Harley-Davidson Amp Module – Base Kit Installation Manual

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Filed Under (Harley Davidson) by admin on 10-03-2012

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Technique for removal of Ampseal contacts from the connector housing (refer to Photos 5 and 6): Grab the wire to be removed (shown in the next section) with needle nose pliers or hemostats. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Photo 5- Pin Removal, Step 1 Photo 6- Pin Removal, Step 2 End of Removal Technique Installing Kennedy Harnesses part #85910 and 85911 Locate Kennedy harnesses part #85910 and 85911 and 5 pieces of 1/8″ diameter x 2″ shrink-wrap, from kit part number 85615-10. Refer to Figure 1 (Pre-’06) and Figure 1a (2006 and Newer) on the next page, and make the connections between Ampseal connector 28B and Kennedy harness 85910, and harness 28B and Kennedy Harness 85911.

Harley Davidson MC/ MIC HARNESS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2012

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Use the diagonal cutters and razor blade to cut any tie wraps or harness coverings away from the harness connected to C28. At least 3 ” of wire must be unsheathed. Use a 1/16″ wide blade flat screw driver to push the Ampseal connector wedge lock tabs away from the red wedge lock as shown in Photo 3. Pull the wedge lock up as shown in Photo 4. The wedge lock should never be removed from the housing for insertion or removal of the contacts. Photo 3 – Connector Disassembly Step 1 Photo 4- Connector Disassembly Step 2 Technique for removal of Ampseal contacts from the connector housing (refer to Photos 5 and 6): Grab the wire to be removed with needle nose pliers or hemostats. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Photo 5- Pin Removal, Step 1 Photo 6- Pin Removal, Step 2 End of Removal Technique
3 of 5 Document part number: 65298R2 Installing Kennedy Audio Interface Harness part #85582 Locate Kennedy harness part #85582 and 3 pieces of 1/8″ diameter x 2″ shrink-wrap. The sequence for installing the harness is: Locate and remove the appropriate contact from the Ampseal connector (refer to Figure 1, below). Place a piece of heat shrink over the corresponding mating pin on Kennedy harness #85582. Press the mating pin and the Ampseal connector contact together (See Photos 7 and 8)

Harley Davidson Motorcycles Hot Grips Installation Manuals

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Filed Under (Harley Davidson) by admin on 23-02-2012

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End weights or other need to open the ends: You may drill out the outboard ends of the grips for installation of end weights or other purpose, if you use a fine tooth hole saw and do not go larger than the handlebar’s inside diameter. We have molded in a visual guide on the grip’s ends, and we recommend 7/8″ or at most 1″ diameter and be sure to center drill carefully. DO NOT use a hacksaw or you will destroy the grip, because there are resistance wires molded into the grip outboard of the handlebar diameter. Some Harley throttle sleeves are molded with raised plastic ribs or ridges to help hold the original Harley grip in place, and these will mate up with four (4) of our internal ribs by sliding our heated handgrip over the sleeve. HOWEVER, there are two axial ribs, which go circumferentially around the throttle sleeve as illustrated below, and they may have to be carefully removed with a knife of razor blade. They must be trimmed off with a file or razor knife until the Hot Grips slides over them. Do not force the Hot Grips over the ridges as the grip cannot stretch and will be damaged if forced on. These Hot Grips® have a heat output of 8 watts on “low” and 15 watts on “high” per grip. As a pair they will consume 20 watts of electrical power on “low” and 30 watts on “high”. They consume more than 8 x 2 on “low” because the resistor consumes a little

KTM Rear Wheel Bearing Installation and REMOVAL

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Filed Under (KTM) by admin on 23-01-2012

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1 Insert a long punch (with a good square edge) into the center of the aluminum wheel bearing spacers and push up against the inner edge of the spacer on the opposite side of the wheel (Fig. 1). 2 Using a hammer, tap the punch around the entire circumference of the spacer until it completely slides out of the bearing (Fig. 2). Turn the wheel over and remove the other spacer in the same way. 3 Use a long screwdriver or narrow pry bar and pry the seals out of each side of the wheel (Fig. 3). 4 Using snap ring pliers, remove the bearing retaining snap ring from either the disc or sprocket side of the wheel (Fig. 4). 5 Insert a long punch (with a good square edge) into the center of the wheel bearing, and push up against the inner edge of the bearing on the opposite side of the wheel. Using a hammer, tap the punch around the entire circumference of the bearing until it completely slides out of the hub. Turn the wheel over and remove the other bearing in the same way. NOTE: It may be necessary to tap on the punch sideways at first to knock the center aluminum sleeve off center so that you are able to get the punch on the edge of the bearing. 6 Clean areas where bearings will be inserted back into hub and apply a thin coat of grease around the machined hub surface. Tap the bearing on the snap ring side of the hub into the machined hub surface, making sure to keep it square with the hub as it goes in and only tap on the outer race of the bearing. Once you get the bearing flush with the outer edge of the hub, use a socket or piece of pipe that is just smaller than the outside diameter of the bearing to finish tapping the bearing into the hub. (Fig. 5)

HONDA CBR 1000 RR ALFANO systems Installation

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Filed Under (Honda) by admin on 26-11-2011

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If the sensor doesn’t start to the passage on the magnetic field, use one or several spacers to bring the sensor closer to the ground. – When fixing the cable with nylon tighten-cables, take care to move this one most possible away of the exhaust Fix the magnetic support (supplied) on one of the arms of the disc brake support with a nylon tighten-cable (see photos). Fix it on the narrowest part of the arm. – With a scorer, draw a feature on the mudguard in front of the magnetic support n this case, install the speed sensor to « 90° ». – Put down the mudguard and fix the speed sensor and its cable with nylon tighten-cables. For that to make, pierce holes of diameter 3mm (to see photos)

2008-2009 HONDA CBR 1000 RR DUAL CANISTER SLIP-ON INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 22-11-2011

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INSURE THE EXHAUST SYSTEM AND EXHAUST COMPONENTS ARE FULLY COOLED. 2. INSURE THE MOTORCYCLE IS STABLE ON KICKSTAND OR REAR CENTERSTAND OR SERVICE TABLE. 3. REMOVE THE 3 PLASTIC BUTTONS HOLDING THE PLASTIC COVER OVER THE EXHAUST SERVO. (THIS IS LOCATED DIRECTLY INSIDE THE RIGHT REAR PASSENGER PEG BRACKET) DETACH THE CABLE END FROM THE SERVOnWHEEL AND REMOVE THE ENTIRE CABLE FROM THE RETAINING CLIP. THE ENTIREnCABLE WILL NOW REMOVE WITH THE REST OF THE EXHAUST.REPLACE THE PLASTIC COVER FOR THE SERVO AND REINSTALL THE 3 PLASTIC BUTTONS. 6. REMOVE THE STOCK MUFFLER MOUNTING BOLT. REMOVE 7. REMOVE THE STOCK EXHAUST CLAMP. (IT IS NOT UNCOMMON FOR THE CLAMP BOLT TO BREAK DURING REMOVAL.)b8. REMOVE THE ENTIRE STOCK EXHAUST ASSEMBLY. BE CAREFUL NOT TO SCRATCH THE SWING ARM DURING REMOVAL. 9. REMOVE THE STOCK EXHAUST GASKET FROM HEADER PIPE IF IT DID NOT COME OFF WITH THE STOCK EXHAUST. THIS GASKET WILL
NOT BE USED. 10. PREASSEMBLE THE HYPERFLO EXHAUST BEFORE INSTALLING. HYPERFLO RECOMMENDS YOU DO THIS PORTION ON CARPET OR A CLEAN PADDED AREA. YOU MAY ALSO USE THE PLASTIC BUBBLE PACKAGING AS A PAD TO PROTECT THE CANISTERS DURING PREASSEMBLY. 11. PREASSEMBLE THE LARGE DIAMETER CAN TO THE S-PIPE FIRST. INSTALL THE SPRING ON THE CANISTER FIRST AND PULL AWAY FROM THE CANISTER TO INSURE YOU DO NOT SCRATCH THE CANISTER

HARLEY DAVIDSON ENGINE-GUARD MOUNTED FOOTPEGS (CHROME WITH RUBBER INSERT) INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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Installation Footpegs must be positioned so rider can operate all foot controls throughout their range of motion without interference. Failure to have full, unlimited access to foot controls could cause loss of control, which could result in death or serious injury. 1. See Figure 1. Remove the bolt (6) and lockwasher (5) from the footpeg assembly (1). NOTE When installing the footpegs on a 1 inch (25 mm) diameter engine guard, use both clamps. . For 1 inch (25 mm) dia. engine guards: Place both the large clamp (2) andthe small clamp (1) around the engine guard as shown. Position the clamps on the straight, upright section of the guard. For 1-1/4 inch (32 mm) dia. engine guards: Discard the small clamp (1). Place the large clamp (2) around the engine guard. Position the clamp on the straight, upright section of the guard. 2. For ALL engine guards: Install two step spacers (4) inside the clamp on either side of the engine guard as shown. 3. Put the lockwasher (5) on the bolt (6). Insert the bolt through the clamp and spacers, and thread into the footpeg assembly as shown. Mount the footpegs so they will not strike the ground during cornering. Footpegs striking the ground during cornering could result in death or serious injury. 4. Position the footpeg for rider comfort, and rotate the footpeg assembly so it folds upward and to the rear. Tighten bolt (6) to 30 ft-lbs (41 Nm) so the footpeg does not rotate on the bar. 5. Repeat Steps 1 through 4 for the right side

HARLEY DAVIDSON BOOM! AUDIO BASS BOOSTER TOUR-PAK PORT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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PREPARATION NOTE For vehicles equipped with security siren: • Verify that the Hands-Free Fob is present. • Turn the ignition key switch to IGNITION. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the owner’s manual and follow the instructions to remove the main fuse. INSTALLATION NOTE The Tour-Pak does not need to be removed from the vehicle to perform this installation. 1. Open the Tour-Pak lid and remove all items from the Tour- Pak base. 2. Models equipped with mat: Remove the mat. Models equipped with liner: Open the map pocket, and remove the acorn nuts with flat washers. Remove the map pocket and liner. 3. Remove four screws from the left-side speaker grille on the Tour-Pak. Remove the speaker grille from the speaker pod. 4. Remove the speaker from the speaker pod. Carefully pull the two socket terminals from the speaker spade contacts. 5. Remove the grommet, and draw the rear speaker/passenger controls connector out of the speaker pod. Separate the connector halves. 6. Repeat Steps 3 through 5 for the right-side speaker. 7. See Figure 1. Get the drill template (3) from the kit. If NOT equipped with power port: a. Remove one speaker pod mounting screw and flat washer. b. Align the drill template on the inside of the Tour-Pak with the speaker pod holes, and hold in place with the mounting screw and washer. c. Repeat for the remaining template mounting holes. If equipped with power port: a. Remove the two screws and flat washers to free the power port from the Tour-Pak. b. Align the drill template on the inside of the Tour-Pak with the power port holes, and hold in place with the mounting screws and washers. c. Repeat with the top speaker pod mounting screw and flat washer. NOTE Tighten the screws enough to hold the speaker pod in place as the pilot hole is drilled. 8. Where indicated on the template, drill a 3/16 inch (5 mm) diameter pilot hole through the Tour-Pak wall and speaker pod. 9. Remove the screws and speaker pod, and set aside. Turn the template over, and repeat Steps 7 and 8 on the left side of the Tour-Pak. NOTE Hole size will affect the fitment of the ports. The hole saw needs to be sharp. 10. Carefully drill a two inch (51 mm) diameter hole with a sharp hole saw, at the pilot location, through each speaker pod and in both locations on the Tour-Pak wall. 11. Temporarily install the Tour-Pak liner (if equipped), and mark the location of the two inch (51 mm) diameter holes on the outside of the liner. Remove the liner, and carefully cut the two holes in the liner front wall

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HARLEY DAVIDSON AILERON HAND GRIPS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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LEFT GRIP REMOVAL AND INSTALLATION 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp, and position the clutch hand lever assembly away from the handlebar. 2. Using a T25 TORX drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left hand grip if so equipped. With “glueless” grip: Remove the grip from the han- dlebar. With glued grip: Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. NOTE Make sure that the handlebar surface and the inside of the new grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) 4. Position the new left grip (4) so the larger diameter portion of the flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8- 9.0 Nm). 9. Using a T25 TORX drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4.0-5.1 Nm)

HARLEY DAVIDSON CHROME FUEL TANK TRIM PANEL INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-02-2011

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INSTALLATION 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat. Retain all seat mounting hard- ware. 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) 2. See the Figure 5. Remove the original fuel filler cap (A) from the tank and set it aside. Obtain a small diameter Harley-Davidson fuel filler cap (B) and screw it into the fuel filler opening. For Model XL883C, or other models equipped with Genuine Motor Parts Large Capacity Fuel Tank 3. To ensure surface cleanliness, clean the top of the fuel tank with a mixture of 50 to 70% isopropyl alcohol and 30 to 50% distilled water. Allow to dry thoroughly. 4. Measure and mark the centerline of the fuel tank, with a wax pencil or water-based marker, at the rear of the tank as shown in Figure 3. Proceed to Step 10. For Model XL1200C 2 1 is 01910 1. Original fuel tank trim panel liner 2. Fishing line (or string) Figure 1. Removing the Existing Trim Panel (XL 1200C) 5. See Figure 1. Insert the fishing line (2) between the rear of the fuel tank and the liner (1) on the underside of the original trim panel. NOTE Raise the ends of the fishing line away from the fuel tank to avoid scuffing the tank finish 6. Using a side-to-side “sawing” motion, work the fishing line toward the front of the fuel tank to break the adhesive bond between the trim panel and the tank. 7. Carefully pull the trim panel and liner off of the tank and discard it. NOTE Be careful not to scratch the paint on the fuel tank when removing the adhesive

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