Toyota Engine Control Module (ECM) Parts Information

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Filed Under (Toyota Manuals) by admin on 20-10-2011

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2005-2008 Corolla Engine(s): 1ZZ Transmission(s): 5MT, 4AT VDS(s): BR30E, BR32E 2005-2008 Matrix Drive Type(s): 2WD Engine(s): 1ZZ Transmission(s): 4AT, 5MT VDS(s): KR30E, KR32E Introduction The purpose of this TSB is to provide the Engine Control Module/ECM (SAE term: Power train Control Module/PCM) parts information necessary for proper identification and vehicle application. A vehicle with an incorrect ECM (PCM) installed may cause one or both of the following conditions: •M.I.L. “ON”DTCP0741-Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve SL). •Failureto complete On-Board Diagnostic (OBDII) Readiness Monitors. NOTE If the part number is correct, the ECM (PCM) is NOT the cause of the DTC or OBDII Readiness Monitor concern.

TOYOTA Tacoma 2005 – STAINLESS STEEL EXHAUST TIP Procedure

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Filed Under (Toyota Manuals) by admin on 18-10-2011

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Safety (eye protection, rechecking torque procedure, etc.).  Vehicle Disassembly/Reassembly (panel removal, part storage, etc.).  Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Installation. (a) Make sure the vehicle’s tail pipe is free from dirt and debris. (b) Remove exhaust tip from box and set on a soft surface to prevent scratching. (c) Slide the Stainless Steel clamp over the vehicle tailpipe as shown. (Fig 1-1 & 1-2) (1) Locate the bolt of the clamp on the right side (3:00 Position) with the nut on the top as shown. (Fig 1-1) (2) Continue sliding up out of the way so it won’t interfere when you install the exhaust tip and aluminum bushing. (Fig. 1-2) (d) Slide the exhaust tip over the tail pipe with the bump facing toward the rear of the vehicle as shown. (Fig 1-3) (1) If necessary, a rubber mallet may be used to aid installation

STEERING GEAR/ STEERING WHEEL REMOVAL AND INSTALLATION

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Filed Under (Uncategorized) by admin on 05-10-2011

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TEERING GEAR/STEERING WHEEL REMOVAL & INSTALLATION Page 3 of 4 STEERING GEAR/STEERING WHEEL INSTALLATION PROCEDURES (Cont’d) 2. Center spiral cable. a. Turn the cable counterclockwise by hand until it becomes harder to turn. b. Then rotate the cable clockwise about 2.5 or 3 turns to align the marks. (See Fig. 4) 3. Install the steering wheel. a. Align the matchmarks on the wheel and steering main shaft. b. Temporarily tighten the wheel set nut. c. Connect the spiral cable connector. 4. Bleed Power Steering System (when applicable). 5. Check steering wheel center point. 6. Torque steering wheel set nut. See the applicable vehicle’s repair manual for the torque specification. 7. Install and center steering wheel pad. NOTICE: Make sure the pad is centered and installed to the specified torque. If the pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one. When installing the pad, take care that the wiring does not interfere with other parts and is not pinched between other parts. a) Connect the airbag wiring connector. b) Install the pad after confirming that torx screws are in the screw case. c) Using a torx socket, torque the screws to the specification in the vehicle’s Repair Manual. (See Fig. 5) d) Install the steering wheel lower cover

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Honda GL 500 MiniTrike Installation Manual

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Filed Under (Honda) by admin on 29-04-2011

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Refer to diagram for bracket identification 1. Secure motorcycle in an upright stable position 2. Attach bracket A (left) to rear footpeg mount. 3. Attach bracket B (right) to rear footpeg mount. 4. Remove rear saddlebags. 5. Attach top of brackets C/D to saddlebag sub frame hardware as in photo. Place enclosed 3/8 spacer between brackets C/D and inside of sub frame. 6. Attach axles and wheels to MiniTrike frame and place in proper position and relation behind motorcycle. 7. Attach bracket A (left) / B (right) to TOP of forward attaching points on MiniTrike frame. 8. Attach bottom of brackets C/D to rear mounting plate on MiniTrike frame 9. Ensure MiniTrike is square with motorcycle and tighten all bolts. 10. Remount saddlebags. Wheel Alignment Wheel alignment is critical for proper tire wear and handling. With MiniTrike installed measure A and B . Loosen axle plates and align wheel so A and B are equal to within 1/16th of an inch. Tighten axle bolts and torque to 45 pounds. Repeat for C and D . It may be necessary to shim axle plates for proper alignment. NOTE : The measurement of A and B may not be the same as C and D. This is normal and presents no difficulty

HARLEY DAVIDSON REAR SADDLEBAG GUARDRAILS INSTALLATION MANUAL

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Filed Under (Harley Davidson, Uncategorized) by admin on 18-04-2011

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Installation KITNUMBER 49087-01 1. Remove and save fasteners that retain saddlebag guardrails. 2. Replace stock saddlebag guardrails with new guardrails from kit. 3. Screw in and torque each stock fastener as follows: a. Four stock screws, Part No. 3678, using two new locknuts (1), Part No. 7667. Torque each screw to 19 ft-lbs. b. Two stock screws, Part No. 3601 using two new locknuts (2), Part No.7686. Torque each screw to 9 ft-lbs. For Domestic FLHRC/I Vehicles Only. (Does not apply to Harley Davidson International (HDI) vehicles): Federal Motor Vehicle Safety Standard (FMVSS) 108 requires all motorcycles to be equipped with side reflectors. Install, or have Dealer install, the reflectors, Part Nos. 59370-98 and 59371-98, which are purchased separately. Loss of visibility to other motorists could result in death or serious injury. 1. See Service Parts illustration. Position reflector so it is centered on the vertical portion of the saddlebag guard 1″ above the top end of the lower bend where the radius turns upward. Measure and use a small piece of tape to mark location for attachment of the lower edge of the reflector at the 1″ mark. 2. Remove protective tape backing from one reflector. Locate reflector above the 1″ mark. Apply reflector, using even pressure by rubbing back and forth on reflector. Repeat for other side. Note Reflectors are specific for each side. Reflectors have a flat end and a curved end. The curved end goes down. Top edge should be horizontal when positioned on guard. If not, reflector is for opposite side. KITNUMBER 49088-01 1. Remove and save fasteners that retain saddlebag guardrails. 2. Replace stock saddlebag guardrails with new guardrails from kit. 3. Using four hexsocket button head screws (4) removed earlier, attach saddlebag guards using the remaining two existing holes in each guardrail. 4. Screw in and torque each stock fastener as follows: a. Four stock screws, Part No. 3678, using two new locknuts (1), Part No. 7667. Torque each screw to 19 ft-lbs. b. Two stock screws, Part No. 3601 using two new locknuts (2), Part No.7686. Torque each screw to 9 ft-lbs

HARLEY DAVIDSON DYNA DOCKING HARDWARE FOR FXDX WITH WIDE TIRE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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Installation NOTE Perform the following procedures on one side of the motorcycle until instructed to go to the other side. To keep fender in alignment the front docking point will be mounted first. INSTALLING DOCKING POINTS NOTE Save the acorn nuts and washers removed from the fender support bracket for use when installating docking points. 1. Loosen and remove the acorn nuts, washers, and screws from the fender support (right-hand) bracket. Save the washers and acorn nuts for docking point installation. Discard screws. 2. Obtain 1 plastic bushing, labeled 01, from a bushing set. 3. Place the bushing (4) (beveled side out) into the front support hole as shown in Service Parts illustration. 4. Place the countersunk side of the front docking point (2) so that it engages bushing (4). 5. From underneath (inside) the fender, insert hex-head screw (1) through fender, support bracket and front docking point (2). 6. Install washer (7) split lockwasher (5) and acorn nut (6) to screw and tighten to 27 ft-lbs (37 Nm). Take care to avoid scratching or marring component finish. 7. Obtain another plastic bushing, labeled 01 , from the bushing set. 8. Place bushing (4) (beveled side out) into the the rear support hole as shown in Service Parts illustration. 9. Place the countersunk side of the rear docking point (3) so that it engages bushing (4). 10. From underneath (inside) the fender, insert hex-head screw through fender, support bracket and rear docking point (3). 11. Install washer (7) split lockwasher (5)and acorn nut (6) to screw and tighten to 27 ft-lbs (37 Nm). Take care to avoid scratching or marring component finish. 12. Repeat procedures 1 through 11 for opposite (left-hand) side of the motorcycle. NOTE In time docking points may wear, causing the sideplates to become loose. The fit may be tightened using the following procedure. 1. Loosen docking hardware. 2. Rotate docking points clockwise approximately 45°. 3. Tighten docking hardware to the appropriate torque values. Repeat as often as required, up to 3 times

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HARLEY DAVIDSON PRIMARY COVER CHROME HARDWARE KIT INSTALLATION MANUAL

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

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INSTALLATION 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. Disconnect the negative (-) battery cable from the battery. Disconnect the positive (+) battery cable from the battery. 2. Replace existing zinc hardware with chrome plated hardware one at a time so the primary chaincase and clutch cover gasket do not need to be replaced. 3. Consult the Service Manual for screw locations and torque values. 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. Connect the positive (+) battery cable to the battery. Connect the negative (-) battery cable to the battery

HARLEY DAVIDSON VRSC CHROME WHEEL KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 18-03-2011

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Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. 4. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 5. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier. 6. Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. 3. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. 4. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 5. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. 6. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. 1. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. 2. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. 3. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84

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HARLEY DAVIDSON FRONT SPOILER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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Installation NOTE The spoiler in kit number 58882-04BDK is finished with a primer coat. Before installation, have the spoiler painted 1. Mount the motorcycle on a lift table. 2. See the Service Parts illustration. Attach the upper front spoiler bracket (4) to the bosses on the inside front of the spoiler (1) with the two Hi-Lo screws (10) from the kit. Tighten to 15-20 in-lbs (1.7-2.3 Nm). 3. Attach the lower front spoiler bracket (5) to the two weld nuts in the cross bar at the bottom front of the motorcycle frame with two hex head machine screws (6) and split lockwashers (7) from the kit. Torque to 30 ft-lbs (41 Nm). 4. Remove the protective film from the back of the medallion. Carefully center the medallion on the recessed area on the front of the spoiler. 5. Press the Bar and Shield medallion (3) firmly into position. Hold the medallion in place, pushing hard with your thumbs, for about five seconds. Take care not to shift the medallion on the spoiler. 6. After releasing pressure, avoid direct contact with the medallion for about 20 minutes. 7. Place a flat washer (9) on one of the pan head machine screws (8) from the kit. Position the spoiler to the front of the frame. Insert the screw through the large hole in the bottom of the spoiler and thread it into the upper front spoiler bracket, but do not fully tighten at this time. 8. Place a flat washer on each of the two remaining pan head machine screws from the kit. Insert the screws through the slots in the bottom of the spoiler and thread them into the lower bracket, but do not tighten fully. 9. Position the spoiler next to the vehicle frame allowing an equal amount of minimal clearance. Alternately tighten the three screws to 72 in-lbs (8 Nm)

ULTIMA 6 SPEED BUILDERS KIT INSTALLATION MANUAL

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Filed Under (Tips and Review) by admin on 03-03-2011

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DISASSEMBLY For 5 speed gear set removal refer to your factory service manual. You willneed to remove the main drive gear, main drive gear bearings, retaining clip & countershaft needle bearings. NOTE: Removal of the shifter arm is notnecessary for 99 & earlier transmissions. NOTE: Removal of the shifter arm isnecessary for 2000 & later transmissions. After trans. housing is disassembled thoroughly clean & inspect. ASSEMBLY For 2000 & later models removal of approximately 1/4 of an inch off of the shifter arm bushing is likely required. Doing so will allow installation of the retaining clip & washer onto the shifter arm. It is good practice to double check how much material should be removed before cutting the bushing. See fig. 1 & 2 Install supplied Main drive gear bearings & countershaft needle bearings using special tool # 97-164 NOTE: Lightly coat bearings with assembly lube or gear oil for easier installation. Install supplied Main drive gear retaining clip & verify that it is fully seated and cannot come out. Do not re-use old bearings or retaining clip. Install supplied Main drive gear into bearings using special tool # 97-166 See fig. 3 Install supplied trap door gasket & verify that it is on correctly. Install supplied 6 speed gear set making sure to align the countershaft with the needle bearing assembly. Slowly slide in gear set until the mainshaft & countershaft will not slide in any further. Lightly tapping on the trap door (while verifying that there is no interference) with a soft blow hammer will then fully seat the shafts & trap door. See fig. 4 Once gear set is installed use the supplied 5/16-18×1-1/2 & 1/4-20×1-1/2 bolts to secure the trap door. Torque the 5/16 bolts to 15 ft-lbs w/ red loctite (high strength) Torque the 1/4 bolts to 9 ft-lbs w/ red loctite (high strength) See fig. 5

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