how to wire a winch on a 4 wheeler

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SR-C400 Motorcycle Security System INSTALLATION MANUAL AND USER'S GUIDE

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Filed Under (Tips and Review) by admin on 29-01-2011

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Routing the Antenna Wire The MCM includes an 18″ antenna wire. The first 12″ is a coaxial wire; the remaining 6″ is the reception antenna wire. When routing, try to avoid running the antenna along or near metal. For best performance, have the antenna wire as vertical as possible and exposed. Wire Connections The system includes one harness (HAR-1a) that connects directly into the MCM. The harness is split into three plugs: one for the GEN-1a connector, one for the optional SN-5 connector and one for the data output for future expansion. Note: Each plug is unique and will only fit the appropriate component one way. Main Harness Note: If the optional factory connector kit is being used, please disregard this section of the instructions and refer to the instructions supplied with the factory connector kit. The main harness consists of two harnesses. One is labeled (HAR-1a) and the second is labeled (GEN-1a). Plug in the white 4 pin connector from the (HAR-1a) into the matching 4 pin connector from the (GEN-1a). The (HAR-1a) also has a waterproof connector that plugs into the MCM. The wires should be connected as follows: HAR-1a Black wire with fuse and ring terminal – To battery Positive (+). GEN-1a Black wire – To ground (-). Orange wire – To tail light wire or any other wire that is hot (+) when ignition is ON (NOTE: this is an input to the alarm this connection is not designed to flash the tail light). Color Codes: Ground (-) Tail Light Honda Green wire Brown wire Kawasaki Black wire Red wire Suzuki Black/White Brown wire Yamaha Black wire Blue wire Harley Davidson Black wire Blue wire

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1982-2005 Harley Motorcycle Removal and Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-03-2012

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” bolt from the mounting stem on the Signal® mirror. While seated on the motorcycle, position the Signal® mirror on the handle bar. Secure the Signal® mirror to the handle bar using the 5/ 16 ” bolt. Make sure the bolt is tight! Guide the Signal® mirror wire harness into the cowling by going along side the existing factory wire harness. 4 Remove any slack in the wire harness. Secure the wire harness to the handle bar using a supplied tie wrap. 5 6 Adjust the position of the Signal® mirror and tighten the ball retention screws. Remove the motorcycle seat. Remove the aft mounting bolts on the fuel tank. 7 Guide the Signal® mirror wire harness along the inside of the fuel tank’s front mounting bolt and between the crossover tube. 8 9 Lift up the aft portion of the fuel tank and guide the Signal® mirror wire harness down the backbone of the motorcycle frame, alongside the existing factory wire harness. The motorcycle’s electrical wiring for turn indicators is located aft of the gas tank on the backbone of the frame. Guide the new wire harness from the Signal® mirror to the electrical wiring. Cut off any excess slack in the wire. Locate the SOLID BROWN wire from the wire connector. Turn the ignition key so that electrical power is on and activate the right side turn indicator. Probe the wire with the wire tester to verify that flashing turn indicator power is present. Label that wire as ‘right side turn’. Repeat all of the previous steps to replace the left side factory mirror with the new Signal® mirror. Locate the SOLID VIOLET wire from the wire connector. Activate the left side turn indicator and probe the wire with the wire tester to verify that flashing turn indicator power is present. Label that wire as ‘left side turn

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KYMCO MXU 375 ATV WINCH MOUNT KIT INSTALLATION INSTRUCTIONS

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

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WINCH MOUNT INSTALLATION INSTRUCTIONS 1. Remove molded plastic bumper guard from the ATV. 2. Mount the winch mount weldment (Item 1) to the ATV as shown below. 3. Mount the roller hawse to the winch mount weldment as shown above. 4
4. Mount the winch to the winch mount weldment and route the winch cable through the rollers. (Installer may need to remove rollers to allow cable end to pass through). 5. Wire the winch according to the manufacturer instructions. 6. Re-install the molded plastic bumper guard. 5 *CAUTION BE AWARE OF WHEN THE CABLE STOP CONTACTS THE ROLLER HAWSE AS CABLE IS WOUND IN. FAILURE TO RELEASE MAY CAUSE DAMAGE TO WINCH PARTS OR TO THE ATV. When using the winch to raise and lower a blade a cable stop must be installed. Carefully raise the blade until the top of the push tube’s are no closer than 1″ anywhere on the ATV. Place the Cable Stop onto the Winch Cable up against the Winch Hawse. Secure the Cable Stop to the Winch Cable using the Cable Clamp Assembly as shown in the pictures below.

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BMW R1200GS Dual Function LED Running Lights and Flashing Brake Lights installation instructions

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Filed Under (BMW) by admin on 08-11-2010

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The flasher is set to flash continuously as long as the brake is applied. To convert to a 5 second flash and then stay solid while the brake is applied, cut the green wire loop on the flasher. Use electrical tape to protect and secure the green wires to the other wires. 2. Remove the rider’s seat. Locate the wire bundle that starts at the rear of the motorcycle. At the most accessible spot carefully remove 3″ to 3½” of protective wire loom. I know, I know…it’s really beautifully done. Cowboy up! Take it off! 3. Mount the flasher in a location that will not crimp wires or interfere with the other bike assemblies. Locate the +12 volt wire ( GRAY wire with BLACK stripe and YELLOW banding) from the brake light Attach the kit RED wire to the brake light positive wire using one of the Posi-Tap connectors in the kit. 4. Locate the Ground wire ( BROWN wire) from the brake light. Attach the kit BLACK wire to the motorcycle ground wire using a Posi-Tap connector. 5. If you have a Fuse Block with ignition switched relay installed, route the Hyper-Lite GRAY wire to a fused circuit on the (relay activated) fuse block . 6. If you do not have a Fuse Block installed, find the alarm circuit connector under the seat . The alarm circuit has a rectangular connector and five wires, White with Black stripe; White with Brown stripe; Red with White; Brown with White; and Green with White stripe. Use a Posi-Tap to attach the Hyper-Lite GRAY wire to the green wire with white stripe. Pull the wire loom back from the wire. Tap into the wire with the Posi-Tap provided. . 7. If using the Hyper-Lite License Plate Mounting bracket, install it now. OR: Clean the side facing reflectors at the rear of the bike with alcohol. Mount the LED modules vertically on the reflectors so that the LEDs point straight back. Press in place for about 5 seconds. The tape can be used only once! If you goof, new tape is required. 8. Route the BLUE and BROWN wires from the flasher and the LED modules. Trim the Blue and Brown wires to remove any excess wire . Use a Posi-Twist to connect the 3 BLUE wires together. Use a Posi-Twist to connect the 3 BROWN wires together. (see Posi-Twist Connector instructions)

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2002-2005 Honda VFR800/A Wire Harness Replacement Manual

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Filed Under (Honda) by admin on 21-04-2011

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If the 18P (light blue) connector is in abnormal condition as shown below, contact TechLine at (800) 421-1900, option 9. FRONT SUB-HARNESS REPLACEMENT 1. Remove the front sub-harness from the cowl stay hooks. Disconnect all the electrical components from the front sub-harness. 2. Temporarily set the main wire harness aside, and disconnect the 6P (natural) con- nector. Then, carefully remove the front sub-harness. 3. Install the new front sub-harness by con- necting the 14P (natural) and 18P (light blue) connectors. NOTE: For routing specifications, refer to the WIRING & HARNESS ROUTING SECTION on pages 7-8. 4. Attach the front sub-harness on the cowl stay hooks. Make sure the front sub-harness is routed elow the main sub-harness. ABNORMAL CONDITION STAY HOOKS 6P (NATURAL) CONNECTOR FRONT UB-HARNESS 14P (NATURAL) CONNECTOR 18P (LIGHT BLUE) CONNECTOR FRONT SUB-HARNESSSTAY HOOK Page 4 VFR800/A #4 4 of 12 NOVEMBER 2007 5. Place the front sub-harness between the radiator and the frame, and below the rec- tifier. Be careful not to damage the front sub-harness or other components. 6. Re-connect the front sub-harness to the 6P (natural) connector. 7. Secure the main wire harness and the front sub-harness using the longer wire band. 8. Secure the main wire harness and the upper side of the front sub-harness using the shorter wire band. Adjust the wire har- ness located within the frame and the radi- ator hose accordingly. 9. Secure the main wire harness fuse box to the front sub-harness using the shorter wire band. FRONT SUB-HARNESS STAY HOOK MAIN-HARNESS FRONT SUB-HARNESS FRONT SUB-HARNESS 6P CONNECTOR (Male) 6P CONNECTOR (Female) WIRE BAND (LONG) WIRE BAND (SHORT)
WIRE BAND (LONG) WIRE BAND (SHORT) MAIN WIRE HARNESS FUSE BO

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DRAG SPECIALTIES MINI SPEEDOMETER WITH LED INDICATOR LIGHTS INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 29-01-2011

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1. Place the motorcycle on a level and secure area. Disconnect the battery. 2. Refer to the appropriate factory service manual and remove the OEM speedometer and indicator lights. The indicator lights usually unplug either in the rear of the headlight or under the gas tank area. 3. Mount the new speedometer in the desired location. 4. Locate the OEM wire for the high beam indicator light. Connect it with the blue wire from the wire harness on the speedometer. Connect the blue/black wire from the speedometer to ground. 5. Locate the OEM wire for the gauge illumination (back) lighting. Connect this wire to the orange wire on the speedometer. Connect the black wire on the speedometer to ground. 6. Locate the OEM wires for the turn signals. Usually they are brown and violet wires. NOTE: You will notice only one bulb for the turn signals in the gauge and two wires from the bike to the harness. If you connect both of these wires directly to the yellow wire on the speedometer, this will allow feedback and cause all the signals to flash at once. To prevent this, you will need to add a diode between each OEM turn signal wire and the yellow wire coming from the speedometer. We recommend that you utilize a Dyna tach adapter, Part #D-101, available separately. This tach adapter includes the diodes necessary to allow the turn signal indicator light to operate correctly. Follow the instructions for the tach adapter, substituting the wires from the original wire harness found in step 6 for the two ignition terminals shown in the wire schematic. Hook the white wire on the tach adapter to the yellow wire for the turn signal indicator on the speedometer. If you use the D-101 adapter, skip steps 7-9 and go directly to step 10. 7. Take one of the diodes, making sure to observe the correct polarity, and attach it to the brown turn signal wire on the bike. 8. Take the remaining diode, again making sure to observe the correct polarity, and attach it to the violet turn signal wire on the bike

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Kawasaki Winch Mount Installation Manual

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

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1. You will need to remove the lower Front Moulding of the ATV for installation of the Winch Kit. 2. Position the Winch with the motor on the LEFT side in the mounting location and slide the Winch Mount Plate in under the winch. Attach the Winch Mount Plate to the frame with the U-bolts and Nylock Nuts provided. Tighten at this time. See Picture Winch Mount Plate 3. Install the Roller Hawse Bracket to the Lower Winch Plate and to the front bars (behind the bars) of the ATV using the U-bolts, Carriage Bolts and Nylock Nuts. See Picture Below. Winch Mount Plate Roller Hawse Bracket 4 4. After winch installation is complete, reinstall lower Front Moulding of ATV. Remove one of the long rollers and the two side rollers and feed the winch cable through the roller hawse. Reinstall the rollers and be sure rollers move freely. Attach the Roller Hawse to the Roller Hawse Mount Plate using the 3/8″ x 1″ Bolts and Nylock Nuts provided with the winch. Tighten all hardware

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HI-4 DUAL FIRE MOTORCYCLE IGNITION INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 09-11-2010

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Turn ignition switch off and disconnect battery ground cable. 2. Refer to Figure 3. Remove OE ignition module and wire harness (items 1-4). You will disconnect two wires at the coil (15), a wire going to the VOES (Vacuum Operated Electrical Switch) (18), a black ground wire at the ignition module, and the 3 pin plug (20) that connects to the sensor plate (11). Refer to shop manual for locations. 3. Remove ignition cover plates and gasket (items 5- 9). This will require drilling out two rivets. The rivets will later be replaced with two supplied self- threading screws. 4. In order to remove the sensor plate cable, the cable plug (20) must be removed first. Use needle nose pliers to pull the terminals out of the plug. Then pull the cable through the exit hole at the bottom of the timing cover. 5. Note location of sensor plate (11). There is a V notch in the sensor plate used for alignment. When you install the HI-4, you should align the V notch in the same location. This should set the timing close enough to start the engine. Remove and save the two standoffs and washers (10). Remove the sensor plate (11). HI-4 INSTALLATION Refer to Figure 4. The HI-4 requires use of the OE timing rotor P/N 32402-83 (used only on 1985 and newer models). If you have an older model or are not sure, check the rotor (9) for the correct part number. For models prior to 1980, use the supplied 10-32 x ¾”bolt and washer to mount the rotor. 1. Install the HI-4 system in place of the OE breaker or sensor plate. Rotate the HI-4 about 90 degrees to give better access to the cable exit hole. Install the HI-4 first, then push the cable through the hole. On some early models it may be necessary to enlarge the wire harness exit hole in the gear cover. Align the V notch on the HI-4 same as the OE plate you removed. Use the OE standoffs to secure the HI-4. You must use lockwashers under the standoffs for proper clearance between the HI-4 and cover plate. Do not fully tighten the standoffs until the timing has been set. 2. Route the HI-4 wire harness along the frame rails up to the coil. Make sure that harness will not be chafed or burned by exhaust heat. Secure harness with tie wraps. Do not install timing cover. HI-4 HOOKUP Crimp terminals and hardware are supplied for your convenience. Use the ring terminals for coil hookup. Use male-female quick disconnects for connections to the tach and vacuum switch (VOES). Tape up any unused wires. 1. Circuit Breaker Cover Screws (2) 2. Circuit Breaker Cover 3. Circuit Breaker Cover Gasket 4. Breaker Plate Screws (2) 5. Breaker Plate Screw Lockwashers & Washers (2 each) 6. Retainer (1971 to early 1972) 7. Circuit Breaker Cam Bolt 8. Breaker Plate Assembly 9. Breaker Cam 10. Advance Assembly 11. Gear Case Cover 11 10 9 8 7 6 5 4 3 2 1 NOTE: Damage will result if the brown tach wire comes in contact with +12V. Figure 1. Harley-Davidson®OE Points System
9000-4002A REV A 3 2/05 1. Identify switched +12 volt wire and tach wire (if equipped) going to the coil. Refer to your service manual, or reconnect the battery and use a test light or voltmeter. The switched +12 volt wire will be hot when the ignition key is turned on. 2. Refer to Figure 5. Connect the HI-4 red wire and switched +12 volt wire to Coil positive. 3. The HI-4 white wire is not used and should be taped. 4. Connect the HI-4 black wire to the Coil negative terminal. 5. Connect the HI-4 green wire to the vacuum switch (Figure 3, item 18), if used. 6. Connect the HI-4 brown wire to the tach wire, if equipped with tach. Tape up if unused. 7. The HI-4 is grounded via the timing housing; a separate ground connection is not required. 8. Reconnect battery ground cable. Verify proper ground connections to the frame and engine. VOES HOOKUP The OE vacuum switch (VOES) is normally an open circuit. Above 3-5 inch-Hg vacuum, the VOES closes and grounds the vacuum input on the OE ignition module. This increases the total advance generated by the OE ignition module. Vacuum advance improves part throttle 17 16 1. Cover Screws (2) 2. Ignition Timer Cover 3. Ignition Module 4. Timer Plate Screws (2) 5. Washers (2) 6. Screws & Washers (2 each) 7. Shield 8. Sensor 9. Trigger Rotor Bolt 10. Timer Plate 11. Trigger Rotor 12. Advance Assembly 13. Gear Case Cover 14. Ignition Coil 15. Spark Plug Wires (2) 16. Ignition Coil Terminal (FX) 17. Ignition Coil Terminal (FL) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 NOTE: Most motorcycle coils do not have terminals marked. Use either terminal for Coil+ (positive) and the other one for Coil- (negative). Warning: The HI-4 (8-1100) Dual Fire ignition will not work with 2 plugs per head, dual coil application. Damage will result if attempted. Use the HI-4 (8-2100) single fire ignition for 2 plugs per head applications

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Kawasaki KVF 360 Winch Mount Installation Manual

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

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1. Remove the bottom and middle bumper mounting bolts. 2. Pull the front bumper outwards while sliding the winch mount behind the bumper with the roller fairlead mount tabs facing downward and towards the front. Slide the roller fairlead mount tabs through the upper opening of the bumper. 3. Bring the back of the winch mount up to the bottom of the middle bumper mounting tubes and install the (2) 5/16″ x 1-1/8″ x 1-3/4″ u-bolts over the tubes and through the winch mount. Install (4) 5/16″ flat washers and Nylock nuts. 4. Install the (2) 5/16″ x 1-1/4″ x 2″ u-bolts over the middle bumper cross tube then through the winch mount. Install (4) 5/16″ flat washers and Nylock nuts and tighten all nuts. 5. Install the winch to the bottom of the mount using the hardware provided with the winch. Be sure the winch winds in the correct direction. 6. Install the roller fairlead using (2) 5/16″ x 3/4″ hex bolts and 5/16″ Nylock nuts provided (rollers should turn freely). Note: Bottom roller may need to be removed to run wire rope through. 7. Push the bumper back into place and reinstall the original bolts. 8. Using the instructions provided with the winch, wire accordingly

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HONDA Ground Effects Installation Instructions

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Filed Under (Honda) by admin on 10-11-2010

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Wiring Installation: 1. Remove the four M8x1.25 socket head cap screws from the seat and remove the passenger handles and seat. 2. Remove both rear side covers, and right front side cover. 3. Remove the two M3 Phillips head screws and two trim clips from the right front storage pocket. 4. Place the three relays of the Ground Effects Ground Effects Ground Effects Ground Effects wiring harness underneath the relay box. 2001 2001 2001 2001 — – 2005 MODELS 2005 MODELS 2005 MODELS 2005 MODELS Route the long end of harness (blue wire and orange wire), behind the fuel tank to the brake lines. The shorter section of the harness will end at the brake lines. Continue along the brake lines to the main harness of the motorcycle to the shelter, then up through the shelter to the pocket area. 5. Locate the harness connectors under the pocket. Go to step 6. 2006 & NEWER MODELS 2006 & NEWER MODELS 2006 & NEWER MODELS 2006 & NEWER MODELS Route the long end of harness (blue wire and orange wire), under the relay box and connect to the Positions Relay. 6. Connect the orange wire to the orange wire with white tracer using a scotch-lok connector. Connect the blue wire to the light blue wire with white tracer using a scotch-lok connector. 7. Route the red and white wires behind the fuel tank, along the left side wiring harness to the fuse box. 8. Connect the RED wire with eyelet connector attached, to the positive side of the accessory terminal in the fuse box. 9. Connect the WHITE wire to the negative battery terminal. 10. Connect the brown wire with white tracer to the brown wire with white tracer (tail relay in relay box) using a scotch-lok connector. 11. Route the orange wire with black tracer and the white wire behind the fuel tank, with at least 6 inches of wire left hanging below the bike. 12. Reinstall the right fairing pocket with the two M3 Phillips head screws and two trim clips. 13. Replace the right front side cover and the right and left rear side covers. 14. Replace the seat and passenger grip handles with the four M8 x 1.25 socket head cap screws

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