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1982-2005 Harley Motorcycle Removal and Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-03-2012

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” bolt from the mounting stem on the Signal® mirror. While seated on the motorcycle, position the Signal® mirror on the handle bar. Secure the Signal® mirror to the handle bar using the 5/ 16 ” bolt. Make sure the bolt is tight! Guide the Signal® mirror wire harness into the cowling by going along side the existing factory wire harness. 4 Remove any slack in the wire harness. Secure the wire harness to the handle bar using a supplied tie wrap. 5 6 Adjust the position of the Signal® mirror and tighten the ball retention screws. Remove the motorcycle seat. Remove the aft mounting bolts on the fuel tank. 7 Guide the Signal® mirror wire harness along the inside of the fuel tank’s front mounting bolt and between the crossover tube. 8 9 Lift up the aft portion of the fuel tank and guide the Signal® mirror wire harness down the backbone of the motorcycle frame, alongside the existing factory wire harness. The motorcycle’s electrical wiring for turn indicators is located aft of the gas tank on the backbone of the frame. Guide the new wire harness from the Signal® mirror to the electrical wiring. Cut off any excess slack in the wire. Locate the SOLID BROWN wire from the wire connector. Turn the ignition key so that electrical power is on and activate the right side turn indicator. Probe the wire with the wire tester to verify that flashing turn indicator power is present. Label that wire as ‘right side turn’. Repeat all of the previous steps to replace the left side factory mirror with the new Signal® mirror. Locate the SOLID VIOLET wire from the wire connector. Activate the left side turn indicator and probe the wire with the wire tester to verify that flashing turn indicator power is present. Label that wire as ‘left side turn

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SR-C400 Motorcycle Security System INSTALLATION MANUAL AND USER'S GUIDE

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Filed Under (Tips and Review) by admin on 29-01-2011

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Routing the Antenna Wire The MCM includes an 18″ antenna wire. The first 12″ is a coaxial wire; the remaining 6″ is the reception antenna wire. When routing, try to avoid running the antenna along or near metal. For best performance, have the antenna wire as vertical as possible and exposed. Wire Connections The system includes one harness (HAR-1a) that connects directly into the MCM. The harness is split into three plugs: one for the GEN-1a connector, one for the optional SN-5 connector and one for the data output for future expansion. Note: Each plug is unique and will only fit the appropriate component one way. Main Harness Note: If the optional factory connector kit is being used, please disregard this section of the instructions and refer to the instructions supplied with the factory connector kit. The main harness consists of two harnesses. One is labeled (HAR-1a) and the second is labeled (GEN-1a). Plug in the white 4 pin connector from the (HAR-1a) into the matching 4 pin connector from the (GEN-1a). The (HAR-1a) also has a waterproof connector that plugs into the MCM. The wires should be connected as follows: HAR-1a Black wire with fuse and ring terminal – To battery Positive (+). GEN-1a Black wire – To ground (-). Orange wire – To tail light wire or any other wire that is hot (+) when ignition is ON (NOTE: this is an input to the alarm this connection is not designed to flash the tail light). Color Codes: Ground (-) Tail Light Honda Green wire Brown wire Kawasaki Black wire Red wire Suzuki Black/White Brown wire Yamaha Black wire Blue wire Harley Davidson Black wire Blue wire

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HARLEY DAVIDSON VRSC BRACKET FOR BILLET HEADLAMP SHELL REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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REMOVAL VRSCA Models 1. Remove windshield (if equipped). Refer to appropriate Instruction Sheet for procedures. 2. Remove right side cover and maxi-fuse. Refer to MAXI- FUSE in Service Manual. 3. See Figure 1. Disconnect headlamp connector (1) from vehicle wire harness. 4. Remove two screws (2), headlamp mounting bracket (3), and headlamp assembly (4) from upper bracket. 2 3 4 5 1 is03046 1. Connector 2. Screw (2) 3. Bracket 4. Headlamp assembly 5. Screw (2) Figure 1. VRSCA Headlamp Assembly VRSCB Models 1. Remove windshield (if equipped). Refer to appropriate Instruction Sheet for procedures. 2. Remove right side cover and maxi-fuse. Refer to MAXI- FUSE in Service Manual. 3. See Figure 2. Disconnect headlamp connector (1) from vehicle wire harness. 4. Remove two screws (2), headlamp assembly (3), and headlamp mounting bracket (4) from upper bracket. 5. Remove nut (5), screw (6), and trim ring (7) from head- lamp. 6. Remove lens assembly (8) from headlamp shell (9). Save lens assembly for Billet Headlamp Shell Kit 67704-03 installation INSTALLATION 2004-Earlier VRSCA and VRSCB Models 1. Assemble Chrome Billet Headlamp Shell Kit (67704-03). Refer to Instruction Sheet-J03018. NOTES VRSCA models use Headlamp 68297-05, while VRSCB models use original equipment lens assembly (including gasket and boot). Adapter ring from kit (Figure 6, Item 1) will be used to install billet headlamp assembly on Instruction Sheet-J03018. 2. See Figure 3. Cut the two connectors (1) from existing headlamp wire harness (2). Be sure to cut the wires as close to the back of the connector as possible. 3. See Figure 6. Route new wire harness (2) through the hole in bottom of the billet headlamp shell (A). NOTE Only one 16 AWG wire will fit into pin terminals included in kit. Both black wires (ground) can be joined together, then connected to a single wire, if desired. 4. Tape end of one black wire with electrical tape and secure it to wire harness. 5. See Figure 3 and Figure 6. Install terminal pin (3) and socket housing (4) onto new wire harness (Figure 6, Item 2). Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual for installing socket/pin terminals. 3 4 1 2 is03025 1. Connector (2) 2. Wire harness 3. Terminal pin (4) 4. Socket housing Figure 3. 2004-Earlier VRSCA and VRSCB Headlamp Wire Harness 2005-Later VRSCA and VRSCB Models 1. Assemble Chrome Billet Headlamp Shell Kit (67704-03). Refer to Instruction Sheet-J03018. NOTES VRSCA models use Headlamp 68297-05, while VRSCB models use original equipment lens assembly (including gasket and boot). Adapter ring from kit (Figure 6, Item 1) will be used to install billet headlamp assembly on Instruction Sheet-J03018. 2. Disconnect and discard existing wire harness. 3. See Figure 6. Connect new wire harness (2) to billet headlamp shell (A). 4. Route wire harness (2) through hole in bottom of billet headlamp shell (A) before installing socket housing (4) provided in kit

Harley-Davidson Road King Handlebar Removal and Installation Manual

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Filed Under (Harley Davidson) by admin on 18-03-2012

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If the wire length appears to be too short, you will have to lengthen the wires. If that’s the case, I must stress that soldering your wires is far superior to using butt splices. Wiring can be pulled from the splices and the splices themselves will take up a lot of room, making your harness bulky. To extend your wires, ensure the wire segments you are going to splice into the harness are of the same gauge as the original harness. Also, it’s a good idea to cut all of the wire segments now, ahead of time, to the same measured length. This will ensure that once all of the new wire Figure 4. Handlebar harness plug wires as they appear from the back of the plug (where the wires enter the plug from the harness) segments are spliced in, all of the finished wires are of the same length and the pins are lined up. Work from wire to wire, cutting them by staggering the cuts about an inch or so apart (see figure 5). This will prevent a bulge in your harness where all the soldering connections are. After cutting each wire, slide on a two-inch piece of heat shrink tubing before starting your soldering. Remove about ¾” of insulation from the ends of the two wire ends (one wire end being the harness, the other being the segment of new wire being spliced in). Halfway down the length of its exposed section, bend each wire 90 degrees and hook the two wire segments together at the bends. Holding the wires securely with a pair of pliers, twist them in opposite directions around each other. Make sure the ends of the wires are wrapped as tight as possible so their sharp points will not cut through the heat shrink tubing when it’s applied. Apply some soldering flux (a little is all you need) and solder the connection by first applying your soldering iron (or gun) to the wire and then applying the solder to the wire. You should not apply the solder directly to the iron as overheating the solder can lead to poorly made solder joints and improper conduction of electricity. When the connection has cooled, slide your heat shrink tubing over the joint and heat it so that the tubing shrinks, making a nice tight seal.

BMW R1200GS Dual Function LED Running Lights and Flashing Brake Lights installation instructions

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

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The flasher is set to flash continuously as long as the brake is applied. To convert to a 5 second flash and then stay solid while the brake is applied, cut the green wire loop on the flasher. Use electrical tape to protect and secure the green wires to the other wires. 2. Remove the rider’s seat. Locate the wire bundle that starts at the rear of the motorcycle. At the most accessible spot carefully remove 3″ to 3½” of protective wire loom. I know, I know…it’s really beautifully done. Cowboy up! Take it off! 3. Mount the flasher in a location that will not crimp wires or interfere with the other bike assemblies. Locate the +12 volt wire ( GRAY wire with BLACK stripe and YELLOW banding) from the brake light Attach the kit RED wire to the brake light positive wire using one of the Posi-Tap connectors in the kit. 4. Locate the Ground wire ( BROWN wire) from the brake light. Attach the kit BLACK wire to the motorcycle ground wire using a Posi-Tap connector. 5. If you have a Fuse Block with ignition switched relay installed, route the Hyper-Lite GRAY wire to a fused circuit on the (relay activated) fuse block . 6. If you do not have a Fuse Block installed, find the alarm circuit connector under the seat . The alarm circuit has a rectangular connector and five wires, White with Black stripe; White with Brown stripe; Red with White; Brown with White; and Green with White stripe. Use a Posi-Tap to attach the Hyper-Lite GRAY wire to the green wire with white stripe. Pull the wire loom back from the wire. Tap into the wire with the Posi-Tap provided. . 7. If using the Hyper-Lite License Plate Mounting bracket, install it now. OR: Clean the side facing reflectors at the rear of the bike with alcohol. Mount the LED modules vertically on the reflectors so that the LEDs point straight back. Press in place for about 5 seconds. The tape can be used only once! If you goof, new tape is required. 8. Route the BLUE and BROWN wires from the flasher and the LED modules. Trim the Blue and Brown wires to remove any excess wire . Use a Posi-Twist to connect the 3 BLUE wires together. Use a Posi-Twist to connect the 3 BROWN wires together. (see Posi-Twist Connector instructions)

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2002-2005 Honda VFR800/A Wire Harness Replacement Manual

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Filed Under (Honda) by admin on 21-04-2011

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If the 18P (light blue) connector is in abnormal condition as shown below, contact TechLine at (800) 421-1900, option 9. FRONT SUB-HARNESS REPLACEMENT 1. Remove the front sub-harness from the cowl stay hooks. Disconnect all the electrical components from the front sub-harness. 2. Temporarily set the main wire harness aside, and disconnect the 6P (natural) con- nector. Then, carefully remove the front sub-harness. 3. Install the new front sub-harness by con- necting the 14P (natural) and 18P (light blue) connectors. NOTE: For routing specifications, refer to the WIRING & HARNESS ROUTING SECTION on pages 7-8. 4. Attach the front sub-harness on the cowl stay hooks. Make sure the front sub-harness is routed elow the main sub-harness. ABNORMAL CONDITION STAY HOOKS 6P (NATURAL) CONNECTOR FRONT UB-HARNESS 14P (NATURAL) CONNECTOR 18P (LIGHT BLUE) CONNECTOR FRONT SUB-HARNESSSTAY HOOK Page 4 VFR800/A #4 4 of 12 NOVEMBER 2007 5. Place the front sub-harness between the radiator and the frame, and below the rec- tifier. Be careful not to damage the front sub-harness or other components. 6. Re-connect the front sub-harness to the 6P (natural) connector. 7. Secure the main wire harness and the front sub-harness using the longer wire band. 8. Secure the main wire harness and the upper side of the front sub-harness using the shorter wire band. Adjust the wire har- ness located within the frame and the radi- ator hose accordingly. 9. Secure the main wire harness fuse box to the front sub-harness using the shorter wire band. FRONT SUB-HARNESS STAY HOOK MAIN-HARNESS FRONT SUB-HARNESS FRONT SUB-HARNESS 6P CONNECTOR (Male) 6P CONNECTOR (Female) WIRE BAND (LONG) WIRE BAND (SHORT)
WIRE BAND (LONG) WIRE BAND (SHORT) MAIN WIRE HARNESS FUSE BO

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1999-2002 Indian Motorcycle Mirror Housing Removal and Replacement

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Filed Under (Indian) by admin on 31-10-2010

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1. Remove seat. 2. Disconnect battery. 3. Remove handlebar cover on top-center of handlebar. 4. Remove left-side clutch-bracket assembly. This exposes an access hole on the underside of the handlebar. 5. Pass the end of the Signal® mirror wires through one of the small holes located on the underside of the clutch-bracket assembly housing. 6. Take piano wire/fish tape and insert at the access hole located on the underside of the handlebar to the center of the handlebar (center handlebar cover removed). 7. Fasten the end of the Signal® mirror wires to the piano wire/fish tape and pull through the handlebars to the center opening. 8. Pull excess wire through the handlebars leaving approximately 2″ of extra wire at the mirror side. 9. Re-assemble clutch-bracket assembly allowing the Signal® mirror wire to wrap around the outside edge of the cover assembly into the underside access hole. Secure Signal® mirror with enclosed 1.5″ long 5/ 16 ” – 24 Allen head bolt. 10. Loosen throttle assembly side and slide back to expose access hole. DO NOT REMOVE THROTTLE ASSEMBLY. Proceed to pass the Signal® mirror wire through the handlebar at the opposite side and re-assemble the throttle assembly. 11. Run both sets of wires under the fuel tank along the topside of the frame to the battery compartment. 12. Connect both black wires to the enclosed ring connector for connection to the battery ground terminal. 13. Locate the male/female electrical connector that is located behind the battery. This wiring assembly is for your tail lamp assembly for braking and turning (see photo). 14. Make sure the harnesses are routed securely to the wire connectors and enough slack is left for splicing or soldering. Cut the heat shrink into (4) equal pieces (approx. 2″ each). 15. Slide the heat shrink over the passenger side Signal® mirror wire. Solder the Right Signal® mirror wire to the Brown wire. Slide the heat shrink over to cover the soldered area. Heat the shrink tube into place with a heat shrink gun or hair dryer. 16. Repeat sliding the heat shrink over the driver side Signal® mirror wire. Solder the Left Signal® mirror wire to the Purple wire. Slide the heat shrink over to cover the soldered area. Heat the shrink tube into place with a heat shrink gun or hair dryer. 17. Connect ground and positive battery connections. 18. Re-install seat.

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DRAG SPECIALTIES MINI SPEEDOMETER WITH LED INDICATOR LIGHTS INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 29-01-2011

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1. Place the motorcycle on a level and secure area. Disconnect the battery. 2. Refer to the appropriate factory service manual and remove the OEM speedometer and indicator lights. The indicator lights usually unplug either in the rear of the headlight or under the gas tank area. 3. Mount the new speedometer in the desired location. 4. Locate the OEM wire for the high beam indicator light. Connect it with the blue wire from the wire harness on the speedometer. Connect the blue/black wire from the speedometer to ground. 5. Locate the OEM wire for the gauge illumination (back) lighting. Connect this wire to the orange wire on the speedometer. Connect the black wire on the speedometer to ground. 6. Locate the OEM wires for the turn signals. Usually they are brown and violet wires. NOTE: You will notice only one bulb for the turn signals in the gauge and two wires from the bike to the harness. If you connect both of these wires directly to the yellow wire on the speedometer, this will allow feedback and cause all the signals to flash at once. To prevent this, you will need to add a diode between each OEM turn signal wire and the yellow wire coming from the speedometer. We recommend that you utilize a Dyna tach adapter, Part #D-101, available separately. This tach adapter includes the diodes necessary to allow the turn signal indicator light to operate correctly. Follow the instructions for the tach adapter, substituting the wires from the original wire harness found in step 6 for the two ignition terminals shown in the wire schematic. Hook the white wire on the tach adapter to the yellow wire for the turn signal indicator on the speedometer. If you use the D-101 adapter, skip steps 7-9 and go directly to step 10. 7. Take one of the diodes, making sure to observe the correct polarity, and attach it to the brown turn signal wire on the bike. 8. Take the remaining diode, again making sure to observe the correct polarity, and attach it to the violet turn signal wire on the bike

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HI-4 DUAL FIRE MOTORCYCLE IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 09-11-2010

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Turn ignition switch off and disconnect battery ground cable. 2. Refer to Figure 3. Remove OE ignition module and wire harness (items 1-4). You will disconnect two wires at the coil (15), a wire going to the VOES (Vacuum Operated Electrical Switch) (18), a black ground wire at the ignition module, and the 3 pin plug (20) that connects to the sensor plate (11). Refer to shop manual for locations. 3. Remove ignition cover plates and gasket (items 5- 9). This will require drilling out two rivets. The rivets will later be replaced with two supplied self- threading screws. 4. In order to remove the sensor plate cable, the cable plug (20) must be removed first. Use needle nose pliers to pull the terminals out of the plug. Then pull the cable through the exit hole at the bottom of the timing cover. 5. Note location of sensor plate (11). There is a V notch in the sensor plate used for alignment. When you install the HI-4, you should align the V notch in the same location. This should set the timing close enough to start the engine. Remove and save the two standoffs and washers (10). Remove the sensor plate (11). HI-4 INSTALLATION Refer to Figure 4. The HI-4 requires use of the OE timing rotor P/N 32402-83 (used only on 1985 and newer models). If you have an older model or are not sure, check the rotor (9) for the correct part number. For models prior to 1980, use the supplied 10-32 x ¾”bolt and washer to mount the rotor. 1. Install the HI-4 system in place of the OE breaker or sensor plate. Rotate the HI-4 about 90 degrees to give better access to the cable exit hole. Install the HI-4 first, then push the cable through the hole. On some early models it may be necessary to enlarge the wire harness exit hole in the gear cover. Align the V notch on the HI-4 same as the OE plate you removed. Use the OE standoffs to secure the HI-4. You must use lockwashers under the standoffs for proper clearance between the HI-4 and cover plate. Do not fully tighten the standoffs until the timing has been set. 2. Route the HI-4 wire harness along the frame rails up to the coil. Make sure that harness will not be chafed or burned by exhaust heat. Secure harness with tie wraps. Do not install timing cover. HI-4 HOOKUP Crimp terminals and hardware are supplied for your convenience. Use the ring terminals for coil hookup. Use male-female quick disconnects for connections to the tach and vacuum switch (VOES). Tape up any unused wires. 1. Circuit Breaker Cover Screws (2) 2. Circuit Breaker Cover 3. Circuit Breaker Cover Gasket 4. Breaker Plate Screws (2) 5. Breaker Plate Screw Lockwashers & Washers (2 each) 6. Retainer (1971 to early 1972) 7. Circuit Breaker Cam Bolt 8. Breaker Plate Assembly 9. Breaker Cam 10. Advance Assembly 11. Gear Case Cover 11 10 9 8 7 6 5 4 3 2 1 NOTE: Damage will result if the brown tach wire comes in contact with +12V. Figure 1. Harley-Davidson®OE Points System
9000-4002A REV A 3 2/05 1. Identify switched +12 volt wire and tach wire (if equipped) going to the coil. Refer to your service manual, or reconnect the battery and use a test light or voltmeter. The switched +12 volt wire will be hot when the ignition key is turned on. 2. Refer to Figure 5. Connect the HI-4 red wire and switched +12 volt wire to Coil positive. 3. The HI-4 white wire is not used and should be taped. 4. Connect the HI-4 black wire to the Coil negative terminal. 5. Connect the HI-4 green wire to the vacuum switch (Figure 3, item 18), if used. 6. Connect the HI-4 brown wire to the tach wire, if equipped with tach. Tape up if unused. 7. The HI-4 is grounded via the timing housing; a separate ground connection is not required. 8. Reconnect battery ground cable. Verify proper ground connections to the frame and engine. VOES HOOKUP The OE vacuum switch (VOES) is normally an open circuit. Above 3-5 inch-Hg vacuum, the VOES closes and grounds the vacuum input on the OE ignition module. This increases the total advance generated by the OE ignition module. Vacuum advance improves part throttle 17 16 1. Cover Screws (2) 2. Ignition Timer Cover 3. Ignition Module 4. Timer Plate Screws (2) 5. Washers (2) 6. Screws & Washers (2 each) 7. Shield 8. Sensor 9. Trigger Rotor Bolt 10. Timer Plate 11. Trigger Rotor 12. Advance Assembly 13. Gear Case Cover 14. Ignition Coil 15. Spark Plug Wires (2) 16. Ignition Coil Terminal (FX) 17. Ignition Coil Terminal (FL) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 NOTE: Most motorcycle coils do not have terminals marked. Use either terminal for Coil+ (positive) and the other one for Coil- (negative). Warning: The HI-4 (8-1100) Dual Fire ignition will not work with 2 plugs per head, dual coil application. Damage will result if attempted. Use the HI-4 (8-2100) single fire ignition for 2 plugs per head applications

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SUZUKI SV650 ELECTRICAL SYSTEM REMOVAL AND INSTALLATION MANUAL

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

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CAUTIONS IN SERVICING CONNECTOR • * When connecting a connector, be sure to push it in until a click is felt. • * Inspect the connector for corrosion, contamination and breakage in its cover . COUPLER • With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it . • * When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires . • * Inspect each terminal on the coupler for being loose or bent . • * Inspect each terminal for corrosion and contamination. CLAMP • * Clamp the wire harness at such positions as indicated in “WIRE HARNESS ROUTING”. ( r- 79-14 to 9-16) • * Bend the clamp properly so that the wire harness is clamped securely. • * In clamping the wire harness, use care not to allow it to hang down. • * Do not use wire or any other substitute for the band type clamp. FUSE • * When a fuse blows, always investigate the cause, correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . i SEMI-CONDUCTOR EQUIPPED PART • * Be careful not to drop the part with a semi-conductor built in such as a ECM. • * When inspecting this part, follow inspection instruction strictly . Neglecting proper procedure may cause damage to this part . BATTERY • The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment) . • * During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources (e.g., short circuit) nearby when charging the battery . • * Be sure to recharge the battery in a well-ventilated and open area. •Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery . CONNECTING THE BATTERY •When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the O battery lead wire, first. • * When connecting the battery lead wires, be sure to connect the OO battery lead wire, first . • * If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush . • * After connecting the battery, apply a light coat of grease to the battery terminals. • * Install the cover over the O battery terminal. WIRING PROCEDURE • * Properly route the wire harness according to the “WIRE ROUTING” section. (C’9-14 to 9-16) ELECTRICAL SYSTEM 8- 3
8-4 ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER •Properly use the multi circuit tester Oand Oprobes. Improper use can cause damage to the motorcycle and tester. • * If the voltage and current values are not known, begin measuring in the highest range . • * When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged . • * After using the tester, be sure to turn the switch to the OFF position. CAUTION Before using the multi circuit tester, read its instruction manual.

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