Kawasaki Voyager 1700 Hitch Removal both saddlebags and Installation Instructions

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Filed Under (Kawasaki) by admin on 08-05-2012

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Remove the seat. Remove both saddlebags by removing the 3 bolts shown below Remove the plastic liner in the bottom of the trunk by gently pushing in on the center of the plastic clips Once the liner is removed remove the trunk rear light assembly by removing the 4 black screws in side the trunk and 4 on the bottom side of the light assembly. Unplug the light assembly and set it aside. Remove the bolts for the trunk Have a friend hold the trunk up and remove the 4 screws (two on each side) for the side trim Put the bolts back inside the trunk and tighten finger tight to make sure it does not fall. Remove the remaining side trim screws, 5 on each side, and remove the side trim and set it aside Remove 2 bolts from the saddle bag supports. Place the side plate mounting bracket behind the saddlebag supports and replace the two bolts you removed in the previous step. (We recommend using a few drops of Loctite). Do this step for both sides of the bike. Place the side plate behind the mounting bracket and attach the side plates to the mounting brackets with the two bolts supplied with the hitch (We recommend using Loctite on this step) Repeat this step for both sides of the bike

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Yamaha WR 250F and WR450F Dual Sport Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 20-01-2012

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license Plate Mount Installation: Locate the aluminum license plate mount and license plate light assembly. Remove the rear most nut securing the stock taillight assembly (underneath the fender) (don’t lose the little compression tube and washer). Temporarily install the license plate mount to this location and mark the fender where it needs to be drilled for the rear mounts. Drill the fender in two places with a ¼” drill and reinstall the license plate assembly using the stock taillight mount and the 6 x 20 mm countersunk screws, bezels and nylock nuts Rear Turn Signal Installation: Locate the two rear turn signals in the kit – they’re the ones with the longer wires. Drill a 3/8 hole in each side of the fender as shown in Photo 3 and attach them as shown in Photo 4. It does no matter which signal goes on which side. Run the left turn signal wires forward along with the taillight wires, up through the grommet in the fender to the area just behind the air box cross member and above the fender. Run the right turn signal wires forward along the right frame rail, and through the same hole you made for the license plate wires Brake Light Switch Installation: The WR250/450 uses a hydraulic brake switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the rear brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the rear master cylinder guard. Remove the bolt holding the brake fluid reservoir to provide access to the master cylinder. Loosen the banjo bolt securing the rear brake line to the master cylinder. Typically, this bolt will be very tight and loosening it will bend the support hanger for the master cylinder if not supported. Brace the master cylinder with a wrench or lever. Remove the banjo bolt and replace with the hydraulic switch. Make sure to install the copper crush washer from the stock bolt under the switch. Torque the switch assembly to 25 lb-ft.

HARLEY DAVIDSON TOUR-PAK SPOILER LIGHT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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Installation 1. If the motorcycle was previously equipped with a Tour-Pak Spoiler Light, disconnect the light wires from the motorcycle. 2. Remove the Tour-Pak Spoiler from the Tour-Pak and disassemble original light or chrome trim (as equipped). Save the original mounting hardware for later installation. 3. Attach light assembly to spoiler using 10-24 x 7/8 in. long screws. 4. See Figure 1. Route light wires through 3/8 in. hole in Tour-Pak lid. Attach spoiler to Tour-Pak lid using original hardware removed in step 2. 5. See Figure 1. Attach the wires to the inside of the Tour- Pak with adhesive backed clips as shown. Route wires out front left corner of Tour-Pak bottom and support wires inside Tour-Pak bottom with the remaining adhesive backed clips as needed. Wires will exit out the bottom of the Tour-Pak through the antenna cable grommet. NOTE On Chopped Tour-Paks drill a 3/8 in. hole in the front left corner of the Tour-Pak bottom. Route the spoiler light wires through this hole for connection to the main motorcycle wiring. 6. On 1994 and later models, proceed to step 7 for wire connection instructions. On 1993 and earlier models, go to step 11 for wire connection instructions. WIRING INSTRUCTIONS FOR 1994 AND LATER MODELS 7. Remove the seat and locate the accessory circuit connector. Route the light wires along the frame and secure with cable straps from kit. 8. Refer to the Deutsch connector section in a 1994 or later FLT Service Manual and assemble the spoiler wires into the socket connector half supplied with the LED assembly. The wire terminals shall be inserted in the connector half as follows: WIRE COLOR CODECONNECTOR CAVITY Blue 1 Red/yellow 2 Sealing plug 3 Black 4 9. Remove the plug from the accessory connector located under the seat (connector number [4A] in wiring diagram in Service Manual). Connect wire from spoiler. Turn on ignition switch and test the spoiler light operation with taillight and brake light. 1 WARNING Always connect the positive battery cable first. If the positive cable should contact the ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 10. Reattach battery

HONDA GL-1500 Trailer Wire Harness with Relay INSTALLATION MANUAL

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Filed Under (Honda) by admin on 27-02-2011

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Seat: (if optional accessory wire is to be used) After removing trunk pan, run a stiff piece of wire from the bottom of the left saddlebag frame behind the rear tire up until it comes out under the trunk. Then hook open end of wire harness to fish wire and tape with electrical tape. Pull the harness back down to the bottom of the saddlebag frame. Route the long part of harness wire around the back of the license plate light to the right side 6-pin vertical connector just in front of tail light assembly. Unplug the stock connector and plug wire harness in between the stock plugs. Do the same for the left side with the short side of the Y on the harness. Now pull the slack down from the bottom of the harness and tuck all of the wires under the frames tubes so that the pan can be reinstalled without any problems. You can now hook up the loose ends of the harness to any style connector to match your trailer connector using the following color codes: GREEN GROUND ORANGE- LEFT TURN YELLOW- BRAKE BLUE- RIGHT TURN BROWN- TAIL RED POWER . Note : This accessory is an electronic isolated trailer wire harness. It should be installed by a qualified mechanic . 1. Disconnect the negative from the battery. 2. Install the harness. 3. When connecting to the trailer make sure all wires are used for the proper use and are waterproof. Make sure there are not exposed wires. Consult the trailer manufacturer for proper wiring. 4. Reconnect the battery negative. Double check the functions

HARLEY DAVIDSON AIR WING SADDLEBAG LID RAIL LIGHTS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1. If saddlebag rails have not yet been installed: Perform the Air Wing Saddlebag Rail installation up to the point of final assembly of the rails to the saddlebag lids. If saddlebag rails are already installed: Open one saddlebag and remove all loose contents. Remove one saddlebag from the vehicle per service manual instructions. From the underside of the saddlebag lid, remove the fasteners retaining the saddlebag rail to the lid. Note fastener position and save all components for installation. 2. ALL installations: See Figure 3. Obtain a saddlebag rail light assembly (1) from the kit. 3. Insert the light wires through the hole (B) in the side of the saddlebag rail (A) mounting post, and out through the bottom of the post. 4. Install the light to the underside of the saddlebag rail rear cross bar with two screws (4) from the kit. Tighten the screws >securely. 5. Insert the light wires through the left rear saddlebag rail mounting pad (C) and the left rear hole (H) in the saddlebag lid (G). Assemble the saddlebag rail to the lid per the instructions in the Air Wing Saddlebag Rail Kit, feeding the wires through the left rear saddlebag rail nylon washer (D), plain washer (E) and the hex head hollow screw (F). Tighten the two Phillips head screws to 27-31 in-lbs (3.1- 3.5 Nm) . Tighten the hex head hollow screw to 30-50 in- lbs (3.4-5.6 Nm) .

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HARLEY DAVIDSON HERITAGE REAR FENDER RAIL DISASSEMBLY AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-02-2011

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DISASSEMBLY NOTE See Figure 1. Saddlebags must be removed to insert spacer (1). 1. Using a small flat head screw driver, remove rear fender tip light lens cover (A) by gently prying cover away from assembly. (There is a notch at top of cover to ease removal.) Remove and retain cover (A) and gasket (C). 2. Remove fender tip light assembly (B) by removing two screws, four star washers, and two nuts (not shown) using a #2 Phillips screw driver and a 3/8 inch wrench. Retain all hardware for reassembly. 3. Remove hole plugs from rearmost fender strut holes on both sides of fender. 4. Mark fender on both sides of bike using rear most fender strut hole as a template. Do not contact tire with drill bit when drilling fender holes. Drill bit contact with tire can lead to premature tire failure, which could result in death or serious injury. (00403f) 5. Carefully remove fender strut and drill a 11/32 inch hole through each side of fender in locations marked in Step 4. 6. Loosely reinstall fender strut (D), allowing enough room to slip spacer (1) between fender (E) and strut. INSTALLATION 1. Align rear fender rail (2) from kit with rearmost fender strut (D) mounting holes, making sure lower mounting tab (3) is inside fender (E). Place large chrome washer (4) from kit next to head of button head socket bolts (5) from kit. Insert bolt through fender rail (2), fender strut (D), spacer (1) and fender (E), in that order. Install large unfinished washer (6) from kit onto end of bolt (5). Secure assembly into place by threading locknuts (7) from kit onto ends of bolts (5) from inside of fender (E). Tighten loosely at this time. 2. Install truss head screw (8) from kit through fender (E) and rear fender rail mounting tab (3). Secure into place using small washer (9) and locknut (10) from kit. Use #2 Phillips screwdriver and a 3/8 inch wrench to tighten rear mounting assembly securely. 3. Tighten fender strut bolts (5) to 21-27 ft-lbs.(28-37 Nm) 4. Reinstall fender tip light assembly (B), gasket (C) and lens (A) using original hardware (not shown)

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HARLEY DAVIDSON FLSTS MUD FLAP KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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Installation For installation on rear fender with marker light: 1. Cut out Rear Fender Template. 2. Use a paper punch to punch out holes marked A and C . Holes A are the locations of the marker light screws, and hole C is the location of the marker light wiring. Cut along centerline of template from top down to hole C . 3. Remove light lens by carefully pressing down on top center of light to disengage tab. 4. Remove the two screws, washers, and nuts that hold the marker light assembly in place and carefully pull the light assembly away from the fender. Disconnect the wire connector and remove the light assembly. 5. Slip template over marker light wires, align holes marked A with marker light holes, and align lower edge of template with lower edge of fender. Tape template in place. 6. Prick punch holes marked B at indicated centers on template. 7. Carefully, and as accurately as possible, drill holes marked B in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 8. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure outer holes with buttonhead screws (3), washers (6), and locknuts (7) contained in kit. The mud flap is split to fit around light assembly wires. 9. Using the longer panhead screws provided in the kit, install fender tip light and check that light is operational. For installation on rear fender without marker light: 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Rear Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes marked B and C at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked B and C in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit. For installation on front fender (FLSTS only): 1. Using a high quality masking tape, mask the lower three inches of the middle of the fender for the purpose of drawing a centerline on the fender. 2. Using a machinist’s square, locate the centerline of the fender by measuring in from each side of the fender flats. Mark the centerline on the masking tape. 3. Cut out Front Fender Template. 4. Align centerline of template with centerline drawn on fender. Align lower edge of template with lower edge of fender. Tape template in place. 5. Prick punch holes at indicated centers on template. 6. Carefully, and as accurately as possible, drill holes marked in two steps. First drill holes with a 1/16″ drill, then finish holes with a 7/32″ drill. 7. See Service Parts illustration. Place the mud flap and reinforcement inside fender and secure with buttonhead screws (3), washers (5 and 6), and locknuts (7) contained in kit

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HARLEY DAVIDSON SISSY BAR MOUNTED AUXILIARY BRAKE AND TAIL LIGHT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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These kits fit 1999 and later XL models, 1996 and later Dyna™ and 1996 and later Softail models (except 2006 FXSTC) equipped with a Medallion Plate-Style Sissy Bar Upright. Will not fit with Backrest Pads that have mounting brackets that match the contour of the sissy bar medallion. Will not fit with sissy bar mounted storage bags INSTALLATION 1. Follow the instructions in the Service Manual to remove the seat. 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) 2. Disconnect battery cables, negative (-) cable first. 1 2 is 01457 1. Adhesive mounted medallion 2. Push nut mounted medallion Figure 1. Medallions 5 2 1 3 4 is 01458 1. Screw 2. Screw (2) 3. Backrest bracket 4. Backrest pad 5. Mounting hole spacing (center to center) Figure 2. Backrest Pad and Bracket -J03063 1 of 5 Remove the Backrest Pad NOTE Medallions are attached to a medallion plate between the uprights of the sissy bar using either adhesive or push nuts. 1. See Figure 1. Remove and retain any existing medallion. Adhesive Mounted Medallion (1): Carefully pry the medallion (1) from the plate. Remove any adhesive residue from the back of the medallion and the sissy bar medallion plate. To avoid contaminating the adhesive backing, place the medallion in an area away from dirt and debris. Push Nut Mounted Medallion (2): Carefully pry the edge of the medallion until the medallion is free of the push nuts. 2. See Figure 2. Remove and retain the screw (1) that secures the backrest pad to the plate. 3. Remove and retain the two screws (2), backrest bracket (3) and backrest pad (4). Install the Light Assembly 1. See Figure 3. Clean the front of the medallion plate (2) with a 50/50 solution of isopropyl alcohol and water. 2. Peel the adhese bracket kit (Part Number 59545-04) and sandwich the light assembly between the bracket frame and the medallion plate. The bracket clamps will fit around the back of the sissyive backing from the adhesive tape located on the light assembly (1). Fit and hold the light assembly to the front of the medallion plate (2). 3. See Figure 6. For 2.55 inch (64.8 mm) center to center mounting hole backrest pads, use th bar arms.

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HARLEY DAVIDSON TOUR-PAK RACK LIGHT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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INSTALLATION 1. Remove all contents from Tour-Pak®. 2. For easier installation, remove Tour-Pak rack, if installed, by removing cap screw, washers and mounting pads. 3. See Figure 1. Remove rubber plug from bottom rear rail on left side of rack. 4. See Figure 2. Use line wire feeder in kit to thread through left rear rack foot and out through the back opening of rail. 5. Attach light harness wires to line wire feeder loop. 6. Carefully pull line wire feeder and light harness wires through rack mounting foot. 7. See Figure 5 and Table 1. Apply foam pads (5) to top surface of light. 8. Secure light (1) to rack with socket head screws (4) and washers (6). 1 is05242 1. Plug Figure 1. Left Side Rack Plug 1 is05244 1. Line wire feeder Figure 2. Thread Wires Through Rack 9. Position rack/light assembly to Tour-Pak lid and route wires through lid, washer and hollow mounting bolt. 10. Attach rack/light assembly to Tour-Pak using instructions and hardware provided with rack except for use of hollow bolt from Step 9. 11. Remove Tour-Pak liner. 12. Thread wires through black vinyl conduit. 13. Ultra Classic models: Follow Steps 14 through 2114. Locate and disconnect three pin AMP connector for Tour- Pak lights. 15. See Figure 3. Attach the Y-harness (2) to the three pin male connector (1) of Tour-Pak harness. 16. Route light wires from back of Tour-Pak along left side to front. Secure conduit with adhesive clips provided in kit. 17. Trim length of light wires and conduit to reach Y-harness. 18. Refer to the Service Manual electrical appendix to install terminal pins (8) to rack light wires and install terminals to three pin housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead 19. Connect rack light to remaining Y-harness connector. 20. Replace Tour-Pak liner. 21. Check operation of Tour-Pak tail and stop light functions before operating motorcycle. 22. Classic models: See Figure 4. If necessary, drill hole in lower left bottom of Tour-Pak and install grommet. Route rack light wires through grommet. 23. Refer to the Service Manual electrical appendix to install terminal receptacle (8) to rack light wires and install terminals to three pin receptacle housing (7) as follows: a. #1 cavity = blue lead b. #2 cavity = red with yellow lead c. #3 cavity = black lead NOTE To prevent corrosion, fill the cavities of the connectors with dielectric grease (included in kit) prior to making connections. As an additional precaution against moisture seepage into the Tour-Pak, apply silicone sealant (not included in kit) to the entrance of the light harness wire tunnel. See figure 2 for location reference. 24. Connect rack light to male connector of two connector wire harness (12) and connect to accessory connector under seat. 25. Replace Tour-Pak liner. 26. Check operation of Tour-Pak tail and stop light functions before operating motorcycle

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Hammerhead La Vita 150cc OWNERS MANUAL

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Filed Under (Hammerhead) by admin on 27-11-2010

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1. Left and Right rear Mirror 2. Left and Right Brake 3. Front storage compartment (option) 4. Speedometer/ Digital Gauge 5. Main Switch 6. Battery 7. Air Cleaner 8. Seat Lock 9. Rear Light Assembly 10. Left and Right Rear turn Lights 11. Fuel Tank 12. Center Stand 13. Kick Start 14. Side Stand 15. Muffler 16. Left and Right Turn Lights 17. Head Lights 18. Rear Reflector Instrument Panel Speedometer Riding speed is indicated by KM/H and MPH. Odometer The total riding distance is in KM and Miles. The black figures in black background indicate total miles traveled. Indicating lamp or turning light It flashes when turning light is in use. Fuel Gauge Fuel Gauge indicates the remaining fuel in the fuel tank (the gauge does not work when main switch is in the “OFF” position). The gauge moves from “F”(full) to “E” (empty) as fuel decreases in the fuel tank. Fill the tank with 90 Octane or higher gasoline when the needle is approaching the “E” position. There is no reserve tank. Indicating Lamp of High beam It indicates high beam is in use. Note: apply low beam to avoid obstructing the view of oncoming drivers and drivers ahead. 1. Speedometer 2. Odometer 3. Left turn signal indicator 4. Right turn signal indicator 5. High beam indicator 6. Fault signal indicator 7. Battery Gauge 8. Fuel Gauge Instrument Control Main Switch NOTE: – Do not leave the main switch in “ON” position for an extended period of time when the engine is stopped. The battery may drain itself empty. – Lock the steering and remove the key after park to avoid theft. “ON” Position: Electric Circuits are switched on. The engine can now be started. The key can not be removed in this position. “OFF” Position: All electrical circuits are switched off. The engine stops. The key can be removed in this position. “LOCK” Position: The steering is locked when in this position. The key can be removed. Steering Lock Turn the handle bar fully to the left to lock the steering to prevent theft. Push the key in when it is in “OFF” position and while pushing the key in, turn the switch to “LOCK” position to lock the steering. Pull the key out once you are done

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