Filed Under (Toyota Manuals) by admin on 31-05-2011

FRONT OF 4RUNNER/FJ CRUISER 1. Park vehicle on level concrete surface. 2. Center and lock the steering wheel.
3. Block the rear wheels of the vehicle to prevent vehicle from moving in either direction. 4. Before lifting vehicle, remove rear shock absorbers and discard. 5. Jack up the vehicle from the lift point in Figure A. 6. Support the vehicle with jack stands from the points in Figure A. 7. Remove the front wheels. 8. Remove sway bar end links from spindle using 17mm socket (both sides). See Figure B. 9. Remove front skid plate using 12mm socket. 10. Remove sway bar from frame using 14mm socket. See Figure C. 11. Using 19mm socket, remove lower bolt and nut from the bottom of the strut (both sides). 12. Remove cotter key and 19mm nut from outer tie rod end, rack &
pinion utilizing a tie rod end puller (or pickle fork). 13. Remove the three nuts (14mm) from the top of the strut. See Figure D. 14. Remove the struts from the vehicle, making sure that they are marked driver and passenger side respectively for reinstallation.



Filed Under (Harley Davidson) by admin on 09-03-2011

REMOVAL Front Fork Assembly 1. Refer to the XR model section of the service manual and remove the front forks. INSTALLATION Front Fork Assembly 1. Install front forks from kit to motorcycle according to service manual instructions but do not tighten the fork bracket pinch screws at this time. 2. See Figure 1. Measure the distance from the top of upper fork bracket to top of fork assembly. Both sides must be exactly the same and measure 0.388-0.468 inch (9.85- 11.89 mm) above the top fork bracket. Align the adjustment screws inline with the handlebars (see Figure 5). is06083a Figure 1. Fork Installation Height Measurement. NOTE If new pinch screws are not readily available, use a wire grinder wheel to remove all remaining lock patch from original pinch screws, wash screws in clean solvent and dry thoroughly. Apply two drops of LOCTITE® 262 to the first 1/4 in. (6.35 mm) of the end threads. 3. Install pinch screws to upper and lower fork brackets. 4. Verify fork tube installation measurement is 0.388-0.468 inch (9.85-11.89 mm). 5. Tighten pinch screws to 30-35 ft-lbs ( (40.7-47.5 Nm)) See Figure 2. The top edge of reflector should be 1-1/2 inches (38.10 mm) below the lower edge of the bottom fork clamp. 6. Remove the adhesive backing. Place reflector in position and press reflector firmly into place to activate the adhesive. Repeat for reflector on opposite fork. REMOVAL OEM Rear Shock Absorbers 1. Refer to the XR model section of the service manual and remove the rear shock absorbers. INSTALLATION Rear Shock Absorbers 1. See Figure 3. Install the rear shock absorbers according to service manual instructions. The shocks are installed with the external gas reservoir to the rear of the shock absorbers and the thick side of the grommet installed to the frame rail mounts. is06142 Figure 3. Install Thick Side Of Grommet To Frame Rail SUSPENSION ADJUSTMENTS Front Fork Suspension Adjustment Whenever a wheel is installed and before moving the motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00284a) Adjust both forks equally. Improper fork adjustment can lead to loss of control, which could result in death or serious injury. (00124c) Compression and rebound adjusting valves may be damaged if too much force is used at either end of the adjustment range. (00237a) NOTES Damping is set at the factory for the average solo rider under normal riding conditions. The rider may make adjustments to compensate for individual riding styles and varying road conditions. Evaluating and changing the rebound and compression damping is a very subjective process with many variables and should be approached carefully. The front and rear preload setting will need to be adjusted for the rider’s weight and cargo. This adjustment should be made before the motorcycle is ridden any distance and after changing the overall vehicle weight (adding saddlebags, etc.). If the preload adjustment is correct, and you have the rebound and compression damping set at the factory recommended points, the motorcycle should handle and ride properly. Changes in the load carried requires changes in the preload setting(s). Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload. Increasing the load carried requires adding more preload. The following tools are needed to make suspension adjust- ments. • 5 mm hex key (front fork preload adjustment tool). • Spanner wrench with extension handle (shock absorber preload adjustment). • Screw driver (front fork damping adjustment). 1. Front fork preload adjustment: a. See Figure 4 and Table 1. Using the 5 mm hex key, turn the preload adjuster counterclockwise until it stops. This is the minimum preload setting. b. Turn the preload adjuster clockwise the recommended amount specified for the rider weight



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

SADDLEBAG INSTALLATION 1. See Figure 3. Remove the rear shock absorber bolt (Figure 1, Item 1). Position the 0.531 x 0.75 x 0.25 inch spacer (7) and the front saddlebag bracket attachment hole over the rear shock absorber bolt location. Secure with the 1/2- 13 x 3.75 inch screw (5). 2. See Figure 3. Position the 0.325 x 0.75 x 0.25 inch spacer (8) and the rear saddlebag attachment hole over the second hole on the rear of the fender, fender support cover, and relocation pad. From the underside of the fender, insert a 5/16-18 x 3.00 inch screw (6) and secure with locknut (10). Tighten locknut (10) to 24-27 ft-lbs (32.5-36.6 Nm) . 3. Tighten the front screw (5) to 21-27 ft-lbs (28.5-36.6 Nm) . 4. See Figure 3. Assemble an isolator washer (12) onto an isolator bushing (13). Place a screw (15) through the bushing. 5. Place the screw and bushing assembly into the top hole inside the saddlebag back. 6. See Figure 3. Push a saddlebag isolator (14) over bushing with cone shape toward saddlebag. 7. Place saddlebag in position on bracket and insert the new screw (15) into the bracket. Do not tighten. 8. Repeat steps 4 through 7 for remaining holes. With all isolators in place, tighten screws to 96-120 in-lbs (10.8- 13.6 Nm) . 9. Repeat Steps 1 through 8 for the opposite saddlebag. 10. Raise rear wheel until the rear shock absorbers align with shock absorber mounting holes on the swingarm. Support the wheel to prevent it from falling during the following step. 11. See Figure 1. Attach rear shock absorber to swingarm by installing bolt (1), washer (2) and nut (4). Tighten bolt to 45-50 ft-lbs (61.1-67.9 Nm) . Repeat step on opposite side of motorcycle. INSTALL REFLECTORS Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b) 1. See Figure 3. Measure approximately 1-1/2 in. (38 mm) from the bottom edge of the saddlebag. Orient the reflector horizontally and carefully center the reflector mount between the straps of bags with straps or locate it at the rearward portion of bags without straps. Mark hole location. 2. Using appropriate tool, make two 3/16 in. holes in sad- dlebag. 3. Install reflector mount (3) on saddlebag using two pushnuts (2). 4. Remove adhesive backing from reflector (4) and install on mount. 5. Repeat steps 1 through 4 for the opposite saddlebag. INSTALL SEAT After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 1. See Service Manual instruction to install the seat