honda gl1500 reverse relay

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HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

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Audio Oil Pressure Alert Relay Installation Instructions

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Filed Under (Tips and Review) by admin on 27-10-2010

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Step 1) Wire Connection: Using 18-gauge automotive wire, connect the audio alert relay as shown in the Wiring Diagram – Figure 1. • Connect the supplied wire from #3 terminal on the audio alert relay to the oil pressure switch post. Note: The supplied wire is not reversible. The eyelet end must hook to the oil pressure switch. • Connect a wire from #2 terminal on the audio alert relay to the ignition switch post that receives power when the ignition switch is first turned on. • Connect a wire from #1 terminal on relay to the positive side of existing horn, or alternate sound device. • Note: The audio alert relay uses the oil pressure switch as its ground. On most motorcycles, this audio alert relay can be installed easily under the dash. Figure 1- Wiring Diagram Cot a Oil Pressure Switch Ignition Switch Audio Alert Relay 2 1 3 load Horn + + – Caution: Make sure all connections are insulated away from potential grounds. Do not disconnect any existing wire. Step 2) Testing : Turn ignition switch on and ensure oil pressure light is on. Leave ignition switch on. Wait 30 sec (T1) and ensure the audio alarm sounds for ½ second (T2). If the electrical test is successful, proceed to Step 3. If not, you may have to use a pezio alert in place of the horn. (Which is available at most Radio Shack stores.) If audio alert still doesn’t work, consult the wiring diagram and recheck all wiring connections. Verify timer set points have not been altered. If problems persist, contact us at (518) 884-9591. Step 3) Mount relay switch: Use standard zip ties (not provided) or similar means to mount the relay to dash mount post or dash base. Note: The timer relay can be mounted almost anywhere on the bike that will not be exposed to direct rain or weather

2001 YAMAHA TDM900 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760

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HARLEY-DAVIDSON 5 and 6 Speed OEM Transmissions ReverseGear User Operating Instructions

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Filed Under (Harley Davidson) by admin on 16-02-2011

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A. It is good practice to first engage first gear to stop the gearbox from spinning (This will prevent the “grinding” noise when reverse gear is engaged) and then place the bike in neutral and immediately engage reverse. If Reverse Gear still “grinds” after the above procedure – check the clutch adjustment to ensure the clutch is not dragging and causing the gearbox shafts to spin. B. Do not let the bike “free wheel” backwards while in reverse gear and the clutch engaged or disengaged (i.e. when rolling down a slope when in reverse) – The reverse gear will automatically try to disengage and will result in a “grinding” sound. To prevent this – Always stop immediately after the reverse action is completed. WARNING! Reverse gear is intended for light duty use only – like slowly backing in/out of parking spaces etc. Do not drive for long periods in reverse. WARNING! Do not attempt to engage reverse while the motorcycle is up on a lift stand. Maintenance Check transmission fluid levels regularly and fill with Manufacturer’s suggested lubricants. Warranty One year on reverse gear parts only. Champion will not warranty the Reverse Gear if it is deemed to be “abused” by the user like: – Engaging First Gear while the Reverse Gear is still engaged and/or – Over powering the Reverse Gear by revving and dropping the clutch and/or – For an Installation Error (not following the installation instructions exactly). Any attempt to modify this product without written permission from the manufacturer will void the warranty and may cause damage to vehicle and injury to persons.

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Honda GL1500 Gold Wing Motorcycles Trike Conversion Installation Guide

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Filed Under (Honda) by admin on 19-12-2011

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Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. • Left and right side-covers (to be re-installed with minor modification). • Seat (to be re-installed without modification). • Trunk. • Left and right passenger foot rests (to be re-installed without modification). • Left and right side-covers above passenger foot rests. • Battery and holder (to be re-installed without modification). • Left and right saddle bags (retain side cover mounting grommets for re-use). • Left and right mufflers. • Rear wheel. • Rear brake line to master cylinder.** • Reverse resistor assembly (to be relocated). • Swing Arm (Drive shaft boot will not be used). • Bank angle sensor. • Shocks. Air shock (non coil-over) to be reused. ** Thoroughly vacuum drain rear brake system, including feed line to left front caliper Modification to Trunk / Luggage Stay Removal from vehicle frame is not necessary. a. Cut the down tubes of the trunk stay and remove the lower section as shown in Figures 1 & 2 b. Trim rear upper tube-end rounded corners just outboard of welded nut. Trim line should be parallel with center line of vehicle. This will provide clearance for body when installed. Figure 2 (Inset) c. Remove the Hazard and Turn Signal relays from the center holder; bend Relay Holder Tab up 90°. Relays will be relocated to left and right sides. Figure 3

Honda GL1500 Gold Wing Trike Conversion Installation Manual

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Filed Under (Honda) by admin on 17-02-2011

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REMOVAL OF ORIGINAL PARTS Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. • Left and right side-covers (to be re-installed with minor modification). • Seat (to be re-installed without modification). • Trunk. • Left and right passenger foot rests (to be re-installed without modification). • Left and right side-covers above passenger foot rests. • Battery and holder (to be re-installed without modification). • Left and right saddle bags (retain side cover mounting grommets for re-use). • Left and right mufflers. • Rear wheel. • Rear brake line to master cylinder.** • Reverse resistor assembly (to be relocated). • Swing Arm (Drive shaft boot will not be used). • Bank angle sensor. • Shocks. Air shock (non coil-over) to be reused. ** Thoroughly vacuum drain rear brake system, including feed line to left front caliper PREINSTALLATION PREPARATION 3.1 Modification to Trunk / Luggage Stay Removal from vehicle frame is not necessary. a. Cut the down tubes of the trunk stay and remove the lower section as shown in Figures 1 & 2 b. Trim rear upper tube-end rounded corners just outboard of welded nut. Trim line should be parallel with center line of vehicle. This will provide clearance for body when installed. Figure 2 (Inset) c. Remove the Hazard and Turn Signal relays from the center holder; bend Relay Holder Tab up 90°. Relays will be relocated to left and right sides. Figure 3 d. Disconnect and remove Bank Angle Sensor from its mount tab (Bank Angle Sensor will not be re-used). Cut wires midway between sensor and plug. e. On plug end, splice / connect red and green wires together to close the circuit. f. Cut and remove the Bank Angle Sensor mount tab from the Trunk stay. Figure 4 3.2 Modification to Rear Inner Fender Removal of fender and attached parts is not necessary for modification. a. Place supplied template (See last page) on fender (left and right sides) as shown and mark outline. With box cutter, cut fender along template outline. Once material is removed, make a vertical cut up the side (line indicated by arrow Figure 5) of the fender. Do not continue cut across top of fender. Figure 5 b. Carefully heat underside of fender with heat gun and bend fender upward until aft end contacts frame cross member. c. Drill holes in plastic fender through cross brace at locations indicated and secure fender to cross with zip ties. Figure 6

HONDA VTX 1800 AIR HORNS AHVTX INSTALATION INSTRUCTIONS

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Filed Under (Honda) by admin on 23-12-2010

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1. Remove the right and left frame side covers and the seat. 2. Unplug and remove the stock horn located behind the left foot peg. Re-route the horn wires up over the front cylinder head and to the rear. Next cut two pieces of wire 36″ long, strip both ends ¼”, crimp two male spade terminals to one end and two females to the other ends. Attach these wires to the stock horn wires and route them over the rear cylinder and behind the frame tube. The end of the wires should come out near the center of the left side cover area (see photo 1 A). Connect these two wires to the relay terminals 85 & 86 (these will be the two that are parallel to each other see wiring diagram for terminal identification). 3. Using a blade screwdriver pry the two hoses with the “Y” connector off of the air horns. Cut a new piece of hose 2 ¾” long, replace the old short hose on the “Y” with this. Re-install the “Y” hose assembly onto the horns with the short hose on the long trumpet, route the hoses behind the horns and connect the long hose to the short horn (see photo 2A). 4. Remove the upper 8mm (12mm wrench size) motor mount bolt (see photo 2B). Install the horn assembly using the 8 x 55mm bolt and spacer tube provided. If the motorcycle is fitted with Honda line tubular radiator or engine guards the above mounting will not work. You will need instead to locate the “J” shaped bracket and small hose clamp provided in the hardware kit (see photo 2 on instructions of multi -application instruction sheet). Thread the hose clamp thru the bracket and attach to the frame or Honda line guards as shown ( see photos 2&3 ) tighten the hose clamp securely using a socket or wrench. Attach the horn set to the “J” bracket using the 5/16 x ¾” bolt, nut and lock washer provided. Position the horns so that they are angled down just slightly then tighten the bolt securely. Attach the remaining air hose to the “Y” connector, route the hose up over the top and to the rear of the engine. Cross the hose over to the right side of the rear cylinder head, then behind the electricals of the right side cover and coming out as shown ( see photo 3 A & B ). 5. Remove the center relay from its mounting bracket by lifting it upward and re-attach it lower and at an angle as shown (see photo 3C) using a small cable tie. Route two long cable ties thru the hole in the relay mounting bracket as shown (see photo 3D). Next cut a 16″ wire, strip both ends, crimp female spades to both ends. Attach this wire to the compressors pos (+) terminal. Cut an 8″ wire, strip both ends, crimp a female spade to one end and a fork terminal to the other. Attach this wire to the compressors neg. (-) terminal. Cable tie the compressor securely in place as shown (see photo 4). Route the hose to the compressor making sure there are no tight bends or kinks cut the hose to the desired length and attach it to the compressor. Route the neg. (-) wire with the fork terminal up and attach it to the 10 mm bolt as shown (see photo 4A) . Route the pos. (+) wire over to the relay on the left side of the motorcycle and attach it to terminal 30 or 87 on the relay (see wiring diagram)

HONDA GOLD WING GL1500 AND GL1800 TRIKE CONVERSION KIT Owner's Maintenance Notes

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Filed Under (Honda) by admin on 16-02-2011

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1. Tire Pressure and Rotation : Keep the nominal tire pressure at about 20-25 psi. It is not necessary to periodically rotate the trike tires unless you experience unusual tire wear. 2. Bearing Lubrication . Your Swing Arm and wheel bearings are sealed and do not require greasing. However, should you experience unusual wheel bearing noise you should take your trike to a Champion Trike Dealer or to your motorcycle mechanic for a checkup. 3. Body Lubrication . There are no grease fittings on the trike body and no required body lubrication points. 4. Rear end lubrication . Your differential comes filled with 1 quart of SAE 85W140 API GL-6 gear oil. You should not have to top-off the differential unless you experience axle seal or pinion seal leaks. Check the oil level every 10,000 miles, or sooner if you experience leaks, and refill as necessary. Do not fill higher than the fill-hole. Change the differential oil every 30,000 – 35,000 miles. 5. Brakes . Check your front and rear brake system fluid levels every 3,000 miles and top-off as necessary. Inspect brake pads every 10,000 miles and replace as necessary. Pads are Volkswagen Part # D101P. 6. Drive Train . If your driveshaft U-joint and/or splines are fitted with grease fittings, pump the fittings with wheel-bearing, graphite or high-pressure grease every 3000 to 5,000 miles. If yours does not have grease fittings then lubrication is not required. 7. Suspension System : The suspension system is designed to give you the best ride with a load of no more than 500 pounds (passengers plus cargo plus trailer tongue weight): GL1500: The OEM adjustable air shock is used in conjunction with two (2) new Progressive 416 air shocks. The three shocks should be pressurized to about 20 psig, but to no more than 70 psig; GL1800: You can still use your OEM mono-shock pre-load adjustment. Your two (2) new coil-over shocks do not have an air system connection. However, there is a pre-load adjuster ring on each new shock that is factory-set at the “lowest” setting, for the softest ride. Changing this setting will result in a stiffer ride. 8. EZ-Steer (rake kit) : If your trike is equipped with Champion’s EZ-Steer, the bearings are a wear item. You should follow your motorcycle manufacturer’s recommended front-end triple-tree maintenance requirements. Generally these call for an initial service at 1,000 miles followed by periodic maintenance at 10,000 mile intervals. 9. Electrical : Your trike is pre-wired for a trailer connection. The harness is just below the trunk door on the underside of the body.

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Balancing Honda GL1500 Carburetor Manual

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Filed Under (Honda) by admin on 08-04-2011

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First pry off the plastic clip covering the screw as in the first picture. Note the type of screw used, as shown in the third picture. You must put this one back in the right place. Tip; When refitting this clip later on, a bit of Blutack or similar will stop it falling off and getting lost. Pull the L piece trim away, taking care not to break the tab shown in the fifth picture Now pry off the small black plastic cover at the rear of the running light. Blutack will be a good idea here as well when refitting the cover. The owner of this GL1500 didn’t use it and the cover on each side of the Goldwing got lost, which is why you can’t see them in the pictures. Note the type of screw used here as well, same as the one mentioned earlier. The third picture shows the two normal Phillips screws at the front of the running light, remove them. Remove the running light and pull the lower fairing panel away Remove the rubber plug from the right side fan. The adjuster screw for balancing the carbs is about 6″ behind and up, and hard to see. I removed the fan so I could get the camera in and the second picture shows the adjuster screw

HONDA GL1500 FRONT WHEEL INSTALLATION MANUAL

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Filed Under (Honda) by admin on 27-02-2011

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1. Rotor Covers. Tri-chromed ABS rotor covers replace the painted ones. Light weight, beautiful and functional. Include a rear strap and sold in pairs. Also, available are chrome rotor covers with amber strip lights installed. Fits 1988 to 2000. 2. Fork Light Mounts . Specially designed mounts are tri-chromed metal and hold a total of 6 lights. Lights not included. Sold in pairs 3. LED Lighted Rotor Cover Trim Rings . NEW Update your bike with LED lights. Tri-chromed ABS rings include amber or red, blue and amber LED lights. Sold in Pairs 5. 252-216 Rotor cover Plugs. These¾” chromed steel plugs fill the holes on the GL1500 rotor covers. Sold in a 4 pack

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