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Ducati SPORT TOURING HEADLIGHT UPGRADE INSTALLATION AND REMOVAL INSTRUCTIONS

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Filed Under (Ducati) by admin on 25-10-2010

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1. Remove the following fairing components per the instructions in the Ducati owners manual: • Instrument surrounds • Headlight fairing • Chin fairing (under headlight/air intake) • Right-side middle fairing (covers battery) 2. Disconnect the speedometer cable from the speedometer. Unthread the ring nut at the top of the speedometer cable and retract the cable downward about 4-6 inches. 3. Disconnect the headlight wiring from the headlight bulbs. Retract the rubber boots at the rear of the headlight assembly to gain access to the wire terminals. Note that the two ¼ inch terminals at the high- beam bulb have locking clips that should be depressed before pulling the terminal away from the bulb. 4. Unplug the parking light from the headlight body by grasping the wires and carefully pulling it out. 5. Remove the two rubber plugs covering the lower headlight mounting screw access holes beneath the air intake horn. 6. Using an 8mm hex socket inserted through the lower access holes remove the two hex-head bolts securing the bottom of the headlight to the frame. 7. Using the same socket wrench, remove the two 8mm hex-head bolts securing the top of the headlight assembly to the frame. 8. Remove the headlight assembly from the frame. 9. Remove the two rubber grommets and steel reducing sleeves from the frame at the top mounting locations for the headlight. Leave the lower pair in place; these will be re-used, as shown in Figure 6

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YAMAHA V-MAX PERIODIC MAINTENANCE AND MINOR REPAIR

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Filed Under (Yamaha) by admin on 25-11-2010

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PERIODIC MAINTENANCE AND MINOR REPAIR -. 1. Screw (x 2) EAU03003 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by re- moving the screws. 2. Disconnect the headlight coupler, and then remove the headlight unit and bulb cover. 1. Headlight bulb holder 3. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb. EWOOOl19 Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 4. Place a new bulb into position, and then secure it with the bulb holder. 1. Do not touch this area. EC000105 Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 5. Install the bulb cover, and then connect the coupler. 6. Install the headlight unit by install- ing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 6-40 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (x 2) 1. Tail/brake light bulb (x 2) EAU00855 Replacing a turn signal light bulb or the tail/brake light bulb 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops. 1. Remove the lens by removing the screws. 2. Remove the defective bulb by pushing it in and turning it counter- clockwise. 1. Turn signal light bulb 4. Install the lens by installing the screws. EC000108 Do not overtighten the screws, oth- erwise the lens may break

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Ducati streetfighter HID headlight system installation Manual

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

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The installation of this kit requires the removal of the Helmholtz air box between the air intakes, located directly in front of the main air box. You will also need to run a wire from the front of the bike to the back of the bike where the battery is located. 1. Remove the seat, tail section, and fuel tank. 2. Remove the headlight assembly. 3. Replace the headlight bulb with the included HID bulb. You will need to modify the cap for the back of the headlight to allow the wires to pass through. 4. You will need to mount the Ballast, igniter, and the relay for the switch box in the area where the Helmholtz was. (see image) 5. Run the red power wire to the back of the bike and connect directly to the positive lead on the battery terminal. 6. Connect the ground wire the frame where the Helmholtz was previously bolted. 7. Plug the HID bulb into the ballast. There are 3 plugs. They can only be connected one way. 8. Connect the main wire harness to the ballast. 9. Turn the key on and turn the ignition on and check that the headlight comes on. 10. Switch on the brights to make sure this is working as well. 11. Once everything is confirmed to be working make sure the wirings are well attached won’t interfere with the fan or with any of the steering components. 12. Re-install the tank, tail section, and seat

2000 YAMAHA YZF-R1 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 27-11-2010

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CABLE ROUTING SPEC AProperly insert the meter assembly coupler and rubber boot into the meter assembly. BRoute the meter assembly lead through the left side of the headlight housing. CThe speedometer lead with not be tighten. DInstall the headlight relays onto the headlight housing bridge. EConnect to the right front turn signal connectors. FRoute the turn signal leads upper the headlight housing boss. 1 Clutch cable 2 Left handlebar switch lead 3 Starter cable 4 Main switch lead 5 Steering cover EB206000 CABLE ROUTING -21- NRoute the thermo switch/temperature sender sub- wire harness to the outside of the radiator cap. ORoute the right handlebar switch lead behind the throttle cables. Do not cross the throttle cables and the right handlebar switch lead. PRoute the right handlebar switch lead in front of the throttle cables. GFasten the headlight lead with a plastic clamp at white tape mark. HFasten the wire harness to the headlight housing boss with a plastic locking tie. IRoute the headlight lead through the plastic guide. JRoute the throttle cable to the front side of the brake hose. KRoute the clutch cable behind the front fork leg. LMake sure that the horn leads face out. MRoute the throttle cables and right handlebar switch lead between the lower bracket and steering cover. CABLE ROUTING SPEC -22- CRoute the rollover-valve-to-fuel-tank hose to the inside of the fuel hose (California only). DRoute the coolant reservoir breather hose over the timing chain tensioner. EInsert the plastic clip through the hole in the plastic frame panel and then fasten the wire harness and coolant reservoir breather hose with it. FRoute the clutch cable between the radiator bracket and frame and in front of the thermostat assembly breather hose. GRoute the clutch cable to the inside of the radiator inlet hose. HInsert the plastic clamp into the hole in the coolant reservoir’s tab

YAMAHA FJR1300N PERIODIC MAINTENANCE AND MINOR REPAIR

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Filed Under (Yamaha) by admin on 17-12-2010

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Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● To charge a sealed-type (MF) battery, a special (constant- voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. EAU04076* Replacing the fuses The fuse box, which contains the fuses for the individual circuits, is located under panel D. The fuel injection system fuse box is located under panel D. The main fuse box is also located under panel D, beside the battery. (See page 6-7 for panel removal and installation procedures.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. Fuel injection system fuse 2. Spare fuel injection system fuse 1. Headlight fuse 2. Signaling system fuse 3. Ignition fuse 4. Windshield motor fuse 5. Radiator fan fuse 6. Backup fuse (odometer and clock) 7. Spare fuse (〈 4)
PERIODIC MAINTENANCE AND MINOR REPAIR 6-31 6 EC000103 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EAU04099 Replacing a headlight bulb This motorcycle is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove panel B (if replacing the left headlight bulb) or panel C (if replacing the right headlight bulb). (See page 6-7 for panel removal and installation procedures.) 2. Disconnect the headlight coupler, and then remove the headlight bulb cove

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YAMAHA V-STAR 650/ 1100 CLASSIC F ATS/ SLIMS MOUNTING KIT INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 10-11-2010

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1. Cover gas tank and front fender with towels to avoid damage during installation. 2. Install the two mounting plates onto the windshield, using the bottom and third bolt up. Leave the nylon washers off. The small tab goes to the bottom, big one at the top. (see Figure 1) Tabs face out away from the headlight when installed correctly. 3. Remove the headlight lens and chrome Turn Signal Bar cover and set them in a safe place. (see figure 2) 4. Remove the (3) socket head cap screws that hold the Headlight housing and let it rest carefully so that it does not fall. 5. Remove the turn signal bar by extracting the two socket head cap screws and let it dangle. (see figure 2) 6. Loosely install the throttle-side Bracket and Headlight using one of the (3) new longer 6mm x 30mm socket head cap screws. The nylon washer goes in between Headlight Housing and Headlight Bracket. (see figure 3) Install one of the (2) new 8mm x 45mm SS flat head screw and spacer in the lower hole to mount the turn signal bar. Insert the bolt in this order: bolt – windshield bracket – spacer – turn signal bar, and loosely tighten . (see Figure 3) Repeat these steps for the Clutch side. (See figure 4 for optional Cobra Light Bar installation, or to move Turn Signals forward to mount Lowers closer to the windshield.) 7. Once both windshield brackets are in place and all the new bolts are in place, Tighten all bolts. Re-install the chrome Turn Signal Bar cover. (Leave the chrome cover off if you use the alternate installation for Light Bar or Lowers). Re-Install the Headlight lens. 8. Loosen the (4) anchor bolts on the side of the windshield brackets. Slip the windshield mounting plates onto the brackets starting with the upper slot first then slip the bottom slot in. Adjust height, angle and tighten all bolts. This is a quick change kit. ALWAYS tighten all mounting bolts after removing or installing the windshield

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HARLEY DAVIDSON CHROME FORK COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 30-01-2011

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INSTALLATION OF KIT 66440-05 1. Kit 66440-05 , Loosen the fuel tank. Refer to FUEL TANK- PARTIAL REMOVAL in the appropriate section (carbureted or EFI Engine) of the Service Manual. 2. Disconnect the headlight connector from the main harness. 3. Start with one side and remove the screws fastening the trim strip and rear triple clamp cover. Remove trim strip and rear triple clamp cover. Repeat procedure for other side. 4. Remove the nut, washers, lockwashers and bolt holding the headlight housing to the tripletree. Retain all hardware for future use. Remove headlight housing. 5. Remove front panel. 6. See Figure 2. From kit, place front panel (1) into position. 7. Install headlight using the bolt, washer, lockwasher and nut removed earlier. Tighten fastener. Refer to your service manual for torque specifications and headlight alignment procedures. 8. Insert headlight wiring through hole (2) in front panel and connect wiring to main electrical harness. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 9. Install fuel tank. Refer to FUEL TANK-PARTIAL REMOVAL in the appropriate section (carbureted or EFI Engine) of your Service Manual. 10. Start with the left side and install the chrome rear triple clamp cover (4), and trim strip using screws removed earlier. Tighten fasteners. 11. Install the headlight switch thru switch hole (5) removed earlier. 12. Install the chrome right side rear triple clamp cover (3) and trim strip and tighten fasteners

2000-2010 KTM X2 SWITCH WIRING HARNESS Removal and Installation Manual

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Filed Under (KTM) by admin on 25-01-2012

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The included 3600-SWHA switch harness is intended for use with offroad models that do not come with a Hi/Low beam switch from the factory. The harness is compatable with stock AC lighting electrical systems as well as high output DC electrical systems. 1. Remove the stock numberplate or headlight. Remove the stock kill switch from handlebars and replace with the 3600-SWHA switch. 2. Remove the gas tank. Route the white and black leads from the 3600-SWHA under the tank following the wires from the stock kill switch. Disconnect the stock kill switch bullet and connect the white wire of the 3600-SWHA to the wiring harness. Disconnect the stock kill switch ring terminal and connect the ring terminal of the 3600-SWHA. Fully remove the stock kill switch. Be sure all the wires are safe from being burned or pinched and re-install the gas tank. 3. Disconnect the two female spade terminals from the stock headlight switch (if present). Connect the terminal with the yellow wire to the red power lead from the switch. Connect the white wire to the blue accessory output from the switch. Be sure the clear silicone sleeves are covering the stock plastic housings. 4. Connect the X2 headlight to the switch headlight plug. Note: The stock headlight plug will not be used for the X2 installation, but is still functional for connecting the stock headlight. The stock plug will turn on and off with the new headlight switch, and will be powered in either of the Low or High Beam positions

Hot-Start Kit For Yamaha YZ/ WR 400F

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Filed Under (Yamaha) by admin on 16-12-2010

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Blaster Rear Brake Kits 121-01298 • YFS200 Blaster ’88-’98 • This cable will eliminate the stock cable from the handlebar. Cable will go from the rear brake pedal to the caliper. 121-01299 • Same as 121-01298 +4″ • Cable is 4″ longer for extended swingarms. 121-01027 Replacement Ratchet Spark Plug Wrench 121-08147 • Designed specifically to fit where there is limited space • Ratchet mechanism works one way • Fits standard 13/16″ plugs
INDEX PAINT HANDLEBARS STREET LEVERS FORK SEALS CABLES SUSPENSION ELECTRICAL FILTERS BRAKE LINES BRAKES CABLE MAKING SUPPLIES CONTROLS DUAL SPORT MANUALS FSO PRODUCTS EMGO DRIVE DISPLAY JETS BEARINGS EYEWEAR VINTAGE MIRRORS EUROPEAN KICKERS SHIFTERS MISC HARD PARTS SHOP TOOLS CHEMICALS TOOLS R . 03-15-06 21 (626) 792-7384 www.FlandersCompany.com Fax: (626) 792-5341 www.FlandersCo.com Specialty Tools Swingarm Bearing Tool 121-080213 • Designed for installation of the swing arm bearings on late model Japanese motorcycles • Using the correct size insert (various sizes included in kit) and the puller, the mechanic can draw the bearing into the swingarm without beating on it with a hammer Main Jet Wrenches • High-quality die cast construction • 6mm round and hex jets and 8mm round • Cap holds a few spare main jets • Sold each 121-08023 6mm Hex (Fits 6mm hex main jets) 121-08024 8mm Round (Fits 8mm round main jets) 121-08025 6mm Round (Fits 6mm round main and pilot) Allen Extension 121-080184 • 5mm allen on a 6.25″ long, 3⁄8-drive extension for hard-to-reach case bolts • Designed for use with air tools • Great for splitting engine cases

Kawasaki VN2000 LIGHT BAR INSTALLATION AND OWNER'S MANUAL

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Make certain the motorcycle is securely positioned for this installation. Cover the front fender with a protective cloth to avoid scratches. 2 . Remove caps that cover the headlight screws. Remove headlight screws. (Small Screwdriver and #2 Phillips Screwdriver) Figure 1 and 2. 3. Disconnect headlight at two places. Set light aside. Figure 3. 4. Disconnect the Right (Orange) and Left (Blue) turn signal connectors. 5. Remove the Screws with the 8mm hex head that hold the turn signal bar to the under side of triple clamp. Remove turn signal bar. Bar and screws will not be re-used. (8mm Socket) Figure 4. PREPARATION INSTALLATION 6. Mount the Light Bar Assembly. Hold Light Bar in place at underside of triple clamp. Use the M6 x 16 Screws with a Flat Washer to install the Light Bar assembly. Tighten Firmly. (5mm Hex Key) Figure 5. 7. Route the Light Bar Wires to the back and into headlight shell. WIRE LIGHT BAR HELPFUL WIRE TIPS: A. Keep the Right and Left Wires of the Light Bar in separate groups. B. Inside the headlight shell, the wires bundled in the Blue Connectors are for Right side operation and Orange Connector is Left. C. You will need to remove 2-3″ of electrical tape from the Blue/Yellow Stripe, Low Beam Wire inside the headlight to have room for two Scotchlok Connectors going to this wire. (Scissors) Figure 6

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