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Tacoma Power Steering Pump Improving Power Steering Reservoir modification

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Filed Under (Toyota Manuals) by admin on 02-10-2011

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For my SAS I decided to add hydraulic steering assist as it comes in real handy for rock crawling. I got the Redneck Ram setup from the folks at West Texas Off-road that includes rebuilding an earlier IFS steering box along with drilling and tapping the box for the included ram. One of the down sides of adding a ram is that it slows the steering down because the stock steering pump has to supply the added volume for the hydraulic ram. Another is that it creates a fluid volume change in the system reservoir that needs to be compensated for in some way. After doing some reading on the West Texas site about how to go about modifying a Saginaw pump and reading up on earlier Toyota pump mods for steering assist setups on the Pirate board, I decided to give it whirl and see what I could do about the Tacoma pump. Chuck Gardella was kind enough to supply me with a blown pump that I could rebuild and submit to my endless fiddling and tinkering. I plan to give him my pump in return when I get this one done and installed. You need to do something to allow for more room in the reservoir for the standard hydraulic ram assist setup so I decided to tackle the reservoir first. The reason you need the extra space is because the ram is unbalanced. That is there is a rod on one side of the cylinder and not on the other side so the volume of the fluid has to change in the system to account for the volume of the rod as it travels back and forth. I calculated the volume of the rod that I have at full stroke to be about 2 oz or so. This would equate to plus or minus up to 2 oz. in the pump reservoir. Well first off, it’s no wonder why so many folks boil their steering pumps over with heavy wheeling and have so many other steering problems. The stock power steering reservoir doesn’t even rate pint sized

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Toyota and Lexus Clogged Power Steering Reservoir Filter

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Filed Under (Toyota Manuals) by admin on 02-10-2011

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Clogged Power Steering Reservoir Filter – Toyota & Lexus Toyota and Lexus vehicles with power steering. Noise coming from the power steering pump or reduced assist from the power steering system. Noise or reduced assist may be caused by restriction in the power steering fluid reservoir. Most Toyota/Lexus-style reservoirs have a filter screen at the bottom. Over a period of time this filter could get clogged causing the restriction of fluid. Replace any hose that shows signs of cracking or internal deterioration. Thoroughly flush the power steering system; then remove the reservoir for cleaning as follows: 1. Clean the exterior and interior of reservoir with new power steering fluid or suitable solvent. 2. Blow off the filter screen using pressurized air until restriction or clog is removed. 3. Using a flashlight, check to make sure that the filter screen is free of debris. Note: Contamination may be an indication of internal breakdown of hoses, which must be replaced before operating the vehicle. Failure to replace bad hoses could damage both the pump and steering unit. 4. Reinstall reservoir, referring to the service manual for tightening specs and bleeding procedures.

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KAWASAKI MULE Electric Steering Installation Manual And Removal

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Filed Under (Kawasaki) by admin on 05-05-2012

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Remove plastic center cap on steering wheel by prying off with a small screwdriver. Remove steering wheel nut and remove steering wheel by pulling up on wheel. If wheel is tight have a partner tap on the shaft while pulling up on wheel. Note: Do not mushroom threads on shaft. Remove all screws that retain dash to body of vehicle. Disconnect all electrical connections at back of dash. Mark all wires to ensure easy install. Remove lower steering shaft bolt at rack and pinion. Remove upper bolt at base of steering column. Remove the 2 bolts that retain the steering column to the frame and remove the column and the shaft assembly. Remove lower u-joint on steering column shaft & replace it with supplied u-joint. There is a welded wire retainer on the lower dash tube where the electric motor will sit. You will need to grind off this piece and smooth. Remove the master cylinder bolt closest to the driver side and discard bolt. Your motor and module has been shipped together bolted to the bracket. It is important to follow the install sequence to ensure a proper installation. The lower shaft on the steering motor is marked on the shaft and on the motor. These marks must not be changed. If you remove the shaft it needs to be installed back in the same spot.

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STEERING GEAR/ STEERING WHEEL REMOVAL AND INSTALLATION

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Filed Under (Uncategorized) by admin on 05-10-2011

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TEERING GEAR/STEERING WHEEL REMOVAL & INSTALLATION Page 3 of 4 STEERING GEAR/STEERING WHEEL INSTALLATION PROCEDURES (Cont’d) 2. Center spiral cable. a. Turn the cable counterclockwise by hand until it becomes harder to turn. b. Then rotate the cable clockwise about 2.5 or 3 turns to align the marks. (See Fig. 4) 3. Install the steering wheel. a. Align the matchmarks on the wheel and steering main shaft. b. Temporarily tighten the wheel set nut. c. Connect the spiral cable connector. 4. Bleed Power Steering System (when applicable). 5. Check steering wheel center point. 6. Torque steering wheel set nut. See the applicable vehicle’s repair manual for the torque specification. 7. Install and center steering wheel pad. NOTICE: Make sure the pad is centered and installed to the specified torque. If the pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one. When installing the pad, take care that the wiring does not interfere with other parts and is not pinched between other parts. a) Connect the airbag wiring connector. b) Install the pad after confirming that torx screws are in the screw case. c) Using a torx socket, torque the screws to the specification in the vehicle’s Repair Manual. (See Fig. 5) d) Install the steering wheel lower cover

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2008 KTM Model Engine Oil Recommendation Chart

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Filed Under (KTM) by admin on 24-11-2010

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2008 Model Type Recommended Engine Oil Type Quantity SPORTMINICYCLES AC 50 SX MINI Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L SPORTMINICYCLES LC 50 SX JUNIOR Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 50 SX Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 65 SX Motorex Top Speed 4T 15W50 0.5L SX 2 STROKE 85 SX Motorex Top Speed 4T 15W50 0.5 L 105 SX Motorex Top Speed 4T 15W50 0.5 L 125 SX Motorex Top Speed 4T 15W50 0.7 L 144 SX Motorex Top Speed 4T 15W50 0.7 L 250 SX Motorex Top Speed 4T 15W50 0.7 L SX 4 STROKE 250 SX-F Motorex Power Synt 4T 10W50 1.1 L 450 SX-F Motorex Power Synt 4T 10W50 1.35 L 505 SX-F Motorex Power Synt 4T 10W50 1.35 L CROSS COUNTRY 2 STROKE 65 XC Motorex Top Speed 4T 15W50 0.5L 85 XC Motorex Top Speed 4T 15W50 0.5L 105 XC Motorex Top Speed 4T 15W50 0.5 L 200 XC Motorex Top Speed 4T 15W50 0.7 L
200 XC-W Motorex Top Speed 4T 15W50 0.7 L 250 XC Motorex Top Speed 4T 15W50 0.7 L 250 XC-W (e) Motorex Top Speed 4T 15W50 0.7 L 300 XC Motorex Top Speed 4T 15W50 0.7 L 300 XC-W (e) Motorex Top Speed 4T 15W50 0.7 L CROSS COUNTRY 4 STROKE 250 XC-F Motorex Power Synt 4T 10W50 1.1 L 250 XC-F-W Motorex Power Synt 4T 10W50 1.1 L 450 XC-F Motorex Power Synt 4T 10W50 1.35 L 450 XC-W (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L 505 XC-F Motorex Power Synt 4T 10W50 1.35 L 530 XC-W (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L ENDURO RACING 450 EXC (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L 530 EXC (R) Engine – Motorex Power Synt 4T 10W50 Gearbox – Motorex 4T 10W50 0.7 L 0.9 L SUPERMOTO LC4 690 Supermoto Motorex Power Synt 4T 10W60 Approx. 2.0 L SPORT ATV 450 XC Motorex Power Synt 4T 10W50 2.0 L 525 XC Motorex Power Synt 4T 10W50 2.0 L LC8 950 Super Enduro (R) Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure Orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure Black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Adventure S Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Super Duke Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 990 Super Duke R Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L

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Toyota Power Steering Conversion Kit Installation Instructions

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Filed Under (Toyota Manuals) by admin on 04-10-2011

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Remove the stock steering box and column. Be sure to clear the area of all wiring, brake lines and fuel lines. 2. Bolt the Toyota box to the mounting bracket so that the long arm of the bracket points in the same direction as the steering column input shaft (small shaft.) To mount the bracket and box correctly, the longer end should be towards the rear of the vehicle. It may be necessary to grind on the power steering box where the two flanges protrude above the bracket. For technical help call Classic Performance Products Monday thru Friday 8:30am to 5:00pm at (714) 522-2000. Rev. 8/17/2009 3. Locate the box/bracket assembly into the frame by centering the Toyota sector shaft through the original hole in the frame. This hole will need to be elongated approximately 3/8″ to allow the sector shaft to clear the frame. Bolt the bracket directly into the mounting holes for the original steering box. 4. With the first bolt in, check the fit by reattaching the steering box. Make sure the splined shaft goes through the frame without interference. Torque down the mounting bolts to 45 lbs. 5. Attach the pitman arm to the steering box. Before this is done the steering sector must be centered. Turn the input shaft clockwise as far as it can go. Make a reference mark. Now turn the shaft counter clockwise as far it can go and be sure to count the turns. Turn the shaft back half the distance and now the box is centered. Be sure to double and triple check this procedure. Attach the pitman arm to the output shaft with the output shaft nut. Torque the bolt down to 110ft/lbs. Reconnect the stock drag link and you are on your way

1953 Toyota Ford Truck Power Steering Conversion Kit Installation Instructions

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Filed Under (Toyota Manuals) by admin on 01-10-2011

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of all wiring, brake lines and fuel lines. 2. Bolt the Toyota box to the mounting bracket so that the long arm of the bracket points in the same direction as the steering column input shaft (small shaft.) To mount the bracket and box correctly, the longer end should be towards the rear of the vehicle. It may be necessary to grind on the power steering box where the two flanges protrude above the bracket. For technical help call Classic Performance Products Monday thru Friday 8:30am to 5:00pm at (714) 522-2000. Rev. 8/17/2009 3. Locate the box/bracket assembly into the frame by centering the Toyota sector shaft through the original hole in the frame. This hole will need to be elongated approximately 3/8″ to allow the sector shaft to clear the frame. Bolt the bracket directly into the mounting holes for the original steering box. 4. With the first bolt in, check the fit by reattaching the steering box. Make sure the splined shaft goes through the frame without interference. Torque down the mounting bolts to 45 lbs. 5. Attach the pitman arm to the steering box. Before this is done the steering sector must be centered. Turn the input shaft clockwise as far as it can go. Make a reference mark. Now turn the shaft counter clockwise as far it can go and be sure to count the turns. Turn the shaft back half the distance and now the box is centered. Be sure to double and triple check this procedure. Attach the pitman arm to the output shaft with the output shaft nut. Torque the bolt down to 110ft/lbs. Reconnect the stock drag link and you are on your wa

2006 Model Engine Oil Recommendation Chart

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

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2006 Model Type Recommended Engine Oil Type Quantity SPORTMINICYCLES AC 50 MINI ADVENTURE Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L 50 SENIOR ADVENTURE Motorex ATF Super (Dexron II Gear Oil) 0.15-0.2 L SPORTMINICYCLES LC 50 SX JUNIOR Motorex Top Speed 4T 15W50 0.15-0.2 L 50 SX Motorex Top Speed 4T 15W50 0.15-0.2 L 65 SX Motorex Top Speed 4T 15W50 0.3L SX 2 STROKE 85 SX Motorex Top Speed 4T 15W50 0.5 L 105 SX Motorex Top Speed 4T 15W50 0.5 L 125 SX Motorex Top Speed 4T 15W50 0.7 L 250 SX Motorex Top Speed 4T 15W50 0.7 L SX 4 STROKE 250 SX-F Motorex Power Synt 4T 10W50 1.1 L 450 SX Motorex Power Synt 4T 10W50 1.25 L 525 SX Motorex Power Synt 4T 10W50 1.25 L CROSS COUNTRY 2 STROKE 200 XC Motorex Top Speed 4T 15W50 0.7 L 200 XC-W Motorex Top Speed 4T 15W50 0.7 L 250 XC Motorex Top Speed 4T 15W50 0.7 L 250 XC-W Motorex Top Speed 4T 15W50 0.7 L 300 XC Motorex Top Speed 4T 15W50 0.7 L 300 XC-W Motorex Top Speed 4T 15W50 0.7 L CROSS COUNTRY 4 STROKE 450 XC Motorex Power Synt 4T 10W50 1.25 L 525 XC Motorex Power Synt 4T 10W50 1.25 L ENDURO RACING 400 EXC Motorex Power Synt 4T 10W50 1.25 L 450 EXC Motorex Power Synt 4T 10W50 1.25 L 525 EXC Motorex Power Synt 4T 10W50 1.25 L ADVENTURE LC8 950 Adventure orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Adventure black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Adventure S Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L SUPERMOTO RACING 450 SMR Motorex Power Synt 4T 10W50 1.25 L 560 SMR Motorex Power Synt 4T 10W50 1.25 L SUPERMOTO LC4 625 SMC Motorex Power Synt 4T 10W50 Approx. 2.1 SUPERMOTO LC8 950 Supermoto orange Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L 950 Supermoto black Motorex Power Synt 4T SAE 10W50 (for temperatures over 32° F) and 5W40 (for temperatures under 32° F) Approx. 3.0 L

POWER STEERING CONVERSION TOYOTA LAND CRUISER

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Filed Under (Toyota Manuals) by admin on 08-06-2011

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Advance Adapters has been manufacturing steering conversion parts for installation of the Saginaw steering boxes into Toyota vehicles for more than twelve years. The parts we furnish are of the highest quality available and we utilize only proven design components for our kits. Before you consider the conversion, we recommend that you thoroughly read and understand the complete procedure (located in the Land Cruiser Manual). Do not take short cuts on steering installations. We recommend that these conversions be installed by a qualified technician. All universal joints must be safety wired for double protection. Do not overlook any details. Remember that the control of your vehicle depends on the steering gear performance. Failure of your steering system can result in severe damage and possible injury.

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POWER STEERING CONVERSION TOYOTA LAND CRUISER REMOVAL

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Filed Under (Toyota Manuals) by admin on 03-10-2011

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ADVANCE ADAPTERS INC. P/N: 716808 P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 PAGE 4 OF 4 Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 02-10-10 POWER STEERING CONVERSION TOYOTA LAND CRUISER SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion, we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment. These manuals are normally available at automotive dealerships and parts stores. Installation Tips We recommend Weldless DD and Double Splined universal joints for the best steering system. Weldless DD universal joint features two set screws for maximum holding power. Position yoke, tighten set screws to mark the shaft. Remove yoke and drill the set point on the shaft. When installing the universal joint, set screws are tightened into the countersink mark, then tighten the jam nut and the shaft will not move. We recommend the use of Loctite. Spline both ends (3/4″-36) universal joint is the preferred design, as it allows the shaft to be rotated in small increments during installation to properly align or phase the steering system. The same installation procedure as the Weldless DD should be used, or it is acceptable to simply grind a flat surface on the spline to let the set screw.

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