1988-1989 ENGINES Toyota 1.6L 16- Valve 4 – Cylinder REMOVAL & INSTALLATION

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Filed Under (Toyota Manuals) by admin on 25-09-2011

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Removal 1) Mark and remove hood. Remove battery. Remove engine under cover (splash) shields. Drain coolant, engine oil and transaxle fluid. Mark and disconnect vacuum hoses and electrical connectors. 2) Remove air cleaner assembly. Disconnect coolant hoses. Mark and disconnect throttle, cruise, and kickdown cables (ifequipped). Mark and disconnect fuel inlet and return hoses. 3) Remove fuel tank protectors. Remove airflow meter assembly. Remove transaxle protector (if equipped). Remove accessory drive belts. Remove alternator. 4) Disconnect oil cooler hoses (if equipped). Disconnect power steering pump and A/C compressor and set aside (if equipped). Disconnect speedometer cable from transaxle. Remove clutch slave cylinder (if equipped). Mark and remove shift control cable(s). 5) Remove cruise control actuator assembly (if equipped). Raise vehicle and disconnect exhaust pipe from exhaust manifold.

HARLEY DAVIDSON CRUISE CONTROL KIT FOR FLHR/I AND FLHRS/I MODELS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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INSTALLATION 1. Remove seat, left saddlebag, left side cover and air cleaner assembly following instructions in applicable Service Manual. 2. Review the CRUISE CONTROL-ULTRA MODELS section in the applicable Service Manual before attempting to install this kit. Install Cruise Control Module To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 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) 1. Refer to the appropriate Service Manual and remove bat- tery. 1 is04799 1. Cruise control module mounting hole (3) Figure 1. Battery Box (Right Side View) 2. See Figure 1. In battery box, identify the location of the three mounting holes (1) (on left side of panel) for mounting the cruise control module. 3. See Figure 10. Obtain the cruise control module (1) with cruise cable attached and three grommets (5) from kit. Install the grommets on studs of cruise control module with small diameters outward. 4. See Figure 2. While holding cruise control assembly in place near its mounting location, feed the cruise control cable through the hole in frame crossmember plate and route under rear spark plug wire staying on inner side of fuel line components. Carefully curve cable toward the right and continue routing up under the fuel tank and over the top of the engine stabilizer bracket, then down between cylinder heads. Leave in place temporarily. 5. See Figure 10 and obtain a harness retainer (4) from kit and secure the cruise cable to crossmember plate with barb as shown. On California models, remove the EVAP hose from cable clip and secure hose with one of the cable strap (8)

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HARLEY DAVIDSON MID-FRAME AIR DEFLECTORS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION Model Years 2001-2007 1. Refer to Owner’s Manual and remove seat. 2. Remove stock plastic cruise control cable clip from frame near end of fuel tank if equipped. 2 1 is04321a 1. Mounting Strap Assembly 2. Speed Nuts Figure 1. Install Speed Nuts to Mounting Strap 1 is04324a 1. Mounting Strap Assembly Figure 2. Mounting Strap Location – View of Frame from Above with Seat Removed 1 3 2 4 5 6 is04546a 1.3/4 in. long button head screw and 1 in. OD flat washer 2.7/8 in. long button head screw, P-clamp and 1 in. OD flat washer 3. Well nut, 3/4 in. long button head screw and 3/4 in. OD flat washer 4. U-clip 5. Right side deflector 6. Left side deflector Figure 3. Fastener Locations – View of Frame Rearward of Rear Cylinder, Engine Removed for Clarity 3. See Figure 1. Assemble speed nuts (2) to both ends of mounting strap (1) and align edges of nuts to angled ends of strap. -J04399 4. See Figure 2. Install mounting strap assembly (1) through window of frame. Position strap so speed nuts are aligned over the 1/4 inch diameter holes in frame as shown. 5. See Figure 3. Attach strap assembly to frame using a 3/4 inch length button head screw (1) and the 7/8 inch length button head screw (2) by inserting them from the underside of frame plate. Tighten screws enough to keep strap from moving and prevent it from shifting position during deflector installation. 6. Insert well nut (3) into underside of frame plate. Apply liquid soap to the outer surface of the well nut to ease installation. 7. Remove 3/4 inch screw (1), then position right side deflector as shown and secure with the 3/4 inch screw and 1 inch washer. Do not tighten. 8. Install screw and small washer (3). Do not tighten. 9. Firmly push the deflector against the outer side of frame and tighten screws to 25-35 in-lbs (2.8-3.9 Nm) . 10. Remove left side mounting strap screw (2). 11. Install cable clamp (Figure 5, Item 9) to cruise control cable (if equipped). 12. See Figure 3. Insert screw through cable clamp (if necessary), washer (2) and left side deflector (6) and install to mounting strap speed nut. Firmly push deflector against outside of rail and tighten screw to 25-35 in-lbs (2.8-3.9 Nm) .

HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/ IDLE CABLE KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be placed into the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 4. Remove the right upper and lower switch housing screws INSTALLATION Throttle and Idle Cable Installation 1. See Figure 3. Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar. NOTE The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle control cable. For assembly, apply a drop of light oil on the retaining rings of the crimped inserts. 2. See Figure 7. Push the throttle cable housing and retaining ring into the larger hole of the switch housing, located in front of the tension adjuster screw. 3. Push the idle cable housing and retaining ring into the smaller hole of the switch housing, located behind the tension adjuster screw. 4. Push the throttle and idle control cable housings into the lower switch housing until each snaps into place. NOTE For models not equipped with factory-installed cruise control, if the friction shoe has fallen out or become dislodged, install the shoe with the concave side facing up and position it so the pin hole is over the point of the adjuster screw. 5. Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip until the ferrule notches are at the top. To prevent binding, pull the grip back about 0.12 inch (3.2 mm). 6. See Figure 3. Position the lower switch housing beneath the throttle control grip. Install two brass ferrules (Item 3, Figure 11) from this kit onto cables, seating the ferrules in their respective notches on the throttle control grip. The cables must be captured in the grooves molded into the grip. 7. Position the upper switch housing over the handlebar and lower switch housing. Route the wire harness conduit through the depression at the bottom of the handlebar. 8. Tighten the upper and lower switch housing screws finger- tight. 9. Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket. 10. Align the holes in the handlebar clamp with those in the master cylinder housing and tighten the lower screw and flat washer finger-tight. Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm)

CCS- 100 ELECTRONIC CRUISE CONTROL INSTALLATION MANUAL

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Filed Under (Tips and Review) by admin on 10-11-2010

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UNDER HOOD INSTALLATION Connecting the Cruise Control Cable to the Throttle NOTE: Prior to attaching servo cable to throttle, locate an accessible area to mount the cruise control servo, but do not mount it. Leave the servo in this area (unmounted) and route cable to throttle attachment area. CAUTION: Attach the cruise control cable so that it parallels the existing throttle cable as nearly as possible. Choose a mounting method from the figures below: Attachment area for securing cable Bead Chain Coupling Sleeve (#23) Bead Chain Coupling (#24) 3 BEAD CONNECTOR FIG. 6 FIG. 7 FORD LINKAGE ADAPTOR Rubber Ring WIRE LOOP FOR PULLEY Carburetor Existing Snap-On Throttle Arm On Vehicle FIG. 2 SNAP-ON THROTTLE ARM MOUNT FIG. 3 CLAMP-ON THROTTLE ARM MOUNT Determine a suitable point on the throttle linkage to mount the cable connector. The mounting point chosen should have between 1-1/2″ to 2″ total linkage travel. It must operate smoothly by hand. There should be at least 5 beads between the throttle connector and servo cable end. The cable must pull in a straight line from throttle linkage. Some vehicles that do not have enough total linkage travel have to be connected at the accelerator pedal. The bead chain and servo cable end must be inserted into the bead chain connector. Then the bead chain coupling sleeve must slide over bead chain connector to insure that the end will not hang in the connector. FIG. 1 Cable Bead Chain Eyelet Connector (#25) Pull off Throttle Arm and Insert Bead Chain Connector between it and Carburetor Arm. Be sure additional thickness of adaptor does not bind linkage. 20° Bead Chain Eyelet Connector (#25) Cable Must Be within 20° of same angle as Throttle Rod Throttle Cable Throttle Wire Loop (#29) Barrel Wire Adaptor (#30) WIRE BARREL FOR PULLEY FIG. 5 FIG. 4