CYCLE SOUNDS T-TAP POWER HARNESS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 21-04-2012

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This t-tap plug is designed to work with Cycle Sounds audio systems. However it can be used to wire many add on 12 volt accessories to you Harley Davidson motorcycle. This plug is rated for 6-8 amps of power and should not be used for adding any product that is rated for more than the t-tap plug is rated for. Take the time to check the products power rating for which you want to install to make sure it is compatible with the t-taps amperage rating. Failure to do so couldlead to electrical failures, which could result in serious injuries or even death. it is possible to overload your motorcycles charging system by adding too many electrical accessories. U se amp meter to verify all power connections. Also check product power ratings for anything you are trying to install. Exceeding the maximum amperage can lead to electrical failures, which could result in serious injuries or even death. INSTRUCTIONS: Step 1: remove seat on bike and locate the wire harness under the seat that matches the plugs on the t-tap harness (2120-0026.) Location may vary between bike models. Step 2: unplug bike harness and snap each end of t-tap harness in correct plug opening. When finished connect power wires to the male plug.(all Cycle Sounds audio systems come pre wired with correct wire colors and terminals). When using this t-tap for any other 12 volt accessory, make sure the red and black wires are snapped into their proper pin connectors. Kit does not come with power terminals for the accessories device. See your local bike dealer for purchase of terminals

Harley Davidson Sportster 4 Piston Rear Brake Caliper installation Manual

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Filed Under (Harley Davidson) by admin on 02-04-2012

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Installing Rear Caliper – Sportster Models Removing The Stock Brakes SPORTSTER REAR BRAKE SYSTEM 84 & UP MODELS The basic steps are the same to install a PM rear brake caliper kit on any of the late model Harley Davidson “swingarm” style motorcycles; all require the removal of the rear wheel. Using a suitable lift, raise the motorcycle high enough off the ground to allow you to remove the rear wheel assembly. PHOTO 2 W a r n i n g Center the motorcycle on the lift so that it will not fall while you are working on it. Photo 2: Remove the rear brake caliper assembly by unscrewing the 2 caliper mounting bolts that go through the caliper into the caliper mounting bracket. Lift the caliper up and off the mounting bracket and brake rotor, move the caliper back out of your working area. Don’t remove the brake line from the caliper yet; you will do this just before you are ready to hook it up to the new caliper. The brake pads are held into the caliper mounting bracket by 2 spring clips; slide the brake pads out of the mounting bracket and remove the retaining springs. PHOTO 3 Remove Cotter pin and rear axle nut, slide rear axle completely out. Photo 3: Remove nut from Right rear shock and rotate belt guard up. Slide belt off of pulley and roll rear wheel back 6 – 8″. Photo 4: Remove original caliper bracket from swingarm

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BULLET & MINI-BULLET TACHOMETERS INSTALLATION MANUALS

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Filed Under (Tips and Review) by admin on 22-02-2012

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UNDER THE HANDLEBAR MOUNTING A: Can the Tach be mounted inverted under the handlebars? A: Yes, if you have enough room to mount under the handlebars for the tach to mount and still be able to turn from lock to lock without hitting the tank or dash. See note in next paragraph for details on how to rotate the face of the Tach for appropriate positioning. BE AWARE: Chances of water intrusion are increased in this position! FACE ROTATION Q: How do I rotate the face of the Tach? A: With the Tach housing removed from the handlebar, unscrew the bezel (counterclockwise) and remove it from the housing, using a 5/32 Allen wrench loosen the the set-screw located inside the clamp area or at the rear of the clamp area. Rotate the face of the Tach to your preferred position, tighten the set screw and replace the bezel. COIL IDENTIFICATION Q: How can I tell positive from negative on my coil? A: Most motorcycles will have two wires going to each of the coils, and each coil will share one common-color wire and have one unique color wire. The common-color is the positive and the unique color is the negative. For example, a Yamaha set-up has a red/black on both coils – that is positive. The other coil wire would be orange or gray – that is the negative side. Hondas set-up is blue/yellow and yellow/blue for the negative, and black/white for the positive. Suzuki has orange/white on both coils as positive and has white or black/yellow as the negative side. COIL SELECION Q: My bike has two (or four) coils – Which one/ones do I use? A: Most multi-cylinder bikes have one coil per cylinder. You only need to connect to one of the coils – choose the one most convenient for wire routing. (Single-fire motorcycles require the Tach adapter we include with each assemble

Suzuki SV 650s OXFORD "Hot Grips" INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 14-02-2012

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Installation of heated grips on motorcycles is popular in the UK since it’s not unheard of for even the “fair weather biker” to be caught out by a cold snap. Add to this the fact that many operations on a bike are performed by the hands and fingers, which will not perform well when frozen! 1) Before fitting the grips to the SV, a position must be chosen for the controller. The grips, needless to say, have their mounting places predetermined. I chose to make a small bracket for mounting on the top yoke. This allows the control box to sit level with the top surface for an integrated look whilst remaining accessible for operation. First of all- The mounting bracket in place: Picture shows a strip of rubber on either side of the bracket to stop rubbing / vibrations. Using the flat base and sticky pad supplied, mount the controller on the bracket. 2) With the easy bit done, we need to turn attention to the installation of the power feed cable. It would be too easy to leave the grips switched on with the bike parked up, or for kids to switch them on draining the battery and leaving you stranded. With this in mind, we really want to use a suitably rated power feed that is only “on” when the ignition key is turned on. Fortunately enough, the “pointy” SV has a couple of spare contacts in the fuse box which can be tapped for this purpose

A Comparison of Stopping Distance Performance for Motorcycles Equipped with ABS, CBS and Conventional Hydraulic Brake Systems

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Filed Under (Tips and Review) by admin on 09-02-2012

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Surface Tests On the ABS-equipped motorcycles, the operator was tasked with braking sufficiently to assure the operation of the ABS. The measured stopping distance values were corrected to compare data from the speeds of 48 km/h and 128 km/h, except for the BMW F650 data, which was corrected to 48 km/h and 117 km/h, the latter figure limited by that model’s top speed of 157 km/h (i.e. 75% of 157 km/h). In the ABS-enabled mode, for each load/speed/brake combination, the stopping distances were very consistent from one run to another. In this mode, the braking force was applied in a controlled and consistent manner by the ABS mechanism. With the exception of having to react to the possibility of the rear wheel becoming airborne under high deceleration, the rider did not require significant experience or special skill in order to achieve a high level of performance. In the ABS-disabled mode, the stopping distances were less consistent because the rider while modulating the brake force, had to deal with many additional variables at the same time. Up to six runs were allowed for the rider to become familiar with the motorcycle’s behavior and to obtain the best stopping distance. Test results from non-ABS motorcycles were noticeably more sensitive to rider performance variability. The data in Table 2 include the best stopping distances obtained without ABS, compared to the average braking performance obtained with ABS. The average results were favored for presenting the performance with ABS because the best results could be more representative of threshold braking, whereby the ABS operated for only a portion of the entire test. Despite being compared to the best stopping distances without ABS, the average results with ABS provided an overall reduction in stopping distance of 5%. The stopping distance reduction was more significant when the motorcycle was loaded (averaging 7%). The greatest stopping distance reduction (averaging 17%) was observed when only the rear foot pedal was applied to stop the motorcycle from 128 km/h

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YAMAHA V-Star 1100 Carburetor Bowl Screw Repair and Removal After Stripping and Pilot Cap Removal

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Filed Under (Yamaha) by admin on 19-01-2012

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When I first started working on bike many years ago, I learned the danger of stripping the heads of Philips screws when removing or installing them on motorcycles. I remember the two worst screws were the casing side-cover aluminum screws and carburetor bowl screws. I think I tried every method of screw removal after they were stripped. Vice grips, better tipped screwdriver, hammer, drill, and other tools were used. One way I learned to remove stripped screws is to re-make the Philips head into a flathead screw. Cutting a slot in the top of the screw and then use a flat-head screwdriver to remove the screw. On some parts this technique can work, other parts and screws it may not. The Philips screws on the bottom of the V-Star carburetor bowls are VERY prone to stripping. In fact, I will not start a carburetor cleaning without new hex head screws to replace the original Philips bowl screws. Replace the bowl screws for yourself if you keep the bike, or for the next rider that will appreciate the hex-head screws when they clean the carburetors. Not many other parts on a V-Star have screws that are prone to stripping. This documentation is to help riders with motorcycle maintenance. Some riders will find themselves with the problem of removing stripped screws. A carburetor cleaning can quickly double in time when you realize the hardest part of the job is removing bowl screws after they strip. And then realizing you do not have the replacement hex-head screws available and must now go to the hardware store.

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New Automatic Transmission for Motorcycles Human-Friendly Transmission

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Filed Under (Honda) by admin on 18-12-2011

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High-pressure fluid flow The engine rotates the pump swash plate, which has a gear mechanism. The rotating swash plate pushes the pump pistons to increase the pressure on the hydraulic fluid and feed it to the high-pressure annular chamber. The high- pressure fluid is then fed to the oil motor piston chamber where it pushes the pistons forward, which then push the motor swash plate. Power Fluid flow from pump to motor Fluid flow from motor to pump Low-pressure fluid flow The lower-pressure hydraulic fluid returns to the pump through the low-pressure annular chamber. In this way, the fluid circulates between the pump and the motor. Movement of distributor valves and pistons The distributor valves play an important role in fluid circulation. The valves are placed both in the oil pump and motor. When the pump pistons move to the compression side, the valves connect the piston chamber and the high- pressure chamber. When the pump pistons move to the expansion side, the valves allow a connection between the piston chamber and the low-pressure chamber. The valve in the oil motor moves opposite to its counterpart in the pump, ensuring the circulation of fluid within the system

HONDA VFR800, CBR1100XX Blackbird, ST 1300 Sport Brake Lever Part INSTALLATION

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Filed Under (Honda) by admin on 02-11-2011

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Congratulations on your purchase of an ASV C/5 Sport Streetbike lever. The correct installation of control
levers on a sport/street motorcycle is critical. Incorrect installation or the installation of an incorrect part
can result in a malfunction of your clutch and / or front brake system. This lever should be installed by a
certified mechanic; preferably at your local motorcycle dealer service dept. ASV Inventions, Inc. accepts no
liability for malfunctions as a result of incorrect installation or the installation of a part that was not
designed specifically for your motorcycle. Please check the list below to confirm that the correct year, make
and model of your motorcycle is listed. If the correct year, make and model of your motorcycle is not listed
below, then this part is not the correct part for your motorcycle and must not be installed onto your
motorcycle. ASV C/5 Sport front brake lever part number: BRC541 fits only the following motorcycles:
Please disregard any dashes or letters after this part number that are listed on the part number label of
this box that your lever came in, (ex; BRC541-SK) Any dashes or letters following your part number are for
colors and/or length of the lever and do not affect the application of the lever to the bike.

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HARLEY DAVIDSON REAR SADDLEBAG GUARDRAILS INSTALLATION MANUAL

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Filed Under (Harley Davidson, Uncategorized) by admin on 18-04-2011

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Installation KITNUMBER 49087-01 1. Remove and save fasteners that retain saddlebag guardrails. 2. Replace stock saddlebag guardrails with new guardrails from kit. 3. Screw in and torque each stock fastener as follows: a. Four stock screws, Part No. 3678, using two new locknuts (1), Part No. 7667. Torque each screw to 19 ft-lbs. b. Two stock screws, Part No. 3601 using two new locknuts (2), Part No.7686. Torque each screw to 9 ft-lbs. For Domestic FLHRC/I Vehicles Only. (Does not apply to Harley Davidson International (HDI) vehicles): Federal Motor Vehicle Safety Standard (FMVSS) 108 requires all motorcycles to be equipped with side reflectors. Install, or have Dealer install, the reflectors, Part Nos. 59370-98 and 59371-98, which are purchased separately. Loss of visibility to other motorists could result in death or serious injury. 1. See Service Parts illustration. Position reflector so it is centered on the vertical portion of the saddlebag guard 1″ above the top end of the lower bend where the radius turns upward. Measure and use a small piece of tape to mark location for attachment of the lower edge of the reflector at the 1″ mark. 2. Remove protective tape backing from one reflector. Locate reflector above the 1″ mark. Apply reflector, using even pressure by rubbing back and forth on reflector. Repeat for other side. Note Reflectors are specific for each side. Reflectors have a flat end and a curved end. The curved end goes down. Top edge should be horizontal when positioned on guard. If not, reflector is for opposite side. KITNUMBER 49088-01 1. Remove and save fasteners that retain saddlebag guardrails. 2. Replace stock saddlebag guardrails with new guardrails from kit. 3. Using four hexsocket button head screws (4) removed earlier, attach saddlebag guards using the remaining two existing holes in each guardrail. 4. Screw in and torque each stock fastener as follows: a. Four stock screws, Part No. 3678, using two new locknuts (1), Part No. 7667. Torque each screw to 19 ft-lbs. b. Two stock screws, Part No. 3601 using two new locknuts (2), Part No.7686. Torque each screw to 9 ft-lbs

HARLEY DAVIDSON AIRFOIL RIDER HEEL REST KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-04-2011

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1989 and later FX Softail Models with Original Equipment (OE) Forward Controls, •1990 and later Dyna models (except 2003 and later FXDWG), •Dyna models equipped with Forward Control Kit 49080-93 or 49080-93A. Kit 50227-01 does notfit Dyna models equipped with Forward Control Kit 49080-03or Forward Control Footrest Support 33695- 03 (left) or 33697-03 (right). Proper installation of this kit also requires installing a pair of Airfoil Foot Rests, Part Number 50133-95 (large) or 50134- 95 (small), not included in this kit. Airfoil Foot Rests are available from your Harley-Davidson Dealer. See the Service Parts illustration for kit contents. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley- Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. NOTE A Service Manual for your motorcycle is available at your Harley-Davidson Dealer. Installation NOTE When performing the following step, note the location and orientation of the spring washer when removing each footrest. 1. See Figure 1. On the right side of the motorcycle, remove the fastener securing the footrest to the footrest bracket. Save the hardware for installation. NOTE On motorcycles equipped with Airfoil Foot Rests, remove the adjusting screw fastening the foot rest to its footrest mount. Save the foot rest and screw for heelrest installation. 2. Fasten the Airfoil Rider Heel Rest mount and spring washer to the footrest bracket using the hardware saved from step 1. Tighten the fastener to 19 ft-lbs (26 Nm). 3. See Figure 2 and the Service Parts illustration. Place the right-side Airfoil Rider Heel Rest (2) on the Airfoil Rider Heel Rest mount (3), positioning the heelrest at the desired angle

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