4
nism. etc.} into plastic boxes (C.
Figure
3) to keep
them separated.
1
3.
When disassembling
tr
ans
mi
ssion sha
ft
asse
mbli
es, use an
egg
fl
at (
th
e type th
at
restaurants
ge
l their eggs in) (D.
Figure
3) and set the parts
from
the
s
haft
in
onc
of
the
depre
ssio
ns in
the
sa
me
position from which
it
was removed.
14
. Wiring should
be
tagged with
ma
sking tape and
marked as each wire is removed. Again. do
nOI
re
ly
on
memory al
one
.
1
5.
Protect finished surfaces from physical dam-
age or co
rr
osion. Keep gasoline a
nd
hydraulic
brake fluid off
pl
as
ti
c parts and painted and plated
surfaces.
16
. Frozen or very
ti
ght bolts and sc rews can of-
len
be
loosened by soaking with penetrat
in
g oil.
s
uch
as
WD
-40 or Liquid Wr
enc
h.
then
sharp
ly
striking the
bo]1
head a
few
limes with a hammer
a
nd
punch (or screwd
ri
ver for screws). A
voi
d heat
unless abso
lu
tely
ne
cessary. s
in
cc
it
may
mclt.
warp or remove the temper from many parts.
17
. No pnrts. except those assembled with a press
fit
. require unus
ual
force during assembly. If a
pan
is hard to rem
ove
or
in
stall. find out why before .
proceeding.
1
8.
Cover a
ll
openings after removing parts to keep
dirt, small tools. etc .. from falling in.
19
. Wiring co
nn
ections a
nd
brake components
should
be
kepI clean and
fr
ee
of
grease a
nd
oi
l.
20. When assembling 2 parts.
stan
a
ll
fa
steners.
th
en tighten evenl
y.
21.
Wh
en assembling parts,
be
sure all shims and
washers are
in
sta
ll
ed exac
tl
y as they came out.
22. Whenever a rotating
pan
butts aga
in
st a
stationory
pan
. l
oo
k for a shim
or
washer.
23.
Use new gaskets if there is any doubt abo
ut
the
co
ndition
of
the o
ld
ones. A thin coat
of
oil
on gaskets may help them seal effec
ti
ve
l
y.
24. Heavy grease can
be
used
to
hold small pa
rt
s
in
place if they tend to
fall
out during assembly.
However, keep grease a
nd
oil away from electrical
a
nd
brake
co
mponents.
25.
High spots may be sanded off a piston with
sandpaper, but fine emery cloth and oil
wi
ll
do a
much more professional job.
26.
Carbon can be removed from the head,
th
e pis-
ton crown and the exhaust port with a dull
screwdriver. Do
not sc ratch machined s
urf
aces.
Wipe off the surface with a clean cloth when
finished.
CHAPTE
R ONE
27.
The
ca
r
bure
tor
s
are
best
cleaned
by
disassembling them and soaking the parts in a
co
mm
erci
al
carburetor cleaner. Never soak gaskets
and rubber parts
in
these cleaners. Neve r use
wi
re
to clean out
je
ts and air
pa
ssages; they are eas
il
y
damaged.
Use compressed
ai
r to bl
owout
the
carburetor
after the noat has been removed.
28. A baby bottle makes a good measuring device
for adding oil to the front
fo
rk
s. Get one that
is
groduated in fluid o
un
ces and cubic centimeter
s.
After
it
has been used for thi s purpose. do
IIot
let
a sma
ll
child drink out
of
it
as there
wi
ll
always
be
an
oil residue
in
it.
29.
Some operations require special equipment,
for example. use
of
a press.
It
would
be
wi
ser to
h
ave
these
pe
rformed
by
a shop equipped for such
wo
rk
. rather than trying to do the
job
yourself with
makeshift equipment.
Other procedures require
pr
ecise measurements. Unless you have the skills
and equipment required,
it
would
be
better to have
a qualified repair shop make the measurements for
you.
SPEC
IAL
TIPS
Because
of
the extreme demands placed on a
bike. several points should be
kepI in mind when
performing service and repair. The
fo
ll
owing items
are
ge
neral suggestions that
may
improve the
ove
ra
ll
life
of
the machine and help avoid costly
failures.
CAUTION
Wh
en
apply
in
g Loctite Threadlocker.
or similar locking compound, to /as-
lener
(screw
or
bolt) Ihreads. it will
make it much harder to
remO\'e
the
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