User guide

ManualsBrandsS&S Cycle ManualsFor motorcyclesEFI Wire Harness for Custom Frame Applications Using S&S Fuel Injected Engines and Delphi Style Modules

S&S

Cycle, Inc.

235 Causeway Blvd.

La Crosse, Wisconsin 54603



Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

Assembly Installation Instructions for S&S® EFI Wire Harness

for Custom Frame Applications Using S&S Fuel Injected

Engines and Delphi® Style Modules

Because every industry has a leader

IMPORTANT NOTICE:





WARNING



CAUTION



NOTE





WARRANTY:

            

















     

            

    













ADDITIONAL WARRANTY PROVISIONS:











           

       





 





SAFE INSTALLATION AND OPERATION RULES:







 





           

         



 





         

      







 

  



        

           

         



 

         





           

           



DISCLAIMER:





    

  















         





Instruction 106-2031

8-26-08



 





Summary of content (16 pages)

PAGE 1
8-26-08 S&S Cycle, Inc Copyright © 2008 by S&S® Cycle, Inc. Phone: 608-627-1497 • Fax: 608-627-1488 Instruction 106-2031 ® . All rights reserved. Printed in the U.S.A. 235 Causeway Blvd. La Crosse, Wisconsin 54603 Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.
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WARNING The safety of the motorcycle rider is dependent on proper installation of this product. If you are not certain of your capabilities or do not have the correct tools for this installation, please consult a shop to have it done for you. Improper installation of this product could result in injury or death to the rider. WARNING Do not connect the battery until told to do so in these instructions.
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Closed Loop A closed loop exhaust monitoring system is not only critical to fuel economy on fuel injected motorcycles but also to engine performance. A closed loop system operates with the goal of achieving performance gains for a motorcycle by reading oxygen sensors (not included) mounted in a motorcycle exhaust stream. The oxygen sensors in turn tell the ECM to deliver more or less fuel to the engine depending on throttle position and engine load.
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A. LAYING OUT THE S&S® EFI WIRE HARNESS WARNING Take special care not to route the wire directly over areas prone to reach high temperatures. Failure to do so may result in damage to your wire harness and other motorcycle electronics which can result in costly repair and service fees. WARNING Do not connect the battery until told to do so in these instructions. Failure to do so may result in damage to your wire harness and other motorcycle electronics which can result in costly repair and service fees.
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CAUTION Knock sensor must be mounted to the rear cylinder or rear top motor mount. Mounting the knock sensor on the front cylinder will provide an incorrect signal. 1- Knock sensor mounting at Location 1: Rear cylinder head A. Remove the plug from the knock sensor mounting location in the rear head (if present). B. Insert the 5/16” x 1 ½” coarse thread bolt through the 5/16” lock washer, knock sensor, and ¼” thick spacer. C.
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C. OXYGEN SENSOR INSTALLATION CAUTION Some machining and welding is required for this installation. If you are not comfortable with either procedure, please take your motorcycle to an S&S® certified facility for the work. WARNING Do not connect the battery until told to do so in these instructions. Failure to do so may result in damage to your wire harness and other motorcycle electronics which can result in costly repair and service fees.
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CAUTION If the exhaust mounting flanges are installed on the head pipes, make sure the flange is above the hole before you weld in the oxygen sensor boss. Picture 4 6- Weld the boss in place using stainless-steel filler rod. When it cools, run a M18 x 1.5 tap through the boss to verify that the threads were not damaged or distorted during the welding process. Picture 5 7- Install the oxygen sensors in each pipe and torque them to 30-44 ft-lbs.
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D. INSTALLING CONNECTORS NOTE: In order to crimp terminals onto the wire leads of the additional components you plan to use on your motorcycle, you will need a Deutsch® crimping tool or equivalent. Since there are two types of terminals supplied with the S&S® EFI wire harness for the Deutsch connectors, two Deutsch crimpers will be needed. The terminals, which are DTM and DT type, should not be interchanged.
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- Next, pull approximately three inches of the components wires through the seal and strip off the top insulation of each wire to about .200” (5mm). See Picture 7. Picture 7 10- Place a single terminal that mates with the intended S&S® EFI wire harness terminal inside the Deutsch® crimper tool, taking special care not to crimp the terminal until the wire is installed. NOTE: Proper crimping of the terminals is necessary in order for the component to operate to its full potential.
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WARNING Failure to correctly match the component wires with the correct wires on the S&S® EFI wire harness may result in permanent damage to the component or the S&S EFI wire harness when power is supplied to the assembly. Please take special care when identifying wire colors and where they should go. If in any doubt, consult a professional at a shop with the component instructions and the wiring diagram supplied with your S&S EFI wire harness. Improper installation could result in injury or death.
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E. CONNECTING THE BATTERY WARNING This is the last step of installing your S&S® EFI wire harness. Until now S&S recommended to not connect the battery until told to do so in these instructions. Failure to do so may result in damage to your wire harness and other motorcycle electronics which can result in costly repair and service fees.
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Picture 14 12
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Picture 15 14
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Because every industry has a leader 16