HONDA GL1100 AM/FM RADIO INSTALLATION MANUAL/ WIRING DIAGRAM

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Filed Under (Honda) by admin on 22-04-2011

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INSTALLATION ■ Outline Procedures This section gives general information needed for mounting the individual radio components on and in the fairing. A) Fairing 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove fairing parts. 3) Drill unit mount holes. 4) Install six wire clips. 5) Install windshield on fairing before install- ing speakers. 6) Install radio indicator I on indicator panel II , then install indicator panel on fairing. 7) Install speakers III. 8) Install nutplate IV. 9) Install Power Amplifier in fairing. 10) Install radio funer VI. 11) Install the radio controller VII. 12) Install controller base panel VIII 13) Install radio switch sub-wire. 14) Connect adapter harness and wires inside fairing by working through left turn signal lens hole. B) Motorcycle frame and handlebar 1) Remove travel trunk and seat. Unscrew four shelter bolts (M6, one on each side at front and rear) to route antenna feeder. 2) Install antenna mount and antenna IX. 3) Route antenna feeder along the frame tube. 4) Install radio switch X on left handlebar lever bracket and route the wires. 3 of 11 Page 4 C) Fairing instllation 1) Install fairing on motorcycle. 2) Connect motorcycle wire harness 9-P coupler to fairing wire 9-P coupler. 3) Connect radio switch wire to switch sub- wire.4) Connect antenna feeder. 5) Confirm that radio operates properly. Reinstall parts removed in step 2 or (A) and in step 1 of (B). REWORKING ■ Remove Fairing and Fairing Parts (Fig.10) 1) Install radio on fairing before mounting fairing on motorcycle. (Remove fairing from your motorcycle when already mounted). 2) Remove right and left fairing pockets, right and left turn signal lenses, right and left nutplates, left hole cover and indi- cator base panel from fairing. (Fig.10) Fig. 10 LEI-1 NU I PLATE 4 of 11■ Reworking on Fairing — Speaker mounting holes- 1) Remove 18 mm grommet. 2) Lightly roll template so that it will follow contour of fairing snugly. 3) Position template on fairing with its upper and outer edges aligned with those offairing as indicated by arrows. 4) Attach template to fairing using adhesive tape where shown. 5) Punch mark centers of four holes with a
drift and hammer. 6) Drill 6 mm holes through marked centers. To obtain a more balanced response with richer, deeper bases, drill two 50 mm holes in the fairing so as to link the speaker box with the inside of the fairing. Fig. 11-1
—Power amplifier mounting holes- 7) Drill two 5.5 mm holes through concaves in fairing. Fig. 11-2 RIGHT HAND SHOWN, LEFT SIMILAR ADHESIVE TAPE

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2002-2005 Honda VFR800/A Wire Harness Replacement Manual

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Filed Under (Honda) by admin on 21-04-2011

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If the 18P (light blue) connector is in abnormal condition as shown below, contact TechLine at (800) 421-1900, option 9. FRONT SUB-HARNESS REPLACEMENT 1. Remove the front sub-harness from the cowl stay hooks. Disconnect all the electrical components from the front sub-harness. 2. Temporarily set the main wire harness aside, and disconnect the 6P (natural) con- nector. Then, carefully remove the front sub-harness. 3. Install the new front sub-harness by con- necting the 14P (natural) and 18P (light blue) connectors. NOTE: For routing specifications, refer to the WIRING & HARNESS ROUTING SECTION on pages 7-8. 4. Attach the front sub-harness on the cowl stay hooks. Make sure the front sub-harness is routed elow the main sub-harness. ABNORMAL CONDITION STAY HOOKS 6P (NATURAL) CONNECTOR FRONT UB-HARNESS 14P (NATURAL) CONNECTOR 18P (LIGHT BLUE) CONNECTOR FRONT SUB-HARNESSSTAY HOOK Page 4 VFR800/A #4 4 of 12 NOVEMBER 2007 5. Place the front sub-harness between the radiator and the frame, and below the rec- tifier. Be careful not to damage the front sub-harness or other components. 6. Re-connect the front sub-harness to the 6P (natural) connector. 7. Secure the main wire harness and the front sub-harness using the longer wire band. 8. Secure the main wire harness and the upper side of the front sub-harness using the shorter wire band. Adjust the wire har- ness located within the frame and the radi- ator hose accordingly. 9. Secure the main wire harness fuse box to the front sub-harness using the shorter wire band. FRONT SUB-HARNESS STAY HOOK MAIN-HARNESS FRONT SUB-HARNESS FRONT SUB-HARNESS 6P CONNECTOR (Male) 6P CONNECTOR (Female) WIRE BAND (LONG) WIRE BAND (SHORT)
WIRE BAND (LONG) WIRE BAND (SHORT) MAIN WIRE HARNESS FUSE BO

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2003 Honda ST1300/A Wire Harness Inspection and Repair Manual

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Filed Under (Honda) by admin on 21-04-2011

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REPAIR PROCEDURE Note: While completing this procedure DO NOT disconnect the 2-pin connector unless repair of the wire harness is required. 1. If not previously done, complete the ST1300/A #1 Service Bulletin before starting this procedure. 2. Remove the seats, left saddlebag, and left side panel by following the instructions in section 2 of the Service /l/Ianua/on pages 2-5 and 2-6. 3. Secure the centerstand assist handle out of the way. 4. Remove the rear shock adjuster support bar top bolt and move the bar out of the way. 5. Locate the ignition cord leading to the 2P connector and check the two black and white wires for chafing. |GNlTl6N con BLACK AND WHITE WIRES Chafing V I may OOCUF _ in this area 2-PIN CONNECTOR 2of6 – If the insulation is still intact and copper wire is not showing, proceed to the Preventative Measure section of this bulletin. – lf copper wire is showig, wrap the exposed area of the wire with a good quality electrical tape and proceed to the Preventative Mea- sure section of this bulletin. Preventative Measure: 1. Place the length of PVC split tubing around the ignition cord, butting up against the con- nector. Rotate the split toward the inside of the motorcycle. 2. Use good quality electrical tape to cinch the end of the PVC split tubing together (at the end that is touching the 2-pin connector), together. Secure the PVC split tubing to the ignition cord at the other end with electrical tape. 3. Secure the ignition cord and wire harness cord to the rear sub-frame with a commer- cially available wire band. The 2-pin connector should be routed behind and to the rear of where the rear shock adjuster support bar is located. ~! IR ARNESS C R COR W EH O D

2001 Honda GL1800 Oxygen Sensor Replacement Manual

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

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REPAIR PROCEDURE 1. Remove the top shelter (see page 2-10 in the Service Manual). 2. Remove the left and right O 2 sensors from the exhaust pipes. • You do not have to remove the exhaust pipes to remove the O 2 sensors. • Be sure to note the wire routing for proper reassembly. 3. Install the new O 2 sensors and route the wires properly (see pages 1-33 and 1-34 in the 2001- Service Manual). 4. Connect the black 4P female coupler of the sub- harness kit to the wire harness side black 4P male coupler (for the left-side O 2 sensor). 5. Connect the new left O 2 sensor to the black 4P coupler on the sub-harness. 6. Route the sub-harness from left to right, across the front edge of the fuel tank and secure it with the clip on the cruise actuator 7. Cut off the right 4P male O 2 sensor coupler (on the wire harness side). 8. Install a PVC cap onto the end of the Black/yellow wire and Green/red wire (these are the wires that were connected to the coupler that was removed in step 7). Fold each cap back and tape it securely to its wire; these wires are no longer used. • Do not cut the wires off, just tape them back. • The tape is supplied in the replacement kit. 9. Strip the ends of the White and Black/red wires (which were connected to the coupler that was removed in step 7) on the wire harness side and the 2P coupler on the sub-harness. Install a heat shrink tube on each wire of the sub harness. 10. Twist the ends of the White and Black/red wires of the sub-harness 2P coupler to the White and Black/red wires of the main harness. 11. Solder the wires using the solder from the kit. 12. Use a heat gun to secure the heat-shrink tubing over the soldered wires. 13. Connect the right O 2 sensor coupler to the white 4P male coupler on the sub harness.

HARLEY DAVIDSON HIGH INTENSITY DISCHARGE (HID) DUAL BULB HEADLAMP KIT INSTALLATION MANUAL

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

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REMOVAL 1. Remove seat according to the instructions in the service manual. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 2. 2003-Earlier Models: Disconnect battery cables, negative (-) cable first. Refer to the service manual. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 3. 2004-Later Models: a. Remove left saddlebag. Refer to the service manual. b. Remove left side cover and main fuse. Refer to the service manual. 4. Remove fuel tank according to the instructions in the service manual. 5. See Figure 1. Remove the Phillips screw (1) at the bottom of the bezel and remove the bezel. Save parts for installa- tion. 1 2 is03916 1. Phillips screw 2. Bezel Figure 1. Remove Bezel 6. See Figure 2. Remove and save Phillips screws (1) that secure mounting ring assembly (2) to nacelle. 7. Gently pull headlamp assembly out far enough to disconnect wiring. Save short wire harness for installation. 8. Remove wire connector at the back of the headlamp bulb. 9. See Figure 2. Remove three screws (3) securing the retaining ring (4) and headlamp assembly to mounting ring assembly. Discard mounting ring assembly, but save three screws and retaining ring for installation

HARLEY DAVIDSON TLE/TLE-ULTRA SIDECAR ATTACHMENT KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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REMOVAL NOTES Refer to the service manual for more information on these generalized steps. Save all removed parts (unless otherwise noted) for installation of this kit or for motorcycle operation without the sidecar. 1. For TLE-Ultra Models: Remove both lower fairings. 2. Remove the bolt and lockwasher securing the right passenger footrest bracket and remove the bracket with footrest. 3. Remove the three right side exhaust heat shields. Some models may require removal of the right side exhaust pipes. 4. Remove stock clutch cable. 5. Remove rear master cylinder/rear brake pedal assembly. Remove rear brake pedal from master cylinder assembly. Remove and save rubber pedal pad and brake pedal. Discard cotter pin. 6. Cut the cable straps holding front oxygen sensor connector to frame bracket. 7. Remove wire harness/brake line clip from right lower frame tube. INSTALLATION New Clutch Cable Installation 1. Refer to the service manual and follow instructions to remove stock clutch cable. 2. Refer to the service manual and follow instructions to connect the new clutch cable to clutch hand lever. 3. For FLHT/C/CU: Follow the instructions in the service manual to route new clutch cable through fairing. 4. For FLHR/C Models: Capture the cable in a clamp at the left upper passing lamp bolt. On FLTR models, capture the cable in a clamp at the left upper bolt securing the speedometer and tachometer housing to the upper fork bracket. These locations are identical with stock cable routing. 5. See Figure 1. Route clutch cable down along left frame downtube (1). 6. Continue to route cable down between left front engine isolator and crankcase. Clutch cable will cross to the right side of motorcycle beneath the crankcase, to the clutch release cover on the right side of the transmission. 7. Install clutch cable fitting into clutch release cover. Refer to the service manual. NOTES The final positioning and attachment of the clutch cable and clutch cable adjustment will be performed after sidecar mounts have been installed. Verify that the clutch cable and the rear brake line do not make contact. Damage could result. 1 2 3 is05785 1. Downtube 2. Clutch cable 3. Route clutch cable behind left front engine iso- lator Figure 1. Route Clutch Cable Relocating Oil Pressure Sending Unit NOTES Perform this procedure on all models equipped with an oil pressure gauge or Police models. All other models proceed to “Master Cylinder Assembly/Rear Brake Pedal Modification.” 1. Remove cable strap securing oil pressure wire harness to frame. 2. Locate the latch on connector to oil pressure sender (next to lower right frame downtube). Raise latch on connector and disconnect connector from oil pressure sender. 3. Remove the oil pressure sender using a 1-1/16 inch open- end crowfoot wrench. 4. See Figure 16. Coat threads of elbow (44) with Loctite 565 and install into crankcase oil pressure sender threads. 5. See Figure 2. Install elbow (1) until snug so open end is in the five-o’clock position (2). Do not over-tighten or crankcase may be damaged. 6. Coat threads of oil pressure sender with Loctite 565 and install into 90 degree brass elbow. Use a 1-1/16 inch open- end crowfoot and tighten to 96-120 in-lbs (11-14 Nm) . 7. Install connector on oil pressure sender unit. Verify that slight clearance to the right engine isolators is present. Adjust position of elbow as required to provide clearance

HARLEY DAVIDSON BOOM! AUDIO MUSIC AND INTERCOM KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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Intercom system flash (H-D Part No. 76441-06DT) Non-Ultra Overlay Harness (H-D Part No. 70169-06) NOTE For a more integrated appearance of the rider headset connector, the console may be replaced using an Ultra Classic Electra Glide console and/or console pod. See FLHTCU parts manual for applicable parts, and service manual for installation instructions. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 7 and Table 2. REMOVAL 1. Refer to the service manual and remove the following: a. Main fuse. b. Outer fairing. c. Seat. d. Fuel tank and console. e. Inner fairing cap. f. Wire trough cover. g. Left hand control. h. Left side saddlebag. INSTALLATION Install Switch Housing on Passenger Headset Harness 1. See Figure 1. Install push-to-talk switch housing (2) to passenger headset plug housing (3), included as part of passenger headset wire harness (see Figure 7, Item 6). 2. Position the switch housing so the knob is located close to the flip cap on the passenger headset connector. 3. Install self-tapping screws (1) to the switch housing but do not fully tighten at this time. Location adjustment may be required based on the motorcycle model, seats and accessories installed on the vehicle Secure Headset Connector and Switch Housing 1. 2006-2008 FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, See Figure 7. Use the fender support cover fastener to install the smaller P-clamp (11) from the kit. For vehicles WITH docking hardware, use the front docking point fastener. Install the smaller P-clamp (11) between the outside face of the docking point behind the screw and washer. 2009-later FLHX, FLTR, FLHT/C models: For motorcycles WITHOUT docking hardware, see Figure 2. Use the threaded hole in the frame using screw (4), washer (3), spacer (2) and the smaller P-clamp (5) from the kit. For motorcycles WITH docking hardware, use the docking point shown in Figure 3. Install the smaller P-clamp from the kit to the outer end of the docking point using the docking point washer and screw. 2009-later Trike models without the Tour-Pak (FLHXXX): See Figure 4. The headset/switch assembly (1) will be secured to the frame at the location shown using the 1/2- 13 screw (3) and the larger P-clamp (2) from the kit. 2. For ALL models: Once the position of the PTT/VOL switch has been established, securely tighten the self-tapping screws installed to the switch housing earlier.

HARLEY DAVIDSON BILLET HEADLAMP WITH SHORT/ TALL MOUNTS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Kit 68593-06 is a 5-3/4 inch headlamp and kit 69851-06 is a 4-1/2 inch headlamp. Both kits will fit the models listed in Table 1. Table 1. Short and Tall Mount Kits Models Kits 1984-1999 FXSTC, 1998- Later FXST/B, and 2000-Later FXSTD; 1994-2005 FXDWG Short Mount Kit 68595-06 1996-Later XL 1200C and 1998-Later XL 883C; All 2006 Dyna Models; 1999-2000 FXR2/3/4 Tall Mount Kit 69611-06 Additional Parts Required This kit also requires the separate purchase of a Short or Tall Mounting Kit 68595-06 or 69611-06 for your model motorcycle, and can be purchased from a Harley-Davidson dealer. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 21, Table 2 and Figure 22, Table 3. REMOVAL Remove Headlamp and Mounting Bracket for Softail Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. 2. Remove fuel tank. Refer to FUEL TANK in Service Manual. 3. Disconnect 4-place headlamp connector [38] from main wire harness. Headlamp connector is located under fuel tank on left side. 8 5 7 5 6 2 1 3 4 is01835 1. Screw 2. Washer 3. Nut 4. Lockwasher 5. Washer (2) 6. Screw 7. Mounting block 8. Headlamp assembly Figure 1. Softail and Dyna Headlamp Assembly with Mount (except FXSTD) NOTE All Softails (except FXSTD) complete steps 4 through 6. For FXSTD models complete steps 7 through 9 4. All Softails (except FXSTD): See Figure 1. Remove screw (1) and washer (2) from stem and bracket. Discard screw but save washer for later use. 5. Remove and discard mounting block (7) and headlamp assembly (8). 6. FXSTD models: See Figure 2. Remove screw (1) and washer (2) from stem and bracket. Save screw and washer for later use. 7. Remove and discard nut (3), washers (4), and screw (5). 8. Remove and discard mounting block (6) and headlamp assembly (7). 7 3 4 2 1 4 6 5 is01838 1. Screw 2. Washer 3. Acorn nut 4. Washer (2) 5. Screw 6. Mounting block 7. Headlamp assembly Figure 2. FXSTD Headlamp Assembly with Mount Remove Headlamp and Mounting Bracket for Dyna Models 1. Remove seat following the instructions in the Service Manual. 2. Disconnect negative (-) battery cable. 3. Remove fuel tank. Refer to FUEL TANK in Service Manual. 2 1 is01750 1. Cable strap 2. Wire harness Figure 3. Dyna Service Loop (2005-Earlier) 4. 2005-Earlier FXDWG: See Figures 3 and 4. Remove plug on right side of top frame tube. At service loop, remove cable clip and push wire harness into top frame tube. Pull connector out from hole on right side of tube. 2006-Later FXD: See Figure 5. Remove cover under top frame tube, then pull connector out from opening under tube. 5. Disconnect 4-place headlamp connector [38] from main wire harness

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HARLEY DAVIDSON TRIBAR LED TAIL LIGHT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove main fuse. Refer to service manual for location. 2. Remove seat using service manual instructions. 3. Remove rear tail light using service manual instructions. 4. Remove rear turn signals using service manual instruc- tions. 5. See Figure 1. Clip the cable strap (1) to free the rear harness from the chassis seat pan. 6. Unplug the 8-place connector (2) from the rear harness connector. 1 2 is05510 1. Cable strap 2. Harness connector Figure 1. Rear wire harness 1 2 4 3 is05511 1. Screws 2. Fender cover 3. Frame rail 4. Mounting bracket Figure 2. Remove Fender NOTE The fender support covers do not have to be removed from the upper shock absorber bolts. 7. See Figure 2. Remove the two rear fender support cover screws (1) and remove covers (2) and fender mounting -J04721 bracket (4). Repeat for opposite side and carefully remo ve fender and place it on a non-scratch surface. 8. See Figure 3. Clip and remove two cable straps (1). Pull wire harness three inches towards the license plate bracket. 9. Remove flange nuts (2) from both sides of license/tail light bracket stud plates (3) and remove bracket. Save stud plates and flange nuts. 1 3 2 is05517 1. Cable straps 2. Flange nuts 3. Stud plates Figure 3. Rear Harness Cable Straps, Flange Nuts and Stud Plates 10. Install new license/tail light bracket using stud plates and flange nuts previously removed. Tighten nuts to 5-6 ft-lbs (6.8-8.1 Nm) . 11. See Figure 2. Install rear fender by installing two screws (1) on each side through the fender support covers (2), frame rails (3) and into the fender mounting brackets (4). Tighten to 12-18 ft-lbs (16.3-24.4 Nm) 12. See Figure 1. Connect rear harness connector to 8-place connector on main harness. 13. Use a large cable tie strap from kit to secure the rear harness to seat pan. 14. Install rear turn signal lights using service manual instructions. 15. Verify that there is no excess wire harness near the stud plate then secure the harness with a large cable strap where the straps were previously removed. 16. See Figure 4. Secure the turn signal harness (3) to the stud plate (1) using small cable strap (2) and route the turn signal wire through the tail light bracket clip (4) as shown.

SUZUKI SV650 Fl SYSTEM DIAGNOSIS SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system . ELECTRICAL PARTS CONNECTOR/COUPLER • * When connecting a connector, be sure to push it in until a click is felt. •With a lock type coupler, be sure to release the lock when isconnecting, and push it in fully till the works when connecting it. • * When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires . • * Inspect each terminal on the connector/coupler for looseness or bending. • * Inspect each terminal for corrosion and contamination. The terminals must be clean and free of any foreign material which could impede proper terminal contact . •Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. •When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector/coupler . 0 4 40 O/ 40 16~ Id •When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open . Connect the probe as shown to avoid opening of female ter- minal. Never push in the probe where male terminal is supposed to fit. •Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc . FUSE • * When a fuse blows, always investigate the cause correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . ECMNARIOUS SENSORS •Since each component is a high-precision part, great care should be taken not to apply any sharp impacts during removal and installation. • * Be careful not to touch the electrical terminals of the ECM . The static electricity from your body may damage this part . FI SYSTEM DIAGNOSIS 4-3
4-4 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch, or electronic parts may get dam- aged. • * Battery connection in reverse polarity is strictly prohibited . Such a wrong connection will damage the components of the FI system instantly when reverse power is applied . • * Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electromotive force will be applied to the ECM which may result in serious damage.

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