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HARLEY DAVIDSON FLUSH-MOUNT LED FUEL GAUGE AND GAS CAP KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Remove stock gas cap from fuel tank. 2. Clean and wipe inside surface of fuel tank filler cup, O-ring seal surface, and trim ring adhesive surface with a mixture of equal parts of isopropyl alcohol and distilled water. 3. See Figure 1. Install gas cap into fuel tank. is00407 Figure 1. Screw in Gas Cap is00466 Figure 2. Note Position of Arrow on Trim Ring 4. Push down on gas cap and rotate clockwise one-eighth of a turn to lock. To unlock, push down on gas cap and rotate counterclockwise one-eighth of a turn. 5. See Figure 2. Before removing adhesive backing, note position of arrow on inside diameter of chrome trim ring. NOTE As you rotate trim ring, you will see gaps between trim ring and fuel tank. Rotate trim ring to position that best eliminates gaps between fuel tank and trim ring. Rotation of trim ring should be minimal. 6. See Figure 3. With the arrow pointing toward front of motorcycle, rotate chrome trim ring slightly to determine best position of bottom chrome trim ring to contour of the fuel tank 7. See Figure 4. Mark position of chrome trim ring with masking tape or grease pencil. 8. Carefully cut masking tape with a hobby knife making sure not to scratch chrome trim ring or paint surface on fuel tank. 9. Peel off adhesive backing from chrome trim ring. 10. Using gas cap to center and masking tape (or grease pencil mark) to align, press chrome trim ring firmly into position for about ten seconds. 11. Peel off masking tape (or remove grease pencil mark) from chrome trim ring and fuel tank. 2 1 is00414a 1. Masking tape 2. Cut masking tape Figure 4. Align Trim Ring and Press into Place NOTE Allow adhesive trim ring to cure for about 5-7 minutes before you continue with kit installation. Install Flush-Mount LED Fuel Gauge 1. Remove the seat following the instructions in the service manual. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 2. Disconnect battery cables, negative (-) cable first. 3. Remove stock fuel gauge. Refer to service manual for instructions. 4. Insert wires down tube of fuel tank from LED fuel gauge. 5. See Figure 5 and Figure 6. Insert LED fuel gauge in the fuel tank cup

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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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HARLEY DAVIDSON PASSING LAMP TRIM RINGS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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1. Loosen the screw from one original equipment passing lamp trim ring and remove the ring. 2. See the Service Parts illustration. Remove the screw (3) and nut (2) from the accessory trim ring (1) and set aside temporarily. 3. If not already installed, place the rubber strip (4) inside the trim ring. Align so the gap in the rubber strip is opposite the split in the trim ring as shown. 4. Insert the passing lamp sealed unit (C) inside the new trim ring and rubber strip assembly. NOTE Rotating the lamp unit may help insertion. 5. Position the bottom of the lamp unit to line up with the split in the trim ring. 6. For 2002 and later models Install the adapter ring (D) onto the passing lamp housing, lining up the tab on the ring with the notch in the lamp housing. Install the trim ring and lamp assembly onto the adapter ring, aligning the lug (or lugs) on the back of the glass lamp unit with the notches in the adapter ring. For 1962 through 2001 models Install the trim ring and lamp assembly onto the passing lamp housing, aligning the lug (or lugs) on the back of the glass lamp unit with the notches in the passing lamp housing. 7. Assemble the screw and nut to the trim ring and tighten securely. 8. Perform steps 1 through 7 for the second passing lamp. SERVICE PARTS 4 2 B C F H 3 G E 1 A D

BMW PISTONS AND RINGS INSTALLATION INSTRUCTIONS

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Filed Under (BMW) by admin on 26-10-2010

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1. Always clean the grooves before installing rings. Carbon build-up in the groove will lead to ring “bottoming” and can result in engine seizure. 2. Check the fit of rings in the groove. A maximum of .003″ side clearance is allowable. 3. Check the cylinders for taper and out-of-roundness. Any taper of out-of-roundness will have an adverse effect on the performance of an engine. Excessive piston clearance will detract from maximum performance as well. 4. Allow ample ring gap. There is far more danger of ring butting than of an appreciable compression loss through the ring gap. Gaps, if staggered, do not cause any measurable reduction of compression. Compression rings should be fitted with a minimum of .004″ end gap per inch of cylinder deglazing. 5. Always deglaze cylinder walls before installing new rings. A 400 grit stone is recommended for deglazing. 6. All parts should be spotlessly clean before installation. Dirt in any form is the worst enemy of a hi- performance engine. You may wash all parts in hot, soapy water. Ring Gap Installation 1. Do not gap oil control rings. Start with the oil control expander. Expander Ring ends butt together. Do not overlap them. 2. Install oil control rings. Set gap 90 from where expander ring butts together. Gap top oil control ring 180 from lower oil control ring gap. 3. Install 2nd and top ring also with marks up. Stagger gaps

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HARLEY DAVIDSON 5-3/ 4 INCH HEADLAMP TRIM RING INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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These kits fit 1994 and later FXLR, FXST, FXSTC, FXSTB models, 1994 and later Dyna models, 2004 and later XL883, XL883L, XL883R, XL1200L, and XL1200R models and 2005 VRSCB model motorcycles1. Loosen screw from the original equipment headlamp trim ring and remove ring. 2. Remove screw and nut from accessory trim ring assembly and set aside temporarily. 3. See Figure 1. If not already installed, place one rubber strip (2) inside trim ring (1) as shown. 4. See Service Parts Illustration. Insert the glass lens assembly (A) inside rubber strip (4) and trim ring (3), as shown. NOTE Rotating the lens may help insertion. 5. Install trim ring onto the main lamp housing (B). Assemble nut (2) and screw (1). Tighten securely. 1 2 is 01501 1. Trim ring 2. Rubber strip Figure 1. Installed Rubber Strip SERVICE PARTS See Figure 2 and Table 1

HARLEY DAVIDSON HEADLAMP VISORS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 06-02-2011

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These kits fit all motorcycle models equipped with 7-inch headlamps. These kits do not fit models equipped with Headlamp Trim Ring Kits part numbers 69626-99, 69627-99, 69733-05, and 69734-05.INSTALLATION 1. See Figure 1. Remove original equipment bottom screw (1) and trim ring (2). Save parts for later use. 2. See Figure 3 and Table 2. Install headlamp visor (1) from kit and trim ring (A) previously removed. NOTE Make sure the screw holes in the trim ring and the headlamp assembly are aligned as it is difficult to rotate the trim ring when it is fully seated. 3. Loosely install bottom screw (C) previously removed on trim ring. Do not tighten at this time. 4. See Figure 2. Visually check to ensure that rubber bumpers on inside face of headlamp housing are not caught. 5. Snug bottom screw on trim ring and headlamp visor. 6. Rotate visor from side to side around headlamp assembly (B) if ring is caught on face of headlamp. 7. Push down on top of trim ring and push in on the bottom of the trim ring to fully seat the headlamp visor. 8. While tightening the bottom screw, continue to maintain inward pressure on bottom of headlamp visor, until screw is tight and trim ring is fully seated. 3 2 1 is00923 1. Bottom screw 2. Trim ring 3. Headlamp Figure 1. Original Equipment Headlamp Trim Ring

2003 Honda Shadow Spirit 750 VT 750DC Custom speedometer dial installation

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Filed Under (Honda) by admin on 06-11-2011

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DO NOT REMOVE THE 3 PHILLIP SCREWS ON THE BACK OF THE SPEEDOMETER. This will unscrew the circuit board and the main components inside the speedometer, and possibly damage it. Just leave those 3 screws alone. They won’t make your customization any easier if they are removed. This is the hard part. Turn the speedometer face down on a soft towel on a sturdy table, bench, etc. I used a regular flat screwdriver to do this step. There is a chrome metal ring holding the glass on the speedometer. It is factory sealed. On the bottom side of this ring start prying with a flat screwdriver under the bottom lip of the metal ring. This will be a slow process (patience, patience, patience) so don’t get in a hurry and ruin the wife’s kitchen table like I did. Go around the metal ring with a flat screwdriver prying it up as straight as you can. It’s easier doing this every millimeter or two. I had to do this about 3 times all the way around the ring. After you pry the lip of the ring up all the way around enough to loosen it up considerably, gently pull the ring off of the speedometer. The glass should come off with it. Put the glass with the chrome ring aside for later. You might want to use a soft lint free towel to rest it on

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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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HARLEY DAVIDSON 5-3/4 INCH HEADLAMP TRIM RING INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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These kits fit 1994 and later FXLR, FXST, FXSTC, FXSTB models, 1994 and later Dyna models, 2004 and later XL883, XL883L, XL883R, XL1200L, and XL1200R models and 2005 VRSCB model motorcycles. KIT CONTENTS See Figure 2 and Table 1. INSTALLATION 1. Loosen screw from the original equipment headlamp trim ring and remove ring. 2. Remove screw and nut from accessory trim ring assembly and set aside temporarily. 3. See Figure 1. If not already installed, place one rubber strip (2) inside trim ring (1) as shown. 4. See Service Parts Illustration. Insert the glass lens assembly (A) inside rubber strip (4) and trim ring (3), as shown. NOTE Rotating the lens may help insertion. 5. Install trim ring onto the main lamp housing (B). Assemble nut (2) and screw (1). Tighten securely

HARLEY DAVIDSON STAINLESS STEEL BRAIDED CLUTCH CABLE KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVE CLUTCH CABLE 1. See Figure 1. Loosen clutch adjuster to obtain slack in the clutch cable (2) by performing the following: a. Locate cable adjuster (1) and slide off rubber boot (4). b. While holding cable adjuster with 1/2-inch wrench, loosen jam nut (3) using a 9/16-inch wrench. c. Turn cable adjuster until there is a large amount of free play at hand lever. 1 2 3 4 is 00889 1. Cable adjuster (1/2-inch) 2. Cable end 3. Jam nut (9/16-inch) 4. Rubber boot Figure 1. Clutch Cable Adjuster 2. See Figure 2. Remove the retaining ring (1), pivot pin (2) and clutch cable anchor pin (3) from the hand lever. 2 3 1 is 00891 1. Retaining ring 2. Pivot pin 3. Clutch cable anchor pin Figure 2. Clutch Cable Compoments 3. See Figure 3. Drain transmission lubricant and remove fill plug dipstick. Remove the six screws that hold the clutch release cover in place. Remove the clutch release cover, being careful not to damage the gasket. NOTE The clutch release cover gasket (P/N 36801-87B) will need to be replaced if torn or damaged to prevent transmission fluid from leaking from the release cover. 4 3 5 2 6 1 is 00894 Figure 3. Clutch Release Cover Screw Sequence 4. See Figure 4. Note position of retaining ring opening. Retaining ring opening must be positioned in approximately the same location during reassembly. Remove retaining ring (1). 5 4 1 3 2 is 00895 1. Retaining ring 2. Inner ramp 3. Cable fitting 4. Clutch cable 5. Ramp coupling Figure 4. Clutch Cable Connection 5. Pull inner ramp (2) and coupling (5) out of side cover. Hold inner and outer ramps together to keep balls from falling free. 6. Rotate the inner ramp to a position that will allow the coupling (5) to be disconnected from the inner ramp lever arm. Disconnect coupling from inner ramp. Disconnect cable end from coupling. 7. Back out threaded cable fitting from side cover. Ensure that o-ring is removed with cable. Discard o-ring. INSTALL CLUTCH CABLE 1. See Figure 4. Obtain braided stainless steel clutch cable from kit. Apply a light coat of oil on new o-ring and install o-ring (Part Number 11179) onto threaded portion of clutch cable (4). Insert clutch cable fitting (3) into clutch release cover. Do not tighten cable fitting at this time. 2. Connect cable end to coupling. Rotate ramps for best access and install coupling on inner ramp. Place ramp assembly in position in side cover. 3. Install retaining ring. Position retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). NOTE Replace clutch release cover gasket if torn or damaged. 4. See Figure 3. Place gasket, if removed, on side cover and install side cover. Tighten the six screws in the order shown to 84-108 in-lbs (10-12 Nm) . 5. Tighten the clutch cable fitting to 36-60 in-lbs (4-7 Nm) . 6. Place a few drops of oil inside cable housing. 7. Route clutch cable as follows: SOFTAIL MODELS FXSTD, FLSTS, FXSTS and FXST – Route clutch cable from the clutch release cover, across the frame, up along the front frame downtubes and across the front of the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. FLSTF and FLSTC – Route clutch cable from the clutch release cover, across the frame and up along the front frame down- tubes, up to and behind the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. DYNA MODELS FXDWG – Route clutch cable from the clutch release cover, under frame and across to the left side. See Figure 5. Insert cable (1) into clip (2) at the bottom left side of the frame

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