POWER STEERING CONVERSION TOYOTA LAND CRUISER REMOVAL

0

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

download
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.

HARLEY DAVIDSON TOURING CHROME PASSENGER FOOTBOARD PAN KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 13-04-2011

download
Installation 1. See Service Parts illustration. Remove socket head cap- screw (2) from footboard support (3). Place support on a clean flat surface. 2. From bottom of footboard (1), use a small flat blade screwdriver to push rubber beads on pad (5) up through holes in footboard. Remove pad from footboard. 3. Using a brass drift and rubber mallet, tap two retaining pins (4) toward center of footboard and remove. 4. Remove footboard from support bracket taking care to remove and retain detent ball (6) and spring (7) from footboard support (3). 5. Insert spring (7) and detent spring (6) into footboard support (3). 6. Place new chrome footboard pan in position with footboard support and insert retaining pins using a brass drift and rubber mallet. 7. Moisten rubber beads on pad with soapy water. Place pad into position on footboard. From bottom of footboard, use needle nose pliers to pull rubber beads down through holes in footboard. 8. Engage nubs on inboard corners of pad with holes in foot- board. 9. Install socket head cap screw into footboard support and tighten 120 in-lbs (13.6 Nm). 10. Repeat procedure for other passenger footboard

HARLEY DAVIDSON DYNA GLIDE ADJUSTABLE HIGHWAY PEG MOUNTING KIT INSTALLATION MANUAL

0

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

download
Installation 1. See Figure 1. Install setscrew (14) into lower hole on frame tube boss (2) leaving .20 in. of setscrew (or three threads) exposed. 2. Place highway peg mounting plate (1) into position. For a lower peg position, place bottom hidden hole in mounting plate over setscrew. For a higher peg position place upper hidden hole in mounting plate over setscrew. Attach mounting plate to frame tube boss using 1 in. long screw (3), lockwasher (4), and flat washer (5) from kit. Tighten screws to 33 ft-lbs. 3. Install footrest support (6) onto highway peg support plate using hex nut (7), lockwasher (8) and flat washer (9) from kit. Tighten nut (7) to 47 ft-lbs. 4. Locate spring washer (10) from kit. While holding spring washer in position on inside of footrest support (with square edge towards motorcycle), position footpeg (not included with this mounting kit) between footrest support mounting tabs, as shown. 5. Insert 1-1/2 in. long screw (12) from kit through footrest support mounting tabs, footpeg, and spring washer. Secure using locknut (13) from kit. 6. Repeat these steps for the other side of vehicle. 1 WARNING These footrest pegs must fold upward and toward the rear at about a 45°angle when retracted. If they do not, peg could contact ground while motorcycle is in a turn, causing loss of control or startling the rider, resulting in possible personal injury. If pegs do not fold up and back at a 45°angle, remove pegs and turn them over so the flat surface is facing forward.

HARLEY DAVIDSON XLH 1200cc BIG BORE KIT INSTALLATION MANUAL

0

Filed Under (Harley Davidson) by admin on 06-03-2011

download
Boring and Honing Procedures 1. Check again for burrs on cylinder gasket surfaces and remove burrs before performing Step 2. 2. Install original head and base gaskets, CYLINDER TORQUE PLATES (Part Number 33446-A) and TORQUE BOLTS (Part Number 33446-4). Tighten TORQUE BOLTS following tightening procedure given in the INSTALLATION, CYLINDER HEAD procedure in the ENGINE section of the Service Manual. NOTE Torque plates, properly tightened and installed with gaskets, simulate engine operating conditions. Measurements will vary as much as 0.001 inch without torque plate. 3. The cylinder must be bored with gaskets and torque plates attached. Bore the cylinder to 0.003 inch under the desired finish size. 1 WARNING CAUTION CAUTION 1 WARNING Kit Number 4. Hone the cylinder to its finished size (See Figure 1) using a 280 grit rigid hone followed by a 240 grit flexible ball hone. Honing must be done with torque plates attached. All honing must be done from the bottom (crankcase) end of the cylinder. Work for a 60 degree crosshatch pattern. 5. See Figure 1. After machining and honing, chamfer the bottom edge of the cylinder liner. the chamfer provides a beveled surface for easier installation of the cylinder over the piston rings. Break leading edge of liner to a flat surface. The bottom edge of the liner will be somewhat sharp after machining. This sharp edge could easily be damaged during installation of the cylinder. Piston Installation The 1200cc pistons have an arrow on the top of the piston. This arrow must face the front of the engine when piston is installed. There is no front cylinder piston or rear cylinder piston. New pistons can be installed in either cylinder. Check piston rings for proper side clearance and end gap (See XLH Service Manual). Be sure end gaps of adjacent rings are installed 90 degrees apart. Assembly Follow assembly and torque specifications given in the ENGINE section of the applicable Service Manual. Replace original gaskets, O-rings and seals with new components furnished in kit. NOTE Push rod covers on 1991 and later models are one-piece and the correct O-rings are as follows: Bottom – Part Number 17944-89 Upper – Part Number 11190 Engine Break In For the first 500 miles, to wear-in critical parts, observe these few simple driving rules: During the first 50 miles, keep the engine speed below 2500 RPM in any gear. Up to 500 miles, vary the engine speed, avoiding any steady speed for long distances. Engine speed up to 3000 RPM is permissible in any gear. Avoid fast starts at wide open throttle. Drive slowly until engine warms up. Avoid running the engine at extremely low RPM in higher gears. 2 of 3 -J00001 1200cc CYLINDER FINAL BORE SIZE AFTER HONING STANDARD BORE DIAMETER 3.4980 inch + 0.0002 inch Figure 1. Bottom Edge of Cylinder Liner Chamfer i04852 Break Edge to Flat Surface

Incoming search terms:

HARLEY DAVIDSON ELECTRA-GLO LIGHT POD KITS INSTALLATION INSTRUCTIONS

0

Filed Under (Harley Davidson) by admin on 08-02-2011

download
INSTALLATION NOTES Clean the controller mounting area and the areas where the light pods will be mounted with soap and water before beginning the installation, and allow to dry thoroughly. Remove debris, dirt and grime from the vehicle areas to be highlighted. Ambient temperature should be at least 50 °F (10 °C) for proper adhesion of the light pods and controller box to vehicle surfaces. Light pods should not be located closer than 2.5 inches (63.5 mm) from exhaust pipes or mufflers, and must have 1.5 inches (38.1 mm) clearance from engine cylinders and heads. Do not install light pods with the light source facing directly away from the vehicle. Installation should be done in a way that allows the light to be seen indirectly by reflecting from chrome or painted surfaces of the vehicle. Prepare the Motorcycle To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) 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 owner’s manual and follow the instructions given to disconnect the battery cables, negative (-) cable first. NOTE For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase . Locate and Install the Controller NOTE Do not mount the controller box in a location where vehicle suspension travel could result in contact with the ON/OFF switch or dimmer control. Damage to the controller box will occur. 2. See Figure 2. Locate the controller box (10) on a flat surface that will allow the red (+) and black (-) leads to reach the battery terminals and the rider to access the controls (with the vehicle parked) and, if necessary, the in-line fuse holder (A). a. Test-fit the controller box to the selected surface before installation. Do not remove the adhesive backing until ready to attach the controller box. b. Clean the controller box mounting area with one of the included alcohol swabs. Allow to dry thoroughly. c. Remove the liner from the adhesive backing of the controller box. Carefully position the controller box to the surface, and press firmly into place. Hold the controller box in position with steady pressure for about one minute. Connect the Battery Cables NOTE Verify that the ignition/light key switch is in the OFF position before attaching the battery cables. 3. Verify that the ignition/key switch is turned to the OFF position. Apply a light coat of Harley-Davidson electrical contact lubricant (part number 99861-02), petroleum jelly or corrosion retardant material to the battery terminals. Connect positive (+) 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. (00068a) 4. Refer to the owner’s manual and follow the instructions given to install first the vehicle’s positive (+) battery cable then the red (+) light pod controller lead ring terminal to the positive (+) battery terminal. Tighten to owner’s manual specifications. Install first the vehicle’s negative (-) battery cable then the black (-) light pod controller lead ring terminal to the negative (-) battery terminal. Tighten to owner’s manual specifications. Arrange the Electra-Glo Light Pods NOTES Electra-Glo light pods (1) can be installed in a variety of locations. They are best installed on a flat surface to provide indirect lighting illuminating mechanical features, vehicle finish or for ground effects. Refer to the notes at the beginning of the Installation section. 5. Select the area or lines of the motorcycle to highlight, and suitable locations for each light pod. DO NOT permanently affix the light pods at this time. Lightly tape the pods in place temporarily until the desired visual effect is achieved Verify clearance from movement of rubber mounted engine or other moving parts, heat sources, or chafe points

Incoming search terms:

Titan 1500-XLT INSTALLATION, OPERATION, And MAINTENANCE MANUAL

0

Filed Under (Titan) by admin on 01-11-2010

download
UNPACKING AND SET-UP *REFER TO PARTS LIST FIG. 1 1. Carefully unpack the lift making sure that all of the parts have been included. 2. Remove the lift and all parts from delivery pallet and place on a clean, solid flat surface. 3. Take end of black hydraulic hose and attach to pneumatic/hydraulic pump (48). 4. Raise the lift with pump foot pedal (58) to expose the top of casters. Note: If the lift is not raising level, check to make sure that the wheels (42) are in their tracks. 5. Use the provided Allen wrench and place in top of casters (22) and turn it clock-wise. Raise all four casters until the lift rolls freely. 6. If using the front extension (9), slide the front extension over the front of the deck plate. Use the second and third connecting bars (5) and secure to the deck plate with the pipe guards (3), and R-pins (4), or use short connecting bar (68) without side extensions. 7. If using side extensions (7) then use the connecting bar (5) to assemble the side extensions (7) to the deck plate (8) securing them with the pipe guards (3) and R-pins (4). Slide the side extensions (7) to the deck plate (8). 8. Take ramp stands (43) and screw into bottom ramps (44) (45) and (46). Place the extension ramp (47) over matching holes on the center ramp (45). 9. Take the fixed clamp (10) and bolt to location “B” on the deck plate (8) or front extension (9) using bolts (11), washers (12), lock washers (13), and nuts (14) . 10. Take the movable clamp (16) and bolt to location “C” on the deck plate (8) or front extension (9) using bolts (11), washers (12), lock washers (13) and nuts (14). 11. Insert the tire stop (15) onto the fixed clamp (10) using the pin (60). 12. Place stands (1) on holes located on the end of the deck plate (8). 13. If you have access to compressed air, attach air nozzle to compressed air hose and raise the lift by pressing lever on air nozzle. Requires 70-160PSI. 14. If necessary, raise or lower the adjustment legs (6) to make the lift deck plate level with the ramps.