Servicing

INSPECTION PROCEDURE (Figures 2-31 and 2-36) If the hydraulic fork does not work properly or an appreciable amount of oil leakage should develop, inspect the fork as follows Check the oil level in each fork side by completely draining and refilling fork as described in CHANGING FORK OIL. Insufficient oil in either fork side will result in faulty recoil action and excess oil will cause leakage from the top of fork tubes. When checking oil level in each fork side, also check for water in fork oil...

Valve Tappets And Guides

Tappets and tappetguides seldom require replacement. Primarily, they are only removed for the purpose of checking end play of the cam gears, when reassembling an engine. Clean all dirt from around crankcase and blow loose particles from the area with compressed air. Remove push rods. This procedure is covered under REMOVING AND INSTALLING PUSH RODS, this section. For 1976 and earlier models guides are press fit into crankcase (see SPECIFICATIONS, this section). Remove tappet guide screw (1) and...

Repair Procedure

When an engine needs repair, it is not always possible to definitely determine beforehand whether repair can be made with only cylinder head, cylinders and pistons removed from engine or whether engine must be completely disassembled for crankcase repair. Most commonly, only cylinder head and cylinder repair is needed (valves, rings, pistons, etc.) and it is recommended procedure to service these units first, allowing engine crankcase to remain in frame. Follow the procedure under STRIPPING...

Cylinder And Piston

See STRIPPING MOTORCYCLE FOR ENGINE REPAIR. steps 1-5, 20-21 and REMOVING CYLINDER HEAD ASSEMBLY FROM ENGINE, this section. See Figure 3-12, and proceed as follows Clean crankcase around cylinder base to prevent dirt from falling into crankcase when lifting cylinders. Remove cylinder base stud nuts (1 ). Raise cylinder and piston just high enough to permit placing a rag over crankcase opening this will prevent dirt and possibly pieces of broken ring from falling into crankcase. With piston at...

95991-69 Fork Holding Tool

Part No. 94630-67 Wheel Hub Bearing Locknut Wrench Used to remove fork piston rod retainer from fork tube. Used to remove fork piston rod retainer from fork tube. Part No. 94694-52 Fork Piston Rod Retainer Wrench For small wheel spoke nipples .205 across flats . For small wheel spoke nipples .205 across flats . Part No. 94678-18 Spoke Nipple Wrench Used to adjust rear shock absorber units for more or less spring compression 1974 and earlier . Used to adjust rear shock absorber units for more or...