KTM EXC / MXC DUAL SPORT KIT REMOVAL AND INSTALLATION

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

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Using a small phillips head screwdriver, loosen the locking screw ( B ) on the kill switch ( C ). Remove any cable ties and unplug kill switch from existing wiring. Step 2 Loosen clutch cable perch ( D ) and move inboard about 1/2 inch. Important Note Regarding Magura Brakes The KTM uses the Magura hydraulic brake, which may cause potential interference between the turn switch and the lever adjuster. Make sure you have enough clearance between the parts. You can either move the grip out slightly, or take a file and sand away a small notch in the turn switch where it may rub. Install Turn Switch Step 1 Open and wrap the new turn switch ( E ) around handlebar and securely fasten with two screws ( F ) as shown. Make sure you have clearance between the grip, the switch and the lever! Step 2 Route turn switch wiring down and along handle bar behind Dakar headlight unit and in through frame cable guide. Secure switch wiring to handlebars with one cable tie. For more information, please refer to the Cable Routing Diagram

HONDA CB650/ CB750F/ CB900F/ CB1100F 4 CYLINDER TWO CABLE TIE ADHESIVE MOUNTING BASES REMOVAL

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Filed Under (Honda) by admin on 29-11-2011

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All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation.
2. Remove the seat and/or petrol tank to gain access to the original spark units (if fitted); these are normally fitted under the seat between the top frame tubing. Each of these units consists of a small alloy metal box with sleeved wires terminated by a small connector (coupler). They also have a mounting tab with a single fixing hole. 3. On four cylinder machines there will be two units, normally mounted back o back; one for cylinders 1&4 and one for cylinders 2&3. 4. For safety, disconnect the battery. 5. Unplug the couplers from each of the units. Undo the fixings and remove the units. 6. Fit the new spark units in the place of the old ones or find a suitable alternative, close to the connectors. Secure the units to the frame or mounting platform using the supplied tie-straps and adhesive mounting base (if required). If required, a thin sheet of rubber or double-sided tape can be used to keep the units in position. Do not completely wrap the units in foam rubber. 7. Push the wiring harness plugs into the new spark unit socket connectors; they will only fit one way. Reconnect the battery. 8. If you are rewiring the machine or do not have the standard wiring harness, the spark unit wire colours & functions are as follows

HARLEY DAVIDSON FXD (Dyna Super Glide) TACHOMETER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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1995 Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. 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) 1.1995 MODELS, REMOVAL OF ELECTRONIC SPEEDOMETER AND BRACKET 1a. Refer to applicable Service Manual procedure and remove seat. 1b. Refer to applicable Service Manual procedure and remove fuel tank. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 1c. Remove speedometer sensor cable from mounting clips under tank. See Figure 1. The 3-place speedometer sensor connector [65] is located on the frame beneath the seat. Remove connector from t-stud and disconnect. Cut cable tie holding sensor wires to right rear frame tube. 1d. Refer to applicable Service Manual procedure and remove headlamp, for work clearance. 1e Remove handlebar clamp screws securing speedometer bracket. Remove speedometer, bracket, and harness. 2.1995 MODELS, DISCONNECT MAIN WIRING HARNESS 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 2a. Disconnect the battery, negative cable first. Refer to applicable Service Manual procedure and disconnect main wiring harness 8-place connector [21A, B], at the front of the motorcycle. 3.1995 MODELS, REMOVE SPEEDOMETER LEADS FROM 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 3a. See Figure 2 and Service Manual wiring schematic. Pull the following wires and terminals out of connector [21B]. Wire Color Cavity Number Orange/white 5 White/green 1 Black 2 3b. Remove the large female connector from the fuel gauge black wire. 3c. Slide the wires removed in step 2a out of the plastic conduit covering the wires connected to the 8-place connector. 1 WARNING 1 WARNING 1 WARNING Figure 1. Speedometer Sensor Connection [65] 4973 Speedometer sensor connector [65] Figure 2. Tachometer/Speedometer Wire Splices and Terminal Connections [21B, A] i00240-.tif Splices 4.1995 MODELS, REMOVE INDICATOR LAMPS FROM BRACKET 4a. Remove the screws that secure the indicator lamps assembly to the speedometer bracket. Retain screws and indicator lamps assembly for installation on speedometer/tachometer bracket later. 5.1995 MODELS, REMOVE SPEEDOMETER FROM BRACKET 5a. Unscrew boot from speedometer reset switch. Remove cover screws and rear cover. 5b. See Figure 3. Note position of rear speedometer gasket and remove it. Push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket. Do not remove front gasket from the speedometer. 6.1995 MODELS, INSTALL SPEEDOMETER IN KIT BRACKET 6a. See Figure 5. Place wires from speedometer through front of left opening in double bracket. Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation. 6b. Insert speedometer into the front of the double bracket. Be sure wire guides are aligned with opening at bottom of bracket. 6c. Place rear gasket in position and align gasket tabs. Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into position at the opposite side. 6d. Add amber bulb assembly from kit to speedometer in order for tachometer and speedometer backlighting to match. 6e. Replace cover and boot from reset switch.

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HARLEY DAVIDSON TRIBAR LED TAIL LIGHT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove main fuse. Refer to service manual for location. 2. Remove seat using service manual instructions. 3. Remove rear tail light using service manual instructions. 4. Remove rear turn signals using service manual instruc- tions. 5. See Figure 1. Clip the cable strap (1) to free the rear harness from the chassis seat pan. 6. Unplug the 8-place connector (2) from the rear harness connector. 1 2 is05510 1. Cable strap 2. Harness connector Figure 1. Rear wire harness 1 2 4 3 is05511 1. Screws 2. Fender cover 3. Frame rail 4. Mounting bracket Figure 2. Remove Fender NOTE The fender support covers do not have to be removed from the upper shock absorber bolts. 7. See Figure 2. Remove the two rear fender support cover screws (1) and remove covers (2) and fender mounting -J04721 bracket (4). Repeat for opposite side and carefully remo ve fender and place it on a non-scratch surface. 8. See Figure 3. Clip and remove two cable straps (1). Pull wire harness three inches towards the license plate bracket. 9. Remove flange nuts (2) from both sides of license/tail light bracket stud plates (3) and remove bracket. Save stud plates and flange nuts. 1 3 2 is05517 1. Cable straps 2. Flange nuts 3. Stud plates Figure 3. Rear Harness Cable Straps, Flange Nuts and Stud Plates 10. Install new license/tail light bracket using stud plates and flange nuts previously removed. Tighten nuts to 5-6 ft-lbs (6.8-8.1 Nm) . 11. See Figure 2. Install rear fender by installing two screws (1) on each side through the fender support covers (2), frame rails (3) and into the fender mounting brackets (4). Tighten to 12-18 ft-lbs (16.3-24.4 Nm) 12. See Figure 1. Connect rear harness connector to 8-place connector on main harness. 13. Use a large cable tie strap from kit to secure the rear harness to seat pan. 14. Install rear turn signal lights using service manual instructions. 15. Verify that there is no excess wire harness near the stud plate then secure the harness with a large cable strap where the straps were previously removed. 16. See Figure 4. Secure the turn signal harness (3) to the stud plate (1) using small cable strap (2) and route the turn signal wire through the tail light bracket clip (4) as shown.

HARLEY DAVIDSON HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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REMOVAL See the service manual for removal procedures. INSTALLATION See the service manual and follow the wiring procedures. NOTE For Non-FXDF Models Only: See Figure 1. Cut the mesh tubing from the kit into two equal length pieces. Slide the switch wire bundles through mesh conduit. Position conduit into switch control housing. Tie each end of conduit with cable tie from kit. Handlebar Installation See the service manual and follow the installation procedures. SAFETY CHECK Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) •Be sure wires, clutch cables, throttle/idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops. 1. Verify that the ignition/light key switch is turned to the OFF position. Install the main fuse. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 2. Turn the ignition/light key switch to IGNITION, but do not start the engine. Test each handlebar switch for proper operation. Before starting engine, be sure thr ottle control will snap back to idle position when released. A throttle control that prevents engine from automatically returning to idle can lead to loss of control, which could result in death or serious injury. (00390a) SERVICE PARTS

Honda Goldwing GL1800 Independent Rear Suspension Installation Manual

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Filed Under (Honda) by admin on 16-02-2011

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Removal of Original Parts Most tasks necessary in this guide can be accomplished with the vehicle on its center stand. Secure the center stand to one of the forward crash bars with a ratchet strap to keep vehicle from rolling forward and off the center stand. Be sure that the vehicle is laterally stable as well. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for return of deposit or re-installation after modification shall be duly noted. □ Seat (to be re-installed without modification) □ Left and right side covers (to be re-installed without modification) □ Battery and battery box (to be re-installed without modification) □ Left and right saddle bags □ Remove taillight and locking assemblies from saddlebags (to be returned for refund of deposit) □ Trunk (to be re-installed without modification) □ Left and right passenger foot rests (to be re-installed without modification) □ Left and right foot rest under covers (to be modified and re-installed) □ Left and right rear crash bars □ Saddle bag trunk stay (to be modified and re-installed) □ Left and right mufflers (Mufflers only, do not remove decorative covers) . Retain OEM muffler rubber mounting bushings and flanged spacers for re-installation of the mufflers. □ Rear wheel □ Left and right pivot bolt covers (to be re-installed without modification) □ Reverse resistor (to be relocated) □ Swing Arm and Driveshaft IMPORTANT : Carry out brake system modifications (See Section 5) prior to removing Swing Arm. Evacuating all the brake fluid from the system will prevent brake fluid spills when the OEM swing arm is removed. Note : Upper bolt of mono shock can be removed without removing the fuel tank. □ Rear Shock and Hydraulics. Unscrew angle sensor from OEM shock and secure to frame with cable tie. □ Shock arm and shock link Note : You may need to cut out the bolt that attaches the shock link to the frame Brake System Modification Note : Modification to the vehicle brake system should be carried out prior to removal of the swing arm . 5.1 Explanation of OEM brake system and changes From the manufacturer, your Honda Gold Wing brake system utilizes both front and rear brakes when the foot brake is applied. In order to insure safe operation of your Gold Wing when converted to a Champion Trike, the brake system must be modified to isolate the front and rear brake systems from each other. Once modification is complete, four of the six pistons in the front calipers operate only when the hand brake lever is applied. The rear brakes operate only when the foot brake pedal is applied. The diagrams below outline the difference between the GL1800 OEM brake system and the system as modified by the Champion Trike Conversion Kit.

TRIUMPH AMERICA AND SPEEDMASTER HANDLEBAR RISERS INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 29-01-2011

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1. Place a blanket folded several times over the fuel tank to help prevent any damage during the installation of the risers. Loosen the two 14mm riser mounting nuts located on the bottom side of the upper steering head. Loosen the four handlebar top clamp 6mm socket head screws. 2. It will help having a second person to hold the handlebars while you change the risers. Remove the four screws from the clamps and then remove the clamps. Pull the handlebars up off the risers, pull them back and rest them on top of the blanket. 3. Remove the nuts from the bottom of the risers and remove the risers carefully without allowing the risers to rotate, as this will scratch the clear coating on the upper steering head. Using the bolts, lock washers and washers supplied install the new risers making the bolts finger tight only. (NOTE; again, take care not to allow the risers to rotate as this will scratch the clear coating on the upper steering head). 4. Place the handlebars back up onto the new risers. Install the new top clamps supplied using the four M8 X 30mm socket head screws supplied. Set the height of the handlebars to the desired position, tighten the front bolts first and then the rear securely. (15-18 ft. lbs.) (There should be no gap between the riser and clamp at the front side) Tighten the two riser mounting bolts securely. (20-25 ft. lbs.). 5. Turn the handlebars all the way to the left and then right checking for any pulling or binding of the wires, hoses or cables. YOU MUST! Check to see that the throttle returns freely on its own when the handlebars are at full left and full right turn THIS STEP IS VERY IMPORTANT FOR OBVIOUS SAFETY REASONS! If you have a windshield installed it may be necessary to reroute the throttle cables, wires or hoses around the other side of the windshields mounting hardware to obtain adequate free play and free throttle return. You may also wish to remove the plastic clips or cable tie which secure the wiring to the handlebars and secure them to the brake hose and clutch cable (not the throttle cables) for a cleaner appearance

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HARLEY DAVIDSON TOURING MODEL DRESSER DUALS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 24-12-2010

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1. Remove both left and right saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffl er. 3. Remove the two 5/16″ bolts that mount the muffl er to the saddlebag supports. Repeat this step on the opposite muffl er (save these parts, they will be re-used). 4. Remove the stock muffl ers with sliding hangers and set them aside. NOTE: It may be necessary to use a penetrating lubricant to loosen the muffl er from the head pipe. 5. Find and unplug the O2 sensor wires from the wiring harness and remove cable tie holding front wire to frame. F eed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 6. Remove the right hand fl oor board. 7. Remove both passenger fl oor boards. 8. Loosen the heat shield clamps on both front and rear exhaust pipes. 9. Loosen the rear head pipe clamp located behind the rear cylinder. Remove the section of head pipe connecting the left side muffl er. 10. Remove the nut and carriage bolt holding the front head pipe to the bracket on the transmission housing (save these parts, they will be re- used). 11. Remove the two mounting nuts from each head pipe, located at the cylinder head. Carefully remove the head pipes and set them aside. 12. Using a 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 13. Remove the rear cylinder bracket by removing the two starter mounting bolts. Install new bracket (stamped 422-P)(supplied) and torque to 13-16 ft. lbs. (Figure 1). NOTE: Twist breather hose down towards the left hand side to get it as far away from the pipe as possible. 14. Install mounting post (from stock system) so the nut is accessible from right side of motorcycle and saddle will support underside of exhaust pipe. 15. Replace the bracket on the transmission housing with new bracket (stamped 423-P)(supplied) and torque to 13-16 ft. lbs. (Figure 2). 16. Carefully remove the exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: If circlips look bent or twisted, replace them.

Honda GL1800 Front Mount Air Horn Installation Instructions

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Filed Under (Honda) by admin on 23-12-2010

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1. Place the motorcycle on the centerstand. 2. Remove the left side cover (painted) to expose the battery. Remove the left plastic engine cover (chrome) . Remove the lower center fairing cowl or spoiler; there are 2 pull pin rivets and 6 allen screws holding this panel in place. Drop the panel down and slide it out to the right or left. 3. Horns and Mounting Bracket: Attach the large “L” shaped bracket with the split clamp to the engine guards as shown in photo #1. NOTE: Make the screws snug only! Install the horn set onto the “L” bracket using the 2 allen screws provided, tighten securely. Align the horn set to be level and to have clearance between the fairing as shown in photo #2, tighten securely. 4. Compressor: Remove the stock left hand horn and loosely re-install the 12mm mounting bolt (see photo #4A). Next as shown in photo # 3, to the compressor attach the air hose, the short red wire to the (+) positive terminal and the white wire to the (-) negative. The mounting bracket should be bolted to the compressor as shown. Install the compressor assembly as shown in photo #4 onto the 12mm bolt and tighten securely. Note! It you may need to adjust the angle or bend of the bracket for a good fit. Try to maintain at least a one-inch clearance between the exhaust header pipe and the compressor, wires and air hose. 5. Relay and Wiring: Attach the red wire from the compressor to the relay terminal 30 (see wiring diagram). Attach the long red wire to the relay terminal 87. Attach the stock horn wires to the remaining terminals 85 & 86 it does not matter which wire goes to which of these two terminals. Attach the white ground (-) wire from the compressor to the lower cowl-mounting bolt as shown in photo # 4B. Cable tie the relay in place as shown in photo #4C. Route the long red wire up and back over the left side of the engine to the battery, This is easiest done using a stiff piece of wire (a coat hanger works good) with a small loop bent at one end. Push the wire from rear of the engine towards the front. Attach the red wire with electrical tape and pull the wire back towards the rear of the engine. Route the wire back to the battery (+) positive terminal, cut the wire to the desired length, strip back insulation 3/8″ crimp on the fuse holder provided and attach to the battery (+). Replace the side covers Route the air hose as shown in photo #5 so as not to kink it or be less than 1″ from the exhaust, then over the front of the engine, up and out to the horns just behind the engine guards, trim to the desired length and attach to the “Y” fitting. Using a lighter or match, heat seal or melt the end of the hoses braided cover to prevent it from fraying. Turn on the ignition and test the horns

Installation manual for fork springs

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Filed Under (Tips and Review) by admin on 30-11-2010

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1.) Motorcycle is securely jacked up on an assembly stand Jack up the bike at the front axis so that the fork is completely extended, not loaded and free to be moved. You might also hang up your bike using a cable or a hydraulic jack. 2. ) It is advisable to dismount the forks’ inner tubes because otherwise oil rests might remain in the lower part of the fork and the cartridge systems oil cannot be exchanged during drain off. Even degassing the fork is going to be much simpler this way. .) Take off brake callipers, front wheel and front fender Tip: 1. Check the owner’s repair manual of your motorbike for disassembly instruction. 2. Do not let the brake callipers dangle on the lines; rather fasten them with a cable tie or put them aside 4.) Measure the position of the fork inner tube inside the fork bridges Measure how far the fork bars jut out from the upper fork bridge then note down the exact amount in the text-box below. The protrude of the fork bars in mm Tip: Both bars should protrude exactly the same distance. 5.1) Loosen the clamping screws of the upper fork bridge 5.2) Release the fork caps for approximately one turn of the thread. 5.3) Loosen the clamping screws of the lower fork bridge. Tip: With some models, the clamping screws must be taken out completely.