Have a 2008 SG originally with 96 motor upped to 110 by dealer at time of purchase.

Having trouble starting the bike. Tested both my ACR's with an ohm meter and found the front cylinder is not working. Purchased a new ACR and am ready to replace it.

Does anyone have a copy of the ACR replacement bulletin? My shop manual does not cover ACR's as it was not part of the 2008 bike line.

I have tank off, rocker cover off and also the special tool to remove and install the ACR.

 

hi,

just unhook connector, unscrew ACR, screw new one in, plug connector back in and off you go

just like putting spark plug in
thanks
mirrmu

 

Much appreciated. I was hoping someone had the shop bulletin that would have come with the procedure.

Could not wait any longer, so just dove into the job. Its pretty easy, a little intimidating to the novice I wold think but on a scale of 1-10 for difficulty I would say its a 4. Here is what I did.

Prepare fuel tank to remove, this is actually very easy, two bolts, some wires, lift the sucker off.

 

Having the tank off one can see the engine rocker tops very easy now.. So the next thing is to remove the rocker cover. Its just bolted on, remove the fasteners and now your into the top rocker of the engine.





Ok that was very easy, you might have to use a screw driver and some leverage too break the gasket seal,I did on mine and did not damage gasket either.

So I was sad to see that the ACR was still not accessible to me, so we ned to go deeper. In the middle of the exposed power unit you can see a plate which I was hoping could be removed to expose the ACR, BUT it actually is the breather, so go ahead and pull that cover plate off, then next pull the 4 bolts holding the Rocker assembly on as well.


I did not get a pic of just the rocker assembly but it comes off as a unit. Next pry the (intermediate) or rocker plate off.


AHA, now I can see the ACR, yay

 

Here is another shot of it


Here is it removed and comparing with new one


I made my own removal and installation tool, you can buy one from the dealer for a reasonable price, the job CAN NOT be done without one! I highly recommend buying one. I made my own but found the socket would spread out at the bottom as I was tightening it, I just macgivered a way to make it work but for the $40 I would buy one next time.


Cleaned up the hole in preparation to re-install


Put the ACR in place and re-assembled in reverse of the removal..

SUGGEST, you have a shop manual, socket to remove and install ACR, thread locking paste (Locktight BLUE), torque wrench and about 2 hours time.
I reused my gaskets, they were fine, I used a gasket product on them after I cleaned them up, BUT if your in buying the ACR and socket why not grab the 3 gaskets you need.

One thing I did not mention, (I got lucky and the engine was on a down stroke for that cylinder, pull your spark plugs put the bike in gear and turn the engine over til the valves are closed on the cylinder your working on so that the rocker assembly will drop into place without having to tighten it down against the valve springs.
ACR torqued to same as the spark plug spec.
ACR -12-18 foot-lbs

Follow your manual for torque values and tightening sequence. Hope this helps a little.

 

hi,

good write up, well done, my apologies on that first reply

yeah pretty easy to make ACR socket, if going to shop its a good buy

you soon see how simple a machine they are

thanks
mirrmu

 

Hi NiteOwl
Having trouble with my bike starting suspect ACR's are not working how did you di the ohm test on the ACR's

 

Up above the throttle body, between the cylinders, you will find two plugs, one going to after cylinder and one to the front cylinder. Unplug each separately and put your ohm meter across the two terminals leading to the cylinder head, (ACR is at the other end). If there is continuity the ACR should be good, if not, then you must replace.

 

Ok thanks will check to see if there is continuity on them both.