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Harley- Davidson Bagger Audio factory service manual for removal

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Filed Under (Harley Davidson) by admin on 03-04-2012

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POWER & SPEAKER HARNESS INSTALLATION- (Read electrical connections prior to connecting center power and ground wires) 1. Disconnect battery (negative cable first!) 2. Remove outer faring cover 3. Route long speaker wires from fairing area through tank channel to seat area. 4. Route one pair of speaker wires under each fender strut support; purple and purple and black wires to the right and green and green and black wires to the left. AMPLIFIER INSTALLATION- 1. Factory installed electronics will determine suggested placement of amplifier. 2. Position and attach amplifier to outer fairing support bars with supplied wire ties. (Electra/Ultra/Street Glide) BAGGER AUDIO™ LIDS INSTALLATION- Detach factory lid by removing the 2 screws holding the factory strap to inner lid and 5 small torque screws holding lid to factory latch assembly. (Consult factory service manual for further instructions) Remove metal strap from behind factory seal (This is the metal strap that the previous 5 small torque screws were removed from) Position metal strap in same location on your new lid. (If you purchased your product unpainted, you must install the supplied seal to your finished lid) Reattach BAGGER AUDIO™ LIDS by installing the 5 small torque screws in the same location as on the factory lid. (We suggest that you have an assistant hold the lid in place while attaching your new lids) Replace factory nylon Hinge straps with new nylon straps supplied in kit. Use metal straps and machined screws to secure the nylon hinge straps. 
 Place a small bead of silicone on the inside rim of the speaker basket to create a watertight seal between the inside of the lid and the speaker. 
 Install speaker into the bottom of the lid (not through the top opening) with supplied stainless screws and washers (4 per lid). Be sure to center speaker in lid opening to ensure proper speaker grill placement. Install speaker with terminals facing toward the front of the lid. One 1/4″ hole must be drilled in each bag. Holes can be positioned at the ownerʼs discretion. Place rubber grommet in drilled hole before running wires

SUZUKI GSX-R1000 SERVICE MANUAL

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Filed Under (Suzuki) by admin on 12-11-2010

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Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. 5. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft) ! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. ! Cover the throttle bodies to prevent anything from dropping into the engine. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.

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FC Shock Spring Installation Guide

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Filed Under (Tips and Review) by admin on 14-12-2010

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Installation: 1. Remove the fork springs according to the OEM Owner’s Manual. 2. Check/adjust fork oil level and weight according to OEM Specifications. Caution: Most inverted forks will not require the use of any shim washers or spacers. In cases where use is necessary with the twin chamber style fork, the shims must be placed at the bottom of the spring. Most conventional forks (non-inverted) will use shim washers or spacers at the top of the fork spring. 3. Install Factory Connection fork springs and refer to OEM Owner’s Manual for proper assembly procedures. 4. Be sure to double check all fasteners. Note: Most modern day forks require special tools for disassembly and assembly of the components. Examples : Showa 47/49mm Twin Chamber, KYB 48mm Twin Chamber, WP 07 SX Models/SXS Components. Installing fork springs is an intricate process that should be performed with extreme care by a qualified suspension technician. Failure to install the springs correctly could cause damage to one or more components of the fork. This damage, although not readily apparent, could lead to unexpected failure or rider injury. Factory Connection manufactures models specific fork springs. Installation of a Factory Connection spring not designed for your motorcycle may result in unexpected failure and rider injury. Please consult your Factory Connection spring dealer or call Factory Connection directly if you are unsure about a spring/or springs. 1. Factory Connection’s Limited Lifetime Warranty Factory Connection warrants, to the original retail purchaser (“consumer”) who retains ownership of the vehicle on which the suspension spring(s) (“products(s)”) was originally installed, all suspension springs for life against factory defects in material and workmanship (other than defects in finish) when used under normal use and operating conditions. 2. Your Remedy Upon verification of warranty coverage, Factory Connection at its option will replace defective or prematurely worn-out product (s), without charge, or refund the purchase price of the products(s). This is the Consumer’s sole and exclusive remedy for any loss or damage, however arising, due to a nonconformity or defect in the product(s). 3. Warranty Claim Procedure To make claim under this warranty, the consumer should contact the Factory Connection dealer or Factory Connection where the product(s) was purchased. Factory Connection reserves the right to test the returned product(s) to evaluate the nonconformity or possible defect. The Consumer is responsible for all costs of returning the defective or prematurely worn-out product(s) to the Factory Connection dealer as well as all costs for removing the product(s) from and installing the products(s) on the vehicle.

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SUSPENSION SERVICE TOOLS/ FORK DAMPER ROD BLEED TOOL

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Filed Under (Tips and Review) by admin on 30-11-2010

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33 SHOP EQUIPMENT & TOOLS SUSPENSION SERVICE TOOLS K&L FORK TUBE U-BLOCKS Precision machined from billet aluminum, these quality three piece sets are a handy, accurate and safe way to straighten and check fork tubes. 35-9411 36mm (for 33 thru 36mm tubes) 35-9412 40mm (for 37 thru 40mm tubes) 35-9413 43mm (for 41 thru 43mm tubes) 35-9414 46mm (for 44 thru 46mm tubes) 35-1964 35-8579 35-7995 DAMPER ROD HOLDERS Holds damper rod when disassembling forks. 35-8578 Yamaha front forks, 43mm Kayaba YZ125/250 (1988) YZ490 (88-90) 35-8579 Yamaha YZ125/250 with UD(upside down) forks FORK DAMPER ROD TOOLS Sold each. 35-7995 Combination Fork Damper Tool Designed to hold the damper rod during assembly & disassembly of Honda XR400′s or Suzuki DR-Z400S. One end features spanner type prongs for the XR400 and the other a 27mm hex for Suzuki. 35-1964 Combination Damper Rod Fork Tool Designed for assembly and disassembly of most inverted Kayaba and Showa 41mm, 43mm, 46, and 47mm forks. Use one end for Kayaba forks and the other for Showa forks. (not required for 91-92 Honda CR models) ROD HOLDER Double sided damper rod holder. Works on Kayaba U.D (upside down) 41mm forks. 35-8580 Yamaha YZ125/250Amodels (89-90) FRONT FORK CAP SOCKET Designed to remove and install Yamaha front fork caps with female hex head. Sold each. 35-8571 14mm female socket 35-8573 19mm female socket FORK DAMPER ROD HOLDERS Holds damper rod when disassembling and assembling front forks. 35-8576 Use for Yamaha 43mm Kayaba forks, 30mm hex YZ125 (84-87), YZ250 (81-87) IT250 (1983) YZ490 (82-87) 35-8577 Use for Yamaha 38mm Kayaba forks, 24mm hex YZ125 (81-83), IT175 (82-83), IT250 (81-82) YZ250 (77-80), YZ400 (77-79), IT465 (81-82) FORK CAP WRENCH Designed to remove the front fork caps on late model Honda CR’s and Suzuki RM’s. Can also be used for adjusting compression. One end of wrench is 49mm, the other is 50mm. Sold each. 35-7803 Fork Cap Wrench 35-8576 35-8577 35-8571 35-8573 6 Point Hex 35-8578

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1994 TOYOTA SPECIAL SERVICE TOOLS

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Filed Under (Toyota Manuals) by admin on 07-06-2011

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The following TSB contains information regarding the 1994 Special Service Tools (SST’s). Both the Essential and Available SST’s are listed by part number, tool name, model application, illustration / usage (for Essential SST’s only) and appropriate reference in repair manual. All Special Service Tools (SST’s) may be ordered by contacting OTC at 1-800-933-8335.

PRO-CYCLE AND PRO-CYCLE XLT 1,000-Lbs. Capacity Motorcycle Lift

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Filed Under (Tips and Review) by admin on 27-11-2010

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1. Always inspect the lift for freight damage and make note of any damage on the bill of lading. 2. In case of freight damage, call the truck line immediately and report the damage as a freight claim. Final Set-Up for model Pro-Cycle This lift is more than 90% factory pre-assembled. The following steps will guide you through the final set-up. IT WOULD BE EASIER FOR TWO MEN TO COMPLETE FOLLOWING STEPS. 1. Unpack the lift from the shipping skid. With the lift table up side down, connect the air hose to the air cylinder (Part # 26). 2. After tightening the hose to the cylinder, flip the lift over with the table surface up. 5 3. Lift up the table manually to the first lock position to make sure the lift is rising freely. Lubricateing the joints again before use will ensure a better performance of the lift. 4. Connect the other end of the air hose to the foot-operated valve. Then connect the foot- operated valve to 100 PSI air supply. DO NOT USE AIR SUPPLY WITH PRESSURE MORE THAN 100 PSI. 5. Release the safety bar by pushing the handle down. Operate the foot valve by stepping on the footpad forward to raise the lift. The safety bar should engage the ladder automatically while lift is rising. Step on the footpad again to set the pad in middle position to stop the lift when it reaches the desired height. ALWAYS LOWER LIFT IN THE NEAREST LOCKED POSITION BEFORE BEGINNING WORK. NEVER USE THE LIFT UNLESS YOU ARE IN A LOCKED POSITION. The lift should never be left unattended while attached to air pressure. Disconnect the air pressure when lift is not attended by qualified persons. 6. Install the vise using bolts and nuts supplied with the lift (part # 6 to 12). See fig #1. 7. Install the approach ramp by dropping it into the holes punched on the rear edge of the table. The final Set-Up for the Pro-Cycle model is complete

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1995 Camry WIPER MOTOR CIRCUIT BREAKER INSPECTION PROCEDURE

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Filed Under (Toyota Manuals) by admin on 15-10-2011

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INSPECTION PROCEDURE: Inspect the Wiper Fuse. Verify there is power and ground to the Wiper Motor on all speeds (including “Intermittent” or “Mist” if applicable). After verifying power and ground to the Wiper Motor, follow the procedure below to prevent unnecessary Wiper Motor replacement because of a temporary open in the Wiper Motor Circuit Breaker. 1) Disconnect the Wiper Motor Harness Connector. 2) Wait (10) minutes before checking continuity. 3) Check the continuity of the motor with an ohmmeter. REPRESENTATIVE CHECKING PROCEDURE: NOTE: Continuity check can be performed between either the low speed or high speed terminal and the ground terminal of the wiper motor. The standard resistance of a good wiper motor is approximately 1.5 to 4.5 ohm

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YAMAHA FZS 600 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 26-11-2010

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CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Check: all connections Loose connection Connect properly. If the pin 2 on the terminal is flattened, bend in up. 4. Connect: lead coupler connector Make sure that all connections are tight. 5. Check: continuity (with a pocket tester) Pocket tester 90590-03112 If there is no continuity, clean the termi- nals. When checking the wire harness, perform steps 1 to 3. As a quick remedy, use a contact revitaliz- er available at most part stores.
1-5 GEN INFO SPECIAL TOOLS 1 2 1 2 1 2 1 EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Tool name/Usage Illustration 90890-01268 Ring nut wrench This tool is used to loosen and tighten the steering ringnut. 90890-01304 Piston pin puller This tool is used to remove the piston pin. 90890-01460 -01326 Damper rod holder T-handle These tool ar used for holding the damper rod when removing or installing the damper rod. 90890-01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber. 90890-01325 -01352 Radiator cap tester Adaptor These tools are used for checking the cooling system. 90890-01362 -01382 Flywheel puller Crank shaft protector These tools are used for removing the rotor and starter clutch. 90890-01367 -01381 Fork seal driver weight Fork seal driver attachment (ø41 mm) These tools are used when installing the forkseal.

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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CL-1000 CONDOR CYCLE LOADER USER INSTRUCTION MANUAL

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Filed Under (Tips and Review) by admin on 25-11-2010

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Confirm that the cradle is set in the optimized position setting (See RECOMMENDED CRADLE SETTINGS) for the entering tire and wheel. Adjustment of cradle is crucial for optimum retention. Optimum retention is achieved by trying different settings. ( REFER TO CAUTION PARAGRAPH BELOW ): If the optimum vertical support is achieved, the motorcycle will hold itself upright. If optimum retention is not achieved try different cradle settings. ( REFER TO CAUTION PARAGRAPH BELOW ). Once cradle is positioned, tighten the brakes using the eye bolts and place the Cycle Loader in front of the motorcycle. Push or drive the motorcycle, centered into unit, until the cradle of the Cycle Loader has fully engaged the wheel. Once the wheel is cradled, proceed to push further into the Cycle Loader until the wheel has engaged the front stop. If the optimum vertical support is achieved, the motorcycle will hold itself upright. As an extra precaution, an optional Velcro strap may be used to strap the cradled wheel to the front stop (Optional Velcro strap purchased separately). Always strap Velcro through the wheel and around the front stop below the upper front stop flange. Loosen the brakes and use two (2) tie-down straps to secure the motorcycle to the two front eyebolts of the Cycle Loader. Hook wench to Ω” ‘U’ hook in front of Cycle Loader. Use the wench to pull the Cycle Loader with motorcycle up the flat bed. Once the motorcycle is all the way on the flat bed, the bike should be secured to the flat bed itself. For more information on use, refer to www.condor- lift.com. RECOMMEDED CRADLE SETTINGS: The Condor® Cycle Loader is designed so that for every tire/wheel size within the ranges specified a minimum of 2 cradle settings is suitable. **The optimum cradle setting for a specific tire would be, the setting that allows the cradle to tilt flush with the unit/ or º” below the opening in the main unit where the cradle sits, without touching.** The 2nd optimum setting would be the setting forward from the optimum setting away from the entry direction. If less retention is desired at any time due to too much retention or sticking, the cradle may be moved away from the entry direction one notch. RACING APPLICATIONS: For bikes with GP or low durometer front tires compounds, use the 5th cradle setting from the entry directions. CAUTION: Always make sure that all fasteners are tight and all pins are in place prior to use. Understand the limitations of this product and do not exceed these limitations. Always make sure that the unit’s cradle settings are optimum for the tire size of the motorcycle before use. For bikes with very low fenders and or cowlings, a custom cradle may be purchased fitted to specific tire sizes, so as not to make contact. For standard sport bike front wheel combinations, the 1, 2, 3, front settings may be suitable. If instructions are not clear, additional information is available at www.condor-lift. com or call 1-800-461-1344. Technical Components Development & Design is not responsible for any damage incurred by exceeding this product’s limitations in structure and/or functionality.