SUZUKI PKT-045 V-STROM LEFT FRONT PANEL Installation Manual

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Filed Under (Suzuki) by admin on 19-02-2012

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STEP #1 – Remove the seat & the left side fairings. See the Suzuki service manual. STEP #2 – Drill a 18mm hole into the panel (11/16″ hole saw recommended and is available on our site) where shown [A]. If the hole is too small for the socket open it with emery cloth or a file. Watch the clearance behind the panel; make sure the socket has room. Attach the socket to the panel; use a dab of Silicone on the socket and jam nut. Important: Do NOT use Loctite or over-tighten. STEP #3 – Install the cable starting at the battery through to the front of the bike. Route the cable under the bracket [B]. You’ll find it a bit tight to get through between the frame and motor [C]. Ty-wrap the cable to the frame. Run the cable up to the front fairing. Slip the fuse-holder in the location shown [D]. Disconnect the black and red battery terminals. Connect the ground wire to the bolt [E]. You can cut a notch in the ref boot [F]. Connect the red wire to the battery posts as follows: RED WIRE = BATTERY POSITIVE STEP #4 – Reconnect the positive & negative battery terminals. Install the fuse in the fuse-holder. The center terminal is plus and the outer ring is negative (see dwg below). Apply either dielectric grease or Vaseline to terminals. Connect the red wire to the POSITIVE terminal and the black wire to the NEGATIVE terminal. Use a voltmeter to check if the polarity is correct. STEP #5 – Apply the remaining ty-wrap to the wiring harness where needed. Do NOT allow the harness to directly contact the motor or exhaust.

HARLEY DAVIDSON 45-AMP. UPGRADE ALTERNATOR ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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This 45-amp Rotor Kit is designed for installation on 1999 and later FLHT, FLHTC, FLHR, FLHRI, FLHRCI and FLTR Model Motorcycles. Existing Rotor Removal 1. Remove seat and disconnect battery terminals, negative cable first. 2. Follow instructions in applicable Service Manual and remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly. 3. Remove the alternator rotor spacer, if present. Installation The laminated high-output rotor in this kit contains magnets that are considerably more powerful than those used in most previous rotors. The ROTOR REMOVER/INSTALLER and SHAFT PROTECTOR SLEEVE (HD-41771) must be used to prevent parts damage during rotor removal and installation. 1. See Figure 1. Verify threads are clean and thread the Shaft Protector and Rotor Remover/Installer, if removed. NOTE The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to ensure that the rotor is properly centered. 2. Turn thumbscrews of Rotor Remover/Installer into threaded holes in rotor face. CAUTION 1 WARNING 1 WARNING 1 WARNING Kit Number 29999-97B Figure 1. Install Shaft Protector and Rotor Installer Engine Sprocket Shaft 1. Make Sure Threads are Clean 2. Install shaft protector sleeve. Shaft protector sleeve 3. Install Rotor Remover/Installer i04153 Handle Thumbscrew Forcing screw . Center ball on forcing screw in recess at end of engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator. 4. Loosen thumbscrews and remove Rotor Remover/Installer. Remove Shaft Protector Sleeve. 5. Install the shaft extension on engine sprocket shaft. No alternator rotor spacer is necessary). 6. Follow instructions in applicable Service Manual and install the clutch assembly, primary chain and shaft extension as a single assembly. 7. Apply two drops of Red LOCTITE®262 to threads of clutch nut and engine sprocket nut. Tighten nuts as fol- lows: Clutch nut- (left hand threads), 70-80 ft-lbs (94.9-105.5 Nm) Engine sprocket nut- 150-165 ft-lbs (203-223 Nm). 8. Follow instructions in Service Manual and install the Primary Chaincase Cover using new gasket from kit, if necessary.

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HARLEY DAVIDSON BATTERY CHARGING HARNESS (THREE-PIN) INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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1. Follow the instructions in your Owner’s Manual to remove the seat and any other components (side covers, etc.) necessary to provide access to the battery. 2. Refer to the applicable view in Figure 1 for your model. Break the battery negative (-) connection by removing the hardware assembly from the negative battery terminal. 3. Break the positive (+) battery connection by removing the hardware assembly from the positive battery terminal. 4. Clean the battery terminals and cable connectors using a wire brush or sandpaper to remove any oxidation. 5. Apply a light coating of Harley-Davidson electrical contact lubricant (Part Number 99861-02) to the battery terminals, cable connectors, battery charging harness ring terminals and connector located under the weather- shield cap. 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. Refer to the view in Figure 1 used for disassembly. Install the positive (RED) lead of the harness to the positive (+) battery post following the sequence shown. • On 1999 and earlier models (with original equipment), torque the positive (+) terminal post bolt to 40 in-lbs (4.5 Nm). • On 2000 and later models (with original equipment), torque the positive (+) terminal post bolt to 60-96 in-lbs (6.8-10.9 Nm). 7. Attach the negative (BLACK) lead of the harness to the negative (-) battery post following the sequence shown. • On 1999 and earlier models (with original equipment), torque the negative (-) terminal post bolt to 40 in-lbs (4.5 Nm). • On 2000 and later models (with original equipment), torque the negative (-) terminal post bolt to 60-96 in-lbs (6.8-10.9 Nm). Harness Routing Do not route the harness near any moving parts. Contact with moving parts may result in damage to harness. Refer to the following sections to determine the correct harness routing for your model. Be sure to avoid any components that may pinch or cut the harness, and avoid components that radiate heat. Take up any slack in the cable and store out of sight. Secure the harness with cable straps (H-D Part Number 10006), which can be purchased separately from any Harley Davidson Dealer. VRSC Model Harness Routing 1. See Figure 2. Route the battery harness/ connector (3) toward the front of the bike following the upper left frame tube. Cleanly tuck the in-line fuse (2) into the space in front of the battery. 2. Continue to route the harness/ gray connector to the front of the bike and behind the vent cover. Secure the harness with a cable strap and let the connector protrude past the cover for easy access. Trim any excess from the cable strap

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HARLEY DAVIDSON ELECTRA-GLO LIGHT POD KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION NOTES Clean the controller mounting area and the areas where the light pods will be mounted with soap and water before beginning the installation, and allow to dry thoroughly. Remove debris, dirt and grime from the vehicle areas to be highlighted. Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the light pods and controller box to vehicle surfaces. Light pods should not be located closer than 2.5 inches (63.5 mm) from exhaust pipes or mufflers, and must have 1.5 inches (38.1 mm) clearance from engine cylinders and heads. Do not install light pods with the light source facing directly away from the vehicle. Installation should be done in a way that allows the light to be seen indirectly by reflecting from chrome or painted surfaces of the vehicle. Prepare the Motorcycle 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) 1. Refer to the owner’s manual and follow the instructions given to disconnect the battery cables, negative (-) cable first. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . Locate and Install the Controller NOTE Do not mount the controller box in a location where vehicle suspension travel could result in contact with the ON/OFF switch or dimmer control. Damage to the controller box will occur. 2. See Figure 2. Locate the controller box (10) on a flat surface that will allow the red (+) and black (-) leads to reach the battery terminals and the rider to access the controls (with the vehicle parked) and, if necessary, the in-line fuse holder (A). a. Test-fit the controller box to the selected surface before installation. Do not remove the adhesive backing until ready to attach the controller box. b. Clean the controller box mounting area with one of the included alcohol swabs. Allow to dry thoroughly. c. Remove the liner from the adhesive backing of the controller box. Carefully position the controller box to the surface, and press firmly into place. Hold the controller box in position with steady pressure for about one minute. Connect the Battery Cables NOTE Verify that the ignition/light key switch is in the OFF position before attaching the battery cables. 3. Verify that the ignition/key switch is turned to the OFF position. Apply a light coat of Harley-Davidson electrical contact lubricant (part number 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. 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) 4. Refer to the owner’s manual and follow the instructions given to install first the vehicle’s positive (+) battery cable then the red (+) light pod controller lead ring terminal to the positive (+) battery terminal. Tighten to owner’s manual specifications. Install first the vehicle’s negative (-) battery cable then the black (-) light pod controller lead ring terminal to the negative (-) battery terminal. Tighten to owner’s manual specifications. Arrange the Electra-Glo Light Pods NOTES Electra-Glo light pods (1) can be installed in a variety of locations. They are best installed on a flat surface to provide indirect lighting illuminating mechanical features, vehicle finish or for ground effects. Refer to the notes at the beginning of the Installation section. 5. Select the area or lines of the motorcycle to highlight, and suitable locations for each light pod. DO NOT permanently affix the light pods at this time. Lightly tape the pods in place temporarily until the desired visual effect is achieved Verify clearance from movement of rubber mounted engine or other moving parts, heat sources, or chafe points

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KYMCO MAXXER 300/ 250 MONGOOSE 300/ 250 SERVICE MANUAL

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

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apply or add designated greases and lubricants to the specified lubrication points. ÑAfter reassembly, check all parts for proper tightening and operation. ÑWhen two persons work together, pay attention to the mutual working safety. ÑDisconnect the battery negative (-) terminal before operation. ÑWhen using a spanner or other tools, make sure not to damage the motorcycle surface. ÑAfter operation, check all connecting points, fasteners, and lines for proper connection and installation. ÑWhen connecting the battery, the positive (+) terminal must be connected first. ÑAfter connection, apply grease to the battery terminals. ÑTerminal caps shall be installed securely. 1 . GENERAL INFORMATION 1-6 ATV 300/250 ÑIf the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. ÑAfter operation, terminal caps shall be installed securely. ÑWhen taking out the connector, the lock on the connector shall be released before operation. ÑHold the connector body when connecting or disconnecting it. ÑDo not pull the connector wire. ÑCheck if any connector terminal is bending, protruding or loose. Confirm Capacity 1 . GENERAL INFORMATION 1-7 ATV 300/250 ÑThe connector shall be inserted completely. ÑIf the double connector has a lock, lock it at the correct position. ÑCheck if there is any loose wire

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