2003 shadow idle adjuster

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Honda GL 500 Installation Manual

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

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Wheel Alignment Wheel alignment is critical for proper tire wear and handling. With MiniTrike installed measure A and B . Loosen axle plates and align wheel so A and B are equal to within 1/16th of an inch. Tighten axle bolts and torque to 45 pounds. Repeat for C and D . It may be necessary to shim axle plates for proper alignment. NOTE : The measurement of A and B may not be the same as C and D. This is normal and presents no difficulty. Wheel Height / Traction Adjuster The wheel height/traction adjuster (right and left side) allows you to selectively adjust the position of your trike wheels in order to customize ride, handling, level, and traction characteristics. Your trike is shipped with the adjuster preset to an optimum position for your model of motorcycle however you can make whatever adjustments necessary to customize to your bike and personal preference. Shortening the adjuster arm raises the trike wheels and places more of the weight of your motorcycle on the motorcycle wheel. This increases motorcycle traction and gives a generally softer ride. 1) Loosen jam nuts 2) Shorten adjuster arm by turning adjuster nut A toward bolt C desired amount. 3) Turn adjuster nut B until it tightens against adjuster bracket and adjuster nut A 4) Tighten nuts A and B and jam nuts Lengthening the adjuster arm lowers the trike wheels and places more of the weight of your motorcycle on the trike wheels. This gives a firmer ride and increases handling/cornering. 1) Loosen jam nuts 2) Lengthen adjuster arm by turning adjuster nut B toward bolt D desired amount. 3) Turn adjuster nut A until it tightens against adjuster bracket and adjuster nut B 4) Tighten nuts A and B and jam nuts

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KTM Preload Adjuster frontfork Disassembly And assembling

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Filed Under (KTM) by admin on 13-02-2011

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Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 5 Preload Adjuster Frontfork 03/2002 Screw the screw-cap to the right so that the spring washer is turning out of the screw-cap PA. Remove the spring washer. Pay attention to the assembling direction!!! Turn the plastic adjustment tube holder out of the screw-cap. 12_021 12_022 12_023Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 6 Preload Adjuster Frontfork 03/2002 1. Remove the O-ring inside. Unscrew the air release plug. 12_024 12_025 12_026 2. Remove the O-ring.Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 7 Preload Adjuster Frontfork 03/2002 Disassemble the adjusting knob from the screw-cap. Pay attention to the steel balls and spring!!! 12_027 12_028 12_029 Heat the steel nut. Unscrew the nut (size 32) clockwise .Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 8 Preload Adjuster Frontfork 03/2002 The nut. Pay attention to the assembling direction!!! Remove the O-ring. 12_030 12_031 12_032 Push the holder rebound PA out of the screw-cap.Product Exploded View Disassembly & Assembling Workshop manual Preload Adjuster frontfork 9 Preload Adjuster Frontfork 03/2002 – springring – spring washer – O-rings – holder rebound adjustment tube – rebound adjusting knob with steel balls and spring – air release screw with O-ring – nut – holder rebound adjustment cpl. with O-ring – screw-cap PA

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HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/IDLE CABLE KITS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be installed in the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3 2 1 is00825 1. Brake lever 2.5/32 inch (4 mm) cardboard insert 3. Brake lever bracket Figure 1. Install Cardboard Insert 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 3 4 1 2 5 is 02071 1. Upper switch housing 2. Lower switch housing 3. Throttle cable adjuster 4. Idle cable adjuster 5. Adjuster jam nut Figure 2. Handlebar Throttle Control 4. Remove the right upper and lower switch housing screws. 5. Loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw and flat washer. NOTE If possible, leave the friction shoe in place. The friction shoe is a loose-fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken. 6. See Figure 3. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings. 1 2 4 3 is 02072 1. Throttle cable 2. Idle cable 3. Brass ferrule 4. Notch Figure 3. Throttle/Idle Control Cables 7. Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing. For best results, use a rocking motion while pulling. Remove cables with retaining rings from switch housing. Apply a drop of light oil on the retaining ring, if necessary, to help in removal. NOTE If installing different handlebars, measure the change in distance that will be required from the end of the cable housing to the throttle grip. Compare this additional required length to the cables provided in the kit. If the cables are more than 2.0 inches (51 mm) longer or more than 1.0 inch (25 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. Install proper length throttle cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00396b) 8. Follow instructions in the applicable service manual and remove air cleaner and backplate.

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HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/ IDLE CABLE KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be placed into the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 4. Remove the right upper and lower switch housing screws INSTALLATION Throttle and Idle Cable Installation 1. See Figure 3. Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar. NOTE The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle control cable. For assembly, apply a drop of light oil on the retaining rings of the crimped inserts. 2. See Figure 7. Push the throttle cable housing and retaining ring into the larger hole of the switch housing, located in front of the tension adjuster screw. 3. Push the idle cable housing and retaining ring into the smaller hole of the switch housing, located behind the tension adjuster screw. 4. Push the throttle and idle control cable housings into the lower switch housing until each snaps into place. NOTE For models not equipped with factory-installed cruise control, if the friction shoe has fallen out or become dislodged, install the shoe with the concave side facing up and position it so the pin hole is over the point of the adjuster screw. 5. Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip until the ferrule notches are at the top. To prevent binding, pull the grip back about 0.12 inch (3.2 mm). 6. See Figure 3. Position the lower switch housing beneath the throttle control grip. Install two brass ferrules (Item 3, Figure 11) from this kit onto cables, seating the ferrules in their respective notches on the throttle control grip. The cables must be captured in the grooves molded into the grip. 7. Position the upper switch housing over the handlebar and lower switch housing. Route the wire harness conduit through the depression at the bottom of the handlebar. 8. Tighten the upper and lower switch housing screws finger- tight. 9. Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket. 10. Align the holes in the handlebar clamp with those in the master cylinder housing and tighten the lower screw and flat washer finger-tight. Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm)

Ural carburetors Installation and idle adjustment

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Filed Under (Ural) by admin on 02-11-2010

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1. First you must adjust the idle. It is acceptable per the manual to adjust the idle by using the idle adjust screws (11). This usually involves screwing them then backing out 1 to 1.5 turns. Or you can adjust looking at the sliders 2. If installing the carburetors: a. Remove the cover (2) b. Reomve the slider (3) c. Place the throttle cable through the guide (18) with the spring (4) on the cable. d. Route the cable through the slide catch (6) e. Insert the slide assembly into the chamber and make sure it easily slides up and down. Direct the needle (8) into the opening of the diffuser (angled side visible). f. Screw assembly together and verify via throttle movement that slide moves freely. Attach fuel delivery lines to (12). 3. Using the idle set screw (11) raise the slider so the lower edge is 1-2 mm. 4. Assemble to engine using the proper gaskets (paper – felt – paper). 5. Using the locknut (26) adjust the free play of the throttle cable (2-3 mm) 6. Adjust the idle mixture screw – turn in completely then out 1 to 1.5 turns 1. Remove one of the spark plug caps, and with the cap shorted, adjust (11) to decrease RPM’s to a point of being minimally steady. 2. Adjust the mixture (15) out until RPM’s decrease. Turn in until RPM’s increase slightly. Then turn in screws ¼ to 1/3 revoultion. 3. Do the same for the second carburetor with the first spark plug cap shorted. 4. With both cylinders, adjust each idle (11) on each carburetor the same amount each until it’s at a steady, minimal RPM. Use small changes. (at this point you can use your airflow tool to check). 5. Sharply increase, then decrease throttle. Then engine must return to low RPMs smoothly. If the engine goes below limits, readjust (11) from step 4. Synchronization of the K68 Note: Rather than using the opposite cylinder shorted to test the pull of the live cylinder carburetor, you can use something like a Twinmax connected to the test ports (27 Fig 1). Or, if you have a model without these ports, use a Synchrometer (Appendix 2) held against the face of the carburetor. These tools merely show airflow passing through each carburetor (which is dependent on the position and wear on the slide). If using these tools, it’s not necessary to do the following steps. You wil want to use a throttle guide (Appendix 1), to show airflow at various throttle settings. Using the flow meter of your choice make sure each carburetor is the same at the various throttle settings. 1. Place the motorcycle on the center stand ensuring the rear wheel is suspended 2. Make sure you have large area to work with (safety issues here) 3. Shift into the highest gear with the engine running 4. Short one spark plug cap to the cylinder (using a nail or something in the fins) 5. Increase the speed to 40-50 km/hr 6. Fix the throttle using the throttle (maybe using a throttle stop screw under the throttle housing). 7. Reconnect other cylinder and using the opposite carburetor determine the speed which should be the same as the first. 8. Adjust the position of this slide to achieve the referenced speed using the locknut at the top of the carburetor.

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2003 Honda Shadow Spirit 750 VT 750DC Custom speedometer dial installation

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Filed Under (Honda) by admin on 06-11-2011

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DO NOT REMOVE THE 3 PHILLIP SCREWS ON THE BACK OF THE SPEEDOMETER. This will unscrew the circuit board and the main components inside the speedometer, and possibly damage it. Just leave those 3 screws alone. They won’t make your customization any easier if they are removed. This is the hard part. Turn the speedometer face down on a soft towel on a sturdy table, bench, etc. I used a regular flat screwdriver to do this step. There is a chrome metal ring holding the glass on the speedometer. It is factory sealed. On the bottom side of this ring start prying with a flat screwdriver under the bottom lip of the metal ring. This will be a slow process (patience, patience, patience) so don’t get in a hurry and ruin the wife’s kitchen table like I did. Go around the metal ring with a flat screwdriver prying it up as straight as you can. It’s easier doing this every millimeter or two. I had to do this about 3 times all the way around the ring. After you pry the lip of the ring up all the way around enough to loosen it up considerably, gently pull the ring off of the speedometer. The glass should come off with it. Put the glass with the chrome ring aside for later. You might want to use a soft lint free towel to rest it on

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HARLEY DAVIDSON BILLET CLUTCH CABLE ADJUSTER COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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INSTALLATION 1. Dyna Models: Remove the plastic clip that fastens the clutch cable to the frame downtube just below the clutch cable adjuster and boot. Leave the clip above the adjuster in place. Softail Models: Remove the plastic clip and screw that attaches the clutch cable to the frame downtube just above the clutch cable adjuster and boot. 2. ALL Models: See Figure 1. Cut the original rubber boot (B) from the clutch cable (A). Make sure that the clutch cable covering is not cut or damaged. 3. Obtain the two halves of the clutch cable adjuster cover (items 1 and 2) and two cushions (8). Peel the paper backing from one cushion (8), and center the cushion on the inside of one cover half. Repeat for the other cushion and cover half. 4. Obtain the two screws (7) from the kit. Position the cover halves on each side of the cable adjuster, and align the screw holes at each end. Place a drop of Loctite 243 – Blue on the screw threads, and fasten the cover halves with the two screws. Tighten to 21 in-lbs (2.4 Nm)

2001 – 2003 Prius 2003 4Runner, Camry, Land Cruiser and Sequoia VEHICLES EQUIPPED WITH TRANSPONDER ECU

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Filed Under (Toyota Manuals) by admin on 07-10-2011

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When replacing the ECM (SAE term: PCM) or the Transponder ECU a “handshake” procedure must be performed. This ECU ID communication is necessary to enable the Transponder ECU and the ECM to recognize each other before the vehicle will start. Complete ECU communication using the following steps: 1. Insert a Master key into the ignition cylinder. 2. Turn the ignition ON (engine OFF). 3. Short Tc and CG terminals of DLC3 using the Diagnostic Check Wire (SST 09843-18020 or equivalent) and leave for 30 minutes. 4. After 30 minutes, turn the ignition OFF and remove check wire from DLC3. 5. Register any additional keys as necessary. 6. Start the vehicle to confirm successful ECU communication. Key Programming: To program or delete a key, a registered Master key is necessary unless the Transponder ECU has been reset or replaced. The Transponder ECU system incorporates a black “Master” key and a gray “Sub” key. The process during registration of these two keys is identical. The key itself now determines if it functions as Master or Sub, not the registration procedure. The maximum number of allowable Master and Sub keys vary by model. Refer to the chart below.

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Honda ST 1300 Series Single Shock Supplement

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Filed Under (Honda) by admin on 13-02-2011

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Check the orientation of the adjuster on the shock body – looking at the top of the shock, the hydraulic line port should be165 degrees (clockwise) from the nitrogen pressure valve (see figure 2) . If it is not properly oriented, you will need to reposition it. To do this, hold the upper shock eye securely in a vice and carefully rotate the Remote Adjustable Pre-Load adjuster the desired direction. This may be somewhat difficult due to spring tension, and may require slight loosening of the locking ring. Also, the spring, shaft, and lower mount may rotate while repositioning the adjuster. This is OK, just be sure to realign it with the upper mount (also be sure the rebound adjuster on the lower mount is properly oriented as noted below). Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the same path as the stock line was routed to the same location. n Do not loosen or attempt to rotate the line between the shock and the adjuster. n Make sure the shock rebound adjustment is facing the right side of the motorcycle and the pressure valve is facing up and towards the rear (figure 3) . n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket adapter using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80- 90 in/lbs (9-10 N-m). Then mount the bracket and adjuster to the bike in the same location as the stock preload adjuster using the supplied M6-1.0X20mm SHCS fasteners & nuts, and torque them to 80-90 in/lbs (9-10 N-m) (figure 4 & 5) . n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources.

HARLEY DAVIDSON DETACHABLE WINDSHIELD AND DOCKING HARDWARE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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These kits fit 1984 and later FXST, FXSTB, FXSTC, and 1993 and later FXDWG model motorcycles when equipped with passing lamps. INSTALLATION 1. To protect against scratches, cover gas tank and front fender before installation. is 01985 Figure 1. New Clutch Cable Routing 2. For FXSTB Models: Proceed to Step 3. For all except FXSTB: See Figure 1. Relocate the clutch cable to the inside of the handlebars as follows: a. Locate cable adjuster halfway along clutch cable by the front frame downtube and slide off rubber boot. b. Holding cable adjuster with 1/2 inch wrench, loosen jam nut using a 9/16 inch wrench. Back jam nut away from cable adjuster. Move adjuster toward jam nut to introduce a large amount of free play at hand lever. c. Remove small snap ring from pivot pin groove at bottom of clutch lever bracket. Remove pivot pin and clutch hand lever from bracket. Remove anchor pin and clutch cable eyelet from clutch hand lever. d. See Figure 1. Route clutch cable to the inside of the handlebars and reconnect clutch cable to clutch lever. e. See Figure 2. Turn cable adjuster away from jam nut until slack is eliminated at hand lever. Pull clutch cable ferrule away from clutch lever bracket to check free play. Turn cable adjuster to obtain 1/16-1/8 inch (1.6- 3.2 mm) free play between end of cable ferrule and clutch lever bracket. f. Hold adjuster with 1/2 inch wrench. Using 9/16 inch wrench, tighten jam nut against cable adjuster. Cover cable adjuster mechanism with rubber boot

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