Harley Davidson Ignition Switch Installation Manual

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Filed Under (Harley Davidson) by admin on 27-02-2012

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Ignition Switch a. Harley Davidson i. P/N 71313-96 ii. P/N 71510-93 b. Drag Specialties i. P/N DS-272187 c. JP Cycles i. Cat # 370333 3. Wires and Connectors a. 14 gage wire – Red, 15 inches long b. 14 gage wire – Orange, 15 inches long c. 14 gage wire – Grey, 15 inces long d. 14 gage wire – Brown, 15 inches long e. 14 gage Female Wire Terminals (x3) 4. Miscellaneous a. Radio Shack i. 100 Ohm Resistor (1/4 Watt, 5% Tolerance) – P/N 271-1108 ii. Also recommended – piece of PC board to solder wires and resistor to b. Heat Shrink Tubing – Pack of Assorted Sizes c. Duct Tape or Masking Tape d. 6″ (or longer) Zip (Cable) Ties 2. Nuts and Bolts a. For Switch Mount: i. 4x 6-32 (Chrome or SS) countersink screws ii. 4x nuts for above iii. 4x washers for above b. For Door Locking Mechanism: i. 5/16-18 Bolt (or stud) ii. 2x 5/16-18 nuts iii. Block of rigid material 1. Dimensions: 5/16″ x 9/16″ x 3/8″ 2. Material: Aluminum, Stainless Steel, PVC, etc (Anything rigid will do) iv. 5/16-18 Tap v. Series of drill bits up to 9/32″ (drill size required for 5/16-18 tap) i. Roll (or Spring) Pin and drill bit 1/32″ smaller than pin

Harley-Davidson FL Caliper Mount Installation Manual

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Filed Under (Harley Davidson) by admin on 26-02-2012

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Motolight® Caliper mounts are designed to be mounted on the brake caliper mounting boss. Before removing the caliper bolt make certain you have the manufacturer’s recommended torque settings for your make, model and year. 2 . Disconnect your battery. Never work on the electrical system of a motorcycle while the battery is connected. If you’re not sure how, check your owner’s manual, or consider having your dealer install the lights. 3 . Motolights®, like any light, get hot when operating. Do not touch any part of the housing when the Motolights® are in operation and for at least 15 minutes after they have been turned off. 4 . If you are transferring your Motolights® to another bike or have obtained the lights secondhand, it is VERY IMPORTANT that you contact us at 800-567-8346 or 513-474-7530 for new caliper bolts of proper grade and size. Step 1. Unpack the Motolight® system . Take this chance to familiarize yourself with everything. Below is the list of included items: Item # Quantity Description 1 (2) º” x 20 x 5/8″ stainless steel socket head cap screws 2 (2) Housings, aluminum, assembled with lens, lamp and leads 3 (2) Mounting blocks, aluminum, left and right 4 (2) Caliper replacement bolts 5 (2) Lock washers 6 (1) Motolight wiring harness with relay and 20 amp fuse 7 incl. Special Harley auxiliary plug connector in wiring harness (included) 8 (2) Motolight decals (1 helmet size, 1 regular) 9 (1) Aiming tube (cardboard ring) 10 (1) 3/16″ hex wrench 11 (1) Pin wrench (for standard lamp retaining rings-not required for knurled/grooved rings) 12 (15) Cable ties, long and short

Suzuki GSX-R 1000 AFR Tuner INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 20-02-2012

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The installation of the AFR Tuner should be done by experienced technicians only. Always disconnect the battery from the motorcycle before making any modification to the wiring harness. Remove the negative terminal from the battery before starting the installation work. The quality of the installation work greatly affects the reliability of the AFR Tuner and the motorcycle. Work precisely and very carefully when modifying the wiring harness of the vehicle. Always double check that the wire you are about to cut or tap into is the correct one. The ECM or the AFR Tuner can be destroyed by a faulty installation. 3.2. Installing the AFR Tuner to the wiring harness 3.2.1. Main cable The AFR Tuner connects to the motorcycle through its Main connector . Figure 2 shows the wiring diagram and the necessary modifications, which needs to be made when installing the unit into the fuel injection system of the motorcycle. Information about the ECM terminal numbers and wire colors for some popular motorcycles can be found in Chapter 6 . The best location for installing the AFR Tuner main unit is at the passenger seat area of the motorcycle mounted in the trunk space or on the subframe under the fairing, as this place provides protection from engine heat and the weather. Electrical contact between the metal casing of the AFR Tuner and the rear subframe must be prevented by using insulating material, such as the included self adhesive velcro strips. If necessary use some cable ties to secure the unit in place. The installation of the AFR Tuner into the wiring harness involves tapping into some wires and cutting others while connecting the two ends to the AFR Tuner. The harness modifications are best done near the ECM, since most of the wires can be found there. Part of the wiring modifications are related to connecting the AFR Tuner in-line between the ECM and the fuel injectors. In such cases when the motorcycle is equipped with primary and secondary injectors the AFR Tuner has to be installed on the primary injectors, which operate under all engine conditions. Correct grounding of the AFR Tuner is very important for electrical noise reduction. The above mentioned insulation of the metal case from the motorcycle frame is necessary for the same reason, which is to avoid the forming of a ground loop. An even more important requirement is the correct connection of the three ground wires of the AFR Tuner. As shown on Figure 2 , these three wires must be led out separately to the ECM and connected together at same point where the ECM ground wire is tapped into. This point should be as close to the ECM terminal as possible. For best quality of the electrical contacts all connections should be done by soldering and covering the exposed part of the wire with heat shrink tubing. For reliability reasons do not use clip on type wire taps

HARLEY DAVIDSON FLH AND FLT TRAILER HITCH OR RACK LIGHTING WIRE HARNESS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Remove the seat and locate the tail light plug, this should be attached to the frame with a plastic clip where the fender meets the frame cross member. Unplug the connector and plug in the male and female ends of the supplied wire harness. Route the harness as shown following the other wire looms and then down along the main frame of the trailer hitch or your fender support to the bottom of the rear fender. Secure the harness using the supplied cable ties. Install a plug that matches that of your trailer. The wires in the harness functions/colors are as follows: Black = Ground Brown = Tail Light Red = Brake Light Orange = Left Turn signal Blue = Right Turn signal NOTE: If your trailer has only four (4) wires you will need to use a 5 to 4 wire converter. These are available at most auto parts stores or thru RIVCO Products. NOTE: If your trailer uses more than two (2) incandescent tail light bulbs the use of a trailer wiring isolator is strongly advised as this additional load is too much for the motorcycles wiring to support and may cause damage to the electrical system. Trailer wiring isolators are available although not as common in auto parts stores and are also available thru RIVCO Products. If you are installing both you must first install the 5 to 4 wire converter then the isolator then to the trailer plug.

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Honda Valkyrie Air Horns Installation Instructions

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Filed Under (Honda) by admin on 29-12-2010

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Horns: Remove the stock horn by unplugging the wires and removing the 12mm acorn nut. This will leave an 8mm stud exposed. Notice in the hardware kit there are two brackets supplied. Locate the “L” bracket with a tab welded to it. Place the end with an angle cut close to the hole over the stud and secure with the acorn nut see photo(1) . Bolt the horn set to this bracket using the 5/16 ” x ¾” bolt and lock washer. ( NOTE: When installing with “Baker” air wings use the additional bracket, bolt & nut supplied to move the horns forward to clear the air wings) . Hose and wires: Plug the long hose into “Y” fitting on the horn set, plug the gray cord into original horn wires, and wrap the connections with electrical tape. Route both under fuel tank then back to right side cover go behind the ignition switch and between the frame rails. (A piece of stiff wire pushed from the back of the fuel tank to the front will make this much easier, Tape the wires and hose to this wire and pull back through. ) Wiring: See photo (2) Install white wire on compressor (­) terminal. Install red wire onto the compressor (+) terminal. Push hose onto compressor air fitting. Attach compressor to frame tube as shown with hose barb and mounting bolt tab straddling the frame using the two long cable ties provided. NOTE: Be sure air hose is not pinched or kinked. Attach gray cable wire terminal ends to relay terminals #85 and #86. (see wiring diagram) It doesn’t matter which wire goes to which terminal. Attach red wire to one of the remaining relay terminals. Attach the fuse wire to the remaining terminal of the relay. Remove the 1″ x 3″ black plastic cover from the main fuse holder (see photo 2A) . Attach the opposite end of the fuse to the upper­most screw. Re­install the cover. Attach white ground wire to side cover mount ing stud as shown in photo #2B

NORTON LIGHTWEIGHT TWIN ELECTRONIC IGNITION Installation Instructions

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Filed Under (Norton) by admin on 31-10-2010

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1. All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation. 2. Remove the petrol tank and/or seat to gain access to the ignition coils, condensers and wiring. 3. For safety, disconnect the battery (preferably both terminals). 4. Remove timing cover. 5. Disconnect the two wires (usually black-white & black-yellow) and remove the contact-breaker plate. At the other end, these two wires must be disconnected from the ignition coils & condensers. The condensers are no longer required and can be removed. They should not be connected to the electronic ignition system. 6. Remove auto-advance unit. 7. Disconnect the remaining wires from the ignition coils. These come from the ignition switch supply. The colour of this ignition supply wire may be different on some machines; if so check using a test lamp or meter to find the live wire when the ignition is switched on. 8. Find a suitable place for the ignition module, preferably near to the ignition coils. Secure the ignition module to the frame using one or more large cable ties. An adhesive mounting base is provided; this can be affixed to the underside of the module and the cable tie passed through and around the module and frame. Do not completely wrap the module in foam rubber. 9. Using the black coil link wire, connect the negative (—) terminal of one ignition coil to the positive (+) terminal of the other ignition coil. See figs. 1/2 on page 7. • BLACK COIL LINK WIRE • RED EARTHING WIRE • CRIMP CONNECTORS & INSULATORS • LARGE & SMALL CABLE TIES • CABLE TIE ADHESIVE MOUNTING BASE 3 10. Take the black wire from the ignition module, cut to length and fit an insulator and female spade connector to the end. Connect to the negative (—) terminal on ignition coil #2. See figs. 1/2 on page 7. 11. Take the red wire from the ignition module, cut to length and fit an insulator and female spade connector to the end. Connect to the positive (+) terminal on ignition coil #1. See figs. 1/2 on page 7. 12. For NEGATIVE EARTH electrics go to step 15. 13. For POSITIVE EARTH electrics (standard): Take the white wire from the ignition module, cut to length and fit an insulator and male spade connector to the end. Connect to one of the negative ignition feed wires previously removed in step 7. The other wire (if fitted) is spare and should be covered with insulation to prevent shorting to the frame etc. 14. Take the red earthing wire, fit an insulator and female spade connector on one end and connect to the positive (+) terminal on ignition coil #1. Cut to length and fit a ring terminal on the other end and connect to a good earth point on the frame, ideally the battery positive (+) terminal. See fig.1 GOTO STEP 17.

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TRIUMPH TWIN CYLINDER MOTORCYCLES WITH POINTS IN THE SIDE CASING INSTALLATION INSTRUCTIONS

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Filed Under (Triumph) by admin on 30-10-2010

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1. All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation. 2. Remove the petrol tank and/or seat to gain access to the ignition coils, condensors and wiring. 3. For safety, disconnect the battery (preferably both terminals). 4. Remove timing cover. (The Atlas engine has the points housing behind the cylinder head). 5. Disconnect the two wires (usually black-white & black-yellow) and remove the contact-breaker plate. At the other end, these two wires must be disconnected from the ignition coils & condensors. The condensors are no longer required and can be removed. They should not be connected to the electronic ignition system. 6. Remove auto-advance unit. 7. Disconnect the remaining wires from the ignition coils. These come from the ignition switch supply. On the Norton Commando, remove the white-blue wire from the ballast resistor between the two ignition coils; the ballast resistor is no longer required. The colour of this ignition supply wire may be different on some machines; if so check using a test lamp or meter to find the live wire when the ignition is switched on. 8. Find a suitable place for the ignition module, preferably near to the ignition coils. Secure the ignition module to the frame using one or more large cable ties. An adhesive mounting base is provided; this can be affixed to the underside of the module and the cable tie passed through and around the module and frame. Do not completely wrap the module in foam rubber. 9. Using the black coil link wire, connect the negative (—) terminal of one ignition coil to the positive (+) terminal of the other ignition coil. See figs. 1/2 on page 7. 10. Take the black wire from the ignition module, cut to length and fit an insulator and female spade connector to the end. Connect to the negative (—) terminal on ignition coil #2. See figs. 1/2 on page 7. 11. Take the red wire from the ignition module, cut to length and fit an insulator and female spade connector to the end. Connect to the positive (+) terminal on ignition • BLACK COIL LINK WIRE • RED EARTHING WIRE • CRIMP CONNECTORS & INSULATORS • LARGE & SMALL CABLE TIES • CABLE TIE ADHESIVE MOUNTING BASE 3 coil #1. See figs. 1/2 on page 7. 12. For NEGATIVE EARTH electrics go to step 15. 13. For POSITIVE EARTH electrics (standard): Take the white wire from the ignition module, cut to length and fit an insulator and male spade connector to the end. Connect to one of the negative ignition feed wires previously removed in step 7 (white-blue wire for Norton Commando). The other wire (if fitted) is spare and should be covered with insulation to prevent shorting to the frame etc. 14. Take the red earthing wire, fit an insulator and female spade connector on one end and connect to the positive (+) terminal on ignition coil #1. Cut to length and fit a ring terminal on the other end and connect to a good earth point on the frame, ideally the battery positive (+) terminal. For the Norton Commando, the earth tag on the end of the condensor pack can be used (fit a female spade connector to the end of the red earthing wire). See fig.1 GOTO STEP 17

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