Remove the reverse driven washer; then remove the low driven gear locking washer. Account for a cap screw, washer, pin, and spacer. Remove the fixed drive face. Slide the hub out of the knuckle and set aside. Connect the coolant hoses to the water pump and secure with the hose clamps.
Inspect the sealing surface for any indication of high spots. Camshaft lobes directed down toward the pis- ton. Place a new O-ring in the intake pipe; then position the pipe onto the engine and secure with two cap screws. Secure the wires to the frame with nylon ties. Appears as if someone rebuilt this carb, because it is extremely clean.
Close the bleeder screw before releasing the brake lever. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle. Remove the nuts securing the rear exhaust pipe to the 16. Apply grease to the hub and drive axle splines; then 13. Place the side storage box into position on the frame; then secure with the two cap screws A and B. With engine moved rearward, engage the splines of the front driveline into the front output drive yoke; then move into position and install the two through-bolts. Just print it out and take it with you into the garage or workshop.
Install the reverse driven bushing and bearing; then 5. This manual is an easy layout format that covers all repair procedures in great detail. Place the cylinder head on the surface plate covered with 400 grit wet-or-dry sandpaper. Install the wheel and tighten to 40 ft-lb steel wheels install the hub assembly onto the drive axle. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. Block the engine up in this position.
Remove the gas tank cap and set the rear body panel in position; then install the cap and connect the tail- 1. Covers complete tear down and rebuild, pictures and part diagrams, torque specs, maintenance, troubleshooting, etc. Thanks in advance for the help! Loosen the clamps securing the coolant hose to the water pump; then remove the crossover tube from the cylinder head. Remove the secondary driven shaft assembly A noting the location of the bearing locating pins. Place the differential with the open side down; then lift the housing off the spider assembly. Install a new seal F , output yoke G , washer, and nut H and tighten to 200 ft-lb. Remove the two cap screws and lock nuts securing the rear gear case to the frame; then remove the gear case through the left side.
This is the same type of service manual your local dealer will use when doing a repair. Measure the cylinder front to back in six places. Tons of pictures and diagrams at your fingertips!! Remove the cap screws and lock nuts securing the front rack to the frame;. Secure the throttle body assembly up and away from remove the air filter housing. Remove the two cap screws securing the gear posi- tion switch;. Secure the hub assembly with the nut.
Slide the grommet out of the lower half of the throt- tle control; then remove the cable from the actuator arm. Loosen the cap screws securing the valve cover to the head. To adjust tooth contact, use the following chart to correctly shim the driven shaft. The countershaft is now ready for installation. Remove the oil pump drive gear cap screw.
Remove the cotter pin and slotted nut securing the tie and nuts. Tighten the 6 mm cap screws to 10 ft-lb and the 8 bearings are correctly seated in the crankcase. Remove the cam chain guide. Just print it out and take it with you into the garage or workshop. Place the battery into position in the battery compart- Tighten securely. Closely observe the note introducing each sub-section for this important information. Tire inflation pressure low 3.
This Manual is a must for the Do-It-Yourselfer! Place tab-washer onto the sprocket making sure it covers the pin in the alignment hole. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores. Lubricate the inside wall of the cylinder; then using a 5. If backlash measurement is more than specified, 2. Using light pressure, move the cylinder head cover in a fig- ure eight motion. Squeeze the element by pressing it between the 1.
Camshaft lobes directed down toward the piston. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. If damaged, the camshaft must be replaced. Install the side panels into position. Using an awl, remove one piston-pin circlip. If any of the above conditions exist, replace the starter clutch assembly.