HONDA GL1500 Headlamp Adjustments Manual

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Filed Under (Honda) by admin on 08-04-2011

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Headlamp Adjusting Procedure Tools needed • Long, slender #1 Phillips screwdriver (for adjusters behind the rubber plugs) • #2 Phillips screwdriver (for the other adjuster screw) • 12-inch square of cardboard • Flat wall or garage door • Paper, tape, marker NOTE: All adjustments are very fine. You have to turn the screws A LOT to see changes in adjustment. This procedure is best done after dark, because you will need to do some test rides. Preparation 1. Set the bike on its center stand, 10 feet away from an unobstructed wall or garage door, and square to the wall or door. 2. Remove the front fairing cover and lower vent grille to gain access to the headlamp adjusters. 3. Idle the engine or connect a battery charger to the battery, to prevent battery drain. Headlamp assembly viewed from the front, showing positions of mirrors and adjusters (pretend the lens has been removed) . Low Beam Vertical Alignment 1. With the lights on low beam, cover the right half of the lamp assembly with the cardboard square, so only the left bulb is shining on the wall. 2. Using a marker, mark the top of the left low beam on the wall (use paper taped to the wall if you don’t want to mark the wall itself) . 3. Move the cardboard so it blocks the left bulb, so only the right bulb is shining on the wall. 4. The top of the right low beam should be even with the mark you made for the left low beam. If it’s not, adjust by turning the screw behind the rubber plug at the top of the lamp assembly, using a long, slender #1 Phillips screwdriver. 5. Move the cardboard back and forth between the bulbs to verify that the low beams are at the same height. On high beam, the two hotspots should line up vertically. High Beam Vertical Adjustment 1. With the lights on high beam, note the position of the beams’ hot spots on the wall in relation to the mark you made in step 5 above. 2. Most owners complain about their low beams being too low on the roadway. To correct this, lower the high beams by turning the screw behind the rubber plug at the bottom of the headlamp assembly, using a long, slender #1 Phillips screwdriver. You can watch the high beam hot spot being lowered on the wall in relation to the mark you made. 3. Take a test ride. Get out on a dark street, and adjust the high beams using the dash knob until you like what you can see. Then switch to low beam and see how that looks. 4. Repeat these steps until you get the low beam pattern you want. Left/Right Adjustment 1. Back to the wall. Set the bike on its center stand at a distance of 25 feet from the wall and square to the wall. Center the front wheel. 2. Shine the high beams on the wall. 3. Step to the back of the bike, and level your eye with the center of the passenger backrest. Use the center of the backrest and the center of the windshield like a gunsight. The center of the hotspot of the high beam should hit the wall in this line. 4. Adjust by turning the uncovered screw at the bottom of the headlamp assembly, using a #2 Phillips screwdriver.

HARLEY DAVIDSON AUXILIARY BRAKE/RUN/TURN SIGNAL CONVERTER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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. Disconnect the battery cables, negative side first. 2. Remove the seat according to the procedures in the applicable Service Manual. NOTE Federal regulations require that red turn signal lenses need to be a minimum of 4 inches from the tail or stop lamp, edge to edge. In order to ensure this spacing requirement, new directional stand-offs are provided in kit and must be used to replace the original (stock) directional stand-offs. To install the new directional stand-offs, perform the following. 3. See Figure 1. Insert a small screwdriver into middle hole (1) of license plate light cover assembly (2). Push forward to release tail lamp spring clip. -J03679 1 of 4 2 1 is01493 1. Middle hole 2. License plate lamp assembly Figure 1. Removing Tail/Stop Lamp Assembly 4. See Figure 2. Lift tail lamp assembly upward and disconnect tail lamp connector (1). Disconnect left (2) and right (3) turn signal 2-place connectors. 5. See Figure 3. Remove two left side fender support front socket head screws (1). Save hardware for installation. 6. Remove left fender support capscrew (2) (under fender) near end of support and washer (3). Remove capscrew (4) at approximate midpoint of fender support and washer (5). Save hardware for installation. 7. Remove directional lamp screw (6) and washer (7). NOTE Prior to removing turn signal wires, carefully note routing. In particular, pay close attention to the locations of cable straps which must be replaced. 8. Carefully remove fender support (8), turn signal lamp (9) and directional lamp support (10) along with wiring through elongated hole in fender (11). Discard directional lamp support and cap screw. Save turn signal lamp for installa- tion. 9. Perform Steps 5 through 8 for the right fender support and signal lamp assembly. NOTE At this point, the two turn signal pin terminals must be removed from the two-place connector in order to remove the turn signal and directional stand-off from the fender support. The pin terminals will be re-installed to the connector after routing wiring through new directional stand-off and installing stand-off and turn signal to fender support. Follow the instructions under AMP MULTILOCK CONNECTORS in the applicable Service Manual to remove the pin terminals from the two-place con- nector. 10. See Figure 3. Obtain new directional stand-off and cap- screw from kit. Route wiring from turn signal lamp (9) through new directional lamp support (10) and elongated fender support hole (11). Install capscrew (6) through fender support, new directional lamp support then into turn signal. Tighten capscrew securely. 1 3 2 is 01494 1.4-place tail/stop lamp connector 2. Left turn signal 2-place multi-lock connector 3. Right turn signal 2-place multi-lock connector Figure 2. Disconnect Tail Lamp and turn Signal Connectors 11. Perform step 10 for the right side

HARLEY DAVIDSON FRONT AND REAR FENDER TIP TRIM INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation GENERAL The original equipment (stock) fender tip lamp assemblies must be removed and the wire(s) must be unplugged or removed as specified in the following instructions. FRONT FENDER TIP REMOVAL OF STOCK FRONT FENDER TIP LAMP ON 1994 AND LATER FLT MODELS 1. Refer to the applicable FLT Service Manual. Remove headlamp assembly with housing. 2. Locate the 3-place connector [32 in wiring diagram] through which 12vdc and electrical ground are connected to the fender tip lamp assembly. The connector locations are as follows: FLTC Ultra: Under fuse and circuit breaker block FLHT/C/C-U: On bottom of left outer fairing bracket FLHR: On left front above air suspension valve NOTE Before disassembling the connector in the next step, refer to the applicable wiring diagram and check wire colors and connections to assure that connector [32] has been located. 3. Refer to the “DEUTSCH ELECTRICAL CONNECTOR” section in the FLT Service Manual and remove the leads, connected to the fender tip lamp, from the socket half, connector [32B]. 4. Insert a small screwdriver blade in rectangular slot at top center of fender tip lamp lens and gently pry lens from lamp. 5. Remove two screws and nuts that fasten fender tip lamp assembly to front fender. Gently remove the lamp assembly taking care not to damage wires connected to lamp assembly. 6. Reach under left side of fender and gently pull wires through rear hole in left side of fender and then through clips on left side of fender and finally through front hole and out of trim strip. REMOVAL OF STOCK FRONT FENDER TIP LAMP ON 1993 AND EARLIER FLT MODELS, FLSTC AND FLSTN 1. Insert a small screwdriver blade in rectangular slot at top center of fender tip lamp lens and gently pry lens from lamp. 2. Remove two screws and nuts that fasten fender tip lamp assembly to front fender. Gently remove the lamp assembly taking care not to damage wire connected to lamp assembly. 3. Unplug wire connector located about 3 in. from lamp assembly. Cover the socket half of connector (connected to motorcycle wiring) with electrical tape. INSTALLING FRONT FENDER TIP TRIM FROM KIT-ALL MODELS 1. Position fender tip trim over holes in fender and guide outer ends of fender tip trim into trim strips on sides of fender. 2. Insert studs on fender tip trim through holes in fender and secure with locknuts included in kit. Tighten locknuts to 6 in-lbs . REAR FENDER TIP REMOVAL OF STOCK REAR FENDER TIP LAMP ON ALL MODELS Follow steps 1 through 3 given above for “1993 AND EARLIER FLT MODELS, FLSTC & FLSTN” INSTALLING REAR FENDER TIP TRIM FROM KIT-ALL MODELS 1. Position fender tip trim over holes in rear fender. 2. Insert studs on fender tip trim through holes in fender and secure with locknuts included in kit. Tighten locknuts to 6 in-lbs

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HARLEY DAVIDSON HERITAGE SOFTAIL WIND DEFLECTORS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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This kit is designed for 1986 and later FLSTC, FLST, FLSTF and FLSTN model motorcycles equipped with a windshield and/or passing lamps. If your FLST, FLSTC, FLSTF or FLSTN is equipped with a windshield but not a passing lamp assembly, you will need two washers 5/16 x 1 x 1/8 in. (HD Part Number 6645). These washers will be used as spacers for the bottom of the deflector. This kit is also designed to fit with accessory five gallon Fat Bob Gas Tanks. Installation 1. See Figures 1 and 2. On Rigid Mount Windshields, remove the bolts (1), lockwashers (2), and flat washers (3) securing one side of the windshield support bracket. Save all hardware for reinstallation. NOTE On Rigid Mount Windshields, be sure the large spacer (4) between the tip of the windshield support bracket and the fork stays in position. On Detachable Windshields, remove the bolts (1) and flat washers (2) securing one side of the windshield support bracket. Save all hardware for reinstallation. 2. Place the wind deflector in position and install the hardware removed in Step 1. Do not tighten the bolt at this time. NOTE On Rigid Mount Windshields, be sure you install the large spacer between the windshield support bracket and the fork. NOTE On 2000 and later models, be sure the wind deflector is outside of the windshield docking points. 3. Position the wind deflector parallel with the fork leg and install the other flat washers, lockwashers and bolts. Do not tighten the bolts at this time. NOTE If you have a motorcycle equipped with a windshield, but no passing lamps assembly, use the washer (6645) to space the deflector away from the fork leg. 4. Position the wind deflector so it does not touch the bottom of the windshield or the turn signal. The deflector bolt holes are slotted for th is purpose. 5. When the deflector is correctly positioned, tighten the bolts to 17 ft-lbs (23 Nm). 6. Repeat steps 1-5 for the opposite side of the vehicle

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HARLEY DAVIDSON TRI-BAR AUXILIARY RUNNING LIGHT/ BRAKE LIGHT ASSEMBLY REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2011

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REMOVAL 1. Remove the saddlebags and left side cover. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Remove the main fuse. 3. See Figure 1. Remove six flange nuts (1) from the right and left fender stud plates (2). 1 2 3 5 4 is04366a 1. Nut 2. Stud plate 3. Rear fascia 4. TORX screw 5. Lamp assembly Figure 1. FLHX Rear Fascia and Lamp 4. On the left side of the motorcycle, loosen the set screw and unscrew the radio antenna mast. 5. Gently open the adhesive conduit at the split line to release the rear fascia light harness. 6. At the rear of the motorcycle, spread the top of the fascia to release from the top studs at the side of the fender and then pull the bottom in a downward direction to release the fascia from the fender. If necessary, gently wiggle the fascia while pulling. 7. 2006-2008 models only: On the left side of the motorcycle, remove the bolt (with flat washer) to remove the passenger seat strap and saddlebag front mounting bracket from the chrome frame tube cover. 8. Remove the screw and chrome frame tube cover. NOTE ALL models: Make note of the wire routing and location of all cable straps. New light wiring installs the same way. 9. See Figure 2. Release the rear fascia light wires from the wire clip (1). Cut the cable straps (2) to release the rear fascia light harness (3) and radio antenna cable. 10. 2006-2008 models: Disconnect the rear fascia light connector [12B] located inboard of the upper frame tube. 2009 and later models: Disconnect the rear fascia light connector [12B] located to the rear of the fuse panel. 11. See Figure 1. Remove the two T-20 TORX® screws to release the light assembly from the fascia. Save the screws for installation of the new light. 1 3 4 2 is04378 1. Wire clip 2. Cable strap 3. Fascia light harness 4. Flange nut Figure 2. Rear Fascia Light Harness INSTALLATION 1. Route the rear fascia light wires forward through the cable clip at the top of the radio antenna bracket and then upward in front of the saddlebag rear mounting bracket to the inboard side of the upper frame tube. 2. 2006-2008 models: On the inboard side of the upper frame tube, mate the pin and socket housings of the rear fascia light connector [12]. 2009 and later models: To the rear of the fuse panel, mate the pin and socket housings of the rear fascia light connector [12]. 3. Using the slotted hole, install a new cable strap to secure the rear fascia light wires and radio antenna cable to the rear fender support. 4. Install a new cable strap to secure the rear fascia light wires and radio antenna cable to the shoulder of the upper frame tube (just in front of the air valve mounting bracket).

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HARLEY DAVIDSON AUXILIARY LAMP WITH CLEAR LENS AND VERTICAL REFLECTOR OPTICS INSTALLATION MANUAL

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

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1. Disconnect the battery cables, negative cable first. 2. See Figure 1. Remove passing lamp molding screw (1) and nut (2) from passing lamp molding (3). Remove molding and hardware. Retain for future use. 3. Disconnect the wire harness plug from back of auxiliary lamp assembly (4). 4 See Figure 2. Remove assembly (1) and nesting ring (2). Discard lamp but retain nesting ring. 5. Place the nesting ring at back of new lamp with concave side facing away from lamp. Install new harness provided in kit. Attach leads to the wires inside the lamp hous- ing. 6. Connect new wire harness to the new lamp. Locate lamp in housing and be sure to align tabs on lamp (3) with pockets in the nesting ring. 7. Install passing lamp molding over lamp. Rotate lamp molding so that screw is centered at bottom. Install nut and screw and secure until snug. 8. Repeat for the lamp on the opposite side. 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) 9. Connect the battery cables, positive cable first. 10. Test the auxiliary lamps for proper operation. If necessary, aim the lamps (see AUXILIARYLAMPS, ADJUSTMENT in the Service Manual), and tighten the lamp mounting nuts

HARLEY DAVIDSON SMOKED AND CLEAR FENDER TIP LENS KITS Preparation MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) 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. Disconnect the battery cables, negative cable first. 2 . See Figure 1. Insert blade of small screwdriver into slot at top of front fender tip lamp lens (2). Rotate end of screwdriver to unsnap lens from lamp bracket. Repeat for rear fender tip lamp lens. 3. Remove bulb (3) from socket (4). 4. From the kit, find the LED marked “Amber” (5) and install into front fender tip lamp assembly.lamp socket. 5. From the kit, find the LED marked “Red” (5) and install into rear fender tip lamp assembly.lamp socket. Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 6. Connect the battery cables, positive cable first. 7. Apply power and check for proper function of front and rear fender tip lamps

HARLEY DAVIDSON LED TAIL LAMP WITH BAR AND SHIELD LOGO INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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INSTALLATION For models WITH maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and maxi-fuse. Retain all seat mounting hardware. For models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. NOTE Figure 1 shows the original equipment tail/stop lamp mounted to a full fender. The lamp is rotated 180° when mounted to a Bobtail fender. 2. See Figure 1. Loosen the two Phillips head screws (2) retaining the tail/stop lamp assembly (1) to the lamp base (3), and pull the lamp assembly away from the base. 3. Depress the locking tab (button), and disconnect the tail/stop lamp four-way Multilock socket housing [93B] (4) from the circuit board. Remove the lamp from the vehicle. 3 1 4 2 is02969 1. Tail/stop lamp assembly 2. Tail/stop lamp retaining screw (2) 3. Tail/stop lamp base 4. Tail/stop lamp connector [93B] Figure 1. Removing the Tail/Stop Lamp Assembly 7 6 2 5 1 3 4 is02970 1. Socket housing 2. Secondary lock 3. Locking tab (button) 4. Cavity 5. Socket terminal 6. Slot 7. Crimp tails Figure 2. Socket Terminal Installation 4. On the new tail/stop lamp assembly, the Blue wire and socket terminal are not installed in the four-way socket housing. Refer to the original lamp removed in Step 3, and observe which cavity contains the Blue wire. Note that the cavities are numbered on the face of the secondary lock. The Blue wire and terminal must be

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HARLEY DAVIDSON PASSING LAMP TRIM RINGS INSTALLATION INSTRUCTIONS

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

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1. Loosen the screw from one original equipment passing lamp trim ring and remove the ring. 2. See the Service Parts illustration. Remove the screw (3) and nut (2) from the accessory trim ring (1) and set aside temporarily. 3. If not already installed, place the rubber strip (4) inside the trim ring. Align so the gap in the rubber strip is opposite the split in the trim ring as shown. 4. Insert the passing lamp sealed unit (C) inside the new trim ring and rubber strip assembly. NOTE Rotating the lamp unit may help insertion. 5. Position the bottom of the lamp unit to line up with the split in the trim ring. 6. For 2002 and later models Install the adapter ring (D) onto the passing lamp housing, lining up the tab on the ring with the notch in the lamp housing. Install the trim ring and lamp assembly onto the adapter ring, aligning the lug (or lugs) on the back of the glass lamp unit with the notches in the adapter ring. For 1962 through 2001 models Install the trim ring and lamp assembly onto the passing lamp housing, aligning the lug (or lugs) on the back of the glass lamp unit with the notches in the passing lamp housing. 7. Assemble the screw and nut to the trim ring and tighten securely. 8. Perform steps 1 through 7 for the second passing lamp. SERVICE PARTS 4 2 B C F H 3 G E 1 A D

1999-2002 Indian Motorcycle Mirror Housing Removal and Replacement

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

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1. Remove seat. 2. Disconnect battery. 3. Remove handlebar cover on top-center of handlebar. 4. Remove left-side clutch-bracket assembly. This exposes an access hole on the underside of the handlebar. 5. Pass the end of the Signal® mirror wires through one of the small holes located on the underside of the clutch-bracket assembly housing. 6. Take piano wire/fish tape and insert at the access hole located on the underside of the handlebar to the center of the handlebar (center handlebar cover removed). 7. Fasten the end of the Signal® mirror wires to the piano wire/fish tape and pull through the handlebars to the center opening. 8. Pull excess wire through the handlebars leaving approximately 2″ of extra wire at the mirror side. 9. Re-assemble clutch-bracket assembly allowing the Signal® mirror wire to wrap around the outside edge of the cover assembly into the underside access hole. Secure Signal® mirror with enclosed 1.5″ long 5/ 16 ” – 24 Allen head bolt. 10. Loosen throttle assembly side and slide back to expose access hole. DO NOT REMOVE THROTTLE ASSEMBLY. Proceed to pass the Signal® mirror wire through the handlebar at the opposite side and re-assemble the throttle assembly. 11. Run both sets of wires under the fuel tank along the topside of the frame to the battery compartment. 12. Connect both black wires to the enclosed ring connector for connection to the battery ground terminal. 13. Locate the male/female electrical connector that is located behind the battery. This wiring assembly is for your tail lamp assembly for braking and turning (see photo). 14. Make sure the harnesses are routed securely to the wire connectors and enough slack is left for splicing or soldering. Cut the heat shrink into (4) equal pieces (approx. 2″ each). 15. Slide the heat shrink over the passenger side Signal® mirror wire. Solder the Right Signal® mirror wire to the Brown wire. Slide the heat shrink over to cover the soldered area. Heat the shrink tube into place with a heat shrink gun or hair dryer. 16. Repeat sliding the heat shrink over the driver side Signal® mirror wire. Solder the Left Signal® mirror wire to the Purple wire. Slide the heat shrink over to cover the soldered area. Heat the shrink tube into place with a heat shrink gun or hair dryer. 17. Connect ground and positive battery connections. 18. Re-install seat.

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