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2001 – 2004 Camry, Highlander, Solara & 2004

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

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2004 model year Camry, Highlander, Solara and 2004 model year RAV4 vehicles with the 2AZ-FE engine may exhibit squealing and/or rattling noises coming from the engine compartment during vehicle operation especially after a cold soak. The belt tensioner assembly has been improved to correct this condition. 2001 – 2004 model year Camry, Highlander and Solara vehicles equipped with 2AZ-FE engines produced BEFORE the Production Change Effective VINs shown below. 2004 model year RAV4 vehicles produced BEFORE the Production Change Effective VINs shown below. MODEL ENGINE LINE PRODUCTION CHANGE EFFECTIVE VIN TMMK Line 1 4T1BE3#K#4U358206 Camry TMMK Line 2 4T1BE3#K#4U914052 y 2AZFE Tsutsumi JTDBE3#K#40296732 Highlander 2AZ-FE TMK JTE#D2#A#40100501 Solara TMMK 4T1CE3#P#4U914074 RAV4 Tahara JTE#D2#V#40029797 PREVIOUS PART NUMBERCURRENT PART NUMBER PART NAME QTY 16620-28010 16620-28011 Tensioner Assembly, V-ribbed Belt 1 OP CODE DESCRIPTION TIME OFP T1 T2 EG8001 R & R Accessory Belt Tensioner 0.9 16620-28010 91 55 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. *Warranty application is limited to correction of a problem based upon a customer’s specific complaint

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2003 – 2004 4Runner & Tundra, 2004 Camry, Highlander, Sienna & SolaraREPAIR MANUAL SUPPLEMENT LEV II EVAP SYSTEM CHECK

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Filed Under (Toyota Manuals) by admin on 24-10-2011

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this TSB provides detailed instructions for a new LEV II EVAP System Check function using the Diagnostic Tester. The LEV II System Check allows the Diagnostic Tester to display the fuel tank vapor pressure as the EVAP VSV and the CCV are operated in a specific six-step pattern. Problems with the EVAP system are quickly isolated by observing the change in vapor pressure during each step. Once the vehicle condition is corrected, the LEV II System Check can also be used to confirm the repair before the vehicle is returned to the customer. The inspection procedure using the LEV II System Check (LEV II SYS CHECK) is described in this bulletin. This function is available using a Diagnostic Tester with version 11.0a software (or newer

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2003 – 2004 4Runner, 2004 Highlander, Prius, Sienna And Solara POWER WINDOW / ROOF INITIALIZATION PROCEDURES

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Filed Under (Toyota Manuals) by admin on 17-10-2011

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Turn the ignition switch ON. 2. Open the window halfway by pressing the power window switch. 3. Fully pull up the switch until the power window is fully closed and continue to hold the switch for at least three (3) seconds after the power window is fully closed. 4. Check that the “AUTO UP/DOWN” function operates normally. B. Back Door Power Window (4Runner) 1. Turn the ignition switch ON. 2. Open the back door glass. 3. Press the back door power window switch until the door glass is fully closed and continue to hold the switch one (1) second or more after the door glass is fully closed. 4. Check that the “AUTO UP/DOWN” function operates normally. C. Power Sliding Roof (4Runner, Sienna, Solara) 1. Turn the ignition switch ON. 2. Initialize the sliding roof by pressing and holding the TILT UP switch until the roof glass tilts upward fully (the roof glass automatically tilts downward slightly after fully tilting upward). 3. Release the switch. 4. Check that the “AUTO OPEN/CLOSE” function operates normally

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2004 Highlander, Land Cruiser and Prius MULTI-DISPLAY FUNCTIONS ARE INOPERATIVE

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Filed Under (Toyota Manuals) by admin on 26-10-2011

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Confirm the connectors to the multi-display are fully seated. Replace any damaged connectors. 3. If all the TX
terminals are tight and the connectors are fully seated, replace the multi-display. NOTE: For Highlander multi-display Removal and Replacement, refer to the Technical Information System (TIS), 2004 model year Highlander Repair Manual: Audio & Visual System: Multi-display (CRT display): Replacement. For Land Cruiser multi-display Removal and Replacement, refer to TIS, 2004 model year Land Cruiser Repair Manual: Body (Mechanical): Instrument Panel: Removal. For Prius multi-display Removal and Replacement, refer to TIS, 2004 model year Prius Repair Manual: Audio & Visual System: Multi-display Assy: Replacement.

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2004 CM shock valving REMOVAL

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

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If you took receipt of your Cobra CM50 prior to April 22, 2004 the valving in the rear shock is incorrect causing excessive bottoming and bouncing of the rear end. The serial number of the shocks needing corrected is CO4940. Owners of 2004 model CM50s are being asked to send the shock to Öhlins USA, Inc. , at no charge, to receive the production intent valving. Please follow these steps when sending your shock with spring to Öhlins. 1. Remove the spring a. Clean the unit of dirt. b. Secure the end bushings in place with safety wire or ‘zip’ tie. c. Include your name and return address (indicate whether residential or business address)

2001-2004 HONDA GL1800/A Trunk Opener Unit Removal/ Installation instructions

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Filed Under (Honda) by admin on 29-01-2011

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come customers may experience trunk or saddlebag lids not opening when the corresponding latch lever is pulled. To correct this condition, the opener mechanism must be replaced with a new opener mechanism. Follow the Trunk Opener Unit Removal/Installation instructions in the GL1800/A Gold Wing Service Manual. Opener Unit P/N: 81310-MCA-A22 H/C: 7700768 The normal GL1800/A warranty applies. Follow all normal warranty procedures and guidelines. Labor Operation: 412122 Flat Rate Time: 0.6 If you feel that goodwill consideration is appropriate, contact your District Service Manager or TechLine BEFORE starting this repair. 2001-2004 GL1800/A Trunk Opener Unit MTB 10535 (0403) GL1800/A #15 MAY 2004 REPAIR PROCEDURE PARTS INFORMATION WARRANTY INFORMATION QUESTIONS PART DESCRIPTION TRUNK OPENER UNIT

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2004 Harley Davidson Micro Tach Tachometer Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-03-2012

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Tachometer Installation Instructions for 2004+ Harley Davidson Sportster Custom Look for other model instructions online at www.speedwayinstruments.com Introduction: Installation of the Speedway Instruments microTach+ TM tachometer Tachometer requires some basic mechanical skills, including removing decorative covers, cutting protective tubing around wires, and using suitcase splice connectors to splice existing wiring harness. These actions may void your warranty, and if done incorrectly may cause damage to your motorcycle. Only you know your capabilities, if you do not feel capable of making modification please have a qualified motorcycle technician install it. Speedway Instruments, LLC is not responsible for damage to your motorcycle due to improper installation. These instructions utilize a 2004 Harley Davidson XL1200C motorcycle as basis for the all descriptions and pictures. Variations in location, color and procedure may be required for different year and make. Please refer to the Service manual to confirm the proper color and location of wires. Please make sure you have the proper service manual and tools before starting the installation. 1. Turn ignition off and disconnect Battery. 2. Determine a mounting position. Each motorcycle is unique and the microTach+TM tachometer is small enough to be placed in many different locations to provide an attractive appearance and vital engine status. Possible locations are: a. Front Brake Reservior b. Top handle bar clamp

2004 Kawasaki VN2000 Power Commander Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1 Remove the main seat and the passenger seat. 2 Remove the chrome left hand engine cover below the fuel tank. 3 Remove the fuel tank. To remove the fuel line squeeze the orange tabs of the connector and push in (Fig. A). 4 Unplug the three electrical con- nectors. 5 Remove the battery cover by removing the five screws (Fig. B). 6 Lay the PCIII in front of the battery temporarily (Fig. C). 7 Attach the black ground lead from the PCIII to the negative side of the battery. Fig. A Fig. B Fig. C i211-411 2004 Kawasaki VN2000 – PCIII USB – 2 Unplug these connectors Squeeze this line to remove Remove these screws Ground wire 8 Route the PCIIIharness towards the front of the bike (Fig. D). Follow the stock wiring harness through the guides. 9 Locate the stock 12 pin black connector from the throttle body. 10 Unplug this connector (Fig. E). There is a tab on the backside of this connector that if you push will allow the connector to be removed from the frame. 11 Plug the connectors from the PCIII in-line of the stock connector (Fig.F). Fig. D Fig. E Fig F i211-411 www.powercommander.com 2004 Kawasaki VN2000 – PCIII USB – 3 Unplug this connector PCIII harness Stock connectors PCIII connectors 12 Reinstall the battery cover. 13 Slide the PCIII into the supplied protective sleeve. 14 Lay the PCIII in front of the battery cover and under the seat bracket (Fig.G). Note: The picture shows the PCIII without the protective sleeve. Make sure to use the sleeve to prevent any damage to the unit. 15 Reinstall the fuel tank and connect the fuel line and connectors. 16 Reinstall the seat. Make sure the PCIII harness will not get damaged

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1999-2004 Kawasaki 1500 Drifter Power Commander Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1 Remove the seat. 2 Remove the left side cover. 3 Remove the speedometer assembly. 4 Unbolt the fuel tank. NOTE: It is not necessary to remove the fuel tank. It does however make the installation easier. If you do remove the tank, pay attention to the vent hose routing. Pressing the tabs on the black fuel line connector will allow the fuel line to be disconnected (Fig. A) 5 Remove the battery/ECU hold down bracket (Fig. B). 6 Unbolt and move the bank angle (tip over) sensor out of the way (Fig. C). Fig. A Fig. B Fig. C i201-411 www.powercommander.com 1999-2004 Kawasaki 1500 Drifter – PCIII USB – 2 Bank angle sensor (tip over switch) Remove these 2 bolts 7 Loosen the bolts holding the plastic tray on the left side of the bike (under the left side cover) (Fig. D). 8 Route the wire from the PCIII behind the plastic tray and under the frame side rail (Fig. E). 9 Retighten the bolts holding the plastic tray. 10 Continue routing the wires from the PCIII under the frame near the lower fuel tank mount and go up to the throttle body area (Fig. F). Fig. D Fig. E Fig F i201-411 www.powercommander.com 1999-2004 Kawasaki 1500 Drifter – PCIII USB – 3 Route PCIII harness between plastic tray and frame Route wires under frame Loosen these bolts 11 Disconnect the injector connector from the rear injector (Fig. H). 12 Plug the female PCIII connector with ORANGE/WHITE wire onto the rear injector (Fig. H). 13 Connect the male PCIII connector with ORANGE wire onto the stock injector connector (Fig. H). 14 Repeat steps 11 thru 13 for front injector using the PCIII connectors with the YELLOWcolored wires. 15 Locate the wires coming from the throttle position sensor. (Fig. H). The throttle position sensor is located on the right hand side of the throttle body. It is between the frame and engine

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2004 CBR 1000RR CYLINDER HEAD COVER INSTALLATION

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Filed Under (Honda) by admin on 17-12-2011

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COLOR TABLE MARCH, 2004 ©2004 American Honda Motor Co., Inc. 9 When ordering a colored part: 1. Confirm the color code for the required part from the color table according to the part name and color type. 2. Select the corresponding part number from the appropriate PAGE/GRID. 3. Parts marked “X” are unused. 4. “*” = Basic Part Number, no extension (i.e. ZA, ZB). CBR1000RR’04 2004 No. COLOR CODE BASE COLOR NH1 Black NH1 R258B Winning red R258 NH411B Force silver metallic NH411M A R E A DESCRIPTION BASIC PART NO. 1CLIP, PANEL FIXING 91549-MW0-790 ZA ZA ZA 2COWL (UPPER) 64211-MEL-000 ZA ZB ZC 3COWL SET, L. (LOWER) (WL) 64450-MEL-670 ZF ZG ZH 4COWL SET, L. MIDDLE (WL) 64350-MEL-670 ZA ZD ZE 5COWL SET, R. (LOWER) (WL) 64400-MEL-670 ZF ZG ZH 6COWL SET, R. MIDDLE (WL) 64300-MEL-670 ZA ZD ZE 7COWL SET, RR. SEAT (WL) 77210-MEL-010 ZE ZF ZG 8FENDER, FR. 61100-MEL-000 ZA ZC ZB 9FRAME 50100-MEL-670 ZAZAZAA 10 FRAME 50100-MEL-770 ZA ZA ZAAC 11LABEL, COLOR 87565-MEL-000 ZD ZE ZF 12MARK, COWL (LOWER) 64819-MEL-000 ZD ZE ZB 13MARK, L. TOP SHELTER 64852-MEL-000 — ZA ZC 14MARK, L. TOP SHELTER 64856-MEL-000 ZA — — 15MARK, MIDDLE COWL 64811-MEL-000 ZA — — 16MARK, R. TOP SHELTER 64851-MEL-000 — ZA ZC 17MARK, R. TOP SHELTER 64855-MEL-000 ZA — — 18MARK, RR. SEAT COWL 64841-MEL-000 ZA ZB ZD 19MARK, RR. SEAT COWL 64842-MEL-000 ZA ZB ZD 20RAIL ASSY., SEAT 50200-MEL-010 ZA ZA ZA 21SHELTER SET, TOP (WL) 83150-MEL-670 ZA ZD ZE 22STRIPE A, L. MIDDLE COWL 64814-MEL-670 — ZC ZA 23STRIPE A, R. MIDDLE COWL 64813-MEL-670 — ZC ZA 24STRIPE C, L. MIDDLE COWL 64817-MEL-670 — ZA ZB 25STRIPE C, L. MIDDLE COWL 64818-MEL-670 — ZA ZB 26STRIPE, L. TOP SHELTER 64854-MEL-000 — ZB ZB 27STRIPE, R. TOP SHELTER 64853-MEL-000 — ZB ZB 28STRIPE, WINDSCREEN 64805-MEL-000 ZA ZA ZA 29WHEEL SUB-ASSY., FR. 44650-MEL-000 ZA ZA ZA 30WHEEL SUB-ASSY., RR. 42650-MEL-010 ZA ZA ZA 31WINDSCREEN SET 64250-MEL-000 ZA ZA ZA

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