Stripping Motorcycle For Engine Repair

Use the following procedure to strip the Duo-Glide for either cylinder head and cylinder removal for repair with engine in chassis, or for engine removal for complete overhaul.

1. To remove instrument cover take out mounting base center screw and pry off cover side plate located at trip mileage set screw.

2. Release seat clevis spring, pull clevis pin and tip seat forward.

3. Disconnect fuel line from left tank and interconnecting pipe from right tank, and drain into a proper container. Gasoline may be pumped out through tank filler opening before disconnecting pipes.

4. Remove upper and lower bolts at the front and the two stud nuts between the gasoline tanks at the rear. Remove tanks. On hand shift models, remove shift lever bottom bolt so shift lever may be removed with left tank.

5. Remove cylinder head bracket. Note washers between bracket and frame lug, use same washer when bracket is assembled. Turn bracket to disengage choke lever from carburetor.

6. Remove spark plugs to avoid damaging. Disconnect ground wire at battery.

7. Turn out center screw and remove horn power pack cover. Disconnect two wires from horn power pack. Remove two bolts mounting horn power pack to bracket. Loosen horn trumpet nut and turn horn power pack off trumpet. Remove carburetor intake manifold clamps.

8. Remove air cleaner cover, filter element, four bolts, lock washers and air cleaner back plate from carburetor body.

9. Disconnect throttle control wire from carburetor. Disconnect fuel line with fuel strainer. Remove top center crankcase nut and washer and slip carburetor mounting bracket off stud. Remove carburetor to right. ^

10. Remove horn trumpet mounting bolt and horn trumpet. Loosen exhaust pipe clamps and slip clamps down. Remove regulator mounting screws and move regulator away from engine cylinders. It is not necessary to disconnect wires from regulator.

At this stage, the cylinder heads and cylinders may be removed. To remove engine crankcase or complete engine, continue stripping motorcycle as follows:

11. Remove chain guard cover. If motorcycle is equipped with compensating sprocket, use Compensating Sprocket Shaft Nut Wrench, Part No. 94557-55, to remove compensating sprocket shaft nut. If not equipped with compensating sprocket, use 1-3/8 inch socket or box wrench to remove nut. Loosen nut by striking wrench handle several sharp blows with hammer. Remove push rod adjusting screw lock nut (nut on center screw on clutch sprocket), slip washer (any metal washer about 1-3/4

in. in diameter with 3/8 in. hole) over push rod adjusting screw and replace lock nut. Remove three spring tension adjusting nuts and pull clutch outer disc and spring collar assembly off clutch drive hub pins. Move clutch sprocket and motor sprocket out shafts just far enough to slip motor sprocket off shaft.

12. Remove three stud bolts, lock washers and shim washers (located between inner chain cover and engine crankcase) from inner chain cover at engine sprocket shaft.

13. Disconnect timer wire at coil. Disconnect two wires from generator.

14. Remove left rear and front motor mounting bolts.

15. Remove breather and return oil lines from oil pumps and oil tank connections.

16. Remove footboard rear stud nut from inside of frame member and front footboard mounting stud bolts from brake master cylinder by removing nut and lock washer on back side. Remove rear brake cylinder attaching stud bolt which passes through master cylinder and frame with a lock washer and nut on back side of frame member. Remove brake master cylinder sideplate bolt located behind master cylinder plunger boot. Master cylinder arid sideplate assembly is free to swing down away from engine crankcase.

17. Remove muffler rear hanger clamp, muffler front hanger clamp and rear end front clamp. Remove muffler. Remove rear hanger bolt and front exhaust pipe frame clamp and remove front exhaust pipe.

18. Loosen oil feed line at tank and remove at oil pump. Have plug for pipe ready or drain oil tank before removing feed line connections. Shift line out of way and tighten connection at tank.

19. Remove spark advance control wire at circuit breaker. Remove two rear screws from horn trumpet bracket and slip out spark advance control wire.

20. Remove front and rear righthand engine mounting bolts. Engine is now completely stripped and may be removed from right side of motorcycle.

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