Harley-Davidson FXWG, FXST (all except FXSTS), FXDWG Light Bar INSTALLATION AND OWNER'S MANUAL

0

Filed Under (Harley Davidson) by admin on 20-03-2012

download
1. Put a pair of male and female clamp halves together just above the lower triple-clamp. Squeeze the ends of the clamp together with a pair of pliers. Diagram A. 2. Have an assistant position the Light Bar Assembly so the lightbar bracket is to the outside of the clamp assembly. Make sure the wires from the Light Bar Assembly are below the lower triple clamp. Diagram B. 3. Insert a Screw through the clamp and Light Bar Assembly mounting bracket and thread on an Acorn Nut. 4. Hold the Light Bar Assembly in place in front of the lower triple clamp, assemble and attach the remaining clamps. 5. With all four clamp assemblies in place, tighten the clamping screws and nuts to 15 ft. lbs. (21 Nm). Refer to the service manual to gain access to the wire harness inside the fuel tank tunnel or inside the frame backbone. Also, verify the appropriate color wires for hook-up of the passing lamps and turnsignals and running lights. Route the wires from the Light Bar Assembly, around the lower triple- clamp, and up to the frame backbone. Secure the wires so they cannot become pinched when turning the fork. A. The short black wires from the Light Bar Assembly connect to the wires powering the running lights. B. The short red wires from the Light Bar Assembly connect to the wires powering the turnsignals. C. The long blue wires from the Light Bar Assembly connect to the wire powering the headlight low beam. After the wires are connected, verify the operation of the passing lamps, running lights and turnsignals. Correct any connection problems before reassembling the motorcycle. Reinstall the fuel tank. Check all fasteners used during this installation for tightness

Incoming search terms:

2010 Harley Davidson Touring Model Power Commander Installation manual

0

Filed Under (Harley Davidson) by admin on 29-02-2012

download
1 Remove the stock seat. 2 Unplug the stock wiring harness from the ECM (Fig. A) . 3 Plug the PCV connectors in-line of the stock ECM and wiring harness (Fig.B). 4 Tuck the PCV to wiring harness connection into the opening in front of the battery box (Fig. C). 5 Using the supplied velcro attach the PCV to the top of the ECM (Fig. C) FIG.A FIG.C Remove Ground wire FIG.B PCV connector PCV connector Stk connector Connection 15-011 www.powercommander.com 2010 Harley Davidson Touring PCV – 4 6 Remove the right hand saddlebag and sidecover. 7 Locate the stock O2 sensor connections and unplug both connectors (Fig. D) The stock O2 sensors will NOT be connected to anything at this time. The sensors can be removed from the exhaust if you have a way to plug the hole. Unplugging the sensors does NOT cause an engine light but will cause a historic code in the ECM for non-active O2 sensor. This is not causing any issues with the running of the bike. FIG.D Follow these instructions when using the Auto tune kit – part #AT-100B 1 Remove the left hand side cover. 2 Place the Autotune modules in front of the battery as shown in Figure H. If using velcro make sure the velcro does not cover the designation of the unit on the back (AT #1 or AT#2). The modules are coded to the front and rear cylinders. FIG.E 3 Remove the rubber plug for the diagnostic connector. Plug the lead from the Autotune kit into the stock diagnostic connector (Fig. J).This connection is under the LH sidecover. DO NOT connect to the accessory connection in front of the battery. 4 Reinstall the sidecover. FIG.F 15-011 www.powercommander.com 2010 Harley Davidson Touring PCV – 5 5 Connect the longer harness to the front O2 sensor. Route the harness along the front down tube and along the backbone of the frame to Autotune module AT#1. Wire the harness to the module per Figure G. The harness can be cut to length if desired. 6 Repeat step 4 for the rear cylinder. Wire the harness to Autotune Module AT#2. The harness can be cut to length if desired. If your exhaust does not accept the M18x1.5mm O2 sensor you will need to install the supplied O2 bungs with the Auto tune kit into your exhaust. See Auto tune instructions for more information

Ktm 950 SMR Installation and Removal Manual

0

Filed Under (KTM) by admin on 27-01-2012

download
Be sure the triple clamp in your kit has a part # 3012R- 27 -6-0208 on the bottom side. This is very important. 2. Warning: Once the triple clamp is loose, the forks can roll away from the bike . Block it up properly to start with. 3. Block the front tire securely before removing the top triple clamp, so the tire cannot move forward. It’s best to tie the forks up to something above you, like the rafters, using tie downs, or a tie down from the front axle up and over the frame backbone and then underneath the lower triple clamp. Once the forks start to come off while working, it’s extremely difficult to get them back together without help. Block the back wheel up also, so it puts pressure on the front end, forcing it to stay in position. Spend the time setting this up correctly and your installation will go easier. 4. This kit requires removal of the headless “Security” bolts that hold the key switch in place. These bolts will need to be drilled out in order to remove them, pictures below. Removal is fairly easy, if you follow these instructions. 5. Examine all the wire and cable routing before removal and make notes of where everything goes. 6. Remove 2 bolts that hold the headlight shroud in place. Be careful not to lose the small bushings that fall out easily. 7. Follow the wire from the ignition switch to the wire loom in the headlight shroud and unplug it. There is no locking tab on this plug so you can usually undo it without having to disassemble the wiring. 8. Remove the 4 bolts that hold your bars tight and lay the bars forward out of the way (Bungie or tie to the front of bike). 9. Be sure the front end is securely blocked or tied to something above the bike. Remove the top triple clamp, taking note of how tight the 27mm main nut is, so you can re-tighten to the exact tension for the bearing. The main nut merely provides the correct tension on the head tube bearing, so the tension is critical. The nut will NOT be tight coming off. Once the fork and triple clamp pinch bolts are loose, the main nut can be removed. It’s difficult to get a wrench on the main nut. We were able to sneak the stock KTM axle wrench in there, otherwise, you may have to loosen the lower bar perches using an 8mm Allen wrench and a 17mm socket for the underside nuts. Once the main nut is off, lift the triple clamp off carefully , trying not to disturb the blocked-front-wheel. A rubber mallot is helpful here

Incoming search terms:

The Honda VTX 1300 Keyless Ignition Switch Installation instructions

0

Filed Under (Honda) by admin on 04-11-2011

download
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

Incoming search terms:

HARLEY DAVIDSON ENGINE GUARD-MOUNTED FOG LAMP KIT INSTALLATION MANUAL

0

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

download
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

2004 HARLEY DAVIDSON SPORTSTER XL, XL CUSTOM TANK BRA KIT Installation Instructions

0

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

download
1. See Figure 1. Beginning at the front of the tank, position the elastic strap over front edge of fuel tank against frame backbone making sure elastic strap does not pinch off fuel tank vent tube located underneath left side of tank. When properly positioned, strap will run down front of tank and along bottom toward rear of tank. Adjust, if necessary. Pull bra to the rear of tank and fit bra snugly around rear of tank. When performing the following step, route the elastic strap and steel “S’ hook between the main wiring harness and the frame backbone. If the strap is not routed between the main harness and frame backbone, the “S” hook could eventually cut into the main harness wiring causing electrical system failure which could result in death or serious injury. 2. Position the rear elastic strap around the frame backbone making sure the strap and “S” hook, when fastened, pass between the main wiring harness and frame backbone. 3. Smooth out any wrinkles in bra.

Incoming search terms:

RIVCO POWERMASTER EFI MODULE Installation AND Tuning Manual

0

Filed Under (Tips and Review) by admin on 29-01-2011

download
Locate the fuel injectors and their connectors on the intake manifolds between the “V” of the engines cylinders. You may remove the fuel tank to gain easy access to the plugs or you can make the connections with the tank on as follows. Remove the rear fuel tank mounting bolt and loosen the front two bolts. Lift the rear of the tank as high as possible (2-3 inches) and place a piece of wood between the tank and frame to hold the tank up. 2. Mounting the POWERMASTER™ EFI Module. While you can mount the module most anywhere it is recommended to mount it under the right hand side cover for easy access when making adjustments. Find a suitable surface to mount the Velcro Adhesive Square supplied. Clean the surface with rubbing alcohol, peel the backing and press firmly in place. Press the Module onto the Velcro. Route the wires with the plugs for the injectors between the frame rails and up toward the injectors with the other wires located on the backbone of the frame. If yours is a model with wires and plugs for the oxygen sensors route these wires downward with the short lead going to the plug on the rear exhaust pipe (about 6″ from the cylinder head) and the longer following along the right frame tube under the engine and forward to the front oxygen sensor and its plug.3. Connect the wires to the injectors under the fuel tank as follows. Unplug the bike’s wire harness from the injectors. Connect the male and female connectors from the injectors and the wire harness to the RIVCO POWERMASTER™ EFI Module. This places it electrically between ECU and the injectors. Repeat this process for each injector. NOTE it does NOT matter which lead goes to which injector.

BMW R259 Installation Instructions Fuel Control For BMWOilheads

0

Filed Under (BMW) by admin on 12-11-2010

download
Installation R1200 C -Removethechrome right air filter cover. Release the brake fluid reservoir from its mount. Follow the oxygen sensor lead from the exhaust to the connector. It is mounted to the back of the brake fluid reservoir mounting bracket with cable ties. Cut the cable ties to release the connector from the bracket. Gently pull the connector apart. Insert the male O2 connector from the R259 into the oxygen sensor lead. Connect the female side of the R259sO2 connector to the bike’swiringharness side. Make sure both sets of connectors are fully seated. Cable tie the sensor lead connector back to the bracket and tuck the other O2 connector under the front of theairhorn. -Depressthe retaining bail on the right fuel injector connector and gently pull off the connector. Install this connector on the male R259 injector lead. Install the remaining R259 connector on the right injector. -Connecttheground lead by removing the allen screw (5mmhex) that secures theairboxtothe frame. Place the screw through the lug on the ground lead and reinstall and tighten the screw. Go to section 3 and verify power-up. Tuck the wiring below and behind theairhornand cable tie as necessary. Using the supplied velcro, attach the controller box to the top of theairhorn. Reinstall the brake fluid reservoir in its mount and reinstall the side-cover. Seethe Techlusionwebsite for more detail. Installation R850, R1100, R1150, R1100S -Refertothe appropriate BMW service guides and remove the fuel tank. On some models it maybe possible to have an assistant lift the tank up and to the left to expose the oxygen sensor connector, without fully disconnecting the tank. Locate the oxygen sensor connector by following the lead from the exhaust system. It will be cable tied to the right frame backbone. Cut the retaining cable ties and pull the connector away from the frame. Open the connector and insert the male R259 O2 connector into the oxygen sensor lead, and the female to the bike’swiringharness. Cable tie these back to the right frame backbone. -Routethe R259 wiring harness down the right frame, in-between the battery tray and the rear fuel tank mount. Using the supplied velcro attach the R259 to theairboxlid. Locate the lead on the right fuel injector, and while depressing the locking bail on the connector, gently pull the leadoff. Install this lead on the R259 male injector connector; install the remaining connector on R259 harness to the right injector. Make sure all of the connectors are fully seated. Cable tie any excess wiring away from the fuel lines and throttle mechanism. -Connecttheground lead to the battery negative terminal or an alternate good ground. -Re-install the fuel tank. Make sure the fuel lines are connected and their routing is correct. Insure that both throttle cables are correctly seated in their adjusters on the throttle bodies, and that nothing interferes with the throttle mechanisms on either throttle body. Turn the key on and allow the fuel system to pressurize. CHECK FOR ANY FUEL LEAKS and repair as necessary. Go to section 3 to verify power-up. Re-install any other bodywork removed. Seethe Techlusionwebsite for more detail.

Incoming search terms:

XR 600 Dual Sport Kit Installation Manual

0

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

download
1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the side panels, seat, and gas tank. 3. Unplug the headlight and taillight from the stock wiring and remove. 4. Locate the AC voltage regulator mounted on the left side of the frame backbone, (Fig.1) unplug from wiring harness, and remove the regulator. This regulator is located above the air box on ’87 and earlier XR 600′s and 500′s. AC Regulator (Remove) Pulsar Coil Alternator (Stator) Wiring Alternator (Stator) Contains both exciter coil and lighting coils Figure 1: If you are colorblind or even think you might be a little color blind, now is the time to get someone to assist you. Successful installation of the kit requires good color recognition. You want to go riding this weekend, don’t you? 5. A three wire group consisting of a black/red wire, a green wire, and a white/yellow wire (may appear light gray/yellow) are the output leads from the stator. 1990 and earlier models only have two wires coming up from the alternator, a black/red wire and a blue wire. On 1991 – 1999 XR 600′s, unplug the green wire and the white/yellow wire. (This should have already been done 3 when you removed the voltage regulator in Step 4.) On 1990 and earlier XR 600′s see the Stator Modification Instructions enclosed. 6. Temporarily disconnect the black/red wire and remove the rubber boot that shields the wire bundle. Reconnect the black/red wire making sure that it plugs in tightly, as this lead is responsible for powering the bike’s ignition. 7. Voltage Regulator Installation: The voltage regulator/rectifier mounts to the top right rear corner of the air box (Photo 1). Use the template provided to determine the location at which to drill the two 1/4 inch mounting holes in the air box lid. The outside edge of the regulator should be nearly flush with the outside edge of the air box when mounted properly.

Installation Instructions Fuel Control For BMW Oil heads

0

Filed Under (BMW) by admin on 26-10-2010

download
Removethechrome right air filter cover. Release the brake fluid reservoir from its mount. Follow the oxygen sensor lead from the exhaust to the connector. It is mounted to the back of the brake fluid reservoir mounting bracket with cable ties. Cut the cable ties to release the connector from the bracket. Gently pull the connector apart. Insert the male O2 connector from the R259 into the oxygen sensor lead. Connect the female side of the R259sO2 connector to the bike’swiringharness side. Make sure both sets of connectors are fully seated. Cable tie the sensor lead connector back to the bracket and tuck the other O2 connector under the front of theairhorn. -Depressthe retaining bail on the right fuel injector connector and gently pull off the connector. Install this connector on the male R259 injector lead. Install the remaining R259 connector on the right injector. -Connecttheground lead by removing the allen screw (5mmhex) that secures theairboxtothe frame. Place the screw through the lug on the ground lead and reinstall and tighten the screw. Go to section 3 and verify power-up. Tuck the wiring below and behind theairhornand cable tie as necessary. Using the supplied velcro, attach the controller box to the top of theairhorn. Reinstall the brake fluid reservoir in its mount and reinstall the side-cover. Seethe Techlusionwebsite for more detail. Installation R850, R1100, R1150, R1100S -Refertothe appropriate BMW service guides and remove the fuel tank. On some models it maybe possible to have an assistant lift the tank up and to the left to expose the oxygen sensor connector, without fully disconnecting the tank. Locate the oxygen sensor connector by following the lead from the exhaust system. It will be cable tied to the right frame backbone. Cut the retaining cable ties and pull the connector away from the frame. Open the connector and insert the male R259 O2 connector into the oxygen sensor lead, and the female to the bike’swiringharness. Cable tie these back to the right frame backbone. -Routethe R259 wiring harness down the right frame, in-between the battery tray and the rear fuel tank mount. Using the supplied velcro attach the R259 to theairboxlid. Locate the lead on the right fuel injector, and while depressing the locking bail on the connector, gently pull the leadoff. Install this lead on the R259 male injector connector; install the remaining connector on R259 harness to the right injector. Make sure all of the connectors are fully seated. Cable tie any excess wiring away from the fuel lines and throttle mechanism. -Connecttheground lead to the battery negative terminal or an alternate good ground

Incoming search terms:

Incoming search terms: