2000-2003 KTM MXC / EXC Dual Sport Kit Installation Manual

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Filed Under (KTM) by admin on 01-02-2012

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Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3 4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit 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 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 stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install

HARLEY DAVIDSON DYNA SECURITY SYSTEM SMART SIREN II KIT INSTALLATION MANUAL

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

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This kit fits 1996 through 2003 Dyna INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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. Refer to the Owner’s Manual and follow the instructions given to disarm the security system, remove the seat, and disconnect the battery cables (negative cable first). Retain all seat mounting hardware. 2 1 is 01366 1. Siren connector 2. Dust cap Figure 1. Siren Connector 2. See Figure 1. Locate the siren connector (1). It is covered by a black dust cap (2) and is at the end of an unconnected 10 inch (254 mm) long harness leg starting near the rear fender, close to the rear lighting connector. Free the siren connector from its constraints. 3. Remove the dust cap from the connector. 4. See Figure 2. Snap the siren (2) into the siren bracket (3) so that the sounder disc (4) fits the notch in the bracket as shown. Connect the siren connector (1) to the siren.

YAMAHA FZR 400 ELECTRICAL CIRCUIT DIAGRAM

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Filed Under (Yamaha) by admin on 29-11-2010

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CHECKING OF SWITCHES Check the switches for the continuity between the terminals to determine correct connection. Read the following for switch inspection. SWITCH CONNECTION AS SHOWN IN MANUAL The manual contains a connection chart as shown left showing the terminal connections of the switches (e.g., main switch, handlebar switch, brake switch, lighting switch, etc.) The extreme left column indicates the switch positions and the top line indicates the colors of leads connected with the terminals in the switch component. “C’&-0″ indicates the terminals between which there is a continuity of electricity; i.e., a cl.osed circuit at the respective switch positions. In this chart: “R and Br” and “L/W and L/R” are continuous with the “ON” switch position. “B and B/W” is continuous with the “OFF” switch position. “B and B/W” is continuous with the “LOCK” switch position. “B and B/W” and “R and L/R” are continuous with the “P” switch position. CHECKING SWITCH FOR TERMINAL CONNECTION Before checking the switch, refer to the connection chart as shown above and check for the correct terminal connection (closed circuit) by the color combination. To explain how to check the switch, the main switch is taken for example in the following

motorcycle Turn Signal Conversion Kit Installation Instructions

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Filed Under (Tips and Review) by admin on 09-11-2010

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1. Place motorcycle on solid, level ground and on center stand if equipped. 2. Remove your turn signal lens. Place it upside down and clean the lens interior with the supplied alcohol wipe. Allow to completely air dry. Note: the LEDs are mounted to the inside of the turn signal lens with the LEDs making direct contact with the lens. The supplied silicone is used to secure the LED board to the lens. It remains flexible but can be removed. Test fit the board in your lens prior to using silicone. 3. Using a small screwdriver, poke a small hole in the end of the tube of silicone. Place a dab of silicone on each of the 12 LEDs on the circuit board. CAUTION : Note the position of the metal pins on the back of the LED board, They must be located 90 degrees from where the holes are that secure the lens to the housing. See attached diagram. 4. Position the round circuit board over the inside of your turn signal lens with the LEDs facing down. Get the board as centered as possible. Allow the silicone to make contact with the inside of the lens and then push down and slightly rotate the board back and forth to allow the LEDs to make contact with the lens surface. Repeat other side. NOTE : the silicone will require 30 minutes in 70 degree weather to tack up. Full cure will occur within 24 hours. We suggest not riding for several hours if possible to allow the best adhesion. 5. You will need to access the following wires; running light (license plate can be used), brake lights, right turn and left turn. Disassemble the bike as needed to gain access to the wiring. Shop Tip: we have found that on the Yamaha Star Series and the Kawasaki Cruisers that installation is much easier when you remove the turn signal bar from the fender. On the Yamahas, there are 3 bolts holding the moustache in position. The wires will unplug from behind the license plate. On the Kawasakis, unplug the signals under the seat and bend the tabs under the fender to be able to remove the wires. 6. We have provided some tubing to slide over the wires so that when you re-install the bulb socket, our wires for the LED boards will not be pinched. This tube should be slid all the way into the turn signal housing. You may have to shorten the tubing for your installation. 7. You will need to run wires through the stem of the turn signal. You can see samples of how the various manufacturers signal housings come apart on our web site. Click on “Other Lighting Products” and then “Turn Signal Conversion Kits” and follow the link. We suggest placing the removed turn signal assembly on a towel on your work area. 7. You will need to leave 2″ of slack in the wires at the turn signal housing to allow for wire connection. 8. Reinstall the turn signal housing back on the motorcycle if removed. NOTE: both of the run/brake circuits must be used. You may shorten the wires only on the run/brake circuits as needed. Do not change the circuits under the heat shrink. T-Tap instructions. Lay the “donor” wire in the slot in the burgandy connector. Close and snap together with pliars. Strip some insulation off of the wire which will be tapping into the factory wire. Crimp one of the pink connectors on the bare wire and plug it into the burgandy T-Tap 9. Connect the green wires from the run/brake circuits to the bikes running lights. The 2 greens can be connected together. 10. Connect the blue wires from the run/brake circuits to the bikes brake lights. The 2 blues can be connected together. 11. Take one of the red wires from a run/brake circuit and connect it to one of the black with white stripe wires coming from one of the LED boards using the supplied red butt connector. Connect the other run/brake circuit red wire to the remaining black with white stripe wire on the other LED board. 12. Connect the black wire from the LED board on the right side of the bike to the right turn signal positive (+) wire on the motorcycle. 13. Connect the black wire from the LED board on the left side of the bike to the left turn signal positive (+) wire on the motorcycle. 14. Plug the wires into the LED boards. If you hold the turn signal lens so that you are viewing the back of the LED board, position the connectors on the board at the 12 o’clock (top) position. The connector on the left is the positive (+) terminal. Connect the red wire to it. Connect the black wire to the remaining connector on the right side. 15. Check operation. LEDs should come on with running lights. LEDs will brighten when brake lights are applied. LEDs will shut off when the amber turn signal comes on. 16. Should you have any problems, please see the troubleshooting chart on our website.* * 17. Reassemble bike

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1961 MODEL G2CS ELECTRICAL CONVERSION FOR COMPETITION

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

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The entire electric system except the battery, ignition switch, ignition wiring and coil can be removed for off-the-highway competition. 1. Remove the saddle and gasoline tank. 2. Pull the lighting harness wires from the connectors, leaving the connectors in place, unless removal is specified. Follow the code for easiest disconnection. a. Translucent. b. Purple. c. Double Brown from four way connector and horn connector. d. Black from connector at tail lamp. e. Orange. f. Yellow – keep the connector on this wire. g. Light Green. 3. Connect the Yellow wire from the ignition harness into the double connector with the Light Green wires. 4. Pull the Brown wire at the four wire connector and at the tail lamp. Pull out and remove the stoplight harness and switch. 5. Remove the horn. 6. Disconnect the speedometer cable at the drive gearbox. NOTE: The gearbox cable socket should be taped to keep out dirt or the gearbox may be removed. Be sure to reinstall all wheel supporting and spacing parts. 7. Remove the left grip, loosen the set screw, slide the dip switch from the handlebar and replace the grip. 8. Remove the headlamp with the wiring harnesses and speedometer cable. 9. Remove the tail lamp and bracket. Service Release #6-82 (con’t) March 27, 1961 The wiring left on the motorcycle is shown on page 45 of the 1961 G2 Instruction Book. With the connections as shown, the ignition is normally from the battery but the emergency start circuit is available in case the battery becomes discharged