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Twin Tec Installation Instructions for TC88A-IH Ignition

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Filed Under (Tips and Review) by admin on 29-11-2010

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INSTALLATION ON 2004 MODELS 1. Turn off the ignition switch and disconnect the battery ground cable before proceeding. 2. Refer to Figures 2 and 3 for wiring details. 3. Remove the Gill Module. 4. Cut off the OE 18 terminal AMP connector used with the Gill module. Refer to the terminal list. Crimp new Deutsch terminals on the wires, and install into the 12 terminal Deutsch connector required by the TC88A-IH module. 5. Install the new TC88A-IH module. 6. Reconnect the battery ground cable. INSTALLATION ON 2005 AND LATER MODELS 1. Turn off the ignition switch and disconnect the battery ground cable before proceeding. 2. Refer to Figures 4 and 5 for wiring details. 3. Remove the Gill Module. 4. Cut off the OE 18 terminal AMP connector used with the Gill module. 5. The crankshaft position (CKP), MAP, and engine temperature (ET) sensor share a common ground Daytona Twin Tec LLC, 933 Beville Road, Suite 101-H, S. Daytona, FL 32119 TC88A-IH (386) 304-0700 www.daytona-twintec.com 10/2009 Page 2 return. This is not compatible with the TC88A-IH and some rewiring will be required. The temperature sensor is not used, but does not require removal. 6. Trace the BK/GN ground return wires from terminal B of the ET sensor and terminal A of the MAP sensor to where they join the BK/GY ground return wire from the CKP sensor. Cut the ET and MAP sensor ground return wires off at this point. You can tape up the ground return wire from the ET sensor – this wire will not be used. 7. Extend the ground return wire from terminal A of the MAP sensor up to the ignition module, crimp on a Deutsch terminal and install in position 4 on the Deutsch connector. 8. Refer to the terminal list. Crimp new Deutsch terminals on the remaining wires, and install into the 12 terminal Deutsch connector required by the TC88A-IH module. 9. Use a DVM to verify isolation (no continuity) between terminals 4 and 9 on the Deutsch connector. 10. Verify continuity between terminal A at the MAP sensor and terminal 4 on the Deutsch connector. 11. Verify continuity between terminal 2 at the CKP sensor and terminal 9 on the on the Deutsch connector. 12. Install the new TC88A-IH module. 13. Reconnect the battery ground cable. Terminal List for American IronHorse Ignition Conversion TC88A Deutsch Connector OE AMP Connector Signal Wire Color Code 1 2 +12V Power W/R

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HONDA Ground Effects Installation Instructions

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

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Wiring Installation: 1. Remove the four M8x1.25 socket head cap screws from the seat and remove the passenger handles and seat. 2. Remove both rear side covers, and right front side cover. 3. Remove the two M3 Phillips head screws and two trim clips from the right front storage pocket. 4. Place the three relays of the Ground Effects Ground Effects Ground Effects Ground Effects wiring harness underneath the relay box. 2001 2001 2001 2001 — – 2005 MODELS 2005 MODELS 2005 MODELS 2005 MODELS Route the long end of harness (blue wire and orange wire), behind the fuel tank to the brake lines. The shorter section of the harness will end at the brake lines. Continue along the brake lines to the main harness of the motorcycle to the shelter, then up through the shelter to the pocket area. 5. Locate the harness connectors under the pocket. Go to step 6. 2006 & NEWER MODELS 2006 & NEWER MODELS 2006 & NEWER MODELS 2006 & NEWER MODELS Route the long end of harness (blue wire and orange wire), under the relay box and connect to the Positions Relay. 6. Connect the orange wire to the orange wire with white tracer using a scotch-lok connector. Connect the blue wire to the light blue wire with white tracer using a scotch-lok connector. 7. Route the red and white wires behind the fuel tank, along the left side wiring harness to the fuse box. 8. Connect the RED wire with eyelet connector attached, to the positive side of the accessory terminal in the fuse box. 9. Connect the WHITE wire to the negative battery terminal. 10. Connect the brown wire with white tracer to the brown wire with white tracer (tail relay in relay box) using a scotch-lok connector. 11. Route the orange wire with black tracer and the white wire behind the fuel tank, with at least 6 inches of wire left hanging below the bike. 12. Reinstall the right fairing pocket with the two M3 Phillips head screws and two trim clips. 13. Replace the right front side cover and the right and left rear side covers. 14. Replace the seat and passenger grip handles with the four M8 x 1.25 socket head cap screws

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Pulsar Electronic LED Turn Signal Flasher Unit Installation & Operation Instructions

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Filed Under (Pulsar) by admin on 27-10-2010

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1. Locate the stock flasher unit on your motorcycle and remove it. Refer to your motorcycle’s shop manual. 2. Using either the test light or voltmeter, connect or touch one lead to the chassis or ground. Turn on the ignition switch. 3. Then touch the probe of either the test-light or the other lead of the voltmeter to one of wires or contacts where the flasher was removed from. If using the test-light, the light will light up when the supply line has been located. If using the voltmeter, the meter will indicate a voltage value, if present. Important Notice: Verify which grounding type your motorcycle is using before performing one of the following procedures. This can simply be done by seeing which terminal of the battery is connected to the motorcycle’s chassis or frame. Figure 3 • Positive Earth: Connect the black wire (-V) into the contact that indicated power was present. Plug the white wire (O/P) into the other contact, which did not have any power present. Turn off the ignition switch. Cut off the connector on the red wire w/ fuse holder (+V); strip the insulation back about ¼” (6 mm) and install the ring terminal on the wire, then ground the ring terminal to a chassis bolt or screw. If ground is not available via the chassis, then connect to an earth (ground) wire from the wiring harness. • Negative Ground: Connect red wire w/ fuse holder (+V) into the contact that indicated power was present. Plug the white wire (O/P) into the other contact, which did not have any power present. Turn off the ignition switch. Cut off the connector on the black wire (-V); strip the insulation back about ¼” (6 mm) and install the ring terminal on the wire, then ground the ring terminal to a chassis bolt or screw. If ground is not available via the chassis, then connect to a ground wire from the wiring harness

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2003 – 2005 Sequoia, 2004 – 2005 Highlander, Sienna, And Tundra DIAGNOSTIC GUIDE FOR REAR SEAT ENTERTAINMENT SYSTEMS

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Filed Under (Toyota Manuals) by admin on 08-10-2011

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Check the power, ground, and TX+, TX- wiring between the RSE ECU and the display. Perform the following check without disconnecting any connectors. A. Using the EWD, check the resistance of the wires between the DVD player ground terminal or integrated DVD player/RSE display and chassis ground. The resistance of the wires should be below 1 Ω. Refer to the Technical Information System (TIS): applicable model year Wiring Diagrams. B. Check the resistance of the wires between the RSE ECU ground terminal and chassis ground. The resistance of the wires should be below 1 Ω. C. Check the voltage on the power terminals on the DVD player and the RSE ECU. Voltage should be greater than 12 V. D. Check the voltage between terminals TX+ and chassis ground and TX- and chassis ground at both the RSE ECU and the DVD player. Voltage should be between 2.0 V and 3.0 V Check the resistance of the wires between the RSE ECU and the radio/player. The resistance of the wires should be below 1Ω. C. Check the resistance of the wires between the RSE ECU and the radio/player to ground. The resistance of the wires should be 10 kΩ or higher

PGR-1000-F Programmable Gear Readout Fairing Mount Installation Manual

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Filed Under (Tips and Review) by admin on 31-10-2010

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The PGR-1000 is designed for motorcycles with an Electronic VSS signal. Most modern motorcycles use a 3-wire hall-effect type speed sensor in the transmission with a power, ground, and a signal wire. The SEN-1019 is available for motorcycles without a factory VSS signal, fabrication will be required for sensor mounting. 1996-2003 Harley Davidson wiring All signal wires should be found behind the speedometer or tachometer along with power and ground. Neutral should be at the indicator lights. Signal Wire Color Speed White/Green Tach Pink Neutral Tan Power Orange Ground Black MAN#650194 2004-2007 Harley Davidson wiring The power, ground, and neutral can be found behind the speedometer and indicator lights. Speed signal and Tach need to be run to the ECU or cruise control module where you should find the wire colors listed here. This is due to the data bus configuration. Signal Wire Color Speed White/Green (Pin 33 @ ECU) Tach Pink (Pin 3 @ ECU) Neutral Tan Power Orange Ground Black 2008-2009 Harley Davidson wiring The power, ground, and neutral can be found behind the speedometer and indicator lights. Speed signal and Tach need to be run to the ECU or cruise control module where you should find the wire colors listed here. This is due to the data bus configuration. Signal Wire Color Speed White/Green (Pin 40 @ ECU) Tach Blue/Orange (Pin 54 @ ECU) Neutral Tan Power Orange Ground Black

HARLEY DAVIDSON CHROME DISPLAY STAND INSTALLATION MANUAL

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

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INSTALLATION 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) 1. Refer to the service manual and disconnect the battery negative (-) cable or remove the main fuse. NOTE Make sure that the cutout (B) of the strap (3) is oriented to the rear of the motorcycle after installation. 2. See Figure 2. Install strap (3) and weld nut (4) to the frame in the locations shown. 3. Position the center display stand over the mounting holes under the frame, oriented so that the skid plate faces for- ward. 4. Apply a small amount of Loctite 271 – Red to the two long screws (1) and secure the rear of the display stand to the frame by installing the two screw to the strap. 5. Apply a small amount of Loctite 271 – Red to the short screw (2) and secure the front of the display stand to the frame by installing the screw to the weld nut. 6. Tighten screws to 60-96 in-lbs (7-11 Nm) . 7. Refer to the service manual and connect the battery cables or install the main fuse. 1 2 is05370 1. Flange side 2. Flat side Figure 1. Chrome Display Stand Foot Orientation ADJUSTING THE DISPLAY STAND The left and right feet of the display stand are independently adjustable to vertically level the vehicle with the display stand extended. To adjust the display stand: NOTE The display stand can be adjusted with rear tire to ground contact or with rear tire off the ground. With the rear tire to ground contact adjustment, the rear wheel is on the ground but enough weight is on the display stand legs to make the motorcycle stable from side-to-side and front-to-back. Using the display stand to center the motorcycle will require effort. With the rear tire off the ground adjustment, the rear tire clears the ground so tire can be rotated for cleaning or maintenance purposes. Using the display stand to lift rear tire off the ground will require more effort. Do not center the vehicle with someone on the vehicle. To reduce effort, remove stored items from saddlebags, if equipped

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Honda Shadow Aero 750 Turn Signal Cancellation Unit Installation Procedures

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Filed Under (Honda) by admin on 29-11-2010

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Left TurnSignal Right TurnSignal Turn Signal Switch (for ref. Only) CIRCUIT CONNECTIONS AFTER INSTALLATION of Cancellation Unit Original+12 volts motorcycle supply power for flasher Ground (thiswiredoesnot exist on all models) Output to switch Power Power Red Yellow Gray Green Ground Green/Red Blue/Red Turn Signal Cancellation Unit Identify the positive power wire to the turn signal flasher. A test light with the probe touched to this wire will stay on steady and flash with the turn signals. Cut the wire and install the connectors observing the polarity as shown. Connect the Red and Yellow wires as shown. not Identify the flasher output wire to the signal switch and attach the gray wire by soldering or use the supplied red tap connector. Place the unit in a suitable area on your particular motorcycle. It is suggested under the seat providing access to the turn signal flasher. Connect the units ground (green) wire to frame (neg) ground Assure it’sareliable connection. IF THE GROUND WIRE BECOMES DISCONNECTED THE UNIT WILL BURN UP. using the supplied ring terminal. Identify the brake light circuit per the motorcycle wiring diagram. Using a test light verify the correct circuit using the following procedure. Connect the test light alligator clip (negative side) to frame ground. Using the positive tip probe the circuit. The proper circuit will illuminate the the brake is applied. Attach the Green/Red wire to this circuit. test light when The factory cancellation time is set at approximately 23 flashes. The length of time for cancellation can be decreased to approximately 15 counts by setting the program listed in the programming box

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Yamaha TDM 900 Disconnecting the battery ground REMOVAL AND INSTALLATION

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Filed Under (Yamaha) by admin on 29-01-2012

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Remove the seat. • Disconnect the battery ground (negative terminal). Remove the fairing side panels. • Remove the four marked hex screws with plastic washers. Note the positions the screws come from as they are not all the same. • Note that the bottom, rear hex bolt has a retaining plastic washer INSIDE the fairing. The long bolt goes under the ‘twin’ label. • Remove the hex screw indicated on the inside of the fairing panel. • Remove the grey Phillip’s head screw as indicated on the inside panel. • Remove the plastic locking clip on the underside of the fairing behind the radiator.

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HARLEY DAVIDSON ENGINE GUARD-MOUNTED FOG LAMP KIT INSTALLATION MANUAL

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

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VRSC models: See Figure 3. Place the wire harness from the kit into the area in front of the battery. Do not block the air intake opening. All models except VRSC and 2004 and later XL models: See Figure 4. Install the wire harness from the kit. Place the relay in the opening of the frame under the seat area, and route the long leg of the harness forward along the frame backbone. 2004 and later XL models: See Figure 5. Remove the nuts retaining the ignition module (1) and temporarily reposition the module as shown. Place the relay in the recessed area (2) of the oil reservoir. Install the ignition module. Route the long leg of the harness along the frame backbone. CAUTION 1 WARNING -J02798 Figure 3. Install Fog Lamp Wiring Harness (VRSC Models) Place harness into this area but do not block air intake Air intake i04372 Battery Figure 4. Install Fog Lamp Wiring Harness (All Models Except VRSC. Dyna Model Shown) i02286.eps 1. Relay 2. Ground stud 3. Long leg of harness 2 1 3 2 of 6 Figure 2. Fog Lamp Wiring Harness Figure 1. Fog Lamp Schematic Ground To low beam To main circuit breaker Fuse N.O. Contact Switch Coil Fog lamp Fog lamp i01360a Relay 1. Fuse block 2. Relay 3. Connector to power 4. Ring terminals (Ground) 5. To fog lamps 6. Unterminated wire to low beam 7. Switch with boot and bracket 4 2 5 6 7 1 3 i05708 5. All 2003 and earlier models and VRSC: Cut the connector from the white power lead, and replace it with the ring terminal supplied in the kit. 6. All 2003 and earlier models, except VRSC: Connect the white wire with the ring terminal to the copper stud (BAT) terminal of the main circuit breaker. All 2004 and later models, except VRSC: Connect the white wire with connector to the B+ connector on the harness. All VRSC: Connect the white power lead to the battery positive terminal. 7. See Service Part illustration. Connect the black ground wires with the two ring terminals to the ground stud under the seat, or at any good electrical ground point. Secure the kit harness to the adjacent harnesses with cable straps (item 6) from the kit. When routing wires through the front fork, make sure the wires are clear of moving parts, to avoid pinching and possible short circuits. 8. Route the forward end of the harness past the steering head, and route the lamp switch leg of the harness along the left side of the handlebar to the clutch control. 9. See the Service Parts illustration. Obtain the switch mounting bracket (item 11) from the kit. Unscrew the boot from the lamp switch, and install the switch into the bracket. Replace the boot on the switch. NOTE If the boot becomes worn or damaged, or is lost, replace the boot to prevent moisture from entering the switch. See the Service Parts illustration (Item 12). 10. See Figure 6. Remove the lower screw (1) and washer from the clutch control clamp (3), and install the lamp switch and bracket assembly (2). Install the screw and washer and tighten to 60-80 in-lbs (7-9 Nm). 11. See the Service Parts illustration. Secure the lamp switch leg of the harness to the handlebar using the wire harness retainers already on the bike. Snap the retainers into the holes in the handlebar. 12. Remove the headlamp assembly. See HEADLAMP – REMOVAL instructions for the correct model in the Service Manual. CAUTION 3 of 6 -J02798 Figure 6. Install the Lamp Switch on the Clutch Control Clamp i04370 3 1 1. Lower clamp screw 2. Lamp switch and bracket assembly 3. Clutch control clamp 2 Figure 5. Install the Wiring Harness (2004 and Later Models) i05712 3

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How to Replacing Rear Main Seal 1

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Filed Under (Tips and Review) by admin on 24-11-2010

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The next day I woke up early and drank lots of coffee before going out to the garage. I knew I had two distinct problems confronting me. First, I would have to purchase an impact tool in order to loosen the six bolts holding the clutch together. Also, I would have to purchase at least three 8mm by 50mm bolts and nuts in order to prevent the clutch from exploding when the six bolts were unscrewed. For the third time in two days, I went to Sears and asked the salesman, (who I now I knew as Art,) where I could find an impact tool. He did not know what it was I was looking for, but he asked another employee and soon I had the tool as well as a 6mm Allen socket. Unfortunately, the Allen socket only came in 3/8″ drive, and the impact tool only came in 1/2″ drive. Thinking quickly, I purchased a 1/2″ to 3/8″ adapter, as well as a 3lb. dead- blow hammer. On the way home, I stopped at a Chief Auto Parts to buy the bolts I would need. The closest size they had were 8mm by 40mm, which was nearly 10mm too short. I was unsure whether the clutch cover bolts were coarse thread or fine thread, so I bought three of each, along with corresponding nuts. Finally, around 11 o’clock in the morning, I was back at the garage ready to work. I prepared the impact tool and placed the adapter and the Allen socket on it. I began to hammer on the end of the tool, trying to loosen each of the six bolts. None of them seemed to move, even though it seemed the impact tool was turning. Finally, I put the Allen socket on the breaker bar and found that all of the bolts had actually come loose. The tension from the clutch spring made it nearly impossible to see, however. I removed three of the bolts in a triangular pattern. Into these empty holes I threaded the fine- thread 40mm bolts with nuts attached and tightened them evenly. I was now able to remove the remaining Allen bolts. By slowly turning and loosening the nuts evenly on the 40mm bolts, I relieved the pressure from the clutch spring until the cover plate was free. I removed the cover plate, the clutch, the pressure plate, and finally the clutch spring. I had already marked each of the elements with Whiteout to insure that they would fit together the same way on installation. Apparently, this is essential as the flywheel could be rendered out-of-balance if the clutch components are not installed correctly. The flywheel itself was now exposed. I could see the five bolts that attached it to the crankshaft. I now used a tool I had fabricated. Although the manual describes two possible tools that can be fabricated, I found a piece of metal that resembled the tool and decided to use it. Unfortunately it was not strong enough and broke. I turned and looked at my workbench, and noticed a bracket which I had previously fabricated for mounting a mirror on my Vespa. The piece of steel was extremely strong and was already pre-drilled with correct-sized holes. It fit perfectly, so I placed it over the exposed bolt which protruded from the case, and placed the other end on one of the 40mm bolts, which I then bolted into the flywheel itself. I used the breaker bar again and removed the five bolts. The flywheel came loose after inserting two more 40mm bolts and tugging on them evenly

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