Disassembling Alternator

Remove left footrest and chain housing 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 in. socket or box wrench to remove nut. Loosen nut by striking wrench handle several sharp blows with hammer. 2. Remove chain adjuster mounting bolt and large brass starter shaft thrust washer. 3. Remove push rod adjusting screw locknut...

Repair Procedure

When operating troubles develop in a transmission component, it is recommended procedure to first check following adjustments. If adjustments do not remedy the trouble, then proceed to disassembly and repair procedures. 4. Adjusting Foot Shifter Cover If above adjustments do not correct trouble, disassemble and repair as described in repair sections. See Locating Operating Troubles, Section 1, for aids to diagnosing trouble. It is not necessary to remove transmission from chassis to disassemble...

Stripping Motorcycle For Transmission Repair

Remove battery ground wire and battery. Remove foot shifter lever and cover plate. Remove chain housing cover. Remove compensating sprocket nut. 2. Remove clutch as described in Disassembling Clutch. 3. Remove mainshatt key. Loosen the tive transmission base mounting nuts. Remove the four bolts attaching chain housing to engine crankcase and four bolts attaching housing to transmission. Remove the two chain housing stud nuts attaching starter housing to chain guard. Remove wires connected to...

Adjusting Rear Shock Absorber Spring

The rear shock absorber springs can be adjusted to three positions for the weight the motorcycle is to carry. The average weight solo rider would use the extended spring position (off cam) when in low position (off cam), the cam lobes should be next to each other that is, single lobes and double lobes matched. If necessary, rotate the cam to line them up properly. A heavy solo rider might require the position with springs slightly compressed (first cam step) buddy seal riders require the fully...

Troubleshooting

Disengage spark plug cable and insert a metal rod, screwor nail into each spark plug cable. Arrange cable end so tip of inserted metal object is 1 4 in. away from cylinder head. Turn on the ignition, break the points by hand. See if a hot of blue spark is obtained. If not, it is an indication of a weak coil, dead battery, broken or loose wires, etc. Arcing of the points and hard starting indicates a faulty condenser.

Operating Oil Pressure

Operating oil pressure may be checked as follows Fill oil tank to proper level. Disconnect oil pressure switch wire at top of switch and remove switch. Install Oil Pressure Gauge, Part No. 96921-52. Attach gauge bracket to motorcycle and road run or simulate road running until engine is completely warmed. A full operating temperature is essential for accurate gauging. Oil pressure should be 12-35 psi at 2000 rpm with oil at normal operating temperature. The tank is equipped with a large mouth...

Replacing Rear Wheel Sprocket 1972 And Earlier

To replace a worn rear wheel sprocket remove wheel from motorcycle as described in Rear Wheel, Removal. Remove brake drum and place in a vise. Chisel heads off all rivets and dowel pins from brake shell side and punch them out. If the rivet holes are not worn, use the rivet holes again. If the rivet holes are found slightly worn or elongated and drum is in good condition, drill a new set of rivet holes in drum flange midway between original dowel and rivet holes. To drill new rivet holes,...

Compression Testing Procedure

Satisfactory engine performance depends upon a mechanically sound engine. In many cases, unsatisfactory performance is caused by combustion chamber leakage. A compression test can help determine the source of cylinder leakage. Use a compression tester such as the Sun model UTC-48 that has a screw-in type adapter. A proper compression test should be performed with the engine at normal operating temperature when possible. Proceed as follows 1. Disconnect spark plug wires, clean around plug base...

Tools

Part No. 94557-55 Compensating Sprocket Shaft Nut Wrench Part No. 95635-46 All Purpose Claw Puller Part No. 94635-41 Mainshaft Ball Bearing Locknut Wrench Used in combination with claw puller for pulling close fitting gears or bearings. Used in combination with claw puller for pulling close fitting gears or bearings. Part No. 95637-46 Wedge Attachment for Claw Puller

Sun Vat26 Tester

Testing Battery Capacity CHARGING BATTERY Figure 5-25. Testing Battery Capacity CHARGING BATTERY Never allow a battery to stand in a discharged condition. Start charging it at once at the recommened continuous charge rate. Be sure charger is properly connected and adjusted observing positive (+) and negative (-) polarity to battery. To determine the amount or condition of a battery charge, check solution in each cell with a battery hydrometer or individual cell voltage with a...

Adjusting Steering Damper

Turn steering damper adjusting screw (26, Figure 2-36) clockwise to apply dampening action and counterclockwise to reduce dampening action. Apply steering damper only when operating under conditions where some degree of dampening stabilizes steering. It is best to keep the damper set a little snug when operating with a sidecar. ADJUSTING FRONT FORK TRAIL - ADJUSTABLE FORK (Figure 2-36) To adjust fork trail for use with sidecar, turn off nut on bracket bolt (35). Tap bolt head back far enough to...

Lapping Connecting Rod Races

Connecting rod lower races that are likely to clean up within the range of oversize bearing rollers and are otherwise in serviceable condition, should be trued and sized with Connecting Rod Lapping Arbor, Part No. 96740-36 as shown in Figure 3-42. 2. Turn lap in lathe at 150 to 200 rpm. Adjust lap by means of adjusting nut to a dragging but free fit in rod race. Clean lap before using, then apply fine lapping compound (No. 220 grit grinding compound mixed with oit) to lap. A loose or right lap...

Removing Shifter Cover

Remove transmission from chassis as described in Stripping Motorcycle for Transmission Repair. Remove the 12 screws securing shifter cover to gear box. Shifter cover is registered on two dowel pins. Two of the screws are extra long. Notice that the screw in hole nearest the dowel pin on right side of transmission is vented to relieve gear box heat expansion pressure. This screw must be installed in the same hole when assembling shifter cover or transmission oil may be forced out into clutch....

Straightening Connecting Rods

In refitting and reassembling connecting rods, and finally fitting pistons, rods may be bent or twisted, throwing upper bearing and lower bearing out of alignment with each other. After pistons have been installed, rods must be checked and realigned as necessary. If a rod is bent or twisted, piston has a cocked relation to cylinder bore and the result is excessive noise and rapid wear. Check rod alignment with Piston Squaring Plate, Part No. 96179-18, as shown in Figure 3-17. Be sure crankcase...

Repairing Steering Head And Bearings

Each steering head bearing consists of two pieces, the bearing outer race, and the roller bearing with inner race. The outer races are pressed into the steering head cups in the frame head. The lower roller bearing is assembled over the fork stem and the upper roller bearing is held in place on the fork stem by the upper fork bracket and nut on the upper threaded end of the fork stem. After fork is removed inspect bearings and races for pitting, roughness or wear. Roughness of the roller...

Stripping Motorcycle For Engine Repair

Use the following procedure to strip the motorcycle for either cylinder head and cylinder removal for repair with engine in chassis, or for engine removal for complete overhaul. 2. Drain gas tank. Disconnect fuel line and remove gas tank. 3. To remove instrument cover take out mounting base center screw and pry off cover side plate located at trip mileage set screw. 4. Release seat clevis spring, pull clevis pin and tip seat forward. 5. Remove upper cylinder head bracket. Note washers between...

Fitting Rod Bearings

Oversize rollers are available in .0002, .0006, .0008 and .0010 in. There are three ways to determine oversize rollers to use. All will result in properly fitted bearings if applied correctly. 1. Use a micrometer to measure the outside diameter of the crank pin at its center. Use an inside micrometer or telescoping hole gauge to measure the inside diameter of the rod races. Subtract the diameter of the crank pin from the inside diameter of the bearing race. Subtract from this figure the...

Disassembling Ignition Light Switch

Remove instrument panel cover by prying out side cover clip located at trip mileage set knob and turning out mounting base center screw located in the center of instrument panel below speedometer. Disconnect all wires connected to switch terminals and remove four switch mounting screws. See Figure 5-2. All directions for disassembly apply with switch in an inverted position. Switch must be in OFF position and unlocked. Grasp end of roller contact retainer with pliers and simultaneously move it...

Fl Front Fork

INSPECTION PROCEDURE (Early 1977 and Earlier) If hydraulic fork does not work properly that is, if it leaks oil or lacks original snubbing action, check the following before disassembling. OIL LEAKS FROM VENT HOLE. If oil leaks from vent hole in upper bracket bolt (2, Figure 2-35) and filler screw (38, Figure 2-36) when fork flexes, check for over-filling. Drain and refill with exact amount of oil. If oil leaks from vent hole in upper bracket bolt when fork tubes contain correct amount of oil,...

Removing Fork Stem And Bracket Assembly From Steering Head

Remove fork sides as described previously. Remove horn. Remove flasher mounting hardware. Bend tab on lockwasher (17) down and remove fork stem nut (18). Lift up upper bracket (19) and handlebar assembly and set it aside. Use wrench. Part No. 96219-50 to remove head bearing nut (20). Remove dust shield (21). Pull lower fork bracket and stem (22) out bottom of frame steering head. Remove bearing cones (23). Remove fork sides as described previously. Remove horn. Remove flasher mounting hardware....

General

The gearcase, located on the right side of the engine crank-case. contains a train of gears which transmit engine power to the camshaft and circuit breaker, crankcase breather and oil pump. The gearcase is lubricated with engine oil through the bypass circulatory system and through the breather valve from engine crankcase. Shafts run in bushings except the crankcase side of the camshaft which operates in a needle roller bearing. DISASSEMBLING GEARCASE Figure 3-29 Before disassembling gearcase,...

Straightening Fork Stem And Bracket Assemble

Straightening a fork stem and bracket assembly requires a great deal of skill, experience and several tools and fixtures. Special tools necessary include Fork Tube Straightening blocks, Part No. 96246-50, four blocks are needed Bending Bar, Part No. 96806-40 Fork Stem and Bracket Aligning Gauge, Part No. 96245-51. In addition, the following pieces of bar stock are needed Two bars, 1 -5 8 in. diameter, about 12 in. long two bars 1 in. x 4 in. x 12 in. approximately assorted pieces of rectangular...

Note

Late 1977 and later forks do not have removable bushings. If slider is worn to excessive looseness on fork tube, slider must be replaced. 3. Damper valve stud locknut 2 6. Damper tube bushing gasket 2 7. Damper tube lower bushing 2 8. Damper valve stud gasket 2 9. Damper tube valve 2 10. Spring ring 2 11 Spring ring washer 2 12. Upper oil seal felt 15. Slider upper and lower bushing 2 each Figure 2-37. Fork Side Early 1977 and Earlier The front fork slider bushings 15, Figure 2-3,7 may be...

Voltmeter 020

Test Arrangement with Individual Components Figure 5-9. Test Arrangement with Individual Components Figure 5-10. Test Arrangement with Sun Vat-26 Tester 2. Output Check Run engine at 2000 rpm and adjust load rheostat carbon pile to obtain a constant 13.0 volts. The alternator output current should be 10.5 amperes minimum. If check is unsatisfactory proceed to check No. 3. 3. If output in check No. 2 is unsatisfactory, check module as follows Remove module plug from stator plug. With...