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YAMAHA FJR1300N PERIODIC MAINTENANCE AND MINOR REPAIR

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Filed Under (Yamaha) by admin on 17-12-2010

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Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. ● To charge a sealed-type (MF) battery, a special (constant- voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. EAU04076* Replacing the fuses The fuse box, which contains the fuses for the individual circuits, is located under panel D. The fuel injection system fuse box is located under panel D. The main fuse box is also located under panel D, beside the battery. (See page 6-7 for panel removal and installation procedures.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. Fuel injection system fuse 2. Spare fuel injection system fuse 1. Headlight fuse 2. Signaling system fuse 3. Ignition fuse 4. Windshield motor fuse 5. Radiator fan fuse 6. Backup fuse (odometer and clock) 7. Spare fuse (〈 4)
PERIODIC MAINTENANCE AND MINOR REPAIR 6-31 6 EC000103 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EAU04099 Replacing a headlight bulb This motorcycle is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove panel B (if replacing the left headlight bulb) or panel C (if replacing the right headlight bulb). (See page 6-7 for panel removal and installation procedures.) 2. Disconnect the headlight coupler, and then remove the headlight bulb cove

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HARLEY DAVIDSON DETACHABLE TOUR-PAK LIGHT HARNESS KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION 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. 2. ALL models: Install the Detachable Tour-Pak Rack Kit per the instructions in that kit, up to the point where the saddlebags are to be re-installed. NOTE Make note of the cable strap locations before releasing the harness from the upper frame tube. New straps will be fastened in the same location. 3. Cut the larger cable strap fastening Tour-Pak circuit [12] (see the Service Manual Wiring Diagram) of the vehicle main harness to the left-side upper frame tube, rearward of the shock absorber. Cut the small cable strap at the end of the circuit [12] conduit. 4. Slit the conduit open along its length to expose the final ten inches (0.25 M) of main harness circuit [12] wiring. Cut the three wires (Black, Blue, and Red with Yellow tracer) nine inches (0.23 M) from the three-way Multilock socket housing [12B]. The socket housing and cut wires can be discarded. 5. Obtain the socket housing, secondary lock (locking wedge), and three socket terminals from the kit. See the illustration at DEUTSCH ELECTRICAL CONNECTORS: REMOVING/INSTALLING SOCKETS in the Service Manual. Refer to CRIMPING INSTRUCTIONS in the Service Manual, and follow the instructions to install the terminals to the three wire leads of main harness circuit [12]. 6. Per the instructions under DEUTSCH ELECTRICAL CONNECTORS, insert the Blue lead and terminal into Cavity 1 of the new socket housing. Insert the Red/Yellow lead and terminal into Cavity 2. Insert the Black lead and terminal into Cavity 3. 7. Cut the excess conduit from main harness circuit [12]. 8. Obtain the two cable straps from the kit. As noted in Step 3, use one strap to bind the end of the main harness circuit [12] conduit. Use the second strap

Ignition Upgrade Module for 2004-up Carbureted Harley Davidson Motorcycles Owner's Manual

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Filed Under (Harley Davidson) by admin on 25-11-2010

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1. Disconnect the negative battery cable. 2. Grasp the sides of the electrical caddy (located next the ignition coil) and pull outward to remove. 3. Remove the relay and fuse panels from the electrical caddy. a. Insert a small screwdriver into the slot under each fuse and relay panel. b. Using a screwdriver, disengage the panel from the electrical caddy. 4. Disconnect the main fuse connector from the electrical caddy a. Remove the main fuse from the connector b. Insert small screwdrivers into the slots on each side of the main fuse c. Depress the tabs of the main fuse connector to disengage it from the electrical caddy
Thunder Heart Performance Corp. 615-672-8811 www.thunder-heart.com 2 EI5075.doc 5. Depress the tab located on the electrical caddy securing the TSM/TSSM. Pull it from the electrical caddy. Disconnect the TSM/TSSM connector. 6. Slide the data link connector towards the front of the motorcycle to disengage it from the electrical caddy. 7. Disconnect the ignition control module connector. 8. Disconnect the ignition coil connector and spark plug cables from the coil. 9. Remove the electrical caddy fasteners (3 total). 10. Remove the wiring from the electrical caddy. 11. Remove the fasteners securing the factory ignition control module from the electrical caddy. 12. Installation of the Digital Ignition Module is the reverse of removal. 2.2 Touring Models 1. Disconnect the negative battery cable. 2. Remove the right saddlebag. 3. Gently pull the side cover from the frame downtubes (no tools required). 4. Depress the external latches and use a rocking motion to remove the electrical connector from the ignition control module. 5. Remove the two socket screws to detach the ignition control module from the electrical bracket. 6. To install the Digital Ignition Module, install and tighten the socket screws to 50-60 in-lbs . The remainder of installation is the reverse of removal. 2.3 Softail Models 1. Remove the seat. 2. Disconnect the negative battery cable. 3. Remove the two screws to free the ignition control module from the mounting bracket. 4. Depress the external latches and use a rocking motion to remove the electrical connector from the ignition control module. 5. To install the Digital Ignition Module, install and tighten the socket screws to 15-21 in-lbs . The remainder of installation is the reverse of removal

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Harley Davidson Power Pod Switch Housing Throttle Bracket Installation Instructions

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Filed Under (Harley Davidson) by admin on 19-03-2012

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Attach the “Y” bracket to the Power Pod by using the two Power Pod socket head screws that come in your parts kit. (This bracket may already be attached from the factory. ) 2) Remove the two screws on the Right Hand switch housing on your Harley Davidson motorcycle and reinstall them through the two “Y” bracket open holes and back into the switch housing holes. Tighten snugly. In this mounting position, the heads of the two socket head screws holding the “Y” bracket to the Power Pod should be touching the handlebar; this is necessary as it grounds the unit for proper operation. If the unit is not grounded properly, it will not operate. 3) Run the Power Pod’s 60″ power cord to your battery. Make sure as you hide the cord on the way to the battery, that your handlebars turn freely and that the cord does not come in contact with hot engine parts that may melt the wire over time. 4) At some point, before reaching the battery, attach (using the two butt connectors) the in-line fuse holder. TIP: Keeping the in-line fuse holder in an easy to access place (like under a side panel etc) rather than under the seat, may help you service the fuse easier in case of a blown fuse. In most cases, it’s easier to pull a side panel off than it is to remove a seat! 5) Attach the Power Pod lead wire (with in-line fuse now already attached) directly to the battery for power at anytime without using the key. The hot lead can also be run to the fuse box which will require using the ignition switch to “Accessory” or “ON” in some cases. TIP : Always use the in-line fuse for safety. 6) Insert the 20 amp fuse into the in-line fuse holder. Strap down with zip-ties any loose wires and you’re done!

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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HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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REMOVAL 1. Refer to the owner’s manual and follow the instructions to disarm the security system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. For All Models except 2002-2003 Touring and 2003- Later Softail: Refer to the owner’s manual and follow the instructions to disconnect the battery, negative (-) cable first or remove the main fuse. For 2002-2003 Touring and 2003-Later Softail Models: Remove seat following the instructions in the service manual and disconnect the battery, negative (-) cable first. Save seat hardware for installation. INSTALLATION 2002-2006 VRSCA, VRSCB, VRSCD Models 1. Open the seat. 2. See Figure 1. Remove the splash guard (mud flap) nuts. 3. See Figure 2. Lower the mud flap from the installed position and allow it to rest on the rear tire 3. Slide the siren into place on the left side of the electrical caddy so the sounder disc (6) faces out. 4. Refer to the owner’s manual and follow the instructions to install the main fuse. 5. Align the barbed studs on the side cover with the grommets in the frame and push side cover firmly into place. 6. Install the left side saddlebag per the instructions in the owner’s manual. 2003 and later Softail Models EXCEPT FXCW/C 1. Remove the right side saddlebag (if equipped) per the instructions in the owner’s manual. NOTE The siren connector is installed on an electrical panel under the rear fender on all Softail models. The rear of the motorcycle may have to be raised slightly to allow removal of the splash guard. 2. Remove the two bolts at the bottom of the splash guard. Bend the upper right corner of the splash guard toward the rear tire and lift upward to unhook the splash guard from the tab on the rear fork. Remove the guard from beneath the fender. 2 1 3 is01316 1. Siren mounting area 2. Siren connector [142B] 3. Harness clip Figure 16. Siren Connector (Softail Models EXCEPT FXCW/C) (Rear Fender View with Rear Wheel Removed) 3. See Figure 16. Remove the siren connector [142B] (2) from the receptacle in the siren mounting area (1) of the electrical panel. 4. See Figure 17. Insert security siren (1) connector [142B] into the siren box receptacle until the connector latches securely. 5. Orient the siren (1) as shown, with the harness connector (2) toward the bottom and the sounder disc (5) facing out. Carefully snap the siren into the electrical panel. 6. Insert the siren harness lead (4) into the harness clip (3) to keep the harness clear of other components. 7. If necessary, secure the connector wiring to the electrical panel wiring with a cable strap (not provided). 8. Hook the slot at the top of the splash guard over the tab on the rear fork and install the guard with the two screws removed earlier. Tighten securely. 9. Install the right side saddlebag (if equipped) per the instructions in the owner’s manual. 10. Refer to the owner’s manual and follow the instructions given to connect the battery cables or install the main fuse

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HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN AND SMART SIREN II KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION 1. Refer to the owner’s manual and follow the instructions given to disarm the security system and remove the left- side cover. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Refer to the owner’s manual and follow the instructions given to remove the main fuse. ALL models: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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) 3. Refer to the owner’s manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 4. Remove the battery from the vehicle. 2 1 3 4 is 01377 1. Three-pin connector on siren harness 2. Three-pin connector [142B] on vehicle harness 3. Siren harness 4. Frame rear crossmember (not visible) Figure 1. Connect the Siren Harness to the Vehicle Harness 5. See Figure 1. Locate the siren connector (2) on the main harness, behind the harness shield forward of the battery location. It is covered by a dust cap. Pull the dust cap from the connector, and feed the connector downward and out from behind the shield. 6. Select the correct siren harness (3) for this model year vehicle from the kit. Route the three-pin connector (1) of the siren harness from the bottom of the motorcycle, between the primary cover and frame tube. Plug the connector into the siren harness connector (2) on the vehicle main harness. 7. Secure the connectors to the diagnostic harness using a cable strap from the kit. Route the long lead of the siren harness over the frame rear crossmember

BMW F650 CS Front belt wheel not correctly secured

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Filed Under (BMW) by admin on 23-11-2010

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2.1 Removal of the front belt wheel Remove the front belt wheel in accordance with the instructions detailed in the F 650 CS Repair Manual. Remove the securing screw of the activated charcoal filter and let the filter canister hang by one side by the hoses, or remove it and lay it aside. Clean the splines and threads of the main shaft in order to remove all traces of Loctite. If necessary, remove corrosion from the main shaft spline (use only a brass bristle brush). 2.2 Visual inspection Check the splines of the main shaft for damage. Replace the main shaft if the splines are damaged (broken, chipped, bent or damaged teeth). Refer to the F 650 CS Repair Manual for this procedure 2.3 Wear check gearbox main shaft- It is extremely important that the techni- cian always check that the dimensions of the gearbox main shaft splines are to specification before proceeding with the installation of a new front belt wheel. This note only applies to motorcycles with accumulated mileage, not to new motorcycles from the crate. If the visual inspection was satisfactory and the main shaft was not replaced for visual damage, a main shaft wear check will be necessary. This check requires the use of BMW Special Tool # 23 4 571 . The adapters are designed for micrometer gauges with stud diameters from 6.35 mm to 6.6 mm. Do not use cellulose-lacquer thinners to clean the adapters as there is a risk of damaging the measuring instruments. Make sure that the micrometer gauges and the adapters are perfectly clean

Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

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1991 Bimota YB10 DYNOJET KIT INSTALLATION MANUAL

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Filed Under (Bimota) by admin on 01-11-2010

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1. Remove the vacuum slide from the carbs. Remove the stock needles & spacers, noting the order of assembly (Fig.A). 2. Install the Dynojet needles on groove #3 , using all stock spacers (Fig. A). Install the Dynojet washer above the E-clip. 3. Replace the stock slide springs with Dynojet slide springs provided. 4. Remove the stock main jets and replace with the Dynojet main jets provided. Use the DJ116 main jets with stock exhaust pipe, or use the DJ120 main jets with aftermarket header or slip-on with high flowing baffles. Use the DJ112 main jets at high altitude. Be sure that the jets you are changing are the main jets. 5. Locate the fuel mixture plug (Fig. B), if you see a screw head, proceed to adjusting procedure. With the plug drill (DD #5/32) provided, carefully drill thru the plug(s). The mixture screw is directly underneath this plug, be ready to pull back on the drill the instant you break thru. Use the screw provided to secure and remove the plug. Carefully turn mixture screw clockwise until seated, then back out 3 turns. 6. Locate the main air correctors (Fig.C). Using the plugs provided (DCO400), plug the main air passage. Place the plug in the carb flat end first.Tap in lightly. Using DT002. STAGE ONE INSTRUCTIONS Fig. B Place E-clip in groove #3 from the top Fig. A Notes: 1. Proper EXUP value adjustment is very important for good midrange performance. 2. If experiencing fueling problems below 4,000 rpm, under full throttle, that the needle can’t fix, try changing fuel level. If you feel it is too rich, lower the fuel level. If you feel it is too lean, raise the fuel leve

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