how to connect the headlight of bajaj 100

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Ducati SPORT TOURING HEADLIGHT UPGRADE INSTALLATION AND REMOVAL INSTRUCTIONS

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

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1. Remove the following fairing components per the instructions in the Ducati owners manual: • Instrument surrounds • Headlight fairing • Chin fairing (under headlight/air intake) • Right-side middle fairing (covers battery) 2. Disconnect the speedometer cable from the speedometer. Unthread the ring nut at the top of the speedometer cable and retract the cable downward about 4-6 inches. 3. Disconnect the headlight wiring from the headlight bulbs. Retract the rubber boots at the rear of the headlight assembly to gain access to the wire terminals. Note that the two ¼ inch terminals at the high- beam bulb have locking clips that should be depressed before pulling the terminal away from the bulb. 4. Unplug the parking light from the headlight body by grasping the wires and carefully pulling it out. 5. Remove the two rubber plugs covering the lower headlight mounting screw access holes beneath the air intake horn. 6. Using an 8mm hex socket inserted through the lower access holes remove the two hex-head bolts securing the bottom of the headlight to the frame. 7. Using the same socket wrench, remove the two 8mm hex-head bolts securing the top of the headlight assembly to the frame. 8. Remove the headlight assembly from the frame. 9. Remove the two rubber grommets and steel reducing sleeves from the frame at the top mounting locations for the headlight. Leave the lower pair in place; these will be re-used, as shown in Figure 6

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YAMAHA V-MAX PERIODIC MAINTENANCE AND MINOR REPAIR

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Filed Under (Yamaha) by admin on 25-11-2010

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PERIODIC MAINTENANCE AND MINOR REPAIR -. 1. Screw (x 2) EAU03003 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by re- moving the screws. 2. Disconnect the headlight coupler, and then remove the headlight unit and bulb cover. 1. Headlight bulb holder 3. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb. EWOOOl19 Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 4. Place a new bulb into position, and then secure it with the bulb holder. 1. Do not touch this area. EC000105 Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 5. Install the bulb cover, and then connect the coupler. 6. Install the headlight unit by install- ing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 6-40 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (x 2) 1. Tail/brake light bulb (x 2) EAU00855 Replacing a turn signal light bulb or the tail/brake light bulb 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops. 1. Remove the lens by removing the screws. 2. Remove the defective bulb by pushing it in and turning it counter- clockwise. 1. Turn signal light bulb 4. Install the lens by installing the screws. EC000108 Do not overtighten the screws, oth- erwise the lens may break

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Ducati streetfighter HID headlight system installation Manual

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

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The installation of this kit requires the removal of the Helmholtz air box between the air intakes, located directly in front of the main air box. You will also need to run a wire from the front of the bike to the back of the bike where the battery is located. 1. Remove the seat, tail section, and fuel tank. 2. Remove the headlight assembly. 3. Replace the headlight bulb with the included HID bulb. You will need to modify the cap for the back of the headlight to allow the wires to pass through. 4. You will need to mount the Ballast, igniter, and the relay for the switch box in the area where the Helmholtz was. (see image) 5. Run the red power wire to the back of the bike and connect directly to the positive lead on the battery terminal. 6. Connect the ground wire the frame where the Helmholtz was previously bolted. 7. Plug the HID bulb into the ballast. There are 3 plugs. They can only be connected one way. 8. Connect the main wire harness to the ballast. 9. Turn the key on and turn the ignition on and check that the headlight comes on. 10. Switch on the brights to make sure this is working as well. 11. Once everything is confirmed to be working make sure the wirings are well attached won’t interfere with the fan or with any of the steering components. 12. Re-install the tank, tail section, and seat

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

Sanyang JET 50/100 and JET Euro 50/100 Specifications And Service Manual

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Filed Under (Sym) by admin on 24-11-2010

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Carbon monoxide If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor. Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death. Gasoline Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored. Caution Gasoline is highly flammable, and may explode under some conditions, keep it away from children. Used engine oil Caution Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children. Hot components Caution Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off. Battery Caution y Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery. y Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water and then go to hospital to see an ophthalmologist. y If you swallow it by mistake, drink a lot of water or milk, and take some laxative such as castor oil or vegetable oil and then go to see a doctor. y Keep electrolyte beyond reach of children. Brake shoe Do not use an air hose or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid dust flying. Caution Inhaling dust may cause disorders and cancer of the breathing system. Brake fluid Caution Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake fluid beyond reach of children

MODEL 8100 HID/ HALOGEN MOTORCYCLE HEADLIGHT INSTALLATION

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Filed Under (Tips and Review) by admin on 29-11-2010

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1) Remove seat. 2) Refer to service manual to locate the following wires: An ignition signal that has power while the ignition is in the “ON” position. Terminal 30 on start relay . A “CRANK” signal (start signal) that has power while the starter motor is being activated. Terminal 86 on start relay . 3) Locate a mounting position for the module that will fit in front of or next to the battery. DO NOT MOUNT the module until all connections to the module have been made. 4) Verify the operation of the ignition and crank signals using the voltmeter or test light. Disconnect battery and make the following connections: • Connect the Blue wire from the lamp module to the ignition feed wire Terminal 30 on start relay . • Connect the Grey wire from the lamp module to the starter crank feed Terminal 86 on start relay . • Connect the Red wire from the module to one end of the fuse harness provided in the kit. • Crimp a ring terminal to the other end of the fuse harness (for connection the POSITIVE battery terminal) . • Crimp a ring terminal to the Black wire from the module. This will need to be routed to the NEGATIVE terminal of the battery • Do not in any way (lengthened or shortened) . Ensure that the ballast is close enough to the lamp to use the length of cable provided. 5) Securely mount ballast in chosen location. Plug the 2 wire sealed connector (RED AND BLACK 16 AWG WIRES) to the ballast. Route the Red and Black wires along the frame, and follow the harness under the fuel tank (recommended) to the battery compartment. Connect the Orange wire from the lamp module to the red wire from the ballast using connector. Crimp ring terminal to black wire coming from the ballast, and connect to the NEGATIVE battery terminal. • IT IS NOT RECOMMENDED THAT THE BALLAST BE MOUNTED IN CLOSE PROXIMITY TO ECU OR FUEL INJECTION WIRING. • Do not mount near sources of high heat (i.e. Cylinder head or exhaust manifold) . • Do not mount in a location where there is a possibility of mechanical interference from moving parts (i.e. Steering components or linkage) . • There is a 3-foot length of cable provided for connection between the BALLAST and the HID LAMP. This cable MUST NOT be modified in any way (lengthened or shortened) . Ensure that the ballast is close enough to the lamp to use the length of cable provided

Yamaha V-Star 650 REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 10-01-2012

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Instruction sheet 54-600 1 Front head pipe 54-600-01F 1 Rear head pipe 54-600-01R 1 Front heat shield 54-600-02F 1 Rear heat shield 54-600-02R 1 Outlaw muffler 50-103-127 1 Muffler bracket 54-600-40 1 Head flange 54-110-41 7 2″ standard hose clamps 70-100-35 2 1 3/4″ HD Hose clamp 70-100-37 2 5/16″-18 carriage bolts 70-100-10 2 5/16″-18 flange nuts 70-100-15 1 8mm x 1.25 x 25mm flange bolt for front head flange 70-100-09 2 8mm x 1.25 x 20mm bolts /muffler bracket 70-100-05 2 10mm x 1.25 x 35mm bolts 70-100-85 2 Spacer .250 x .438 x .875 50-100-74 2 8mm x 1.25 Flange nut 70-100-22
Disassembly 1. Remove both Allen bolts that hold the muffler together (Fig. 1) . Also Loosen clamp from the front muffler to front head pipe (Fig. 2) , and remove allen bolts from rear head pipe and remove in one peace carefully (Fig. 3) . Figure 1 Figure 2 Figure 3 2. Once the two mufflers are removed with the rear head pipe, remove bracket by removing two 8mm bolts as shown and remove bracket. (Fig 4) Figure 4
3. Remove spring from brake light switch to the brake rod located on the right side footrest. (Fig 5) Figure 5 4. Remove two bolts holding the footrest, and brake pedal (Fig. 6) . Carefully rest right side footrest on the floor or you can use a two by four to rest the footrest onto. Figure 6

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HERO HONDA CD-100 / SS100 / SLEEK / SPLENDOR / PASSION

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Filed Under (Honda) by admin on 14-11-2011

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1500 91255-169-003 30-42-11 FRONT FORK SEAL (S/S) (SLEEK) Improved Quality 200 20 PCS
1500A ————— SET OF 2 PCS FRONT FORK DUST SEAL (S/S) 100 10 PCS 1501 90756-198-000 7-37-7.5 FRONT FORK TRIPLE (COLLER) (CD-100) 200 20 PCS 1502 91202-302-01013.8-24-5 KICK SHAFT 200m20 PCS 1502A 91202-302-010m13.8-24-5+1514 KICK SEAL(SPL.GRADE O.E TYPE) MATERIAL WITH PUCH ROD RUBBER 100 10 PCS 1503 91205-350-000 6-25-6 CLUTCH 200 20 PCS 1504 91202-GK4-722 18.9-30-5 MAGNET
200

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HARLEY DAVIDSON CHROME FORK COVER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION OF KIT 66440-05 1. Kit 66440-05 , Loosen the fuel tank. Refer to FUEL TANK- PARTIAL REMOVAL in the appropriate section (carbureted or EFI Engine) of the Service Manual. 2. Disconnect the headlight connector from the main harness. 3. Start with one side and remove the screws fastening the trim strip and rear triple clamp cover. Remove trim strip and rear triple clamp cover. Repeat procedure for other side. 4. Remove the nut, washers, lockwashers and bolt holding the headlight housing to the tripletree. Retain all hardware for future use. Remove headlight housing. 5. Remove front panel. 6. See Figure 2. From kit, place front panel (1) into position. 7. Install headlight using the bolt, washer, lockwasher and nut removed earlier. Tighten fastener. Refer to your service manual for torque specifications and headlight alignment procedures. 8. Insert headlight wiring through hole (2) in front panel and connect wiring to main electrical harness. 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) 9. Install fuel tank. Refer to FUEL TANK-PARTIAL REMOVAL in the appropriate section (carbureted or EFI Engine) of your Service Manual. 10. Start with the left side and install the chrome rear triple clamp cover (4), and trim strip using screws removed earlier. Tighten fasteners. 11. Install the headlight switch thru switch hole (5) removed earlier. 12. Install the chrome right side rear triple clamp cover (3) and trim strip and tighten fasteners

KTM EXC taillights Installation manual

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Filed Under (KTM) by admin on 23-01-2012

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Step1: Remove headlight, (headlight switch) seat and gas tank from KTM. Step 2: Partially install the headlight assembly using the top right band only to hold it in place temporarily. You will need to plug wires to this assembly and if you put all four bands on you will not be able to make the connections. Step 3: Install handlebar switch on clutch side. You will need to move clutch perch to the right (about ½ inch to1 inch) to make room for the switch. The red knob on the clutch adjuster should just miss the handlebar switch. The switch plugs into the circuit board on the bottom of the headlight using the 8-pin plug (the only unused 8-pin one on the circuit board) Step 4: Behind the gas tank and in front of the air box is a small rectangular hole in the frame. You will be feeding two lines with the plug ends first down through this hole. They must be fed one line at a time and you may need to use needle nose pliers to grab them and help pull them through. The lines you want to feed through this hole are the power line with two-pin molex plug and the line for the taillight with the six-pin plug. Route these wires all the way to the headlight assembly along the left side of the bike on the bottom of the gas tank frame tube. In this step we will connect the power line only. With the handlebars turned all the way to the right, plug the power wire into the back of the headlight assembly making sure to leave some extra wire so you can turn the handlebars both ways without tugging on the wires. The other end of the power line has battery terminal loops. The positive has an in-line fuse and the other black wire is the negative. Connect these to the battery.

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