2000-2010 KTM X2 SWITCH WIRING HARNESS Removal and Installation Manual

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Filed Under (KTM) by admin on 25-01-2012

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The included 3600-SWHA switch harness is intended for use with offroad models that do not come with a Hi/Low beam switch from the factory. The harness is compatable with stock AC lighting electrical systems as well as high output DC electrical systems. 1. Remove the stock numberplate or headlight. Remove the stock kill switch from handlebars and replace with the 3600-SWHA switch. 2. Remove the gas tank. Route the white and black leads from the 3600-SWHA under the tank following the wires from the stock kill switch. Disconnect the stock kill switch bullet and connect the white wire of the 3600-SWHA to the wiring harness. Disconnect the stock kill switch ring terminal and connect the ring terminal of the 3600-SWHA. Fully remove the stock kill switch. Be sure all the wires are safe from being burned or pinched and re-install the gas tank. 3. Disconnect the two female spade terminals from the stock headlight switch (if present). Connect the terminal with the yellow wire to the red power lead from the switch. Connect the white wire to the blue accessory output from the switch. Be sure the clear silicone sleeves are covering the stock plastic housings. 4. Connect the X2 headlight to the switch headlight plug. Note: The stock headlight plug will not be used for the X2 installation, but is still functional for connecting the stock headlight. The stock plug will turn on and off with the new headlight switch, and will be powered in either of the Low or High Beam positions

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Yamaha WR motorcycle ProEFX 12V Hot Start Installation

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Filed Under (Yamaha) by admin on 06-01-2012

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1. Remove seat, tank and shrouds. Remove existing hot start lever, cable and valve from the carburetor. 2. Tip: Clean all dirt from hot start bore and mating surfaces on the carburetor body with gas and a q-tip. 3. Tip: Use a small amount of Teflon tape (one wrap) on the threads of the aluminum mounting nut to ensure a water tight seal. 4. Install the Pro EFX hot start valve in the hot start bore (as shown in picture), with return spring, impact washer and delrin plunger in place. • Tip: Installation of the solenoid valve may require temporary rotation of the carburetor away from the top engine mount bracket. • Install with the solenoid valve assembly disconnected from wiring harness. • Screw in by hand and finish tightening with needle nose pliers. Do not over-tighten. Solenoid valve assembly: 5. Mount activation switch on preferred handle bar location. Pictured on clutch side, in place of the stock kill switch.
6. Route wiring harness around steering column and down frame backbone. Insert battery leads through slot in rubber protective boot. (follow existing wiring to battery) 7. Connect positive (red) and negative (black) leads to motorcycle battery. 8. Connect male and female terminals to wiring harness on previously installed solenoid valve assembly. 9. Depress activation button and listen for valve actuation. Plunger should freely “snap” between open and closed position in hot start bore, as activation button is depressed and released. If you don’t hear the valve “snap” open and closed, follow the trouble shooting guidelines or call /email for support. 10. Maintenance: Periodically ensure proper tightness of solenoid valve in carburetor body as part of standard motorcycle maintenance. Keep the battery terminal connections free from corrosion.

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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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