Harley-Davidson FXWG, FXST (all except FXSTS), FXDWG Light Bar INSTALLATION AND OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2012

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1. Put a pair of male and female clamp halves together just above the lower triple-clamp. Squeeze the ends of the clamp together with a pair of pliers. Diagram A. 2. Have an assistant position the Light Bar Assembly so the lightbar bracket is to the outside of the clamp assembly. Make sure the wires from the Light Bar Assembly are below the lower triple clamp. Diagram B. 3. Insert a Screw through the clamp and Light Bar Assembly mounting bracket and thread on an Acorn Nut. 4. Hold the Light Bar Assembly in place in front of the lower triple clamp, assemble and attach the remaining clamps. 5. With all four clamp assemblies in place, tighten the clamping screws and nuts to 15 ft. lbs. (21 Nm). Refer to the service manual to gain access to the wire harness inside the fuel tank tunnel or inside the frame backbone. Also, verify the appropriate color wires for hook-up of the passing lamps and turnsignals and running lights. Route the wires from the Light Bar Assembly, around the lower triple- clamp, and up to the frame backbone. Secure the wires so they cannot become pinched when turning the fork. A. The short black wires from the Light Bar Assembly connect to the wires powering the running lights. B. The short red wires from the Light Bar Assembly connect to the wires powering the turnsignals. C. The long blue wires from the Light Bar Assembly connect to the wire powering the headlight low beam. After the wires are connected, verify the operation of the passing lamps, running lights and turnsignals. Correct any connection problems before reassembling the motorcycle. Reinstall the fuel tank. Check all fasteners used during this installation for tightness

Harley-Davidson 39mm Fork FXR, FXD, XL from 87 to Current, Light Bar N935 & N935E INSTALLATION AND OWNER'S MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2012

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1. Remove Headlight from Headlight Shell (Screwdriver) set aside. 2. Disconnect Turnsignal wires behind or inside Headlight Shell. 3. Unbolt Headlight Shell from Eyebrow (3/4″ Socket & Wrench). Let hang from wires. 4. Remove front Turnsignal Assemblies from motorcycle. 4a. If Turnsignals are mounted to the Handlebar use the 1/2″ Wrench. 4b. For fork mounted Turnsignals, 1996 to current, use the Torx Wrench 4c. For fork mounted Turnsignals 1987-92 use the 5/16 Hex Key Set turnsignals aside, they will not be reused. 5. Remove screw from Brake Hose Clamp and Clutch Cable Guide (Hex Key Wrench, 3/16″) located on the bottom of the lower Triple Clamp. Set aside, it will not be reused. 6 . Remove the Pinch Bolts from the lower Triple Clamp (Torx Wrench, 1993 to Current, or 5/16 Hex Key, 1987 to 92). Set aside, they will not be reused. INSTALLATION 1. Mount the Light Bar Assembly: A. Hold the Light Bar assembly up to the lower Triple Clamp, the center bracket will be below the Triple Clamp. B. Start the 1/4-20 x 3/4 Screw, with Washer, through the Brake Hose Clamp, clutch cable guide then the center bracket and into the threaded hole previously used for the Brake Hose Clamp. C. Position a Spacer between the Outer Brackets and the Triple Clamp and start the 3/8-16 x 2″ Hex Bolts through the Outer Bracket, then the Spacer and into the Pinch bolt location on the lower Triple Clamp. Do this on both sides of the lower Triple Clamp.

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2001 HONDA CRF 230 Dual Sport Kit Installation Manual

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Filed Under (Honda) by admin on 21-11-2010

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1. Remove the seat, fuel tank, side panels, and front number plate. 2. Taillight and Turn signal Installation: Note that Baja Designs has updated this kit to use the new style LED taillight. The mounting is the same. Mount the rear taillight assembly to the rear fender as shown in Photos 1 and 2. Transfer drill the mounting holes in the taillight assembly into the fender and mount using the countersunk fasteners provided. The tail light lens should just line up with the end of the fender. Mount the turn signals into the side of the taillight assembly as shown in Photos 1, 2 and 3. The taillight has not been pre-drilled to allow placement of the turnsignals to be varied to accommodate different exhausts. Use a 3/8″ drill for the turn signal mounting hole 3 Photo 3 Photo 2 Photo 1
. 3. Brakelight Switch Installation: This is a tight fit on the CRF230 – take your time and it’ll work. Drill a 1/8″ hole in the brake lever 4 ½” from the center of the brake pedal pivot point (Photo4). 4 Photo 5 Drill 1/8″ hole here Photo 4 Install the brake-switch bracket under the right case bolt directly above the oil filler cap (Photo 5). Attach the spring to the hole you drilled in the pedal. Adjust the switch in the bracket so it engages about halfway through the pedal throw. You may need to lengthen (stretch) the spring slightly to allow proper switch adjustment. Turn-Signal Switch Installation: Install the turn signal switch on the handlebar next to the grip as shown in Photo 6 . The switch has a single screw that pinches it together on one side. Two tabs secure the switch halves on the other side. Remove the screw to separate the halves so that it can be installed on the handlebar. When installing the switch to the handlebar, make sure the tabs are seated in their locating holes and then tighten the pinch screw. DO NOT OVER TIGHTEN THIS SCREW, as too much force can strip the body of the switch. The clutch perch may have to be moved inward slightly to make room for the switch. Run the wires along the bottom of the handle