HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

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Basic Motorcycle Maintenance/ Repair Manual

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Filed Under (Tips and Review) by admin on 24-11-2010

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1. Types of Motorcycles and Components a. Identify off-road, street bikes, three and four wheel cycles. b. Identify motorcycle components. 2. Demonstrate Safe Working Habits in the Shop. a. Demonstrate, list, and discuss personal safety habits. b. Demonstrate, list, and discuss shop safety. 3. Correct use of Tools (common and measuring) and Equipment a. Perform work on cycles using proper hand tools. b. Perform work on cycles using shop equipment correctly. 4. Specifications in a Shop Manual a. Locate engine tune-up specification. b. Locate engine lubrication and cooling capacities. 5. Identify and Describe Different Types of Fasteners a. Threaded and non-threaded. b. Nuts, bolts, and washers. c. Metric and English. d. Strength and Grade. e. Thread inserts. 6. Identification and Description of Engine Fundamentals a. Basic two cycle engine. b. Basic four cycle engine. c. Displacement and compression ratios. d. Horsepower and torque. 7. Disassembly, Service, and Reassembly of the Components of the Clutch and Final Drive Assembly a. Remove, measure and replace clutch components. b. Clean, lubricate, and measure chain. c. Clean and measure sprockets. d. Adjust and align rear wheel. e. Discuss shaft drive. 8. Service of Brakes, Tires, and Wheel Assemblies a. Service and adjust drum brake. b. Service disc brake caliper. c. True a wheel by adjusting spokes. d. Replace or repair a tire. 9. Attitudes and Work Habits a. Identify and develop positive attitudes toward tasks and fellow employees appropriate for the workplace, including giving and accepting criticism and praise. b. Identify and develop productive work habits, including attending to detail, completing tasks, maintaining the work setting and recording data. c. Identify and develop collaborative/teamwork skills, including solving problems in groups, building consensus, and responding to supervision

BMW R850, R1100, R1150, R1200 Oilhead Maintenance Manual

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Filed Under (BMW) by admin on 16-11-2010

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cold Engine and Drivetrain Procedures Check Alternator Belt Tools Parts T-handle hex – 4mm none Note: In most cases the alternator belt does not need to be checked any more. Early models should have the pulley and belt upgrade that came out a few years ago. Current recommendations are that the belt is installed and adjusted, then not disturbed until 36K when replacement is specified. 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Check the belt for cracks or shredding. 4. Check the belt tension, quite tight, ~1/4″ deflection when you press on the center. Note: Paul Glaves suggests that proper belt tension is when you can twist the belt ~90 degrees, midway between the pulleys. If you can twist it more than 90 degrees, it is too loose. If you cannot twist it 90 degrees, then it is too tight. 5. Leave the cover off for the valve adjustment procedure on the next page. Change Alternator Belt Tools Parts T-handle hex – 4mm alternator belt socket – 13mm ratchet wrench – 13mm torque wrench 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Loosen the 2 nuts and 1 bolt, 13mm, that hold the alternator – one is on top and one is on each side, thus allowing the alternator to pivot down. 4. Remove the old belt. (Some bikes have a pipe that traps the belt – loosen it enough to get the old belt out and the new belt in) 5. Install the new belt being sure it is properly seated. 6. BMW calls for a tensioning torque of 5.9 ft.lb. (8 Nm) on the adjuster bolt on the left side of the bike. You have to get at this bolt from the alternator side and you may have to lift the tank. Alternatively, you can pry the alternator up with a large screwdriver to tension the belt. 7. Once the belt is under proper tension, tighten the 2 nuts and 1 bolt, 13mm, to 15 ft.lb. (20 Nm). 8. Check the belt for proper tension (see above) and proper seating alignment

BMW Motorcycle R 1100 RS – Rear Frame

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Filed Under (BMW) by admin on 16-11-2010

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Complaint: On R 1100 RS models (above serial numbers only) with luggage racks, a crack may develop in the rear section of the frame (see drawing) if a load exceeding the permitted 11 lb. is applied to the luggage rack, or if a top case is used. Remedy: Please check all R 1100 RS models (in serial number range above) which pass through your workshops for cracks on the rear section of the frame. Cracked frames should be exchanged with the new part listed below. The new rear frame has been reinforced to use with larger loads. New Part: 46 51 2 320 698 (reinforced rear frame) Caution: Since the introduction of the rear luggage grid to accommodate the 33 liter removable top box, it is vital that this luggage grid and 33 liter top box not be installed on any of the above unless the reinforced rear frame is fitted, or a frame reinforcement kit is installed (a kit will be made available in the future to reinforce the rear frame of the above models, in order to install the 33 liter top box). The new reinforced rear frame (46 51 2 320 698) has been fitted since May 1995 production. Use of the new rear section of frame on an earlier production bike requires a new rear section of the dual seat as follows: Parts 52 53 2 325 121 Flash Green 52 53 2 325 122 Red Needed: 52 53 2 325 123 Black 52 53 2 325 120 Light Gray 52 53 2 325 211 Anthracite Warranty: Please explain to your customers that the top case can only be installed on bikes with reinforced rear frames. Claims for frame cracks which result from operation with large loads beyond specification will not be honored under the terms of the Limited Motorcycle Warranty.

SHOCK CUTAWAY SADDLEBAG INSTALLATION INSTRUCTIONS

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Filed Under (Tips and Review) by admin on 10-11-2010

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1. Saddlemen saddlebags mount over the back of the seat or rear fender of most motorcycles. When properly installed there will be one saddlebag on each side of the motorcycle with the split yoke resting on the fender or the seat. Both saddlebags must be securely mounted and tied down in a manner that does not interfere with any part of the motorcycle’s operation. Be certain the saddlebags or their mountings do not contact brake components, turn signals, taillight, brake light, suspension, swingarm, or drivetrain. These Shock Cutaway saddlebags have been designed to fit over your bike’s shock absorbers (see Fig. A), which allow for larger bags on bikes otherwise limited by shock and turn signal location. 2. We highly recommend that your bike be equipped with Saddlemen’s S4 saddlebag supports (see Fig. B) or equivalent. Saddlemen also offers Quick Disconnect rigid-mounting hardware kits for most bikes, that allow easy on, easy off bag installation and eliminate the yoke. For more information, see your dealer or contact Saddlemen at 310- 638-1222. 3. Your saddlebags must be at least two inches away from any exhaust pipe while the motorcycle is stationary or moving. You can adjust the split yoke to change the height of the bag on the motorcycle by adjusting the position of the hook and loop fastening system (Fig. C). Adjust the split yoke shorter to raise the height of the saddlebags, and longer to lower the height of the saddlebags. The split yoke can also be reversed by unbolting each yoke half from each saddlebag, and reversing the yoke’s position on your bike. This allows for the offset in the yoke to be positioned either forward or backwards providing clearance for the motorcycle’s components (Fig. D). 4. In addition to the hook and loop fastener, the bags rely on a nylon safety strap system to ensure proper and secure installation. This strap must be used, and tightened snugly. Assure that the strap’s short end with D-rings is pushed through the slot in the split yoke and resting on the topside it. Once the split yoke is set to the proper position, run the long safety strap over the top of the split yoke and secure it to the D-rings (see Fig E and F), and tighten it. 5. Once you’ve placed the saddlebags on your bike and have them adjusted properly, use the straps located on the bottom of each saddlebag (see Fig. E and G) to connect the saddlebag to the saddlebag support (if you are using Saddlemen’s S4 Saddlebag bracket refer to the instructions shipped with it). These lower straps adjust in length to assure a tight fit. Wrap them around the saddlebag support, snap the buckle halves together, and adjust the length of the strap assuring the strap is tight and supporting some of the saddlebags’ weight. Repeat this step on the other saddlebag.

Kawasaki ZX10R Muffler Bracket Installation Instructions

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

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1. Remove the 8mm bolt that secures the mounting strap to the muffler. 2. Remove the two 8mm bolts that secure the existing muffler bracket to the bikes sub-frame. 3. Install the new bracket to the sub frame with the 8X20 socket capscrews included in the kit. Place a small amount of Loctite on the threads of the screws before assembly. 4. Mount the lower part of the bracket to the muffler strap with the existing hardware. 5. Adjust the muffler strap as needed and tighten the lower 8mm bolt. 6. Double check all your work before riding.

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