Unscrew and remove the starting enrichment valve and cable Figure 22. Each sleeve number equals 0. Drain the oil tank as described in Chapter Three. Install the second countershaft gear Figure 43 so the shift dogs are down. Can a butcherd down harness just for spark work. Install the adjusting screw assembly Figure 50 by aligning the two tabs on the release plate perimeter with the two recesses in the pressure plate. Inspect the valve stem seal.
If the starter turns, perform the solenoid pull-in and hold-in tests as described in Solenoid Testing Bench Tests in this section. Carefully separate the switch housing Figure 108 to access the defective switch. The check engine, battery and security symbols should illuminate. Immediate hard application glazes the new pads and greatly reduces their effectiveness. If neces- sary, have an assistant help or place wooden blocks under the wheel. In some applications, it may be necessary to replace snap rings after removing them.
Adjust the clutch as described in Chapter Three. This product can speed up the removal process and prevent damage to the mating surface that may be caused by using a scraping tool. If the wheel bearings are acceptable, replace the cast or disc wheel as it cannot be serviced. Install a new cylinder base gasket B, Figure 85 onto the crankcase. If the pushrods are not labeled, or new pushrods are being installed, identify them as follows: a. Blow out the jets and the needle jet holder with com- pressed air. Lower left handlebar clamp 9.
Turn the ignition key off and arm the security system. Remove the O-rings around the cylinder dowel pins Figure 24. Connect a hand-operated vacuum pump Figure 83 to the fuel valve vacuum hose fitting. Rotate the hinged secondary lock down and inward until the tabs are fully engaged with the latches on both 6-pin connector sides of the connector. Then align and install the hex portion on the nut into the outer ramp recess. Clean bulbs and Check for corrosion on all sockets. Using oil additives is not recommended as they may cause clutch damage.
Inspect the needle jet holder, pilot jet and main jet Figure 43. Loosen the axle nut and move the rear wheel fully forward in the swing arm. When purchasing replacement piston pins, note the difference. Repair open Repair open be- Check for continu- ground circuit. Install the fifth countershaft gear A, Figure 44 and snap ring B. Remove and install the bearings with a suitable size socket and extension.
Press and release left turn Turn signals flash when signal to change mode. Push a suitable rod through the vent hole in the handle- bar bracket to push the speedometer out of the housing. Measuring brake rotor runout is a typical use for a dial indicator. Adjust the oil level if necessary. Never use an oil-based solvent that may leave an oil residue on the disc. Extension bars allow the socket setup to reach difficult areas. Press the engine sprocket off the rotor.
Remove the starter as described in Chapter Nine. Install the separator plate Figure 72 into the oil pump body; align the separator plate slots with the tabs inside the pump body. Remove the drive belt as described in Chapter Ten. If a procedure requires more than mi- the following: nor disassembly, reference to the appropriate chapter is 1. Hold the housing with the bearing side down and tap the bearing out. Install the spring pin Figure 29 and snap it into place. Push in the terminal wire requiring removal.
Tighten the locknut to 120-180 in. Make sure the throttle operates smoothly with no binding. Check the headlight beam lateral alignment. Install the engine into the frame. Carefully push the front of the engine to the left and remove the right isolator mount.
Gather as much infor- run. Remove the seat as described in Chapter Fourteen. Cover the loose end with a re-closable plastic bag. Remove and discard the cylinder head gasket. The brake fluid level must be even with the casting ridge Figure 38 on the reservoir housing.
Refer to appro- ate troubleshoot- ate troubleshoot- priate trouble- ing section in this ing section in this. Shock absorber and spring 8. Apply Loctite 272 red to the pinion shaft nut B, Fig- ure 39 prior to installation. Tighten the mounting bolts to 60-70 ft. Front suspension and steer- ing specifications are in Table 1 and Table 2 at the end of 1.