SUZUKI SV650 REAR SET POWERLET Installation Manual

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Filed Under (Suzuki) by admin on 15-02-2012

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STEP #1 – Remove the seat. See the Suzuki service manual. STEP #2 – Stretch out the wiring harness. Run the harness down the LEFT side of the battery cover, between the frame and the plastic water protectors/inner fender. There is a hole through which the harness may pass, visible when looking down to the left side of the battery cover, and toward the rear [B]. Insert a tie wrap, upward, though the black ring behind the silver footpeg bracket [A]. Let the wire hang down by the rearset for now. Next remove the negative battery connection, followed by the positive battery connection. Route the red lead forward toward the battery through the “notch” on the left side of the battery cover. Connect the red & black wire as follows: RED WIRE = BATTERY POSITIVE BLACK WIRE = CHASSIS GROUND Chassis bolt [D]. Tuck the fuse holder into a cavity in front of the plus terminal of the battery [C] under the battery cover. Ty-wrap the fuse-holder to the nearby wiring. STEP #3 – Apply either dielectric grease or Vaseline to the terminals. The center terminal is plus and the outer ring is negative (see dwg below). Install the fuse in the fuse holder. Connect the red wire to the positive terminal & the black wire to the negative terminal. Use a voltmeter to check if the polarity is correc

APRILIA FUTURA LEFT FRONT PANEL Installation Instructions

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Filed Under (Aprilia) by admin on 26-10-2010

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STEP #1 Remove the left side panel & seat. STEP #2 Mount the socket. STEP #3 Route wires starting at the battery and finishing at the bracket. STEP #4 Attach the wires to the socket and test. STEP #5 Look over your work. STEP #6 Put everything you took off back on. Detailed Instruction: STEP #1 – Remove the seat & the left side fairing. See the Aprilia service manual. STEP #2 – Drill a 18mm hole into the panel (11/16″ hole saw recommended and is available on our site) where shown [A]. There is plenty of room for the knee of a tall rider. An alternate position is show at [E]. There is no need to completely remove the front fairing, just unscrew the bolt under the left handgrip; the panel will flex enough to work behind it. Watch the clearance behind the panel; make sure the socket has room. Attach the socket to the panel; use a dab of Silicone on the socket and jam nut after assembly. Important: Do NOT use Loctite or over-tighten. STEP #3 – Disconnect the battery ground & positive connections. Install the fuse in the fuse-holder. Mount the fuse-holder to the round cross tube [B]. Route the harness up on the inside of the frame piggyback with the seat release cable. The harness can be inserted in the same clip that the seat- release cable uses [F]. Use wire ties to secure it from touching the engine. Connect the red wire to the positive battery posts [C]. The red rubber boot may need to be notched to allow the wire to exit. Connect the ground connection under bolt [D]. Run the black wire along the inside of the frame rail, then pass under the frame rail near the attachment point. STEP #4 -The center terminal is plus and the outer ring is negative (see dwg below). Apply either dielectric grease or Vaseline to terminals. Connect the red wire to the POSITIVE terminal and the black wire to the NEGATIVE terminal. Use a voltmeter to check if the polarity is correct

DUCATI ST2/ ST4 Stock Socket Rewire Installation Instructions

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

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STEP #1 Remove necessary fairings. STEP #2 Unplug the stock connector; plug in the new harness. STEP #3 Route wires starting at the bracket end and finishing at the battery. STEP #4 Look over your work. STEP #5 Check the polarity & test. STEP #6 Put everything you took off back on. Detailed Instruction: STEP #1 – Remove the seat, front, right side, & left side tail fairings. See the Ducati service manual. STEP #2 -Locate the white connector on the back of the stock socket. Unplug this connector and ty-wrap it into a safe location. Plug the new wiring harness into the back of the stock socket. The center terminal is plus and the outer ring is negative (see dwg below). Apply either dielectric grease or Vaseline to the terminals. STEP #3 – The harness is designed so the wires leave the connector toward the back of the bike, (this way they will not be seen). Loop the wires up through the gap between the frame & the engine controller (or storage bin). On the left side there is a small gap; do not pinch the wiring. You will need to remove four screws on the engine controller to accomplish this. Next cross over behind the engine controller (or storage bin). Re-tighten the engine controller. The harness is now routed toward the front of the bike [A]. Loosen right tail fairing front clip screw & pass the wiring harness under it [B]. Route the harness between the frame and the engine going towards air box. Using a ty-wrap attach the fuse holder to the back, right, air-box post [C}. In this location the fuse can be easily accessed under the tank. The ground wire is attached to a gas tank hinge bolt [D]. Connect the two wires as follows: RED WIRE = BATTERY POSITIVE BLACK WIRE = GAS TANK HINGE BOLT STEP #4 – Apply the remaining ty-wraps in useful locations. Do NOT allow the harness to directly contact the motor or exhaust

1991-1998 DUCATI 750ss 900ss POWERLET Installation Instructions

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

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STEP #1 Remove tail fairing & seat. STEP #2 Route wires starting at the battery and finishing at the bracket. STEP #3 Attach the wires to the socket and test. STEP #4 Mount the bracket. STEP #5 Look over your work. STEP #6 Put everything you took off back on. Detailed Instruction: STEP #1 – Remove the tail fairing, & seat. See the Ducati service manual. STEP #2 – Stretch out the wiring harness. Locate a wiring harness behind the frame rail[B]. Grab the socket end of the harness and start routing the harness by looping the wires up through the gap between the frame members just behind the battery[B]. You should be following the wiring harness behind the frame rail. The wires will exit in the underside of the seat area, just like the existing harness[D]. Attach the ground (black) wire under the hinge mounting bolt[C]. Tie wrap the harness under the cross member[E]. Go back to the battery area and install the fuse in the fuse holder than, tuck the fuse holder under the rubber strap in front of the plus terminal of the battery[F]. Slip the red wire under the red battery boot[F]. Connect the red wire to the battery posts as follows: RED WIRE = BATTERY POSITIVE STEP #4 -Attach the wires to the socket. The center terminal is plus and the outer ring is negative (see dwg below). Apply either dielectric grease or Vaseline to the terminals. Use a voltmeter to check if the polarity is correct

Kawasaki ZZR1200 REARSET KIT Installation Manual

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

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STEP #3 – Install the fuse in the fuse-holder [C]. Attach the spade connectors to the socket. The center terminal of the Powerlet socket is plus and the outer ring is negative (see dwg below). Attach the wires to the socket. Apply either dielectric grease or Vaseline to the terminals. Connect the red wire to the positive terminal & the black wire to the negative terminal. The spade lugs on the back of the socket are oriented so the wiring harness will route straight up from the socket, hiding it under the tail fairing. STEP #4 – Attach the bracket to the rearset-mounting lug [D]. It is easiest to loosen both bolts then remove one bolt at a time, sliding the spacer & bracket into place, one at a time. The supplied spacer must be placed in the front hole to maintain proper alignment. Install the replacement bolts one at a time. Tighten the rearset bolts with the bracket & spacer sandwiched between the rearset & the frame. STEP #5 – Apply the remaining ty-wrap to the wiring harness and the tail frame rail. Do NOT allow the harness to directly contact the motor or exhaust. STEP #6 – Use a voltmeter to check if the polarity is correct. Replace the toolbox, tools & seat. Enjoy!