Instruction manuals are always a good way to explain the way things should work. (i.e. plug in the battery, turn on the switch, power comes on). Problems will get lost in instructions because problems don't happen to everyone. The instructions should be the "best case scenario, if everything goes smoothly."

I like the troubleshooting section idea. Then a person can say, "I followed the instructions, now it does or doesn't do this...". Regarding the manual and reading it. I did read it front to back when I bought my first castle motor (about 8 months ago). I went off the memory of that to get this one running. I'd imagine that most of the folks that are buying your product are repeat customers. From what I read in these forums, many will use the motor over and over, taking from one car/truck to the next, re-calibrating it everytime. Unless something goes wrong, they never look at the book. The troubleshooting with really help these folks out.

I'd take the post that you get from these forurms (which are not only an amazing tool for customers, but even better for the manufacture as you get immediate feedback from the customers. Not something I have access to in my industry) and create your troubleshooting/FAQs page. Rather than put it in the manual, I'd put it on the web and make it more interactive... searchable, and easy to update. As you see these different posts, you update the webpage.

My two cents...