2005-2007 FL models - Revolution Performance
Contents
1. necessary to ensure a good connection Step 12 Route the front 02 sensor wires from the Revolution Performance Precision EMS along the bottom of the frame rails and plug it into the front 02 sensor On 07 models also route the feed back wire from the EMS with the 02 sensor wire and plug the feedback wire into the factory 02 sensor plug on the vehicle wiring harness Make sure that these wires are secured tightly to the lower frame rail of the vehicle and that the wires route on top of any frame braces so that they cannot come in contact with the ground Step 13 Route the wire from the rear 02 sensor back to the left side of the Revolution Performance Precision EMS and plug in the connector On 07 models route the rear feedback wire through the frame and plug the connector into the stock wiring harness Secure all wires as pictured in the photo Step 14 Install the maxi fuse and switch the vehicle to the run position Verify that both sensor lights on the control box are flashing slowly After 30 seconds the lights will either flash rapidly or be solid on Place a screw driver on the calibration screw and adjust it so that the light has just turned from flashing rapidly to steady on Repeat this for cylinder 2 Step 15 Reassemble side covers and saddlebags and install your seat Step 16 Start your vehicle Let it idle up to operating temperature at least 5 minutes Try not to blip the throttle unless necessary to2. Engine Management System 604 001 INSTRUCTIONS For 2005 2007 Harley Davidson FL Models Revolution Performance was founded with two major goals in mind to go that extra mile providing a superior level of customer service and support in the V Twin performance industry and to provide an outlet for a complete line of performance components and services for Harley Davidson Evo Big Twin and Twin Cam 88 as well as Buell American Motorcycles Revolution Performance carries a full line of aerospace aluminum alloy cylinders for Harley Davidson and Buell American motorcycles as well as a complete inventory of performance components to make your package work together The staff at Revolution Performance brings a great deal of engine development experience to the table not only in several disciplines of professional racing but in street applications as well From the individual who wants a one stop shop for all his performance component needs to the shop owner seeking a reliable supplier of parts and services we are here to help We also have a long history in professional race team support so we can not only assist in your R amp D efforts but with our manufacturing capabilities we can make your ideas reality with the utmost in security We use our expertise to help OEMs produce better racing components as well as parts that make it to the street We work closely with premier engineers at Harley Davidson on many of their projects and ou
3. gs installed in it simply install the provided 02 sensors and omit steps 4 through 6 Step 4 If your vehicle is not equipped with 02 bungs they will need to be installed The ideal placement for the sensors is 6 to 8 inches from the exhaust port on each cylinder The bungs should be installed so that the 02 sensor inclination is between horizontal and vertical This allows water that naturally condenses in a cool exhaust system to drain out of the sensor and prevents sensor damage from occurring The easiest way to locate the sensor on the pipe is to partially thread the sensor into the bung and hold it up to the exhaust to check for clearance Once a good spot has been found use a permanent marker to outline the bung and mark it for welding Photos illustrating ideal placement on both the front and rear pipes are shown above Step 5 Remove the exhaust system from the vehicle Drill holes for the 02 sensors at the locations marked in step 4 Make sure that the holes are large enough that the snout of the sensor can stick into the exhaust stream without contacting the sides of the hole Weld the sensor bungs to the exhaust system After the exhaust system has cooled carefully thread each sensor into the bungs If the sensor does not thread in easily after welding a M18 X 1 5 spark plug thread chase commonly available at auto parts stores may be used to clean the threads Step 6 Reinstall the exhaust system New exhaust gaskets shou
4. keep the engine running The vehicle may run poorly initially until the Revolution Performance Precision EMS finds the correct parameters for your engine You will notice that after several minutes your vehicle will Tun increasingly better After your vehicle is at operating temperature shut it off 10 Step 17 Gear up and go ride Your vehicle is now equipped with the finest dynamic fuel injection controls available It will optimize as you ride and grow with you as your bike does As equipped it will self compensate for minor changes in intake and exhaust configurations heads and cams The ECU functions like normal and your vehicle can be serviced by any dealer Want to perform significant modifications to your motor No problem simply download a new customer information form from the Revolution Performance web site www revperf com and send your ECU and form to us For a small fee we will update your ECU for the new engine and you are good to go Your bike will tune itself NO Dealer NO DYNO NO PROBLEM E BEVOLUDIO PERFORMANCE Revolution Performance 1312 Pilgrim Road Plymouth WI 53073 Toll Free 1 866 892 2109 Phone 920 892 2109 Fax 920 893 4830 info revperf com www revperf com 2010 Millennium Technologies All rights reserved Harley Davidson Buell Twin Cam Evolution and Big Twin are registered trademarks of Harley Davidson Inc RP0008 VA 8 9 2010
5. ld be used at the ports to reduce the chance of leaks that could affect the 02 sensor performance Make sure that all potential leaks at slip joints in the pipes are sealed orange 02 sensor safe silicone may be used Now install and tighten the 02 sensors 707 model motorcycles omit steps 7 through 9 Step 7 Locate the ECU connector on the right side of the vehicle Using a small flat blade screwdriver depress the locking tab on the side of the clear portion of the ECU connector Pull on the clear portion of the connector to remove it from the connector body see photo above Separate the back of the connector body halves by inserting the blade of the screwdriver between them and prying the 2 halves apart see photos on next page Step 8 Remove the blue seal pins from the back of the ECU connectors at locations 8 amp 23 by prying them up with a screwdriver and using a pliers to pull them from their sockets Locate the Revolution Performance Precision Controller and insert the white wire from the controller into hole 8 and the blue wire into hole 23 Make sure the pins are fully seated When this is accomplished reinstall the clear plastic cover over the end of the ECU connector note Make sure all pins are seated If the clear cover will not slide on and lock in place easily there is a pin out of place Step 9 Locate a blue easy turn wire connector from the Revolution Performance Precision kit and disas
6. or bung will cause the product to malfunction If you are not comfortable in the ability to get an air tight weld please have the sensors welded to your pipes by a qualified welder Details about sensor placement prior to welding can be found in step 4 Revolution Performance can supply 02 sensor bungs for a nominal fee Please contact Revolution Performance if 02 bungs are needed Before beginning installation verify that all necessary components have arrived The kit should include Control Box Wide Band 02 Sensors Easy Turn Wire Connectors 2007 models only have 1 connector ECU Shipment Box Customer Information Data Sheet Step 1 Remove the seat saddlebags and side covers from your vehicle Refer to your owners or service manual for details i fuse and ECU from your vehicle Refer to your owner s or service manual for details Step 3 Fill out the customer information sheet This sheet needs to be filled out as completely as possible Your VIN number needs to be written on the sheet or the sheet will be returned to you so that the VIN may be completed Be sure to include your return address and a phone number where you may be reached When completed fold your information sheet up and pack it into the mailer preaddressed and posted to Revolution Performance with your ECU and send it in the mail Your ECU will be processed and in several days you will receive your ECU back If your exhaust system already has 02 sensor bun
7. r customers receive that same level of dedication Our commitment to providing the best components and customer service in the industry is a basis for everything we do so that the customer can meet any realistic performance goal that they set for themselves HD Tuner Installation Instructions for 2005 2007 FL Models Revolution Performance LLC makes no claims to the suitability of this product for your motorcycle Use of this product may void the manufacturer s warranty and may void federal emissions compliance of your vehicle This product is intended for closed course racing use only Use of leaded fuels will significantly shorten the life of 02 sensors and may over time cause poor vehicle performance It is suggested that if leaded fuels are being used that the 02 sensors be changed every 10 hours of vehicle operation to ensure peak performance Installation of this performance Kit requires a moderate level of vehicle mechanical knowledge If you feel that you may not be capable of the safe installation of this product please contact your local service provider for professional assistance Installation of this product on your motorcycle requires an exhaust system with 02 sensor bungs installed You may either upgrade your exhaust system to a 07 system that would have the sensor bungs already installed in it or weld 02 bungs into your system If welding is required it is critical that the welds be air tight An air leak at the sens
8. semble the connector Using a razor knife slice 4 of wire harness sheath back at the ECU connector to expose some wire length Locate the black wire with the White stripe coming from pin 26 on the ECU connector Place the U portion of the easy turn connector around this wire and screw the connector body together Insert the single black wire from the Revolution Performance Precision EMS through the cap of the connector and twist it tight to make a secure connection When this is accomplished use zip ties to secure all wires and sheath in place Step 10 Reinstall your ECU Connect the ECU connector and secure the Revolution Performance Precision EMS to the ECU as pictured in photo A above Route the red power wire from the Revolution Performance Precision EMS under the seat and over to the left side of the motorcycle Remove the fuse block from the motorcycle and locate the headlight circuit usually a blue wire Using an easy turn wire connector attach the power wire from the EMS to the headlight circuit Using zip ties neatly secure the wires making sure to provide strain relief for the new power wire Step 11 Secure the ground ring terminal from the Revolution Performance Precision EMS to the factory grounding lug in the backbone of the frame On 2005 and 2006 models use a 34 20 bolt Ye in length and attach the ground wire to the pre threaded hole in the backbone of the frame Scratch paint away from ground wire if
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