Filed Under (Kawasaki) by admin on 05-05-2012
Remove plastic center cap on steering wheel by prying off with a small screwdriver. Remove steering wheel nut and remove steering wheel by pulling up on wheel. If wheel is tight have a partner tap on the shaft while pulling up on wheel. Note: Do not mushroom threads on shaft. Remove all screws that retain dash to body of vehicle. Disconnect all electrical connections at back of dash. Mark all wires to ensure easy install. Remove lower steering shaft bolt at rack and pinion. Remove upper bolt at base of steering column. Remove the 2 bolts that retain the steering column to the frame and remove the column and the shaft assembly. Remove lower u-joint on steering column shaft & replace it with supplied u-joint. There is a welded wire retainer on the lower dash tube where the electric motor will sit. You will need to grind off this piece and smooth. Remove the master cylinder bolt closest to the driver side and discard bolt. Your motor and module has been shipped together bolted to the bracket. It is important to follow the install sequence to ensure a proper installation. The lower shaft on the steering motor is marked on the shaft and on the motor. These marks must not be changed. If you remove the shaft it needs to be installed back in the same spot.
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Filed Under (Harley Davidson) by admin on 03-04-2012
POWER & SPEAKER HARNESS INSTALLATION- (Read electrical connections prior to connecting center power and ground wires) 1. Disconnect battery (negative cable first!) 2. Remove outer faring cover 3. Route long speaker wires from fairing area through tank channel to seat area. 4. Route one pair of speaker wires under each fender strut support; purple and purple and black wires to the right and green and green and black wires to the left. AMPLIFIER INSTALLATION- 1. Factory installed electronics will determine suggested placement of amplifier. 2. Position and attach amplifier to outer fairing support bars with supplied wire ties. (Electra/Ultra/Street Glide) BAGGER AUDIO™ LIDS INSTALLATION- Detach factory lid by removing the 2 screws holding the factory strap to inner lid and 5 small torque screws holding lid to factory latch assembly. (Consult factory service manual for further instructions) Remove metal strap from behind factory seal (This is the metal strap that the previous 5 small torque screws were removed from) Position metal strap in same location on your new lid. (If you purchased your product unpainted, you must install the supplied seal to your finished lid) Reattach BAGGER AUDIO™ LIDS by installing the 5 small torque screws in the same location as on the factory lid. (We suggest that you have an assistant hold the lid in place while attaching your new lids) Replace factory nylon Hinge straps with new nylon straps supplied in kit. Use metal straps and machined screws to secure the nylon hinge straps.
Place a small bead of silicone on the inside rim of the speaker basket to create a watertight seal between the inside of the lid and the speaker.
Install speaker into the bottom of the lid (not through the top opening) with supplied stainless screws and washers (4 per lid). Be sure to center speaker in lid opening to ensure proper speaker grill placement. Install speaker with terminals facing toward the front of the lid. One 1/4″ hole must be drilled in each bag. Holes can be positioned at the ownerʼs discretion. Place rubber grommet in drilled hole before running wires
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Filed Under (Suzuki) by admin on 21-02-2012
The first thing to do is remove the seat, fuel tank, and possibly the front fairing if equipped. You will need plenty of room to work. Electrical Connections – You will need to locate and test a few things on your bike before you start wiring. A good ground, an ignition switched 12 volt power source, the horns, and the ignition coils. We have plug n play style harnesses available for some bikes. Check the web site for specific models. Control Box Wiring Coils – Most four cylinder motorcycles use either a individual firing system or a waste spark system. Waste spark is by far the most common. All four cylinder bikes with only two coils use a waste spark system. Most late model four cylinder sport bikes use waste spark systems even though they have four individual coils. Bikes with a waste spark systems will need the 360 calibrated unit. The 360 calibrated Sport Bike Autoshifts are identified by the 360 engraved into the box below the wire lead exit. The P/N for these boxes has the 360 as a suffix. (P/N 1-0299-360) Some of the newest fuel injected bikes (Hayabusa, GSXR1000, ZX12) that have cam sync sensors are individual firing. These bikes will require 720 calibration and will have no outside identifiers and the P/N 1-0299. The Sport Bike Auto Shift has four brown wire leads that are connected to the negative of each individual coil on a four coil system. You will notice that the connector for the four brown wires has a molded in ridge that marks the brown wire that is used as the rpm sensor. This must be connected to the number one cylinder coil negative wire.
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Filed Under (Honda) by admin on 15-12-2011
Hi/Low Switch Installation Choose a location for the switch, which is convenient and has sufficient rear clearance for the electrical connections and is within 18″ of a voltage-controlled wire (a wire in the lighting circuit). Drill a 1/2″ (13mm) hole and install the switch from the back. Leave the strain relief nut on the switch. On the front install the Hi/Low indicator tab and secure the switch and tab using the metal nut. The amount of switch barrel protruding can be adjusted by moving the strain relief nut. Wire Routing and Connections Route the electric cord along the handlebar to switchmarea and secure with supplied tie wraps, electrical tape, or both. Cut and strip to proper length. Attach a ground wire of sufficient length to go from the red wire to a good ground. WARNING: Lead wire slack in the area of the throttle must be neither excessive nor tight. Ensure no binding occurs when the throttle is open fully.,Soldering connections is the most durable method, but the following will provide years of service. Attach the 1/4″ female slip-on connectors to the white and blue wires and #10 ring terminal to warmer leads as shown in Figure 2. (A crimping tool works best, but a Vise Grips or pliers will work). Figure 2. Switch Connections (Option B) Connect the single yellow or red wire to a regulated (lighting) circuit using Option A (ATV has a switch in a lighting circuit with a 1/4″ tab) or Option B: Option B: Locate a power wire (usually yellow) leading to a headlight, taillight, or dash light (Figure 2). Using the red tap connector, place this power wire into the continuous channel and insert the red wire (do not strip insulation) completely to stop in the second channel. Make the connection by squeezing (w/pliers) the metal contact until flush with the top of the connector. Close the hinged cover until latched. Complete connections to switch and ground circuit.
Filed Under (Toyota Manuals) by admin on 21-06-2011
1) Disconnect negative battery cable. Remove air cleaner case
with air intake hose. Remove cruise control actuator. Remove clutch
release cylinder with hose attached and secure aside.
2) Remove starter. Disconnect necessary ground straps,
electrical connections and control cables from transaxle. Remove upper
transaxle mounting bolts from cylinder block.
3) Raise and support vehicle. Remove front wheels. Remove
lower engine covers. Drain transaxle fluid. Remove axle shafts from
transaxle. See appropriate AXLE SHAFTS article in AXLE SHAFTS &
TRANSFER CASES section. Remove stabilizer bar mount and bushing from
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Filed Under (Harley Davidson) by admin on 05-03-2011
REMOVAL Remove Pillion and Rear Fender NOTE If possible, lift the rear of the motorcycle up so the rear wheel drops to the bottom of shock travel. This will help provide clearance between the rear tire and fender when installing the mounting brackets. 1. Open the rider seat. 2. See Figure 1. Remove rider seat post (1), nut (2), and washer (3) from passenger pillion. Slide grabstrap (4) forward off pillion. Save mounting hardware for kit installation. 3. Push passenger pillion forward to release slot on bottom of pillion from post on fender tongue. 4. See Figure 2. Lift pillion up to remove lanyard (1) from hole in center of passenger pillion (2). Then lift pillion away from motorcycle. 5. Disconnect turn signal and tail light electrical connections from back of rear electrical caddy. Note position for later installation. 6. See Figure 3. Unsnap rear electrical caddy (1) from rear inner fender. 7. Remove and save two fender support bolts (2), washers (3), and grabstrap (4) from rear fender. 1 2 3 4 is03548 1. Rider seat post 2. Nut 3. Washer 4. Grabstrap Figure 1. Passenger Pillion and Mounting 2 1 3 i03571 1. Seat lanyard 2. Hole in pillion 3. Passenger pillion Figure 2. Seat Lanyard and Passenger Pillion 8. Remove four remaining fender support bolts (2) and washers (3) near center of rear fender. 9. Remove rear fender from vehicle. 3 2 4 2 3 2 3 1 is03544 1. Rear electrical caddy 2. Fender support bolt (6) 3. Washer (6) 4. Grabstrap Figure 3. Grabstrap, Rear Electrical Caddy, and Fender INSTALLATION Install Attach/Release Weldment, Rear Fender, and Grabstrap NOTE Apply Loctite 243 (blue) to last four threads of leave-on bracket screws. 1. See Figure 4. Install leave-on bracket (1) to outside surface of inner fender using two button head screws (2) and nuts (3). Tighten screws to 48 Nm (35 ft-lbs). Repeat for opposite side. 2. See Figure 5. Install release/attach weldment (1) to leave- on brackets (2) using two washers (3) and socket head cap screws (4). Tighten screws to 25 Nm (18 ft-lbs). Repeat for opposite side.
Filed Under (Triumph) by admin on 30-10-2010
1. Remove OEM Tail Unit from Motorcycle (ref: underside four socket head bolts). 2. Disconnect all electrical connections (ref: Turn indicators & License light). 3. Remove Turn indicators from OEM Tail unit and install on to Skyking Products License Plate Relocation Assembly using OEM hardware. 4. Remove License light from OEM Tail unit and install on to Skyking Products License Plate Relocation Assembly using OEM hardware. 5. Reconnect all electrical connections. Install wire loom for connector protection and secure with tie wraps . (ref: Turn indicators & License light). 6. Install Skyking Products License Plate Relocation Assembly using OEM hardware. 7. Double check all hardware and electrical are secure. 8. Check proper operation of Turn indicators and license light. 9. Test ride and final check proper operation of Turn indicators and license light.
Filed Under (TVS) by admin on 27-10-2010
INSTALLATION 2.1 Initial Setup After receiving the TVS, remove the packaging materials. Remove the wooden skid secured to the base of the unit and inspect all parts for damage. If any parts are damaged contact shipping company to file claim for damaged equipment. Select a location for the unit where adequate service clearance is provided for replacing the media in the unit. The media is removable from either the top, or the 150 mm port located on the side of the unit. Ample clearance (about 0.5 meters) should also be provided for space for media removal by vacuum. (This may be provided by others). 2.2 Electrical Connections (Optional) An electrical wiring diagram may be necessary and included with these instructions. 230/460 volt, 3 phase systems require a motor starter and disconnect. Refer to the wiring diagram for proper wiring connections. Check for proper motor rotation before operating the unit. All external wiring must be in accordance with National and Local Electrical Codes. Pay particular attention to proper grounding of the unit. 2.3 Media Bed Fill the Tank Vent Scrubber as follows: NOTE: Gloves and a dust mask should be worn when handling media. See MSDS sheet for proper handling requirements. 2.3.1 Remove the cover by loosening the bolts on top of the unit. 2.3.2 Inspect the interior of the tank to be certain it is empty. 2.3.3 Close and secure vacuum discharge port. 2.3.4 Select the correct media type and load the tank to a depth of 610 mm. 2.3.5 Replace the cover by securing the bolts on top of the unit. After 48 to 72 hours of operation, open cover and check media level for settlement. Media level must be 152 mm below lip of tank to reach proper fill requirement. Add media as required
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Filed Under (Kawasaki) by admin on 25-10-2010
1. Place the mounting plate into position on the front bumper tube assembly and attach with the four ¼- 20 u-bolts, hex nuts, and lock washers. See the illustration below for detail. 2. Place winch onto the mounting plate and attach with the four 5/16-18 hex bolts and lock washers that came with the winch. See the illustration below for detail. NOTE: There are two sets of mounting holes to accommodate the 3.0ci winch, A2000 and A2500 winches. 3. Tighten all fastners securly at this time. Place the vinyl caps on the ends of the ¼-20 u-bolts, to cover up the sharp edges of the u-bolts that are exposed. 4. Make all electrical connections. Use the winch manuel that came with the winch for instructions to make all electrical connections