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2001-2002 HONDA GL1800/A CD Changer Replacement

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Filed Under (Honda) by admin on 03-03-2011

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2001-2002 GL1800/A CD Changer Replacement ORDERING AND REPLACING THE CD CHANGER 1. Before calling the CD Changer Order Desk, have the following information ready: • VIN • Failure Information (i.e., symptom) • Warranty Status 2. To order, call the CD Changer Order Desk toll free: (888) 997-7278 . The CD Changer Order Desk hours are Monday thru Friday, 8:30am – 8:00pm EST. Part Number: 08A06-MCA-100RM Honda Code: 7097009 3. After calling the CD Changer Order Desk, an exchange CD Changer will be shipped overnight (freight prepaid). 4. Replace the faulty CD Changer with the exchange unit (see REPAIR PROCEDURE ). DO NOT remove the faulty CD Changer until you receive the exchange unit. DO NOT ATTEMPT TO REMOVE ANY STUCK CD’S. CHANGERS DAMAGED IN THIS WAY WILL BE RETURNED TO THE DEALER AND NO CORE CREDIT WILL BE ALLOWED. You will be billed $300.00 for the replacement unit. You must return the faulty CD Changer for a core credit and file a warranty claim to receive your total reimbursement (see TRANSACTION SUMMARY on page 3 for details). REPAIR PROCEDURE 1. Refer to the Installation Instructions included with the replacement CD Changer. 2. NOTE: You MUST remove the shipping bracket from the replacement unit before you complete the installation. If a CD is stuck inside the faulty unit, leave it there : • The vendor needs it for diagnosing and testing. • If you try to remove it, you’ll damage the unit. • The vendor will return the unit if it has been damaged during attempted CD removal. Fill in the customer information on the Audio System Diagnosis and Core Return form. The vendor will remove the CD and mail it back to the customer. IDENTIFICATION No identification is necessary for this repair

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BMW Motorcycles F 650 GS Dakar fuel tank replacement

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Filed Under (BMW) by admin on 12-11-2010

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Your center has been requested in a recent e-mail, to forward VIN, color Information: and status information on all F 650 GS(A) and Dakar models remaining in your inventory. Fuel tanks, together with the appropriate colored trim pieces, will be forwarded to your center for each bike in your inventory as replacement parts arrive in BMW NA inventory. Warranty Please enter a warranty campaign claim , encompassing the following Reimbursement: Work Package information, when claiming reimbursement for the updates called for in this bulletin. Even though there is no charge for the parts, a sublet of $60.00 will be applied to each claim. This sublet amount is intended as a combination of both the handling and as reimbursement for incidental items that may be required in the replacement of the fuel tank. Work Package #1 is to be used in the replacement of all F 650 GS(A) and Dakar model fuel tanks. Defect Code: 00 00 16 1100 Description: Fuel Tank – Leaking Flat Rate Code: 00 60 059 Description: Remove and reinstall fuel tank (USA only) FRU: 12 FRU Sublet #4: $60.00 Pick up & In the recent Sales and Marketing Bulletin # B23/00 introducing the “Customer Delivery: Demonstration Program”, (e-mailed to your center on September 7, 2000), each BMW motorcycle retailer was asked to arrange to pick up, complete the updates and deliver the motorcycle back to the customer and to offer the use of a demonstrator where appropriate.

VESPA GTS 250 i. e. EXHAUST MANIFOLD REPLACEMENT

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Filed Under (Vespa) by admin on 11-11-2010

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VE SPA GTS 250 i. e. EXHAUST MANIFOLD REPLACEMENT To replace the exhaust manifold, order part number 872659 as spare part following standard proceedings. OPERATION PROCEDURE The above picture references the old exhaust flange and the replacement exhaust flange kit part number 872659. Replacement Old Page 5 of 16 With the complete exhaust system removed from the vehicle remove the lambda sensors. Refer to page 88 and 89 of your Vespa GTS workshop manual for exhaust removal. Loosen the 13 mm bolt to loosen the clamp. Bolt Remove lambda sensor Page 6 of 16 Remove the header pipe from the exhaust box. Remove the exhaust packing and clamp. Remove exhaust manifold Gasket Clamp Page 7 of 16 Once all packing is removed check and make sure all surfaces are clean. This will help the installation of the exhaust gasket. Install the new clamp supplied with the kit, but do not tighten down at this point. Fit the exhaust gasket onto the new manifold. Push the new exhaust gasket in with the manifold until fitted all the way down to the flange. Check surfaces. Manifold Gasket Clamp Flange Page 8 of 16 Replace the lambda sensor and tighten down to 40- 50 Nm (29.5 -36.8 ft lbs. ) .

FC Shock Spring Installation Guide

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Filed Under (Tips and Review) by admin on 14-12-2010

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Installation: 1. Remove the fork springs according to the OEM Owner’s Manual. 2. Check/adjust fork oil level and weight according to OEM Specifications. Caution: Most inverted forks will not require the use of any shim washers or spacers. In cases where use is necessary with the twin chamber style fork, the shims must be placed at the bottom of the spring. Most conventional forks (non-inverted) will use shim washers or spacers at the top of the fork spring. 3. Install Factory Connection fork springs and refer to OEM Owner’s Manual for proper assembly procedures. 4. Be sure to double check all fasteners. Note: Most modern day forks require special tools for disassembly and assembly of the components. Examples : Showa 47/49mm Twin Chamber, KYB 48mm Twin Chamber, WP 07 SX Models/SXS Components. Installing fork springs is an intricate process that should be performed with extreme care by a qualified suspension technician. Failure to install the springs correctly could cause damage to one or more components of the fork. This damage, although not readily apparent, could lead to unexpected failure or rider injury. Factory Connection manufactures models specific fork springs. Installation of a Factory Connection spring not designed for your motorcycle may result in unexpected failure and rider injury. Please consult your Factory Connection spring dealer or call Factory Connection directly if you are unsure about a spring/or springs. 1. Factory Connection’s Limited Lifetime Warranty Factory Connection warrants, to the original retail purchaser (“consumer”) who retains ownership of the vehicle on which the suspension spring(s) (“products(s)”) was originally installed, all suspension springs for life against factory defects in material and workmanship (other than defects in finish) when used under normal use and operating conditions. 2. Your Remedy Upon verification of warranty coverage, Factory Connection at its option will replace defective or prematurely worn-out product (s), without charge, or refund the purchase price of the products(s). This is the Consumer’s sole and exclusive remedy for any loss or damage, however arising, due to a nonconformity or defect in the product(s). 3. Warranty Claim Procedure To make claim under this warranty, the consumer should contact the Factory Connection dealer or Factory Connection where the product(s) was purchased. Factory Connection reserves the right to test the returned product(s) to evaluate the nonconformity or possible defect. The Consumer is responsible for all costs of returning the defective or prematurely worn-out product(s) to the Factory Connection dealer as well as all costs for removing the product(s) from and installing the products(s) on the vehicle.

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Street Fork Spring Installation Instructions

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Filed Under (Tips and Review) by admin on 13-02-2011

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1. Remove fork springs according to instructions contained in your shop manual. For maximum performance we highly recommend that the forks be thoroughly cleaned, inspected and new fork oil installed. Note: If your motorcycle comes equipped with two fork springs in each leg (long & short), remove and discard both springs and the flat washer between the springs. If a stock spacer exits, remove it. If there is a short spring on the damper rod, do not remove it! 2. Use the recommended fork oil viscosity as noted in your owners manual with the following exceptions: GL1100 20 weight, GL1200/1500 15 weight required. See fine tuning for more in- formation. Fork oil level/volume should be checked according to the steps outlined in your authorized shop manual. Measurement of your fork oil by level is the preferred method. However, some manuals only specify a volume measurement. Due to the design of a progressive wound fork spring it will displace more oil thus requiring a maximum oil level of 5.5″ (140mm). Caution: This is not a recommendation, it is only a precautionary statement. If your manual specifies an oil level higher than 5.5″ (140mm) set the oil level at 5.5″ (140mm). (Oil level is the distance from the top of the fork tube to the top of the oil with the fork completely collapsed and the fork spring removed see figure 1.) This measurement can be made by using either one of the Progressive Suspension Fork Oil Level Adjusters (FOL-1 or FOL-2). 3. Install your new fork springs into the forks. Mechanically, it makes no difference which way the springs are installed. Some manuals will state; install the spring with the close wound end towards the bottom. This is done because sometimes there will be less spring noise. The springs will perform exactly the same regardless of which direction they are placed. Check the spacer length requirement for your motorcycle in the enclosed supplement. If not listed, you must calculate the pre-load. What is pre-load? Pre-load is the distance the spring compresses when the fork cap is installed. You may or may not utilize a spacer to achieve proper pre-load. The spacer in itself is not “pre-load”. It just helps to achieve it. Why is pre-load important? It determines the proper ride height which in turn affects how the bike handles.

SUZUKI GSX-R1000K7 IDLE SPEED CONTROL VALVE REPLACEMENT

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Filed Under (Suzuki) by admin on 26-11-2010

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1. Check the repair status by checking the Vehicle History in the Suzuki Connect Service Menu. If the repair needs to be performed to the motorcycle, you will see the message “CAMPAIGN NOT YET PERFORMED” displayed and the ISC valve will need to be replaced. Refer to the replacement procedure in this bulletin. 2. Inspect the right side of the frame head tube for an identification punch mark located at the end of the Vehicle Identification Number. If a punch mark is presentthe recall repair has already been performed. NOTE: A punch mark may already be present at the beginning of the Vehicle Identification Number if the Generator Rotor Replacement campaign (#2M97) has been completed. 1. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.

HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN AND SMART SIREN II BATTERY REPLACEMENT MANUAL

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Filed Under (Harley Davidson) by admin on 07-03-2011

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SECURITY SYSTEM SMART SIREN AND SMART SIREN II BATTERY REPLACEMENT KIT SIREN BOX REMOVAL Read the following instructions and make sure you fully understand them prior to replacing the battery. If the procedure is not within your capabilities, or you do not have the correct tool, have a Harley-Davidson dealer replace the battery. Improper installation could result in damage to this product. (00419b) 1. Refer to the Owner’s Manual and follow the instructions given to disarm the security system. 2. Remove the siren box from the vehicle. Reference the siren installation procedures found in the Siren Kit Instruction Sheet or contact a Harley-Davidson dealer for specific information on locating and removing the siren box from your model. Battery replacement, Smart Siren 1. See Figure 1. Remove the battery cover (2) from the siren box as follows: a. Place the siren on a sturdy, flat surface with the potting (1) and battery cover facing up. b. Using a blunt, stiff blade such as a table knife, insert the blade between the case and cover at a 45 degree angle to the side of the case. Insert the blade until it touches the snaps on the inside face of the cover. Figure 2 shows the four barbed snaps (2). c. Twist the blade slowly so the inserted edge presses against the inside face of the cover. The cover will pop off and can be replaced later using silicone adhesive if necessary

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VICTORY BLACK LIGHT LEAK DETECTOR KIT

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

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AMMCO HONE KIT Rigid hone to correct tapered and out of round cylinders. Range: 47.6 mm – 69.8 mm (1 7/8″ – 2 3/4″). Contains 60 and 220 grit stones, driveshank with depth stop and metal storage box. Oversize stone kits increase range to 92 mm ( 35/8″). Replacement Stone Kits are shown below. All stones shown below are included in the kit including the new PU-49876. 2870304 – REPLACEMENT STONE KIT – 60 Grit (47.6 0 69.8mm) 2870305 – REPLACEMENT STONE KIT – 220 Grit (47.6 – 69.8mm) 2870306 – REPLACEMENT STONE KIT – 60 Grit (69.8-92.8mm) 2870307 – REPLACEMENT STONE KIT – 220 Grit (69.8 0 92.8mm) 2871536 – REPLACEMENT STONE KIT – 69.8 for Ni-Ca-Sil deglazing PU-49876 – 320 GRIT REPLACEMENT STONE SET 2870386 PISTON PIN PULLER Removes 18 mm piston pins from all Polaris pistons. Required for many Polaris puller attachments. Note: Some engines require adapters. Available Adapters: 2871342 2871445 2870390 PISTON SUPPORT BLOCK Safely supports piston while disassembling or assembling engine top end. 2870569 CRANKSHAFT TRUING STAND For holding crankshaft while checking runout for all Polaris engines. 2870588 HONING OIL 12 oz can with dispensing tip. Promotes better finishes, faster cutting and longer stone life. Engine VICTORY 83 PU-46219 OIL EXTRACTOR Used to draw the engine oil from the crankcase. PV-35457 BLACK LIGHT LEAK DETECTOR KIT The Black Light Oil Leak Detector provides an effective time saving method for pinpointing engine oil leaks. Simply add 1 oz. of fluorescent oil additive to the engine crankcase (6 – 1 oz. bottles included). Run the engine for ten minutes to circulate the fluorescent oil additive throughout the engine. Oil leak will fluoresce a bright yellow when illuminated with PV-35457 Black Light. Includes: Fluorescent Black Light PV-28431-6 Oil Additive (6) 1 oz. Bottles (available separately) PV-28431-6 – LEAK DETECTION DYE PV-35667-A CYLINDER LEAKDOWN TESTER PV-35667-A will test for worn piston rings, cylinder walls, valves, gaskets and any other related leakage problems. Uses shop air. M12 x 1.25 Adapter and instructions included. PV-39951-A ENGINE TACHOMETER This digital tachometer accurately measures engine RPM and maximum RPM of 2 or 4-stroke engines. The dual display allows for readings of current RPM alone or current and maximum RPM. Also features two maximum RPM memories for comparison

2006 Saturn ION Window Regulator Replacement – Front Door

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Filed Under (Uncategorized) by admin on 30-10-2011

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regulator. Refer to Water Deflector Replacement – Front Door (See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ComponentsWater Deflector Replacement – Front Door) . Disengage the door glass to the regulator sash channel clips (2). Separate the door glass from the sash channel (1). 6. Push the window to the up position and tape in place. 7. Loosen the power window regulator bolts. Remove the rear regulator bolt. 8. Lift the window regulator, disengaging the loosened bolts from the door. 9. Disconnect the regulator electrical connector. 10. Remove the power window regulator from the door. Installation Procedure

Cobra JR/ OI Radiator with Louvers Replacement

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Filed Under (Cobra) by admin on 10-11-2010

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The 2009 model year radiator for Cobra JR (also remaining OI ) model will be FCCJ0004 which now has provisions for louvers. On the 2009 models these louvers also rely on a feature on the frame down-tube for mounting the plastic louvers. Older models do not have these features on the frame and so it is not possible to utilize the louver mounts on the radiator. Customers with older models JR/CM or OI/P3/PW3 needing a replacement radiator for ECMU0061 or ECMU0225 will be sold a radiator kit FKMU0001 which includes the new style radiator, FCCJ0004C (with louver mounting tabs removed), and all mounting hardware. This will allow the mounting of the new style radiator onto these products without mounting the louvers. As the 2009 frame is now the service replacement frame for JR/CM & OI/PW3/P3 models from 2004 – 2008, the louvers are able to mount on all older models JR/CM & OI/PW3/P3 that have the appropriate mounting provisions. Welding on the highly stressed down-tube frame member is not recommended by Cobra because it can cause premature structural failure to the frame and possible injury to the rider.

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