HONDA CB650/ CB750F/ CB900F/ CB1100F 4 CYLINDER TWO CABLE TIE ADHESIVE MOUNTING BASES REMOVAL

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Filed Under (Honda) by admin on 29-11-2011

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All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation.
2. Remove the seat and/or petrol tank to gain access to the original spark units (if fitted); these are normally fitted under the seat between the top frame tubing. Each of these units consists of a small alloy metal box with sleeved wires terminated by a small connector (coupler). They also have a mounting tab with a single fixing hole. 3. On four cylinder machines there will be two units, normally mounted back o back; one for cylinders 1&4 and one for cylinders 2&3. 4. For safety, disconnect the battery. 5. Unplug the couplers from each of the units. Undo the fixings and remove the units. 6. Fit the new spark units in the place of the old ones or find a suitable alternative, close to the connectors. Secure the units to the frame or mounting platform using the supplied tie-straps and adhesive mounting base (if required). If required, a thin sheet of rubber or double-sided tape can be used to keep the units in position. Do not completely wrap the units in foam rubber. 7. Push the wiring harness plugs into the new spark unit socket connectors; they will only fit one way. Reconnect the battery. 8. If you are rewiring the machine or do not have the standard wiring harness, the spark unit wire colours & functions are as follows

HONDA CB650/ 750F/ 900F/ 1100F/ GL1100 Spark Unit Set Installation Manual

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Filed Under (Honda) by admin on 05-04-2011

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INSTALLATION INSTRUCTIONS: 1. All connections must be of the highest quality, use crimped or soldered connections; twisted wires will not give a satisfactory operation. 2. Remove the seat and/or petrol tank to gain access to the original spark units (if fitted); these are normally fitted under the seat between the top frame tubing. Each of these units consists of a small alloy metal box with sleeved wires terminated by a small connector (coupler). They also have a mounting tab with a single fixing hole. 3. On four cylinder machines there will be two units, normally mounted back to back; one for cylinders 1&4 and one for cylinders 2&3. 4. For safety, disconnect the battery. 5. Unplug the couplers from each of the units. Undo the fixings and remove the units. 6. Fit the new spark units in the place of the old ones or find a suitable alternative, close to the connectors. Secure the units to the frame or mounting platform using the supplied tie-straps and adhesive mounting base (if required). If required, a thin sheet of rubber or double-sided tape can be used to keep the units in position. Do not completely wrap the units in foam rubber. 7. Push the wiring harness plugs into the new spark unit socket connectors; they will only fit one way. Reconnect the battery. 8. If you are rewiring the machine or do not have the standard wiring harness, the spark unit wire colours & functions are as follows: GREEN Ö GROUND (0 VOLTS) BLACK/WHITE Ö IGNITION SUPPLY (+12 VOLTS) VIA ENGINE STOP SWITCH YELLOW Ö IGNITION COIL OUTPUT (TO COIL —) WHITE Ö PULSE GENERATOR (WHITE RING) BLUE Ö PULSE GENERATOR (UNMARKED) There are two pulse generators, one for cylinders 1&4 and one for cylinders 2&3. The left hand one is normally for cylinders 1&4 (see fig.1). There are two wires of the same colour coming from each pulse generator, one of these wires is normally marked with a white band. The pulse generator wire with the white band connects to the white wire from the corresponding spark unit, the other pulse generator wire connects to the blue wire on the corresponding spark unit. If the white band is missing, this is normally the upper wire coming from the pulse generator. 9. Refit the seat and tank (if removed earlier). 10. Fitting is now complete, although for best results you may wish to verify the ignition timing, see the following guide

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ULTIMA ELECTRONIC WIRING SYSTEM INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 03-03-2011

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1. Find a mounting location for control box. The box is designed to be mounted to the top frame rail between split tanks, but can be mounted in a wide variety of places. If possible the box should be fastened using small screws or rivets but can be wire tied in place. Make sure the location is away from moving parts and heat sources. 2. Pre-fit harness to bike. Attach rear harness to control box. Each wire is color coded and labeled. Route individual wires to their destinations and do not cut to length. Keep wires in a bunch until they need to branch off. Use electrical tape to hold main wire bunch wherever individual or multiple wires branch off. Keep wires away from sharp edges or pinch points and leave extra wire for suspension movement. Repeat this for front and right/left harnesses. All wires not being used should be cut off at connector or secured to prevent shorts. When all wires are routed, cut excess length from ends leaving a couple extra inches for final fitment. 3 Remove pre-fitted harness from bike to install heat shrink tubing. Start at main connector and cut tubing approximately 1 inch past first branch. This will allow the next piece of tubing to slide into the first. Repeat this along entire harness. After encasing harness with heat shrink, use a heat gun to shrink tubing starting at main connectors. Be careful to not burn through the tubing with too much heat. Refit the harness to the bike, attaching to frame where necessary. Cut the ends of harness to length and strip the ends. Attach the terminals to the wire ends and use heat gun to shrink ends. Attach terminals to their destinations. 4. The diagnostic LED’s are used to locate shorts or overloads. Pinched or bare wires, faulty components or too much current draw usually causes these. If an LED is on, turn off the bike, locate and correct the problem, then turn the bike back on. The bike must be turned off to reset the protection circuit. If no LED’s are lit, but turn signals and dash lights do not work properly, make sure the control box main ground has a good connection to the chassis ground. 5. The control box operates the turn signals as listed: First command – flash 10 times then cancel Second command on same side – cancel Second command opposite side – cancel current sequence, flash 10 times then cancel Both sides at same time – hazard, all signals flash Brake switch – flash rear signals three times then stay on for 30 seconds