Harley Davidson Ignition Switch Installation Manual

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Filed Under (Harley Davidson) by admin on 27-02-2012

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Ignition Switch a. Harley Davidson i. P/N 71313-96 ii. P/N 71510-93 b. Drag Specialties i. P/N DS-272187 c. JP Cycles i. Cat # 370333 3. Wires and Connectors a. 14 gage wire – Red, 15 inches long b. 14 gage wire – Orange, 15 inches long c. 14 gage wire – Grey, 15 inces long d. 14 gage wire – Brown, 15 inches long e. 14 gage Female Wire Terminals (x3) 4. Miscellaneous a. Radio Shack i. 100 Ohm Resistor (1/4 Watt, 5% Tolerance) – P/N 271-1108 ii. Also recommended – piece of PC board to solder wires and resistor to b. Heat Shrink Tubing – Pack of Assorted Sizes c. Duct Tape or Masking Tape d. 6″ (or longer) Zip (Cable) Ties 2. Nuts and Bolts a. For Switch Mount: i. 4x 6-32 (Chrome or SS) countersink screws ii. 4x nuts for above iii. 4x washers for above b. For Door Locking Mechanism: i. 5/16-18 Bolt (or stud) ii. 2x 5/16-18 nuts iii. Block of rigid material 1. Dimensions: 5/16″ x 9/16″ x 3/8″ 2. Material: Aluminum, Stainless Steel, PVC, etc (Anything rigid will do) iv. 5/16-18 Tap v. Series of drill bits up to 9/32″ (drill size required for 5/16-18 tap) i. Roll (or Spring) Pin and drill bit 1/32″ smaller than pin

HARLEY DAVIDSON CUSTOM TOURING FRONT BULLET TURN SIGNAL KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-04-2011

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INSTALLATION Outer Fairing/Windshield and Auxiliary Lamp Bracket Removal To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2 3 1 2 is 01215 1. Six-position connector 2. Four-position connector 3. Auxiliary lamp connector Figure 1. Disconnect Signal and Auxiliary Lamp 1. Remove Maxi-Fuse. Refer to SYSTEM FUSES, MAXI- FUSE in Service Manual. NOTE Since the outer fairing screws hold the windshield in place, the windshield may fall to the floor if not removed. 2. Remove the windshield and outer fairing. Refer to UPPER FAIRING/WINDSHIELD in Service Manual for the outer fairing/windshield removal procedure. 3. Disconnect auxiliary lamp and turn signal connectors. NOTE See Figure 1. On 2005 and prior year models, the left and right turn signals plug into a 6-place connector located on the left fairing support brace. On 2006 and later models, each turn signal plugs into its own 4-place connector located toward the bottom of the inner fairing on each side. 4. Using a T40 Torx® drive head, remove and save the four bolts securing the auxiliary head lamp bracket to the chassis. 5. Remove auxiliary lamp bracket from motorcycle. Turn Signal Assembly 1 is 01217 1. Triangular opening Figure 2. Insertion of Terminals Through Triangular Opening 1. See Figure 2. Insert wire terminals through the triangular opening in the turn signal mounting bracket included in the kit. 2. Fit turn signal housing onto bracket. 3. Apply a small amount of Loctite (243) blue (99642-97) to threads of hex head cap screw. 4. Tighten cap screw to 15-20 ft-lbs (20-27 Nm) . -J03753 1 of 2 Turn Signal Installation 1 is 01218 1. Turn signal wire Figure 3. Turn Signal Wire Routing 1. See Figure 3. Insert turn signal connector and wiring between bottom of fairing and top of outer fairing skirt. 2. Route turn signal wire under cutout on mounting bracket and place bracket onto motorcycle. NOTE Care must be taken so the turn signal wire is not pinched between turn signal bracket and motorcycle chassis. 3. Install washers onto turn signal bracket mounting bolts and apply Loctite 243 (blue) (99642-97) to the bolt threads. 4. Tighten mounting bolts to 15-20 ft-lbs (20-27 Nm) . 5. Route turn signal leads toward harness connector. Secure loose wiring with tie straps so wires do not rub against any sharp objects

HARLEY DAVIDSON TOUR-PAK SPOILER LIGHT KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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Installation 1. If the motorcycle was previously equipped with a Tour-Pak Spoiler Light, disconnect the light wires from the motorcycle. 2. Remove the Tour-Pak Spoiler from the Tour-Pak and disassemble original light or chrome trim (as equipped). Save the original mounting hardware for later installation. 3. Attach light assembly to spoiler using 10-24 x 7/8 in. long screws. 4. See Figure 1. Route light wires through 3/8 in. hole in Tour-Pak lid. Attach spoiler to Tour-Pak lid using original hardware removed in step 2. 5. See Figure 1. Attach the wires to the inside of the Tour- Pak with adhesive backed clips as shown. Route wires out front left corner of Tour-Pak bottom and support wires inside Tour-Pak bottom with the remaining adhesive backed clips as needed. Wires will exit out the bottom of the Tour-Pak through the antenna cable grommet. NOTE On Chopped Tour-Paks drill a 3/8 in. hole in the front left corner of the Tour-Pak bottom. Route the spoiler light wires through this hole for connection to the main motorcycle wiring. 6. On 1994 and later models, proceed to step 7 for wire connection instructions. On 1993 and earlier models, go to step 11 for wire connection instructions. WIRING INSTRUCTIONS FOR 1994 AND LATER MODELS 7. Remove the seat and locate the accessory circuit connector. Route the light wires along the frame and secure with cable straps from kit. 8. Refer to the Deutsch connector section in a 1994 or later FLT Service Manual and assemble the spoiler wires into the socket connector half supplied with the LED assembly. The wire terminals shall be inserted in the connector half as follows: WIRE COLOR CODECONNECTOR CAVITY Blue 1 Red/yellow 2 Sealing plug 3 Black 4 9. Remove the plug from the accessory connector located under the seat (connector number [4A] in wiring diagram in Service Manual). Connect wire from spoiler. Turn on ignition switch and test the spoiler light operation with taillight and brake light. 1 WARNING Always connect the positive battery cable first. If the positive cable should contact the ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 10. Reattach battery

TRIUMPH ROCKET III ELECTRIC HORN HARDWARE KIT INSTALLATION

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Filed Under (Triumph) by admin on 24-12-2010

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1. Remove the seat and left hand side cover. (held in place by two (2) 10mm bolts) Remove the chrome cover from the stock horn located below the headlights. (held in place by two (2) 5mm allen screws at the top of the cover) 2. Unplug the wires from the stock horn. Locate the supplied jacketed cord and attach the end with the piggyback jumpers to the horn wires. Plug these back onto the horn terminals as shown in photo (1). Remove the black plastic left side steering head frame cover (held in place with two (2) 5mm allen screws). Route the cord behind the headlights, along the left side of the frame and over the engine keeping it neatly out of sight. Route the end if the cord to where the relay will mount as shown in photo (2A). Replace chrome horn cover and steering head frame cover. 3. Using the relay supplied, refer to the wiring diagram included with the horn set and the small numbers next to the terminals on the relay. Connect the 2 wires from the jacketed cord to terminals #85 & #86. Connect the blade terminal of the fuse wire assembly (supplied) to terminal #30 on the relay. Attach the other end of the fuse holder to the positive (+) battery terminal. 4. On the horns bend the wire terminals outward so that they will be parallel to the mounting brackets when installed. Refer to photo (3) and assemble the horns onto their supplied mounting brackets as shown. Bolt two (2) of the four (4) flat silver brackets on each of the horns using the 6mm nuts and lock washers supplied. Bolt the black bracket to the left hand horn using the 6x12mm bolt and nyloc nut supplied. Place the 6 x 35mm bolt with a washer and lock washer thru the right hand horn bracket then the left hand black bracket and place the 3/8″ flange nut over the back of the bolt. Remove the bolt where the horns will mount (see photo 2B) and bolt the horn set on as assembled with the flange nut on the back side of the black bracket. Align the horns as shown in photo (2) being careful that the horns do not make contact with each other or any other parts as this will significantly reduce their output then tighten the bolt securely.

Ducati SPORT TOURING HEADLIGHT UPGRADE INSTALLATION AND REMOVAL INSTRUCTIONS

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

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1. Remove the following fairing components per the instructions in the Ducati owners manual: • Instrument surrounds • Headlight fairing • Chin fairing (under headlight/air intake) • Right-side middle fairing (covers battery) 2. Disconnect the speedometer cable from the speedometer. Unthread the ring nut at the top of the speedometer cable and retract the cable downward about 4-6 inches. 3. Disconnect the headlight wiring from the headlight bulbs. Retract the rubber boots at the rear of the headlight assembly to gain access to the wire terminals. Note that the two ¼ inch terminals at the high- beam bulb have locking clips that should be depressed before pulling the terminal away from the bulb. 4. Unplug the parking light from the headlight body by grasping the wires and carefully pulling it out. 5. Remove the two rubber plugs covering the lower headlight mounting screw access holes beneath the air intake horn. 6. Using an 8mm hex socket inserted through the lower access holes remove the two hex-head bolts securing the bottom of the headlight to the frame. 7. Using the same socket wrench, remove the two 8mm hex-head bolts securing the top of the headlight assembly to the frame. 8. Remove the headlight assembly from the frame. 9. Remove the two rubber grommets and steel reducing sleeves from the frame at the top mounting locations for the headlight. Leave the lower pair in place; these will be re-used, as shown in Figure 6

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