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Harley-Davidson CHROME HANDLEBAR SWITCH CAP KITS installation and REMOVAL manual

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Filed Under (Harley Davidson) by admin on 09-03-2012

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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.

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HARLEY DAVIDSON COMBINATION SPEEDOMETER/TACHOMETER GAUGE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2011

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Removing the Old Speedometer NOTE This Instruction Sheet covers several different Harley- Davidson models and years. Make sure you locate and follow the procedures that apply to the motorcycle receiving the new gauge. 1. Apply power to motorcycle and record the odometer reading. 2. Remove the seat according to the procedure in the applicable Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) 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 battery cables, negative cable first. NOTE Cover the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 3. Remove the instrument console acorn nut (and mounting screw with a flat washer on some models). Lay clean shop towels on the fuel tank. Lift the console from the fuel tank, turn it upside down and lay it on the towels. NOTE If necessary, bend back the flexible metal clip to free the harness conduit from the underside of the console. 4. Unplug the 12-terminal connector (39B) from the back of the speedometer. Depress the external latches and use a rocking motion to separate the pin and socket halves. 5. Remove the back clamp: All models except FXSTD: Gently pry the three latches upward to release the back clamp from the back of the speedometer. FXSTD: Depress the three external legs of the lock ring, then gently pry the three latches upward to release the back clamp from the back of the speedometer. 6. Unscrew the trip-meter reset button, and pull the harness from the clamp (remove the screw if necessary). 7. Lift the console and remove the old speedometer from the console. Discard the old speedometer, but retain the rubber gasket and back clamp for use with the new gauge. NOTE Set the console securely on the towel-covered fuel tank, and take care that it doesn’t fall off during the following opera- tions. 8. Set the console securelyon the fuel tank. Installation and Final Check NOTE Apply window cleaning fluid or mild soapy water to the speedometer gasket as needed to aid installation. 1. Turn the console over, facing upward. 2. Place the speedometer gasket into position around the console speedometer bore. 3. Fit the new gauge into the bore so that it fits snugly against the rubber gasket. Rotate the gauge into approximate visual alignment. The back clamp will complete the alignment. 4. Turn the console over, face down. 5. Install the back clamp

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2004 Kawasaki ER5 C5 Service Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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before starting to perform an inspection service or carryout a disassembly and reassembly opera- tionona motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing anew part, clean off any dust or metal filings. (2) Battery Ground Disconnect the ground (-) wire from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery (3) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if instal- lationorassembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible. (4) Tightening Sequence When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing apart with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in across pattern. Conversely, to remove apart, first loosen all the bolts, nuts, or screws that are retaining the parta 1/4-turn before removing them

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