2011 street glide cruise control installation

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HARLEY DAVIDSON CRUISE CONTROL KIT FOR FLHR/I AND FLHRS/I MODELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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INSTALLATION 1. Remove seat, left saddlebag, left side cover and air cleaner assembly following instructions in applicable Service Manual. 2. Review the CRUISE CONTROL-ULTRA MODELS section in the applicable Service Manual before attempting to install this kit. Install Cruise Control Module To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the appropriate Service Manual and remove bat- tery. 1 is04799 1. Cruise control module mounting hole (3) Figure 1. Battery Box (Right Side View) 2. See Figure 1. In battery box, identify the location of the three mounting holes (1) (on left side of panel) for mounting the cruise control module. 3. See Figure 10. Obtain the cruise control module (1) with cruise cable attached and three grommets (5) from kit. Install the grommets on studs of cruise control module with small diameters outward. 4. See Figure 2. While holding cruise control assembly in place near its mounting location, feed the cruise control cable through the hole in frame crossmember plate and route under rear spark plug wire staying on inner side of fuel line components. Carefully curve cable toward the right and continue routing up under the fuel tank and over the top of the engine stabilizer bracket, then down between cylinder heads. Leave in place temporarily. 5. See Figure 10 and obtain a harness retainer (4) from kit and secure the cruise cable to crossmember plate with barb as shown. On California models, remove the EVAP hose from cable clip and secure hose with one of the cable strap (8)

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Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

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BMW K1100LT Installing Real Cruise Control

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Filed Under (BMW) by admin on 26-10-2010

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The vacuum reserve canister (VRC) is used to provide adequate vacuum for the cruise control servo unit. It uses the throttle body as a vacuum source and, via the vacuum check valve, stores up vacuum for the servo to use to pull the throttle cable. You can also buy one of these at an auto parts store for about $10-15 but I decided to build my own so I could make one that would fit inside the left front of the main fairing body. If you decide to buy one, make sure you can return it if it doesn’t fit inside the fairing or be prepared to mount it somewhere else like inside the tail cowl. I used 8″ of 2″ diameter PVC tubing because that is the length that would easily fit inside the fairing It is mounted inside the fairing in front of the left “bucket.” I used white PVC tubing but, in hindsight, would use black if possible since it is visible to the rider when mounted in the fairing. I suspect that the cruise control may actually work without the use of the vacuum canister so you might want to try the cruise without a VRC. If you do install the cruise control without a VRC, you’ll want to put a vacuum check valve in the vacuum hose that goes from the throttle body to the cruise control servo unit.
11/30/2005 08:23 PM Installing Real Cruise Control on a BMW K1100 Page 4 of 8 used epoxy for assembling the VRC as it’s my permanent adhesive of choice. Cut an 8″ length of 2″ diameter PVC tubing. Sand the edges. Drill two holes as shown for the check valve and vacuum tee. There’s a vacuum tee in the bags of installation miscellany that come with the cruise control. File the webbing from the right angles before gluing it and the check valve in place. Remember to glue the tee into place before gluing the end caps on. Make sure everything has an airtight seal. I used zip-ties to hold it in place inside the main fairing body in front of the left bucket

Harley-Davidson MOBILE RADIO & CONTROL UNIT Installation Manual

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Filed Under (Harley Davidson) by admin on 22-03-2012

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Installation of the ORION mobile radio and control unit consists of: •Assembling and installing the weather resistant motorcycle case assembly, including the adapter bracket, case/antenna mounting bracket, and bottom case (previously assembled) to the motorcycle mounting bracket (user supplied). •Installing the radio in the radio mounting bracket located inside the weather-resistant case, •Installing the control unit, microphone, and speaker •Installing the antenna •Routing the power, control, and option cables •Connecting all cables including: power, control, and option cables. •Installing the Headset Option •Operational check All mounting hardware consists of stainless steel screws, locknuts, nuts, and lockwashers to resist corrosion. TOOLS REQUIRED •Socket wrench set U.S./metric with 3″ extender •Open end wrench, adjustable •Wire clippers •TORX BIT set, small metric 13
EQUIPMENT INSTALLATION Assembling & Installing The Weather Resistant Case As- sembly The motorcycle Weather Resistant Case Assembly may be installed on almost any motorcycle. Installation instructions provided here include information for the Harley-Davidson Dyna and Road King models and the Kawasaki K1000. Figure 5 illustrates installation on Harley-Davidson motorcycles while Figure 6 illustrates installation on a Kawasaki K1000. Refer to these diagrams during installation. Installation on other motorcycles is at the discretion of the installer. Harley-Davidson Installation 1. Unpack the weather resistant motorcycle case, remove the key taped to the top cover and open the case. 2. Refer to Figure 5 and verify that all components shown in the diagram are available. 3. Mount the adapter bracket onto the Dyna or Road King radio mounting bracket (user supplied) using the 1/4-20 x 5/8 screws provided

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HARLEY DAVIDSON XL CHROME FORWARD CONTROL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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2008-05-05 XL CHROME FORWARD CONTROL KIT GENERAL Kit Number 33395-04, 33398-04 Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley- davidson.com (English only). Additional Parts Required 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 5, Figure 6 and Table 1. INSTALLATION Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 5. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is 01887 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is 01901 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod. 3. Remove the two screws (6) and right footrest/brake pedal support bracket with attached brake assembly from frame

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Yamaha Road Star Forward Control Kit Installation Instructions

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Filed Under (Yamaha) by admin on 08-11-2010

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Before starting to assemble this forward kit on your motorcycle check the packing list to make sure that the kit you received is the correct one for your model motorcycle and that the foot pegs are the style you ordered (billet or ISO). Next check the contents hardware kit P.N.0109-1000 against the packing list for completeness. Installing The Shift Control Photo 1 Remove wires from horn. Remove the two hex head bolts (Save for later installation) that mount the OEM shift controls to your motorcycle. Unthread stock shift rod at trans shift arm, leaving OEM rod end connected to stock shift arm. Using Original Metric hardware, place a drop of Loctite #242 (blue) to the bolt threads and mount the shift control plate to the motorcycle frame, Photo 2. FORWARD CONTROL KIT PM SHIFT CONTROL ASSEMBLY Note Before torquing the shift control mounting bolts down, tighten them snug and look behind the shift control mounting plate to where it contacts the mounting lug on the frame. Make sure it fits squarely to the lug before proceeding further. Torque the two shift control mounting bolts down to 25 ft-lb. Using a 3/8″ x 1″ hex head bolt with a lock and flat washer put a drop of Loctite #242 (blue) on the threads and insert the bolt through the rear of the control mounting plate and attach the foot-peg pivot to it. Tighten the bolt while holding the footpeg pivot so that its hinge is lined up in a 45˚ rear facing angle. Thread supplied shift rod coupler to stock shift rod end at trans arm. Mount the shift pedal to the other end of the shift ro d using a 5/16″ x 1″ socket head screw and Nylocnut . Adjust the transmission shift linkage so that the shift arm on the forward controls and the shift arm on the transmission are parallel. Secure it with the jam nuts. Apply a drop of Loctite #242 (blue) to the threads under the jam nut before tightening see Photo 3 After you have assembled the shift control onto your motorcycle you must align the footpeg. The folding footpeg assembly uses a blind stud to attach the footpeg to the footpeg pivot. Shim washers (3/8″ x .015″) are used on the stud between the footpeg and the pivot, see Photo 4, so that the top surface of the footpeg is correctly aligned for your foot when it is tightened down on the pivot. This is done by setting a couple of shim washers on the footpeg mounting stud “A” and then screwing the footpeg onto the mounting stud, if the footpeg is rotated to far forward then add another shim washer, if not far enough then remove a shim washer. After you have the selected the correct number of shims for your footpeg, disassemble the footpeg and put a drop of Loctite #271 (red) on both ends of the stud and reassemble the footpeg. This will also need to be done on the brake control footpeg. Setting Up the Master Cylinder The master cylinder pushrod return spring and pushrod boot must be installed on the master cylinder before it is assembled onto the forward control mount. The parts are shown in Photo 5: pushrod boot (A), pushrod return spring (B), spring seat washer (C), and master cylinder (D). Place the return spring seat washer into bore of master cylinder so that is sits on top of the piston retaining snap ring. Next set the pushrod return spring on the seat washer and slide the pushrod boot over the return spring now slip the big end of the boot over the flange on the master cylinder so that the ridge on the inside of the boot fits into groove “A” that is machined into the end of the master cylinder flange, see Photo 6. Installing The Brake Control Unplug stock brake light switch at master cylinder. Remove brake line from rear caliper. Remove the existing brake controls from your motorcycle down to the control mounting lug that is welded on to the frame’s right side, see Photo 8. Save Metric hardware for later use. A Shim Washer PHOTO 4 A B C D PHOTO 5 A PHOTO 6 PHOTO 7 Note For complete brake system removal instructions and precau – tions refer to the appropriate service manual for your year and model motorcycle

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HARLEY DAVIDSON SPORTSTER FORWARD CONTROL KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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Remove Stock Shift Lever and Footrest Assembly 1. See Figure 1. Loosen the shift lever retaining screw (2) securing the shift lever (1) to the shifter shaft. Slide the shift lever off the splined shaft. Remove shifter peg from lever and save for installation. Discard shift lever. 2. Remove the two socket head screws (4) securing the footrest bracket (3) to the frame and remove footrest. Discard screws. 3. See Figure 6. Obtain two hole plugs (1) from kit and firmly press plugs into frame screw holes remaining from footrest removal. 4. See Figure 2. Remove the retaining ring (1) from the clevis to free the footrest clevis pin (4). Remove the clevis pin and footrest (3) from the footrest support. Save footrest for installation. Discard retaining ring, clevis pin, spring washer and footrest bracket. 1 2 4 3 is03193 1. Shift lever 2. Retaining screw 3. Footrest bracket 4. Socket head screw (2) Figure 1. Remove Shift Lever and Footrest 5 1 3 2 4 is03194 1. Retaining ring 2. Spring washer 3. Footrest 4. Clevis pin 5. Footrest bracket Figure 2. Remove Left Footrest from Support Remove Stock Brake Pedal and Footrest Assembly 1. See Figure 3. At the right footrest, remove the retaining ring (1) clevis pin (2), footrest (3) and spring washer (4). Discard all hardware but save footrest for installation. 2. Remove the exhaust to access the brake rod. Follow the instructions in the appropriate Service Manual. 3. Remove brake rod (5) from brake pedal and master cylinder bell crank. Discard brake rod INSTALLATION Install Forward Control Brake Pedal and Footrest Assemblies 1. See Figure 5 and Figure 6. At the lower front of the right frame downtube, remove the two screws securing the J- clip (B) to the frame. Discard the screws but save J-clip for installation. 2. Install the other end of the brake rod into the brake pedal assembly (8). Tighten to 84-144 in-lbs (9.5-16.3 Nm) . NOTE Assemble the brake pedal and footpeg clevis onto the footrest support bracket (as described in the next step) prior to mounting the support bracket to the frame. This will allow easier installation of the footrest mount clevis retaining ring (installed to grooved end of footrest mount clevis). 3. Slide the brake pedal (8) onto footrest mount clevis (11) then slide clevis into footrest/brake pedal support bracket (9). Align hole in the clevis with hole in the support bracket and install screw (6). Tighten the screw to 18-22 ft-lbs (24.4-29.9 Nm) . 4. Install the footrest mount clevis retaining ring (18) to the groove at the end of the footpeg clevis. 5. Position the J-clip (from Step 1) against the frame aligning the mounting holes. Mount the footrest/brake pedal support bracket (9) and J-clip to frame using the new screws (3). Tighten the bracket to 45-50 ft-lbs (61.1- 67.9 Nm) . 6. Obtain the brake rod (15) from kit and thread one end into the master cylinder bell crank. Tighten to 120-180 in-lbs (13.6-20.3 Nm) . 7. Install footpeg on clevis with spring washer (2). Make sure spring washer is positioned inside clevis (11) with the square edge toward the inside. Align holes and push clevis pin (7) from top down through hole in clevis. Secure clevis pin using the new retaining ring (17). 8. Install exhaust following the instructions in the appropriate Service Manual. Install Forward Control Shift Lever Assembly

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SUZUKI SV1000S EMISSION CONTROL INFORMATION/ SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM SV1000S motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. BEFORE-PRESSURIZED FUEL PRESSURIZED FUEL * I’ RELIEVED FUEL ~%~~~ Ift 0 0 9 0 0 0 EMISSION CONTROL INFORMATION 9-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system . Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body . C * FRESH AIR FUEL/AIR MIXTURE 411111110 BLOW-BY GAS 9-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve . The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, ZAPS and CKPS. H02 sensor (Except for USA) I 0 0 0 0 0 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED : Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW : • * Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases . • * Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air . • * Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label . EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33)

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HARLEY DAVIDSON HAND CONTROL LEVER KITS INSTALLATION INSTRUCTIONS

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

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INSTALLATION The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Dav- idson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) Brake Lever Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Do not remove handlebar clamp or switch housing assembly to remove brake lever. 1. See Figure 3. Remove the retaining ring (4) from the groove in the pivot pin (A). Do not position fingers between hand control lever and handlebar grip. Improper hand positioning can impair control lever operation and cause loss of vehicle control, which could result in death or serious injury. (00032a) 2. Place a 4 mm (5/32-inch) thick insert between the brake lever and the lever bracket. NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 1. 3. See Figure 3. Loosen the brake master cylinder clamp screws. Rotate the master cylinder assembly slightly forward and then slide toward the center of the handlebar. 4. Remove the pivot pin (A) and original equipment (OE) brake lever. Retain the pivot pin for later assembly. 5. Apply a small amount of GM-40M grease (H-D Part No. 42820-04) to the area where the master cylinder pushrod seats against the brake lever. DO NOT apply grease to the stop-light switch contact surface of the lever. See Figure 2. Align the hole in the brake hand lever with the hole in the master cylinder bracket. From the top of the assembly, slide the pivot pin down through the bracket and hand lever. Check that the pushrod (1) is properly seated in the bowl shaped tab (2) on the lever

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BMW K1200RS Electronic Cruise Control installation instructions

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Filed Under (BMW) by admin on 26-10-2010

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We recommend that you take power from a non-critical circuit such as the heated grip circuit. Any power supply wire that is green with a black trace (stripe) is a fused, switched 12V supply. That is, there is a fuse in the line, and the ignition switch turns the power to the wire on and off, and it is NOT powered when the ignition switch is in the ‘park’ position (side lights turned on). Because the ignition switch also powers the ABS system, if the heated grip circuit is live, in theory the ABS system, and therefore the brake light system, will also be live. • On the bikes that we have fitted the cruise control to, there is a three way plug behind the headlight, that goes to the heated hand grip switch (on the right side handlebar). This plug has one green/black wire, a black wire and an orange wire. This photo is taken looking down below the bike’s instruments on the right side. The plug is circled. • This photo is taken from the front of the bike looking back through the head light cavity, under the bikes instruments. The plug is circled. • This is a convenient and accessible location to pick up power for the cruise control. The cruise control orange power wire should be connected to the green/black power wire for the heated grips.

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