how do you change the speaker switch on the dash of a 2012 harley

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Harley-Davidson CHROME HANDLEBAR SWITCH CAP KITS installation and REMOVAL manual

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Filed Under (Harley Davidson) by admin on 09-03-2012

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1. Open or remove seat according to the instructions in the Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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) 2. Disconnect battery cables, negative (-) cable first. 3. Remove left and right-hand switch housing assemblies. Refer to HANDLEBAR SWITCHES in Service Manual. NOTE It is not necessary to disconnect the switch wiring to replace the switch caps. 4. Remove individual switches from switch housing. Refer to SWITCH REPAIR/REPLACEMENT in Service Manual. INSTALLATION Upper Housing Switches 1. For HORN and START switch caps, release torsion spring leg from hole in switch cap tab. Take note of how the spring is installed. The other leg of the spring can remain in the switch bracket hole. 2. See Figure 1 and Figure 5. Carefully pry stock black switch cap up off the splined actuator shaft (2) on left side of switch. -J02633 1 of 5 5 2 1 1 3 4 is 01405 1. Switch cap installed correctly 2. Switch cap removal from splined shaft 3. Switch cap removal from pivot pin 4. Switch cap installation onto pivot pin 5. Switch cap installation onto spined shaft Figure 1. Switch Cap Removal and Replacement 3. Pry the switch cap up and away from pivot pin (3) on right side of switch, and remove cap. NOTE Use the clear protective cover film to protect the chrome surface of the switch caps during installation. Remove the film after the installation is complete. 4. See Figure 5. Select proper chrome replacement switch cap from kit. 5. See Figure 1. Place cap onto switch, angling the hole on right side over pivot pin (4) on switch. 6. Carefully press switch cap down onto splined actuator shaft (5), rocking and moving the cap until shaft snaps into place in splined hole. 7. For HORN and START switch caps, insert torsion spring leg into hole in switch cap tab. 8. Toggle switch back and forth, checking for proper opera- tion. Turn Signal Switches 1. See Figure 1 and Figure 5. Carefully pry stock black switch cap up off the splined actuator shaft (2) on switch. 2. Pry the switch cap up and away from pivot pin (3) on switch, and remove cap. 3. Select proper chrome replacement switch cap from kit. Peel a clear protective installation cover from the sheet and place it over the surface of the cap. 4. See Figure 1. Place cap onto switch, angling the hole on top over pivot pin (4) on switch. 5. Carefully press switch cap onto splined actuator shaft (5), rocking and moving the cap until shaft snaps into place in splined hole. 6. Toggle switch back and forth, checking for proper opera- tion.

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HARLEY DAVIDSON VRSC FUEL TANK SIDE COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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INSTALLATION 1. Note the left and right areas on frame where the covers will be installed. Using a 50/50 mixture of isopropyl alcohol and water, thoroughly clean the frame tubes surrounding the fuel cell on the left and right sides. Let dry completely. 2. Unlock and open seat. NOTE Loosening the ignition/light switch screw (in the following step) will allow much easier alignment of the ignition/light switch cover and ignition/light switch during installation. 3. See Figure 1. At area inside of frame rail just above the ignition/light switch housing, loosen the ignition/light switch screw just enough to allow the ignition/switch switch to move slightly from side to side and up and down. Do not completely remove screw 4. See Figure 4. Obtain the right side cover bracket (ignition/light switch side) from kit. 5. Remove the strips protecting the adhesive at all of the raised sections on the cover. 1 2 is 02045 1. Ignition/Light Switch Screw 2. Ignition/Light Switch Figure 1. Loosen Ignition Switch Assembly 6. See Figure 2. Carefully align the right side cover between the three frame tubes. Beginning with the left portion of the cover, press the cover between the upper and lower frame tubes until the raised portions of cover (with adhesive) begin to snap into place. While carefully aligning the right portion of the cover, move the ignition/light switch as necessary until centered within hole in cover, then firmly press into place. Adjust ignition/light switch until the switch is centered within cover. Make sure all raised locations (with adhesive) are firmly contacting the upper and lower frame tubes and that cushion rests against front vertical frame tube. 7. See Figure 1. Tighten the ignition switch screw to 6-10 Nm (53-88 in-lbs ) . NOTE The right side (ignition/light) switch cover surface can be damaged by the key fob (from vibration) when the key is in the ignition and the bike is running. You can either remove the key fob so it does not damage the cover surface, or you can install the plastic clear sheet (included in kit) onto the side cover for protection. 8. If desired, perform the following to install the plastic clear cover onto the ignition/light switch cover. a. Obtain the plastic (rhino) sheet and hold up to the switch cover to determine proper orientation and spacing. b. Carefully peel the adhesive backing from the plastic sheet and position onto the cover. Use a wet sponge, and working out from the center, rub out any bubbles or overlapped areas under the sheet. Allow to dry completely.

HARLEY DAVIDSON ADVANCED AUDIO COMMUNICATION SWITCH KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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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. Refer to the instructions included with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit, and proceed with that installation until the installation of the items in this kit is called for. 3. Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. 4. On the fairing cap, remove the inner left side hole plug. See Figure 1 and the FAIRING CAP SWITCHES (FLHTC/U) section in the Service Manual. Install the fairing speaker switch (4) in the opening as follows: If a cruise control switch IS present: Follow the instructions in the Service Manual to install the speaker switch. If a cruise control switch IS NOT present: a. Obtain the speaker switch adapter wire (5) from the kit, and the butt splice connector included with the speaker switch. b. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual. Splice the adapter wire to the black/ green speaker switch lead. c. Insert the terminated end of the adapter wire into cavity 12 of the fairing cap switch connector [105B] 5. Remove the original equipment left-hand control switch assembly per the HANDLEBAR SWITCHES, REMOVAL, LEFT HANDLEBAR CONTROLS instructions in the Service Manual. 6. Install the new left-hand control switch assembly (3) from the kit. 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) 7. ALL models: Install the console pod assembly (1), and route the harness forward into the fairing per the instructions packaged with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit. Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) • Be sure the wires do not pull tight when handlebars are turned fully to left or right fork stops. 8. Unless already installed, install the overlay harness per the instructions packaged with the Hands Free Phone Interface, CB Radio or Intercom Kit. 9. Refer to the Service Manual and follow the instructions given to re-install the Maxi Fuse

Harley-Davidson Vacuum Operated Switch Kit Installation MANUAL

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Filed Under (Harley Davidson) by admin on 24-03-2012

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1. Turn off the ignition switch and disconnect the battery ground cable before proceeding. 2. For applications with Harley-Davidson OE ignition modules, simply replace the existing OE VOES switch with the new Twin Tec switch. Use the supplied crimp terminals to connect the new switch in place of the old switch. The wiring is not polarity sensitive and the two wires from the new switch can be interchanged. 3. For Twin Tec ignitions, refer to the installation instructions supplied with the ignition module for VOES switch hookup. Use the supplied crimp terminals to connect the new switch. The wiring is not polarity sensitive and the two wires from the new switch can be interchanged. 4. Reconnect the battery ground cable when you have completed the installation

HARLEY DAVIDSON CHROME ON/OFF SWITCH CAP KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION Models WITH maxi-fuse: 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. Models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. 1 2 is0771a 1. Auxiliary accessory housing cover 2. Cover screw (2) Figure 1. Auxiliary Accessory Housing 2. ALL models: If the Auxiliary Accessory Housing Kit and the Rocker Switch(es) ARE NOT already installed on the motorcycle handlebar: a. Proceed to Step 3 of these instructions. Install a chrome switch cap onto each switch before installing the Auxiliary Accessory Housing Kit onto the vehicle. If the Auxiliary Accessory Housing IS already installed on the motorcycle handlebar: a. See Figure 1. Using a T-25 TORX® driver, remove the two screws (2) retaining the Auxiliary Accessory Housing cover (1), and remove the cover. b. See Figure 2. Remove the switch mounting bracket, along with any attached switch(es) and accessories, from the switch housing. Note: it is not necessary to remove the switch from the mounting bracket, or to disconnect the switch wiring to replace the switch caps

Kawasaki Teryx Dash Frame Installation Manual

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

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The BRP Dash Frame mounts in place of the factory cup holder/storage pocket. Remove the screws holding the cup holder or storage pocket from the back of the dash and remove it. Hold the Dash Frame up on your dash. The top of the frame includes a channel that your dash slips into to provide support. Press the frame firmly up and against the dash. Be sure the frame is centered and straight. Using the frame as your template drill out the two top holes using a 13/64″ drill. Each hole is located at the top corner of the frame. Alternatively, you can mark the location of the holes, then drill them out with the frame removed. Using the smaller button head bolts supplied with this kit, along with the nylock nut and rubber backed washer, mount each of the two top corners of the frame. Use caution when tightening however. The angle of the dash frame is different than the angle of your plastic dash. The two bolts are only needed to snug the frame against your dash. You should only snug the bolt up, but don’t tighten it down. Looking from the back of the dash, you’ll see that the rubber washer does not lay flat against the plastic of the dash. This is correct. Again, these bolts are only to snug the frame against your dash and should not be tightened down. Doing so could damage your dash. The supplied nuts are nylock and will not back off even though the bolt is not tightened.

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

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

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

HARLEY DAVIDSON FLAME HANDLEBAR GRIPS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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REMOVE AND INSTALL THE LEFT GRIP 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar 2. Using a T25 TORX® drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX® drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9 Nm) . 9. Using a T25 TORX® drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4- 5.4 Nm) . 5 3 1 1 4 2 2 is00735 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger flange Figure 1. Left Handlebar Switch Housing REMOVE AND INSTALL THE RIGHT GRIP NOTE Right handlebar switch removal requires a Service Manual for your model and year of motorcycle. A Service Manual can be purchased from your Harley-Davidson Dealer. 1. Refer to the RIGHT HANDLEBAR SWITCH section of the Service Manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the Service Manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

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HARLEY DAVIDSON BOOM! AUDIO BASS BOOSTER TOUR-PAK PORT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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PREPARATION NOTE For vehicles equipped with security siren: • Verify that the Hands-Free Fob is present. • Turn the ignition key switch to IGNITION. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the owner’s manual and follow the instructions to remove the main fuse. INSTALLATION NOTE The Tour-Pak does not need to be removed from the vehicle to perform this installation. 1. Open the Tour-Pak lid and remove all items from the Tour- Pak base. 2. Models equipped with mat: Remove the mat. Models equipped with liner: Open the map pocket, and remove the acorn nuts with flat washers. Remove the map pocket and liner. 3. Remove four screws from the left-side speaker grille on the Tour-Pak. Remove the speaker grille from the speaker pod. 4. Remove the speaker from the speaker pod. Carefully pull the two socket terminals from the speaker spade contacts. 5. Remove the grommet, and draw the rear speaker/passenger controls connector out of the speaker pod. Separate the connector halves. 6. Repeat Steps 3 through 5 for the right-side speaker. 7. See Figure 1. Get the drill template (3) from the kit. If NOT equipped with power port: a. Remove one speaker pod mounting screw and flat washer. b. Align the drill template on the inside of the Tour-Pak with the speaker pod holes, and hold in place with the mounting screw and washer. c. Repeat for the remaining template mounting holes. If equipped with power port: a. Remove the two screws and flat washers to free the power port from the Tour-Pak. b. Align the drill template on the inside of the Tour-Pak with the power port holes, and hold in place with the mounting screws and washers. c. Repeat with the top speaker pod mounting screw and flat washer. NOTE Tighten the screws enough to hold the speaker pod in place as the pilot hole is drilled. 8. Where indicated on the template, drill a 3/16 inch (5 mm) diameter pilot hole through the Tour-Pak wall and speaker pod. 9. Remove the screws and speaker pod, and set aside. Turn the template over, and repeat Steps 7 and 8 on the left side of the Tour-Pak. NOTE Hole size will affect the fitment of the ports. The hole saw needs to be sharp. 10. Carefully drill a two inch (51 mm) diameter hole with a sharp hole saw, at the pilot location, through each speaker pod and in both locations on the Tour-Pak wall. 11. Temporarily install the Tour-Pak liner (if equipped), and mark the location of the two inch (51 mm) diameter holes on the outside of the liner. Remove the liner, and carefully cut the two holes in the liner front wall

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BMW R 1200 RT-P Supplementary Instructions

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

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Switch Layout – Left The left handlebar switch contains the standard operating controls for the police motor. The horn switch also operates the siren air horn when the ignition is turned “On”. A supplementary switch holder is standard, containing two switch blank plugs A & B. These locations are reserved for options such as Cruise Lights, Radio Rebroadcast, Radio Speaker “off” or other desired optional rocker switches. Siren Switch: The BMW/Code 3 siren is operated by one momentary push button switch, but only when the ignition is “on”. Pressing the button engages the siren into wail tone. Each subsequent press of the button advances to yelp, then hyper-yelp, then back to wail (California models only have wail and yelp). Press and hold to turn-off siren at any time. The siren has been programmed to accept a push of the button similar to clicking a computer mouse. This was done to avoid accidentally activating siren by nudging the button. A quick, clean press or “poke” of the button provides crisp activation. Switch Layout – Right The right handlebar switch contains the standard operating controls for the police motor including starter button. However, the additional switch functions are as follows: (A) Emergency Lights: This three-position switch controls the switching power to all emergency lights. Rocking the switch down to the middle position engages rear channel for the emergency lights (remember switch (C) must be down), rocking switch (A) down further engages front and rear channels – all emergency lights (adding front and side lights). With the switch in this position, rocking switch (C) up will cancel rear lights, but keep front and side lights operating. An LED indicator display can be seen through the back of the right front LED emergency light housing, showing whether the rear or front and rear emergency light channels are switched “on

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