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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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HARLEY DAVIDSON ADVANCED AUDIO XM SATELLITE RADIO KIT INSTALLATION INSTRUCTIONS

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

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this kit fits 2006 and later FLHT (Electra Glide®), FLHTC (Electra Glide Classic), FLHTCU (Ultra Classic® Electra Glide), FLHX (Street GlideTM) and FLTR (Road Glide®) model motor- cycles. XM satellite radio is available within the continental United States. It is not available in Alaska or Hawaii. Additional Parts Required FLHT models will require prior installation of an Advanced Audio AM/ FM/ CD Radio Kit (Part Number 76412-06) and an AM/ FM Antenna Kit (Part Number 76325-06 or 76317-06). Unless one has already been fitted as part of another Advanced Audio kit installation: FLHT, FLHTC, and FLHX models will require the additional purchase of a Non-Ultra Overlay Harness (Part Number 70169- 06) and a left-hand Antenna Bracket (Part Number 76456-06). FLHTCU models will require the additional purchase of an Ultra Overlay Harness (Part Number 70164-06) and a left-hand Antenna Bracket (Part Number 76456-06). FLTR models will require the additional purchase of a Non- Ultra Overlay Harness (Part Number 70169-06) and an Antenna Bracket (Part Number 76316-06). If two modules are already installed on top of the radio, two Dual-LockTM mounts, Part Number 76434-06, will be needed. These items are available from a Harley-Davidson Dealer INSTALLATION 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 the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. NOTE If another module has been installed in the location reserved for the XM radio module, relocate that module per the instructions supplied with that kit

HARLEY DAVIDSON ROAD TECH XM SATELLITE RADIO RECEIVER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION NOTE Do not use solvent-based chemicals or waxes directly on the plastic or rubber components as they can affect the overall performance and appearance of the plastic and rubber. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. Models with main CIRCUIT BREAKER: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) -J03989 1 of 8
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 Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. Receiver Mounting Bracket Installation 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) 2. ALL models: See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 3. Using a T-27 TORX drive head, remove the two screws that retain the clutch-lever clamp to the handlebar. 4. See Figure 4. Obtain the correct mounting bracket (2) for your vehicle, and two button-head screws (3) and spacers (4) from the kit. Insert the button-head screws into the mounting bracket, through the holes above and below the slot. Place a spacer over the threads of each screw. Insert the screw threads into the holes in the clutch lever clamp removed earlier. 5. Adjust the hand lever position for rider comfort and posture, then tighten the screws to 60-80 in-lbs (6.8-9.0 Nm) . Receiver and Antenna Bracket Installation 6. Obtain the satellite radio receiver (1), antenna bracket (6), and four lock nuts (8) from the kit. Insert the four studs on the back of the receiver through the four holes in the receiver mounting bracket. 7. See Figure 4 for mounted position of the antenna bracket to the receiver mounting bracket. Assemble a lock nut to each of the bottom two studs. Install the antenna bracket onto the top two studs, and assemble a lock nut to each top stud. Tighten the locknuts securely. Antenna Installation 8. Obtain the XM radio antenna (5) and two-sided adhesive tape (7) from the kit. 9. Use isopropyl alcohol to clean the horizontal antenna mounting surface of the antenna bracket, and the bottom (mounting) surface of the antenna. 10. Peel the liner from one side of the tape, and apply the tape squarely to the bottom surface of the antenna. 11. Peel the liner from the exposed side of the adhesive tape on the antenna base. 12. Position the antenna over the bracket without touching the adhesive to the bracket. Center the antenna over the bracket with the antenna cable toward the center of the vehicle. 13. Press the antenna squarely and firmly onto the bracket, and hold pressure for about 60 seconds. After releasing pressure, avoid direct contact with the antenna for about 20 minutes. HARNESS ROUTING AND CONNECTION

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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 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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Steering Stem Nut Installation Instructions & Owners Manual

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Filed Under (Tips and Review) by admin on 26-11-2010

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Sport Bike Damper Kit Installation Instructions DISCLAIMER: All GPR Sport Bike damper kits are manufactured to be used ONLY w/ the stock top triple clamp and frame. If either is modded, aftermarket or crash damaged, the kit will not install properly and GPR will not be held responsible for the consequences of improper installation due to this or any other improper mounting or modifying. The provided instructions must be followed precisely, as failure to do so can result in the GPR damper kit being installed incorrectly. An improper installation may lead to a variety of undesirable steering problems. Please take your time and carefully follow the installation instructions. As always, give us a call if you have any questions, we’re more than happy to assist you in getting the damper kit mounted on your bike properly 1. Remove the stock Steering Stem Nut (SSN) and washer from the stock top triple clamp steering stem. Carefully set the stock nut aside, as you may be using it later. Bikes requiring a specific GPR SSN to replace the stock SSN are listed at the end of this installation sheet. If your bike is on the chart, throw you stock SSN in the toolbox along w/ the washer, as you may need it at a later date if for any reason you need to remove the GPR kit from your bike. Stock SSN’s that are either ‘domed’ at the top or ‘flanged’ at the bottom will definitely NOT work, may lead to problems and should NOT be reinstalled during the baseplate installation. See #2 below for further instructions about both SSN/Steering stem and arm clearance issues 2. With the stock SSN and washer removed, place the GPR Baseplate over the steering stem on the top triple clamp and reinstall either the stock SSN or the GPR SSN provided. Torque SSN down to the recommended specs as per the owner’s manual for your particular bikes make and model. NEVER reinstall the stock washer that came on the bike! The baseplate is now your new washer. If you do accidentally use the stock washer, the arm on the stabilizer will most likely ‘rub’ on the nut. It will be too high, potentially locking the steering and handlebars, thus making your bike un steerable and unridable. DO NOT ride your bike until all installation steps have been completed and you can visually verify that there is clearance between the arm of the stabilizer and the steering stem and/or SSN. Once the installation is complete, at the #1 setting you

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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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HONDA GL1800 CB RADIO KIT INSTALLATION And REMOVAL

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Filed Under (Honda) by admin on 20-11-2011

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These instructions are for installation of the CB radio. For operation of the CB radio, refer to the Owner’s Manual and FCC Rule Book furnished with the CB radio. • Install the antenna which is sold separately between the installation of the rear trunk and the routing of the wire harness. • It is not necessary to drill four 7 mm holes and install the plate when you are also installing the CD changer. 1. Refer to the Service Manual to remove the right and left side covers and disconnect the negative terminal from the battery

HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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

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REMOVAL 1. Refer to the owner’s manual and follow the instructions to disarm the security system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. For All Models except 2002-2003 Touring and 2003- Later Softail: Refer to the owner’s manual and follow the instructions to disconnect the battery, negative (-) cable first or remove the main fuse. For 2002-2003 Touring and 2003-Later Softail Models: Remove seat following the instructions in the service manual and disconnect the battery, negative (-) cable first. Save seat hardware for installation. INSTALLATION 2002-2006 VRSCA, VRSCB, VRSCD Models 1. Open the seat. 2. See Figure 1. Remove the splash guard (mud flap) nuts. 3. See Figure 2. Lower the mud flap from the installed position and allow it to rest on the rear tire 3. Slide the siren into place on the left side of the electrical caddy so the sounder disc (6) faces out. 4. Refer to the owner’s manual and follow the instructions to install the main fuse. 5. Align the barbed studs on the side cover with the grommets in the frame and push side cover firmly into place. 6. Install the left side saddlebag per the instructions in the owner’s manual. 2003 and later Softail Models EXCEPT FXCW/C 1. Remove the right side saddlebag (if equipped) per the instructions in the owner’s manual. NOTE The siren connector is installed on an electrical panel under the rear fender on all Softail models. The rear of the motorcycle may have to be raised slightly to allow removal of the splash guard. 2. Remove the two bolts at the bottom of the splash guard. Bend the upper right corner of the splash guard toward the rear tire and lift upward to unhook the splash guard from the tab on the rear fork. Remove the guard from beneath the fender. 2 1 3 is01316 1. Siren mounting area 2. Siren connector [142B] 3. Harness clip Figure 16. Siren Connector (Softail Models EXCEPT FXCW/C) (Rear Fender View with Rear Wheel Removed) 3. See Figure 16. Remove the siren connector [142B] (2) from the receptacle in the siren mounting area (1) of the electrical panel. 4. See Figure 17. Insert security siren (1) connector [142B] into the siren box receptacle until the connector latches securely. 5. Orient the siren (1) as shown, with the harness connector (2) toward the bottom and the sounder disc (5) facing out. Carefully snap the siren into the electrical panel. 6. Insert the siren harness lead (4) into the harness clip (3) to keep the harness clear of other components. 7. If necessary, secure the connector wiring to the electrical panel wiring with a cable strap (not provided). 8. Hook the slot at the top of the splash guard over the tab on the rear fork and install the guard with the two screws removed earlier. Tighten securely. 9. Install the right side saddlebag (if equipped) per the instructions in the owner’s manual. 10. Refer to the owner’s manual and follow the instructions given to connect the battery cables or install the main fuse

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HONDA XR/ CRF100 120 BIG BORE KIT INSTALLATION AND REMOVAL INSTRUCTIONS

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Filed Under (Honda) by admin on 15-11-2011

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nstallation of this bore kit is identical to OEM installation. Please re- fer to the Honda shop manual or a qualified machanic for assistance. Note that the larger valve relief in the piston dome is the intake side (it should be installed closer to the rear of the bike). Every effort has been made to insure the quality of this product. Because BBR cannot control the installation or use there is NO warranty or guarantee with this product. Using quality motor- cycle oil will help prolong engine life. Be sure to change it often This kit is intended for use on 1993 and newer XR/CRF100′s using CDI ignition. Engine assembly requires special attention to detail. A new BBR Cylinder and piston kit have been supplied. The following measurments are critical to proper installation and performance

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