Repair Procedure

GENERAL

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 MOTORCYCLE FOR ENGINE REPAIR." steps 1-5, 20-21, to strip motorcycle for removal of cylinder head, cylinder and pistons.

After disassembling "upper end" only, it may be found that crankcase repair is necessary; this requires removal of engine crankcase from chassis outlined under "STRIPPING MOTORCYCLE FOR ENGINE REPAIR," steps 6-19, 22-29.

In cases where it has been definitely determined beforehand that crankcase repair is necessary, the engine, completely assembled, should be removed from chassis as outlined under "STRIPPING MOTORCYCLE FOR ENGINE REPAIR." steps 1-29.

NOTE

The following stripping procedure applies directly to 1974 and earlier models. Models 1975 and later are similar, except that the brake and gear foot shift lever positions have been reversed on the motorcycle. The brake lever is now on the right side; the gear shift lever, on the left.

STRIPPING MOTORCYCLE FOR ENGINE REPAIR (See Figure 3-4 or 3-5)

1. Clean engine thoroughly with "Gunk" to remove all road dirt. Remove "Gunk" and dirt with water spray and blow engine dry with compressed air. Drain gasoline and oil. Remove battery cover and disconnect battery cables Disconnect hoses from carburetor and remove bolts securing gasoline tank. Tank can then be removed from motorcycle.

Remove the following parts from right side of motorcycle.

2. Remove air cleaner assembly (3) including back plate and support brackets.

1975 & 1976 Models

Figure 3-4. Engine - Right Side View

3. Disconnect throttle and choke control at carburetor. Free throttle cable and support bracket from carburetor. Remove cable from between the cylinders and position cable out of working area (to front of frame). Remove carburetor.

4. Remove top engine support bracket bolt. Be sure to note the number of shim washers between cylinder head bracket and frame lug; these will have to be refitted when installing the engine.

5. Loosen exhaust pipe port clamps (6). Remove exhaust system from motorcycle.

6. On XLCH Model, remove starter crank clamp bolt (9) and with a screwdriver pry crank from shaft. Press down on end of starter spring (10), and at the same time pry spring off shaft.

7. Models 1974 and earlier, shift into high gear and remove footrest (11) and foot shift lever (12). Models 1975 and later, remove right footrest (11) and brake foot lever (12A).

8. Remove transmission sprocket cover bolts (13). With a mallet, lightly tap cover at the same time pulling cover from shaft. On 1974 and earlier models, disengage clutch cable end from clutch release lever by moving lever forward (as positioned on motorcycle), and disengage cable from lever. On 1975 and later models, detach shifter link from arm of shifter pedal cross shaft.

1972 Model XLCH

1.

Oil pressure switch wire

12A.

Brake foot lever

2.

Clutch control cable (1970)

(1975 & later)

2 A.

Clutch control cable (1971 & later)

13.

Cover bolt (2)

3.

Cleaner assembly

14.

Rear chain

4.

Clip

15.

Oil return line

5.

Engine support bolt location

16.

Oil vent line

6.

Exhaust pipe port clamp (2)

17.

Oil feed line

9.

Starter crank clamp bolt

18.

Breather pipe

10.

Starter spring

19.

Oil tank

11.

Footrest

12.

Gear shift foot lever (1974 & earlier)

1975 & 1976 Models

Figure 3-5. Engine - Left Side View - 1971 Shown

30 29 28 27 24 23 25

1971 Model XLCH 34 33,33A 32 31

20.

Top front end mounting bolt

27.

Horn cover

33.

Brake foot lever

21.

Engine mounting bolts

28.

Wire

(1974 & earlier)

22.

Front bar bolt hole

29.

Support bracket and

33A.

Gear shift foot lever

23.

Battery

choke control

(1975 & later)

24.

Battery carrier

30.

Support bracket bolt

34.

Left footrest

25.

Ground wire

31.

Regulator ground strap

26.

Spark plugs

32.

Engine mounting bolt

Figure 3-5. Engine - Left Side View - 1971 Shown

9. Disconnect rear chain (14).

10. Remove oil return line (15) at oil tank.

11. Free oil vent line (16) at oil tank and oil feed line (17) at engine.

12. Remove breather pipe (18) and disconnect oil pressure switch wire (1) from switch.

13. On 1970 models, pull clutch cable (2) forward (as positioned on motorcycle), until approximately 1 in. of cable remains in gearcase cover, at the same time press cable inward (towards oil pump), and down to free from gearcase pover. On 1971 and later models, disconnect clutch control cable at handlebar control lever.

14. Remove oil pressure switch from motorcycle.

15. Disconnect speedometer cable from speedometer drive unit (located under transmission sprocket cover). Disconnect tachometer cable.

16. Free speedometer cable from clip (4).

17. Remove lower front bar bolt.

Remove the following parts from left side of motorcycle.

18. Loosen, but do not remove, top front engine mounting bolt (20).

19. Remove three remaining engine mounting bolts (21) and lower front bar bolt (22).

20. Disconnect ground wire (2b) from battery terminal, and spark plug cables from spark plugs (26).

21. Disconnect horn wires and remove horn from engine mount bracket. Remove two engine support bracket bolts (30) and free bracket assembly from engine.

22. Disconnect circuit breaker to coil wire (not shown).

23. Remove battery (23), battery carrier (24). and oil tank

24. Remove two top rear engine mounting bolts (32) and regulator ground strap (31).

25. Models 1974 and earlier, remove rear brake foot lever and spring (33). Models 1975 and later, remove gear shift foot lever (33A).

26. Remove left footrest (34) from motorcycle.

27. Remove two lower rear engine mounting bolts, (located directly above rear brake crossover shaft).

28. Remove front top engine mounting bolt (20).

29. Engine is now free to be removed from chassis. Install a spare engine support bracket and with a hoist cen tered directly over engine, attach hook securely to bracket. Lift engine up off the mounting pad. Then, slip engine from left side of chassis, top of engine tipped slightly towards center of chassis.

INSTALLING ENGINE IN CHASSIS (Figures 3-4 and 3-5)

To install an engine assembly into chassis, reverse the stripping procedure in the following order:

Left side of motorcycle:

Steps 29, 27, 24, 23, 28, 19, 18, 25, 24, 22, 21. 23 and 20. Right side of motorcycle:

Steps 15, 13, 16, 14, 12, 9, 8, 8A, 11, 10, 7, 5, 17, 3, 4, 2 and 1.

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