting the clicks or number of turns while turning in a clockwise direction. -Unscrew all of the adjusting screws in a counterclockwise direction. -Clamp the upper part of the shock absorber in a vise as shown in the photo, using protective jaws. -Loosen the lock screw 1 (AH 4 mm), loosen the adjusting nut 2 using the special tool T106 3 and relieve the spring. NOTE: mark the position of the lock screw. -Press the spring down with the special tool T101S and pull out the spring retainer 4 . -Remove the washers 5 and spring 6 . 4-2 Repair manual WP Shock absorber 990 Super Duke, 950 Supermoto, 950

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HARLEY DAVIDSON SCREAMIN' EAGLE TWIN CAM 103 (1690 CC) CONVERSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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REMOVAL When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 1. Remove maxi-fuse. Refer to MAXI-FUSE INSTALLATION in Service Manual. 2. Remove existing air cleaner assembly. Discard filter element, backplate, and air cleaner cover insert but save remaining parts. Refer to AIR CLEANER REMOVAL in Service Manual. 3. Remove existing exhaust system. Discard mufflers but save remaining parts for kit installation. Refer to EXHAUST SYSTEM REMOVAL in Service Manual. 4. Remove engine from chassis following the instructions in the Service Manual. 5. Remove induction module. Refer to appropriate FUEL INJECTION section in Service Manual. 6. See Figure 1. Remove and save screw (with pilot sleeve) to release fuel supply tube clamp. is03165 Figure 1. Fuel Supply Tube Clamp Screw 7. See Figure 2. Pull fuel supply tube (1) from fuel rail. -J03825 1 of 10 1 2 3 3 4 is03166 1. Fuel supply tube 2. Sealing washer 3. O-ring 4. Screw (with pilot sleeve) Figure 2. Fuel Supply Tube Assembly 8. Remove sealing washer (2) and O-ring (3) from fuel supply tube. Remove second O-ring (3) from fuel rail bore. Discard sealing washer and O-rings. 9. See Figure 3. Pull fuel injectors (1) with attached fuel rail from induction module. To overcome the resistance of the bottom O-ring (2) on both fuel injectors, gently rock assembly back and forth while pulling. 10. Remove spring clips (3) from fuel injectors. Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring (4) on both fuel injectors, gently rock assembly back and forth while pulling. 11. Disassemble engine top end, engine bottom end, crankcase, and crankshaft. Refer to appropriate ENGINE sections in Service Manual. 1 2 4 3 is03167 1. Fuel injector 2. O-ring, bottom 3. Clip, spring 4. O-ring, top Figure 3. Fuel Injector Assembly INSTALLATION Inspect Cam Clearance A clearance problem between the new cam lobe and crankcase housing may exist on certain older model engines. Failure to maintain proper clearance could result in severe engine damage. (00391b) 1. See Figure 4. Prior to starting assembly procedures, insert new cams from kit into inner needle bearings (1) located in the right side crankcase and check for a minimum of 0.030 in. clearance between highest lift point of cam lobes and crankcase housing (2) with feeler gauges. NOTE If inadequate clearance is detected, crankcase housing must be machined to provide 1.060 in. Radius clearance from center of each cam bearing bore. After machining, recheck for minimum of 0.030 in. clearance

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AJP PR5 USER MANUAL/ OWNER'S MANUAL

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Filed Under (Ajp) by admin on 12-12-2010

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DIGITAL SPEEDOMETER The digital speedometer is not available for the MX and MX PRO versions. It gives information about instantaneous speed and total or trip distance travelled. Depending on the selling market, speed and distance are indicated in Kilometres or miles. If you want to switch between these units, please contact your AJP dealer. To switch from total to trip distance push button 1. To reset trip distance the trip distance must be selected; then push button 1 until the distance is reset to zero. LEFT HANDLEBAR 1 – Clutch lever The clutch lever is used for disengaging the drive to the rear wheel when starting the engine or shifting the transmission gear. Squeezing the lever disengages the clutch. 2 – Parking light on With the light knob in this position, parking lights in the headlight and taillight will be switched on. 3 – Lights off In this position, no lights will be switched on. 4 – Low beam on In this position, low beam light will be on in the headlight and presence light will be on in the taillight. 5 – High beam on In this position, high beam light will be on in the headlight and presence light will be on in the taillight. 6 – Turn sign on Turning this button left left turn lights will be on. Turning right, right turn lights will be on. To switch turn lights off, place the button in middle position. 7 – Horn To actuate horn, press this button

HARLEY DAVIDSON FXD (Dyna Super Glide) TACHOMETER KIT INSTALLATION MANUAL

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

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1995 Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1.1995 MODELS, REMOVAL OF ELECTRONIC SPEEDOMETER AND BRACKET 1a. Refer to applicable Service Manual procedure and remove seat. 1b. Refer to applicable Service Manual procedure and remove fuel tank. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 1c. Remove speedometer sensor cable from mounting clips under tank. See Figure 1. The 3-place speedometer sensor connector [65] is located on the frame beneath the seat. Remove connector from t-stud and disconnect. Cut cable tie holding sensor wires to right rear frame tube. 1d. Refer to applicable Service Manual procedure and remove headlamp, for work clearance. 1e Remove handlebar clamp screws securing speedometer bracket. Remove speedometer, bracket, and harness. 2.1995 MODELS, DISCONNECT MAIN WIRING HARNESS 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 2a. Disconnect the battery, negative cable first. Refer to applicable Service Manual procedure and disconnect main wiring harness 8-place connector [21A, B], at the front of the motorcycle. 3.1995 MODELS, REMOVE SPEEDOMETER LEADS FROM 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 3a. See Figure 2 and Service Manual wiring schematic. Pull the following wires and terminals out of connector [21B]. Wire Color Cavity Number Orange/white 5 White/green 1 Black 2 3b. Remove the large female connector from the fuel gauge black wire. 3c. Slide the wires removed in step 2a out of the plastic conduit covering the wires connected to the 8-place connector. 1 WARNING 1 WARNING 1 WARNING Figure 1. Speedometer Sensor Connection [65] 4973 Speedometer sensor connector [65] Figure 2. Tachometer/Speedometer Wire Splices and Terminal Connections [21B, A] i00240-.tif Splices 4.1995 MODELS, REMOVE INDICATOR LAMPS FROM BRACKET 4a. Remove the screws that secure the indicator lamps assembly to the speedometer bracket. Retain screws and indicator lamps assembly for installation on speedometer/tachometer bracket later. 5.1995 MODELS, REMOVE SPEEDOMETER FROM BRACKET 5a. Unscrew boot from speedometer reset switch. Remove cover screws and rear cover. 5b. See Figure 3. Note position of rear speedometer gasket and remove it. Push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket. Do not remove front gasket from the speedometer. 6.1995 MODELS, INSTALL SPEEDOMETER IN KIT BRACKET 6a. See Figure 5. Place wires from speedometer through front of left opening in double bracket. Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation. 6b. Insert speedometer into the front of the double bracket. Be sure wire guides are aligned with opening at bottom of bracket. 6c. Place rear gasket in position and align gasket tabs. Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into position at the opposite side. 6d. Add amber bulb assembly from kit to speedometer in order for tachometer and speedometer backlighting to match. 6e. Replace cover and boot from reset switch.

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HARLEY DAVIDSON VRSC CHROME WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. 4. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the 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) 5. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. 6. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. 4. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the 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) 5. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. 6. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84

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SUZUKI GSX-R1000 SERVICE MANUAL

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Filed Under (Suzuki) by admin on 12-11-2010

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Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. 5. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft) ! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. ! Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.

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HARLEY DAVIDSON SCREAMIN' EAGLE BILLET CAM SUPPORT PLATE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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REMOVAL NOTE For removal, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the Maxi® fuse. 2. Remove the cam cover and gasket. 3. Remove and discard the crank and primary cam sprocket flange bolts and washers. 4. Release the oil pump, and remove the cam support plate and cams. Disassemble the cams from the support plate and discard the support plate. 5. Inspect cams, chain, sprockets, oil pump, chain tensioners and guide for wear and replace as needed. Refer to the Service Manual for inspection and replacement proce- dures. -J04503 INSTALLATION NOTES For installation, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. See Figure 1. When installing Screamin’ Eagle camshaft kits, install the O-ring included in this kit over the splined shaft of the rear camshaft as shown. 1. Using the Camshaft Assembly Tool (HD-47956) and assemble the camshafts, chains and tensioners to the billet cam support plate. 2. Install the cam support plate assembly into the crankcase. 3. Using the Crankshaft/Camshaft Locking Tool (HD-47941), install cam sprockets, chain and tensioner. 4. Install cam cover and gasket. 5. Install Maxi fuse.

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HARLEY DAVIDSON SCREAMIN' EAGLE PERFECT FIT PUSHRODS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the service manual and follow the instructions given for disassembling the motorcycle for service and to gain access to the top end overhaul disassembly of seat, rocker cover, breather assembly, rocker arm support plate and pushrods. 2. Place the motorcycle on a center stand with the rear wheel raised off the ground. Remove the spark plugs. 3. With the transmission in gear, use the rear wheel to turn the engine over until both front cylinder tappets are at their lowest point. Remove and discard the pushrods. 4. Install the new pushrods into the pushrod covers using the appropriate service manual procedures. Be sure the larger end of the tapered pushrods are installed to the tappet sockets. 5. Repeat step 4 for the rear cylinder. NOTE Check for contact between the pushrods and the upper pushrod covers. Check by rotating the engine slowly until both valves have fully opened and closed on the cylinder you are checking. If contact is observed, the rocker arm supports should be shifted toward the engine’s cam side. 6. Complete all the appropriate service manual procedures for assembling the engine. 7. Complete all service manual procedures for the assembly of the motorcycle. 8. Return the transmission to neutral and install the spark plugs. 9. Connect the negative (-) battery cable. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 10. Install the seat

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