Harley-Davidson Amp Module – Base Kit Installation Manual

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Filed Under (Harley Davidson) by admin on 10-03-2012

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Technique for removal of Ampseal contacts from the connector housing (refer to Photos 5 and 6): Grab the wire to be removed (shown in the next section) with needle nose pliers or hemostats. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Photo 5- Pin Removal, Step 1 Photo 6- Pin Removal, Step 2 End of Removal Technique Installing Kennedy Harnesses part #85910 and 85911 Locate Kennedy harnesses part #85910 and 85911 and 5 pieces of 1/8″ diameter x 2″ shrink-wrap, from kit part number 85615-10. Refer to Figure 1 (Pre-’06) and Figure 1a (2006 and Newer) on the next page, and make the connections between Ampseal connector 28B and Kennedy harness 85910, and harness 28B and Kennedy Harness 85911.

Harley Davidson MC/ MIC HARNESS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 02-03-2012

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Use the diagonal cutters and razor blade to cut any tie wraps or harness coverings away from the harness connected to C28. At least 3 ” of wire must be unsheathed. Use a 1/16″ wide blade flat screw driver to push the Ampseal connector wedge lock tabs away from the red wedge lock as shown in Photo 3. Pull the wedge lock up as shown in Photo 4. The wedge lock should never be removed from the housing for insertion or removal of the contacts. Photo 3 – Connector Disassembly Step 1 Photo 4- Connector Disassembly Step 2 Technique for removal of Ampseal contacts from the connector housing (refer to Photos 5 and 6): Grab the wire to be removed with needle nose pliers or hemostats. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Photo 5- Pin Removal, Step 1 Photo 6- Pin Removal, Step 2 End of Removal Technique
3 of 5 Document part number: 65298R2 Installing Kennedy Audio Interface Harness part #85582 Locate Kennedy harness part #85582 and 3 pieces of 1/8″ diameter x 2″ shrink-wrap. The sequence for installing the harness is: Locate and remove the appropriate contact from the Ampseal connector (refer to Figure 1, below). Place a piece of heat shrink over the corresponding mating pin on Kennedy harness #85582. Press the mating pin and the Ampseal connector contact together (See Photos 7 and 8)

KTM EXC taillights Installation manual

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Filed Under (KTM) by admin on 23-01-2012

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Step1: Remove headlight, (headlight switch) seat and gas tank from KTM. Step 2: Partially install the headlight assembly using the top right band only to hold it in place temporarily. You will need to plug wires to this assembly and if you put all four bands on you will not be able to make the connections. Step 3: Install handlebar switch on clutch side. You will need to move clutch perch to the right (about ½ inch to1 inch) to make room for the switch. The red knob on the clutch adjuster should just miss the handlebar switch. The switch plugs into the circuit board on the bottom of the headlight using the 8-pin plug (the only unused 8-pin one on the circuit board) Step 4: Behind the gas tank and in front of the air box is a small rectangular hole in the frame. You will be feeding two lines with the plug ends first down through this hole. They must be fed one line at a time and you may need to use needle nose pliers to grab them and help pull them through. The lines you want to feed through this hole are the power line with two-pin molex plug and the line for the taillight with the six-pin plug. Route these wires all the way to the headlight assembly along the left side of the bike on the bottom of the gas tank frame tube. In this step we will connect the power line only. With the handlebars turned all the way to the right, plug the power wire into the back of the headlight assembly making sure to leave some extra wire so you can turn the handlebars both ways without tugging on the wires. The other end of the power line has battery terminal loops. The positive has an in-line fuse and the other black wire is the negative. Connect these to the battery.

YAMAHA 1996-2003 Road Star BILLET TACH MOUNT KIT INSTALLATION MANUALS

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Filed Under (Yamaha) by admin on 12-01-2012

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Remove and retain the (4) chrome caps from the handlebar clamps. Remove and retain the (4) stock allen head bolts. This hardware will be re-used with the new Billet Tach Mount Kit. Carefully remove the stock handlebar clamps while supporting the handlebars. INSTALLATION: 2. Slide the Electronic Tachometer (#6) into the Billet Tach Mount (#2) and secure with the 10-24 X 1/4″ Socket Set Screw (#10) supplied. Carefully pull the tachometer wire harness through the larger hole in the Billet Tach Cup (#3) and secure the Billet Tach Cup with the 10-24 X 1/8″ Socket Set Screw supplied. (The additional holes in the tach cup are for air circulation). Attach the Billet Tach Mount to the Billet Handlebar Clamp (#1) with the two 10-24 X 1-3/4″ Socket Head Screws (#4) supplied. Install the Billet Tach Mount assembly with the four stock allen head bolts and chrome caps removed in step 1 above. Adjust handlebars to desired height and torque bolts to factory specs. WIRING INSTRUCTIONS: 3. Refer to FIG. #1 . Remove Seat. Disconnect negative cable from battery. Remove fuel tank retaining bolts. Raise fuel tank about 3″-4″ to expose the Left Side Ignition Coil. It is not necessary to completely remove the gas tank on the Road Star. (V-Star 1100 applications use the right front coil and require fuel tank removal.) TIP: Long needle nose pliers are useful in removing and re-installing the coil wires. If desired, tach wire loom may be shortened as necessary. Using an appropriate crimping tool, connect the Tachometer wires in the following manner: Cut Shrink Tubing (#9) into two 1″ pieces

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Yamaha WR motorcycle ProEFX 12V Hot Start Installation

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Filed Under (Yamaha) by admin on 06-01-2012

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1. Remove seat, tank and shrouds. Remove existing hot start lever, cable and valve from the carburetor. 2. Tip: Clean all dirt from hot start bore and mating surfaces on the carburetor body with gas and a q-tip. 3. Tip: Use a small amount of Teflon tape (one wrap) on the threads of the aluminum mounting nut to ensure a water tight seal. 4. Install the Pro EFX hot start valve in the hot start bore (as shown in picture), with return spring, impact washer and delrin plunger in place. • Tip: Installation of the solenoid valve may require temporary rotation of the carburetor away from the top engine mount bracket. • Install with the solenoid valve assembly disconnected from wiring harness. • Screw in by hand and finish tightening with needle nose pliers. Do not over-tighten. Solenoid valve assembly: 5. Mount activation switch on preferred handle bar location. Pictured on clutch side, in place of the stock kill switch.
6. Route wiring harness around steering column and down frame backbone. Insert battery leads through slot in rubber protective boot. (follow existing wiring to battery) 7. Connect positive (red) and negative (black) leads to motorcycle battery. 8. Connect male and female terminals to wiring harness on previously installed solenoid valve assembly. 9. Depress activation button and listen for valve actuation. Plunger should freely “snap” between open and closed position in hot start bore, as activation button is depressed and released. If you don’t hear the valve “snap” open and closed, follow the trouble shooting guidelines or call /email for support. 10. Maintenance: Periodically ensure proper tightness of solenoid valve in carburetor body as part of standard motorcycle maintenance. Keep the battery terminal connections free from corrosion.

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HARLEY DAVIDSON TOURING CHROME PASSENGER FOOTBOARD PAN KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-04-2011

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Installation 1. See Service Parts illustration. Remove socket head cap- screw (2) from footboard support (3). Place support on a clean flat surface. 2. From bottom of footboard (1), use a small flat blade screwdriver to push rubber beads on pad (5) up through holes in footboard. Remove pad from footboard. 3. Using a brass drift and rubber mallet, tap two retaining pins (4) toward center of footboard and remove. 4. Remove footboard from support bracket taking care to remove and retain detent ball (6) and spring (7) from footboard support (3). 5. Insert spring (7) and detent spring (6) into footboard support (3). 6. Place new chrome footboard pan in position with footboard support and insert retaining pins using a brass drift and rubber mallet. 7. Moisten rubber beads on pad with soapy water. Place pad into position on footboard. From bottom of footboard, use needle nose pliers to pull rubber beads down through holes in footboard. 8. Engage nubs on inboard corners of pad with holes in foot- board. 9. Install socket head cap screw into footboard support and tighten 120 in-lbs (13.6 Nm). 10. Repeat procedure for other passenger footboard

HONDA GL1500 Radio Knobs Installation Manual

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

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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 FLHT OIL PRESSURE AND AIR TEMPERATURE GAUGE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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INSTALLATION Oil Pressure Sending Unit To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. 1 2 3 4 is04574 1. Oil pressure sending unit 2. Cam position sensor 3. Crank position sensor 4. Main harness to ECM Figure 1. Electrical Bracket: 2000-2001 Fuel Injected Models (Magnetti-Marelli) 1 2 3 is04575 1. Oil pressure sending unit 2. Crankshaft position sensor 3. P&A siren kit Figure 2. Electrical Bracket (ECM Removed) 2002-2003 Fuel Injected Models (Delphi) -J01875 1 of 4 NOTE For 2002 to 2003 models: See Figure 2. Remove the two screws securing the ECM and remove the ECM to access the electrical bracket. 2. For 2004 and later models: Proceed to the Gauges section. For 2000 to 2003 models: See Figure 1, Figure 2 and Figure 3 for the applicable model and locate the sensor harness connector (2-piece mini-Deutsch® connector). 3 2 4 1 is04576 1. Ignition harness 2. Cam position sensor 3. Oil pressure sending unit 4. Crankshaft position sensor Figure 3. Ignition Module – Carbureted Models 3. Locate the oil pressure sending unit at the front right side of the crankcase and pull wire socket from terminal of the oil pressure sending unit. 4. Carefully draw the conduit and the pin side of mini-Deutsch connector forward and then up between the rear brake master cylinder reservoir and the frame downtube to area of the rear brake pedal. 5. See Figure 4. Remove the secondary locking wedge (3) from the pin side of the connector with a needle nose pliers. 1 3 2 is04577 1. Pin 2. Wire seal 3. Locking wedge Figure 4. Deutsch Connector Pin Side (2-pin connector shown) 6. Gently depress terminal latches inside pin housing and back out the pin in chamber #1 through the hole in wire seal. 7. Pull the oil sending unit wire through conduit and remove wire. Note the routing of the wire. 8. See Figure 9. Route the jumper (6) pins through the conduit from the kit in the same direction as the original wire noted in Step 7. Use cable straps to secure to the wire bundle. 9. See Figure 5. Locate pin chambers #1 and #2 on pin side of connector. Insert brown/green jumper pin into chamber #2 and feed until it clicks into place. Verify that pin will not back out of the chamber by giving a slight tug on the wire to confirm that it is locked

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SUZUKI M109 BRAKE PEDAL INSTALLATION INSTRUCTIONS

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Filed Under (Suzuki) by admin on 29-01-2011

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1. Remove the pinch bolt from the bottom of the stock brake pedal. Notice that the slot in the pedal aligns with a punch mark on the end of the shaft. Using a needle- nose pliers disconnect the return spring from the pedal. Remove the pedal by sliding it outward until it touches the foot peg mount and then pushing the shaft inward. 2. Remove the pinch bolt from the new brake pedal and install it so that the slot is aligned with the punch mark on the end of the shaft. Install the pinch bolt and tighten it securely. Reconnect the pedal return spring

HONDA VTX, VTX RETRO AND VALKYRIE DRIVE SHAFT COVER INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 21-12-2010

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1. Place the cover over the drive shaft housing. 2. Hook one end of the springs provided into the lower holes. Wrap the springs around the backside of the drive shaft housing. Using a needle nose pliers stretch the springs and hook them into the upper holes. 3. Note; if springs are too long, shorten and reform end to be able to hook spring in place.

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