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HARLEY DAVIDSON HORN COVER KIT INSTALLATION MANUAL

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

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INSTALLATION Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Remove seat and disconnect wires from horn. 2. See Figure 1. Remove stock horn bracket nut (2) and the entire stock horn cover assembly (1). Remove the horn (3) and all hardware components from the stock cover including wire clamp, clips, and mounting bracket. Leave rubber mount and locknut on motorcycle. Note assembly order for kit installation. NOTE Do not over-tighten “horn to horn cover” nut. Over-tightening may result in permanent damage to the horn. 3. Apply Loctite 271 (Red) to threads of nut (4) fastening the horn to the horn cover. Tighten nut to 80-100 in-lbs (9.0- 11.3 Nm). Tighten screws fastening the horn cover to the horn bracket to 35-55 in-lbs (4.0-6.2 Nm). 4. Route wiring harness through the clamp (if present) and install the entire horn cover assembly to the mounting stud (5). 5. Tighten nut (2) fastening the horn bracket to the horn rubber mount to 80-100 in-lbs (9.0-11.3 Nm). Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) 6. Connect wires to terminals and reconnect battery. NOTE Horn is not polarity sensitive. Ground and power wire may be connected to either terminal. 2 4 1 5 3 is03958 1. Horn cover assembly 2. Bracket nut 3. Horn 4. Nut 5. Mounting stud Figure 1. Horn Cover Installation 7. Test horn. NOTE Test the horn only when mounted on the vehicle. The sound may be muffled if tested when hand-held. A muffled sounding horn that is mounted to a vehicle may indicate permanent damage to the horn by over-tightening the horn to horn cover nut (Figure 1, Item 4). Attempt to adjust nut torque. Replace horn if necessary. 8. Reinstall seat

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HARLEY DAVIDSON SMOOTH HORN COVER INSTALLATION INSTRUCTION

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Filed Under (Harley Davidson) by admin on 30-01-2011

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INSTALLATION 1. Refer to your model motorcycle’s Service Manual and remove the seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 2. Disconnect the battery cables, negative (-) cable first. 3. See Figure 1. Remove stock horn bracket nut (2) and the entire stock horn cover assembly. Remove the horn wires, horn and all hardware components from the stock cover including wire clamp, clips and mounting bracket. Note assembly order for reinstallation. 4. Position the horn (3) inside the new cover. Apply 1-2 drops of Loctite 271 (red) (Harley-Davidson Part Number 99671- 97) onto threads of nut (4). Install nut onto horn mounting stud (6) and tighten to 90-100 in-lbs (10-11 Nm). NOTE Do not over-tighten “horn to horn cover” nut . tighten to 90-100 in-lbs (10-11 Nm). Use in-lbs torque wrench. Over-tightening may result in permanent damage to the horn. 5. Route wiring harness through the clamp, (if present) and install the entire assembly to the horn assembly mounting stud (5). 6. Connect wires to terminals and reconnect battery. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) NOTE The horn is not polarity sensitive. The ground and power wires are interchangeable on the horn terminals

AIR / HYDRAULIC MOTORCYCLE LIFT REMOVABLE INSPECTION PLATE

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Filed Under (Tips and Review) by admin on 19-11-2010

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For best service, you should incorporate an oiler, regulator, and inline filter, as shown in the diagram on the next page. Hoses, couplers, oilers, regulators, and filters are all available at Harbor Freight Tools. NOTE: If an automatic oiler is not used, put 3-5 drops of pneumatic Tool Oil (not included) in the Motorcycle Lift’s Quick Coupler (38A) before each use. (See Figure B, next page.) To Check The Level Of Hydraulic Oil: 1. The Motorcycle Lift already contains some hydraulic oil in its Hydraulic Pump Reservoir (32P). Even so, it is recommended that you check the oil level in the Reservoir and, if necessary, top off the Reservoir with the proper amount of 15/40 hydraulic oil (not included). (See Assy. Diagram, page 15.) 2. Make sure to screw the two Adjusting Screws clockwise enough to lift the two Caster Wheels (14) off the floor so as to provide stability for the Motorcycle Lift. (See Figure A.) 3. To check the level of hydraulic oil, remove the Sliding Plate (36) from the Platform (35) to expose the Hydraulic Pump Reservoir (32P). (See Assy. Diagrams, pages 13 and 15.) 4. Remove the rubber Filler Plug (33P) located on the top of the Reservoir (32P). If necessary, top off the Reservoir with hydraulic oil. (See Assy. Diagram, page 15.) 5. Connect the air compressor’s hose to the to the Air Motor assembly. Then turn on the air compressor and set its regulator at 120 PSI. (See Assy. Diagram, page 14.) 5. Insert the Lift Foot Pedal (11) onto the Pump Piston Spindle (9), and slowly pump the Lift Foot Pedal until a slight amount of hydraulic oil begins to leak out of the Reservoir (32P). Discontinue pumping the Lift Foot Pedal. Then, replace the Filler Plug (33P) on the top of the Reservoir. (See Assy. Diagram, page 15.) REGULATOR OILER FILTER TO QUICK COUPLER (38A) OF MOTORCYCLE LIFT FIGURE B 6. Insert the Release Foot Pedal (10) onto the Release Valve Spindle (5). Pump the Lift Foot Pedal (11) until the Platform (35) of the Motorcycle Lift reaches its maximum height. Then press down slightly on the Release Foot Pedal until the Platform is fully collapsed to the floor. Repeat this procedure several times to ensure the Motorcycle Lift is operating properly. (See Figure E, page 10.)

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HARLEY DAVIDSON CHROME FAN KIT INSTALLATION MANUAL

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

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INSTALLATION 1. Refer to Service Manual and remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 2. Disconnect battery negative cable. Horn Relocation NOTE This cooling fan is designed to provide supplemental cooling for motorcycles subjected to long periods of idling/parade duty. The fan is mounted on the left side of the engine in the area where the horn is mounted. The stock horn must be removed. Remove Stock Horn 1. Follow Service Manual instructions to remove stock horn and its bracket. 2. Assemble new horn 69043-96B to bracket 69135-04 using screws 3658 and washers 7069. 3. Remove right front fuel tank TORX® screw. 4. Mount horn at front of fuel tank with TORX screw. Verify there is adequate room between horn bracket and fuel tank to prevent paint damage. Tighten screw to 15-20 ft- lbs (20-27 Nm) . 1 is05140a 1. Horn mounting location Figure 1. Horn Relocation Remove Stock Upper Engine Mounting Bracket 1. Remove screw securing rear of fuel tank and gently raise fuel tank to gain access to upper engine mounting bracket. Place suitable blocking under tank. 2. On 2007 models remove bolt attaching stabilizer link to upper engine mounting bracket. 3. Remove two bolts and washers securing upper engine mounting bracket to front and rear cylinder heads. Retain bolts and washers for attaching new upper engine mounting bracket from kit. 4. Note position of fuel hose. Remove upper engine mounting bracket. 5. Connect horn relocation harness to horn. 6. Route stock horn wires forward towards relocated horn. 7. See Figure 7. Cut ends off stock horn wires and strip wires 3/8 inch. Follow instructions in Service Manual, “SEALED

KAWASAKI VOYAGER AIR HORN INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 27-12-2010

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1. Remove the false fuel tank cover to expose the battery. Remove the right hand lower leg fairing. (4 phillips screws). Unplug the stock horn and remove the (2) 10mm bolts securing it to the frame. 2. See photo #1 using the stock horn bolts attach the black horn mounting bracket and the white ground wire supplied as shown. Next locate the relay supplied. Plug the stock horn wires into the relay terminals #85 & #86. (see wiring diagram on back side of instructions) 3. Attach the air hose to the compressor air outlet fitting. Attach the short red wire supplied to the compressors positive (+) terminal and the white wire installed earlier to the compressors ground (-) terminal. As shown in photo #2. Attach the compressor to the frame with the hose clamp provided. Note: position the top of the compressor as shown touching the bottom of the horn mounting bracket and approximately 1 Ω” to the rear of radiator and shroud. Also the air hose and fitting should be in front of the frame tube with the hose routed inside the hose clamp without pinching the hose. Attach the red wire from the compressor to one of the relays remaining outer terminals #30 or #87. Attach the remaining long red wire (supplied) to the remaining relay terminal #30 or #87. Secure the relay to the frame with a cable tie supplied. Route the red wire up to the battery positive (+) terminal. Locate the fuse wire assembly provided. Attach the fork end of the fuse wire to the battery positive (+) terminal. Cut the red wire to the desired length, strip the end and crimp to the fuse assembly. Turn on the ignition and press the horn button, you should hear the compressor motor run. Re-install the false fuel tank lid. Re-install the right lower leg fairing while routing the air hose out next to the black horn mounting bracket 4. See photo #3, Bolt the horn set to the black mounting bracket using the 5/16 x æ”bolt, washer and lock washer provided. Trim the air hose to length if necessary and attach the air hose to the horn assembly. Install the trumpet covers. (see instructions enclosed with covers) Turn on the ignition and test the horns

TRIUMPH ROCKET III ELECTRIC HORN HARDWARE KIT INSTALLATION

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Filed Under (Triumph) by admin on 24-12-2010

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1. Remove the seat and left hand side cover. (held in place by two (2) 10mm bolts) Remove the chrome cover from the stock horn located below the headlights. (held in place by two (2) 5mm allen screws at the top of the cover) 2. Unplug the wires from the stock horn. Locate the supplied jacketed cord and attach the end with the piggyback jumpers to the horn wires. Plug these back onto the horn terminals as shown in photo (1). Remove the black plastic left side steering head frame cover (held in place with two (2) 5mm allen screws). Route the cord behind the headlights, along the left side of the frame and over the engine keeping it neatly out of sight. Route the end if the cord to where the relay will mount as shown in photo (2A). Replace chrome horn cover and steering head frame cover. 3. Using the relay supplied, refer to the wiring diagram included with the horn set and the small numbers next to the terminals on the relay. Connect the 2 wires from the jacketed cord to terminals #85 & #86. Connect the blade terminal of the fuse wire assembly (supplied) to terminal #30 on the relay. Attach the other end of the fuse holder to the positive (+) battery terminal. 4. On the horns bend the wire terminals outward so that they will be parallel to the mounting brackets when installed. Refer to photo (3) and assemble the horns onto their supplied mounting brackets as shown. Bolt two (2) of the four (4) flat silver brackets on each of the horns using the 6mm nuts and lock washers supplied. Bolt the black bracket to the left hand horn using the 6x12mm bolt and nyloc nut supplied. Place the 6 x 35mm bolt with a washer and lock washer thru the right hand horn bracket then the left hand black bracket and place the 3/8″ flange nut over the back of the bolt. Remove the bolt where the horns will mount (see photo 2B) and bolt the horn set on as assembled with the flange nut on the back side of the black bracket. Align the horns as shown in photo (2) being careful that the horns do not make contact with each other or any other parts as this will significantly reduce their output then tighten the bolt securely.

Vengeance Motorcycle Specification And Owner's Manual

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Filed Under (Vengeance) by admin on 20-11-2010

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Vengeance Maxis • Vengeance Raven • Vengeance Banshee • Vengeance Whiplash • Hotrod Drifter • Hotrod CalChop • Hotrod Teacher • Hotrod Bone Shifting Gears Starting off and changing gears requires coordination of the clutch and throttle and gearshift lever. If you don’t do things right, the amount of control you have over the bike is lessened. To start off, pull in the clutch, shift into first gear, roll on the throttle a little, and ease out the clutch. You will become familiar with the friction zone (that’s where the clutch begins to take hold and move the bike), and you add a bit more throttle. You don’t want to stall the engine, nor do you want to over-rev it. There’s a sweet spot in there; find it. Shift while traveling in a straight line. Shifting in a curve is not good practice, and something to be avoided. Become familiar with the sound of your engine, so you can tell when you should shift without looking at your instruments. When you downshift to a lower gear, you should (in one swift, smooth movement) be able to squeeze the clutch, rev the engine a little to let it catch the lower gear smoothly, and shift down. When you come to a stop in traffic, leave the bike in first gear with the clutch disengaged (just in case you want to accelerate out of there in a hurry). Who knows what may be coming up behind you. Braking Don’t ever forget: The front brake on your motorcycle can supply as much as 70 percent or more of your stopping power. The single most important thing you can learn about braking is to use that front brake every single time you want to slow down. Turning When you are riding along the road, you lean a motorcycle into a turn. Learning to lean is an essential part of riding a motorcycle. It is a normal function of the bike when you are changing its path of travel – and quite different from turning the steering wheel of your car. To get the motorcycle to lean in a normal turn, press the handlebar in the direction of the turn and maintain slight pressure on that handlebar to take you smoothly through that particular turn. In other words: press right to go right; press left to go left. Your instincts to keep the motorcycle on a smooth path while keeping it from falling over usually take care of this without you even noticing it. (Demonstrate to yourself how a motorcycle moves by pressing a handlebar slightly while traveling in a straight line. The motorcycle will move in the direction of the handlebar you pushed.) • Slow down before you enter the turn; look as far ahead as possible through the turn. • Keep your feet on the pegs, and grip the gas tank with your knees. • Lean with the motorcycle; don’t try to sit perpendicular to the road while the motorcycle is leaning over. • Keep an even throttle through the turn, or even accelerate a little bit. Checking the Bike before the Ride It’s not fun to have things go wrong on a motorcycle, but if you spend a minute before you go off on a ride, you can increase the chances that nothing will.

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VICTORY HAMMER, KINGPIN, VEGAS AND JACKPOT ELECTRIC HORN INSTALLATION INSTRUCTIONS

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Filed Under (Victory) by admin on 29-01-2011

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1. Remove the left and right plastic side covers and the seat (two allen bolts located below the sides of the seat). Unplug and remove the stock horn (located over the oil cooler). Connect the female ends of the jacketed two wire cable supplied to the original horn wires. Route the other end of the cable up over the engine and back to where the relay will mount as shown in photo (1). 2. Using the relay supplied with this kit and the wiring diagram provided with the horn set, identify the terminals of the relay (there are very small numbers next to each of the terminal). Connect the two (2) wires from the cable to terminals #85 & 86 on the relay. Locate the fuse holder wire assembly supplied and connect the blade terminal to the relay terminal #87 or #30. Connect the other end of the fuse wire to the battery positive terminal (+). 3. Working under the left side of the motorcycle, refer to photo (2) and install the black bracket supplied as shown onto the engine mount. Locate the four thin flat brackets and two (2) 6mm nuts supplied with the horn set and two lock washers supplied with the kit. Bolt two (2) of the brackets to each of the horns using a lock washer and 6mm nut on each and make them snug. Using the remaining 6 x 12mm bolt, nut and lock washer install the horns onto the black bracket and align as shown in photo (3). Adjust the horn location so that they are free to vibrate and do not come in contact with other parts of the motorcycle then tighten all three 6mmm bolts securely. 4. Using the two remaining wire assembles supplied, connect the larger terminals with double wires to one of the horns and the terminals with the single wire to the other horn. Route these wires up thru the frame to the relay. Connect the wire with the female blade connector to the relay terminal #30 or #87. Connect the ring terminal to the battery negative (-) terminal
or any 6m bolt on the frame. Turn on the ignition and test the horns. Secure the relay to the frame or other wiring and all loose wires using the cable ties supplied. Replace the seat and side covers

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EDELBROCK NITROUS SYSTEM UNIVERSAL MOTORCYCLE NITROUS SYSTEM

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

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Wiring Diagram #1 Wiring Diagram #2 Red Red Red Red Black Black Black Black Black Black Factory Harness to Horn Factory Harness to Horn Horn Horn Nitrous Solenoid Nitrous Solenoid Switch Switch Bottom View Bottom View +12V with Key On From Horn Button (Ground when button is pressed) From Horn Button (Ground when button is pressed) To Nitrous Bottle To Nitrous Bottle To Nitrous Nozzle To Nitrous Nozzle Install Relay for OPTIONAL RPM Activated Switch Here. See Section 7.0 for More Details. Install Relay for OPTIONAL RPM Activated Switch Here. See Section 7.0 for More Details ©2007 Edelbrock Corporation Brochure #63-71940 Catalog #71940 Rev. 2/07 – DC/mc Page 4of 4 To Nitrous Bottle To Nitrous Nozzle Nitrous Solenoid To Starter Solenoid Switch Bottom View Ground Starter Button +12V when Pushed Install Relay for OPTIONAL RPM Activated Switch Here. See Section 7.0 for More Details. Wiring Diagram #3 Starter Button Activation for Suzuki Hayabusa 7.0 – WIRING MSD 8950 RPM SWITCH NOTE – This is a suggested wiring application. There are many ways that the RPMswitch may be installed. The installer needs to set RPMswitch to proper RPM and test operation. Use diagrams on page 3 for relay terminal #30 connection. Nitrous Solenoid To Nitrous Bottle To Nitrous Nozzle RPM ACTIVATED SWITCH 10,000 Desired RPM Chip Here Connect as Outlined in Wiring Diagrams White to 4-Coil Tach Adapter #T-101-MSD Black Battery Ground Yellow – N/C Gray – OFF When Set RPMis Exceeded Connect as Outlined in Wiring Diagrams NOTE – RPM Chips are Ordered Separately Red to Switched +12 Volt Tailight Power or any Other +12 Volt Source with the Key On Note – This Method Will Turn the Nitrous Off When Set RPM has Been Exceeded. 85 87A 30 86 87 A Test Light Can Be Used Here to Check Operation 8.0 – OPTIONAL PRODUCTS FOR EFI MOTORCYCLES A Progressive Timing Retard Controller is available from Schnitz Racing for fuel injected motorcycles. The EFIR Series Timing Retard Controllers can be used with or without a Power Commander installed.

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1300 Yamaha V-Star Installation Manual

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Filed Under (Yamaha) by admin on 07-11-2010

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1) Place motorcycle on a firm level surface and secure in a upright position. 2) Remove saddle bags and saddle bag hardware (Tourer model only) Also remove rear riders pegs (Tourer model requires removal of rear footpeg offset hardware as well) 3) Attach bracket A (right) / B (left) to rear footpeg attachment point using new bolts provided. Remount footpegs/saddlebag hardware over top of brackets A/B. NOTE: Do not attach leveling stand bracket at this time 4) Attach bracket C(right) / D(left) to rear fender sub frame using new bolts provided. (Tourer model only – Saddle bag hardware mounts to the outside of brackets C/D. Brackets C/D mount between chrome side rail and saddlebag hardware.) NOTE: Brackets C/D have welded spacers which attach in toward rear fender 5) Attach top of Bracket E(right) / F(left) to rear of brackets C/D. Brackets E/F mount to the inside of brackets C/D. NOTE: Use ½ inch spacer between brackets E/F and C/D on Tourer model ONLY
6) Attach rear of brackets A/B to TOP of forward hitch arms. Attach bottom to brackets E/F to rear hitch plate. 7) Carefully tighten all bolts at this time ensuring hitch is square with motorcycle. Hitch Bracket Identification Leveling stand screw jack installation 1) Attach leveling stand brackets to brackets A and B 2) Thread right side screw jack into threaded hole on leveling stand bracket attached to bracket A sand adjust leveling jack bolt out. 3) Push motorcycle over from left side until right screw jack is touching floor. 4) Thread left side screw jack into threaded hole on leveling stand bracket attached to bracket B and adjust out until motorcycle will rest upright on both screw jacks. 5) Adjust screw jacks until motorcycle is level. 6) After InstaTrike is attached to or removed from receiver hitch, be sure to remove leveling stands and leveling stand brackets. CAUTION – Use screw jacks to hold motorcycle upright and level ONLY. Do not lift motorcycle with screw jacks. CAUTION – Use care when installing screw jacks. Be certain that motorcycle is always in a stable balanced position.
INSTALLATION OF THE TOW-PAC HITCH CART. 1. Place your motorcycle on a smooth flat surface, like a garage floor, and install leveling stands. Install right leveling stand first. Carefully raise motorcycle off of side stand and install left leveling stand. Caution – Use leveling stands to level motorcycle ONLY. Do not raise motorcycle with stands Caution – Be certain that motorcycle is always in a stable balanced position when installing leveling stands. 2. Assemble the axles, tires and wheels, and fenders onto the tow- pac hitch cart. 3. Carefully align the tow-pac hitch cart’s hitch mount with the receiver hitch on the motorcycle. Now push the hitch mount into the receiver hitch. (this might be a little difficult until you get use to doing it. Removing the paint from the hitch mount and applying a little grease will help.) 4. Place the hitch pin through the receiver hitch and hitch mount ( alignment plate ). Install and tighten the tension bolt

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