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REF-4
Maintenance Techniques
Basic
maintenance
spec~fic torque value, which is noted in the
loosened by striking it with a soft-faced
.
Specifications. Be sure to follow the torque rec.
hammer near the mating surfaces. A normal
techni
q
ues
ommendatlons~losely:.
hammer
can
be
used
if
a block
of
wood
is
Fasteners
laId
out
In a pattem
(Ie
cylinder
placed
between
the
hamme
d the art D
head bolts engl
b It
)
r an
p.
0
There are a number of techniques involved in
loosen d 'r
h;e ~a~e
0 s, etc. must
~
not hammer on cast parts or parts that could be
maintenance and repair that will be referred to
Wine
t~ c~
en
In a. ~equence to avoId
easily damaged. With any particularly stubborn
throU~hout this manual. Application of these
S~ldg go on ~:~~i
I~~'allyi theNbo~~uts
part, always recheck to make sure that every
techniques will enable the amateur mechanic to
should be tightened on~ fu~~~;n e:~h Ine~
fasten~r
~
been remo~.
be more efficient, be~er organlsed and capable
criss-cross or diagonal pattem. After each one
Avoid uSIng a scl9Wdnver or bar to pry apart
of. performIng the various tasks properly, which
has been tightened one full tum retum to the
components, as they can easily mark the
will ensure that the repair job is thorough and
first one tightened and tighten th~m all
half
gasket sealing surfaces of the parts (which
complete.
.
one
must
.
th) If
.
.
tum, following the same pattem. Finally, tighten
remain smoo
.
prying IS absolutely
each of them one quarter turn at a time until
necessary, use a piece of wood, but keep In
Fastening systems
each fastener has been tightened to the proper
mind that. extra clean-up will be necessary If the
Fasteners basicall
are nut
I
torque. To loosen and remove the fasteners the
wOOd splInters.
screws used to hOI~' two or s~~etsp=~~
procedure would
be
reversed.
After the parts are separated, the old gasket
together. There are a few things to keep in mind
must be carefully scraped off and the gasket
when working with fasteners. Almost all of them
.
surfaces C~ed.
Stubbom gasket material can
use a locking device of some type (either a lock
Disassembly
sequence
be soaked with a gasket remover (available in
washer, locknut, locking tab or thread locking
Component disassembly should be done
aerosol cans) to soften it so it c~n be easily
compound). All threaded fasteners should be
with care and purpose to help ensure that the
sr:'aped off. A scraper ~an be fashlon~ from a
clean, straight, have undamaged threads and
parts go back together properly during
piece ~f copper tubing by flattening and
undamaged comers on the hex head where the
reassembly. Always keep track of the sequence
sharpening. one end. Copper is recommended
spanner fits. Develop the habit of replacing all
in which parts are removed. Take note of
because It IS usually softer than the surfaces to
damaged nuts and bolts with new ones.
special characteristics or marks on parts that
be scraped, which reduces the chance of
Rusted nuts and bolts should be treated with
can be installed more than one way (such as
gouging the part. Some gaskets can be
a penetrating oil to ease removal and prevent
convex washers and gear pinions). It's a good
removed with a wire brush, but regardless of
breakage. After applying the rust penetrant, let
Idea to lay the disassembled parts out on a
the method used, the mating surfaces must be
it work for a few minutes before trying to loosen
clean surface in the order that they were
left clean and smooth. If for some reason the
the nut or bolt. Badly rusted fasteners may
removed. It may also be helpful to make
gasket surface is gouged, then a gasket sealant
have to be chiselled off or removed with a
sketches or take instant photos of components
thick enough to fill scratches will have to be
special nut breaker, available at tool shops.
before removal.
used during reassembly of the components.
If a bolt or stud breaks off in an assembly, it
When removing fasteners from a component,
For most applications, a non-drying (or semi-
can be drilled out and removed with a special
keep track of their locations. Sometimes
drying) gasket sealant is best.
tool called an E-Z out (or screw extractor). Most
threading a bolt back in a part, or putting the
dealer service departments and motorcycle
washers and nut back on a stud, can prevent
repair shops can perform this task, as well as
mix-ups later. If nuts and bolts can't
be
Hose removal f
others (such
as the repair of threaded
holes
retumed to their original locations, they should
IpS
that have been stripped out).
be kept in a compartmented
box or a series of
Hose removal precautions
closely
parallel
Washers should always be replaced exactly
small bo~es or la~led
plastic bags. A box of
gasket removal precautions.
Avoid scratching
as removed. Replace any damaged washers
thIS type IS
especially helpful when working on
or gouging the surface that the hose mates
with new
ones.
Always use a flat washer assemblies with very small parts
(such
as the
against
or the connection may leak. Because of
between a lock washer and any soft metal carburettors, tappets, shims
etc).
various chemical reactions,
the rubber in hoses
surface
(such
as aluminium), thin sheet metal or
Whenever wiring looms, harnesses or
can bond itself to the metal union that the hose
plastic. Special
locknuts can only be used once
~onn.ectors are
separated, it's a good idea to
fits over. To remove a
hose, first
loosen the
or twice
before they lose their locking ability
Identity
the two halves with numbered
pieces of
hose clamps
that secure it to the union. Then,
and must be replaced.
masking tape
so they
can be easily with
slip joint pliers, grab the hose at the clamp
reconnected.
and rotate it arolKld the union. WOI'k it back and
forth until
it is completely free, then pull it off
(silicone or other
lubricants will ease removal If
Tightening
sequences
and
Gasket
sealing
surfaces
they can be applied between the hose and the
procedures
Gaskets are used to seal the mating surfaces
outsid~ o~ the union). Apply the same lubricant
between components and keep lubricants,
to the InSIde of the hose and the outside of the
When threaded fasteners are tightened, they
fluids, vacuum or pressure contained in an
union to simplify installation.
are often tightened to a spe~ific torque value
assembly.
If the hose is particularly stubborn, slit the
(torqu~ IS basically a twisting force). Over-
Many times these gaskets are coated with a
hose with a sharp knife and peel it off the union.
~Ightenlng the fastener ca.n
weaken it and cause
liquid
or paste
type gasket seating compound
The hose will obviously be destroyed uq
this
It to break,
while under-tightening can cause it
before assembly. Age, heat and pressure can
method.
to eventually co":e loose. Each bolt, depending
sometimes
cause the two parts
to stick
If a hose clamp is broken or damaged,
do
on the
material it s made of, the
diameter of its
together so tightly that they are very difficult to
not reuse it. Also do not reuse hoses that
shank and the material
it is threaded into, has a
separate. In most cases, the part can be
cracked, split or t~m.
are
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