1998 harley softail starter relay

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HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

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2001 YAMAHA TDM900 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760

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Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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Audio Oil Pressure Alert Relay Installation Instructions

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

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Step 1) Wire Connection: Using 18-gauge automotive wire, connect the audio alert relay as shown in the Wiring Diagram – Figure 1. • Connect the supplied wire from #3 terminal on the audio alert relay to the oil pressure switch post. Note: The supplied wire is not reversible. The eyelet end must hook to the oil pressure switch. • Connect a wire from #2 terminal on the audio alert relay to the ignition switch post that receives power when the ignition switch is first turned on. • Connect a wire from #1 terminal on relay to the positive side of existing horn, or alternate sound device. • Note: The audio alert relay uses the oil pressure switch as its ground. On most motorcycles, this audio alert relay can be installed easily under the dash. Figure 1- Wiring Diagram Cot a Oil Pressure Switch Ignition Switch Audio Alert Relay 2 1 3 load Horn + + – Caution: Make sure all connections are insulated away from potential grounds. Do not disconnect any existing wire. Step 2) Testing : Turn ignition switch on and ensure oil pressure light is on. Leave ignition switch on. Wait 30 sec (T1) and ensure the audio alarm sounds for ½ second (T2). If the electrical test is successful, proceed to Step 3. If not, you may have to use a pezio alert in place of the horn. (Which is available at most Radio Shack stores.) If audio alert still doesn’t work, consult the wiring diagram and recheck all wiring connections. Verify timer set points have not been altered. If problems persist, contact us at (518) 884-9591. Step 3) Mount relay switch: Use standard zip ties (not provided) or similar means to mount the relay to dash mount post or dash base. Note: The timer relay can be mounted almost anywhere on the bike that will not be exposed to direct rain or weather

KTM Starter Gear Maintenance Instructions

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Filed Under (KTM) by admin on 26-11-2010

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Checking the electric starter motor for wear -Check Bendix 1 for smooth operation and signs of wear. -Check the sprocket of the electric starter for wear and radial clearance. -Replace O-ring 2 of the electric starter. -Replace gasket 3 . -Check starter idler gear 4 for smooth operation and wear, check that the bearing bushings are seated firmly. Electric starter motor – checking for and adjusting play -Mount the electric starter and the starter idler gear. -Mount the tighten cover 5 . -Move starter idler gear 4 back and forth in the direction of rotation, the maximum play may not exceed half the width of a tooth. -If play is larger, cover 5 must be removed and as many shims 6 with a thickness of 0.10 mm as necessary must be added to eliminate all play. Then remove one shim again. -Check the play again; the maximum play may not exceed more than half of the width of a tooth. 1 2 3 4 5 4 5 6

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2007 Harley-Davidson Softail Family Specifications

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Filed Under (Harley Davidson) by admin on 02-11-2010

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frame Mild steel tubular frame; rectangular section backbone; stamped, cast and forged junctions; forged fender supports; MIG welded Mild steel tubular frame; rectangular section backbone; stamped, cast and forged junctions; forged fender supports; MIG welded Mild steel tubular frame; rectangular section backbone; stamped, cast and forged junctions; forged fender supports; MIG welded Swingarm Mild steel, round tube sections, forged junctions, MIG welded Mild steel, round tube sections, forged junctions, MIG welded Mild steel, round tube sections, forged junctions, MIG welded Front Fork 41.3 mm telescopic, “beer can” covers 41.3 mm telescopic, “beer can” covers 41.3 mm telescopic, “beer can” covers Rear Shocks Hidden, horizontal-mounted, coil-over Hidden, horizontal-mounted, coil-over Hidden, horizontal-mounted, coil-over Caliper Type 4-piston front and rear 4-piston front and rear 4-piston front and rear Rotor Type: (diameter x width) Patented, uniform expansion rotors Patented, uniform expansion rotors Patented, uniform expansion rotors Front 292 mm x 5.08 mm 292 mm x 5.08 mm 292 mm x 5.08 mm Rear 292 mm x 5.84 mm 292 mm x 5.84 mm 292 mm x 5.84 mm Front (mm) 130 130 130 Rear (mm) 109 109 109 Engine Torque (EU standard EC95/1)5 86 ft. lb / 117 Nm @ 3200 rpm 89 ft. lb / 120 Nm @ 3300 rpm 89 ft. lb / 120 Nm @ 3300 rpm Right 29° 30° 28° Left 26° 28° 26° Battery Sealed, maintenance-free, 12V, 19-amp/hour, 270 cca (per Battery Council International Rating) Sealed, maintenance-free, 12V, 19-amp/hour, 270 cca (per Battery Council International Rating) Sealed, maintenance-free, 12V, 19-amp/hour, 270 cca (per Battery Council International Rating ) Charging Three-Phase, 38-amp system (439W @ 13V, 2000 rpm, 489W max power @ 13V) Three-Phase, 38-amp system (439W @ 13V, 2000 rpm, 489W max power @ 13V) Three-Phase, 38-amp system (439W @ 13V, 2000 rpm, 489W max power @ 13V) Starting 1.2 kW electric with solenoid shift starter motor engagement 1.2 kW electric with solenoid shift starter motor engagement 1.2 kW electric with solenoid shift starter motor engagement Headlamp Headlamp Headlamp Quartz Halogen, 55-watt low beam, 60-watt high beam Quartz Halogen, 55-watt low beam, 60-watt high beam Quartz Halogen, 55-watt low beam, 60-watt high beam Tail/Stop Lights Tail/Stop Lights Tail/Stop Lights 8W/28W (5W/21W) 8W/28W (5W/21W) 8W/28W (5W/21W) Turn Signal Lights Turn Signal Lights Turn Signal Lights 28W (21W) self-canceling 28W (21W) self-canceling 28W (21W) self-canceling Indicator Lamps Indicator Lamps Indicator Lamps High beam, neutral, low oil pressure, turn signals, engine diagnostics, security system6, 6-speed (overdrive), low fuel warnings High beam, neutral, low oil pressure, turn signals, engine diagnostics, security system6, 6- speed (overdrive), low fuel warnings High beam, neutral, low oil pressure, turn signals, engine diagnostics, security system6, 6-speed (overdrive), low fuel warnings Passing Lamps Chrome Vivid Black Vivid Black Vivid Black Black Cherry Pearl Black Cherry Pearl Black Cherry Pearl Deep Cobalt Pearl Black Pearl Black Pearl Pewter Pearl Fire Red Pearl Deep Cobalt Pearl White Gold Pearl Deep Cobalt Pearl Olive Pearl & Vivid Black Suede Blue Pearl & Vivid Black Suede Blue Pearl White Gold Pearl & Vivid Black Black Cherry Pearl & Pewter Pearl Olive Pearl White Gold Pearl & Deep Cobalt Pearl Fire Red Pearl & Black Pearl Pacific Blue Pearl Deep Cobalt Pearl & Pewter Pearl Pewter Pearl Yellow Pearl White Gold Pearl

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Harley Davidson Softail Motorcycles EZ-Steer Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Softail EZ-Steer Instruction Supplement Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Harley Davidson Softail Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Installation Notes • Note the torque specifications for the items listed below. Item # Description (Qty) Torque Spec. (Lb.Ft.) N/A OEM Steering Stem Bolt (1) 35 7 7/16-20 x 1.5 Socket Head Cap Screw (2) 45 • The supplied fork tube extensions (Item #2) must be used with the Champion EZ-Steer system. • Do not torque the steering stem bolt until fork tubes have been installed to the assembly. • Remove O-rings from OEM fork tube ends and install to Champion fork tube extensions (Item #2) prior to installation onto fork tubes. • The supplied fork tube covers (Item #9) must be installed to lower triple clamp prior to installation of fork tubes. WARNING: If the Champion EZ-Steer system is installed on a motorcycle / sidecar combination and the sidecar is removed, the motorcycle is not safe to ride, and OEM triple clamps should be replaced.

HARLEY DAVIDSON SOFTAIL SPROCKET KIT INSTALLATION NOTES

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Filed Under (Harley Davidson) by admin on 29-01-2011

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NORMAL TOOTH WARRANTY This extended warranty applies only to the normal wear that will occur to the tooth profile geometry on the rear belt sprocket. Normal wear is considered wear that occurs when the protective hard coating has worn away exposing the underlying aluminum, changing the profile of the sprocket tooth significantly. Warranty is for five years from date of purchase with unlimited mileage. Warranty claims will require a dated receipt showing proof of purchase from an authorized Harley-Davidson Dealer. Warranty only applies to original purchaser of the sprocket. Original owners name must appear on the receipt. All applications of the sprocket require installation of upper and lower original equipment belt guard, or Harley-Davidson accessory belt guards where applicable. Warranty is voided if these items are not installed. Excessive chips found in the tooth profile due to abnormal riding conditions will void warranty. Occasional chips in the tooth are to be considered normal and should not be considered a warranty issue. Decorative external chrome carries the standard parts and accessories 90 day warranty. Staking the flange on the backside of the sprocket will pierce through the chrome, this is to be considered a normal process and should not be considered an issue. All warranty claims must be pursued through your authorized Harley-Davidson Dealer

2001-2003 EFI Harley Davidson Softail Deuce Power Commander Installation Manual

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Filed Under (Harley Davidson) by admin on 14-03-2012

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1 Remove the seat. 2 Remove the two bolts that hold the relay bracket (Fig. A). Fig.A Remove these bolts 3 Fig.B 3 Pull straight upwards on the bracket. Lift the bracket enough to expose the 3 zip ties that hold the wiring harness to the bracket (Fig. B). Cut these 3 zip ties. 4 Pull upwards on the retaining plate (which holds the relays) enough to clear the battery (Fig. C). Fig.C Cut these 3 zip ties 4 9 Fig.D Adjusting Your Power Commander Your Power Commander has been programmed with a base map for your application. You can adjust the base map or install an alternate map using your Computer. Please refer to the supplied CD-Rom for more information. You can also adjust your Power Commander using the face plate buttons as described below. 1. With the ignition off, hold down all three buttons on the Power Commander III unit. 2. While still holding down the buttons, turn the ignition on. 3. Release buttons. 4. Select the range you wish to adjust: Low, Med, High, by pushing the corresponding button once. 5. At this point holding that button down will move the lights down ( leaning out the mixture). 6. Pushing the button repeatedly will move the light up (richening the mixture). 7. When the two center light are lit up this is the “0″ setting. After making your adjustments wait 20 seconds before starting the bike or turning it off. This allows the settings to be saved to memory. To verify that it is safe to start the bike, move the throttle and watch to see if the lights move up and down the scale. If they do, you may start or turn off the bike. Tabs 5 Rotate this plate forward to locate the relay retaining tabs (Fig. D). Bend these tabs so they are flush with the plate. This allows the relays to sit lower in the slots

HARLEY DAVIDSON BILLET HEADLAMP WITH SHORT/ TALL MOUNTS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Kit 68593-06 is a 5-3/4 inch headlamp and kit 69851-06 is a 4-1/2 inch headlamp. Both kits will fit the models listed in Table 1. Table 1. Short and Tall Mount Kits Models Kits 1984-1999 FXSTC, 1998- Later FXST/B, and 2000-Later FXSTD; 1994-2005 FXDWG Short Mount Kit 68595-06 1996-Later XL 1200C and 1998-Later XL 883C; All 2006 Dyna Models; 1999-2000 FXR2/3/4 Tall Mount Kit 69611-06 Additional Parts Required This kit also requires the separate purchase of a Short or Tall Mounting Kit 68595-06 or 69611-06 for your model motorcycle, and can be purchased from a Harley-Davidson dealer. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 21, Table 2 and Figure 22, Table 3. REMOVAL Remove Headlamp and Mounting Bracket for Softail Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. 2. Remove fuel tank. Refer to FUEL TANK in Service Manual. 3. Disconnect 4-place headlamp connector [38] from main wire harness. Headlamp connector is located under fuel tank on left side. 8 5 7 5 6 2 1 3 4 is01835 1. Screw 2. Washer 3. Nut 4. Lockwasher 5. Washer (2) 6. Screw 7. Mounting block 8. Headlamp assembly Figure 1. Softail and Dyna Headlamp Assembly with Mount (except FXSTD) NOTE All Softails (except FXSTD) complete steps 4 through 6. For FXSTD models complete steps 7 through 9 4. All Softails (except FXSTD): See Figure 1. Remove screw (1) and washer (2) from stem and bracket. Discard screw but save washer for later use. 5. Remove and discard mounting block (7) and headlamp assembly (8). 6. FXSTD models: See Figure 2. Remove screw (1) and washer (2) from stem and bracket. Save screw and washer for later use. 7. Remove and discard nut (3), washers (4), and screw (5). 8. Remove and discard mounting block (6) and headlamp assembly (7). 7 3 4 2 1 4 6 5 is01838 1. Screw 2. Washer 3. Acorn nut 4. Washer (2) 5. Screw 6. Mounting block 7. Headlamp assembly Figure 2. FXSTD Headlamp Assembly with Mount Remove Headlamp and Mounting Bracket for Dyna Models 1. Remove seat following the instructions in the Service Manual. 2. Disconnect negative (-) battery cable. 3. Remove fuel tank. Refer to FUEL TANK in Service Manual. 2 1 is01750 1. Cable strap 2. Wire harness Figure 3. Dyna Service Loop (2005-Earlier) 4. 2005-Earlier FXDWG: See Figures 3 and 4. Remove plug on right side of top frame tube. At service loop, remove cable clip and push wire harness into top frame tube. Pull connector out from hole on right side of tube. 2006-Later FXD: See Figure 5. Remove cover under top frame tube, then pull connector out from opening under tube. 5. Disconnect 4-place headlamp connector [38] from main wire harness

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