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Airtail Compressor Kit for Airtail Suspension System Installation Instructions

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Filed Under (Tips and Review) by admin on 14-02-2011

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installation • Following steps covers retro fits and new installations. * DENOTES RETRO FIT APPLICATION ONLY. Step 1 – Compressor 1. Jack the bike up and support it so that you can remove the rear wheel. Place your jack in an area that will not lift on the swingarm and leaves access to the space right in front of the front shock mounts. This is the area you will be installing the valve assembly into. 2. Relieve all pressure from the air shock- both “ride height” and “bottoming control” chambers must be drained of pressure. 3. Remove the seat and disconnect the battery. 4. Remove the rear wheel and ” splash guard ” (part number 60363-00) * Retro fit applications only. New applications go to #11 of Step 1. *5. Remove compressor from pivot shaft, disconnecting any airlines and wires from the compressor and solenoid. *6. Remove coil cover with switch housing and air release valves, being sure to disconnect all connections and airlines. *7. With compressor removed, remove the original solenoid valve (Fig. 1) and the 2 “T” fittings (Fig. 2) from the compressor mounting bracket. Figure 1 Figure 2 *8. Un-screw outlet valve from compressor and remove original airline (Fig. 3), being sure to not lose small o-ring around the end of airline. This will be used in the next step.

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HONDA VTX1300 AIR HORN INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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1. Remove the rider and passenger seats, left chrome side cover & original horn located at the top of the radiator. 2. Locate the supplied black horn mounting bracket and supplied smaller hose clamp. Notice the slight twist in the bracket. Using 2 adjustable wrenches or a vise and one wrench remove the twist from the bracket. Route the hose clamp thru the bracket. (As shown in photo 1A) 3. Install the bracket on to the left frame tube, (As shown in photo 1A) and tighten securely. Bolt the supplied horns to the bracket using the supplied bolt, lock washer and nut, (As shown in photo 1) and tighten securely. Install the supplied trumpet covers (As shown in photo 1B) by flexing the spring clips over the trumpets. Check that they fit securely. If not remove covers, make sure the center screw is tight and bend spring clips in towards center of covers and re-install. Using a blade screwdriver pry the two supplied hoses with the “Y” connector off of the air horns cut a new piece of hose 3 ½” long from the hose and replace the short hose on the “Y”. Re-install the “Y” hose assembly with the short hose going on the long or upper trumpet. (See photo 1C) Re-route the original horn wires. (As shown in photo 1D) 4. From the supplied wire cut 2 pieces 28″ long. Strip ¼” of insulation from both ends. Crimp 2 supplied male terminals to one end and 2 supplied female spade terminals to the other end. Plug the male ends into the original horns wires. (As shown in 1D) Attach the remaining air hose to the “Y”. Tape the hose and wires together every 6-8″ using electrical tape to make routing easier and neater. Route the wires and hose up under the fuel tank, over the cylinder heads coming out between the frame rails at the rear of the fuel tank. (See photo 2A) Locate the supplied relay and plug the 2 wires from the original horn onto terminals 85 & 86 on the relay. (See wiring diagram on back of last page of instructions) This will be the 2 outer terminals that are parallel to each other. Locate the supplied fuse, holder & wire assembly. Crimp a supplied fork terminal to one end and a supplied female spade to the other. Attach the spade terminal to one of the remaining outer relay terminals. (#30 or 87 on wiring diagram) Remove the 3 Phillips screws from the battery top cover. Remove the cover and attach the fork end of the fuse wire to the positive (+) terminal. Re-install the battery cover. 5. Cut a wire 9″ long and strip ¼” insulation from each end, crimp a fork to one end and a female spade to the other. Attach this wire to the compressors negative (-) terminal. Cut another wire 18″ long and strip both ends. Crimp a female spade to both ends. Attach this wire to the compressor positive (+) terminal. Route the air hose out under the left side cover as shown in photo (3). Hold the compressor in place against the frame tube. Note: Looking at the large end of the compressor the space between the hose fitting and the bolt mounting flange forms a “V” shape. This is where the compressor should rest against the frame. Next loop the hose around to the compressor hose fitting and trim the hose to the desired length. Attach the hose to the compressor. Secure the compressor to the frame using 2 large supplied cable ties as shown. 6. (See photo 3A) Attach the compressor negative (-) wire to the bolt on the frame (As shown in photo 3B) Route the compressor positive (+) wire along the side up to the relay and attach to the remaining outer terminal 87 or 30. Cable tie the relay in place. (As shown in photo 2B) Use several of the supplied short cable ties to secure the compressor wires to the air hose (As shown in photo 3) as wells as any other loose wire or hose.

Yamaha V-Star 650 Multi Application Air Horns Installation Instructions

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Filed Under (Yamaha) by admin on 21-12-2010

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1. Remove the right side cover. 2. Unplug and remove the original horn. 3. Remove the bolt holding the rectifier to the frame and move it out of the way during installation. 4. Locate the hole in the frame shown in photo #4. This hole must be drilled out to 11/32″ for the compressor- mounting bolt. COMPRESSOR MOUNTING Before mounting the compressor it is necessary to install the hose and wires as follows, refer to photo #1 Cut one wire 30″ long. Crimp a female terminal to one end. Cut one wire 8″ long. Crimp a bare fork terminal to one end and a female blade to the other. 1. Attach the short wire to compressor (-), Long wire to compressor (+) 2. Lube one end of the hose with oil or WD-40 and attach to the compressor. 3. Using the bolt, nut, washer and lock washer provided slide the 8 X 16mm bolt in to the slot in the compressor. 4. Bolt the compressor between the frame and engine with the terminals facing down. 5. Re-Install the rectifier and attach the short (-) ground wire to the rectifier mounting bolt. HORN MOUNTING 1. Assemble the hose clamp onto the frame-mounting bracket as pictured in photo #2. 2. Attach the bracket to the frame as shown in photo #3 3. Attach the horn assembly to the bracket using the 5/16″ bolt nut and washers provided. Align the horns so that they are level or angled down slightly at the front and also so they are vertical when viewed from the front or rear. You may need to twist or bend the mounting bracket. Use 2 crescent wrenches to do so. 4. Tighten the hose clamp and 5/16″ bolt securely.

HARLEY DAVIDSON WIRE LOOM AND HORNS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 27-02-2012

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Remove the stock horn and bracket from the stud it is mounted to and unplug the 2 wires. Remove the seat. Route the end of the wire and hose loom without the connectors. Starting in front of the fuel valve, route this loom behind the valve, over the fuel line over the rear cylinder head along the existing wiring or hoses – if your model has any. Follow the frame to where the back bone and seat support rails come together. Route the loom up into the general area where the compressor will mount (i.e. see diagram). Attach the hose to the ‘Y’ connector on the horns themselves. Attach the two black wires from the loom to the relay terminals #87 and #30, located between the air horns behind chrome cover. Attach the wires from the original horn to the remaining terminals #85 and #86 (NOTE: it makes no difference which wire goes to which terminal). Attach the relay to the back of the horn bracket assembly or up under the fuel tank using the small cable tie provided. NOTE: the terminals must point downward to prevent water from entering the relay! Install the horn assembly using the 1/4″ thick chrome washer provided behind the horn mounting bracket. Use the original acorn nut and tighten securely. Check to see that the horns have at least 1/4″ clearance between the engine, shift linkage and choke knob. They should be horizontal or angle down at the front just slightly. Take any slack out of the loom, keeping it up against the frame and away from the engine or exhaust, using several of the small cable ties provided. COMPRESSOR MOUNTING AND WIRING Due to the vast differences in years and models, it is not possible to have one or two brackets that will fit all models. You may need to mount the compressor in a different position or find an alternative location, such as under one of the side covers. On 2001 and newer Tour models there is room in front of the battery to mount it horizontally. On 1997-2000 fuel injected models, under the front portion of the right hand side cover is an excellent location. On most Softtail models you can attach it to the frame tube behind the rear cylinder. On some models such as Sportsters there may not be a place to conceal the compressor; there is a chrome cover and cap available to dress it up for exposed mounting. (RIVCO part no #CMPCR) If mounting the compressor vertically as pictured, try to keep the end with the electrical terminals pointing downward. You can use the long cable ties provided to attach the compressor to the frame or an existing wiring loom. Once the compressor has been mounted securely, route the hose and one of the wires to it and connect the hose to the air outlet barb or fitting. Trim the wire and crimp on one of the female blade terminals and attach to the (+) terminal. Attach the white ground wire supplied to frame close enough to the compressor, so the wire will reach. Trim and crimp another female terminal to it. Attach this wire to the (-) ground terminal. The remaining black wire from the hose/wire loom goes to the battery (+) terminal through the fuse and holder provided. Trim the black wire allowing for the length and placement of the fuse holder. Crimp together and attach to the battery (+) terminal. Turn ignition on and test horns. Check wires and hoses for neat, secure routing and at least 1″ away from exhaust system. Reinstall seat etc.

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Honda GL1800 Front Mount Air Horn Installation Instructions

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Filed Under (Honda) by admin on 23-12-2010

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1. Place the motorcycle on the centerstand. 2. Remove the left side cover (painted) to expose the battery. Remove the left plastic engine cover (chrome) . Remove the lower center fairing cowl or spoiler; there are 2 pull pin rivets and 6 allen screws holding this panel in place. Drop the panel down and slide it out to the right or left. 3. Horns and Mounting Bracket: Attach the large “L” shaped bracket with the split clamp to the engine guards as shown in photo #1. NOTE: Make the screws snug only! Install the horn set onto the “L” bracket using the 2 allen screws provided, tighten securely. Align the horn set to be level and to have clearance between the fairing as shown in photo #2, tighten securely. 4. Compressor: Remove the stock left hand horn and loosely re-install the 12mm mounting bolt (see photo #4A). Next as shown in photo # 3, to the compressor attach the air hose, the short red wire to the (+) positive terminal and the white wire to the (-) negative. The mounting bracket should be bolted to the compressor as shown. Install the compressor assembly as shown in photo #4 onto the 12mm bolt and tighten securely. Note! It you may need to adjust the angle or bend of the bracket for a good fit. Try to maintain at least a one-inch clearance between the exhaust header pipe and the compressor, wires and air hose. 5. Relay and Wiring: Attach the red wire from the compressor to the relay terminal 30 (see wiring diagram). Attach the long red wire to the relay terminal 87. Attach the stock horn wires to the remaining terminals 85 & 86 it does not matter which wire goes to which of these two terminals. Attach the white ground (-) wire from the compressor to the lower cowl-mounting bolt as shown in photo # 4B. Cable tie the relay in place as shown in photo #4C. Route the long red wire up and back over the left side of the engine to the battery, This is easiest done using a stiff piece of wire (a coat hanger works good) with a small loop bent at one end. Push the wire from rear of the engine towards the front. Attach the red wire with electrical tape and pull the wire back towards the rear of the engine. Route the wire back to the battery (+) positive terminal, cut the wire to the desired length, strip back insulation 3/8″ crimp on the fuse holder provided and attach to the battery (+). Replace the side covers Route the air hose as shown in photo #5 so as not to kink it or be less than 1″ from the exhaust, then over the front of the engine, up and out to the horns just behind the engine guards, trim to the desired length and attach to the “Y” fitting. Using a lighter or match, heat seal or melt the end of the hoses braided cover to prevent it from fraying. Turn on the ignition and test the horns

PEUGEOT HYbrid 3 compressor

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

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HYbrid3 compressor concept is a means of transport with no affi liation to a particular type of vehicle. With its three wheels and its streamlined body, it is something of a missing link between two worlds which to date are quite distinct: that of the scooter and that of the car. With an electric motor in each of its two front wheels, coupled at the rear with a petrol engine, it brings into play very innovative hybrid technologies allowing each of its wheels to provide motive power. In a world of intensifying urban traffi c where everyone is trying to save time, where oil prices are skyrocketing and the environment is more than ever a priority, design departments are vying in ingenuity to develop solutions for the future. Giving full rein to their creativity and expertise, two separate Peugeot teams converged on a similar idea and fi nally worked in tandem to develop a particularly original project: the HYbrid3 compressor . This ”concept car”, or rather ”concept scooter”, is based on the extensive experience of Peugeot Motorcycles, specialists in the scooter fi eld, as well as the creativity and innovative capabilities of stylists and engineers working for Automobiles Peugeot. To create this concept, Peugeot was able to draw on its extensive experience in the world of transportation enabling each individual, according to their age or their needs, to choose from among the Marque’s cycles, motorcycles and cars

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1994 – 1996 Camry L4 A/C COMPRESSOR KNOCKING NOISE REPAIR

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Filed Under (Toyota Manuals) by admin on 23-10-2011

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Ensure that the A/C system high & low side refrigerant pressures are normal before Procedure proceeding with the following repair procedure. NOTE: For abnormal system pressures, use the diagnostic procedure given in the Repair Manual to determine the problem. 1. Remove the A/C Compressor. 2. Replace the Alternator Adjusting Bar with the new part number. 3. Replace the Magnetic Clutch Rotor with the new part number. 4. Adjust the clearance between the pressure plate and rotor from 0.35 to 0.60 mm (from 0.014 to 0.024 inch). NOTE: Use shims to adjust the clearance according to Repair Manual. 5. Install the A/C Compressor. 6. Adjust the drive belt tension to 121 ft. lbs. otherwise the condition may persist

Harley Davidson Touring Bikes TRUMPET INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2012

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COMPRESSOR INSTALLATION TOUR MODELS 1992 -2000 On the Dressers and Tour bikes, remove the seat. If the battery is located underneath the seat, then remove the right saddlebag and right hand side cover. Using a zip tie, mount the compressor to the main wiring harness at the front of the covered area with the compressor air outlet facing down. If the battery is not under the seat and is located beside the right saddlebag, the compressor will be mounted underneath the seat, utilizing a bolt to the frame The air hose routes from the air horns, behind the fuel valve, over the rear cylinder and to the right side cover or underneath the seat. Do not cut hose until you connect it to the compressor. TOUR MODELS 2001 & NEWER On the Dressers and Tour bikes, the compressor will mount under the seat, in the square hole in front of the frame, just in front of the battery. The air output will face left toward the air horns. The hose routes thru a hole at the bottom of the square hole, then to the air horns. WIRING Connect both black wires from the relay to the original horn wires. It does not matter which wire you connect. The fuse wire on the relay will connect to the positive terminal on the battery. Observe negative and positive terminals on compressor. Ground the negative terminal to the battery. The positive terminal connects to red wire on relay. Refer to wiring schematic on the next page

MULTI-APPLICATION AIR HORN INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 27-10-2010

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COMPRESSOR MOUNTING: Find a suitable location to mount the compressor. Under the seat, fuel tank or one of the side covers is the most concealed place. Mount the compressor using the supplied large hose clamp, long cable ties or bolt & nut. NOTE: Keep the compressor terminals pointing downward or horizontal. Locate and area that will be protected from water & dirt. Attach air hose to compressor. HORN MOUNTING: Mount horns to the frame or engine guards only. The most common place is the left front frame down – tube, below the fuel tank using the “L” bracket with the hose clamp routed through the slots. (See photos 2 & 3) If necessary you can bend or twist the bracket using a vise or two adjustable wrenches. Horns should be horizontal or slightly downward. They may be mounted on the right side by reversing the long and short trumpet. Flipping the bracket that mounts to the horns 180 degrees can do this. Route the hose from the compressor to the horns, cut to length & attach. Spraying WD-40 to the end of the hose helps ease assembly. Use a small flame to heat seal the hose outer braided cover to keep from fraying. WIRING: (see photo 1 & the wiring diagram) when mounting the relay be sure the terminals are pointed downward. Remove wires from the stock horn & attach to relay terminals 85 & 86. Find an inconspicuous place to mount the relay. Attach using supplied cable tie being sure the terminals are downward. Refer to diagram & make connections as shown using the supplied wire & terminals. Route wire neatly & wire neatly & where possible hidden. Cable tie the wire to secure. Turn on ignition & push horn button to test. HELPFUL HINTS: When routing wire or hose under fuel tank or difficult to reach place use a stiff piece of wire such as a coat hanger about 3′ or 4′ long for a helpful tool. Bend a small loop at one end. Push wire tool through, attach wire or house with tape and pull back through

KAWASAKI VOYAGER AIR HORN INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 27-12-2010

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1. Remove the false fuel tank cover to expose the battery. Remove the right hand lower leg fairing. (4 phillips screws). Unplug the stock horn and remove the (2) 10mm bolts securing it to the frame. 2. See photo #1 using the stock horn bolts attach the black horn mounting bracket and the white ground wire supplied as shown. Next locate the relay supplied. Plug the stock horn wires into the relay terminals #85 & #86. (see wiring diagram on back side of instructions) 3. Attach the air hose to the compressor air outlet fitting. Attach the short red wire supplied to the compressors positive (+) terminal and the white wire installed earlier to the compressors ground (-) terminal. As shown in photo #2. Attach the compressor to the frame with the hose clamp provided. Note: position the top of the compressor as shown touching the bottom of the horn mounting bracket and approximately 1 Ω” to the rear of radiator and shroud. Also the air hose and fitting should be in front of the frame tube with the hose routed inside the hose clamp without pinching the hose. Attach the red wire from the compressor to one of the relays remaining outer terminals #30 or #87. Attach the remaining long red wire (supplied) to the remaining relay terminal #30 or #87. Secure the relay to the frame with a cable tie supplied. Route the red wire up to the battery positive (+) terminal. Locate the fuse wire assembly provided. Attach the fork end of the fuse wire to the battery positive (+) terminal. Cut the red wire to the desired length, strip the end and crimp to the fuse assembly. Turn on the ignition and press the horn button, you should hear the compressor motor run. Re-install the false fuel tank lid. Re-install the right lower leg fairing while routing the air hose out next to the black horn mounting bracket 4. See photo #3, Bolt the horn set to the black mounting bracket using the 5/16 x æ”bolt, washer and lock washer provided. Trim the air hose to length if necessary and attach the air hose to the horn assembly. Install the trumpet covers. (see instructions enclosed with covers) Turn on the ignition and test the horns

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