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HONDA GL1100 AM/FM RADIO INSTALLATION MANUAL/ WIRING DIAGRAM

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Filed Under (Honda) by admin on 22-04-2011

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INSTALLATION ■ Outline Procedures This section gives general information needed for mounting the individual radio components on and in the fairing. A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts. 3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing. 7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wires. 3 of 11 Page 4 C) Fairing instllation 1) Install fairing on motorcycle. 2) Connect motorcycle wire harness 9-P coupler to fairing wire 9-P coupler. 3) Connect radio switch wire to switch sub- wire.4) Connect antenna feeder. 5) Confirm that radio operates properly. Reinstall parts removed in step 2 or (A) and in step 1 of (B). REWORKING ■ Remove Fairing and Fairing Parts (Fig.10) 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove right and left fairing pockets, right and left turn signal lenses, right and left nutplates, left hole cover and indi- cator base panel from fairing. (Fig.10) Fig. 10 LEI-1 NU I PLATE 4 of 11■ Reworking on Fairing — Speaker mounting holes- 1) Remove 18 mm grommet. 2) Lightly roll template so that it will follow contour of fairing snugly. 3) Position template on fairing with its upper and outer edges aligned with those offairing as indicated by arrows. 4) Attach template to fairing using adhesive tape where shown. 5) Punch mark centers of four holes with a
drift and hammer. 6) Drill 6 mm holes through marked centers. To obtain a more balanced response with richer, deeper bases, drill two 50 mm holes in the fairing so as to link the speaker box with the inside of the fairing. Fig. 11-1
—Power amplifier mounting holes- 7) Drill two 5.5 mm holes through concaves in fairing. Fig. 11-2 RIGHT HAND SHOWN, LEFT SIMILAR ADHESIVE TAPE

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HARLEY DAVIDSON FRONT THUNDERSTAR WHEELS INSTALLATION

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Filed Under (Harley Davidson) by admin on 08-11-2010

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Remove existing front wheel assembly. Save axle, axle nut, brake disc, and wheel spacers for kit installation. Refer to FRONT WHEEL in service manual. For FLSTC and FLSTN Models: Discard moon-style hub cap. -J04065 1 of 8 For FXSTD Models: Discard the tapered r ight side wheel spacer. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c) NOTE • For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771- 07, 43609-07, 44323-07, 44282-07, 44322-07, 43975-07, 43602-07 and 43773-07 install short valve stem (43157- 83A) included in the installation kit. • For Kits 40943-09, 40966-09 and 40996-09 install long valve stem (43206-01) included in the installation kit. 2. See Figure 2. Install valve stem assembly (L, M or N) on wheel. Refer to TIRES in service manual. 3. Assemble wheel installation kit components and brake disc(s) to wheel, using the appropriate service parts table. Refer to FRONT WHEEL in Service Manual. NOTES Install the primary bearing first using appropriate service manual and WHEEL BEARING REMOVER/INSTALLER. For Kits 43573-08, 43575-08, 43703-08, 43978-07, 43771-07, 43609-07, 40943-09, 40966-09 and 40996-09: • The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and/or DOT markings to identify it as the brake disc and primary bearing side. • Install the wheel so that the valve stem is on the right side of the motorcycle. For Kits 44323-07, 44322-07 and 44282-07: • Install the wheel so that the hub markings are on the left side of the motorcycle. The left side of the wheel has a machined groove (item 5, Figure 2) in the hub face and hub markings to identify it as the primary bearing side. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). • The gross axle weight ratings is unaffected by the installation of this wheel on a vehicle equipped with a 21-inch wheel. For Kits 43975-07, 43773-07, and 43602-07: • The wheel has a machined groove (item 5, Figure 2) in the hub face to identify the right side. • For 2007 and later FX Softail Models and 2008 and later FXDWG: The left side of the wheel is the primary bearing side. For all other models the right side of the wheel is the primary bearing side. • For Kit 43602-07: An arrow is engraved into the right side hub to indicate the direction of rotation. • For Kits 43975-07 and 43773-07: An arrow is cast between the spokes on the right side to indicate the direction of rotation. • These kits include one or two hub plates (43985-00) to install between the brake disc and the wheel and a chrome hub cap (43986-00) to install on the wheel opposite the brake-disc side. Hub covers must be installed to prevent water intrusion, which could cause an imbalance condition. Dual brake disc models: Install one stainless steel hub plate (3) between each brake disc and wheel hub. Discard chrome hub cap (2). Install brake discs according to service manual procedures. Single brake disc models: Install one stainless steel hub plate (3) between the brake disc and wheel hub. Install the brake disc according to service manual procedures. Install the chrome hub cap (2) on the side opposite the brake disc. Discard extra stainless steel hub plate (3). 4. Install wheel assembly parts from the appropriate Service Parts table for this fitment and stock brake disc. Discard parts from the installation kit that are not required. Refer to FRONT WHEEL in Service Manual. 5. For FLSTC and FLSTN Models: Install wheel kit and right side wheel spacer provided in installation kit. For FXSTD Models: Install wheel kit, stock left wheel spacer and right side wheel spacer from installation kit in place of the tapered right side wheel spacer discarded in Step 1. Refer to FRONT WHEEL in service manual. For FXSTS Models: Install the left side wheel spacer provided in the kit between the stock left wheel spacer and the left fork. All other models: Install wheel spacers previously removed. 6. Install front wheel (1), stock axle and stock axle nut. Refer to FRONT WHEEL in service manual

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Type 11 Honda Motorcycle Audio system installation

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Filed Under (Honda) by admin on 02-11-2011

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This section gives general information needed for mounting the individual radio components on and in the fairing.
A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts.3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing.
7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wire

Fairing bodywork in glass-reinforced plastic Cruciata Racing

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

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The fairing bodywork that they have I use in contest is made in sturdy and flexible glass-reinforced plastic. The fairing bodywork in glass-reinforced plastic they succeed to replace the fairing bodywork originates them nearly perfectly, thanks to the predisposition holes. The greater part of the fairing bodywork in glass- reinforced plastic in production has the points of attachment with the moto reinforces to you in carbon on every attack with the chassis of the moto. Between the types of fairing bodywork and as point of reference between the fairing bodywork is as an example fairing bodywork it Cruciata Racing, worked always handicraft with passion for it gets passionate to it to you, which has enjoyed in particular way of the progresses and the evolution of the materials and the members. fairing bodywork the Cruciata Racing is constructed entire in woven of glass with reinforces in carbon in correspondence of the attacks to the motor and between the parts in glass-reinforced plastic. In the line racing standards are included plexiglass of height (to pierce), neoprene sponge cm 1,5 (supplied already sagomata). It fairing bodywork Cruciata Racing is which between the types of fairing bodywork is distinguished for its use, that is, this fairing bodywork is born and it is developed in order to answer carefully and to satisfy the requirements of the pilots. Fairing bodywork the Cruciata Racing in glass-reinforced plastic obviously is demanded for that it regards the sport within and the contests in track, because they are the only ones like characteristic to resist to the sollicitations impegnative thanks to theirs reinforces inner. Moreover to being resistant, these fairing bodywork offer to an optimal elasticity and lightness. Fairing bodywork the Cruciata Racing of sure the fairing bodywork better is produced with the best materials on the market. The fairing bodywork in glass-reinforced plastic they can be acquired crude, or can be painted and prepared in in professional way, applying all the processes of preparation that guarantee a final result of elevated quality, is from the aesthetic point of view, the point of view of the duration and from the point of view of I use it of the fairing bodywork.

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Laminar LaMini Fairing Mounting Instructions

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

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Mounting Instructions for the Laminar LaMini Fairing The Laminar LaMini Fairing is designed to mount onto motorcycles having up to 7 inch round headlights and traditional instruments. It is attached to the motorcycle with four clamps, two on each fork tube between the triple clamps. If you plan to paint the fairing be sure to fit it first. Make sure that the front turn signals do not obstruct installation of the
LaMini Fairing. If the turn signals are located between the triple clamps relocating or replacing the turn signals may be desired. When fitting the fairing the greatest potential for damage to your motorcycle lies with the clamps or the back ends of the fairing touching the gas tank when the steering is turned to lock. Monitor this possibility each time the handlebars are turned until installation is completed, padding the front of the tank with some towels is a good idea. Let’s get started 1) Attach the shield to the rear side of the fairing with rubber washers between them, using nylon fasteners. Wrap two clamp gaskets around each fork tube. Unscrew the clamps and slip two of each around each fork leg. The worm screws should be at rear of the fork tube. Slip a clamp gasket between each clamp and fork and finger tighten the clamps. The ž”x ū ” bolts should be sticking straight out to the sides. Center the clamps spaced 3 inches apart between the triple clamps. Carefully turn the handlebars to lock in each direction to assure that the clamps do not touch any other parts of the motorcycle. If the clamp worm gears interfere the clamps may be reversed with the worms at the front side of the forks but this makes tightening or adjusting them with the fairing mounted very difficult. 2) Test fit the fairing (shown upside down in the top photo) over the headlight and in front of the instruments. Try to leave a spacing of ž inch everywhere. If required the fairing may be trimmed to match the gap to the headlight. Do the sides of the fairing cover the ž”x ū ” bolts so that
holes to be drilled through the fairing will securely receive the bolts? Looking from the side of the fairing and with the fairing located with the center above the headlight move the rear of the fairing up and down to determine the best fit to the motorcycles lines. When

HARLEY DAVIDSON MULTI-POCKET FAIRING POUCH KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION 1. Remove the three outer fairing screws located just below the windshield and remove the windshield. 2. See Figure 1 or Figure 2. Apply adhesive pads to the bottom of the bracket in the locations shown. When the bracket is installed, the pads should rest on the top of the inner fairing and support the bracket. 3. Apply clear tape between the screw opening at the base of the windshield on the inside surface of the windshield. 4. See Figure 3. Pull the outer fairing away from the inner fairing to provide sufficient clearance to slide the mounting tabs of the bracket over the top lip of the inner fairing. 5. Center the fairing bracket along the top of the inner fairing. 3 1 2 is04616 1. Bracket 2. Pads 3. Bracket clips Figure 1. Bottom of 3-Pocket Fairing Pouch Over tightening windshield fasteners can crack windshield and/or fairing. (00451b) 6. Reinstall the windshield and three screws removed in Step 1. Tighten screws snugly, but be careful not to over-tighten screw or the fairing may crack. 3 1 2 is04615 1. Bracket 2. Pads 3. Bracket clips Figure 2. Bottom of 2-Pocket Fairing Pouch 4 2 6 5 1 3 is04614 1. Pouch 2. Windshield 3. Tape, clear 4. Outer fairing 5. Pouch bracket clip 6. Top of inner fairing Figure 3. Fairing Clip Attachment, Side View

HARLEY DAVIDSON ILLUMINATED CHROME COVER KIT FOR FAIRING MOUNT MIRRORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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INSTALLATION Preparation Models with main fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow the instructions given to remove the main fuse. Models with main circuit breaker: 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. Installation NOTE Cover the work surface with an H-D Service Cover or clean shop towels to prevent scratching the finish of the outer fairing. 1. Remove the outer fairing per the instructions in the service manual. Lay the fairing face down on a sturdy work sur- face. 2. See Figure 2. Remove the mirrors (2), flange nuts (3) and plastic backing plates (4) securing the mirrors to each side of the inner fairing (1), and retain all items 3. Measure one inch (25 mm) straight down (5) from the large mirror stud hole in the inner fairing, and make a mark. 4. Drill a 1/4 inch (6 mm) diameter hole (6) through the inner fairing at the mark. 5. See Figure 1. Obtain a chrome wire collar (3) from the kit, and press it into the new hole from the outside of the inner fairing. Gently tap into place with a soft-faced hammer. 6. Repeat Steps 3 through 5 on the opposite side of the inner fairing. NOTE Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the mirror cover to the mirror. 7. Clean the back surface of the mirrors with the alcohol pad (7) provided. Allow to dry thoroughly. 8. Obtain the primer tube (8) from the kit, and follow the instructions on the tube to activate the primer. When the primer is activated apply the primer to the back surface of one mirror. 3 6 2 1 4 5 is06091 1. Inner fairing 2. Fairing mount mirror 3. Flange nut (2) 4. Plastic backing plate (2) 5. Measure one inch (25 mm) down 6. Drill 1/4 inch (6 mm) hole (2) Figure 2. Fairing Drill for Illuminated Mirror NOTE The Illuminated Chrome Mirror Covers are side-specific. The covers install with the wire harness exiting from the bottom. 9. Obtain the correct mirror cover from the kit. Rub the liners on the three pads on the back surface of the mirror cover to activate the adhesive, then remove the liners. 10. Place the mirror cover over the back surface of the mirror and press into place for a minimum of 60 seconds. 11. Repeat Steps 8 through 10 for the remaining mirror and cover. NOTE The plastic backing plates (removed earlier) are identified with a letter “L” (left) or “R” (right) stamped on the post. The mirrors are marked with a letter “L” or “R” stamped on the swivel block. Use the correct backing plate for each mirror by matching the letters. 12. Position the mirror on the outer face of the inner fairing, with the rounded side of the mirror outboard and the Bar & Shield logo upright. a. Insert the mirror cover wiring harness through the chrome wire collar installed in Step 5. b. Insert the mirror post through the original mirror mounting hole. c. Place the correct plastic backing plate against the inner face of the inner fairing, engaging the two holes in the backing plate with the threaded stud and index pin on the mirror swivel block. d. Install the flange nut on the threaded stud and tighten to 30-40 in-lbs (3.4-4.5 Nm) . e. Repeat for the remaining mirror on the other side of the fairing

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HARLEY DAVIDSON VENTED FAIRING LOWERS KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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INSTALLATION 1. See Figure 1. From the kit, obtain the left side fairing lower (1), left side fairing lower cap (2), two flange locking nuts (3) and two stud clips (4). Place fairing lower cap in front of the left side engine guard and left side fairing lower behind engine fairing guard. With both pieces in place around engine guard, install the two flange locking nuts onto the studs clips and hand tighten. Repeat procedure for right side fairing lower. 2. Secure bottom of fairing lower to lower engine guard with round clamp (5) from hardware kit. Position clamp around engine guard with tabs toward rear of vehicle and flat side of clamp against fairing lower and with the rubber washer (6) between clamp and engine guard. Place Torx pan screw (7) through fairing lower, rubber washer and clamp. Secure assembly with flanged locknut (8). Repeat for right side fairing lower. Tighten to 144 in-lbs (16.3 Nm). 3. Tighten all left and right side upper flange locking nuts (3) to 72 in-lbs (8.1 Nm). 4. Install left side door assembly glovebox (9) to fairing lower using the attachment cord (10). Insert glovebox door into fairing lower. Repeat for right side fairing lower. NOTE Do not press reflector firmly into place until you have it positioned in desired location. The adhesive is very strong and once it comes in contact with a surface, it will be difficult to remove without damaging the reflector. 5. Peel adhesive strip off back of reflector from kit. Position reflector on side of front fender above chrome side trim strip and approximately 4 inches rearward from front of fender. Press reflector securely into place. Repeat for opposite side reflector

ROAD TECH ZUMO 660 GLOBAL POSITIONING SYSTEM (GPS) FAIRING MOUNTING KIT INSTALLATION

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

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1. Refer to the service manual and follow the instructions given to remove the main fuse. 2. Remove the outer fairing and windshield. Refer to the service manual. is05900 Figure 1. Road Tech Zumo Drilling Template Placement 3. See Figure 1. Obtain the drilling template from the kit. 4. Position the template on the back side of the inner fairing, in the upper left corner above the fuel gauge, aligning the template to the top of the inner fairing and the plastic rib as shown. 5. Drill a 5/16 inch (8 mm) diameter hole through the inner fairing per the template. 6. See Figure 4. Position the gasket (2) and GPS mount (1) onto the face of the inner fairing, aligning the upper hole in the mount with the hole drilled in the previous step. 7. Temporarily install one of the screws (4) through the upper hole to help align the GPS mount. 8. See Figure 2. Mark the location of the lower mounting hole on the face of the inner fairing, using the GPS mount and gasket as a template. Mark the location of the wire routing hole using the guide hole (3) in the gasket as a template. 9. Remove the screw, GPS mount and gasket from the inner fairing. 10. Drill a 5/16 inch (8 mm) diameter hole through the inner fairing in the lower mounting location. Drill an 11/16 (17 mm) diameter hole through the inner fairing in the wire routing location. 1 2 3 is06149 1. Gasket 2. Wire routing guide hole and ribs 3. Guide hole Figure 2. Remove Gasket Ribs and Guide Hole 11. See Figure 2. Remove the wire routing guide hole and four ribs (2) from the gasket (1). 12. See Figure 4. Install the GPS mount and gasket to the inner fairing with screws (4) flat washers (5) and locknuts (6). Tighten to 50-60 in-lbs (5.6-6.8 Nm) 13. Obtain cradle with harness from GPS system kit. NOTE The fuse holder on the harness must be opened to fit through the hole. 14. Insert harness through the 11/16 inch (17 mm) diameter hole drilled earlier. 15. Insert the split grommet into the 11/16 inch (17 mm) diameter hole around the harness. Installing the Cradle 1. See Figure 4. Install four bushings (H) from the GPS system kit and insert them into the back of the cradle mounting holes. 2. Position the cradle to the GPS mount. Direct the harness out through the slot (G) of the mount. 3. Insert a button head screw (3) through one of the holes in the cradle and into the corresponding hole in the GPS mount, but do not fully tighten

HARLEY DAVIDSON FAIRING BRA INSTALLATION INSTRUCTIONS

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

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This kit is designed for installation on 1996 and later FLHT, FLHTC, FLHTCU AND FLHTCU/I Model Motorcycles. Installation 1. Align each of the sewn-in pockets on the fairing bra with each of the outer edges of the fairing at handlebar level. 2. See Figure 1. Standing in front of the vehicle, remove the three T27 Torx screws (1) with washers securing the windshield along the front of the fairing. NOTE In the following Step, the Chrome Windshield Strip (purchased separately) , will serve as a mounting bracket for the fairing bra 3. Obtain the Chrome Windshield Strip (P/N 59213-96) and screws supplied with strip. While aligning holes in the chrome strip over the bra, install the new screws with washers through the strip and bra, then tighten securely into the windshield. 4. The six straps (three on each side near the bottom) will be captured between the inner and outer fairing. Refer to Figure 1. Remove the four screws (2) from the inner fairing. NOTE: The bottom two screws are below the fairing cap. Save screws for installation. Separate the inner and outer fairings just enough to install the straps into the fairing. Adjust the straps, then reinstall the screws and tighten securely. 5. Remove the Phillips screw located at the bottom of the headlamp trim ring. Save screw for installation 6. See Figure 2. Orient the elastic portion of the bra around the headlamp, however in front of, the retaining ring as shown. 7. Install the bottom elastic strap below the fairing seal under the headlamp. 8. Install the headlamp trim ring using the Phillips screw removed in Step 5.

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