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Turbo+2 , Roadstar , Quantum Sport , Quantum"GL" , Entourage Owners Manual

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Filed Under (Uncategorized) by admin on 03-12-2010

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tracking Any parting within the tread, sidewall, or inner liner of the tire extending to cord material. CT A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the rim flanges inside the air cavity of the tire. Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel, oil, and coolant, and, if so equipped, air conditioning and additional weight optional engine. Extra load tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire. Groove The space between two adjacent tread ribs. Gross AxleWeight Rating The maximum weight that any axle can support, as published on the Certification /VIN label on the front left side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached to the towing vehicle. Gross Vehicle Weight Rating The maximum weight of the fully loaded trailer, as published on the Certification /VIN label. Actual weight determined by weighing trailer on a public scale, without being attached to the towing vehicle. Hitch Weight The downward force exerted on the hitch ball by the trailer coupler. Innerliner The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire. Innerliner separation The parting of the innerliner from cord material in the carcass. Intended outboard sidewall The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle. Light truck (LT) tire A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. Load rating The maximum load that a tire is rated to carry fora given inflation pressure. Maximum load rating The load rating fora tire at the maximum permissible inflation pressure for that tire. Maximum permissible inflation pressure he maximum cold inflation pressure to which a tire maybe inflated.
-9- Maximum loaded vehicle weight The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight. Measuring rim The rim on which a tire is fitted for physical dimension requirements. Pin Weight The downward force applied to the 5thwheelor gooseneck ball, by the trailer kingpin or gooseneck coupler.

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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

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)

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

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 – 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

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 KING Owners / Service Manual

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Filed Under (Cobra) by admin on 01-12-2010

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Specifications – General Items KING Dimensions Wheelbase 39″ (991mm) Wheel size 10″ (254mm) rear, 12″ (305mm) front Seat height 26″ (660mm) Engine Type 2-stroke, single cylinder, reed valve Cooling system Liquid-cooled Displacement 49.8 cc Bore and stroke 39 mm x 41.7 mm Ignition system Electronic Spark plug Splitfire SF406B Gap 0.023″ – 0.025″ (0.58 – 0.64 mm) Ignition timing 0.050″ (1.3 mm) Before To Dead Center (BTDC) Fuel type Sunoco MO2 X or 93 octane pump gasoline OTHER RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2-cycle Race Oil Fuel / oil mix ratios Between 32:1 and 40:1 (after engine Break-In is complete) Carburetion 19 mm Dell’Orto Main Jet 94 Slow (Pilot) jet 65 Float Height 16mm + 0.5mm (0.63″ + 0.020″ Transmission Speed Single Clutch Cobra 3 shoe Final drive ratio 13/39 T Chain 100 links 420 Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III Quantity 235 ml (8.0oz) 5 Chassis Front tire 2.50 – 12 Pressure 15 psi minimum Rear tire 2.75 – 10 Pressure 15 psi min. (20 psi for hard pack or rocky conditions) Front fork Cobra 30mm USD Fork oil type SAE 5 weight Fork oil amount 118 ml (4.0 oz) Optional Components • Carburetor jets • Sprockets o Front o Rear • Suspension Springs Weight of Rider (lb) Fork Spring Shock Spring Less than 51 7 lb/in, KCKG0007 SCKGOH10 (yellow, 175lb/in) 51 – 60 9 lb/in, KCKG0009 SCKGOH85 (gray, 185 lb/in) Greater than 60 12 lb/in, KCKG1200 SCKG0H, (white, 195 lb/in) • Suspension Valving Damping Rate Fork Valving Compression (base valve) Fork Valving Rebound (mid valve) Shock Valving (kit) Soft (fast) KAKG0013 KAKG0016 SCKGOH24A Standard KAKG0014 KAKG0017 SCKGOH24 Hard (slow) KAKG0015 KAKG0018 SCKGOH24B • Cobra BIG AIR SX Fork Kit part #KKKG2003 6 Specifications – Torque Values Torque Value Fastener ft-lb in-lb Nm Size & Remarks Cylinder head nuts 9.2 110 12 ¼” Crankcase bolts 6.6 80 9 6 x 1.0 Spark plug (SP) (SP) (SP) 14 x 1.25 Stator bolts 2.1 25 2.8 #8 Stator cover bolts 1.7 20 2.3 #8 Clutch cover bolts 5.8 70 7.9 6 mm Clutch 40 480 54 10*** Front axle nut 25 300 34 12 x 1.25 Front brake caliper Engine mount bolts 22 265 30 8 mm Swingarm Pivot 21 250 28 14 mm Intake manifold bolts 4.6 55 6.2 6 mm Rear Axle Bolt 25 300 34 12 mm Rear Sprocket Bolts 18 216 24 7 mm Fork cartridge rod 12 144 16 Triple clamp bolts 6 72 8 6 x 1.0 Fork cap 5 60 6.7 1.25″ x 18 Ignition rotor nut 40 480 54 10 mm** ** Use green (wicking / bearing retainer) thread locker, with primer, on the flywheel / crankshaft taper but none on the threads.

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