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HONDA GL1100 AM/FM RADIO INSTALLATION MANUAL/ WIRING DIAGRAM

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Filed Under (Honda) by admin on 22-04-2011

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INSTALLATION ■ Outline Procedures This section gives general information needed for mounting the individual radio components on and in the fairing. A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts. 3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing. 7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wires. 3 of 11 Page 4 C) Fairing instllation 1) Install fairing on motorcycle. 2) Connect motorcycle wire harness 9-P coupler to fairing wire 9-P coupler. 3) Connect radio switch wire to switch sub- wire.4) Connect antenna feeder. 5) Confirm that radio operates properly. Reinstall parts removed in step 2 or (A) and in step 1 of (B). REWORKING ■ Remove Fairing and Fairing Parts (Fig.10) 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove right and left fairing pockets, right and left turn signal lenses, right and left nutplates, left hole cover and indi- cator base panel from fairing. (Fig.10) Fig. 10 LEI-1 NU I PLATE 4 of 11■ Reworking on Fairing — Speaker mounting holes- 1) Remove 18 mm grommet. 2) Lightly roll template so that it will follow contour of fairing snugly. 3) Position template on fairing with its upper and outer edges aligned with those offairing as indicated by arrows. 4) Attach template to fairing using adhesive tape where shown. 5) Punch mark centers of four holes with a
drift and hammer. 6) Drill 6 mm holes through marked centers. To obtain a more balanced response with richer, deeper bases, drill two 50 mm holes in the fairing so as to link the speaker box with the inside of the fairing. Fig. 11-1
—Power amplifier mounting holes- 7) Drill two 5.5 mm holes through concaves in fairing. Fig. 11-2 RIGHT HAND SHOWN, LEFT SIMILAR ADHESIVE TAPE

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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

Fairing bodywork in glass-reinforced plastic Cruciata Racing

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Filed Under (Tips and Review) by admin on 27-10-2010

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The fairing bodywork that they have I use in contest is made in sturdy and flexible glass-reinforced plastic. The fairing bodywork in glass-reinforced plastic they succeed to replace the fairing bodywork originates them nearly perfectly, thanks to the predisposition holes. The greater part of the fairing bodywork in glass- reinforced plastic in production has the points of attachment with the moto reinforces to you in carbon on every attack with the chassis of the moto. Between the types of fairing bodywork and as point of reference between the fairing bodywork is as an example fairing bodywork it Cruciata Racing, worked always handicraft with passion for it gets passionate to it to you, which has enjoyed in particular way of the progresses and the evolution of the materials and the members. fairing bodywork the Cruciata Racing is constructed entire in woven of glass with reinforces in carbon in correspondence of the attacks to the motor and between the parts in glass-reinforced plastic. In the line racing standards are included plexiglass of height (to pierce), neoprene sponge cm 1,5 (supplied already sagomata). It fairing bodywork Cruciata Racing is which between the types of fairing bodywork is distinguished for its use, that is, this fairing bodywork is born and it is developed in order to answer carefully and to satisfy the requirements of the pilots. Fairing bodywork the Cruciata Racing in glass-reinforced plastic obviously is demanded for that it regards the sport within and the contests in track, because they are the only ones like characteristic to resist to the sollicitations impegnative thanks to theirs reinforces inner. Moreover to being resistant, these fairing bodywork offer to an optimal elasticity and lightness. Fairing bodywork the Cruciata Racing of sure the fairing bodywork better is produced with the best materials on the market. The fairing bodywork in glass-reinforced plastic they can be acquired crude, or can be painted and prepared in in professional way, applying all the processes of preparation that guarantee a final result of elevated quality, is from the aesthetic point of view, the point of view of the duration and from the point of view of I use it of the fairing bodywork.

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HARLEY DAVIDSON CHROME 1.00 INCH (25.4 MM) DIAMETER HANDLEBAR KITS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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REMOVAL 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. 2. Remove the outer fairing. See the service manual. 3. Remove the fairing cap. See the service manual. 4. FLHX Models: Handlebar-mounted mirrors (purchased separately) are required for proper installation of this handlebar. Removal of the inner fairing may be required, refer to the service manual. If fairing-mounted mirrors are being removed: Install the two small black plugs and large black plugs (purchased separately) to plug the fairing mirror holes. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splashes of DOT 4 brake fluid. 5. Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual. NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. 6. Models with Radio: Remove the radio. See the service manual. Models without Radio: Remove the storage box. See the service manual. a. The four socket head screws fastening the radio or storage box to the left and right radio support brackets can be accessed through the oblong holes in the fairing brackets. Use a long shank ball-end socket to remove the screws. b. Pull the radio or storage box forward to remove it from the opening in the inner fairing. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 7. Remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. 8. Note the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See the service manual. 9. Remove the front brake line assembly. NOTES Refer to the parts catalog for this year and model for a replacement OE brake line assembly and clutch cable, if needed. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory Custom Braided Clutch Cables and Brake Lines that are available. 10. Remove the front brake master cylinder and clutch lever assemblies from the handlebar. 11. Disconnect the clutch cable from the clutch lever. See the service manual.

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Laminar LaMini Fairing Mounting Instructions

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Filed Under (Tips and Review) by admin on 27-10-2010

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Mounting Instructions for the Laminar LaMini Fairing The Laminar LaMini Fairing is designed to mount onto motorcycles having up to 7 inch round headlights and traditional instruments. It is attached to the motorcycle with four clamps, two on each fork tube between the triple clamps. If you plan to paint the fairing be sure to fit it first. Make sure that the front turn signals do not obstruct installation of the
LaMini Fairing. If the turn signals are located between the triple clamps relocating or replacing the turn signals may be desired. When fitting the fairing the greatest potential for damage to your motorcycle lies with the clamps or the back ends of the fairing touching the gas tank when the steering is turned to lock. Monitor this possibility each time the handlebars are turned until installation is completed, padding the front of the tank with some towels is a good idea. Let’s get started 1) Attach the shield to the rear side of the fairing with rubber washers between them, using nylon fasteners. Wrap two clamp gaskets around each fork tube. Unscrew the clamps and slip two of each around each fork leg. The worm screws should be at rear of the fork tube. Slip a clamp gasket between each clamp and fork and finger tighten the clamps. The ž”x ū ” bolts should be sticking straight out to the sides. Center the clamps spaced 3 inches apart between the triple clamps. Carefully turn the handlebars to lock in each direction to assure that the clamps do not touch any other parts of the motorcycle. If the clamp worm gears interfere the clamps may be reversed with the worms at the front side of the forks but this makes tightening or adjusting them with the fairing mounted very difficult. 2) Test fit the fairing (shown upside down in the top photo) over the headlight and in front of the instruments. Try to leave a spacing of ž inch everywhere. If required the fairing may be trimmed to match the gap to the headlight. Do the sides of the fairing cover the ž”x ū ” bolts so that
holes to be drilled through the fairing will securely receive the bolts? Looking from the side of the fairing and with the fairing located with the center above the headlight move the rear of the fairing up and down to determine the best fit to the motorcycles lines. When

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HARLEY DAVIDSON BLACK ENGINE GUARD KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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REMOVAL NOTE This Instruction Sheet covers several different Harley-Davidson models and years. Be sure to locate and follow the procedures that apply to the motorcycle receiving the new guard. For Models without Lower Fairings 1. Proceed to For All Models section. For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Remove the lower fairings following the instructions in the appropriate Service Manual. 2. When the lower fairings have been removed, proceed to For All Models section. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley-Davidson Genuine Motor Accessory Lower Fairings 1. See Figure 1. Remove the two black screws (1) that attach the fairing cap (2) to the lower fairing (5). Remove the cap. Set the parts aside for re-installation. 2. Remove the screw (7), rubber washer (8) and locknut (10) and the clamp (9) that attaches the bottom of the lower fairing to the engine guard and set aside. 3. Remove the two locknuts (3), U-bolt (6) and U-bolt retainer (4). 4. Remove the lower fairing by sliding it out from behind the engine guard. 5. Repeat Steps 1 through 4 for the opposite side. 6. Proceed to For All Models section. For Model FLTR/I (Road Glide) with Harley-Davidson Genuine Motor Accessory Lower Fairings 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. Disconnect the battery, negative (-) battery cable first, following the instructions in the appropriate Service Manual. 2. Remove the seat following the instructions in the appropriate Service Manual. 3. Remove the cable strap holding the clutch cable to the engine guard. 4. See Figure 2. Remove the TORX screw (8), rubber washer (9) and locknut (11) and the clamp (10) that attaches the bottom of the lower fairing (4) to the engine guard and set aside INSTALLATION 1. Hold the engine guard in position, and loosely fasten the top of the guard with the new hex socket screw and flat washer from the kit. 2. Install the bottom brackets to the motorcycle frame with the two new TORX screws and locknuts. 3. Tighten all three screws to 15-20 ft-lbs (20.3-27.1 Nm) . For Model FLHTCUI (Ultra Classic Electra Glide) with Factory-Installed Lower Fairings 1. Install the lower fairings following the instructions in the appropriate Service Manual. For Models FLHR/I (Road King), FLHT (Electra Glide Standard) or FLHTC/I (Electra Glide Classic) with Harley- Davidson Genuine Motor Accessory Lower Fairings 1. Carefully place one lower fairing in position from behind the engine guard. 2. See Figure 1. Install the lower fairing to the top of the new engine guard with the U-bolt (6) from the back, through the holes at the top of the fairing. Install the retainer (4) in position on the U-bolt and secure to the engine guard with the two locknuts (3). Do not tighten the locknuts at this time. 3. Attach the bottom of the fairing to the engine guard with the clamp (9) removed earlier. Install the clamp around the engine guard in the direction shown, with the tabs toward the rear of the vehicle and the flat side of the clamp against the lower fairing. Insert the screw (7) through the lower fairing, rubber washer (8) and clamp (9). Secure the assembly with the locknut (10). Tighten to 12 ft-lbs (16.3 Nm) .

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HARLEY DAVIDSON TALL HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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INSTALLATION Preparation Models WITH maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. Models WITHOUT maxi-fuse: 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. 2. Remove the outer fairing. See UPPER FAIRING/WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL in the Service Manual. Remove the fairing cap. See UPPER FAIRING/WINDSHIELD; FAIRING CAP: REMOVAL in the Service Manual. 3. Bleed the brake fluid from the front brakes per the instructions in the Service Manual. Original Handlebar Removal NOTE Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 1. Models WITH radio: Remove the radio. See RADIO: REMOVAL in the Service Manual. Models WITHOUT radio: Remove the storage box. a. The four socket head screws fastening the storage box to the left and right radio support brackets can be accessed through the oblong holes in the fairing brackets. Use a long shank ball-end socket to remove the screws. b. Pull the storage box forward to remove it from the opening in the inner fairing. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 2. Disconnect the front brake lines from the vehicle. See FRONT BRAKE MASTER CYLINDER, FRONT BRAKE LINE, REMOVAL, FLHX, FLHT/C/U in the Service Manual

HARLEY DAVIDSON MULTI-POCKET FAIRING POUCH KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION 1. Remove the three outer fairing screws located just below the windshield and remove the windshield. 2. See Figure 1 or Figure 2. Apply adhesive pads to the bottom of the bracket in the locations shown. When the bracket is installed, the pads should rest on the top of the inner fairing and support the bracket. 3. Apply clear tape between the screw opening at the base of the windshield on the inside surface of the windshield. 4. See Figure 3. Pull the outer fairing away from the inner fairing to provide sufficient clearance to slide the mounting tabs of the bracket over the top lip of the inner fairing. 5. Center the fairing bracket along the top of the inner fairing. 3 1 2 is04616 1. Bracket 2. Pads 3. Bracket clips Figure 1. Bottom of 3-Pocket Fairing Pouch Over tightening windshield fasteners can crack windshield and/or fairing. (00451b) 6. Reinstall the windshield and three screws removed in Step 1. Tighten screws snugly, but be careful not to over-tighten screw or the fairing may crack. 3 1 2 is04615 1. Bracket 2. Pads 3. Bracket clips Figure 2. Bottom of 2-Pocket Fairing Pouch 4 2 6 5 1 3 is04614 1. Pouch 2. Windshield 3. Tape, clear 4. Outer fairing 5. Pouch bracket clip 6. Top of inner fairing Figure 3. Fairing Clip Attachment, Side View

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HARLEY DAVIDSON ADVANCED AUDIO COMMUNICATION SWITCH KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 2. Refer to the instructions included with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit, and proceed with that installation until the installation of the items in this kit is called for. 3. Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. 4. On the fairing cap, remove the inner left side hole plug. See Figure 1 and the FAIRING CAP SWITCHES (FLHTC/U) section in the Service Manual. Install the fairing speaker switch (4) in the opening as follows: If a cruise control switch IS present: Follow the instructions in the Service Manual to install the speaker switch. If a cruise control switch IS NOT present: a. Obtain the speaker switch adapter wire (5) from the kit, and the butt splice connector included with the speaker switch. b. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual. Splice the adapter wire to the black/ green speaker switch lead. c. Insert the terminated end of the adapter wire into cavity 12 of the fairing cap switch connector [105B] 5. Remove the original equipment left-hand control switch assembly per the HANDLEBAR SWITCHES, REMOVAL, LEFT HANDLEBAR CONTROLS instructions in the Service Manual. 6. Install the new left-hand control switch assembly (3) from the kit. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 7. ALL models: Install the console pod assembly (1), and route the harness forward into the fairing per the instructions packaged with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit. Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) • Be sure the wires do not pull tight when handlebars are turned fully to left or right fork stops. 8. Unless already installed, install the overlay harness per the instructions packaged with the Hands Free Phone Interface, CB Radio or Intercom Kit. 9. Refer to the Service Manual and follow the instructions given to re-install the Maxi Fuse

HARLEY DAVIDSON VENTED FAIRING LOWERS KIT INSTALLATION INSTRUCTIONS

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

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INSTALLATION 1. See Figure 1. From the kit, obtain the left side fairing lower (1), left side fairing lower cap (2), two flange locking nuts (3) and two stud clips (4). Place fairing lower cap in front of the left side engine guard and left side fairing lower behind engine fairing guard. With both pieces in place around engine guard, install the two flange locking nuts onto the studs clips and hand tighten. Repeat procedure for right side fairing lower. 2. Secure bottom of fairing lower to lower engine guard with round clamp (5) from hardware kit. Position clamp around engine guard with tabs toward rear of vehicle and flat side of clamp against fairing lower and with the rubber washer (6) between clamp and engine guard. Place Torx pan screw (7) through fairing lower, rubber washer and clamp. Secure assembly with flanged locknut (8). Repeat for right side fairing lower. Tighten to 144 in-lbs (16.3 Nm). 3. Tighten all left and right side upper flange locking nuts (3) to 72 in-lbs (8.1 Nm). 4. Install left side door assembly glovebox (9) to fairing lower using the attachment cord (10). Insert glovebox door into fairing lower. Repeat for right side fairing lower. NOTE Do not press reflector firmly into place until you have it positioned in desired location. The adhesive is very strong and once it comes in contact with a surface, it will be difficult to remove without damaging the reflector. 5. Peel adhesive strip off back of reflector from kit. Position reflector on side of front fender above chrome side trim strip and approximately 4 inches rearward from front of fender. Press reflector securely into place. Repeat for opposite side reflector

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