HARLEY DAVIDSON XR1200 LUGGAGE RACK KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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Kit 53976-08 (XR1200 Passenger Upright Kit) is available for separate purchase. Contact your Harley-Davidson dealer for more information. Kit Contents See Figure 2 and Table 1. REMOVAL 1. Remove pillion and seat following the instructions in the appropriate Service Manual. 2. Remove the seat base following the instructions in the appropriate Service Manual. 3. See Figure 1. Remove the turn signal mounting screws (3) and discard. Allow the turn signal to hang by the harness until lower bracket installation. 4. Remove the rear fender support strut screws (6) and dis- card. INSTALLATION 1. See Figure 2. Install lower luggage rack mount bracket with screws (9), flat washers (10) and nuts (8). Bracket will mount around nut (Item 2 in Figure 1). Tighten to 19 ft-lbs (26 Nm) . 2. Install screws (7) and nuts (8) through the rear fender support strut and the lower luggage rack mount bracket. Tighten to 19 ft-lbs (26 Nm) . 3. Route the turn signal wire harnesses through the groove in the bracket. Install new turn signal mounting screws (11). Tighten screws to 3-5 ft-lbs (4-7 Nm) . 4. Install seat base following the instructions in the appropriate Service Manual. 5. Install upper luggage rack mount bracket (4) with original equipment seat base screws in the lower holes (A). Do not tighten at this time. 6. Install screws (3) into slotted holes in the upper luggage rack mount bracket (4) and flange nuts (6). Slide the upper bracket as far back in the slots as possible. Tighten screws (3) to 10 ft-lbs (13.5 Nm) 4 1 1 2 5 6 3 is05250 1. Lower luggage rack mount bracket screw (4) 2. Nut (2) 3. Turn signal mounting screw (4) 4. Upper luggage rack mount bracket 5. Luggage rack 6. Rear fender support strut screw (2) Figure 1. Luggage Rack Installation NOTE If installing the Passenger Upright Kit (part number 53976-08) (available separately), do not install spacers (2) and screws (3) in front holes. 7. Install luggage rack (1) aligning the holes with the holes in the upper luggage rack mount bracket. Install spacers (2) and screws (3) in holes. Tighten to 6-10 ft-lbs (8-13.5 Nm) . After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 8. Install pillion and seat following the instructions in the appropriate Service Manual. Do not exceed luggage rack weight capacity. Too much weight can cause loss of control, which could result in death or serious injury. (00373a

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YAMAHA ROADSTAR TRIKE Removal of Clear Taillights and installation of Red Taillights

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Filed Under (Yamaha) by admin on 16-02-2011

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1 Installation of Lights 1.1 Support the trike on jack stands and remove the wheels. 1.2 Remove the clear lights from the inside of the wheel wells by unscrewing the three (3) screws from the light. 1.3 Unplug the wires and remove the lights. 1.4 Remove the chrome bezels and rubber gaskets from the clear lights and install on the red lights (5 screws). 1.5 Re-connect the wire plugs and install the red lights to the trike body using the same three screws. 1.6 Replace the wheels and torque the lug nuts to 75 lb.ft. 2 Wire modification inside trunk 2.1 From the inside of the trunk pull back the carpet on both the left and right hand sides to expose the wire harnesses coming from the wheel wells. 2.2 Locate the resistors in the harness, 2.5″ x 0.5″ x 0.5″, and covered by black shrink wrap. 2.3 Cut the shrink wrap to expose the resistors and cut wire on both side of the resistors. Remove and discard resistors. 2.4 Splice in the supplied 5″ green wires (WITHOUT the diodes) with 2 blue scotchlock connectors per side to reconnect the cut wires. 2.5 Do not glue in carpet until lights are tested. 3 Change to pigtail from Trike to Motorcycle. 3.1 Remove driver’s sear 3.2 Unplug pigtail from motorcycle (MC) wiring and trike body wiring. 3.3 Cut heat shrink on the MC plug side of the pigtail and pull expansion sleeve back to expose the wires. Figure 1 3.4 Cut Green and Yellow turn signal wires and about 3″ from the MC plug and splice in Green and Yellow wires from the supplied resistors with the supplied hest shrink solder connectors (heat to be applied) – (three wires in one connection) Figure 1 3.5 Cut the Red (Brake) and Brown (Running lights) wires and splice in the supplied diodes with the supplied heat shrink solder connectors. Red side of the diode wire facing the Trike plug. Figure 1 3.6 Connect eye lug on the black wire from the resistors to the negative terminal of the battery. Figure 2 3.7 Plug pigtail back into the Trike body and the MC

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2008 SUZUKI GSX 1300 RK IGNITION SWITCH INSPECTION/ REPLACEMENT

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Filed Under (Suzuki) by admin on 29-11-2010

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INSPECT ROUTING 1. Remove the upper and lower meter panels (refer to Service Manual page 9D-15). 2. Check if the ignition switch lead wire is clamped and routed correctly. Incorrect positions are shown in Figures 1 and 2. Correct routing and clamping is shown in Figures 3 and 4 on page 5. REROUTING 1. Reroute the ignition switch lead wire correctly (Figure 3 and Figure 4). The ignition switch lead wire should not be covered by the other wire harnesses. 2. Turn the handlebars back and forth to verify that the steering operates smoothly and the wiring harness does not become kinked or pinched. 3. Proceed to PUNCH MARK AT VIN on page 8. from the motorcycle (refer to Service Manual page 1H-12). Remove the two black plastic covers to access the cylinder cap mounting bolts (Figure 5). Note: The black plastic covers will not be reused. Secure the mount area (bottom) of the ignition switch in a vise (Figure 6). NOTE: Turn the ignition switch to the OFF position and remove the key from the ignition switch before disassembling the switch. Remove the two “break-off” screws from the ignition switch using the special screwdriver. Set the stepped end of the sleeve on the special screwdriver facing toward the “break-off” screws (Figure 7). Strike the special screwdriver 5 to 7 times with a hammer to produce a deep enough groove on the screw head for the screwdriver to work properly (Figure 6). Pay attention not to hit other parts with the hammer. Turn to remove the “break-off” screws in a counterclockwise direction. If the groove becomes damaged, make another groove at a 90o angle to the original groove. Remove the ignition switch from the vise and hold it upright over the workbench and carefully remove the cylinder cap (Figure 8). NOTE: Pay close attention to the order and orientation of the ignition switch parts during disassembly. REPLACEMENT OF IGNITION SWITCH (Customer Sold Units/Dealer Demo Units- Only If Inspection Shows Incorrect Routing And Unit Has Been Ridden) New Ignition Switch Disassembly 2.

Kawasaki Sxi / SXR Tempest 4 (T4) Installation Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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Installation Remove electronics enclosure from its Mounting Location 1. Using a 10mm socket remove the mounting bolts on each side of the electronics enclosure. 2. Remove the enclosure cover and set aside the screws, 2 mounting flanges, ‘O” ring, and enclosure top. Unplug and Remove the OEM Ignition 3. Using 10mm socket, remove bolts from each side of the OEM ignition module. Lift the ignition out then unplug all connectors attached to the ignition. Leave in place the metal shield plate and the two spacers under the plate. Secure the plate and spacers by reinstalling the bolts just removed. 4. 2004 and newer models: remove the wire harness for the two black connectors previously connected to the OEM ignition. Trace each wire from each black connector back to the in-line connectors and separate each of these connectors. Set the two wire harnesses aside. 1 Mount the T4 Ignition on shield plate 5. Remove the protective coverings from the two strips of double-face tape on the back of the T4 ignition, position the ignition on the shield plate such that the T4 connector overhangs the edge of the plate and press the ignition in place. This position is required to allow the mating connector latch to be assessable. Be sure of the position before pressing it into place as the tape cannot be removed once in place. Wiring the T4 Ignition 6a. Attach each wire from the T4 connector the mating connectors with matching colored wire in the electrical box. 6b. 2004 and new models: There are two Yellow/Red wires, one with a male connector, the other with a female connector. These wires do not connect to the T4, simply plug these mating connectors together

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