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STRIPPING MOTORCYCLE FOR ENGINE REPAIR
DISASSEMBLING ENGINE FOR
CYLINDER HEAD REPAIR
1.
Lift and secure the motorcycle.
a.
Place vehicle on a lift and anchor front wheel in
place. Raise lift so the top of the cylinder head is
easy to access.
b.
Raise rear wheel off lift using
PORT STAND (Part No.
WARNING
To avoid accidental start-up of vehicle and possible per-
sonal injury, disconnect the battery cables before pro-
ceeding. Always disconnect the negative cable first. If
the positive cable should contact ground with the nega-
tive cable installed, the resulting sparks may cause a bat-
tery explosion producing personal injury.
CAUTION
Hold battery cable when loosening battery terminal hard-
ware. Failure to hold cable may cause battery damage.
2.
Disconnect both battery cables, negative cable first.
3.
Remove seat and fuel tank. See
4.
Remove air cleaner assembly. See
REMOVAL
in Section 4.
5.
Remove exhaust header. See
Section 2.
6.
Remove carburetor and manifold. See
REMOVAL
in Section 4.
7.
If removing front cylinder, remove ignition coil and horn.
See
IGNITION COIL
in Section 7.
8.
Disconnect spark plug cables.
REMOVING ENGINE CRANKCASE
OR COMPLETE ENGINE
1.
Perform the steps listed above.
2.
Remove tail section. See
Section 2.
Place a floor hoist behind the lift. Attach
3.
See
Figure 3-1.
straps to frame and hoist. Raise hoist until straps tighten.
4.
Detach clutch cable from handgrip.
5.
Remove
REAR FENDER/LOWER BELT GUARD
SPROCKET
COVER. See Section 2.
6.
Remove rear caliper. See
Section 2.
7.
Detach belt from rear sprocket and remove rear wheel.
See
REAR WHEEL
in Section 2.
3-8
REAR WHEEL SUP-
B-41174).
FUEL TANK
in Section 4.
AIR CLEANER,
EXHAUST SYSTEM
CARBURETOR,
TAIL SECTION, REMOVAL
and
REAR BRAKE CALIPER
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5673
Floor hoist
Figure 3-1. Floor Hoist
8.
Drain oil tank and remove oil filter. See
CATION SYSTEM
9.
Disconnect wire to oil pressure signal light switch. See
OIL PRESSURE SIGNAL LIGHT SWITCH
10. Detach feed, vent and return hoses from oil tank. See
OIL TANK
on
page
in
11. Remove both rider footrests from frame. See
RESTS
in Section 2.
12. Remove rear shock mounting bolt (metric) from swing-
arm. Allow rear shock to hang from front mount.
13. Disconnect wiring. See Section 7.
a.
Disconnect neutral switch wire from crankcase.
b.
Unplug ignition timer plate wires from wiring har-
ness.
c.
Disconnect 18-gauge green wire from starter motor.
d.
Disconnect regulator/rectifier from the alternator sta-
tor at the plug near the regulator. See
REGULATOR
e.
Disconnect V.O.E.S. wire from ignition module.
14. Remove muffler. See
15. See
Figure 3-2.
Place a wooden cradle underneath the
crankcase.
in
16. Place a crating strap between the engine cylinders and
around the lift. Tighten crating strap until snug.
17. See
Figure 3-3.
Remove engine ground strap (1) from
swingarm mount block.
18. Detach tie bars from frame mounts.
a.
Remove rear tie bar using a swivel socket.
in
b.
See
Figure 3-4.
cable clamp.
19. Remove front isolator bolt (6), nut (9), D-washer (8) and
washers (7).
Attach straps
to frame
ENGINE LUBRI-
in Section 1.
on
page
3-30.
VOLTAGE
in Section 7.
EXHAUST SYSTEM
in Section 2.
Remove front tie bar (1) and clutch
3-31.
FOOT-
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