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KAWASAKI VOYAGER AIR HORN INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 27-12-2010

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1. Remove the false fuel tank cover to expose the battery. Remove the right hand lower leg fairing. (4 phillips screws). Unplug the stock horn and remove the (2) 10mm bolts securing it to the frame. 2. See photo #1 using the stock horn bolts attach the black horn mounting bracket and the white ground wire supplied as shown. Next locate the relay supplied. Plug the stock horn wires into the relay terminals #85 & #86. (see wiring diagram on back side of instructions) 3. Attach the air hose to the compressor air outlet fitting. Attach the short red wire supplied to the compressors positive (+) terminal and the white wire installed earlier to the compressors ground (-) terminal. As shown in photo #2. Attach the compressor to the frame with the hose clamp provided. Note: position the top of the compressor as shown touching the bottom of the horn mounting bracket and approximately 1 Ω” to the rear of radiator and shroud. Also the air hose and fitting should be in front of the frame tube with the hose routed inside the hose clamp without pinching the hose. Attach the red wire from the compressor to one of the relays remaining outer terminals #30 or #87. Attach the remaining long red wire (supplied) to the remaining relay terminal #30 or #87. Secure the relay to the frame with a cable tie supplied. Route the red wire up to the battery positive (+) terminal. Locate the fuse wire assembly provided. Attach the fork end of the fuse wire to the battery positive (+) terminal. Cut the red wire to the desired length, strip the end and crimp to the fuse assembly. Turn on the ignition and press the horn button, you should hear the compressor motor run. Re-install the false fuel tank lid. Re-install the right lower leg fairing while routing the air hose out next to the black horn mounting bracket 4. See photo #3, Bolt the horn set to the black mounting bracket using the 5/16 x æ”bolt, washer and lock washer provided. Trim the air hose to length if necessary and attach the air hose to the horn assembly. Install the trumpet covers. (see instructions enclosed with covers) Turn on the ignition and test the horns

HONDA VTX1300 AIR HORN INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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1. Remove the rider and passenger seats, left chrome side cover & original horn located at the top of the radiator. 2. Locate the supplied black horn mounting bracket and supplied smaller hose clamp. Notice the slight twist in the bracket. Using 2 adjustable wrenches or a vise and one wrench remove the twist from the bracket. Route the hose clamp thru the bracket. (As shown in photo 1A) 3. Install the bracket on to the left frame tube, (As shown in photo 1A) and tighten securely. Bolt the supplied horns to the bracket using the supplied bolt, lock washer and nut, (As shown in photo 1) and tighten securely. Install the supplied trumpet covers (As shown in photo 1B) by flexing the spring clips over the trumpets. Check that they fit securely. If not remove covers, make sure the center screw is tight and bend spring clips in towards center of covers and re-install. Using a blade screwdriver pry the two supplied hoses with the “Y” connector off of the air horns cut a new piece of hose 3 ½” long from the hose and replace the short hose on the “Y”. Re-install the “Y” hose assembly with the short hose going on the long or upper trumpet. (See photo 1C) Re-route the original horn wires. (As shown in photo 1D) 4. From the supplied wire cut 2 pieces 28″ long. Strip ¼” of insulation from both ends. Crimp 2 supplied male terminals to one end and 2 supplied female spade terminals to the other end. Plug the male ends into the original horns wires. (As shown in 1D) Attach the remaining air hose to the “Y”. Tape the hose and wires together every 6-8″ using electrical tape to make routing easier and neater. Route the wires and hose up under the fuel tank, over the cylinder heads coming out between the frame rails at the rear of the fuel tank. (See photo 2A) Locate the supplied relay and plug the 2 wires from the original horn onto terminals 85 & 86 on the relay. (See wiring diagram on back of last page of instructions) This will be the 2 outer terminals that are parallel to each other. Locate the supplied fuse, holder & wire assembly. Crimp a supplied fork terminal to one end and a supplied female spade to the other. Attach the spade terminal to one of the remaining outer relay terminals. (#30 or 87 on wiring diagram) Remove the 3 Phillips screws from the battery top cover. Remove the cover and attach the fork end of the fuse wire to the positive (+) terminal. Re-install the battery cover. 5. Cut a wire 9″ long and strip ¼” insulation from each end, crimp a fork to one end and a female spade to the other. Attach this wire to the compressors negative (-) terminal. Cut another wire 18″ long and strip both ends. Crimp a female spade to both ends. Attach this wire to the compressor positive (+) terminal. Route the air hose out under the left side cover as shown in photo (3). Hold the compressor in place against the frame tube. Note: Looking at the large end of the compressor the space between the hose fitting and the bolt mounting flange forms a “V” shape. This is where the compressor should rest against the frame. Next loop the hose around to the compressor hose fitting and trim the hose to the desired length. Attach the hose to the compressor. Secure the compressor to the frame using 2 large supplied cable ties as shown. 6. (See photo 3A) Attach the compressor negative (-) wire to the bolt on the frame (As shown in photo 3B) Route the compressor positive (+) wire along the side up to the relay and attach to the remaining outer terminal 87 or 30. Cable tie the relay in place. (As shown in photo 2B) Use several of the supplied short cable ties to secure the compressor wires to the air hose (As shown in photo 3) as wells as any other loose wire or hose.

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HARLEY DAVIDSON HORN COVER KIT INSTALLATION MANUAL

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

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INSTALLATION 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. Remove seat and disconnect wires from horn. 2. See Figure 1. Remove stock horn bracket nut (2) and the entire stock horn cover assembly (1). Remove the horn (3) and all hardware components from the stock cover including wire clamp, clips, and mounting bracket. Leave rubber mount and locknut on motorcycle. Note assembly order for kit installation. NOTE Do not over-tighten “horn to horn cover” nut. Over-tightening may result in permanent damage to the horn. 3. Apply Loctite 271 (Red) to threads of nut (4) fastening the horn to the horn cover. Tighten nut to 80-100 in-lbs (9.0- 11.3 Nm). Tighten screws fastening the horn cover to the horn bracket to 35-55 in-lbs (4.0-6.2 Nm). 4. Route wiring harness through the clamp (if present) and install the entire horn cover assembly to the mounting stud (5). 5. Tighten nut (2) fastening the horn bracket to the horn rubber mount to 80-100 in-lbs (9.0-11.3 Nm). Connect positive (+) 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. (00068a) 6. Connect wires to terminals and reconnect battery. NOTE Horn is not polarity sensitive. Ground and power wire may be connected to either terminal. 2 4 1 5 3 is03958 1. Horn cover assembly 2. Bracket nut 3. Horn 4. Nut 5. Mounting stud Figure 1. Horn Cover Installation 7. Test horn. NOTE Test the horn only when mounted on the vehicle. The sound may be muffled if tested when hand-held. A muffled sounding horn that is mounted to a vehicle may indicate permanent damage to the horn by over-tightening the horn to horn cover nut (Figure 1, Item 4). Attempt to adjust nut torque. Replace horn if necessary. 8. Reinstall seat

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Honda GL1800 Front Mount Air Horn Installation Instructions

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

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1. Place the motorcycle on the centerstand. 2. Remove the left side cover (painted) to expose the battery. Remove the left plastic engine cover (chrome) . Remove the lower center fairing cowl or spoiler; there are 2 pull pin rivets and 6 allen screws holding this panel in place. Drop the panel down and slide it out to the right or left. 3. Horns and Mounting Bracket: Attach the large “L” shaped bracket with the split clamp to the engine guards as shown in photo #1. NOTE: Make the screws snug only! Install the horn set onto the “L” bracket using the 2 allen screws provided, tighten securely. Align the horn set to be level and to have clearance between the fairing as shown in photo #2, tighten securely. 4. Compressor: Remove the stock left hand horn and loosely re-install the 12mm mounting bolt (see photo #4A). Next as shown in photo # 3, to the compressor attach the air hose, the short red wire to the (+) positive terminal and the white wire to the (-) negative. The mounting bracket should be bolted to the compressor as shown. Install the compressor assembly as shown in photo #4 onto the 12mm bolt and tighten securely. Note! It you may need to adjust the angle or bend of the bracket for a good fit. Try to maintain at least a one-inch clearance between the exhaust header pipe and the compressor, wires and air hose. 5. Relay and Wiring: Attach the red wire from the compressor to the relay terminal 30 (see wiring diagram). Attach the long red wire to the relay terminal 87. Attach the stock horn wires to the remaining terminals 85 & 86 it does not matter which wire goes to which of these two terminals. Attach the white ground (-) wire from the compressor to the lower cowl-mounting bolt as shown in photo # 4B. Cable tie the relay in place as shown in photo #4C. Route the long red wire up and back over the left side of the engine to the battery, This is easiest done using a stiff piece of wire (a coat hanger works good) with a small loop bent at one end. Push the wire from rear of the engine towards the front. Attach the red wire with electrical tape and pull the wire back towards the rear of the engine. Route the wire back to the battery (+) positive terminal, cut the wire to the desired length, strip back insulation 3/8″ crimp on the fuse holder provided and attach to the battery (+). Replace the side covers Route the air hose as shown in photo #5 so as not to kink it or be less than 1″ from the exhaust, then over the front of the engine, up and out to the horns just behind the engine guards, trim to the desired length and attach to the “Y” fitting. Using a lighter or match, heat seal or melt the end of the hoses braided cover to prevent it from fraying. Turn on the ignition and test the horns

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Victory Freedom Engines Installation Instructions for S&S Air Cleaner Kit

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Filed Under (Victory) by admin on 31-10-2010

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1-Locate and remove the Intake Air Temperature Sensor (IATS) from the stock Polaris Victory air box. Locate the new position for the IATS on the bottom of the S&S air cleaner. Push the IATS in the lower air cleaner cover and turn1⁄ 4 turnin either direction, make sure you feel it lock into place. Inspect from the inside of the air cleaner to ensure that the barbs are locked into place. See Picture 1. 2-Using the stock Polaris Victory air box gasket (PN 5811908) and S&S supplied (Qty 4) M6 fasteners, assemble the lower air cleaner cover to the throttle body using 243 Blue Loctite®on the treads. Torque the M6 fasteners to 72-96 inch pounds. 3-Position the S&S pre-formed air filter onto the lower air cleaner cover ensuring that it fits into the machined groove. 4-Install the top air cleaner cover on top of the filter ensuring that it fits into the machined groove. 5-Make surethat the filter is situated in the machined grooves on both the top and bottom air cleaner covers. 6-Using 243 Blue Loctite on the threads of the S&S supplied (Qty 3) M6 fasteners tighten down top air cleaner cover evenly until seated. Finish torque the fasteners to 72-96 inch pounds. Now you’re ready for breather hose and barometric pressure hose routing. 7-Locate the S&S supplied 3⁄ 16 “reinforced hose and clamps. Push one end of the hose on the 3⁄ 16 “brass barb in the bottom air cleaner cover and slide clamp up around the end of the hose. The other end of the hose is for the Barometric Pressure Sensor (MAP). Route the hose towardthe back of the engine over the top of the rear rocker cover. 8-Remove the MAP sensor from the stock Polaris Victory air box. Remove the orange rubber gasket from the MAP sensor. Slide the S&S supplied clamp over the 3⁄ 16 “rubber hose that leads to the air cleaner. Push the barbed end of the MAP sensor into the 3⁄ 16 ” rubber hose and slide clamp up to the end of the hose around the barb. A small amount of lubricant may be applied to the barb on the MAP sensor to make installation easier. 2 S&S Air Cleaner Assembly 41-0021 (Calibration cardnot shown) Picture 1 CAUTION WARNING WARNING Plastic barb locked in recess.
9-Assemble and install breather hose as follows: A-Cut the stock Victory®hose on the straight section just behind the 90 degree bend as shown in Picture 2 . B-Slide an S&S supplied 1⁄ 2 “hose clamp over the modified stock breather hose. C-Install the S&S straight barb in Victory breather hose and position a hose clamp around hose end. D-Slide the 90-degree end of breather hose over the brass barb on the air cleaner cover and slide hose clamp in place. E-Position straight end of the S&S breather hose over the 1⁄ 2 “barb to connect to the Victory hose. Slide clamp over connection. F- See Pictures 3 and 4 for breather hose and barometric pressuresensor hose installation positions. NOTE: S&S breather hose can be cut for best fit

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MULTI-APPLICATION AIR HORN INSTALLATION INSTRUCTIONS

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

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COMPRESSOR MOUNTING: Find a suitable location to mount the compressor. Under the seat, fuel tank or one of the side covers is the most concealed place. Mount the compressor using the supplied large hose clamp, long cable ties or bolt & nut. NOTE: Keep the compressor terminals pointing downward or horizontal. Locate and area that will be protected from water & dirt. Attach air hose to compressor. HORN MOUNTING: Mount horns to the frame or engine guards only. The most common place is the left front frame down – tube, below the fuel tank using the “L” bracket with the hose clamp routed through the slots. (See photos 2 & 3) If necessary you can bend or twist the bracket using a vise or two adjustable wrenches. Horns should be horizontal or slightly downward. They may be mounted on the right side by reversing the long and short trumpet. Flipping the bracket that mounts to the horns 180 degrees can do this. Route the hose from the compressor to the horns, cut to length & attach. Spraying WD-40 to the end of the hose helps ease assembly. Use a small flame to heat seal the hose outer braided cover to keep from fraying. WIRING: (see photo 1 & the wiring diagram) when mounting the relay be sure the terminals are pointed downward. Remove wires from the stock horn & attach to relay terminals 85 & 86. Find an inconspicuous place to mount the relay. Attach using supplied cable tie being sure the terminals are downward. Refer to diagram & make connections as shown using the supplied wire & terminals. Route wire neatly & wire neatly & where possible hidden. Cable tie the wire to secure. Turn on ignition & push horn button to test. HELPFUL HINTS: When routing wire or hose under fuel tank or difficult to reach place use a stiff piece of wire such as a coat hanger about 3′ or 4′ long for a helpful tool. Bend a small loop at one end. Push wire tool through, attach wire or house with tape and pull back through

Harley Davidson Touring Bikes TRUMPET INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2012

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COMPRESSOR INSTALLATION TOUR MODELS 1992 -2000 On the Dressers and Tour bikes, remove the seat. If the battery is located underneath the seat, then remove the right saddlebag and right hand side cover. Using a zip tie, mount the compressor to the main wiring harness at the front of the covered area with the compressor air outlet facing down. If the battery is not under the seat and is located beside the right saddlebag, the compressor will be mounted underneath the seat, utilizing a bolt to the frame The air hose routes from the air horns, behind the fuel valve, over the rear cylinder and to the right side cover or underneath the seat. Do not cut hose until you connect it to the compressor. TOUR MODELS 2001 & NEWER On the Dressers and Tour bikes, the compressor will mount under the seat, in the square hole in front of the frame, just in front of the battery. The air output will face left toward the air horns. The hose routes thru a hole at the bottom of the square hole, then to the air horns. WIRING Connect both black wires from the relay to the original horn wires. It does not matter which wire you connect. The fuse wire on the relay will connect to the positive terminal on the battery. Observe negative and positive terminals on compressor. Ground the negative terminal to the battery. The positive terminal connects to red wire on relay. Refer to wiring schematic on the next page

Air Shock Installation Instructions

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Filed Under (Tips and Review) by admin on 24-11-2010

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Air HoseInstallation. Choose the most convenient loca- tiononyour motorcycle for the air fill valve. Drilla 5/16″hole and install the air fill valve as shown in Figure 3orsecure air fill valve to frame tube. 2. Keep hose ends clean during installation because dirt can cause air leaks. 3. Install hose connector, tube clamp and two O-rings onto one end of the air hose (See Figures4&5) Apply rubber lubricant (soap solution, not oil) to the O-rings to ease installation on the air hose& into the shock absorber inlet. Plastic connector should just bottom on fitting. Do not overtighten! The function of the nut is to hold everything together in place, the O- rings do the sealing. Fin- gertightenonly (10 in/lb maximum). 4. After routing the air hose, trim the length to fit air fill valve. Install hose connector, tube clamp, and twoO-rings onto end of hose (See figures 4&5). Lubricate as above and assemble to air fill valve. Use the same procedure formating hose. Important —leaveasmall amount of slack in hose near shock absorber to allow for the slight move- mentofthe shock. Caution! Do not install hose near ex- haustsystem, battery or any other sharp edges or seat movement. Keep hoses clear of moving parts such as wheels or suspension components. Do not allow hoses to have excess slack and sag below the motorcycle. The hoses could catch on road surfaces or debris and could be damaged while the motorcycle is in motion. 5. If necessary the air hose can be secured along the motorcycle’swiringharness with tie-wraps. 6. Testing: Inflate system to 50 psi. Apply soapy water solution to all connections and check for air leaks. If there are any leaks, disconnect the suspected fitting and check for dirt or damage to the air line or the O-rings. Remove any dirt or foreign matter, re-lubricate the O-rings and reinstall. If unable to locate the leak, remove rubber boot from shocks and submerge pressurized components under water (in- cludingT-Valve) and check for leaks. If you cannot solve the air leak problem, please contact our technical staff for assistance

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2009 Kawasaki ULTRA 250X/ 260X FUEL INJECTION CONTROLLERS And REGULATORS INSTALLATION MANUAL

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

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The R&D high performance Air Filter Kit will improve acceleration and top speed performance by increasing air flow and reducing air temperatures that enter directly into the Ultra 250X’s air plenum box area. The O.E.M. air plenum box on the Ultra 250X is a great design that will flow plenty of air. However, the air that feeds the plenum box is heated by the engine. R&D has created an easy to install “flat filter” that installs directly in place of the large center access inspection cover located directly under the main glove box. The R&D Flat Air Filter insert will allow unrestricted fresh and cool air to enter the air plenum box area which will add power you can feel and a nice high performance tone. The R&D Performance Filter Kit also features two filters, one for each of the surge and blowoff protections valves. The O.E.M. surge valve recycles compressed hot air back into the air box plenum at idle and under deceleration conditions. The R&D surge and blowoff valve filter kit removes the air recycling hoses which will keep the hot air from entering the air plenum box reducing the engines intake air temperatures. The R&D Ultra 250X Air Filter Kit offers great performance tips on how to remove the restrictive air vent hoses which will further reduce the under seat ambient air temperatures. The R&D Filter system does not remove or alter the O.E.M. plenum box in any way, therefore there are no questions to be answered regarding water ingestion

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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)

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