1993 honda gold wing cruise control repair

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HARLEY DAVIDSON CRUISE CONTROL KIT FOR FLHR/I AND FLHRS/I MODELS INSTALLATION MANUAL

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

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INSTALLATION 1. Remove seat, left saddlebag, left side cover and air cleaner assembly following instructions in applicable Service Manual. 2. Review the CRUISE CONTROL-ULTRA MODELS section in the applicable Service Manual before attempting to install this kit. Install Cruise Control Module To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the appropriate Service Manual and remove bat- tery. 1 is04799 1. Cruise control module mounting hole (3) Figure 1. Battery Box (Right Side View) 2. See Figure 1. In battery box, identify the location of the three mounting holes (1) (on left side of panel) for mounting the cruise control module. 3. See Figure 10. Obtain the cruise control module (1) with cruise cable attached and three grommets (5) from kit. Install the grommets on studs of cruise control module with small diameters outward. 4. See Figure 2. While holding cruise control assembly in place near its mounting location, feed the cruise control cable through the hole in frame crossmember plate and route under rear spark plug wire staying on inner side of fuel line components. Carefully curve cable toward the right and continue routing up under the fuel tank and over the top of the engine stabilizer bracket, then down between cylinder heads. Leave in place temporarily. 5. See Figure 10 and obtain a harness retainer (4) from kit and secure the cruise cable to crossmember plate with barb as shown. On California models, remove the EVAP hose from cable clip and secure hose with one of the cable strap (8)

BMW K1100LT Installing Real Cruise Control

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

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The vacuum reserve canister (VRC) is used to provide adequate vacuum for the cruise control servo unit. It uses the throttle body as a vacuum source and, via the vacuum check valve, stores up vacuum for the servo to use to pull the throttle cable. You can also buy one of these at an auto parts store for about $10-15 but I decided to build my own so I could make one that would fit inside the left front of the main fairing body. If you decide to buy one, make sure you can return it if it doesn’t fit inside the fairing or be prepared to mount it somewhere else like inside the tail cowl. I used 8″ of 2″ diameter PVC tubing because that is the length that would easily fit inside the fairing It is mounted inside the fairing in front of the left “bucket.” I used white PVC tubing but, in hindsight, would use black if possible since it is visible to the rider when mounted in the fairing. I suspect that the cruise control may actually work without the use of the vacuum canister so you might want to try the cruise without a VRC. If you do install the cruise control without a VRC, you’ll want to put a vacuum check valve in the vacuum hose that goes from the throttle body to the cruise control servo unit.
11/30/2005 08:23 PM Installing Real Cruise Control on a BMW K1100 Page 4 of 8 used epoxy for assembling the VRC as it’s my permanent adhesive of choice. Cut an 8″ length of 2″ diameter PVC tubing. Sand the edges. Drill two holes as shown for the check valve and vacuum tee. There’s a vacuum tee in the bags of installation miscellany that come with the cruise control. File the webbing from the right angles before gluing it and the check valve in place. Remember to glue the tee into place before gluing the end caps on. Make sure everything has an airtight seal. I used zip-ties to hold it in place inside the main fairing body in front of the left bucket

SUZUKI SV1000S EMISSION CONTROL INFORMATION/ SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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EMISSION CONTROL SYSTEMS FUEL INJECTION SYSTEM SV1000S motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. BEFORE-PRESSURIZED FUEL PRESSURIZED FUEL * I’ RELIEVED FUEL ~%~~~ Ift 0 0 9 0 0 0 EMISSION CONTROL INFORMATION 9-3 CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a PCV system . Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the breather hose, air cleaner and throttle body . C * FRESH AIR FUEL/AIR MIXTURE 411111110 BLOW-BY GAS 9-4 EMISSION CONTROL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and THREE-WAY CATALYST system. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve . The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, ZAPS and CKPS. H02 sensor (Except for USA) I 0 0 0 0 0 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM PROHIBITED : Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW : • * Removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other component which conducts exhaust gases . • * Removing or puncturing the air cleaner case, air cleaner cover, baffles or any other component which conducts intake air . • * Replacing the exhaust system or muffler with a system or muffler not marked with the same model specific code as the code listed on the Motorcycle Noise Emission Control Information label . EVAPORATIVE EMISSION CONTROL SYSTEM (FOR E-33)

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Yamaha Road Star Forward Control Kit Installation Instructions

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Filed Under (Yamaha) by admin on 08-11-2010

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Before starting to assemble this forward kit on your motorcycle check the packing list to make sure that the kit you received is the correct one for your model motorcycle and that the foot pegs are the style you ordered (billet or ISO). Next check the contents hardware kit P.N.0109-1000 against the packing list for completeness. Installing The Shift Control Photo 1 Remove wires from horn. Remove the two hex head bolts (Save for later installation) that mount the OEM shift controls to your motorcycle. Unthread stock shift rod at trans shift arm, leaving OEM rod end connected to stock shift arm. Using Original Metric hardware, place a drop of Loctite #242 (blue) to the bolt threads and mount the shift control plate to the motorcycle frame, Photo 2. FORWARD CONTROL KIT PM SHIFT CONTROL ASSEMBLY Note Before torquing the shift control mounting bolts down, tighten them snug and look behind the shift control mounting plate to where it contacts the mounting lug on the frame. Make sure it fits squarely to the lug before proceeding further. Torque the two shift control mounting bolts down to 25 ft-lb. Using a 3/8″ x 1″ hex head bolt with a lock and flat washer put a drop of Loctite #242 (blue) on the threads and insert the bolt through the rear of the control mounting plate and attach the foot-peg pivot to it. Tighten the bolt while holding the footpeg pivot so that its hinge is lined up in a 45˚ rear facing angle. Thread supplied shift rod coupler to stock shift rod end at trans arm. Mount the shift pedal to the other end of the shift ro d using a 5/16″ x 1″ socket head screw and Nylocnut . Adjust the transmission shift linkage so that the shift arm on the forward controls and the shift arm on the transmission are parallel. Secure it with the jam nuts. Apply a drop of Loctite #242 (blue) to the threads under the jam nut before tightening see Photo 3 After you have assembled the shift control onto your motorcycle you must align the footpeg. The folding footpeg assembly uses a blind stud to attach the footpeg to the footpeg pivot. Shim washers (3/8″ x .015″) are used on the stud between the footpeg and the pivot, see Photo 4, so that the top surface of the footpeg is correctly aligned for your foot when it is tightened down on the pivot. This is done by setting a couple of shim washers on the footpeg mounting stud “A” and then screwing the footpeg onto the mounting stud, if the footpeg is rotated to far forward then add another shim washer, if not far enough then remove a shim washer. After you have the selected the correct number of shims for your footpeg, disassemble the footpeg and put a drop of Loctite #271 (red) on both ends of the stud and reassemble the footpeg. This will also need to be done on the brake control footpeg. Setting Up the Master Cylinder The master cylinder pushrod return spring and pushrod boot must be installed on the master cylinder before it is assembled onto the forward control mount. The parts are shown in Photo 5: pushrod boot (A), pushrod return spring (B), spring seat washer (C), and master cylinder (D). Place the return spring seat washer into bore of master cylinder so that is sits on top of the piston retaining snap ring. Next set the pushrod return spring on the seat washer and slide the pushrod boot over the return spring now slip the big end of the boot over the flange on the master cylinder so that the ridge on the inside of the boot fits into groove “A” that is machined into the end of the master cylinder flange, see Photo 6. Installing The Brake Control Unplug stock brake light switch at master cylinder. Remove brake line from rear caliper. Remove the existing brake controls from your motorcycle down to the control mounting lug that is welded on to the frame’s right side, see Photo 8. Save Metric hardware for later use. A Shim Washer PHOTO 4 A B C D PHOTO 5 A PHOTO 6 PHOTO 7 Note For complete brake system removal instructions and precau – tions refer to the appropriate service manual for your year and model motorcycle

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MECHANIC CERTIFICATION REQUIREMENTS MDOS Form: Repair Facility Manual

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Filed Under (Tips and Review) by admin on 18-11-2010

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Chapter 7: Mechanic Certification Requirements Page 4 7-2.2 Heavy-duty Truck Certification Categories. The Heavy-duty Truck Repair categories requiring mechanic certification to repair vehicles over 10,000 pounds G.V.W. are: a) Engine Repair, Gasoline; b) Engine Repair, Diesel; c) Drive Trains; d) Brakes and Braking Systems; e) Suspension and Steering Systems; f) Electrical Systems; g) Collision-Related Mechanical Repair. 7-2.3 Other On-road Vehicle Certification Categories. Repair categories for other on-road vehicles that require mechanic certification to perform repairs are: a) Motorcycle; b) Recreational Trailer. Automobile and Light Truck Certification Categories. The repair categories requiring mechanic certification to repair vehicles under 10,000 pounds gross vehicle weight (G.V.W.) are: a) Engine Repair; b) Engine Tune-up/Performance; c) Front End, Suspension and Steering Systems; d) Brakes and Braking Systems; e) Automatic Transmission; f) Manual Transmission, Front and Rear Drive Axles; g) Electrical Systems; h) Heating and Air Conditioning; i) Collision-Related Mechanical Repair; j) Unitized Body Structural Repair; k) Pre-1973 Vehicle Repair

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HONDA HT1500 GOLD WING CONVERSION KIT INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 25-11-2011

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Cut-off the saddlebag support tubes where the vertical tube meets the angled tube in the front and back. All you want left is the tour pack support. Loosen tour pack support at bottom bolts, remove top bolts, and then lift up a little. This allows the body to go under the support. If you have the fuel tank: Secure the two black control boxes, facing each other, one on top of the other. Secure to frame using the green ground wire hole at center of frame. Use the 2 ¼”
spacer tube and long screw provided to hold them together. If no fuel tank: leave rear half of fender in place Install machined studs in the swing arm pivot hole with some blue Locktite on them. This provides a 5/8” stud on the side of the frame for the suspension side plates. Screw in until flush with frame. Remove the 6mm bolts from the exhaust heat shield on the outside of the frame rail. nInstall the shock replacement bars on the top shock stud and re-install bolts, leave bars hanging loose for now. Install air-compressor relocation bracket (1 ½” x 4″ w/ 3 holes) and remount compressor. After
mounting, secure the compressor to the bracket with a wire tie.

HONDA GOLD WING GL1800 Independent Suspension Owner's Maintenance Notes

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

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1. Tire Pressure and Rotation : Keep the nominal tire pressure at about 23-27psig. It is not necessary to periodically rotate the trike tires unless you experience unusual tire wear. 2. Bearing Lubrication . Your Swing Arm and wheel bearings are sealed and do not require greasing. However, should you experience unusual wheel bearing noise you should take your trike to a Champion Trike Dealer or to your motorcycle mechanic for a checkup. 3. Body Lubrication . There are no grease fittings on the trike body and no required body lubrication points. 4. Rear end lubrication . Your differential comes filled with SAE 85W140 API GL-6 gear oil. You should not have to top-off the differential unless you experience axle seal or pinion seal leaks. If you want to check the oil level, do so by removing the fill plug on the top of the differential housing (Remove seat) and by using a suitable measuring device, the oil level should be 5 1/4″ inch down from the top of the differential housing. Refill as necessary. Change the differential oil every 30,000 – 35,000 miles by draining it and refill with 2 quarts of above gear oil.. 5. Brakes . Check your front and rear brake system fluid levels every 3,000 miles and top-off as necessary. Inspect brake pads every 10,000 miles and replace as necessary. Rear brake pads are Volkswagen Part # D101P. 6. Drive Train . The rear driveshaft U-joint and slip yoke spline are fitted with grease fittings, pump the fittings with wheel-bearing, graphite or high-pressure grease every 3,000 to 5,000 miles. The front u-joint does not have grease fittings. 7. Suspension System : The suspension is a Double A-arm Independent suspension with a standard single setting anti-roll bar or an optional Variable Sway Control (VSC) which can be adjustment for optimal ride, handling characteristics and performance. The A- arms are equiped with bushings that does not require servicing. The suspension system is designed to give you the best ride with a load of no more than 600 pounds (passengers plus cargo plus trailer tongue weight): 8. EZ-Steer (rake kit) : If your trike is equipped with Champion’s EZ-Steer, the bearings are a wear item. You should follow your motorcycle manufacturer’s recommended front-end triple-tree maintenance requirements. Generally these call for an initial service at 1,000 miles followed by periodic maintenance at 10,000 mile intervals

BMW K1200RS Electronic Cruise Control installation instructions

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

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We recommend that you take power from a non-critical circuit such as the heated grip circuit. Any power supply wire that is green with a black trace (stripe) is a fused, switched 12V supply. That is, there is a fuse in the line, and the ignition switch turns the power to the wire on and off, and it is NOT powered when the ignition switch is in the ‘park’ position (side lights turned on). Because the ignition switch also powers the ABS system, if the heated grip circuit is live, in theory the ABS system, and therefore the brake light system, will also be live. • On the bikes that we have fitted the cruise control to, there is a three way plug behind the headlight, that goes to the heated hand grip switch (on the right side handlebar). This plug has one green/black wire, a black wire and an orange wire. This photo is taken looking down below the bike’s instruments on the right side. The plug is circled. • This photo is taken from the front of the bike looking back through the head light cavity, under the bikes instruments. The plug is circled. • This is a convenient and accessible location to pick up power for the cruise control. The cruise control orange power wire should be connected to the green/black power wire for the heated grips.

CCS- 100 ELECTRONIC CRUISE CONTROL INSTALLATION MANUAL

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

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UNDER HOOD INSTALLATION Connecting the Cruise Control Cable to the Throttle NOTE: Prior to attaching servo cable to throttle, locate an accessible area to mount the cruise control servo, but do not mount it. Leave the servo in this area (unmounted) and route cable to throttle attachment area. CAUTION: Attach the cruise control cable so that it parallels the existing throttle cable as nearly as possible. Choose a mounting method from the figures below: Attachment area for securing cable Bead Chain Coupling Sleeve (#23) Bead Chain Coupling (#24) 3 BEAD CONNECTOR FIG. 6 FIG. 7 FORD LINKAGE ADAPTOR Rubber Ring WIRE LOOP FOR PULLEY Carburetor Existing Snap-On Throttle Arm On Vehicle FIG. 2 SNAP-ON THROTTLE ARM MOUNT FIG. 3 CLAMP-ON THROTTLE ARM MOUNT Determine a suitable point on the throttle linkage to mount the cable connector. The mounting point chosen should have between 1-1/2″ to 2″ total linkage travel. It must operate smoothly by hand. There should be at least 5 beads between the throttle connector and servo cable end. The cable must pull in a straight line from throttle linkage. Some vehicles that do not have enough total linkage travel have to be connected at the accelerator pedal. The bead chain and servo cable end must be inserted into the bead chain connector. Then the bead chain coupling sleeve must slide over bead chain connector to insure that the end will not hang in the connector. FIG. 1 Cable Bead Chain Eyelet Connector (#25) Pull off Throttle Arm and Insert Bead Chain Connector between it and Carburetor Arm. Be sure additional thickness of adaptor does not bind linkage. 20° Bead Chain Eyelet Connector (#25) Cable Must Be within 20° of same angle as Throttle Rod Throttle Cable Throttle Wire Loop (#29) Barrel Wire Adaptor (#30) WIRE BARREL FOR PULLEY FIG. 5 FIG. 4

2007 Corolla & Matrix 1ZZ-FE ENGINE NO START CONDITION REPAIR

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Filed Under (Toyota Manuals) by admin on 01-11-2011

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Refer to TIS, 2007 model year Corolla or Matrix Repair Manual: Engine Hybrid System – Engine Control – “1ZZ-FE Engine Control System: ECM: Removal” Engine Hybrid System – Engine Control – “1ZZ-FE Engine Control System: ECM: Installation” 2. Register the VIN into the replacement ECM (PCM). Refer to TIS, 2007 model year Corolla or Matrix Repair Manual: Engine Hybrid System – Engine Control – “1ZZ-FE Engine Control System: SFI System: Registration Some 2007 model year Corolla and Matrix vehicles equipped with a 1ZZ-FE engine may exhibit a “no start” condition. Improvements have been made to the Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM) manufacturing process to reduce the possibility of this condition occurring. Please use the following procedure to repair the vehicle

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