INTRODUCTION TO DISASSEMBLY
Detail has not been spared in this section in order that the motorcycle can not only be taken apart
but also put back together properly as well.
detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account
a certain amount of basic knowledoe is also reauired for successful work.
Especially note the following:
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
Before removal and disassembly, clean the
Any dirt entering the engine, carburetor
or other parts will work as an abrasive and shorten the life of the
For the same
before installing a new part, clean off any dust or metal fillings.
(3) Tightening Sequence
Where there is a tightening sequence indication in this Service Manual; the
nuts, or screws
must be tightened in the order and method indicated. When installing a part with several bolts,
nuts, or screws; they shou Id all be started in their holes and tightened to a snug fit. Then tighten
them evenly, according to the tightening
to the specified
This is to avoid
distortion of the part
or causing gas or oil leakage. Conversely when loosening the
loosen all of them about a quarter of turn and then remove them.
The torque values given in this Service Manual should always be adhered to. Either too little or
too much torque may lead to serious
Use a good quality, reliable torque wrench.
Common sense should dictate how much force is necessary in assembly and disassembly. If a
part seems especially difficult to remove or install, stop and examine what may be causing
Whenever tapping is necessary, tap lightly using a wooden or plastic-faced
Use an impact driver for screws (particu larly for the removal of screws held by a locking agent)
in order to avoid damaging the screw
Don't use just any oil or
Some oils and greases in particular should be used only in certa in
applications and may be harmful if used in an application for which they are not intended.
(7) Battery Ground
Before performing any disassembly operations on the motorcycle, remove the ground (-) lead
from the battery to prevent the possibility of accidentally turning the engine over while partially
(8) Engine Rotation
When turning the crankshaft by
always turn it in the direction of normal rotation
counterclockwise, viewed from the right side of the
This will ensure proper
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing
surfaces have an adequate lubricative film.
During assembly, oil or grease (whichever is more
suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease
and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may
contain abrasive foreign
A part installed using a press or
such as a wheel bearing, should first be coated with oil
on its outer or inner circumference so that it will go into place smoothly
(11) Oil Seal, Grease Seal
Replace any o il or grease seals that were removed with new
as removal generally damages
A seal guide is required for certain oil or grease seals during installation to avoid damage
to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high temperature
grease on the lips to reduce rubber to metal friction.
(12) Gasket,O Ring
When in doubt as to the condition of a gasket or
ring, replace it with a new one. The mating
surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil
or compression leaks.