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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 FLHT ADVANCED AUDIO AM/FM/CD RADIO KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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INSTALLATION Remove Existing Equipment To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. 2. Remove outer fairing and windshield. Refer to OUTER FAIRING/WINDSHIELD REMOVAL in Service Manual. 3 2 1 is 00397 1. Socket head screw (4) 2. Radio support bracket (2) 3. Radio Figure 1. AM/ FM Radio Installation 3. See Figure 1. Using a long shank ball end socket (Snap- on® FABL6E or equivalent), remove the four socket head screws (1) to release the storage box from the left and right radio support brackets (2). Use the oblong holes in the fairing brackets to access the screws. Install Radio 1. Pull the storage box forward to remove the box from the opening in the inner fairing. Discard the storage box. 2. Position the radio (3) between the radio support brackets and push it into the opening in the inner fairing. 3. Align the threaded inserts in the sides of the radio with the oblong holes in the left and right radio support brackets. 4. Starting at the rear, install the four socket head screws previously removed. Alternately tighten the screws to 35- 45 in-lbs (4.0-5.1 Nm). 5. Plug the 23-place radio socket housing [27A] (part of the interconnect harness already installed on the vehicle) into the back of the radio. 6. Remove three T25 TORX® screws that hold the speaker opening cover on one end of the fairing. Discard the cover and screws. Install Speakers 1. See Figure 3. If the speaker (3) and adapter (4) are not assembled, or are assembled incorrectly, orient the speaker on the adapter and grille assembly so the speaker spade contacts are toward the side of the adapter with the widest edge. Snap the speaker into the adapter using finger pressure only.

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HONDA GL1100 AM/FM RADIO INSTALLATION MANUAL/ WIRING DIAGRAM

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Filed Under (Honda) by admin on 22-04-2011

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INSTALLATION ■ Outline Procedures This section gives general information needed for mounting the individual radio components on and in the fairing. A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts. 3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing. 7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wires. 3 of 11 Page 4 C) Fairing instllation 1) Install fairing on motorcycle. 2) Connect motorcycle wire harness 9-P coupler to fairing wire 9-P coupler. 3) Connect radio switch wire to switch sub- wire.4) Connect antenna feeder. 5) Confirm that radio operates properly. Reinstall parts removed in step 2 or (A) and in step 1 of (B). REWORKING ■ Remove Fairing and Fairing Parts (Fig.10) 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove right and left fairing pockets, right and left turn signal lenses, right and left nutplates, left hole cover and indi- cator base panel from fairing. (Fig.10) Fig. 10 LEI-1 NU I PLATE 4 of 11■ Reworking on Fairing — Speaker mounting holes- 1) Remove 18 mm grommet. 2) Lightly roll template so that it will follow contour of fairing snugly. 3) Position template on fairing with its upper and outer edges aligned with those offairing as indicated by arrows. 4) Attach template to fairing using adhesive tape where shown. 5) Punch mark centers of four holes with a
drift and hammer. 6) Drill 6 mm holes through marked centers. To obtain a more balanced response with richer, deeper bases, drill two 50 mm holes in the fairing so as to link the speaker box with the inside of the fairing. Fig. 11-1
—Power amplifier mounting holes- 7) Drill two 5.5 mm holes through concaves in fairing. Fig. 11-2 RIGHT HAND SHOWN, LEFT SIMILAR ADHESIVE TAPE

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HARLEY DAVIDSON ADVANCED AUDIO CB RADIO KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available 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. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

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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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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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2001 HONDA GL1800/ A Radio Muting Improvement

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

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1. Place the faulty radio in the same box in which the exchange radio was sent. THE FAULTY RADIO (CORE) MUST BE RETURNED IN THE SAME BOX IN WHICH THE EXCHANGE RADIO WAS SHIPPED. These boxes are identified by the label shown below which is printed on the inside of the lid. 2. Fill out the pre-printed FedEx airbill that came in the box with the exchange radio. The airbill should have the following address preprinted on it: AHM Remanufactured Parts c/o NK Parts Industries Inc./West 2640 Campbell Rd. Sidney, OH 45365-8836 • Do not use an ordinary FedEx airbill. The pre- addressed airbill has a special account number on it for the exchange program. If you need more airbills, call the Radio Order Desk toll free, not your assigned Parts Center . • Write your dealer number and the warranty claim number in the area shown in the sample airbill ffix the FedEx Airbill to the outside of the box. Radios sent in a box not bearing the correct FedEx airbill will not be accepted for reimbursement under this program. 4. Enclose a copy of the HONDANET for Windows warranty claim in the box. If the claim form is incomplete or not in the box, the faulty radio will be returned to your dealership. 5. Ship the faulty radio to the preprinted address on the airbill. NOTE: Do not ship the faulty radio to the manufacturer or the Warranty Parts Inspection (WPI) Center. 6. For your records, on the repair order include the following: • warranty claim number • original part number • FedEx airbill number When the faulty radio is received, a core credit will be posted to your dealership’s Balance Forward Account. The credit can be identified by the claim number + “CORE” (e.g., 12345/CORE). REMEMBER: A copy of the HONDANET for Windows warranty claim must be included in the box. RETURNING THE FAULTY RADIO The faulty radio must be returned within 20 days of

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HARLEY DAVIDSON RADIO FACEPLATE TRIM INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION NOTE Mounting surface of radio faceplate trim must be above 60°F (16°C), or the trim may not stay attached. 1. Using a 50:50 isopropyl alcohol/water solution, thoroughly clean the surface where the radio faceplate trim will be installed. Do not clean with denatured alcohol, mineral spirits, or other solvent products, or damage to the radio may occur. (00411b) 2. Allow the surface to dry completely before continuing to install kit. 3. Test the fit of the radio faceplate trim prior to removing adhesive backing. 4. Remove the adhesive backing from the back of the radio faceplate trim. 5. Open the auxiliary jack cap and feed it through the radio faceplate trim. 6. See Figure 1. Position the radio faceplate trim and press firmly into place. 7. Let the adhesive cure for at least 24 hours at no less than 60°F (16°C).

2010 Harley-Davidson FLHR Road King front and rear 4-piston braking system Installation

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Filed Under (Harley Davidson) by admin on 31-10-2010

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in Vivid Black with blue and silver pinstripes, six-speed. Air-cooled, Twin Cam 96™ engine with Electronic Sequential Port Fuel Injection (ESPFI), ABS, security system, cast wheels with independent front and rear 4-piston braking system. Motorcycle generously donated by Harley-Davidson Motor Company Police & Fleet Sales. MSRP excludes all taxes title/documentary fees, registration, tags, dealer prep, labor and installation charges, insurance, optional equipment and accessories, certificate of compliance or non-compliance fees, and finance charges. Delivery must be coordinated through Rockville Harley-Davidson by November 30, 2010. Winner is responsible for any applicable fees above. 6,000 tickets printed. Odds of winning are 1:6,000. Ticket holder need not be present to win. Licensed by the D.C. Lottery and Charitable Games Control Board. Must be 18 years or older to win. No substitutes, return for cash, or other models. As per IRS tax code, amounts paid for chances in a raffle do not qualify as a deductible charitable contribution. Taxes on prizes are the responsibility of the winner. Harley-Davidson is proud to be a sponsor of the National Law Enforcement Officers Memorial Fund. Harley-Davidson Motor Company is a prize provider only, and Harley-Davidson, Inc., and Harley-Davidson Motor Company have no responsibility regarding conduct or administration of the raffle.

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Harley Davidson Steering Wheel Radio Control Interface Installation instructions

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Filed Under (Harley Davidson) by admin on 03-05-2012

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1) Turn on the ignition to supply power to the SWI-3. 2) Use a pen to depress the “program mode” button. Remove pen when left LED light comes on. 3) Within 10 seconds press and hold one of the steering wheel function buttons. Continue to hold steering wheel button until the left LED turns off. Release the steering wheel button and the right LED turns on. 4) Place the stereo’s IR remote within 3″ of the “IR Input” port on the side of the SWI-3 next to the program button. Press and hold the remote’s button that corresponds to the steering wheel button that was pressed. Continue to hold the remote’s button until the right LED turns off. Release the button and the left LED will turn on. 5) Repeat steps 3 and 4 until all radio steering wheel functions are programmed. 6) When programming is complete, wait 10 seconds and both LED’s will flash 3 times. This indicates an automatic program exit. Do not stop more than 10 seconds while programming or there will be an automatic program exit and you will have to start over at step number 2 above. Turning off ignition before the automatic exit will require starting over at step 2 above. The SWI-3 can be reprogrammed unlimited times. Testing • Test the SWI-3 by holding it’s infrared LED (LED on the end of 4′ lead) close to the stereo and verify that it works properly. Experiment with various locations for the LED. You should be able to find a hidden and convenient mounting location. Try along the top front and /or bottom of the stereo as well as it’s sides. The LED can be replaced with most any IR LED, like Radio Shack’s # 276-143. The longest lead of the LED connects to the red wire of the 4′ cable and the short lead of the LED connects to the black wire of the 4′ cable

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