how to fit a steering lock on a harley ultra gluide

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STEERING GEAR/ STEERING WHEEL REMOVAL AND INSTALLATION

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Filed Under (Uncategorized) by admin on 05-10-2011

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TEERING GEAR/STEERING WHEEL REMOVAL & INSTALLATION Page 3 of 4 STEERING GEAR/STEERING WHEEL INSTALLATION PROCEDURES (Cont’d) 2. Center spiral cable. a. Turn the cable counterclockwise by hand until it becomes harder to turn. b. Then rotate the cable clockwise about 2.5 or 3 turns to align the marks. (See Fig. 4) 3. Install the steering wheel. a. Align the matchmarks on the wheel and steering main shaft. b. Temporarily tighten the wheel set nut. c. Connect the spiral cable connector. 4. Bleed Power Steering System (when applicable). 5. Check steering wheel center point. 6. Torque steering wheel set nut. See the applicable vehicle’s repair manual for the torque specification. 7. Install and center steering wheel pad. NOTICE: Make sure the pad is centered and installed to the specified torque. If the pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one. When installing the pad, take care that the wiring does not interfere with other parts and is not pinched between other parts. a) Connect the airbag wiring connector. b) Install the pad after confirming that torx screws are in the screw case. c) Using a torx socket, torque the screws to the specification in the vehicle’s Repair Manual. (See Fig. 5) d) Install the steering wheel lower cover

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Motorcycle Derived Steering / Suspension Systems

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

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1. Examine the handlebars and fork yokes. 2. Turn the steering from lock to lock with the steered wheel both on a turning plate and clear of the ground. Cont’d Reason for Rejection 1. A handlebar or fork yoke a. deformed b. fractured c. cracked d. excessively corroded e. clamps not tight, or any bolt loose or missing f. handgrips missing or not secure to handlebars g. handlebar flexible mounting excessively deteriorated. 2. a. any fouling or restriction of the free movement of the steering from lock to lock b. handlebar grip/s or handlebar mounted control/s have no clearance with any other part of the machine when the steering is placed on either full lock c. steering movement excessively stiff or rough Reason for Rejection 5 does not apply to fork gaiters or shrouds. . Cont’d Method of Inspection 3. Examine the steering damper. 4. Examine the steering head bearings. 5. Examine the front fork assembly. Cont’d Reason for Rejection 3. A steering damper a. insecure b. ineffective c. impairing the steering action. 4. Excessive free play in the steering head bearings. 5. A fork assembly component which is a. missing b. loose c. cracked d. excessively bent, misaligned, corroded, worn, or has excessive free play between the sliding members of the forks, the pivot bearings or bushes e. restricted in operation f. fouling

HARLEY DAVIDSON STEERING HEAD WASHER KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. 1. See Figure 1. Remove the fork stem cap (1). Bend the lockwasher (2) tab away from the steering stem nut (3) and remove the fork stem nut and lockwasher. Discard the lockwasher. NOTE Always tighten the steering stem nut (3) to 70 – 80 ft-lbs (95 – 109 Nm) before measuring fall away. Lubricate threads of nut with a small amount of clean engine oil. Avoid applying oil to the mating surfaces of the steering stem nut (3) and the new hardened washer from the kit. 2. Install the new hardened washer from the kit (2) and steering stem nut (3). Tighten steering stem nut (3) to 70 – 80 ft-lbs (95 – 109 Nm). 3. Check fall away following the instructions in STEERING HEAD BEARINGS BEARING ADJUSTMENT (FALLAWAY) in an appropriate Service Manual, however, tighten the steering stem nut (3) to 70 – 80 ft-lbs . Adjust adjusting nut (5), if necessary per instructions. 4. Install fork stem cap (1).

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Tacoma Power Steering Pump Improving Power Steering Reservoir modification

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Filed Under (Toyota Manuals) by admin on 02-10-2011

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For my SAS I decided to add hydraulic steering assist as it comes in real handy for rock crawling. I got the Redneck Ram setup from the folks at West Texas Off-road that includes rebuilding an earlier IFS steering box along with drilling and tapping the box for the included ram. One of the down sides of adding a ram is that it slows the steering down because the stock steering pump has to supply the added volume for the hydraulic ram. Another is that it creates a fluid volume change in the system reservoir that needs to be compensated for in some way. After doing some reading on the West Texas site about how to go about modifying a Saginaw pump and reading up on earlier Toyota pump mods for steering assist setups on the Pirate board, I decided to give it whirl and see what I could do about the Tacoma pump. Chuck Gardella was kind enough to supply me with a blown pump that I could rebuild and submit to my endless fiddling and tinkering. I plan to give him my pump in return when I get this one done and installed. You need to do something to allow for more room in the reservoir for the standard hydraulic ram assist setup so I decided to tackle the reservoir first. The reason you need the extra space is because the ram is unbalanced. That is there is a rod on one side of the cylinder and not on the other side so the volume of the fluid has to change in the system to account for the volume of the rod as it travels back and forth. I calculated the volume of the rod that I have at full stroke to be about 2 oz or so. This would equate to plus or minus up to 2 oz. in the pump reservoir. Well first off, it’s no wonder why so many folks boil their steering pumps over with heavy wheeling and have so many other steering problems. The stock power steering reservoir doesn’t even rate pint sized

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Harley Davidson Steering Wheel Radio Control Interface Installation instructions

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Filed Under (Harley Davidson) by admin on 03-05-2012

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1) Turn on the ignition to supply power to the SWI-3. 2) Use a pen to depress the “program mode” button. Remove pen when left LED light comes on. 3) Within 10 seconds press and hold one of the steering wheel function buttons. Continue to hold steering wheel button until the left LED turns off. Release the steering wheel button and the right LED turns on. 4) Place the stereo’s IR remote within 3″ of the “IR Input” port on the side of the SWI-3 next to the program button. Press and hold the remote’s button that corresponds to the steering wheel button that was pressed. Continue to hold the remote’s button until the right LED turns off. Release the button and the left LED will turn on. 5) Repeat steps 3 and 4 until all radio steering wheel functions are programmed. 6) When programming is complete, wait 10 seconds and both LED’s will flash 3 times. This indicates an automatic program exit. Do not stop more than 10 seconds while programming or there will be an automatic program exit and you will have to start over at step number 2 above. Turning off ignition before the automatic exit will require starting over at step 2 above. The SWI-3 can be reprogrammed unlimited times. Testing • Test the SWI-3 by holding it’s infrared LED (LED on the end of 4′ lead) close to the stereo and verify that it works properly. Experiment with various locations for the LED. You should be able to find a hidden and convenient mounting location. Try along the top front and /or bottom of the stereo as well as it’s sides. The LED can be replaced with most any IR LED, like Radio Shack’s # 276-143. The longest lead of the LED connects to the red wire of the 4′ cable and the short lead of the LED connects to the black wire of the 4′ cable

HARLEY DAVIDSON FRONT BRAKE DISC LOCK INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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INSTALLATION Do not operate vehicle with brake disc lock in place. Operation with lock on disc will restrict movement of the wheel, which could result in death or serious injury. (00457b) NOTE Insert key all the way to the bottom of the cylinder. Turn key clockwise 180 degrees to the open position. DO NOT FORCE KEY! Key should turn freely. If key does not freely rotate, try turning key slightly left and right while inserting to align disks inside cylinder. Failure to insert key all the way to the bottom of cylinder could cause key to jam. For Models with Hydraulic Fork Front Ends 1. See Figure 1. Insert reminder cord (3) into slot on disc lock (1). 2 1 3 is 01599 1. Lock 2. Caliper 3. Reminder cord Figure 1. Installing Disc Lock 2. Slide lock (1) over front brake disc as close to rearward edge of brake caliper (2) as possible. Push button completely down to lock. 3. Roll motorcycle forward slowly until lock gently contacts caliper. 4. See Figure 3. After installing disc lock, place loop end (1) of reminder cord (2) over handlebar grip. For Models with Springer Front Ends 1. See Figure 2. Insert reminder cord (5) into slot on disc lock

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Harley Davidson Installing The Ride Time Ultra Progressive Tour Pak LED Tail Lights

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Filed Under (Harley Davidson) by admin on 31-10-2010

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Remove the light bulbs from the tail light housing by depressing the tab on the bulb socket assembly and turning counter clockwise. Remove the bulb from the bulb socket. 2. Remove the lenses from the warp-around light fixture. These lens are held in place by a non-hardening black sealant. In addition, there are three plastic alignment tabs on the lens body that clip into the lens frame. To remove the lens, insert the supplied push Stick through the hole in the back of the light bulb housing and gently but firmly push the lens outward. This action places a stress on the alignment tabs. 3 . Using a flat blade screw driver, pry the lens away from the frame at the top, side, and bottom to release the lens alignment tabs. Go back to step 2, and use the plastic tube to push the lens outward. It may be necessary to repeat the prying process and pushing process several times to remove the lens. Note: Some users have found it useful to heat the lens area with a hair dryer to soften the adhesive. Included in this kit are: Left and Right LED modules, 1 RTQC Quick Connect Accessory Cable , 2 RTV application sticks, 1 push stick, Approximately 3 inches of shrink tube, and 1 copy of instructions. Required for installation, but not included are: A tube of Permatex RTV (available at Wal-Mart), 1/8 inch drill bit, a drill, small flat blade screwdriver, other hand tools. Window/ body sealer if required to reseat lenses can be obtained at your local glass shop. Tour Pak, Harley Davidson, Electraglide, Raod King, and Ultraglide are registered trade marks of Harley David- son. Harley Davidson does not make or endorse the use of these lights. 4. When the lens begins to emerge from the frame, grasp it at the top and bottom and pull the lens from the housing using a up and down motion. Set the lens aside . Avoid having the sealant contact other surfaces. In most cases, the lens can be reinstalled without adding additional sealant . Note: Do not use RTV to reset the lens. If sealant is needed obtain a non-hardening body/windshield sealant from your local glass shop. 6. When you are comfortable with the location of the circuit board, drill a 1/8 inch hole in the back of the light housing. This hole will be used to bring the turn signal wire from the LED module into the Tour Pak. 7. Using the supplied stick, spread a thin layer of Permatex clear RTV silicone seal along the area where the circuit board will be located. Apply a similar layer to the top of the light housing. Route the turn signal wire through the 1/8″ hole and position the circuit board in the housing. Allow the RTV to cure. 5. Test fit the LED light board in the light housing.

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YAMAHA FZ1 SPECIFICATIONS AND OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 07-11-2010

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INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU26900 ON All electrical circuits are supplied with power, and the meter lighting, taillight, license plate light and position lights come on, and the engine can be started. The key cannot be removed. NOTE: The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”, even if the engine stalls. EAU10660 OFF All electrical systems are off. The key can be removed. EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key. To unlock the steering Push the key in, and then turn it to “OFF” while still pushing it. WARNING EWA10060 Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”. 1. Push. 2. Turn. 1. Push. 2. Turn.
INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights “” and “” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU11080 High beam indicator light “” This indicator light comes on when the high beam of the headlight is switched on. EAU11250 Oil level warning light “” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The

Yamaha XV 1300 V star XVS13AW OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 04-12-2010

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1. Front turn signal/position lights (page 6-34) 2. Headlight (page 6-32) 3. Seat lock (page 3-11) 4. Fuel injection system fuse (page 6-30) 5. Fuse box (page 6-30) 6. Main fuse (page 6-30) 7. Helmet holder (page 3-12) 8. License plate light (page 6-35) 9. Rear turn signal light (page 6-34) 10.Engine oil level check window (page 6-11) 11.Shift pedal (page 3-8) 12.Engine oil filler cap (page 6-11) DESCRIPTION 2-2 2 EAU10420 Right view 1. Tail/brake light (page 6-33) 2. Rear brake fluid reservoir (page 6-22) 3. Owner’s tool kit (page 6-1) 4. Battery (page 6-29) 5. Air filter element (page 6-15) 6. Fuel tank cap (page 3-9) 7. Front brake fluid reservoir (page 6-22) 8. Brake pedal (page 3-9) 9. Engine oil filter cartridge (page 6-11) 10.Engine oil drain bolt (page 6-11) 11.Coolant reservoir (page 6-14) 12.Shock absorber assembly spring preload adjusting ring (page 3-12) DESCRIPTION 2-3 2 EAU10430 Controls and instruments 1. Clutch lever (page 3-8) 2. Left handlebar switches (page 3-6) 3. Multi-function meter unit (page 3-3) 4. Main switch/steering lock (page 3-1) 5. Right handlebar switches (page 3-6) 6. Throttle grip (page 6-16) 7. Brake lever (page 3-8) INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10540 ON All electrical circuits are supplied with power, and the meter lighting, taillight, license plate light and position lights come on, and the engine can be started. The key cannot be removed. NOTE: The headlight comes on automatically when the engine is started and stays on until the key is turned to “OFF”, even if the engine stalls. EAU10660 OFF All electrical systems are off. The key can be removed. EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key.

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Yamaha YZF R1 SPECIFICATIONS AND OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 07-11-2010

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INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10600 ON All electrical circuits are supplied with power, the meter lighting, taillight, license plate light, auxiliary lights and position lights come on, and the engine can be started. The key cannot be re- moved. NOTE: The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”, even if the engine stalls. EAU10660 OFF All electrical systems are off. The key can be removed. EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key. 1. Push. 2. Turn. INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 To unlock the steering Push the key in, and then turn it to “OFF” while still pushing it. WARNING EWA10060 Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”. EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights “” and “” The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU11080 High beam indicator light “” This indicator light comes on when the high beam of the headlight is switched on. EAU11250 Oil level warning light “” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction

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