Slide the finger of the pad spring under the re- taining pin B, Figure 14 and seat the pad spring in the caliper. Pull back the boot and disconnect the positive cable B, Figure 46. Attach an auxiliary fuel tank to the carburetor. Disconnect the clutch cable Figure 46 from the clutch lever. Improper removal of a seal can damage the housing Dust lip or shaft. Take a photograph or make a drawing so you can correctly time the camshaft during assembly.
Remove the clamp from the duct— it will be reused. Lower the ball assembly A, Figure 41 onto the push screw B. Install each swing arm bearing so it sits flush with the outside edge of the bearing bore. If either part is worn or dam aged, replace the starter clutch assembly. Inspection The following procedure requires the use of highly specialized and costly measuring instru- ments. Rotate the crankshaft another 290° clockwise until the I-mark on the flywheel A, Figure 11 aligns with the cutout in the alternator cover B. Install the wire clamps behind the bolts A, Figure 2 noted during removal.
Tie a piece of heavy string or cord to the ends of the throttle cable at the carburetor. Sockets combined with any number of drivers make them undoubtedly the fastest, safest and most convenient tool for fastener removal and installa- tion. Untie the string from the old cable and tie it to the carburetor end of the new cable. Middle drive shaft nut 8. Remove the outer fairing and windshield.
Throttle cables improperly adjusted, pinched or need lubrication. Failed main circuit breaker or ignition switch, check for loose connections and continuity. If the cap does not completely contact the plug, the en gine may falter and cut out at high en gine speeds. Consult your factory service manual for this procedure. Valve Clearance Valve clearance measurement and adjustment must be performed with the engine at room temper- ature below 35°. Remove the brush holder assembly Figure 32 from the armature housing. If these marks are not visible, make new ones.
A 12 point socket will mar the bolt. Because the float bowl screws are easily damage during removal, we have included 8 replacement float bowl screws with socket heads, just in case they are needed. If there is any excessive damage, replace the compo- nents. Carefully slide the steering stem up through the Torque wrench frame steering head Figure 52. If there is any damage, have the frame repaired at a competent frame or welding shop. A failed fuel pump, pressure regulator and or fuel injectors. Remove the upper bearing inner race A, Fig- ure 51 and the bearing B from the steering head.
Remove the cylinder head as described in this chapter. Install the cover as follows: a. Make sure it is firmly seated against the master cylinder. Multi carburetors not in sync. Check the voltage in the illumination light cir- cuit as follows: a.
The vacuum pressure at each cylinder must be within the range specified in Table 5. Remove the reservoir cap, diaphragm plate and diaphragm. Set each neck cover into place on the frame. Remove the plastic tank mounting snap stud. Heat the crankcase to approximately 95-125° C 205-257° F in an shop oven or on a hot plate. Press the upper bead into the rim opposite the valve stem. Upper fork cover spacer 5.
This label is on the lower frame member just beneath the left side cover Fig- ure 1. Correct any leak prior to riding the bike. Install the universal joint holder A, Figure 48 onto the drive yoke and install the middle gear backlash band Figure 49 onto the middle drive shaft assembly. Unless a part is being replaced, install each rocker arm with its original shaft, and install them in their original locations intake or exhaust side in the cylinder head. Replace the wheel gear if it shows signs of wear. They may not properly secure the disc to the hub. Inspect the vacuum piston B, Figure 61 for scoring and wear.