Remove the two nuts securing the right side of the cylinder to the right-side crankcase half. Measuring Valve Stem Outside Diameter 1. If the left-side components have not been cam chain tensioner B. Install the input shaft seal making sure it is flush with the edge of the housing. Then, re-start the engine to reactivate the system. While keeping tension on the cam chain, place 7. Bend the washer tabs and remove the two cap 7.
See illustration for loca- tion of assembly components. Place the cylinder gasket into position; then place a piston holder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase. Account for a washer and a spacer on the bolts. Place a washer on the driveshaft, the counter- onto the driveshaft; then place the 2 drive gear shaft, and the driven shaft. Firmly holding the spring and spring holder, remove the wing nut; then remove the spring. Remove the nut and washer securing the oil pump assembly and starter clutch housing from their drive gear to the crank balancer shaft; then remove respective shafts. Using a suitable driver, install the needle bear- 5.
Using light pressure, move the cylinder in a figure eight motion. Account for a pin, spring, and O-ring with the chain tensioner bolt. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. Poor acceleration Incorrect float level Check and, if necessary, replace the following parts: Float tang Float entire assembly Arm pin Service Manual, Shop Manual, Workshop, Repair Manual, Owner's Manual, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, User's Manual, Riders Manual, Repair Guide, Handbook, Book, Instructions Manual,. Tighten the cap screws to specifications. Right-Side Components in Section 3.
Account for the spring and washer. Inspect the pump for damage. Place the primary gear assembly on a clean, flat surface;. If thickness of either brake pad is less than 3. Increase or decrease shim thickness on the drive bevel gear housing until the correct contact pattern is obtained. Install the 3rd driven lock washer left side. Remove the two cap screws securing the front upper engine mount to the frame.
The lobe heights must not exceed minimum 5. Inspect the handlebar grips for damage or wear. Firmly holding the spring and spring holder, remove the wing nut; then remove the spring. Remove the 12 cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. While an assistant holds the cargo box in the ing the cargo box to the frame; then remove the raised position, place the lower end of the cargo cargo box and discard the lock nuts.
In a crisscross pattern starting from the center and working outward, tighten the cap screws from step 28 securely. Install one shoulder screw and three plastic riv- ets on each side to secure the front of the rear body panel to the footwells. Remove the cap screws securing the recoil starter assembly to the left-side cover; then remove the starter. Maximum diameter must not exceed specifica- 5. Using two open-end wrenches, remove lock C.
Remove the nut from the positive post. Remove the two engine mounting through-bolts. Remove the cap screws securing the V-belt cover noting the location of the differ- ent-lengthed cap screws for installing purposes;. They must be parallel with the valve cover mating surface. .
Shift Shaft with 3 Forks I. Overflow Check and, if necessary, clean the float and float valve. Registration is fast and you can even login with social network accounts to sync your profiles and content. Remove the 1st driven bushing; then remove the 1st driven washer left side from the shoulder of the splined shaft. Remove the reverse idler gear, spacer, and sleeve. Oil Pump Drive Gear G.