Harley-Davidson HEAT DEMONS INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 27-03-2012

download
1. Remove the Right Handlebar Control, upper and lower switch housing screws, and Right Grip from the Handlebar according to the service-manual instructions and set aside or leave hanging. Remember to insert a spacer between the rear brake light switch and the lever to keep the switch from being broken. 2. Remove the Left Hand switch housing from the handlebar according to the service-manual instructions. 3. Using a T27 TORX drive head remove the half of the clamp that secures the clutch hand lever to the handlebar and discard. The Heat Demon controller will replace this clamp when finishing the installation. Separate the clutch hand lever assembly from the handlebar and move away from the bar. 4. Mark the location of the Left Grip and remove it by twisting, heating or with air pressure. Almost all grips can be removed without damage. If this does not work it may be necessary to cut the grip for removal. 5. A hole needs to be drilled in the bottom of the handlebar to route the power wires and wires from the Controller. The location of the hole should be in the groove or recess on the bottom of the handlebar under the Left Switch Housing at the end of the groove toward the grip. Start by punching a hole location with a center punch to pierce the chrome. Use safety glasses that completely cover the eyes to protect from steel chips while drilling! Start with a small drill like a 3/32″ size to make the initial hole. Then use progressively larger drills or a step drill to increase the hole size to 5/16″. After the hole is drilled use a round file or deburring tool to remove the sharp edges. 6. Uncoil the plastic snake from the kit and run it from the right end of the handlebar out the left end. Twisting the snake or inserting it vertically versus flat can help to push around the corners. 7. Attach the white and yellow wires from the Right Grip Heater (Item 3) to the hole in the plastic snake and pull them through the bar so they exit the left end. (See drawing below) 8. Push the right heater into the handlebar by squeezing it together and sliding it fully inside of the bar. The end of the heater with the orange cap should be pushed in first. Cut the white and yellow wire to extend 4 inches beyond the left end of handlebar. 9. Install the Right Throttle Control and Grip according to the service manua

Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

0

Filed Under (Harley Davidson) by admin on 25-02-2012

download
Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

Incoming search terms:

HONDA CB650/ 750F/ 900F/ 1100F/ GL1100 Spark Unit Set Installation Manual

0

Filed Under (Honda) by admin on 05-04-2011

download
INSTALLATION INSTRUCTIONS: 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 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 to 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: GREEN Ö GROUND (0 VOLTS) BLACK/WHITE Ö IGNITION SUPPLY (+12 VOLTS) VIA ENGINE STOP SWITCH YELLOW Ö IGNITION COIL OUTPUT (TO COIL —) WHITE Ö PULSE GENERATOR (WHITE RING) BLUE Ö PULSE GENERATOR (UNMARKED) There are two pulse generators, one for cylinders 1&4 and one for cylinders 2&3. The left hand one is normally for cylinders 1&4 (see fig.1). There are two wires of the same colour coming from each pulse generator, one of these wires is normally marked with a white band. The pulse generator wire with the white band connects to the white wire from the corresponding spark unit, the other pulse generator wire connects to the blue wire on the corresponding spark unit. If the white band is missing, this is normally the upper wire coming from the pulse generator. 9. Refit the seat and tank (if removed earlier). 10. Fitting is now complete, although for best results you may wish to verify the ignition timing, see the following guide

Incoming search terms:

HARLEY DAVIDSON AILERON HAND GRIPS REMOVAL AND INSTALLATION MANUAL

0

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

download
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)

HONDA GL1500 Radio Knobs Installation Manual

0

Filed Under (Honda) by admin on 28-02-2011

download
NOTE: Read instructions carefully before installing. 1. Place bike on center stand. Remove the 5 original knobs. 2. Using needle nose pliers, remove the knob stops from the 2 left hand knob sockets. 3. Install replacement chrome knobs. ® Installation Instructions For Part 15673-235 GL1500 Radio Knobs

HARLEY DAVIDSON TIMER COVER KITS INSTALLATION MANUAL

0

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

download
INSTALLATION 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) NOTE For kits 32972-04A, 32924-04A, 32675-04A, and 32923-04A, refer to step 1 and 2 for installation instructions. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. See Figure 2. Remove and discard the original screws and timer cover. 2. Place new timer cover (1) in position and secure with chrome screws (2). NOTE For kits 32584-88TA, 32668-98A, and 32571-98A, refer to steps 3 through 8. 3. Use a 3/8 in. drill bit and drill the heads off the original timer cover rivets. Remove original timer cover. NOTE If the inner timer cover has been riveted in place and access to the cam position sensor is required, use a left hand drill and carefully remove the rivet heads. If a right hand drill is used, the sensor plate screw heads could break off when trying to remove the rivet. NOTE To make the cam position sensor tamper proof, follow steps 4 through 6. If the cam position sensor is not required to be tamper proof, skip steps 4 through 6. 4. Remove and discard inner cover retaining screws. Leave gasket (if used) and inner cover in position. 5. See Figure 1. Place washers (4) over rivets (3) and place rivets into inner cover holes so the backs of the rivets go into the sensor plate screws’ tapped holes. 6. Use a standard rivet tool and install rivets, securing inner cover to sensor plate screws. 7. Use the self-tapping screw (5) to cut threads into the remaining inner cover holes. Discard screw after use. 8. Place new timer cover (1) in position over inner cover (A) and secure with chrome screws (2). NOTE For kit 32581-90TB, refer to steps 9 and 10. 9. Use 3/8 in. drill bit and drill the heads off the timer cover rivets. Remove original timer cover. 10. Place new timer cover in position and secure with chrome screws (Part Number 9462) from kit

HARLEY DAVIDSON LOCKING FUEL FILLER CAP KIT REMOVAL AND INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 11-02-2011

download
INSTALLATION 1. Prior to installing the gas cap on the vehicle, insert the key into the lock. Firmly grasp the chrome top of the fuel cap and turn the key until it stops. On right hand threaded fuel caps, turn the key counter-clockwise until it stops. On left hand threaded fuel caps, turn the key clockwise until it stops. This assures an unlocked position for the gas cap. Allow the key to return to the neutral position. 2. Remove the key and install the fuel cap on the vehicle. is00770 Figure 1. Right Hand Threaded Fuel Cap Installation NOTE When installing the fuel cap, rotate the cap one full turn past the audible click. This automatically positions gas cap to lock position. A properly locked/installed gas cap will rotate freely in both directions. Failure to do so will give an incorrect assumption that the fuel cap does not work properly. REMOVAL On right hand threaded fuel caps, insert key, and while holding the gas cap in place with hand, turn key counterclockwise until it stops, return key to original position. Gas cap must rotate 270 degrees counter-clockwise before mechanism engages to allow gas cap removal. Continue to rotate counterclockwise to fully remove gas cap. On left hand threaded fuel caps, insert key and while holding the gas cap in place with hand, turn key clockwise until it stops, return key to original position. Gas cap must rotate 270 degrees clockwise before mechanism engages to allow gas cap removal. Continue to rotate clockwise to fully remove gas cap. REPLACEMENT KEYS Record the 4 digit key number stamped on the back of the key opposite the Harley-Davidson logo, in the area provided below. If a replacement key is needed, see your Harley-Davidson Dealer with the 4 digit number to order a replacement

Incoming search terms:

HARLEY DAVIDSON ADVANCED AUDIO XM SATELLITE RADIO KIT INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 30-01-2011

download
this kit fits 2006 and later FLHT (Electra Glide®), FLHTC (Electra Glide Classic), FLHTCU (Ultra Classic® Electra Glide), FLHX (Street GlideTM) and FLTR (Road Glide®) model motor- cycles. XM satellite radio is available within the continental United States. It is not available in Alaska or Hawaii. Additional Parts Required FLHT models will require prior installation of an Advanced Audio AM/ FM/ CD Radio Kit (Part Number 76412-06) and an AM/ FM Antenna Kit (Part Number 76325-06 or 76317-06). Unless one has already been fitted as part of another Advanced Audio kit installation: FLHT, FLHTC, and FLHX models will require the additional purchase of a Non-Ultra Overlay Harness (Part Number 70169- 06) and a left-hand Antenna Bracket (Part Number 76456-06). FLHTCU models will require the additional purchase of an Ultra Overlay Harness (Part Number 70164-06) and a left-hand Antenna Bracket (Part Number 76456-06). FLTR models will require the additional purchase of a Non- Ultra Overlay Harness (Part Number 70169-06) and an Antenna Bracket (Part Number 76316-06). If two modules are already installed on top of the radio, two Dual-LockTM mounts, Part Number 76434-06, will be needed. These items are available from a Harley-Davidson Dealer INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. 2. Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. NOTE If another module has been installed in the location reserved for the XM radio module, relocate that module per the instructions supplied with that kit