2001 fz1 carb problem

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KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

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HW Prowler Carburetor Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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1. Remove both seats and the plastic seat pans under the seats. 2. Remove the engine cover 3. Remove the air-box by removing the cross-bar support that runs under the air-box to the framing on each side by the seat framing and disconnect the air box from the carburetor and from the plastic intake in the rear. 4. Disconnect the engine breather hose from the bottom of the air box 5. Set the air-box to the side 6. Disconnect the plug going to the stock carburetor, this is the electronic choke. Wrap the end left on the vehicle with electrical tape. 7. Cut the fuel line just above the fitting on the passenger side of the carb 8. Remove the side cover off the drivers side of the carb where the throttle cable goes in, see fig. #1 9. Pull the throttle cable out and then remove the throttle cable end from the throttle plate See Fig. #2 10. Loosen the clamp on the rear of the carb holding the carb on 11. Pull the carb out of the intake boot 12. Set OE carb to the side. 13. Push the new Carb into the intake boot making sure the carb is perfectly vertical and then tighten the clamp back up. The new carb is slightly larger than the stock one so some additional pressure will be needed to get it in. 14. Route all the breather lines connected to the carb down under the carb. 15. Connect the throttle cable onto the new carb but putting the cable end in the bottom hole of the throttle plate on the passenger side of the carb allowing the cable to ride in the slot in the plate and then turn the throttle plate clock wise allowing the threaded end of the cable to fit into the lower round hole of the throttle cable connection plate. See Fig. #3 16. Make sure you have a nut on each side of the plate turn the nut on the outside of the plate to take up the slack in the throttle cable then tighten the nut on the inside of the plate. See Fig. #3 17. Push the fuel line onto the fuel inlet on the passenger side of the carb and install the supplied clamp to hold it on. The fuel line will be a little hard to push on. 18. DO NOT ATTEMPT TO INSTALL THE CHOKE CABLE PARTS SUPPLIED IN THE KIT UNTIL AFTER THE CHOKE CABLE ITSELF IS INSTALLED AND READY TO SCREW INTO THE CARBUETOR. 19. To install the supplied choke cable, drill a 3/8″ hole in the dash on the left side of the steering wheel in a location convenient to your left hand. 20. Remove the plastic nut from the bottom of the choke handle on the choke cable. 21. Push the choke cable thru the hole you drilled and then slide the nut over the cable to the inside of the dash and reinstall back on the back of the choke mechanism. Some dash screws maybe needed to be removed to accomplish this

TOYOTA NEW SEAT BELT TONGUE PLATE STOPPER SERVICE PARTS

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

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installation procedures are provided to supplement the Repair Manual. MODEL YEAR Avalon 1995 – 2001 Camry 1983 – 2001 Corolla 1980 – 2001 Camry Solara 1999 – 2001 Sienna (Front Seat Belt Only) 1998 – 2001 RAV4 1997 – 2001 4Runner 1992 – 2001 Land Cruiser 1991 – 2001 Tundra 2000 – 2001 Tacoma 1997 – 2000 ECHO 2000 – 2001 Celica 1980 – 2001 Prius 2001 – 2001 Tercel 1981 – 1999 PREVIOUS PART NUMBERCURRENT PART NUMBER PART NAME N/A 73219-02010 Stopper, Tongue Plate (Black)* N/A 73219-02020 Stopper, Tongue Plate (Gray)* N/A 73219-02030 Stopper, Tongue Plate (Beige)* *Use a stopper color that is closest to the seat belt webbing color. OP CODE DESCRIPTION TIME OPN T1 T2 BD0047 Install Seat Belt Tongue Plate Stopper 0.1 73219-020#0 62 12 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

1999 Toyota Camry LE V6 Body and Interior Maintenance Record

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

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Action Date Mileage Day Cost (with tax) By Interval Notes Oil and Oil Filter Change 8/30/1999 2494 Monday$77.97 Dealer 2494Non-synthetic 5w-30 (Toyota dealer stock) Oil and Oil Filter Change 10/31/1999 5484 Sunday $30 Owner 2988.5Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 12/30/1999 8460 Thursday$30 Owner 2975.9Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 2/21/2000 11414 Monday $30 Owner 2953.3Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 4/22/2000 14479 Saturday$30 Owner 3065.6Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 7/4/2000 17339 Tuesday$30 Owner 2860.1Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Air Filter – Replace 7/4/2000 17339 Tuesday$15 Owner 17339Purolator A24690 Air Filter Oil and Oil Filter Change 9/16/2000 20161 Saturday$30 Owner 2821.9Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Transmission Drain and Fill 10/27/2000 21913 Saturday$15 Owner 21913Drain and Fill 2.5 Quarts Mobil 1 Dexron III Synthetic ATF Transmission Drain and Fill 10/28/2000 21920 Sunday $15 Owner 7Drain and Fill 2.5 Quarts Mobil 1 Dexron III Synthetic ATF Oil and Oil Filter Change 11/19/2000 23066 Sunday $30 Owner 2904.6Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 2/11/2001 26062 Sunday $30 Owner 2996.1Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Transmission Flush 4/30/2001 28351 Monday$135 Dealer 2835113 Quarts Mobil 1 Dexron III Synthetic ATF – TransTech Flush Tires – Rotate 5/12/2001 28766 Saturday$0 Dealer 28766Tires – Rotate Coolant Flush 5/12/2001 28766 Saturday$112 Dealer 28766Toyota Red Coolant + MOC Flush (Extended warranty with service) Oil and Oil Filter Change 5/13/2001 28793 Sunday $30 Owner 2730.6Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Air Filter – Replace 5/13/2001 28793 Sunday $15 Owner 11454Purolator A24690 Air Filter PCV Valve – Replace 5/26/2001 31083 Saturday$10 Owner 31083Toyota OEM PCV Valve Windshield Wipers – Replace 5/26/2001 31083 Saturday$10 Owner 31083Windshield Wipers – Replace Oil and Oil Filter Change 5/27/2001 31296 Monday $30 Owner 2502.8Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Oil and Oil Filter Change 9/15/2001 34374 Saturday$30 Owner 3078.5Mobil 1 5w-30 + Mobil 1 Filter (M1-102) Tires – Replace 9/28/2001 34784 Friday$431.23 Dealer 34784 (4) Bridgestone RE950 Tires (2 of original tires had tread separation – ~30% tread remaining) Oil and Oil Filter Change 11/12/2001 37365 Monday $30 Owner

42MM MIKUNI FLATSLIDE CARBURETOR INSTRUCTIONS

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at 1/2 to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle. The output of the OEM fuel pump is too high and will cause fuel overflow in the HSR carb, resulting in a possible dangerous fire hazard

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2001-2002 GL1800 A ABS Speed Sensor Wire Clamp Location INSPECTION/ REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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1. If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9*GL1800 #9*0112*2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location*GL1800, ABS Speed Sensor Wire Clamp Location*Motorcycle*1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. 3. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly. Torque the bolts,. Torque: 12 N • m (1.2 kgf • m, 9 lbf • ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly. Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service. AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474*2A100001 – 1HFSC474*2A101643 * = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin.

Mikuni HSR 42/ 45 Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at ½ to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle.

2001 – 2002 GL1800/ GL1800A Rear Tire Inspection

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Filed Under (Honda) by admin on 27-11-2010

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1. Inspect the motorcycle for a punch mark as described in Identification on page 2. If a punch mark is present no further action is necessary, return the unit to the customer. 2. Qualify the unit/customer as follows: •Is the tire on the motorcycle the original factory installed tire? •Is the air pressure loss more than three psi per month? Note: Refer to page 145 in the Owner’s Manual. “Even tires that are in good condition may lose one to two psi per month if not checked and adjusted regularly” . If the GL1800 meets the above qualifications, proceed with the repair procedure. 3. Place the motorcycle on a lift and secure it on the centerstand. 4. Remove the rear wheel as described on page 14-9 of the Service Manual. 5. Starting at the valve stem/balance mark area, carefully remove the rear tire from the wheel. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. 6. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 2001 – 2002 GL1800/GL1800A Rear Tire Inspection GL1800 #6 OCTOBER 2001 MTB 9430 (0109) CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your Honda. These procedures should not be attempted by “do-ityourselfers,” and you should not assume this bulletin applies to your Honda, or that your Honda has the condition described. To determine whether this information applies, contact an authorized Honda dealer. Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800/GL1800A Rear Tire Inspection 0110 GL1800 #6*GL1800 #6*0110*2001-2002 GL1800/GL1800A Rear Tire Inspection*GL1800/GL1800A, Rear Tire Inspection, Bead, Tread*Motorcycle*1800 2 of 4 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #6 OCTOBER 2001 Inside BeadInjury Outside BeadInjury Outside BeadInjury 7. Carefully inspect the entire circumference of both tire beads. Inspect both the inside and outside of the bead for any distortion or injuries. See examples of injuries below. 8. If there is no evidence of bead damage, re-install the tire on the rim. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Be sure to align the balance dot with the valve stem. Inflate the tire to 41 psi. Install the wheel assembly on the motorcycle and proceed to the Identification and then to the Warranty section. 9. If any damage or injury is present replace the tire and valve stem. Be sure to use plenty of commercially available tire lubricant on the inside and outside of both beads. Balance the new tire as necessary

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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

2001 – 2003 Highlander FRONT DOOR OPENING WEATHERSTRIP

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Filed Under (Toyota Manuals) by admin on 27-10-2011

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have been improved to better resist deformation or tearing at the bottom center portion of the front door frame. Replace the front door opening weatherstrips on vehicles with this condition built prior to the VIN breaks listed in the Production Change Information section below. 2001 – 2003 model year Highlander vehicles produced BEFORE the Production Change Effective VINs shown below. MODEL ENGINE TYPE PRODUCTION CHANGE EFFECTIVE VIN 4Cylinder 4×2 JTEGD21A#30052511 Highlander 4 Cylinder 4×4 JTEHD21A#30020710 Highlander 6Cylinder 4×2 JTEGF21A#30085273 6 Cylinder 4×4 JTEHF21A#30113260 PREVIOUS PART NUMBERCURRENT PART NUMBER PART NAME QTY 62311-48020-## Same Weatherstrip, Fr Door Opening, RH 1 62312-48020-## Same Weatherstrip, Fr Door Opening, LH 1 Replace the front door opening weatherstrip as shown in the Technical Information System (TIS). Refer to the 2001 – 2003 Highlander Repair Manual; Exterior/Interior Trim, Roof Headlining Assembly

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