Ken,
Regarding throttle bushing replacement - I have tried to e-mail this to
csnelson@swbell.net - but am cc'ing you and the list in case it fouls up.
Following was my escapade with this replacement:
<< Job took me about 3 hours. I was taking my time, when I had the
accelerator shaft and stuff out I decided to go ahead and clean it all up to
look like new, and I made one mistake costing me about 20 minutes.
1) Remove accelrator shaft. I assume that this is straight forward so I
won't go into it unless you want me to. I did however at this point add the
following: Also disengage clutch and brake pedals from respective forks by
removing cotter pins and pin. Also remove brake light switch. You don't
need to do this to get the shaft out, but it will come in handy later.
2) At this point I cleaned up everything. However Whilst doing so, put a
small pot of water to simmer on the stove. No not for tea, (that comes later
if you don't have any Ale on hand) but to heat the bushings. I let the
bushing heat for 30-45 minutes. Those buggers are HARD.
3) With the shaft out of the car, insert the bushings into the holes. I
inserted mine from the engine compartment side, leaving the squarer side of
the bushing facing in to the engine compartment. This is the HARDEST part.
Those buggers are hard. (did I say that all ready?) The bushing is now
somewhat flexible. Bend in between two fingers, and try to get the lip into
the hole at the bottom. Getting as much of the groove as you can seated in
the hole (it won't be much, but needs to be some) hold the bushing against
the hole with one hand and taking a small bladed, (got a couple of differnt
lengths) screwdriver and putting the blade into the groove of the bushing
next to the point at which you have managed to insert the bushing lip into
the hole, push and work a little of the bushing lip into to the hole.
Continue moving along pushing a little of the bushing lip at a time into the
hole. The thing is hard as a rock (did I say that?) so you have little
danger of poking the screwdriver through the lip, but even if you do, you
really haven't hurt anything.
On both sides I managed this, but each time ran into a point where I the
lip of the bushing left out of the hole would get into a point where I could
not reach it with the screw driver. It was either on the bottom side or up
against the bulkhead. Trick is to have most of the bushing in by the time
you reach this point. (3/4's or so). Take a Large bladed screwdriver, long
handled or a stubby, insert it into the hole where the shaft is going to go
and if it is big enough it will catch part way through, use this to gently
turn the bushing in the hole to get the part you need to complete pushing in
to a point where you can reach it. If you have enough of the thing in, it
will turn without popping out.
If you don't it will pop out. Have a cold drink and regroup. Start over
etc etc.
This is the hardest part, but with patience will work out.
4) After the bushings are in, the trick is to get the shaft through the
bushing on the drivers side. The shaft is too long to be able to be shoved
staight at the bushing from the drivers side tunnel. But with the clutch and
brake pedals moved up slightly by unattaching them, you can get the
accelerator shaft up to the bushing at an angle whereby with a bit of force
you can shove it through the bushing. Don't worry about the force pushing
the bushing out, remember how hard it was to get in? It isn't going
anywhere. After pushing it through 3-4 inches you will be able to move it up
and around to push straight through the bushing and across the engine
compartment to the other side.
5) Only bit of advice, put the whole thing together, but Don't install
the cotter pin on the passenger side until you have tested it out to be
certain that the pedal is where it should be. You have taken the shaft off
the linkage, and in reinstalling I found that I needed to readjust where the
linkage attached to the shaft from where it had previously.
Let me know if this makes any sense to you. Ck out the diagram in any of
the manuals or sales catelogues prior to starting (they all are the same).
JoeSimcoe
P.S. It really made a difference in my car, but then I didn't have ANY to
start with. You can imagine how sloppy the accelerator was before ! ! ! >>
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