2003 xr50 review

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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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2003-2004 HONDA GL 1800/A Frame Weld Safety Recall

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Filed Under (Honda) by admin on 15-12-2010

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there is no punch mark on the VIN plate as specified in this Service Bulletin, proceed to the REPAIR PROCEDURE section of this Service Bulletin. IMPORTANT: Due to the complexity of this campaign it is imperative that you check iN and your Dealer Responsibility Report before you begin repairs. If iN or your Dealer Responsibility Report indicate the Safety Recall has been performed, but you confirm the unit is not punched and the repair has actually been done (by inspecting the weld), please contact the Warranty HelpLine at (800) 421-1900, option 7. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510)  Frame Weld Inspection Chart (S0516) You MUST provide your TIG welder with the following items:  2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511)  2002-2003 GL1800/A Frame Weld Safety Recall Cracked Weld Repair Manual (S0515) Welding Template Box (S0512) All of the above items were shipped to you with Service Bulletin GL1800 #14. If you need additional copies of these materials, you may order them from Resolve at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. DISASSEMBLY OVERVIEW You will be removing the following components from the vehicle as instructed in the Dealer Booklet : Handlebar weights Rear view mirrors Swingarm pivot covers Rider foot pegs Seat Side covers/Engine side covers Fairing pockets Fairing molding Meter panel Top shelter Battery Fuel tank Main wiring harness ground Front lower fairing Front exhaust pipe protector Muffler/exhaust pipe Antenna Whip(s) Coolant reserve tank Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: Before you send the motorcycle to the welder, you MUST check for lower crossmember frame weld cracks.  If your inspection reveals no cracks in or on either the Left or Right lower cross- member frame welds, proceed to the REPAIR PROCEDURE OVERVIEW section of this Service Bulletin.  If your inspection identifies a crack or cracks in or on either the Left or Right lower crossmember frame welds, perform the following procedure: Place the grinding template (S0512) on the crossmember. Using a suitable felt marker, draw a line on the weld with the crack, drawing the line along the entire edge of the the template (this line will be 89 mm long). If the crack falls within the length of this line (89 mm) , prepare the motorcycle for welding per the Dealer Procedures and advise the welder to use the Cracked Weld Repair Manual (S0515). After the bike has returned from the welder, prepare the frame and re-assemble the motorcycle per the Dealer Procedures . Then, proceed

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2002-2003 Honda GL1800/ A Frame Weld REPAIR PROCEDURE OVERVIEW

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Filed Under (Honda) by admin on 14-12-2010

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If your inspection identifies a crack or cracks in or on either Left or Right lower crossmember frame welds, STOP – call your DSM or TechLine for further instructions. • If your inspection reveals no cracks, proceed to REPAIR PROCEDURE. NOTE: Verification of repair can also be found in the Dealer Responsibility Report and on the Honda Interactive Network (iN). If you have any questions about verification, please contact TechLine before proceeding. IMPORTANT: For complete Dealer and Welder Repair procedures, refer to the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Dealer Booklet (S0510) • Frame Weld Inspection Chart (S0513) You MUST provide your TIG welder with the following items: • 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual (S0511) • Welding Template Box (S0512) All of the above items were shipped to you with this Service Bulletin. If you need additional copies of the Dealer Booklet , Welding Manual , Welding Template Box , or Frame Weld Inspection Chart , you may order them at no cost from DDS at (440) 572-0725. For your reference, a brief repair procedure overview is provided below. Disassembly Overview You will be removing the following components from the vehicle as instructed in the Dealer Booklet : • Handlebar weights • Rear view mirrors • Swingarm pivot covers • Rider foot pegs • Seat • Side covers/Engine side covers • Fairing pockets • Fairing molding • Meter panel • Top shelter • Battery • Fuel tank • Main wiring harness ground • Front lower fairing • Front exhaust pipe protector • Muffler/exhaust pipe • Antenna Whip(s) • Coolant reserve tank • Center stand NOTE: You will need to remove any accessories that may contact the ground during the Welding and Re-assembly procedures. IMPORTANT: You MUST cover the following with RED duct tape for welder identification pur- poses: • Negative (-) and positive (+) battery cables • Fuel return hose end • Fuel feed hose end • Main wiring harness ground • Alternator • Exhaust ports Welding Overview A qualified TIG welder will weld the frame following the procedures in the 2002-2003 GL1800/A Frame Weld Safety Recall Welding Manual . Re-assembly Overview You will be inspecting the new TIG welds, painting the frame, and re-assembling the vehicle as detailed in the Dealer Booklet and Frame Weld Inspection Chart (S0513)

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Honda CRF/ XR50 Carburetor Kits, Air Filters INSTALLATION AND REMOVAL

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Filed Under (Honda) by admin on 18-12-2011

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The CRF/XR50 engineers never intended “large” people to be competitively thrashing their design. As a result, failed frames are becoming quite common at the track. Laid-out forks, tweaked, ill-functioning suspensions and bent frames are symptoms we’ve all witnessed. This CRF/XR50 frame kit addresses all these problems with not only a stronger framer but also with added knee-to-bar clearance for taller riders.. Features: • Heat-treated chromoly steel frame • TIG welded • Fully gusseted • Thicker-walled main tube that is also larger in diameter • Conservatively estimated at 4 times stronger than the stock unit • Race legal open cradle configuration, but with fully closed loop rear sub frame under the seat for added strength and safety • Stronger swing arm pivot area prevents wallowing • Frame is 1″ longer than stock, resulting in greatly enhanced handling characteristics This Chromoly 1″ longer frame with chromoly removable subframe is the off the hook! It features a detachable chromoly subframe with all hardware as well as a 1″ rise in gas tank and seat height for more more leg room and to allow bigger carburetor modifications. Extended frame also provides: • Much needed knee-to-bar clearance • Improved rider position • Better Center of Gravity • Better control Features: • Heat-treated chromoly steel frame • TIG welded • Fully gusseted • Thicker-walled main tube that is also larger in diameter • Conservatively estimated at 4 times stronger than the stock unit • Race legal open cradle configuration, but with fully closed loop rear sub frame under the seat for added strength and safety • Stronger swing arm pivot area prevents wallowing • Frame is 1″ longer than stock, resulting in greatly enhanced handling characteristics • Gas Tank is raised 1″ for added clearance

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2002 Chetak And 2003 Legend Evaporative Emission Control System Hookup

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Filed Under (Bajaj) by admin on 31-10-2010

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2002 Legend engines have the carburetor air vent hose connected between the 2 way valve and the canister, with a 108 main jet in the carburetor. The 2003 Legend engines have the air vent connected as shown in this diagram and the main jet increased to 120 to compensate for the reduced bowl pressure. All 2003, and subsequent Legend and Chetak engines, will have this hookup as shown with 120 size main jets. Warning: Seemingly small changes can make a big difference in altering the fuel/air ratio. Disconnect hoses or make changes at your peril. There is no horsepower to be gained by disconnecting this passive emission control system

2003 Aprilia Tuono Installation Instructions

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

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1. Remove the main seat and the passenger seat. 2. Prop the front of the fuel tank in the up position. 3. Route the PCIII harness from the trunk area towards the front of the bike. Route the PCIII harness under the fuel tank bracket (Fig. A). 4. Attach the ground wire from the PCIIIharness to the negative side of the battery. (fig. B). 5. Locate the Throttle Position Sensor on the backside of the throttle bodies (Fig. C). 6. Locate the BROWN wire with the YELLOWtracer and attach the supplied wire tap to the wire. NOTE: It is recommended to use dielectric grease on this connec- tion. Fig. A Fig. B Fig. C 2003 Aprilia Tuono – PCIII USB – 2 i907-411 www.powercommander.com Wire tap Ground wire from PCIII TPSI connector 7. Attach the grey wire from the PCIII to the wire tap (Fig. D). NOTE: It is recommended to use dielectric grease on this connec- tion. 9. Plug the YELLOWcolored wires from the PCIIIharness in- line of this connection. (fig. F) Fig. D Fig. E Fig F 2003 Aprilia Tuono – PCIII USB – 3 i907-411 www.powercommander.com Stock connector Grey wire from PCIII PCIII connectors Stock connector 8. Unplug the stock wiring harness from the rear injector (left hand side of the throttle body). Fig. E 10. Unplug the stock wiring harness from the front injector (right hand side of the throttle body). Fig. G 11. Plug the ORANGE colored wires from the PCIIIharness in- line of this connection

2001 – 2003 Highlander FRONT DOOR OPENING WEATHERSTRIP

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Filed Under (Toyota Manuals) by admin on 27-10-2011

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have been improved to better resist deformation or tearing at the bottom center portion of the front door frame. Replace the front door opening weatherstrips on vehicles with this condition built prior to the VIN breaks listed in the Production Change Information section below. 2001 – 2003 model year Highlander vehicles produced BEFORE the Production Change Effective VINs shown below. MODEL ENGINE TYPE PRODUCTION CHANGE EFFECTIVE VIN 4Cylinder 4×2 JTEGD21A#30052511 Highlander 4 Cylinder 4×4 JTEHD21A#30020710 Highlander 6Cylinder 4×2 JTEGF21A#30085273 6 Cylinder 4×4 JTEHF21A#30113260 PREVIOUS PART NUMBERCURRENT PART NUMBER PART NAME QTY 62311-48020-## Same Weatherstrip, Fr Door Opening, RH 1 62312-48020-## Same Weatherstrip, Fr Door Opening, LH 1 Replace the front door opening weatherstrip as shown in the Technical Information System (TIS). Refer to the 2001 – 2003 Highlander Repair Manual; Exterior/Interior Trim, Roof Headlining Assembly

2003 – 2008 4Runner AND 2007 – 2008 FJ Cruiser FRONT AND REAR DIFFERENTIAL GEAR OIL SPECIFICATION CHANGE

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Filed Under (Toyota Manuals) by admin on 14-11-2011

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75W-85 GL5 synthetic gear oil beginning with the 2008 model year. This new synthetic gear oil is compatible with 2003 – 2007 model year 4Runner and 2007 model year FJ Cruiser differentials. Please refer to the Parts Information section below for information about this gear oil and use this gear oil (or equivalent) when filling front or rear differentials with oil. 2003 – 2008 model year 4Runner vehicles. 2007 – 2008 model year FJ Cruiser vehicles. PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME TYPE QTY N/A 08885-02606 Toyota Genuine Differential Gear Oil LX 75W-85 API GL-5 SAE 75W-85 LSD As Needed N/A 08885-02506 Toyota Genuine Differential Gear Oil LT 75W-85 API GL-5 SAE 75W-85 w/o LSD As Needed Refer to the diagram below to identify if LSD or non-LSD gear oil is used on the vehicle. For applicable vehicles, there is a caution label above the filler plug, as shown below

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2003 – 2007 4Runner SUPPLEMENT DAYTIME RUNNING LIGHTS REPAIR MANUAL

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Filed Under (Toyota Manuals) by admin on 12-10-2011

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2003 – 2007 model year 4Runner vehicles with the DRL factory option. 2003 – 2007 model year 4Runner vehicles equipped with the DRL factory option (RL accessory code). ITEM NO. SPECIAL SERVICE TOOLS (SSTs) PART NUMBERQTYDRW** 1 Toyota Diagnostic Tester Kit* NOTE: All components from this kit/set are required. 12 Megabyte Diagnostic Tester Program Card (P/N 01002593-005) with version 13.4a Software (or later) is required. TOY220036 1 9 2 CAN Interface Module Kit* NOTE: All components from this kit/set are required. 01002744 1 9 *Essential SSTs. **Drawer number in SST Storage System

2000-2003 Aprilia Mille Installation Instructions

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

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1 Remove the seat. 2 Lift up the front of the fuel tank. 3 Disconnect the wiring harness from the injector on the left hand side of the bike by sqeez- ing the connector. 4 Connect one pair of the leads from the PCIII in-line of the stock harness and throttle body (Fig.A). 5 Repeat steps 3-4 for the right hand side (Fig.B). 6 Locate the throttle position sensor on the trottle bodies. Locate the yellow wire with the brown tracer coming from the sensor. Connect the supplied wire tap to this wire. 7 Plug the grey wire from the PCIII to the wire tap (Fig. C). Note: It is recommended to use dialec- tric grease on these connections. Fig. A Fig. B Fig. C Loosen these bolts PCIII connectors Wire tap Stock connector Stock connector PCIII connectors Grey wire from PCIII 2000-2003 Aprilia Mille – PCIII USB – 3 i902-4118 Attach the ground wire from the PCIII to the negative side of the battery (Fig. D

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