Suzuki DRZ 400E & Kawasaki KLX400E Dual Sport Kit Installation Manual

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Filed Under (Suzuki) by admin on 13-02-2012

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1. Remove the seat, side panels, and fuel tank. Kill switch connector Photo 1 2. Unplug and remove the stock headlight. 3. Unplug and remove the stock kill button. See Photo 1. 4. Unplug and remove the stock taillight. Using a utility knife, trim the taillight mounting tabs flush with the underside of the fender. 5. Taillight Installation: Attach the provided LED taillight to the under side of the rear fender using the provided countersunk mounting hardware as shown in Photo 2. Route the taillight wires forward to the area on top of the airbox along the right side of the fender. Secure the taillight wires to the taillight plastic with zip-ties so the tire cannot make contact. Photo 2 6. Rear Turn Signal Installation: Attach the rear turn signals to the flat portions on the sides of the LED taillight. Position them so they are out of the path of the exhaust. Route the wires forward securing with zip-ties. Route the right turn signal wires and the taillight wires around the front of the muffler mount and between the fender and the black plastic splashguard as shown in Photo 3. Route Right Turn Signal & Taillight wires here Photo 3 Page 3 of 10
7. Brake Light Switch Installation: This step requires bleeding the rear brake. If you do not feel comfortable performing this step please refer it to a qualified mechanic. Installation: Remove the guard that protects the rear master cylinder and reservoir. Temporarily remove the bolt that secures the brake reservoir to the frame. Remove the bolt that holds the banjo fitting to the top of the rear master cylinder. Replace this bolt with the provided hydraulic switch retaining the upper and lower crush washers as shown in Photo 4. Bleeding the Brakes: Do not begin this process without a fresh bottle of brake fluid. Remove the lid from the brake fluid reservoir. Put the box end of 8mm wrench over the brake bleed nipple and install the bleed hose (supplied) tightly over the nipple. Position the loop on the hose above the nipple as shown in Photo 5 with the other end of the hose in a container to catch the fluid. Crack the bleed nipple open about 1/8 to a quarter turn keeping the loop in the hose vertical. Slowly depress the brake pedal to fill the hose with fluid. Pump slowly until you have brake fluid extending up into the loop, then you can pump the pedal fairly aggressively to drive air out of the system – The fluid above the bleed nipple will prevent air from re-entering the system. DO NOT LET THE RESERVOIR GO DRY – ADD FLUID AS NEEDED. Pump the pedal until there are no more bubbles, and then close the nipple with the wrench. Double check that the pedal is firm and the brake works properly.

2000-2003 KTM MXC / EXC Dual Sport Kit Installation Manual

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Filed Under (KTM) by admin on 01-02-2012

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Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3 4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit uses a hydraulic brake-switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install

Yamaha WR 250F and WR450F Dual Sport Kit REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 20-01-2012

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license Plate Mount Installation: Locate the aluminum license plate mount and license plate light assembly. Remove the rear most nut securing the stock taillight assembly (underneath the fender) (don’t lose the little compression tube and washer). Temporarily install the license plate mount to this location and mark the fender where it needs to be drilled for the rear mounts. Drill the fender in two places with a ¼” drill and reinstall the license plate assembly using the stock taillight mount and the 6 x 20 mm countersunk screws, bezels and nylock nuts Rear Turn Signal Installation: Locate the two rear turn signals in the kit – they’re the ones with the longer wires. Drill a 3/8 hole in each side of the fender as shown in Photo 3 and attach them as shown in Photo 4. It does no matter which signal goes on which side. Run the left turn signal wires forward along with the taillight wires, up through the grommet in the fender to the area just behind the air box cross member and above the fender. Run the right turn signal wires forward along the right frame rail, and through the same hole you made for the license plate wires Brake Light Switch Installation: The WR250/450 uses a hydraulic brake switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the rear brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the rear master cylinder guard. Remove the bolt holding the brake fluid reservoir to provide access to the master cylinder. Loosen the banjo bolt securing the rear brake line to the master cylinder. Typically, this bolt will be very tight and loosening it will bend the support hanger for the master cylinder if not supported. Brace the master cylinder with a wrench or lever. Remove the banjo bolt and replace with the hydraulic switch. Make sure to install the copper crush washer from the stock bolt under the switch. Torque the switch assembly to 25 lb-ft.

Honda, Polaris (2000 and older) ATV Thumb Warmer Installation Instructions

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Filed Under (Honda) by admin on 15-12-2011

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Hi/Low Switch Installation Choose a location for the switch, which is convenient and has sufficient rear clearance for the electrical connections and is within 18″ of a voltage-controlled wire (a wire in the lighting circuit). Drill a 1/2″ (13mm) hole and install the switch from the back. Leave the strain relief nut on the switch. On the front install the Hi/Low indicator tab and secure the switch and tab using the metal nut. The amount of switch barrel protruding can be adjusted by moving the strain relief nut. Wire Routing and Connections Route the electric cord along the handlebar to switchmarea and secure with supplied tie wraps, electrical tape, or both. Cut and strip to proper length. Attach a ground wire of sufficient length to go from the red wire to a good ground. WARNING: Lead wire slack in the area of the throttle must be neither excessive nor tight. Ensure no binding occurs when the throttle is open fully.,Soldering connections is the most durable method, but the following will provide years of service. Attach the 1/4″ female slip-on connectors to the white and blue wires and #10 ring terminal to warmer leads as shown in Figure 2. (A crimping tool works best, but a Vise Grips or pliers will work). Figure 2. Switch Connections (Option B) Connect the single yellow or red wire to a regulated (lighting) circuit using Option A (ATV has a switch in a lighting circuit with a 1/4″ tab) or Option B: Option B: Locate a power wire (usually yellow) leading to a headlight, taillight, or dash light (Figure 2). Using the red tap connector, place this power wire into the continuous channel and insert the red wire (do not strip insulation) completely to stop in the second channel. Make the connection by squeezing (w/pliers) the metal contact until flush with the top of the connector. Close the hinged cover until latched. Complete connections to switch and ground circuit.

Honda XR 400 Removal and Installation Manual

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Filed Under (Honda) by admin on 09-12-2011

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Turn Signal Switch Installation Front Wiring Connections Field Effect Transistor Installation Taillight Installation: Install the Acerbis DOT taillight over the empty well left in the stock fender using the two 5 x 20 mm bolts and 6 x 16 mm bolt found in the parts bag. Position the taillight over the previous taillight mounting well and transfer the hole locations for the top mounting holes onto the fender with a felt pen or snap punch (Photo 3) so that they are 3/8 of an inch above the edge of the taillight opening as shown in Photo 3. Drill two 3/16 inch holes for the top mounts. Attach the taillight using the top mounting screws, then pull the license plate holder down toward the bottom of the fender so that the taillight is pulled as horizontal as possible. Transfer drill a 1/4” hole at the bottom mounting location with the taillight in this position. When installing the bottom license plate mount bolt, make sure to install the 6 x 16 mm bolt from the bottom up to minimize the opportunity for the tire to grab it. Run the taillight
wires along the left frame rail using the stock wire clamps to support it. 8. Rear Turn Signal Installation: Turn signal mounting requires that you drill a 3/8 inch hole in either side of the rear fender near where it meets the side panels. You can achieve a clean,
durable installation using this mounting location. Mount the rear turn signals by drilling a 3/8 hole in the rear fender in the location shown in Photo 5, 3-3/4 inches back from the front edge (pointed tip of fender where it meets the side panel) and 2-3/4 “ up from the bottom edge Brake Light Switch Installation

The Honda VTX 1300 Keyless Ignition Switch Installation instructions

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Filed Under (Honda) by admin on 04-11-2011

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Remove the seat from the motorcycle.2. Lift the ignition module off of the battery cover and let it drape over the side of the motorcycle. 3. Remove the battery cover and disconnect the negative battery cable. 4. Remove the gas tank and set it aside. There is a vent line at the right rear of the tank, a vacuum line and the gas feed line on the left side of the tank at the petcock, and two speedometer connectors at the left front of the gas tank. 5. Remove the clip from the top of the steering head cover and remove the right hand side cover. See picture at right. 6. Remove the headlight to expose the wiring connectors inside the headlight shell. 7. Remove the left-hand side cover. On the left side of the frame is an electrical wire shroud wire tied to the left side of the frame with a reusable wire tie. Inside this cover is the 3-pin connector that connects the ignition switch to the bike’s wiring harness. Pull the small lever back to release the wire tie and remove the wire tie. Pull back the wire shroud to reveal the wire connectors inside. Disconnect the 3-pin connector that comes from the ignition switch. Remove the two bolts holding the ignition switch to the bike’s frame. See Picture at right. Remove the ignition switch from the bike. You may have to remove the connector body from the ignition switch wires to slide the wires through the frame when removing the ignition switch. You may now reinstall the side cover. 8. Lay the new wiring harness along the backbone of the bike with the two 9-pin connectors at the headlight and the 6-pin and 3-pin connectors at the battery. Insert the two 9-pin connectors through the large hole in the back of the headlight shell. Inside the headlight shell is a red 9-pin connector. Disconnect this red 9-pin connector and insert the new wiring harness connecting each side to the red 9-pin connectors. See picture at right

ATV MOTORCYCLE Full Wave Audio Installation Manual

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Filed Under (Tips and Review) by admin on 28-11-2010

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If installing this system for use with existing marine stereo: Connect RCA Y adapter (sold separately) to music source cable and plug into Low Level outputs of the stereo. Do NOT use the included power switch. Attach the Amplifier Remote wire from stereo to the BLUE wire of the amplifier. The amplifier will now be turned on and off by your stereo. This step replaces the Power On/Off switch installation step. 2. Determine a location suitable for mounting the remote switches and speakers, paying close attention to clearance or obstructions. 3. Place tape over the desired speaker location and mark a center point. Use the speaker template(s) and mark the center of the 4 inch hole to be cut for each speaker. 4. Pre-solder both terminals of each speaker. 5. Using a 4″ hole saw, drill holes for each speaker. 6. Place a speaker in each hole and mark the mounting screw locations before drilling pilot holes. 7. Drill 1/8″ pilot holes for speaker mounting screws at the screw locations. 8. Position amplifier making sure to pick a location that has tolerance for drilling and for the depth (1 inch) of the mounting screws. You will secure the amplifier later. 9. Feed the red/black speaker wires from the amplifier through the speaker holes. 10. Place the red speaker wire from the amplifier against the small pre- soldered speaker terminal and flow the solder together with your soldering iron.

2001 HONDA CRF 230 Dual Sport Kit Installation Manual

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Filed Under (Honda) by admin on 21-11-2010

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1. Remove the seat, fuel tank, side panels, and front number plate. 2. Taillight and Turn signal Installation: Note that Baja Designs has updated this kit to use the new style LED taillight. The mounting is the same. Mount the rear taillight assembly to the rear fender as shown in Photos 1 and 2. Transfer drill the mounting holes in the taillight assembly into the fender and mount using the countersunk fasteners provided. The tail light lens should just line up with the end of the fender. Mount the turn signals into the side of the taillight assembly as shown in Photos 1, 2 and 3. The taillight has not been pre-drilled to allow placement of the turnsignals to be varied to accommodate different exhausts. Use a 3/8″ drill for the turn signal mounting hole 3 Photo 3 Photo 2 Photo 1
. 3. Brakelight Switch Installation: This is a tight fit on the CRF230 – take your time and it’ll work. Drill a 1/8″ hole in the brake lever 4 ½” from the center of the brake pedal pivot point (Photo4). 4 Photo 5 Drill 1/8″ hole here Photo 4 Install the brake-switch bracket under the right case bolt directly above the oil filler cap (Photo 5). Attach the spring to the hole you drilled in the pedal. Adjust the switch in the bracket so it engages about halfway through the pedal throw. You may need to lengthen (stretch) the spring slightly to allow proper switch adjustment. Turn-Signal Switch Installation: Install the turn signal switch on the handlebar next to the grip as shown in Photo 6 . The switch has a single screw that pinches it together on one side. Two tabs secure the switch halves on the other side. Remove the screw to separate the halves so that it can be installed on the handlebar. When installing the switch to the handlebar, make sure the tabs are seated in their locating holes and then tighten the pinch screw. DO NOT OVER TIGHTEN THIS SCREW, as too much force can strip the body of the switch. The clutch perch may have to be moved inward slightly to make room for the switch. Run the wires along the bottom of the handle