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A750 Transmission Solenoid Identification Automatic Transmission/ Transaxle

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Filed Under (Toyota Manuals) by admin on 19-09-2011

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Provided below isachartlisting the Repair Manual name of each solenoid used in the A750 transmission, as well as the part name description provided in the electronic parts catalog. REPAIR MANUAL SOLENOID NAME PARTS CATALOGP ART DESCRIPTION S1 3WayTransmission Solenoid S2 Transmission Solenoid#3 SL1 Clutch Control Solenoid#1 SL2 Clutch Control Solenoid#2 SLT Line Pressure Control Solenoid SLU Lock UpControl Solenoid SR

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SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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HARLEY DAVIDSON STARTER SOLENOID REPAIR KIT

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Filed Under (Harley Davidson) by admin on 31-10-2010

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1. Remove, but do NOT discard, bolt washer 1 and 4 (fig. 1). 2. Remove, but do NOT discard, nut washer 2 (fig. 1). 3. Remove, but do NOT discard, nut washer 3 from shortest copper bolt on cap (fig. 1). 4. Gently remove solenoid cap. 5. IMPORTANT!: Snip wire 5 as close as possible to large copper bolt (fig. 2). 6. Discard old copper bolt and cap. 7. Replace old plunger 6 with new plunger provided in kit. 8. Guide small bolt 7 through hole in new cap as shown (fig. 3). 9. Solder cut wire 5 to new copper bolt terminal 8CAUTION!: Solder wire to terminal, so as not to interfere with contact of plunger to terminal. 10. Install new cap. 11. Re-assemble nuts, bolts and washers 1 2 3 4 as shown (fig. 1). Replace worn parts with those provided in kit.

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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

ABS Solenoid Relay Circuit TOYOTA

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Filed Under (Toyota Manuals) by admin on 21-09-2011

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Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 2 in case
of not using the TOYOTA hand-held tester.1 Check ABS solenoid relay operation. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check the operation sound of the ABS solenoid relay when operating it with the TOYOTA hand-held tester. OK: The operation sound of the ABS solenoid relay should be heard

Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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Yamaha WR motorcycle ProEFX 12V Hot Start Installation

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Filed Under (Yamaha) by admin on 06-01-2012

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1. Remove seat, tank and shrouds. Remove existing hot start lever, cable and valve from the carburetor. 2. Tip: Clean all dirt from hot start bore and mating surfaces on the carburetor body with gas and a q-tip. 3. Tip: Use a small amount of Teflon tape (one wrap) on the threads of the aluminum mounting nut to ensure a water tight seal. 4. Install the Pro EFX hot start valve in the hot start bore (as shown in picture), with return spring, impact washer and delrin plunger in place. • Tip: Installation of the solenoid valve may require temporary rotation of the carburetor away from the top engine mount bracket. • Install with the solenoid valve assembly disconnected from wiring harness. • Screw in by hand and finish tightening with needle nose pliers. Do not over-tighten. Solenoid valve assembly: 5. Mount activation switch on preferred handle bar location. Pictured on clutch side, in place of the stock kill switch.
6. Route wiring harness around steering column and down frame backbone. Insert battery leads through slot in rubber protective boot. (follow existing wiring to battery) 7. Connect positive (red) and negative (black) leads to motorcycle battery. 8. Connect male and female terminals to wiring harness on previously installed solenoid valve assembly. 9. Depress activation button and listen for valve actuation. Plunger should freely “snap” between open and closed position in hot start bore, as activation button is depressed and released. If you don’t hear the valve “snap” open and closed, follow the trouble shooting guidelines or call /email for support. 10. Maintenance: Periodically ensure proper tightness of solenoid valve in carburetor body as part of standard motorcycle maintenance. Keep the battery terminal connections free from corrosion.

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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.

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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. ) .

2009 Honda CRF450R Decompression Plunger PRODUCT UPDATE CAMPAIGN

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Filed Under (Honda) by admin on 21-04-2011

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JH2PE053*9K700001 thru JH2PE053*9K703372 (*) Denotes check digit UPDATE PROCEDURE DEALER VENTORY Any affected unit in your inventory must be updated with a new decompression plunger and weight before delivery to the customer. Refer tothe PARTS INFORMATION and the UPDATE PROCEDURE sections of thisb Service Bulletin. Refer to the 2009 CRF450R Service Manual for specific removal instructions. 1. Remove the seat (page 3-3). 2. Remove the shrouds (page 3-4). 3. Properly hang the fuel tank (page 4-6). 4. Remove the camshaft (page 9-10) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. 5. Replace the decompression weight and plunger with kit parts (page 9-14). 6. Reinstall all previously removed parts. IDENTIFICATION When you have completed the update, place a punch mark before the first digit of the V.I.N. located on the right side of the steering head. 0080 WARRANTY INFORMATION This Product Update Campaign ends on arch 7, 2012. Normal claim submission requirements apply. fter completing the UPDATE PROCEDURE,submit one warranty claim per unit with the following information: WARRANTY CLAIM TEMPLATE: Template: R02A* Flat Rate Time: 1.2 hours *Template reads “R-zero-2-A”.

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