KTM ELECTRICAL SYSTEMS INSTALLATION, REPAIR

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

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DC SYSTEMS STEP DC1 – REGULATOR/RECTIFIER: PRE-2005 KTM If the stock regulator looks like below (the stock connector will not plug into the Trail Tech regulator/rectifier) then the provided stub connector must be soldered into the bike’s wire harness. For models without a stock battery, mount the reg/rec and plug the stub connector into it. Run the red and black wires directly to the (aftermarket) battery, and the yellow wires to the stator. SEE DC CIRCUIT DIAGRAM ON REVERSE SIDE OF PAGE. MODELS WITHOUT A STOCK BATTERY Move stock light to the DC circuit: divert lighting wire from AC circuit to DC circuit. In stock form, the lights are powered by the AC half of the electrical system. In order to continue to use the stock light, find the yellow wire (runs to stock headlight) shown below (wire bundles are found underneath gas tank) and cut the smaller gauge yellow wire. 1. Connect aftermarket light: Wire the light’s red(+) light lead to the positive(+) battery terminal, and the black(-) light lead to the negative(-) battery terminal. Trail Tech lights should use a 10-20 amp fuse as close to the positive(+) battery terminal as possible.

2001-2003 XV16 Fuel Pump and Carburetor Removal

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Filed Under (Yamaha) by admin on 31-12-2011

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Disconnect the carburetor fuel line hose at the fuel pump. •Disconnect the fuel pump wire coupler. •Remove the choke cable from fuel pump bracket. •Remove the upper engine mount, leaving the fuel pump attached to the mount. •Disconnect the TPS and carburetor wire couplers.       Disconnect the throttle cables, and then remove the carburetor. NOTE: The idle adjuster can be removed from its bracket without loosening the bracket screws. PAGE 3 of 12 HIDDEN 6mm SCREW 6mm BOLT UPPER ENGINE MOUNT/ FUEL PUMP CARBURETOR PAGE 4 of 12 Right-Hand Footrest Removal: •Disconnect and remove the brake light switch. •Remove the forward-most tie wrap around the brake hose and frame. •Remove the footrest assembly. NOTE: Leave the brake hose attached. Move the hose to the underside of the foot rest mount and support it as necessary so that it is out of the way Cylinder Head Oil Pipe Removal/ Installation: •Slightly loosen all three banjo bolts before removing them to prevent oil line deformation. NOTE: When loosening the upper banjo bolts, hold the line in place using a wrench at the flat surface on the fitting. Air Injection System (AIS) Removal: •Remove the electric starter motor. •Remove the regulator/rectifier assembly. Remove the AIS pipes from the cylinder head, but leave them attached to the AIS assembly. •Remove the three screws with 8mm heads, and then remove the AIS air filter from the right side. •Remove the three Phillips head screws holding    the AIS assembly on the frame. •Remove the AIS assembly from the left side. FOOTREST ASSEMBLY UPPER BANJO BOLT AIS AIR FILTER AIS ASSEMBLY
PAGE 5 of 12 Transfer Case Removal: •Remove the transfer case bracket first. Then remove the outer chrome cover, inner cover, and drive-sprocket nut. NOTE: There is a sealing washer between the inner case and the transfer case at the 8mm stud. Be sure to replace it during re-assembly. •Remove the two chrome oil lines between the engine and oil tank. NOTE: Retain the four O-rings for re-use. •Remove the drive pulley cover and remove the drive pulley nut. •Loosen the drive belt tension. •Remove the drive pulley, inner cover, collar, and O-ring. NOTE: The collar has a bevel on its inside diameter     for the O-ring facing inward and a bevel on the outside diameter facing the pulley. •Remove the drive and driven sprockets with chain as an assembly. •Remove the collar and O-ring. NOTE: Collar has a bevel on its inside diameter that faces inward for the O-ring. •Remove oil tank filler neck. •Remove the relay bracket on the right-hand side. NOTE: Leave the relays connected. Simply move them out of the way to allow room for transfer case removal. •Slide the transfer case out from the right side.

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XR 600 Dual Sport Kit Installation Manual

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Filed Under (Pulsar) by admin on 27-10-2010

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1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the side panels, seat, and gas tank. 3. Unplug the headlight and taillight from the stock wiring and remove. 4. Locate the AC voltage regulator mounted on the left side of the frame backbone, (Fig.1) unplug from wiring harness, and remove the regulator. This regulator is located above the air box on ’87 and earlier XR 600′s and 500′s. AC Regulator (Remove) Pulsar Coil Alternator (Stator) Wiring Alternator (Stator) Contains both exciter coil and lighting coils Figure 1: If you are colorblind or even think you might be a little color blind, now is the time to get someone to assist you. Successful installation of the kit requires good color recognition. You want to go riding this weekend, don’t you? 5. A three wire group consisting of a black/red wire, a green wire, and a white/yellow wire (may appear light gray/yellow) are the output leads from the stator. 1990 and earlier models only have two wires coming up from the alternator, a black/red wire and a blue wire. On 1991 – 1999 XR 600′s, unplug the green wire and the white/yellow wire. (This should have already been done 3 when you removed the voltage regulator in Step 4.) On 1990 and earlier XR 600′s see the Stator Modification Instructions enclosed. 6. Temporarily disconnect the black/red wire and remove the rubber boot that shields the wire bundle. Reconnect the black/red wire making sure that it plugs in tightly, as this lead is responsible for powering the bike’s ignition. 7. Voltage Regulator Installation: The voltage regulator/rectifier mounts to the top right rear corner of the air box (Photo 1). Use the template provided to determine the location at which to drill the two 1/4 inch mounting holes in the air box lid. The outside edge of the regulator should be nearly flush with the outside edge of the air box when mounted properly.