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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

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HARLEY DAVIDSON DYNA CUSTOM SEAT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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WO-UP SEAT INSTALLATION Currently Installed Seat Removal NOTE When performing the following procedures, avoid scratching painted surfaces (fender, tank, etc.) with tools or metal seat tabs. 1. Remove currently installed seat following the instructions in the Owner’s Manual. 2. If a two-up seat WAS installed: Proceed to Step 6, Grab Strap Installation . If a solo seat WAS installed: See Figure 1. Remove the Bar & Shield hole plug (11) from the rear seat mounting hole (1)Seat mounting hole, rear 2. Fender hole, center 3. Seat mounting hole, front 4. Grab strap mounting hole 5. Wire routing hole (reference) 6. Fender hole, front (reference) 7. Hardware location for two-up seat 8. Hardware location for solo seat 9. Seat retention nut 10. Retention washer 11. Hole plug, Bar & Shield 12. Hole plug, plain Figure 1. Fender Hole Identification and Hardware Locations 3. At the front seat mounting hole (3), remove the retention washer (10) from the seat retention nut (9). From the underside of the fender, remove the seat retention nut from the vehicle. Insert the Bar & Shield hole plug into the front seat mounting hole. 4. See Figure 2. Obtain the cable strap (3) from the kit. a. Place the retention nut (1) over the cable strap (3) so that the wide end of the nut rests on the eye of the cable strap. b. Thread the cable strap up under the fender and through the rearmost seat mounting hole. c. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib on the retention nut seated into the notch in the fender hole, slide the retention washer (2) into place from the rear (this will lock the retention nut in place), then remove the cable strap. 3 2 1 is01955 1. Retention nut 2. Retention washer 3. Cable strap (installation aid) Figure 2. Retention Nut Installation Grab Strap Installation 5. If a two-up seat WAS installed: Remove the existing grab strap and all attaching hardware, then proceed to Step 6. If a solo seat WAS installed: Proceed to Step 6. 6. See Figure 5. Obtain the new grab strap (8), hex head screw (9), plastic retention nut (10), washer (11) and hex nut (12) from the kit. 7. From the underside of the fender, insert the screw up through the grab strap mounting hole and secure with the plastic retention nut.

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Skyteam ST 125 SPECIFICATIONS AND SERVICE MANUAL

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Filed Under (Skyteam) by admin on 24-11-2010

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BRAKES This motorcycle has a hydraulic brake system of front and rear . Brakes are items of personal safety and should be properly adjusted. Remember to check periodically the brake system and these checks should be conducted by qualified Jincheng dealer. Do not use the remained brake fluid from on a unsealed container, never reuse the brake fluid remained in the last repairing, because the used brake fluid may absorb the water from the air. Use DOT 4 brake fluid from a sealed container. Do not spill out the brake fluid, when the brake fluid is glued to the paint, plastic and rubber material, a chemical reaction shall take place, causing the damage. (1)lower level mark Front brake Rear brake BRAKE FLUID (1) (2) (3) (1) (1)Brake fluid cap (2)Max. fluid level mark (3)Min. fluid level mark Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed NOTICE WARINING * 9 BRAKE LINING The main points for checking the front brake lining are to see whether the lining wear is out of the range. Replace the brake lining wear is out of the range. Replace the brake lining if the lining wear is beyond the brake wear limit mark. FRONT BRAKE FLUID LEVEL Check that the fluid level is above the lower level mark(1) with the motorcycle in an upright position. Brake fluid must be added to the reservoir when ever the fluid level begins to reach the lower level mark(1). Fill the reservoir up to upper level mark. REAR BRAKE FLUID LEVEL There are two marks in rear brake fluid cap,keep the fluid lever between the Max. fluid level mark (2) and the Min. fluid level mark (3) always. Check if it is short of brake fluid, check the hose and other components for corrosion or cracks. limit mark Brake Pad Front brake Rear brake If the brake system or brake linings have to be repaired, we suggest that these repair should be performed by your authorized SKYTEAM dealer. SKYTEAM dealer knows your motorcycle best and is dedicated to your complete satisfaction

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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

GL1800 Goldwing Trike Conversion Kit Installation Instructions

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

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Disassembly of motorcycle: 1. Place the motorcycle on the center stand or lift. 2. Set the shock preload to zero. 3. Remove the four m8 x 1.25 SHCS from the passenger handles and remove seat. 4. Remove the rear side covers. 5. Disconnect negative battery terminal. 6. Remove the four m8 x 1.25 SHCS and the passenger floorboards. 7. Remove the six m5 x 0.80 BHCS and the foot rest under cover. 8. Remove the six m5 x .80 BHCS and the swing arm pivot bolt covers. 9. Remove the four m8 x 1.25 flange bolts on the rear crash guards. Remove and discard the rear crash guards and bolts. 10. Remove the four #2 Phillips head screws from the inside of the trunk to remove the trim pieces on the sides. 11. Remove the two #2 Phillips head screws in the rear trim molding and remove molding. 12. Remove the seven #2 Phillips head screws from the lower trunk cover. Remove the lower trunk cover. 13. Remove the five #2 Phillips head screws from the trunk opener cover. Remove the trunk opener cover. 14. Disconnect the left and right saddlebag release cables. 15. Remove the five m6 x 1.0 BHCS in the rear fender panel. Remove and discard the rear fender panel and cap screws. 16. Disconnect the trunk wiring. 17. Remove the four m6 x 1.0 flange screws. Remove the trunk from the saddlebag / trunk stay. 7 18. 2005 and older 2005 and older 2005 and older 2005 and older ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: Remove rubber bungee from ABS Control Unit, and save for reinstallation. 19. Remove the two side cover grommets from each saddlebag. ( 4 grommets total ) 20. Remove the left and right hand saddlebag latches, strikers, and release cables for core parts return. Refer to Honda service manual. 21. Remove the left and right saddlebag taillights and sub- harnesses for core parts return . Refer to Honda service manual. 22. Remove the four m6 x 1.0 flange bolts from each saddlebag. Remove and discard the saddlebags. 23. Remove the six m6 x 1.0 flange bolts from the exhaust tips. Slide the tip off the muffler body. Save tips and bolts for reinstallation. 24. Loosen the four m8 x 1.25 SHCS on the muffler clamps. Remove the two m8 x 1.25 flange bolts. Remove and discard the mufflers and muffler gaskets. 25. Remove the four m6 x 1.0 BHCS, two rubber washers, and front fender A. 26. Remove the four m5 x .80 BHCS and chrome front fender covers. 27. 2006 & UP. 2006 & UP. 2006 & UP. 2006 & UP. Remove the Remove the Remove the Remove the two m6 x two m6 x two m6 x two m6 x 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. 28. Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for reinstallation. reinstallation. reinstallation. reinstallation. 29. Cut lower saddlebag supports off the saddlebag/trunk stay, where the round tubing meets the square, and cut the gusset flush, removing any burrs. See Figure 1. 30. Remove trunk stay for later use. 31. Remove the two m5 x .80 nuts on the license plate light. Remove and discard the license plate ligh

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MC 1200 Motorcycle Trailer – 1200 lbs Assembly Instructions

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

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Tongue: Remove tongue assembly from the frame bundle. Insert into the tongue channel and slide into the front cross member of the frame. Secure with two (2) 3/8″ X 4″ carriage bolts and 3/8″ flange lock nuts. Tighten. Thread the tongue wire harness through the front top hole in the tongue and pull out the hole provided in the left side of the tongue towards the rear. Connect to the frame harness with the plugs provided. Install grommets. Safety Chains: Insert a 3/8″ X 1-1/4″ hex bolt into a 3/8″ flat washer, safety chain and then through the lower hole on the front of the tongue. Place on a 3/8″ flat washer on the inside of the tongue and secure with 3/8″ flange lock nuts. Repeat procedure on the opposite side of the tongue. Tighten. Coupler: Mount the coupler onto the tongue with a 1/2″ X 4″ hex bolt trough the rear mounting holes of the coupler. Using two (2) 1/2″ X 1″ hex bolt attach the coupler to the tongue using the front mounting holes. Secure with flange lock nuts. Tighten. Axle: Attach the spring busing in the rear spring shackles with 1/2″ X 3- 1/4″ hex bolts and 1/2″ flange lock nuts. Position the axle under the trailer with spring eye to the front of the trailer. Slip the flat end of the spring in the rear spring shackle above the bushing just installed. Secure the front spring eye to the front spring shackle with 98/16″ X 3-1/4″ hex bolts and 9/16″ hex lock nuts. Tighten. Mount the tire and rim assemblies to the axle assembly with 1/2″ lug nuts and tighten to 80-90 ft./lbs. of torque using the rotation pattern as shown in the Shore Land’r Owners Manual . Retorque the lug nuts after 50 miles of driving and then periodically thereafter. Ramps: Locate the loading ramp. Note that one end has two holes punched in the bottom of the channel. (See parts drawing) Insert a 3/8″ X 1-1/2″ full threaded carriage bolt into one of these holes. Secure in this position using a 3/8″ flange lock nut. Tighten Place a second 3/8″ flange lock nut onto the same bolt only until the threads of the bolt are exposed through the nut locking it in

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HARLEY DAVIDSON FAIRING MOUNT MIRRORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-02-2011

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INSTALLATION Removing Outer Fairing 1. Standing at the front of the vehicle, use a T-27 TORX® drive head to remove the three outer fairing screws (with flat washers) just below the windshield. 2. Moving to the inner fairing side, use a T-27 TORX drive head to remove the two fairing screws just above the wind deflectors on the left and right side. 3. Turn the handlebar to the right and remove the outer fairing screw (reach in below the fairing cap). Turn the handlebar to the left and remove the fairing screw on the opposite side. 4. Tilting the outer fairing toward the front, squeeze the two external tabs to remove the wire connector at the back of the headlamp assembly. 5. Lift the fairing (with headlamp assembly) off the motor- cycle. NOTE Since the outer fairing screws hold the windshield in place, the windshield may fall to the floor if not removed. 6. Remove the Windshield. Installing Mirrors 1. See Figure 1. Place template on inside of fairing as shown to locate mounting holes for mirror. 2. Begin by drilling a 1/8 inch pilot hole at each location marked on the template. For the center hole (2) where the 3/8 inch threaded stud passes through the fairing use a 13/32 inch diameter twist drill to drill the hole to its final size. For the alignment hole (1), use a 7/32 inch diameter twist drill to drill the hole to the final size. 2 1 is 02115 1.7/32 inch hole location 2.13/32 inch hole location Figure 1. Positioning Template 1 is06315 1. Auxiliary mirror Figure 2. Orientation of Auxiliary Mirror NOTE The flange nut is a self locking nut and must not be tightened more than 30 in-lbs (3.4 Nm). 3. See Figure 3. Place mirror (2) in position and install backing plate (4) with the raised post (B) (with the L and R marking) toward the nut surface. Install the flange nut (6) and tighten nut to 20-30 in-lbs (2.3-3.4 Nm). 4. See Figure 2. Position the mirror so the round auxiliary mirror is in the upper inside corner position. 5. Repeat for right side

BMW R1200RT Sport/ Touring 1100X Kit Installation Manual

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

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Step 1 — Locate ‘mold circle’ indentation on each side fairing panel (Pic 1). With panel mounted on bike, this indentation is center, at rear inside panel edge, and faces inside. Temporarily install bracket as shown in (Pic 2), align bottom bracket hole over indentation and mark for hole. Remove brackets at this time. Step 2 — Remove fairing body side panels. Four screws per side required for removal, see owners manual. Drill a 3/8″ hole at mark. If harness kit has not been installed, do not re-install left side panel until finished unless you remove tank to install harness. Removal of the tank is the best option to route harness from battery area to front of the bike. Step 3 — As required, re-install fairing body side panels. Do not re-install the top factory inner panel Torx Screw yet, as you will re-use this screw to secure the top light bracket mounting hole to the fairing panel. Step 4 — Using 10/32×1/2 screws and black shoulder washers from Hardware package, secure lights to PIAA Ezy-Mount® brackets (See Pics 3 & 4). Right side bracket is stamped ‘EZY-MOUNT’. See note below for Powersports lights. Due to close proximity of the light body to fairing side panel, access to the vertical adjustment screw on the panel side of the light will not be possible after installation. To prepare for this; before installing bracket/light assembly to panel, make sure this screw is tightened so that you can barely move the light body. After bracket is installed, final vertical adjustment can be secured with the inside screw. Torque on this screw is adequate to hold vertical adjustment, and the screw that faces the panel will not come loose. NOTE: WHEN INSTALLING POWERSPORTS LIGHTS, YOU MUST INSERT THE SHOULDER ADAPTER WASHER INTO THE LIGHT FOOT, BEFORE INSERTING SCREW TO SECURE LIGHT FOOT TO BRACKET. THIS ADAPTER CENTERS LIGHT FOOT OVER PEMNUT (TIGHTEN THIS SCREW SECURELY). Step 5 — Insert well nut into previously drilled 3/8″ hole. Place bracket assembly against fairing, aligning top hole with the top fairing mounting position; re-install the factory Torx screw at this location. Adjust as necessary and install the second supplied SS 10/32 x 5/8 Torx screw thru the lower bracket mounting hole to the well nut. With constant pressure on the screw, tighten securely. Constant pressure ensures that the rear expandable section of the well nut captures the back of the plastic inner panel as you tighten the screw. Future removal of fairing panels is now possible with light assembly installed (utilizing the bottom bracket mounting screw), thus re-alignment of lights is not required after normal maintenance.

HARLEY DAVIDSON XL SOLO CUSTOM SEAT KITS INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. 1 2 4 1 3 is03341 1. Stock retention nut and washer 2. Plastic cap 3. Rearward fender hole 4. Center fender hole Figure 1. Retention Nut and Plastic Cap Location 2. For models that had a solo seat: Proceed to Step 3. For models that had a 2-up seat: The retention nut and washer must be moved from the rearward mounting hole to the center fender hole where the rear seat bracket will be attached. Use a cable strap to aid in this step as fol- lows: a. See Figure 1. Remove retention nut from rearward fender hole (3) and plastic cap (2) from center fender hole (4). b. Install plastic cap into the rearward fender hole. c. See Figure 2. Place the retention nut over the cable strap so the wide end of the nut rests on the eye of the cable strap. Thread the cable strap up under the fender and through the center fender hole. Pull up on the cable strap to hold the nut snug against the underside of the fender. d. With the rib of the retention nut seated into the notch in the fender hole, slide the retention washer into place from the rear. This will lock the retention nut in place. 3. Position the solo seat on the motorcycle frame with the mounting bracket at the rear. Bring the seat forward and engage the tab on the seat into the slot at the base of the fuel tank. 4. See Figure 3. Secure the seat to the fender using the knurled knob (3) and neoprene washer (4) from the kit. Install the washer on the knob and tighten the knob securely to the fender seat nut

HARLEY DAVIDSON FLTR DETACHABLE TOUR-PAK ANTENNA RELOCATION KIT

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Filed Under (Harley Davidson) by admin on 19-02-2011

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Drilling Instructions for Antenna Base Mounting and Cable Routing 1. See Figure 1. Measure and determine the center of the outside rear Tour-Pak wall. 2. Lay a strip of 2 inch wide masking tape from top to bottom over the approximate center. 3. Very carefully measure again and mark the center near the top of the tape strip. Measure and mark the center near the bottom of the strip. 4. Draw a line from the top mark to the bottom mark. 5. Facing the centerline you have drawn, measure 9-1/4 inches from the center line to the left side. 6. At the 9-1/4 inch dimension, lay a vertical strip of 2 inch masking tape from the top to approximately the middle of the Tour-Pak wall. 7. Very carefully measure again and mark 9-1/4 inches from the top of center line to the top of the tape strip. Measure and mark 9-1/4 inches from the bottom of the center line to the bottom of the strip. 8. Draw a vertical line from the top mark to the bottom mark. 9. Measure 1-1/4 inches from the top edge, down the vertical line you have drawn and draw a short horizontal line across the vertical line. 10. Measure 1-1/2 inches down the vertical line you have drawn from your FIRST short horizontal line and draw another short horizontal line across the vertical line

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