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harley davidson CRUISE CONTROL KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 23-02-2012

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See Figure 1. Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. 5. Refer to the service manual, and follow the instructions to loosen the brake hand lever/master cylinder assembly and remove the right-side upper and lower switch housing sub-assemblies from the handlebar. It is not necessary to remove the throttle control grip. For FLHR models: Refer to the service manual. Disconnect the left-side handlebar MOLEX socket housing from the gray eight-way main harness pin housing [24B] inside the headlamp nacelle. Refer to the service manual to remove the clutch hand lever and left-side upper and lower switch housing subassemblies from the handlebar. 6. For ALL models: See Figure 2. The friction shoe (1) is a loose fit on the end of the tension adjuster screw (2). Make sure the shoe has been removed with the switch housing sub-assemblies, and is not lodged in the groove of the throttle control grip (4). 3 4 1 2 is06318 1. Friction shoe 2. Tension adjuster screw 3. Right-side lower switch housing 4. Throttle control grip Figure 2. Throttle Tension Adjuster Screw and Friction Shoe 7. See Figure 1. Verify that the 5/32-inch (4 mm) thick insert is in place between the brake lever and the lever bracket. Obtain the new right-side handlebar switch housing assembly (Item 4 or 5, depending on model) from the kit. Separate the upper and lower halves of the housing assembly. Refer to the service manual, and follow the instructions to install the switch housing assembly and brake hand lever/master cylinder assembly to the handlebar. 8. Route the right-side switch harness along the same path as the original harness (along the right handlebar). Connect the pin housing to the black socket housing disconnected in Step 3. 9. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Continue at Step 11. For FLHR models: Obtain the new left-side switch housing assembly (6) from the kit. Separate the upper and lower halves of the switch housing assembly. Refer to the service manual, and follow the instructions to install the left-side switch housing assembly and clutch hand lever assembly to the handlebar. 10. Route the left-side hand control harness along the same path as the original harness (along the left handlebar). Connect the pin housing to the gray socket housing disconnected in Step 5

HARLEY DAVIDSON CHROME INNER PRIMARY HOUSING INSTALLATION INSTRUCTION

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Kit Contents Table 1. Kit Contents Part Number Description (Quantity) Not sold separately Chrome Inner Primary Housing 786A Sealing fastener (5) INSTALLATION NOTES Whenever the sealing fasteners are loosened or removed, they must be replaced. Always replace using Harley-Davidson® Original Equipment sealing fasteners part 786A. Do not use part 786. The primary housing included in this kit installs in the same manner as the stock inner primary housing with the following exception: Use the five sealing fasteners included with this kit. Install and tighten fasteners to the torque specified below. For 2006 Dyna model motorcycles: Remove dowel pins from the chrome inner primary housing before attempting installation. Using a pair of pliers or vice grips, remove the dowel pins by carefully twisting and pulling on the pins. Be careful not to scratch or mar the chrome or sealing surfaces of the chrome inner primary housing. Remove the chain tensioner anchor plate, bolt and screws from the stock inner primary housing after it has been removed, then install it on the chrome inner primary housing. See the appropriate Service Manual for the proper tightening procedure, and torque specifications. 1. See the Drive section of the appropriate Service Manual, and remove the stock inner primary housing. Clean the internal threads in the crankcase and transmission case where the sealing fasteners were removed using a wire brush. Install the chrome inner primary housing as indicated below. Replace the five stock sealing fasteners with the five bolts included in this kit. Put a light coat of primary oil under the head of the sealing fasteners and then tighten to 23-25 ft- lbs (31-34 Nm)

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HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/ IDLE CABLE KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be placed into the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 4. Remove the right upper and lower switch housing screws INSTALLATION Throttle and Idle Cable Installation 1. See Figure 3. Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar. NOTE The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle control cable. For assembly, apply a drop of light oil on the retaining rings of the crimped inserts. 2. See Figure 7. Push the throttle cable housing and retaining ring into the larger hole of the switch housing, located in front of the tension adjuster screw. 3. Push the idle cable housing and retaining ring into the smaller hole of the switch housing, located behind the tension adjuster screw. 4. Push the throttle and idle control cable housings into the lower switch housing until each snaps into place. NOTE For models not equipped with factory-installed cruise control, if the friction shoe has fallen out or become dislodged, install the shoe with the concave side facing up and position it so the pin hole is over the point of the adjuster screw. 5. Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip until the ferrule notches are at the top. To prevent binding, pull the grip back about 0.12 inch (3.2 mm). 6. See Figure 3. Position the lower switch housing beneath the throttle control grip. Install two brass ferrules (Item 3, Figure 11) from this kit onto cables, seating the ferrules in their respective notches on the throttle control grip. The cables must be captured in the grooves molded into the grip. 7. Position the upper switch housing over the handlebar and lower switch housing. Route the wire harness conduit through the depression at the bottom of the handlebar. 8. Tighten the upper and lower switch housing screws finger- tight. 9. Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket. 10. Align the holes in the handlebar clamp with those in the master cylinder housing and tighten the lower screw and flat washer finger-tight. Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm)

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Motorcycle Engine Guard Adjustable Light Housing

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Filed Under (Kawasaki) by admin on 05-11-2010

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ADJUSTABLE HOUSING This highly polished, adjustable aluminum housing provides a very attractive means of adding the safety of Cuda TriOptic LED lighting to the engine guards on your Police Motorcycle. This newly developed 2.5 X 5.5 inch housing comes mounted on a ball swivel and can be adjusted and tightened to point LED lighting in any desired direction. This compact housing fits conveniently into position on the engine guard and is available with an engine guard clamp in a 1.00 inch or 1.25 inch diameter, which fits the engine guards of most popular motorcycles. The entire assembly is constructed of a highly polished aluminum alloy which blends very nicely with the chrome trim and accessories that are common on most motorcycles. COMPACT , LOW PROFILE CUDA LIGHT Our Engine Guard housing contains a newly developed model of the popular Cuda TriOptic light series with six LEDs positioned in a low profile format. This light housing provides a more compact but equally penetrating light source as the larger Cuda models. BUILT IN FLASHER As is Standard with all Cuda TriOptic products, this model can be programmed, prior to installation, to flash any one of eight selectable flash patterns; making the need for an external flasher unnecessary. EFFECTIVE LIGHT OUTPUT Cuda TriOptic lighting incorporates third generation, high intensity LEDs for dramatically bright light output. This high output light power is further enhanced by specially shaped lenses to ensure superior on and off-axis light distribution for maximum visibility. LOW AMP DRAW In addition to being extremely bright, the LEDs significantly reduce power consumption – a critical concern for fully equipped motorcycles. The 351011 (2-up) model, that is contained in this light housing, draws 0.7 amps per unit. RELIABILITY Cuda TriOptic LEDs are rated for over 100,000 hours of useful life – compared to 2500-5000 hours for a typical halogen bulb. Plus, Federal Signal LED products come with a 5- year warranty, and meet SAE and CAC standards for radio frequency interference. See the back of this page for technical specifications and ordering information so you can start specifying Cuda TriOptic LEDs for your motorcycles today!

HARLEY DAVIDSON ENGINE/TRANSMISSION INTERFACE AND TOP COVER INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 19-04-2011

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 1 4 3 2 is03621 1. Transmission top cover screw (3) 2. Upper and lower rear bearing housing screw (2) 3. Upper front bearing housing screw 4. Lower front bearing housing screw Figure 1. Interface Cover Installation 2. See Figure 1. Remove the two rear bearing housing screws (2) from the side of the transmission case. 3. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 4. See Figure 2. Obtain the rear interface mounting bracket (1) from the kit. 5. Apply a few drops of Loctite 243 (Blue) to the threads of the two bearing housing screws removed in Step 2. Install the rear interface mounting bracket to the bearing housing with the screws, and tighten to 13-18 ft-lbs (17.6-24.4 Nm) . 6. See Figure 1. Remove the upper front bearing housing screw (3) from the side of the transmission case. Loosen the lower front bearing housing screw (4). 7. See Figure 2. Obtain the front interface mounting bracket (2) from the kit. 8. Apply a few drops of Loctite 243 (Blue) to the threads of the upper front bearing housing screw removed in Step 6. Hook the slot in the front interface mounting bracket under the loosened lower screw head. Install the bracket to the bearing housing with the upper screw, and tighten both screws to 13-18 ft-lbs (17.6-24.4 Nm) . 9. See Figure 1. Remove and retain the three socket head cap screws (1) that fasten the right side and left front corner of the transmission cover. 10. Remove and retain the screw fastening the rear brake line P-clamp to the rear fork bracket. 11. See Figure 2. Obtain the right rear interface cover (3), two chrome 1/4-20 screws (6) and two flat washers (7) from the kit. 12. From the rear of the motorcycle, bring the right rear interface cover into position behind the rear exhaust pipe, over the bearing housing. The hole in the top surface of the cover should be positioned over the right rear transmission top cover hole. 13. Loosely fasten the interface cover to the rear interface mounting bracket with the two chrome screws and flat washers. 14. Obtain the chrome top interface cover (4) from the kit. 15. Position the top interface cover over the transmission top cover, overlapping the tab at the top front of the chrome right rear interface cover

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HARLEY DAVIDSON V-ROD CHROME REAR TURN SIGNAL INSTALLATION MANUAL

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

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INSTALLATION Prepare the Motorcycle 1. Remove the right cover and the maxi-fuse. 2. Follow Service Manual instructions to remove the air box cover. Remove the Existing Rear Turn Signals 1. For 2006 and Earlier Models: See Figure 1. Insert a screwdriver into middle of hole of license plate light cover. Push forward to release tail lamp housing retaining clip. 2. See Figure 3. Identify the white left [19] (1) and black right [18] (2) 2 pin rear turn signal connectors. 3. See Figure 6. To separate the rear turn signal connector, press the button (1) and separate the pin terminal housing from the socket terminal housing. 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. To remove the rear turn signal wires from the socket terminal housing, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. 6. See Figure 7. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket and remove turn signals. 7. Repeat for the opposite turn signal. 1. For 2007 and Later Models: See Figure 2. Open seat and remove the nut and washer (3), seat post (2), passenger pillion and passenger seat (1) per the instructions in the Service Manual. 2. See Figure 4. Identify the left (1) and right (2) rear turn signal wires and 6 pin rear turn signal connector [94]. 3. See Figure 6. To separate the rear turn signal connector, press the button (1) and separate the pin terminal housing from the socket terminal housing. 4. On the socket terminal housing, press the latch (2) aside and open the secondary lock (3). 5. See Figure 5. Remove the turn signal wires from the 6 pin socket terminal housing. To remove the wires, insert a pin (6) into the front socket cavity. Compress the tang (4) while gently pulling the wire and socket terminal (5) from the back. Repeat for all four turn signal wires. Do not remove the license light wires from the socket terminal housing. 6. Gently pull the loose turn signal wires through the sheath toward the rear of the vehicle until completely removed from the sheath. 7. See Figure 7. Inside the fender, remove the fasteners (1) and the turn signal support plate (2). Pull the turn signal wiring through holes in license plate mounting bracket and remove turn signals. 8. Repeat for the opposite turn signal

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HARLEY DAVIDSON FLAME HANDLEBAR GRIPS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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REMOVE AND INSTALL THE LEFT GRIP 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar 2. Using a T25 TORX® drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX® drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9 Nm) . 9. Using a T25 TORX® drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4- 5.4 Nm) . 5 3 1 1 4 2 2 is00735 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger flange Figure 1. Left Handlebar Switch Housing REMOVE AND INSTALL THE RIGHT GRIP NOTE Right handlebar switch removal requires a Service Manual for your model and year of motorcycle. A Service Manual can be purchased from your Harley-Davidson Dealer. 1. Refer to the RIGHT HANDLEBAR SWITCH section of the Service Manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the Service Manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

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Electronic Speedo Drive for Toyota T50 5 Speed Transmission

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Filed Under (Toyota Manuals) by admin on 20-09-2011

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Disassembly is simple, remove the “C” clip from the drive housing , just above the drive gear. This will allow the shaft/gear assembly to be withdrawn from the housing. Remove the “O” ring from the housing. Wash all parts internally and externally to remove oil, grease and road grime This will allow the shaft/gear assembly to be withdrawn from the housing. Remove the “O” rings from the housing. Remove the three (3) philips head screws from the cover on the top of the drive housing. Carefully remove cover, be aware that the small parts in side may be stuck to the cover. Remove all internal parts, record order of assembly. Wash housing and shaft to remove oil, grease and road grime. The T50 drive shaft needs to be shortened to a similar length to the AE101. I reassembled the AE101 shaft and housing, and then measured from the top face of the AE101 housing down to the top of the AE101 drive shaft. ( Fig.4) Record this reference depth, (I got 17mm)

BMW K1100LT/ RS Repair Manual

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Filed Under (BMW) by admin on 03-12-2010

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00.3 00 Tightening torque Model K 1100 LT K 1100 RS Connection Nm 11 Engine Freewheel Cover plate/freewheel cage at countershaft gear 10 Oil – water pump Oil pressure switch 40 Temperature sensor/screw plug 9 Pressure relief valve 40 Impeller 33 Pump housing to crankcase 10 Cover to pump housing 10 (3-Bond 1209) Intermediate flange Thrust plate at intermediate flange 9 (Loctite 243) Intermediate flange at crankcase 9 Crankshaft Pinion/rotor flange at crankshaft 50 Main bearing cap to crankcase 50 Connecting rod Big end cap Wrench angle 80 ° 30 Input shaft Front bearing 18 Rear bearing 40 Engine block Crankshaft cover 9 Lower part, outer 10 Oil sump 10 Oil filter cover 10 Oil drain plug 30 Cylinder head Cylinder head bolts (SI 11 062 95 (697) Short thread (from 6/93 to 11/94): Wrench angle, 1st stage Wrench angle, 2nd stage Long thread (since 12/94): Wrench angle, 1st stage Wrench angle, 2nd stage 64° 42° 75° 75° 22 20 Cylinder head cover 9 Camshaft Bearing cap 9 (Apply a thin coat of 3-Bond 1209 only at corners and butt edges) Chain sprockets 54 00.4 Timing chain Chain tensioner 9 Slide rail at camshaft bearing cap 9 Timing case cover Timing case cover 10 (3-Bond 1209) Cover for Hall-effect signal transmitter 9 Screw plug 40 Clutch Clutch housing to output shaft Tighten to Release and re-tighten to Wrench angle 50° 140 50 Housing cover 19 Alternator Alternator to intermediate flange 22 Driver 33 Starter motor Starter motor to gearbox 9 Mixture preparation Intake stub pipe 9 Fuel injection rail 9 Cooling system Coolant stub pipe at cylinder head 9 Temperature sensor at coolant stub pipe 30 Air cleaner Lower part of air cleaner housing 21 12 Engine electrical system Starter to transmission 9 Positive lead to starter 5 Alternator to intermediate flange 22 Clutch housing 50 Base plate 3,5 Setting ring 2,5 Hall generator cover 9 Ignition coils to intermediate flange 5 Spark plug 20 Model K 1100 LT K 1100 RS Connection Nm 00.5 13 Fuel preparation and control Injection rail 9 Intake stub pipe 9 Lower section of air cleaner housing 21 Intake air line 9 Motronic control unit 5 17 Radiator Connecting screw, temperature sensor 9 Fastening, thermostat cover 3 Radiator to frame 9 Coolant stub pipe to cylinder head 9 (with Loctite 243) Temperature sensor to coolant stub pipe 30 18 Exhaust System Exhaust system to cylinder head 21 Front silencer (muffler) 12 Exhaust system holder to footrest plate 33 Exhaust system to holder/footrest plate 9 Retaining bracket to gearbox 41 Oxygen sensor Hand-tight 21 Clutch Clutch housing to output shaft tighten to loosen and retighten to tightening angle 50° 140 50 Housing cover

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Yamaha 1100 V-Star Motorcycles Oil Filter Relocation Kit Installation

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

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1. Remove the four bolts that attach the right foot peg and foot brake assembly. Disconnect the electrical connection for the brake light. Leave the hose to the brake fluid reservoir connected. 2. Loosen and remove the muffler assembly from the motorcycle. Loosen the manifold nuts for the lower exhaust pipe (front cylinder) and remove it. 3 3. Remove the five bolts that secure the beauty cover to the motor casing and remove the cover. 4. Remove the oil filter cap and the oil filter. Be aware that the bottom bolt hole has an O- ring. Do not lose or damage this O-ring. Remove the two O-rings from the filter cap with an O-ring pick and inspect them. Replace them if there is any damage or signs of wear. 4 5. Lightly grease the O-rings and install them into their respective locations on the filter plate adapter as shown below. 6. Insert the filter plate adapter carefully into the filter housing to prevent damage to the O- rings. 7. Install the bolts for the filter plate adapter. The bottom bolt location of the filter housing requires a different bolt than all the others. This bolt has a larger head and collar diameter. The top rear bolt hole of the filter adapter will now use one of the short 6x20mm bolts removed from the beauty cover. There are two remaining holes on the motor casing left empty from the removal of the beauty cover. Use two of the bolts from the “Yamaha” cap to fill these locations. Use a thread lock compound such as Loctite ® Blue Threadlocker 243. Evenly tighten the bolts on the filter adapter with quarter turns, until tight. Finish tightening the filter plate adaptor bolts to 7.2 ft-lb each. 58. Install the short end of the spud into the remote filter housing. Do not use thread compound for this step. 9. Install the 45° Elbow to the input port of the remote filter housing as shown below. Position the opening of the fitting to face inward and down slightly to the remote filter housing. Install the fixed end of the oil lines to the remote filter housing. Use Teflon tape or some other type of thread compound on all oil line fittings. 10. Install the compression fittings to the filter plate adapter. 11. Route each oil line between the frame and the brake fluid reservoir and slightly thread the swivel from each oil line into place as shown below. Many different configurations for routing oil lines can be used depending on the height and angle chosen for the remote filter housing when mounted on the frame. Before tightening compression fittings, position the remote filter housing on the frame and adjust the routing of the lines to your preference. After choosing a routing option for the oil lines, tighten the compression fitting

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