Filed Under (Harley Davidson) by admin on 09-03-2012
1. Open or remove seat according to the instructions in the Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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 battery cables, negative (-) cable first. 3. Remove left and right-hand switch housing assemblies. Refer to HANDLEBAR SWITCHES in Service Manual. NOTE It is not necessary to disconnect the switch wiring to replace the switch caps. 4. Remove individual switches from switch housing. Refer to SWITCH REPAIR/REPLACEMENT in Service Manual. INSTALLATION Upper Housing Switches 1. For HORN and START switch caps, release torsion spring leg from hole in switch cap tab. Take note of how the spring is installed. The other leg of the spring can remain in the switch bracket hole. 2. See Figure 1 and Figure 5. Carefully pry stock black switch cap up off the splined actuator shaft (2) on left side of switch. -J02633 1 of 5 5 2 1 1 3 4 is 01405 1. Switch cap installed correctly 2. Switch cap removal from splined shaft 3. Switch cap removal from pivot pin 4. Switch cap installation onto pivot pin 5. Switch cap installation onto spined shaft Figure 1. Switch Cap Removal and Replacement 3. Pry the switch cap up and away from pivot pin (3) on right side of switch, and remove cap. NOTE Use the clear protective cover film to protect the chrome surface of the switch caps during installation. Remove the film after the installation is complete. 4. See Figure 5. Select proper chrome replacement switch cap from kit. 5. See Figure 1. Place cap onto switch, angling the hole on right side over pivot pin (4) on switch. 6. Carefully press switch cap down onto splined actuator shaft (5), rocking and moving the cap until shaft snaps into place in splined hole. 7. For HORN and START switch caps, insert torsion spring leg into hole in switch cap tab. 8. Toggle switch back and forth, checking for proper opera- tion. Turn Signal Switches 1. See Figure 1 and Figure 5. Carefully pry stock black switch cap up off the splined actuator shaft (2) on switch. 2. Pry the switch cap up and away from pivot pin (3) on switch, and remove cap. 3. Select proper chrome replacement switch cap from kit. Peel a clear protective installation cover from the sheet and place it over the surface of the cap. 4. See Figure 1. Place cap onto switch, angling the hole on top over pivot pin (4) on switch. 5. Carefully press switch cap onto splined actuator shaft (5), rocking and moving the cap until shaft snaps into place in splined hole. 6. Toggle switch back and forth, checking for proper opera- tion.
Filed Under (Suzuki) by admin on 29-11-2010
INSPECT ROUTING 1. Remove the upper and lower meter panels (refer to Service Manual page 9D-15). 2. Check if the ignition switch lead wire is clamped and routed correctly. Incorrect positions are shown in Figures 1 and 2. Correct routing and clamping is shown in Figures 3 and 4 on page 5. REROUTING 1. Reroute the ignition switch lead wire correctly (Figure 3 and Figure 4). The ignition switch lead wire should not be covered by the other wire harnesses. 2. Turn the handlebars back and forth to verify that the steering operates smoothly and the wiring harness does not become kinked or pinched. 3. Proceed to PUNCH MARK AT VIN on page 8. from the motorcycle (refer to Service Manual page 1H-12). Remove the two black plastic covers to access the cylinder cap mounting bolts (Figure 5). Note: The black plastic covers will not be reused. Secure the mount area (bottom) of the ignition switch in a vise (Figure 6). NOTE: Turn the ignition switch to the OFF position and remove the key from the ignition switch before disassembling the switch. Remove the two “break-off” screws from the ignition switch using the special screwdriver. Set the stepped end of the sleeve on the special screwdriver facing toward the “break-off” screws (Figure 7). Strike the special screwdriver 5 to 7 times with a hammer to produce a deep enough groove on the screw head for the screwdriver to work properly (Figure 6). Pay attention not to hit other parts with the hammer. Turn to remove the “break-off” screws in a counterclockwise direction. If the groove becomes damaged, make another groove at a 90o angle to the original groove. Remove the ignition switch from the vise and hold it upright over the workbench and carefully remove the cylinder cap (Figure 8). NOTE: Pay close attention to the order and orientation of the ignition switch parts during disassembly. REPLACEMENT OF IGNITION SWITCH (Customer Sold Units/Dealer Demo Units- Only If Inspection Shows Incorrect Routing And Unit Has Been Ridden) New Ignition Switch Disassembly 2.
Filed Under (Honda) by admin on 04-11-2011
Remove the seat from the motorcycle.2. Lift the ignition module off of the battery cover and let it drape over the side of the motorcycle. 3. Remove the battery cover and disconnect the negative battery cable. 4. Remove the gas tank and set it aside. There is a vent line at the right rear of the tank, a vacuum line and the gas feed line on the left side of the tank at the petcock, and two speedometer connectors at the left front of the gas tank. 5. Remove the clip from the top of the steering head cover and remove the right hand side cover. See picture at right. 6. Remove the headlight to expose the wiring connectors inside the headlight shell. 7. Remove the left-hand side cover. On the left side of the frame is an electrical wire shroud wire tied to the left side of the frame with a reusable wire tie. Inside this cover is the 3-pin connector that connects the ignition switch to the bike’s wiring harness. Pull the small lever back to release the wire tie and remove the wire tie. Pull back the wire shroud to reveal the wire connectors inside. Disconnect the 3-pin connector that comes from the ignition switch. Remove the two bolts holding the ignition switch to the bike’s frame. See Picture at right. Remove the ignition switch from the bike. You may have to remove the connector body from the ignition switch wires to slide the wires through the frame when removing the ignition switch. You may now reinstall the side cover. 8. Lay the new wiring harness along the backbone of the bike with the two 9-pin connectors at the headlight and the 6-pin and 3-pin connectors at the battery. Insert the two 9-pin connectors through the large hole in the back of the headlight shell. Inside the headlight shell is a red 9-pin connector. Disconnect this red 9-pin connector and insert the new wiring harness connecting each side to the red 9-pin connectors. See picture at right
Filed Under (BMW) by admin on 17-11-2010
The K 1300 S with 175 hp, the K 1300 R with 173 hp and the K 1300 GT with 160 hp. The new K bikes feature updated transmission and clutch assembly, plus smoother engine performance and new switchgear. Von Kuenheim continues: “By raising capacity to 1300 cc, our engineers have not only increased output but also torque on all three models. At the same time the driveline was intensively revised from air/fuel mixture formation right through to the exhaust system. In this way we have been able to optimize partial load behavior as well as throttle response. Now the clutch can be operated with even less effort and with greater refinement. Shifting has been improved tangibly due to constructional changes to the gearbox and drive.” BMW is introducing new options for the 2009 as well. The popular Electronic Suspension Adjustment that first appeared on the 2005 K 1200 S has now been updated with even more on-the-fly adjustability and it’s called ESA II. Also new is the quick-shifter option, racing-style gear shift assistant, borrowed from BMW’s race-ready HP2 Sport. Automatic Stability Control (ASC) is also offered as an option on the new K bikes. “Both the K 1300 S and also the R will also have the shift assistant – familiar from the HP2 Sport – available as an option for the first time,” von Kuenheim emphasized. “We have also advanced the chassis. The new lower longitudinal strut is now made of aluminum and is thus considerably lighter. This makes the front wheel guidance response even more sensitive. The result of this comprehensive development work is superior handling, improved rideability and lower fuel consumption. The electronically adjustable suspension – called ESA in short – was launched as a world first on the K 1200 S. Now we are presenting the new, well-proven ESA II as an option for the K Series. Apart from the suspension and damping this unique system also allows the spring rate to be adjusted at the press of a button. The K Series model revision also heralds a new and innovative generation of switches and controls.
Filed Under (Yamaha) by admin on 20-11-2010
CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760