,transcriber's note3 ,italic text is denoted by underscores1 bold text is denoted thus4 ,the original spelling1 punctuation and hyphenation has been retained except for apparent printer's errors which have been silently corrected4 ,see further notes at the end of the book4 ,illustration3 ,cover #a,,tm #i-hgi ,,restricted ,,technical ,,manual ,,war ,,department ,no4 #i-hgi ,washington1 #ah ,october #aidc ,,motorcycle1 ,,solo 7,harley,davidson ,model ,,wla7 ,dissemination of restricted matter4--,the information contained in restricted documents1 and the essential characteristics of restricted materiel1 may be given to any person known to be in the service of the ,united ,states1 and to persons of undoubted loyalty and discretion who are cooperating in ,government work1 but will not be communicated to the public or to the press except by authorized military public relations agencies4 7,see also paragraph #ah;b1 ,,ar #chj-e1 #bh ,september #aidb47 ,,contents ,,part ,,one--,,vehicle ,,operating ,,instructions ,paragraphs ,pages ,,section ,i ,introduction #a-b #c-f ,,ii ,description and tabulated data #c-d #g-h ,,iii ,controls and operation #e-ac #i-ai ,,iv ,first echelon1 preventive maintenance services #ad-ah #bj-bi ,v ,lubrication #ai-bj #cj-cd ,,vi ,tools and equipment stowage on the vehicle #ba-bc #ce-ch ,,part ,,two--,,organizational ,,maintenance ,,section ,,vii ,maintenance allocation #bd-be #ci-dd ,,viii ,second echelon preventive maintenance services #bf #de-ei ,,ix ,organization tools and equipment #bg #fj ,x ,trouble shooting #bh-ch #fa-ga ,,xi ,engine #ci-dd #gb-gg ,,xii ,engine--removal and installation #de-df #gh-hd ,,xiii ,clutch #dg-eb #he-ie ,,xiv ,transmission #ec-eh #if-ajd ,,xv ,chains and sprockets #ei-ff #aje-aad ,,xvi ,fuel system #fg-gd #aae-aba ,,xvii ,intake and exhaust system #ge-ha #abb-abh ,,xviii ,ignition system #hb-hi #abi-ada ,,xix ,generating system #ij-ie #adb-adh ,,xx ,brake system #if-ig #adi-aec ,,xxi ,steering control #ih-aja #aed-aff ,,xxii ,sheet metal and equipment #ajb-aaa #afg-ahj ,,xxiii ,battery1 lighting system1 horn #aab-aah #aha-aij ,,xxiv ,instrument panel #aai-aba #aia-aib ,,xxv ,tires1 wheels1 and hubs #abb-abg #aic-aii ,,references #bjj ,,index #bja ,footnote #a3 ,for supersession of quartermaster manuals1 refer to paragraph #b4 ,,part ,,one--,,operating ,,instructions ,section ,i ,,introduction ,paragraph ,scope #a ,supersession of quartermaster manuals #b #a4 ,,scope4 a4 ,this technical manual#b is published for the information and guidance of the using arm personnel charged with the operation1 maintenance1 and minor repair of this materiel4 b4 ,in addition to a description of the ,harley,davidson motorcycle1 this manual contains technical information required for the identification1 use1 and care of the materiel4 ,the manual is divided into two parts4 ,part ,one1 section ,i through section ,,vi1 gives vehicle operating instructions4 ,part ,two1 section ,,vii through section ,,xxv1 gives vehicle maintenance instructions to using arm personnel charged with the responsibility of doing maintenance work within their jurisdiction4 c4 ,in all cases where the nature of the repair1 modifications1 or adjustment is beyond the scope or facilities of the unit1 the responsible ordnance service should be informed so that trained personnel with suitable tools and equipment may be provided1 or proper instructions issued4 #b4 ,,supersession ,,of ,,quartermaster ,,manuals4 a4 ,this technical manual1 together with ,,tm #i-ahgi1 supersedes and replaces the following ,quartermaster ,corps publications3 7#a7 ,,tm #aj-aage--,maintenance manual1 motorcycle1 solo1 ,harley,davidson 7,model #db-,,wla71 #aa ,september #aida4 7#b7 ,,tm #aj-aagg--,maintenance manual1 motorcycle1 solo1 ,harley,davidson 7,models #aidj-da-db71 #aa ,september #aida4 7#c7 ,,tm #aj-acca--,maintenance manual1 motorcycle1 chain drive ,harley,davidson 7,model #db ,,wla1 solo74 7#d7 ,,tm #aj-acei--;,instruction folder 7#de-;,a7 motorcycles1 solo1 ,harley,davidson 7,model #aida ,,wla #de71 #be ,november #aida4 7#e7 ,,tm #aj-acfa--;,instruction folder 7#de-;,b7 motorcycle1 solo1 ,harley,davidson 7,model #aida ,,wla #de71 #be ,november #aida4 ,illustration3 ,,ra ,,pd #caegjh ,figure #a--,top ,view of ,motorcycle ,illustration3 ,,ra ,,pd #caegji ,figure #b--,left ,side ,view of ,motorcycle ,illustration3 ,,ra ,,pd #caegaj ,figure #c--,right ,side ,view of ,motorcycle ,footnote #b3 ,to provide operating instructions with the materiel1 this technical manual has been published in advance of complete technical review4 ,any errors or omissions will be corrected by changes or1 if extensive1 by an early revision4 ,section ,,ii ,,description ,,and ,,tabulated ,,data ,paragraph ,description #c ,data #d #c4 ,,description 7figs4 #a1 #b1 and #c74 a4 ,this #b;cylinder solo motorcycle is powered by a ,vtype1 aircooled gasoline engine1 operating on conventional #dstroke1 #d;cycle principles4 ,aircooled engines rely upon movement of air over cylinder and head radiating fins1 and upon circulation of oil for dissipation of excessive heat4 ,motorcycle engines1 therefore1 under no conditions should be operated for more than #a minute when motorcycle is not in motion4 #d4 ,,data4 a4 ,vehicle ,specifications4 ,type of engine #b;cylinder1 ,vtype ,lhead1 aircooled ,cylinder bore #b-c_/d in4 ,stroke #c-ac_/af in4 ,engine number 7serial7 left side engine base1 below front cylinder4 ,wheelbase #d ft #aa-a_/b in4 ,length overall #g ft #d in4 ,width overall 7handle bars7 #c ft #e in4 ,wheel size #ah in4 ,tire size #d4jj #ah in4 ,tire type ,drop center ,weight of vehicle 7without rider or armament7 #edj lb4 ,ground clearance 7skid plate7 #d in4 ,kind and grade of fuel ,gasoline3 #gb octane or higher ,high gear ratio #d4ei3a ,engine sprocket #catooth ,countershaft sprocket #agtooth ,rear wheel sprocket #datooth b4 ,performance4 ,maximum allowable speed #fe mph ,miles per gallon 7hard surface7 #ce ,cruising range 7without refill7 #ajj miles ,fording depth 7carburetor7 #ah in4 c4 ,capacities4 ,fuel capacity 7left tank7 #c-c_/h ,u4,s4 gal ,oil tank capacity 7right tank7 #a-a_/h ,u4,s4 gal ,transmission capacity #c_/d pt ,section ,,iii ,,controls ,,and ,,operation ,paragraph ,controls #e ,engine prestarting instructions #f ,starting the engine #g ,stopping the engine #h ,operation of vehicle #i ,driving precautions #aj ,stopping and parking vehicle #aa ,towing vehicle to start engine #ab ,runningin new engine 7or vehicle7 #ac ,illustration3 ,,ra ,,pd #cajbja ,figure #d--;,controls #e4 ,,controls 7fig4 #d74 a4 ,controls are peculiar to the motorcycle4 ,the rider must become thoroughly familiar with the location and use of all control devices before attempting to operate vehicle4 b4 ,gasoline ,valve 7figs4 #e and #f74 ,gasoline valve is located in left tank1 forward4 ,valve is closed by turning to the right1 finger tight4 ,turning to left opens valve4 ,valve is in normal operating position when turned to left1 with valve head down4 ,lifting valve head releases emergency supply of fuel 7#c quarts74 ,illustration3 ,,ra ,,pd #cajbjb ,figure #e--;,fuel ,supply ,valve ,illustration3 ,,ra ,,pd #cajbic ,figure #f--;,fuel ,supply ,valve ,positions c4 ,throttle4 ,the throttle is controlled by right handle bar grip4 ,turning grip inward opens throttle1 turning it outward closes throttle4 d4 ,spark4 ,spark is controlled by left handle bar grip4 ,turning grip inward advances spark1 turning it outward retards spark4 e4 ,clutch 7fig4 #g74 ,clutch is operated by left foot 7rockertype7 pedal1 connecting with steel cable1 which actuates clutch release lever4 ,pedal is located on left side of motorcycle above footboard4 ,forward downward 7toe7 position of pedal engages clutch4 ,rear downward 7heel7 position of pedal disengages clutch4 ,foot pedal provided with friction device to retain it in either engaged or disengaged position4 ,illustration3 ,,ra ,,pd #cajbjd ,figure #g--;,clutch ,pedal ,positions ,illustration3 ,,ra ,,pd #cajbje ,figure #h--;,gear ,shifter ,lever ,positions f4 ,service ,brake 7,rear ,wheel74 ,foot pedal is located on right side of motorcycle at forward end of footboard4 g4 ,auxiliary ,brake 7,front ,wheel74 ,auxiliary brake is operated by hand lever located on left handle bar4 ,it is used in conjunction with service brake1 as an emergency brake1 or for holding vehicle while starting engine on grade4 ,,caution3 ,brake is to be applied lightly and cautiously on wet and slippery roads4 h4 ,gear ,shifter 7fig4 #h74 ,shifter lever is located on left tank1 forward position1 and operates within a guide4 ,shifter lever guide is notched for positive location of gears and each position is identified1 front to rear3 8#a0--low gear2 8,n0--neutral2 8#b0--second gear2 8#c0--;direct high gear4 ,illustration3 ,,ra ,,pd #cajbjf ,figure #i--;,carburetor ,choke ,lever ,positions i4 ,steering ,damper4 ,steering damper is an adjustable friction device to damper turning action of forks1 steady front wheel1 and prevent wobble in rough terrain or at high speeds1 and is located on top of steering head in center of handle bars4 ,move handle to right to apply desired friction4 j4 ,foot ,starter ,crank 7fig4 #a74 ,the foot starter crank is located on right side of motorcycle4 ,gear shifter lever must be in neutral position1 and clutch foot pedal in forward engaged position1 before using foot starter crank4 ,starter crank normally is in upward position4 ,straddle motorcycle1 place right foot on starter crank1 and shift weight of body for forceful downward crank operation to start engine4 k4 ,ignition and ,light ,switch4 ,earlier models are provided with switch lock1 later models are nonlocking4 ,switch is off in straightforward position4 ,first position to right is for engine ignition only4 ,second position to right is for ignition and blackout lights4 ,to use vehicle service lights1 depress button to turn switch to third right position4 l4 ,instrument ,panel ,signal ,lights4 ,instead of an ammeter and oil pressure gage1 signal lights indicate generator charging1 and engine oil pressure4 7#a7 ,green light is located on left side of instrument panel4 ,when engine is running1 and light is out1 it indicates generator is charging4 7#b7 ,red light is located on right side of instrument panel4 ,when engine is running1 and light is out1 it indicates engine oil is circulating4 m4 ,carburetor ,choke 7fig4 #i74 ,choke lever is in full prime position when all the way up1 and in normal running position when all the way down4 #f4 ,,engine ,,prestarting ,,instructions4 a4 ,before the engine is started1 perform the ,beforeoperation ,service outlined in paragraph #ae4 ,special care must be taken during starting and warmingup period to avoid unnecessary engine wear4 b4 ,the rider must acquire correct motorcycle engine starting habits1 and learn to do the job the quickest1 easiest1 and most dependable way4 ,the following pointers will be helpful to the beginner as well as to a seasoned rider3 7#a7 ,mount 7straddle7 motorcycle to obtain firm grip on handle bars4 7#b7 ,leave side stand 7jiffy stand7 outward to support vehicle while operating foot starter crank with right foot4 7#c7 ,engine starting will be benefited by use of front wheel1 handoperated brake1 to prevent vehicle from rolling or shifting during starting kicks4 ,this is especially helpful if vehicle is parked on an incline or on soft1 uneven surface4 c4 ,the procedure outlined below is preparatory to starting either cold1 warm1 or hot engine3 7#a7 ,place gear shifter lever in 8,n0 7neutral7 position 7fig4 #h74 7#b7 ,see that gasoline shutoff valve is open 7fig4 #e74 7#c7 ,engage clutch 7fig4 #g74 7#d7 ,spark control 7left7 grip must be turned inward to fully advanced position1 or nearly so4 7#e7 ,foot starter crank may travel #a_/b way downward before starting engine4 ,see that a full vigorous starter stroke is used4 ,a vigorous kick1 using a full swing 7not a jab7 of right leg and hip1 is correct engine starting practice4 #g4 ,,starting ,,the ,,engine4 a4 ,procedure for starting cold1 warm1 or hot motorcycle engines differs4 ,therefore1 following instructions are used with paragraph #f c to cover correct procedure in all three cases4 b4 ,starting ,cold ,engine4 ,when vehicle has not been operated for some time1 and engine is normally cold1 follow progressive procedure for easiest starting4 7#a7 ,set carburetor choke lever in full upward 7closed7 position4 7#b7 ,open throttle wide by turning right grip inward as far as it will go4 7#c7 ,prime cylinders by operating foot starter crank one or two strokes4 7#d7 ,set carburetor choke lever in #a_/d to #a_/b closed position for mild weather starting3 #c_/d closed 7or leave fully choked7 for extremely cold weather starting4 ,,caution3 ,it is only in extremely cold weather that engine may start best with choke fully closed1 and even then it will have to be moved from this position immediately after engine is started4 7#e7 ,set throttle 7right7 grip to slightly open position4 7#f7 ,turn ignition switch on1 first right position4 7#g7 ,start engine with vigorous strokes of foot starter crank4 7#h7 ,when engine starts1 set throttle for moderate idling speed for warming up1 or until ready to set vehicle in motion4 ,do not race engine unnecessarily4 7#i7 ,after engine warms up1 and misfires due to an overrich mixture1 gradually move choke lever downward4 ,after engine has thoroughly warmed up1 move choke lever to fully open 7downward7 position4 c4 ,starting ,warm ,engine4 ,following instructions apply to engine when halfway between hot and cold4 ,with engine in this condition1 carburetor choking must be handled cautiously4 7#a7 ,lift choke lever to first upward position from normal 7#a_/d closed74 7#b7 ,set throttle 7right7 grip to fully closed 7outward7 position4 7#c7 ,operate foot starter crank one or two strokes4 7#d7 ,set throttle grip to between #a_/d and #a_/c open position4 7#e7 ,turn ignition switch on4 7#f7 ,start engine with vigorous strokes of foot starter crank4 7#g7 ,soon after engine starts1 choke lever must be moved to fully open 7downward7 position4 7#h7 ,turn throttle grip to control idling speed of engine4 d4 ,starting ,hot ,engine4 ,if engine has been shut off for only a brief period and is near normal operating temperature1 it is not necessary to use carburetor choke lever4 ,with some engines1 depending upon carburetor condition and adjustment1 hot starting is easier and more dependable if foot starter crank is operated one stroke before turning ignition switch on4 7#a7 ,close throttle grip by turning fully outward4 7#b7 ,turn ignition switch on4 7#c7 ,operate foot starter crank to start engine4 7#d7 ,when hot engine does not start readily after two or three strokes of the foot starter crank1 it is usually due to an overrich 7flooded7 condition1 and the proper procedure then is to open throttle wide so that more air can enter3 close throttle quickly after engine starts4 ,,caution3 ,after engine has warmed up to a normal operating temperature1 do not allow engine to stand idling for longer than a #a minute interval4 e4 ,starting ,engine with ,dead ,battery4 ,see paragraph #ab4 f4 ,behavior of ,instrument ,panel ,signal ,lights4 ,function of generator 7green7 signal light depends upon action of cutout relay2 engine oil pressure 7red7 signal light depends upon action of oil feed pump4 ,rider must1 therefore1 thoroughly understand operating characteristics of both signal lights to judge condition of generatorbattery circuit and pressure in engine oil circulating system4 7#a7 ,when ignition light switch is turned to first 7right7 position1 preparatory to starting engine1 both green and red signal lights should go on4 ,,caution3 ,when switch is turned on1 immediately after engine has been primed by cranking1 red 7oil pressure7 signal light may not light at once1 but will light after a few seconds1 due to oil pressure built up by cranking1 and is most likely to be noticed in cold weather4 7#b7 ,with engine started and running at medium idling speed1 both signal lights should go off4 ,,caution3 ,should oil pressure 7red7 signal light fail to go off at speeds above idling1 conditions must be brought to attention of unit mechanic4 7#c7 ,at slow idle speed1 or under approximately #bj miles per hour road speed 7in high gear71 generator 7green7 signal light will normally flash on and off1 because at that speed generator voltage output is very low and unsteady4 ,,caution3 ,should generator 7green7 signal light fail to go off at speed above approximately #bj miles per hour1 generator is either not charging at all1 or its current output is not up to normal1 and generator should be given attention at once4 #h4 ,,stopping ,,the ,,engine4 a4 ,stop engine only by turning ignition and light switch to off 7straightahead7 position1 to prevent discharge of battery through spark coil primary circuit4 #i4 ,,operation ,,of ,,vehicle4 a4 ,starting on ,level ,ground4 ,the engine having been warmed up and checked for satisfactory operation1 the vehicle 7with operator in riding position7 is put in motion as follows3 7#a7 ,transfer body weight to right leg4 7#b7 ,fold back side stand 7jiffy stand74 7#c7 ,disengage clutch by depressing clutch foot pedal with heel of left foot4 7#d7 ,shift gear shifter lever into 8#a0 7low7 gear position4 7#e7 ,slowly engage clutch by depressing clutch foot pedal with toe of left foot4 7#f7 ,when clutch starts to 8take hold10 open throttle sufficiently to maintain engine speed4 7#g7 ,accelerate gradually to between #ab and #ae miles per hour in low gear4 7#h7 ,close throttle quickly4 7#i7 ,disengage clutch4 7#aj7 ,shift through 8,n0 7neutral7 position into 8#b0 7second7 gear4 7#aa7 ,reengage clutch and accelerate to about #be miles per hour4 7#ab7 ,close throttle quickly4 7#ac7 ,disengage clutch4 7#ad7 ,shift into 8#c0 7high7 gear4 7#ae7 ,reengage clutch and accelerate to desired speed4 b4 ,starting on ,uneven or ,soft ,ground4 7#a7 ,if standing on an incline or in loose1 heavy ground1 more engine power will be required to start vehicle without stalling engine4 7#b7 ,it may be necessary to keep vehicle from rolling by keeping pressure on front brake hand lever4 ,brake pressure is released after vehicle starts in forward motion4 7#c7 ,open throttle and engage clutch at same time to provide power needed for starting1 without racing engine unnecessarily4 7#d7 ,motorcycle starts should be made without excessive application of power1 with consequent unnecessary spinning of rear wheel4 #aj4 ,,driving ,,precautions4 a4 ,practice will enable a rider to judge at what rate of speed the motorcycle should be moving before he shifts from a lower to higher gear1 and engine should never be permitted to labor unduly1 when a shift of gears1 higher to lower1 would improve operation4 7#a7 ,operator must not look down at gear shifter when shifting gears1 but keep his eyes on the road ahead4 ,do not ride the clutch4 ,the operator's foot should rest on clutch foot pedal only when he is operating it4 ,when shifting gears1 disengage clutch fully to avoid gear damage and shifting difficulties4 ,,caution3 ,many transmissions are ruined through failure to disengage clutch fully when shifting gears4 b4 ,braking4 ,rear wheel service brake must be in such condition that mediumhard application will cause rear wheel to lock4 ,application of service brake should be gradual1 with just enough force to accomplish desired result4 7#a7 ,auxiliary front wheel brake1 when used in conjunction with service brake1 must be applied with caution1 especially on wet1 muddy1 or slippery roads4 7#b7 ,after passing through water1 the brakes should be set slightly1 and the vehicle operated for a short distance1 until sufficient heat has been generated to dry the brakes4 c4 ,avoid ,low ,gear ,operation4 ,always operate vehicle in highest gear possible1 consistent with tactical situation1 speed required1 power required1 and kind and nature of road substance1 to prevent overheating of engine4 d4 ,high ,speed ,tips4 ,only experienced riders should indulge in highspeed riding4 ,a motorcycle operated for long distances at high speed must be given closer than ordinary attention to avoid serious engine overheating with consequent damage4 ,for better motorcycle service1 apply the following suggestions3 7#a7 ,develop habit of frequently snapping throttle shut for an instant when running at high speed4 ,this draws additional lubrication to piston and cylinder and assists in cooling engine4 7#b7 ,in cool weather1 operate engine slowly until it is thoroughly warmed up1 to avoid damage to pistons1 rings1 cylinders1 and other parts before oil is warm enough to circulate freely4 7#c7 ,if handle bar windshield and leg shields are used1 engine is more likely to overheat with continued highspeed riding4 ,watch this carefully4 7#d7 ,adjust 8steering damper0 for best control of motorcycle consistent with riding speed and condition and nature of road4 #aa4 ,,stopping ,,and ,,parking ,,vehicle4 a4 ,stopping ,vehicle4 ,rider will make a 8restart0 easier and quicker if he will apply the following instructions upon stopping vehicle3 7#a7 ,close throttle4 7#b7 ,disengage clutch4 7#c7 ,apply brake 7or brakes7 to slow vehicle without sliding rear tire4 7#d7 ,just before coming to a complete stop1 shift into 8,n0 7neutral7 position and engage clutch4 ,,caution3 ,if immediate restart is to be made1 shift into 8#a0 7low7 gear and allow clutch foot pedal to remain in disengaged position4 7,rider will be mounted on motorcycle with engine running47 7#e7 ,continue brake application to complete stop4 7#f7 ,after vehicle slows to point where it can no longer be balanced by steering1 place left foot on ground to maintain balance until right foot can be removed from brake operating pedal4 ,,caution3 ,do not idle engine longer than #a minute4 7#g7 ,stop engine by turning ignition switch off4 b4 ,parking ,vehicle4 7#a7 ,lean motorcycle on side 7jiffy7 stand4 7#b7 ,shift into 8#a0 7low7 gear4 7#c7 ,engage clutch so vehicle cannot roll4 7#d7 ,shut off gasoline supply by turning valve 7to right7 fingertight against its seat4 #ab4 ,,towing ,,vehicle ,,to ,,start ,,engine4 a4 ,in emergencies when engine cannot be started with foot starter crank1 it can be started by towing the motorcycle4 7#a7 ,set gear shifter lever in 8#b0 7second7 gear position4 7#b7 ,disengage clutch4 7#c7 ,choke carburetor4 7#d7 ,turn ignition switch on4 7#e7 ,after momentum of the towed motorcycle reaches between #aj and #ae miles per hour1 engage clutch1 and continue procedure until engine starts4 b4 ,engine ,starting with ,dead ,battery4 ,emergency engine starting with dead battery can be effected by making use of freshly charged battery1 or by towing as outlined above4 ,if vehicle with dead battery is to be towed for engine starting1 proceed as follows3 7#a7 ,disconnect battery negative wire from ground on right side of motorcycle4 7#b7 ,tow motorcycle for engine starting4 7#c7 ,after engine is started1 reconnect battery ground wire to frame to prevent damage to electrical system4 #ac4 ,,running,,in ,,new ,,engine 7,,or ,,vehicle74 a4 ,a new motorcycle engine or newly overhauled engine must be given proper 8breakin0 consideration for at least the first #a1jjj to #a1bjj miles of service4 ,failure to do this may result in damage that will put engine out of active service within a short period of time4 b4 ,at the first #bej miles1 check front and rear drive chains to make sure they are receiving required amount of oil for ample lubrication4 ,if necessary1 have chain oilers adjusted by unit mechanic4 ,drive chains must be inspected for correct adjustment1 and be given attention by unit mechanic as needed4 c4 ,at first #ejj miles1 drain oil tank and refill with fresh oil4 ,check front and rear chains 7step b above74 ,thereafter1 follow instructions in ,maintenance ,operation section4 d4 ,after a new motorcycle has been run #ejj to #a1jjj miles it needs to be thoroughly checked over and any loose screws and nuts tightened4 ,particular attention must be given engine and transmission mounting bolts and nuts1 and to rear wheel mounting socket screws4 e4 ,following pointers must be observed when runningin new engine or newly overhauled engine3 7#a7 ,do not exceed #cj miles per hour during first #ajj miles4 7#b7 ,do not exceed #ce miles per hour during next #bjj miles4 7#c7 ,do not exceed #dj miles per hour during next #djj miles4 7#d7 ,do not exceed #ej miles per hour during next #ejj miles4 7#e7 ,avoid use of low gears during breakin operation as much as possible4 ,section ,,iv ,,first ,,echelon ,,preventive ,,maintenance ,,services ,paragraph ,purpose #ad ,beforeoperation service #ae ,duringoperation service #af ,athalt service #ag ,afteroperation and weekly service #ah #ad4 ,,purpose4 a4 ,to insure mechanical efficiency it is necessary that the vehicle be systematically inspected at intervals each day it is operated and weekly1 so that defects may be discovered and corrected before they result in serious damage or failure4 ,certain scheduled maintenance services will be performed at these designated intervals4 ,the services set forth in this section are those performed by driver or crew before operation1 during operation1 at halt1 after operation1 and weekly4 b4 ,driver preventive maintenance services are listed on the back of 8,driver's ,trip ,ticket and ,preventive ,maintenance ,service ,record10 ,w4,d4 ,form ,no4 #dh1 to cover vehicles of all types and models4 ,items peculiar to specific vehicles1 but not listed on ,w4,d4 ,form ,no4 #dh1 are covered in manual procedures under the items to which they are related4 ,certain items listed on the form that do not pertain to the vehicle involved are eliminated from the procedures as written into the manual4 ,every organization must thoroughly school each driver in performing the maintenance procedures set forth in manuals1 whether or not they are listed specifically on ,w4,d4 ,form ,no4 #dh4 c4 ,the items listed on ,w4,d4 ,form ,no4 #dh that apply to this vehicle are expanded in this manual to provide specific procedures for accomplishment of the inspections and services4 ,these services are arranged to facilitate inspection and conserve the time of the driver1 and are not necessarily in the same numerical order as shown on ,w4,d4 ,form ,no4 #dh4 ,the item numbers1 however1 are identical with those shown on that form4 d4 ,the general inspection of each item applies also to any supporting member or connection1 and generally includes a check to see whether the item is in good condition1 correctly assembled1 secure1 or excessively worn4 7#a7 ,the inspection for 8good condition0 is usually an external visual inspection to determine whether the unit is damaged beyond safe or serviceable limits4 ,the term 8good condition0 is explained further by the following3 not bent or twisted1 not chafed or burned1 not broken or cracked1 not bare or frayed1 not dented or collapsed1 not torn or cut4 7#b7 ,the inspection of a unit to see that it is 8correctly assembled0 is usually an external visual inspection to see whether it is in its normal assembled position in the vehicle4 7#c7 ,the inspection of a unit to determine if it is 8secure0 is usually an external visual examination1 a handfeel1 or a prybar check for looseness4 ,such an inspection should include any brackets1 lock washers1 lock nuts1 locking wires1 or cotter pins used in assembly4 7#d7 8,excessively worn0 will be understood to mean worn close to1 or beyond1 serviceable limits1 and likely to result in a failure if not replaced before the next scheduled inspection4 e4 ,any defects or unsatisfactory operating characteristics beyond the scope of first echelon to correct must be reported at the earliest opportunity to the designated individual in authority4 #ae4 ,,before,,operation ,,service4 a4 ,this inspection schedule is designed primarily as a check to see that the vehicle has not been tampered with1 or sabotaged since the ,afteroperation ,service was performed4 ,various combat conditions may have rendered the vehicle unsafe for operation and it is the duty of the driver to determine whether or not the vehicle is in condition to carry out any mission to which it is assigned4 ,this operation will not be entirely omitted1 even in extreme tactical situations4 b4 ,procedures4 ,beforeoperation ,service consists of inspecting items listed below according to the procedure described1 and correcting or reporting any deficiencies4 ,upon completion of the service1 results should be reported promptly to the designated individual in authority4 7#a7 ,,item #a1 ,,tampering ,,and ,,damage4 ,look for any injury to vehicle in general1 its accessories or equipment1 that may have been caused by tampering1 sabotage1 collision1 falling debris1 or shell fire since parking vehicle4 ,look for loosened or damaged accessories1 loose fuel or oil lines1 or any disconnected linkage4 7#b7 ,,item #c1 ,,fuel ,,and ,,oil4 ,inspect tanks for fuel and oil levels1 add oil and fuel as necessary4 ,any appreciable change in levels since performing ,afteroperation ,service should be investigated and reported to designated authority4 7#c7 ,,item #d1 ,,accessories ,,and ,,drives4 ,examine all accessories such as carburetor1 air cleaner1 generator1 and cutout relay for loose connections1 loose mountings1 or leaks4 ,examine rear chain 7final drive7 for free upanddown movement 7slack71 midway between sprockets4 ,total upanddown movement must not be more than #a inch1 nor less than #a_/b inch4 ,inspect rear chain for adequate lubrication4 7#d7 ,,item #f1 ,,leaks1 ,,general4 ,examine vehicle and ground under vehicle for indications of fuel or oil leaks4 ,normally a few drops of waste oil from chains may be expected to drop from skid plate4 7#e7 ,,item #aa1 ,,glass4 ,clean glass on instruments2 clean and adjust rear view mirror2 inspect glass for breakage4 7#f7 ,,item #ab1 ,,lamps4 ,if tactical situation permits1 observe whether blackout and service lights operate with switch in its respective positions1 and go out when switched off4 ,also see that lights are secure1 and that lenses are clean and not broken4 ,observe whether both filaments of service headlight operate when dimmer switch on left handle bar is moved to its respective positions4 7#g7 ,,item #ac1 ,,wheels1 ,,axle ,,nuts ,,and ,,screws4 ,examine rear wheel mounting socket screws1 front and rear axle nuts1 and front fork rocker stud nuts for tightness4 ,observe rear chain adjusting screws for secure locking4 ,inspect spokes for good condition and tightness4 7#h7 ,,item #ad1 ,,tires4 ,examine tires for cuts or imbedded objects in treads or carcass4 ,if time permits1 check air pressure1 which should be #ah pounds front1 and #bj pounds rear 7tires cold74 ,inspect valve caps for presence and secure mounting4 7#i7 ,,item #ae1 ,,springs ,,and ,,suspension4 ,examine front fork springs for secure mounting and good condition4 ,push down rear of saddle to test for full action of saddle post spring4 7#aj7 ,,item #af1 ,,steering ,,and ,,handle ,,bar ,,controls4 ,test steering head bearing adjustment by exerting strong upward pull at handle bar grips1 and observing whether or not there is any noticeable play in bearing4 ,operate steering damper lever and observe that damper is compressed before lever reaches rightside position1 and is fully released with lever in leftside position4 ,test handle bar grip controls for full1 free action2 also test for complete opening and closing of throttle1 and full advance and retard of timer4 7#aa7 ,,item #ag1 ,,fenders 7,,mudguards71 ,,luggage ,,carrier1 ,,safety ,,guards1 ,,and ,,stands4 ,examine these items for good condition and secure mounting4 7#ab7 ,,item #ba1 ,,tools ,,and ,,equipment4 ,inspect tools and equipment for presence1 serviceability1 and proper stowage4 7,see tool list in par4 #ba47 7#ac7 ,,item #g1 ,,engine ,,warm,,up4 ,start engine1 noting any tendency toward hard starting1 or improper action of foot starter crank4 ,set throttle to moderate idle speed4 ,listen for unusual noises4 ,watch instrument indications and engine performance1 such as misfiring4 ,,caution3 ,do not idle engine longer than #a minute with vehicle standing4 7#ad7 ,,item #h1 ,,choke4 ,during idling of engine1 reset choke as required to prevent excessive choking and dilution of engine oil4 7#ae7 ,,item #i1 ,,instruments4 ,when switch is turned on and engine is idling at moderate speed both red light 7indicating oil pressure7 and green light 7indicating generator action7 should be out4 ,at lower operating speeds generatorindicating light may flicker4 ,,caution3 ,do not operate engine with red light on 7no oil pressure74 7#af7 ,,item #aj1 ,,horn4 ,tactical situation permitting1 test horn4 7#ag7 ,,item #bb1 ,,engine ,,operation4 ,engine should idle smoothly4 ,accelerate and decelerate1 listening for any unusual noises that may indicate compression or exhaust leaks1 worn1 damaged1 loose1 or inadequately lubricated engine parts1 or accessories4 ,note any unusual smoke from exhaust4 7#ah7 ,,item #bc1 ,,driver',s ,,permit1 ,,accident ,,report ,,form ,,no4 #bf1 ,,and ,,vehicle ,,manual4 ,these items must be present on vehicle and safely stowed4 7#ai7 ,,item #be1 ,,during,,operation ,,service4 ,the ,duringoperation ,service should start immediately after vehicle is put in motion1 in the nature of a road test4 #af4 ,,during,,operation ,,service4 a4 ,while vehicle is in motion1 listen for any sounds such as rattles1 knocks1 squeals1 or hums that may indicate trouble4 ,be alert to detect any odor of overheated components or units such as generator1 brakes1 or clutch1 fuel vapor from a leak in fuel system1 exhaust gas1 or other signs of trouble4 ,any time the brakes are used1 gears shifted1 or vehicle turned1 consider this a test and notice any unsatisfactory or unusual performance4 ,watch the instruments constantly4 ,notice promptly any unusual instrument indication that may signify possible trouble in system to which the instrument applies4 b4 ,procedures4 ,duringoperation ,service consists of observing items listed below according to the procedures following each item1 and investigating any indications of serious trouble4 ,notice minor deficiencies to be corrected or reported at earliest opportunity1 usually at next scheduled halt4 7#a7 ,,item #bg1 ,,foot ,,and ,,hand ,,brakes4 ,the foot brake should operate smoothly and effectively1 leaving reserve pedal travel of #a inch4 ,normal free play before operation is #a inch4 ,test hand brake lever for free play1 which should be #a_/d of total handle travel4 ,test for ease and smoothness of operation4 7#b7 ,,item #bh1 ,,clutch4 ,inspect clutch for disengagement at about #a_/b pedal travel4 ,clutch should not chatter1 squeal1 or slip4 7#c7 ,,item #bi1 ,,transmission4 ,gears should shift smoothly1 operate quietly1 and not jump out of mesh during operation4 ,if transmission jumps out of mesh in any gear1 this indicates need of shifter control adjustment4 7#d7 ,,item #ca1 ,,engine ,,and ,,controls4 ,be alert for deficiency in engine performance such as lack of usual power1 misfiring1 unusual noise1 stalling1 indication of engine overheating1 or unusual exhaust smoke4 ,notice whether engine responds to controls satisfactorily1 whether controls appear to be in proper adjustment and are sufficiently tight4 7#e7 ,,item #cb1 ,,instruments4 ,observe instruments for indication of normal functioning of systems to which they apply4 7a7 ,speedometer and ,odometer4 ,speedometer should indicate vehicle speed without excessive noise or fluctuation4 ,odometer should record trip and total mileage4 7b7 ,oil ,pressure ,signal ,light4 ,red light should be off during operation4 ,if light goes on1 stop vehicle and investigate for oil pressure failure4 7c7 ,generator ,signal ,light4 ,green light should be off above #bj miles per hour4 ,battery discharge is indicated by green light being on4 7#f7 ,,item #cc1 ,,steering4 ,adjust steering damper to desired steering friction4 ,observe vehicle steering for wander1 shimmy1 leading to one side1 or wheel hop4 7#g7 ,,item #cd1 ,,running ,,gear4 ,listen for any unusual noises from wheels1 axles1 or suspension parts that might indicate looseness or damage4 7#h7 ,,item #ce1 ,,chassis4 ,be alert for noises that might indicate loose accessories1 controls1 attachments1 or equipment4 #ag4 ,,at,,halt ,,service4 a4 ,athalt ,service may be regarded as minimum maintenance procedures and should be performed under all tactical conditions1 even though more extensive maintenance services must be slighted or omitted altogether4 b4 ,procedures4 ,athalt ,service consists of investigating any deficiencies noted during operation1 inspecting items listed below according to the procedures following the items1 and correcting any deficiencies found4 ,deficiencies not corrected should be reported promptly to the designated individual in authority4 7#a7 ,,item #ch1 ,,fuel ,,and ,,oil4 ,replenish fuel and oil as may be required to reach next refilling point4 ,,caution3 ,left tank is for fuel2 right tank is for oil4 ,filler caps should not be interchanged1 as only fuel tank cap is vented4 7#b7 ,,item #ci1 ,,temperatures4 ,handfeel wheel hubs and brake drums for overheating4 7#c7 ,,item #dj1 ,,vents4 ,make sure that crankcase breather outlet and rear chain oil feed pipe are clear4 ,make sure grease drains in front and rear brake side covers are open and clean4 7#d7 ,,item #db1 ,,springs ,,and ,,suspensions4 ,look for broken springs in fork4 7#e7 ,,item #dc1 ,,steering4 ,investigate any difficulty developed during riding4 7#f7 ,,item #dd1 ,,wheels ,,and ,,mounting ,,screws4 ,inspect wheels for broken1 bent1 or loose spokes4 ,also1 look for loose axle nuts or rear wheel mounting screws4 ,inspect wheel rims for good condition4 7#g7 ,,item #de1 ,,tires4 ,examine tires for low pressure or damage4 ,remove foreign matter from tire treads2 inspect for cuts4 7#h7 ,,item #df1 ,,leaks1 ,,general4 ,inspect vehicle for indication of fuel1 oil1 or battery leaks4 7#i7 ,,item #dg1 ,,accessories ,,and ,,chain4 ,examine accessories for loose connections1 loose mountings1 or damage4 ,examine rear drive chain for broken rollers1 broken link side plates1 and broken or missing connecting link spring clips4 ,inspect chain for adequate lubrication4 7#aj7 ,,item #dh1 ,,air ,,cleaner4 ,air cleaner must be secure1 with air passages in good condition and clean4 ,when operating under extremely dusty or sandy conditions1 inspect air cleaner frequently and service as required4 7#aa7 ,,item #di1 ,,fenders 7,,mudguards71 ,,luggage ,,carrier1 ,,safety ,,guards1 ,,and ,,stands4 ,inspect these items for looseness or damage4 7#ab7 ,,item #eb1 ,,appearance ,,and ,,glass4 ,clean windshield1 rear view mirror1 and light lenses2 inspect for good condition1 secure attachment1 and broken glass4 #ah4 ,,after,,operation ,,and ,,weekly ,,service4 a4 ,afteroperation ,service is particularly important1 because at this time the driver inspects his vehicle to detect any deficiencies that may have developed1 and corrects those he is permitted to handle4 ,he should report promptly1 to the designated individual in authority1 the results of his inspection4 ,if this schedule is performed thoroughly1 the vehicle should be ready to roll again on a moment's notice4 ,the ,beforeoperation ,service1 with a few exceptions1 is then necessary only to ascertain whether the vehicle is in the same condition in which it was left upon completion of the ,afteroperation ,service4 ,the ,afteroperation ,service should never be entirely omitted1 even in extreme tactical situations1 but may be reduced to the bare fundamental services outlined for the ,athalt ,service1 if necessary4 b4 ,procedures4 ,when performing the ,afteroperation ,service1 the driver must remember and consider any irregularities noticed during the day in the ,beforeoperation4 ,duringoperation1 and ,athalt ,services4 ,the ,afteroperation ,service consists of inspecting and servicing the following items4 ,those items of the ,afteroperation ,services that are marked with an asterisk 7997 require additional ,weekly services1 the procedures for which are indicated in step 7b7 of each applicable item4 7#a7 ,,item #ed1 ,,fuel ,,and ,,oil4 ,fill fuel and oil tanks2 fill oil tank within #a inch of top2 be sure to put oil in right tank and fuel in left tank2 do not interchange caps4 ,,caution3 ,when operating under extremely dusty conditions1 drain engine oil tank and refill with fresh oil as frequently as excessive contamination of the oil occurs4 7#b7 ,,item #ee1 ,,engine ,,operation4 ,test for satisfactory engine idle without stalling4 ,accelerate and decelerate engine1 noting any tendency to miss or backfire1 unusual noises1 or vibration that may indicate worn parts1 loose mounting1 incorrect fuel mixture1 or faulty ignition4 ,investigate any unsatisfactory engine operating characteristics noted during operation4 ,learn to recognize noise caused by loose primary 7front7 drive chain4 ,slack in excess of #a_/b inch total upanddown motion can cause excessive noise which sounds like engine knock4 ,remove inspection cover for examination of chain4 7#c7 ,,item #eg1 ,,horn4 ,if tactical situation permits1 test horn4 7#d7 ,,item #ei1 ,,lights4 ,if tactical situation permits1 observe whether blackout and service lights operate with switch in its respective positions1 and go out when switched off4 ,also see that lights are secure1 and lenses clean and not broken4 ,observe whether both filaments of service headlight operate when dimmer switch on left handle bar is moved to its respective positions4 7#e7 ,,item #ef1 ,,instruments4 ,before stopping engine1 inspect instruments to see that indicator lights are still out4 ,stop engine4 ,after #cj seconds1 turn on switch to see that oil pressure and generator signal lights turn on4 ,,caution3 ,be sure to turn off ignition switch after this test4 7#f7 ,,item #eh1 ,,glass4 ,clean rear view mirror1 windshield1 instrument1 and light glass4 ,examine for secure mounting and breakage4 7#g7 ,,item #fb1 99,,battery4 7a7 ,inspect battery carrier for good condition and secure mounting4 ,inspect electrolyte level 7should be #e_/af inch above plates74 ,inspect for any signs of leakage of electrolyte indicating battery has been overfilled1 poorly sealed1 or damaged4 ,,caution3 ,do not add water unless actually needed4 7b7 ,weekly4 ,clean dirt from top of battery1 remove battery caps1 bring electrolyte level to #e_/af inch above plates1 using clean1 drinkable water4 ,clean terminals or posts if corroded2 be sure felt washers are on terminals and properly oiled2 tighten terminal bolts cautiously1 if loose4 ,clean and paint battery carrier if corroded4 7#h7 ,,item #fc1 99,,accessories ,,and ,,chain4 7a7 ,inspect carburetor1 air cleaner1 generator1 and cutout relay for loose connections1 mountings1 or damage4 ,examine rear drive chain for broken rollers1 broken link side plates1 and broken or missing connecting link spring clips4 ,examine rear chain 7final drive7 for free upanddown movement 7slack7 midway between sprockets2 maximum total allowable deflection is #a inch1 minimum1 #a_/b inch4 7b7 ,weekly4 ,tighten any accessory connections found loose4 ,wipe excess dirt from rear chain4 ,check front chain for adjustment1 and inspect for proper lubrication4 7#i7 ,,item #fe1 99,,air ,,cleaner4 7a7 ,examine oil cup for excessive dirt and correct oil level4 ,if air cleaner is excessively dirty1 clean elements in drycleaning solvent1 refill cup with fresh oil4 ,dip elements in oil in oil cup1 replacing elements and attaching oil cup immediately4 ,if gaskets are damaged1 replace4 ,under extremely dusty or sandy conditions it may be necessary to clean and refill the air cleaner more than once daily4 ,inspect hose for leaks4 7b7 ,weekly4 ,inspect air cleaner for proper oil level and excessively dirty oil4 ,clean and service air cleaner1 tighten mounting and hose clamps4 ,,note3 ,earlytype1 round air cleaner does not have removable filter elements4 ,complete cleaner must be removed to wash element4 7#aj7 ,,item #ff1 99,,fuel ,,filter 7,,gasoline ,,strainer74 7a7 ,clean cap and screen of fuel filter4 7b7 ,weekly4 ,clean cap and screen of fuel filter1 remove carburetor bowl drain plug1 and drain off water and dirt4 ,be sure to replace plug1 being careful to avoid cross threading4 7#aa7 ,,item #fg1 ,,engine ,,controls4 ,examine throttle and spark controls for damage to wires or for disconnected linkage4 ,observe for lack of lubrication4 7#ab7 ,,item #fh1 99,,tires4 7a7 ,remove foreign matter such as nails1 glass1 or stones from tire treads4 ,inspect tires for abnormal tread wear1 cuts1 or bruises3 also for presence and tightness of valve caps4 ,inflate tires to #ah pounds front1 #bj pounds rear1 with tires cool4 7b7 ,weekly4 ,replace badly worn or otherwise unserviceable tires4 7#ac7 ,,item #fi1 99,,springs ,,and ,,suspension4 7a7 ,inspect front fork for broken or sagged springs1 loose bolts1 studs1 and nuts4 7b7 ,weekly4 ,tighten wheel axle nuts and rear brake sleeve nut4 ,also tighten rear wheel mounting socket screws very securely4 7#ad7 ,,item #gj1 ,,steering4 ,inspect steering head for proper adjustment of bearings4 ,examine steering damper for correct adjustment4 7#ae7 ,,item #gb1 99,,vents4 7a7 ,make sure that crankcase breather outlet and rear chain oil supply pipe are clear4 ,make sure grease drains in front and rear brake side covers are open and clean4 7b7 ,weekly4 ,clean crankcase breather outlet1 rear chain oil supply pipe1 and grease drains in front and rear brake side covers4 7#af7 ,,item #gc1 ,,leaks1 ,,general4 ,look around mechanism and beneath vehicle for indication of fuel1 oil1 and grease leaks4 ,examine around brake drums for evidence of grease in drums or on linings4 ,normally a few drops of oil may be expected to drip from skid plate4 7#ag7 ,,item #gd1 ,,gear ,,oil ,,levels4 ,inspect transmission oil level with vehicle standing on rear stand 7not jiffy stand72 refill1 if required1 to level of filler plug opening with engine oil4 ,,caution3 ,do not use gear oil4 7#ah7 ,,item #gf1 ,,fenders 7,,mudguards71 ,,luggage ,,carrier1 ,,safety ,,guards1 ,,and ,,stands4 ,examine these items for good condition and secure mounting4 7#ai7 ,,item #hb1 99,,tighten4 7a7 ,inspect all frame and assembly nuts1 bolts1 and cap screws for tightness4 7b7 ,weekly4 ,tighten all vehicle assembly or mounting nuts4 ,driver is cautioned not to tamper with or tighten screws or nuts about the circuit breaker1 as doing so may disturb ignition timing4 7#bj7 ,,item #hc1 99,,lubricate ,,as ,,needed4 7a7 ,lubricate all parts where inspection reveals need for lubrication3 wipe all dirt from fittings before applying lubricant4 ,report any missing fittings4 7b7 ,weekly4 ,when vehicle has been driven a sufficient number of miles so that it is due for a regularly scheduled lubrication1 lubricate according to ,lubrication ,guide in manual and current lubrication directives4 ,refrain from overlubricating wheel bearings1 front brake side cover bushing1 and front and rear brake operating lever camshafts4 7#ba7 ,,item #hd1 99,,clean ,,engine ,,and ,,vehicle4 7a7 ,clean dirt and trash from vehicle and remove excess grease4 7b7 ,weekly4 ,wash vehicle if possible4 ,if not1 wipe off thoroughly4 ,do not rub lustreless paint enough to cause shine4 ,if vehicle is washed in a stream1 care should be taken that water or dirt does not get into bearings1 breather valve1 or brakes4 ,,caution3 ,it is extremely important that highpressure streams or steam should not be directed against wheel hubs1 brakes1 carburetor1 air cleaner1 or electrical units4 7#ab7 ,,item #fd1 99,,electrical ,,wiring4 7a7 ,inspect all ignition wiring to see that it is securely connected1 clean1 and not damaged4 7b7 ,weekly4 ,inspect all wiring to see that it is securely connected and supported1 that insulation is not cracked or chafed1 that loom1 shielding1 and condensers are in good condition and securely attached4 ,clean as required4 ,tighten any loose connections carefully4 ,radio shielding or bonding defects1 except cleaning or tightening1 must be referred to signal corps personnel4 7#bc7 ,,item #he1 99,,tools ,,and ,,equipment4 7a7 ,see that all tools and equipment assigned to vehicle are present1 in good condition1 and properly stowed4 7b7 ,weekly4 ,check tools and equipment assigned to vehicle with vehicle stowage list 7par4 #ba7 to see that they are present4 ,inspect tools for good condition and proper stowage4 ,report missing or unserviceable items to designated authority4 ,section ,v ,,lubrication ,paragraph ,introduction #ai ,lubrication guide #bj #ai4 ,,introduction4 a4 ,lubrication is an essential part of preventive maintenance1 determining to a great extent serviceability of parts and assemblies4 #bj4 ,,lubrication ,,guide 7fig4 #aj74 a4 ,general4 ,lubrication instructions for this materiel are consolidated in a ,lubrication ,guide 7fig4 #aj74 ,these specify the points to be lubricated1 the periods of lubrication1 and the lubricant to be used4 ,intervals indicated on the guide are for normal service4 ,for extreme conditions1 high speed1 heat1 mud1 snow1 rough roads1 dust1 etc41 change engine oil and lubricate more frequently4 ,in addition to the items on the guide1 brake1 gear shifter1 clutch control linkage1 and hinges must be lubricated at frequent intervals4 b4 ,supplies4 ,in the field it may not be possible to supply a complete assortment of lubricants called for by the ,lubrication ,guide to meet the recommendations4 ,it will be necessary to make the best use of those available1 subject to inspection by the officer concerned1 in consultation with responsible ordnance personnel4 c4 ,lubrication ,notes4 ,the following notes apply to the ,lubrication ,guide 7fig4 #aj74 ,all note references in the guide itself are to the steps below having the corresponding number3 7#a7 ,,brake ,,fittings4 ,exercise caution when lubricating brake operating cams and front brake cover bushing1 as excess grease working out of these bearings is likely to get onto brake lining1 reducing brake efficiency4 ,,caution3 ,when using airoperated grease gun1 make sure not to overlubricate brake fittings4 7#b7 ,,brake ,,hand ,,lever ,,oilcan ,,points4 ,oil hand lever fittings and 8oiler0 mounted on cable housing4 ,oil front brake control cable at ends of control cable housing4 7#c7 ,,generator ,,commutator ,,end ,,bearing4 ,handpack with general purpose grease1 ,no4 #b1 at temperatures above zero4 ,below zero1 use lighter grease4 ,this operation requires removal of generator end cover4 ,bearing outer grease retainer must be loosened and swung aside for access to bearing4 ,if not convenient to grease bearing at specified intervals1 at least lubricate with a few drops of engine oil applied to hole in outer grease retainer4 ,do not overlubricate4 ,,caution3 ,generator regulating brush plate must not be shifted while bearing outer grease retainer is loose 7par4 #ib74 ,generator drive end bearing requires no attention1 since it is lubricated by oil circulating through engine4 ,illustration3 ,,key ------------------------------------- ,,lubricants ,,oe--,,oil1 ,,engine 7,,crankcase ,,grade7 ,,cg--,,grease1 ,,general ,,purpose ,no4 #a 7,,above #cb7 ,no4 #a ,,or ,no4 #j 7#cb ,,to #aj7 ,no4 #j 7,,below #aj7 ,,wb--,,grease1 ,,general ,,purpose 7,no4 #b7 ------------------------------------- -------------------------- ,,intervals #a_/d--bej ,,miles #a_/b--ejj ,,miles #a--ajjj ,,miles #f--fjjj ,,miles 99 ,l--,,special ,,lubrication -------------------------- ,,check ,,daily ----------- ,air ,cleaner ,engine ,oil ,tank -------------------------- ,,table ,,of ,,capacities ,,with ,,recommendations ,,at ,,temperatures ,,shown ---------------------------------------- ---------------------- ,,unit ,,capacity ,,above #cb #cb ,,to #aj ,,below #aj ---------------------------------------- ---------------------- ,,oil ,,tank #a ,,gallon ,,oe ,,oe ,,oe ,s4,a4,e4 #ej ,s4,a4,e4 #cj ,s4,a4,e4 #aj ---------------------------------------- ---------------------- ,,transmission #c_/d pint ,,oe ,,oe ,,oe ,s4,a4,e4 #ej ,s4,a4,e4 #cj ,s4,a4,e4 #aj ---------------------------------------- ---------------------- ,,ra ,,pd #cajbjg ,figure #aj--,lubrication ,guide 7#d7 ,,spark ,,and ,,throttle ,,control ,,grips4 ,these grips require disassembly4 ,twice a year1 or whenever grips do not turn freely1 indicating need of lubrication1 remove grips1 clean parts1 apply grease1 and reassemble 7par4 #aja74 7#e7 ,,air ,,cleaner4 ,examine oil cup daily for excessive dirt and correct oil level4 ,under extremely dusty or sandy conditions it may be necessary to clean and refill the air cleaner more than once daily4 ,refill oil cup to indicated level with engine oil4 ,drain1 clean1 and refill oil cup every #bej miles1 depending upon operating conditions4 ,every #a1jjj miles 7oftener if necessary71 remove air cleaner filter units1 wash in drycleaning solvent1 lubricate1 and reassemble 7par4 #gf74 ,,note3 ,early type round cleaner did not have removable filter element4 ,complete cleaner must be removed to wash element4 7#f7 ,,wheel ,,bearings4 ,when wheel hubs are lubricated at regular #ejjmile interval1 #a_/h ounce of grease with each greasing is sufficient4 ,this amounts to about #ae shots of the standard #apound air gun1 or four strokes with a #apound1 handoperated gun4 ,if vehicle has been operated in water1 wheel hubs submerged1 apply hub greasing service immediately afterward 7or soon as situation permits74 ,do not overlubricate wheel hub bearings1 as excess grease may work into brake linings1 reducing brake efficiency4 ,when using airoperated grease gun1 it is easy to overlubricate wheel hub bearings4 7#g7 ,,steering ,,head ,,bearings4 ,every #ej1jjj miles1 repack upper and lower bearings1 or whenever there is occasion to remove rigid fork for repair or replacement 7par4 #ih74 7#h7 ,,tank1 ,,engine ,,oil4 ,oil tank is located on right side of motorcycle4 ,empty tank holds #a ,u4 ,s4 gallon4 ,check daily and add engine oil as necessary to refill tank within #a inch of top4 ,oil level gage rod 7dip stick7 is located directly below tank cap4 ,when oil level is down to 8,,refill0 mark on gage rod1 #b ,u4 ,s4 quarts may be added4 ,drain oil tank every #a1jjj miles and refill with fresh engine oil4 ,drain plug located on underside of tank in forward position4 ,in extremely dusty service1 and in winter weather1 change oil oftener4 7a7 ,winter ,caution4 ,water is a byproduct of combustion in any internal combustion engine4 ,in a condensed state1 the water vapor formed would equal approximately the quantity of gasoline burned4 ,some of this water vapor escapes past the rings into the crankcase4 ,when starting and warming up in cold weather1 considerable vapor getting into crankcase condenses to water before crankcase is hot enough to exhaust the vapor1 without inside condensation1 through outside breather4 ,if engine is driven enough to get crankcase thoroughly warmed up frequently1 most of this water is again vaporized and blown out through outside breather4 ,however1 a moderately driven engine1 making only short runs now and then1 and seldom thoroughly warmed up1 is likely to accumulate an increasing amount of water in oil tank4 ,this water will1 in freezing weather1 become slush or ice and1 if allowed to accumulate too long1 may block oil lines with resulting damage to engine4 ,also1 water mixed with oil for some time1 forms a heavy sludge of considerable acid content that is very harmful to bearings and other internal engine parts4 ,to sum it up briefly1 an engine that is used only for short runs during freezing weather requires frequent oil changes along with thorough flushing of tank to remove any accumulated sludge4 7#i7 ,,transmission ,,filler ,,opening4 ,check oil level in transmission case every #bej miles and add engine oil as necessary to bring level up to filler opening4 ,if motorcycle is run unusually long distances1 inspect more frequently4 ,motorcycle must be on rear stand in straight upright position when checking oil level or filling transmission case4 ,use same grade of oil used in engine1 summer1 and winter4 ,if gear shifting difficulty is caused by oil congealing in extremely cold weather1 thin oil with small amount of kerosene or drycleaning solvent4 ,every #a1jjj miles1 drain and refill transmission to level of transmission filler plug opening with specified grade of engine oil4 ,transmission holds #c_/d pint of oil4 ,to drain transmission case remove filler plug and lay motorcycle on right side4 ,,caution3 ,do not leave motorcycle on side longer than two minutes4 7#aj7 ,,drive ,,chains4 7a7 ,front and rear drive chains are automatically supplied with lubrication by engine oil pumps4 ,chain oilers are adjustable and may need occasional readjustment to meet lubrication requirements of varied operating conditions4 ,every #a1jjj miles 7or more often if operating conditions are extremely severe7 inspect front primary drive chain for adequate lubrication 7fig4 #cf74 7b7 ,at every #a1jjjmile period rear drive chain should have additional lubrication as follows3 ,remove chain1 wash thoroughly in drycleaning solvent and hang it up to dry4 ,then soak chain in ,,sae #aj engine oil for a short period of time to allow oil to penetrate into all chain bearings4 ,drain chain and wipe off excess oil4 ,install rear chain 7par4 #fc74 7,this attention is not required by front chain47 ,readjustment of chain oilers must be made only by organization mechanic 7par4 #fa74 ,,caution3 ,inspect frequently and make sure that rear chain oiler supply pipe is clear1 not bent or damaged4 d4 ,before ,applying ,lubricant4 ,always wipe dirt from the lubrication fittings or plugs so that dirt will not enter with the lubricant4 ,lubricate all chassis points after washing vehicle or after vehicle has been operated in streams or extremely muddy or slushy roads4 ,,caution3 ,it is extremely important that highpressure cleaning streams or steam should not be directed against ends of wheel hubs1 brake side cover bearings1 air cleaner1 handle bar grips1 or electrical system4 ,to do so will seriously affect correct lubrication and functioning of these parts4 e4 ,oilcan ,points4 ,all brake1 transmission1 and clutch control points not fitted with grease connections should be lubricated with engine oil4 ,front brake control cable1 spark1 and throttle control wires must be oiled at the ends of their respective housings1 especially after washing vehicle1 or after operating it in wet weather4 ,keep battery terminal felt washers saturated with engine oil to prevent corrosion of connections4 f4 ,warning ,light4 ,action of the engine oil feed pump is indicated by red signal light in instrument panel4 ,rider must be thoroughly familiar with operating characteristics of this signal light1 to judge condition of engine oil circulating system 7par4 #g f74 ,section ,,vi ,,tools ,,and ,,equipment ,,stowage ,,on ,,the ,,vehicle ,paragraph ,vehicle tools #ba ,vehicle equipment #bb ,vehicle spare parts #bc ,illustration3 ,,ra ,,pd #cajbjh ,figure #aa--,vehicle ,tools #ba4 ,,vehicle ,,tools 7fig4 #aa74 a4 ,kits4 ,included in the tool kit assembly are the following3 ,legend ,letter for ,number ,mfr's ,federal ,stock ,where ,fig4 #aa ,tool ,carried ,number ,number ,carried ,a ,tool roll #a #aahai-dd -- ,in saddle bag ,b ,irons1 tire #b #aaeea-,x #da-;,i-#ggc-ge ,in tool roll 99,c ,handle1 chain tool #a #aahag-dj #da-;,h-#aeaj-djj ,in tool roll ,d ,wrench1 #e_/h-;in4 by #c_/d-;in4 #a #aahjd-dd;,c -- ,in tool roll ,e ,wrench1 #a_/b-;in4 by #i_/af-;in4 #a #aahjd-dd;,b -- ,in tool roll ,f ,wrench1 #g_/af-;in4 by #a_/b-;in4 #a #aahjd-dd;,a -- ,in tool roll ,g ,wrench1 #e_/af-;in4 by #c_/h-;in4 #a #aahjd-dd -- ,in tool roll ,h ,wrench1 #c_/h-;in4 by #g_/af-;in4 7valve tappet7 #a #aaije-,x -- ,in tool roll ,i ,wrench1 adjustable #a #aahac-dd -- ,in tool roll 99,j ,wrench1 #c_/d-;in4 by #a-c_/d-;in4 7rear axle nut and trans47 #a #aahad-ce #da-,w-#aihi-hej ,in tool roll ,k ,gage1 tire #a #aaefb-dc ---- ,in tool roll 99,l ,tool1 chain repair #a #abjci-ch ---- ,in tool roll 99,m ,washers1 #j4jjb-;in4 thick 7chain oiler adj47 #d #fgd-cb ---- ,in tool roll 99,n ,wrench1 #g_/af-;in4 by #a-c_/h-;in4 7valve cover7 #a #aahjf-ca #da-,w-#cfag ,in tool roll 99,o ,wrench1 #g_/af-;in4 by #a-a_/h-;in4 7use with spark plug socket7 #a #aaibi-ci ---- ,in tool roll 99,p ,pliers1 adjustable #a #aahab-dd ---- ,in tool roll 99,q ,screwdriver #a #aahaa-,x ---- ,in tool roll ,r ,wrench1 #i_/af-;in4 socket 7cyl4 head bolt7 #a #abjdg-cj;,a #da-,w#jaebe ,in tool roll 99,s ,wrench1 wheel mounting #a #aahae-ce #da-,w-#chbe-djj ,in tool roll 99,t ,wrench1 socket 7spark plug2 use with ,o7 #a #aahje-dj #da-,w-#cccb ,in tool roll ,pump1 tire #a #aaeec-da,m #h-,p-#dijj ,on frame1 left side ,grease gun 7in case7 #a #aaffa-ch;,a ---- ,in saddle bag 99,,exception3 ,earlier models furnished with smaller tool roll and kit contain the items marked by asterisk4 #bb4 ,,vehicle ,,equipment 7figs4 #ab and #ac74 a4 ,attached to ,vehicle4 ,number ,where ,item ,carried ,carried ,saddlebags #b ,on luggage carrier ,mirror1 rear view #a ,on left handle bar ,box1 submachine gun ammunition #a ,front fender1 left side ,bracket1 submachine gun carrier #a ,front fender1 right side ,guard1 front safety #a ,attached to frame ,guard1 rear safety #a ,attached to frame ,windshield1 cpt #a ,on handle bar ,leg shields1 cpt 7right and left7 #b ,attached to frame ,illustration3 ,,ra ,,pd #cajbaf ,figure #ab--,vehicle ,equipment1 ,left ,side ,illustration3 ,,ra ,,pd #cajbag ,figure #ac--,vehicle ,equipment1 ,right ,side ,illustration3 ,,ra ,,pd #cajbji ,figure #ad--,vehicle ,spare ,parts #bc4 ,,vehicle ,,spare ,,parts 7fig4 #ad74 #c;a4 ,spare ,parts4 ,number ,where ,item ,carried ,carried ,a ,roll1 parts kit #a ,in saddlebag ,h ,plug1 spark 7and gasket7 #a ,in kit roll ,f ,link1 rear chain repair #a ,in kit roll ,g ,link1 front chain repair #a ,in kit roll ,k ,lampunit1 tail blackout #a ,in kit roll ,j ,lampunit1 stop blackout #a ,in kit roll ,l ,lampunit1 tail and stop #a ,in kit roll ,b ,lamp bulk kit1 head lamps1 #e bulbs #a ,in kit roll ,c ,kit1 tire repair #a ,in kit roll ,i ,tape1 friction #a ,in kit roll ,d ,caps1 tire valve 7#e in box7 #a ,in kit roll ,e ,cores1 tire valve 7#e in box7 #a ,in kit roll ,footnote #c3 ,,exception3 ,no spare parts kit supplied with earlier models4 ,rear chain repair link only spare part furnished4 ,,part ,,two--,,vehicle ,,maintenance ,,instructions ,section ,,vii ,,maintenance ,,allocation ,paragraph ,scope #bd ,allocation of maintenance #be #bd4 ,,scope4 a4 ,the scope of maintenance and repair by the crew and other units of the using arms is determined by the availability of suitable tools1 availability of necessary parts1 capabilities of the mechanics1 time available1 and the tactical situation4 ,all of these are variable and no exact system of procedure can be prescribed4 #be4 ,,allocation ,,of ,,maintenance4 a4 ,indicated below are the maintenance duties for which tools and parts have been provided for the using arm and maintenance personnel4 ,replacements and repairs which are the responsibility of ordnance maintenance personnel may be performed by using arm personnel when circumstances permit1 within the discretion of the commander concerned4 ,echelons and words as used in this list of maintenance allocations are defined as follows3 ,,first ,,and ,,operating ,,organization ,,driver1 ,,operator ,,second ,,echelon3 or crew1 companies and detachments1 ,table ,,iii battalions1 squadrons1 regiments1 and ,,ar #hej-ae separate companies and detachments 7first and second echelons1 respectively74 ,,third ,,echelon3 ,technical light and medium maintenance ,table ,,iii units1 including post and port shops4 ,,ar #hej-ae ,,fourth ,,echelon3 ,technical heavy maintenance and field ,table ,,iii depot units including designated post ,,ar #hej-ae and service command shops4 ,,fifth ,,echelon3 ,technical base units4 ,table ,,iii ,,ar #hej-ae ,,service3 ,checking and replenishing fuel1 oil1 7,including preventive grease1 water and antifreeze1 air1 and maintenance7 par4 #bd a battery liquid2 checking and tightening 7#b7 and 7#c7 in part nuts and bolts2 cleaning4 ,,ar #hej-ae ,,replace3 ,to remove an unserviceable part1 assembly1 ,par4 #bd a 7#e7 or subassembly from a vehicle and ,,ar #hej-ae replace it with a serviceable one4 ,,repair3 ,to restore to a serviceable condition1 ,par4 #bd a 7#f7 in part such parts1 assemblies or subassemblies ,,ar #hej-ae as can be accomplished without completely disassembling the assembly or subassembly1 and where heavy riveting1 or precision machining1 fitting1 balancing1 or alining is not required4 ,,rebuild3 ,consists of stripping and completely ,par4 #bd a 7#f7 reconditioning and replacing in serviceable ,,ar #hej-ae condition any vehicle or unserviceable part1 subassembly1 or assembly of the vehicle1 including welding1 riveting1 machining1 fitting1 alining1 balancing1 assembling1 and testing4 ,,reclamation3 ,salvage of serviceable or economically ,,ar #hej-ae repairable units and parts removed from ,par4 #d 7c7 in part ,,cir4 vehicles1 and their return to stock4 ,this #ge1 dated #af ,march '#dc includes the process which recovers and_/or reclaims unusable articles or component parts thereof and places them in a serviceable condition4 ,,notes3 7#a7 ,operations allocated will normally be performed in the echelon indicated by ,x4 7#b7 ,operations allocated to the third echelon as indicated by ,e may be performed by these units in emergencies only4 7#c7 ,operations allocated to the fourth echelon by ,e are normally fifth echelon operations4 ,they will not be performed by the fourth echelon1 unless the unit is expressly authorized to do so by the chief of the service concerned4 ,,echelons ,,clutch #bnd #crd #dth #eth ,bearings1 clutch release--replace ,x ,clutch--replace and_/or repair 7reline7 ,x ,hub1 clutch--replace ,x ,hub1 clutch--repair ,x ,sprocket assembly1 clutch--replace ,x ,sprocket assembly1 clutch--repair ,x ,,controls ,,and ,,linkage ,controls and linkage--service and_/or replace ,x ,controls and linkage--repair ,x ,,electrical ,,group ,battery--service 7recharge7 and_/or replace ,x ,battery--repair ,x ,battery--rebuild ,e ,x ,cables1 battery--replace and_/or repair ,x ,coil1 ignition--replace ,x ,head1 speedometer--replace ,x ,head1 speedometer--repair ,x ,head1 speedometer--rebuild ,x ,horn assembly--replace ,x ,horn assembly--repair ,x ,light assemblies--service and_/or replace ,x ,light assemblies--repair ,x ,panel1 instrument--replace ,x ,panel1 instrument--repair ,x ,switch assemblies--replace ,x ,switch assemblies--repair ,x ,wiring--replace ,x ,,engine 7,v-#de-,twin ,engine7 ,bearings1 main--replace ,e ,x ,bearings1 connecting rod--replace ,e ,x ,breaker assembly1 circuit--replace ,x ,breaker assembly1 circuit--repair ,x ,breaker assembly1 circuit--rebuild ,x ,carburetor--replace ,x ,carburetor--repair ,x ,carburetor--rebuild ,x ,cleaner1 air--service and_/or replace ,x ,cleaner1 air--repair ,x ,cleaner1 air--rebuild ,x ,cylinder assembly--replace ,x ,cylinder assembly--repair ,x ,cylinder assembly--rebuild 7recondition7 ,e ,x ,condenser--replace ,x ,engine assembly--replace 99#d ,x ,engine assembly--repair ,x ,engine assembly--rebuild ,e ,x ,gasket1 cylinder head--replace ,x ,gears1 timing--replace ,e ,x ,generator assembly--replace ,x ,generator assembly--repair ,x ,generator assembly--rebuild ,x ,head1 cylinder--replace and_/or repair ,x ,lines and connections--replace ,x ,lines and connections--repair ,x ,pistons1 rings and pins assembly--replace ,e ,e ,x ,plug1 spark--replace ,x ,points1 circuit breaker--service and_/or replace ,x ,pump assembly1 feed--replace ,x ,pump assembly1 feed--repair ,x ,pump assembly1 feed--rebuild ,x ,pump assembly1 oil--replace ,x ,pump assembly1 oil--repair ,x ,pump assembly1 oil--rebuild ,x ,pump assembly1 oil scavenger--replace and_/or repair ,x ,pump assembly1 oil scavenger--rebuild ,x ,rod1 connecting--replace and_/or rebuild 7recondition7 ,x ,x ,sprocket1 engine--replace ,x ,strained gasoline--replace and_/or repair ,x ,valves--service ,x ,,exhaust ,,group ,muffler and exhaust pipe--replace ,x ,muffler and exhaust pipe--repair ,x ,,miscellaneous ,bars1 safety--replace ,x ,bars1 safety--repair ,x ,boxes1 ammunition1 battery and tool--replace ,x ,boxes1 ammunition1 battery and tool--repair ,x ,carriers1 luggage and scabbard--replace ,x ,carriers1 luggage and scabbard--repair ,x ,frame--replace and_/or rebuild ,e ,x ,guards1 mud--replace ,x ,guards1 mud--repair ,x ,plate1 skid--replace ,x ,plate1 skid--repair ,x ,saddle--replace ,x ,saddle--repair ,x ,saddle--rebuild ,x ,springs1 saddle post--replace ,x ,tank1 fuel--replace ,x ,tank1 fuel--repair ,x ,tank1 oil--replace ,x ,tank1 oil--repair ,x ,,suspension 7,,front7 ,bars1 handle--replace ,x ,bars1 handle--repair ,x ,damper1 steering--replace ,x ,drum1 brake--replace ,x ,fork1 front assembly--replace ,x ,fork1 front assembly--repair ,x ,fork1 front assembly--rebuild ,x ,fork1 spring--replace ,x ,fork1 spring--repair ,x ,fork1 spring--rebuild ,x ,plate1 rocker--replace ,x ,plate1 rocker--repair ,x ,shoe assembly1 brake--service and_/or replace ,x ,shoe assembly1 brake--repair 7reline7 ,x ,springs1 cushion and rebound--replace ,x ,,suspension 7,,rear7 ,chains1 all--replace and_/or repair ,x ,drum1 brake1 rear--replace ,x ,guards1 chains--replace ,x ,guards1 chains--repair ,x ,shoe assemblies1 brake--service and_/or replace ,x ,shoe assemblies1 brake--repair 7reline7 ,x ,sprocket1 rear--replace ,x ,wheels--replace ,x ,wheels--repair ,x ,wheels--rebuild ,e ,x ,,tires ,casings and tubes--replace ,x ,casings--repair ,e ,x ,tubes1 inner--repair ,x ,,transmission ,spring1 kick starter--replace ,x ,sprocket1 transmission countershaft--replace ,x ,starter1 kick--replace ,x ,starter1 kick--repair ,x ,transmission--replace 99#d ,x ,transmission--repair ,x ,transmission--rebuild ,e ,x ,,vehicle ,,assembly ,motorcycle--service ,x ,motorcycle--rebuild 7with serviceable unit assemblies7 ,x ,e ,footnote #d3 ,the second echelon is authorized to remove and reinstall items marked by an asterisk4 ,however1 when it is necessary to replace an item marked by an asterisk with a new or rebuilt part1 subassembly or unit assembly1 the assembly marked by an asterisk may be removed from the vehicle by the second echelon only after authority has been obtained from a higher echelon of maintenance4 ,section ,,viii ,,second ,,echelon ,,preventive ,,maintenance ,paragraph ,second echelon preventive maintenance services #bf #bf4 ,,second ,,echelon ,,preventive ,,maintenance ,,services4 a4 ,regular scheduled maintenance inspections and services are a preventive maintenance function of the using arms1 and are the responsibility of commanders of operating organizations4 7#a7 ,,frequency4 ,the frequencies of the preventive maintenance services outlined herein are considered a minimum requirement for normal operation of vehicles4 ,under unusual operating conditions such as extreme temperatures1 and dusty or sandy terrain1 it may be necessary to perform certain maintenance services more frequently4 7#b7 ,,first ,,echelon ,,participation4 ,the drivers should accompany their vehicles and assist the mechanics while periodic second echelon preventive maintenance services are performed4 ,ordinarily the driver should present the vehicle for a scheduled preventive maintenance service in a reasonably clean condition2 that is1 it should be dry1 and not caked with mud or grease to such an extent that inspection and servicing will be seriously hampered4 ,however1 the vehicle should not be washed or wiped thoroughly clean1 since certain types of defects1 such as cracks1 leaks1 and loose or shifted parts or assemblies are more evident if the surfaces are slightly soiled or dusty4 7#c7 ,if instructions other than those contained in the general procedures in paragraph 7#d7 or the specific procedures in paragraph 7#e7 which follow1 are required for the correct performance of a preventive maintenance service1 or for correction of a deficiency1 other sections of the vehicle operator's manual pertaining to the item involved1 or a designated individual in authority1 should be consulted4 7#d7 ,,general ,,procedures4 ,these general procedures are basic instructions which are to be followed when performing the services on the items listed in the specific procedures4 ,the second echelon personnel must be thoroughly trained in these procedures so that they will apply them automatically4 7a7 ,when new or overhauled subassemblies are installed to correct deficiencies1 care should be taken to see that they are clean1 correctly installed1 properly lubricated1 and adjusted4 7b7 ,when installing new lubricant retainer seals1 a coating of the lubricant should be wiped over the sealing surface of the lip of the seal4 7c7 ,the general inspection of each item applies also to any supporting member or connection1 and usually includes a check to see whether the item is in good condition1 correctly assembled1 secure1 or excessively worn4 ,the mechanics must be thoroughly trained in the following explanations of these terms3 #a4 ,the inspection for 8good condition0 is usually an external visual inspection to determine whether or not the unit is damaged beyond safe or serviceable limits4 ,the term 8good condition0 is explained further by the following3 not bent or twisted1 not chafed or burned1 not broken or cracked1 not bare or frayed1 not dented or collapsed1 not torn or cut4 #b4 ,the inspection of a unit to see that it is 8correctly assembled0 is usually an external visual inspection to see whether or not it is in its normal assembled position in the vehicle4 #c4 ,the inspection of a unit to determine if it is 8secure0 is usually an external visual examination1 a handfeel1 or a prybar check for looseness2 such an inspection should include any brackets1 lock washers1 lock nuts1 locking wires1 or cotter pins used in assembly4 #d4 8,excessively worn0 will be understood to mean worn1 close to or beyond serviceable limits1 and likely to result in a failure if not replaced before the next scheduled inspection4 7d7 ,special ,services4 ,these are indicated by repeating the item numbers in the columns which show the interval at which the services are to be performed1 and show that the parts1 or assemblies1 are to receive certain mandatory services4 ,for example1 an item number in one or both columns opposite a ,tighten procedure1 means that the actual tightening of the object must be performed4 ,the special services include3 #a4 ,adjust4 ,make all necessary adjustments in accordance with the pertinent section of the vehicle operator's manual1 special bulletins1 or other current directives4 #b4 ,clean4 ,clean units of the vehicle with drycleaning solvent to remove excess lubricant1 dirt1 and other foreign material4 ,after the parts are cleaned1 rinse them in clean drycleaning solvent1 and dry them thoroughly4 ,take care to keep the parts clean until reassembled1 and be certain to keep drycleaning solvent away from rubber or other material which it will damage4 ,clean the protective grease coating from new parts1 since this material is not a good lubricant4 #c4 ,special lubrication4 ,this applies both to lubrication operations that do not appear on the vehicle ,lubrication ,guide1 and to items that do appear on such guides1 but should be performed in connection with the maintenance operations1 if parts have to be disassembled for inspection or service4 #d4 ,serve4 ,this usually consists of performing special operations1 such as replenishing battery water1 and draining and refilling units with oil4 #e4 ,tighten4 ,all tightening operations should be performed with sufficient wrenchtorque 7force on the wrench handle7 to tighten the nut according to good mechanical practice4 ,use torqueindicating wrench where specified4 ,do not overtighten1 as this may strip threads1 or cause distortion4 ,tightening will always be understood to include the correct installation of lock washers1 lock nuts1 and cotter pins provided to secure the tightening4 7e7 ,when conditions make it difficult to perform the complete preventive maintenance procedures at one time1 these can sometimes be handled in sections1 planning to complete all operations within the task if possible4 ,all available time at halts and in bivouac areas must be utilized1 if necessary1 to assure that maintenance operations are completed4 ,when limited by the tactical situation1 items with special services in the columns should be given first consideration4 7f7 ,the numbers of the preventive maintenance procedures that follow are identical with those outlined on ,w4,d4 ,,ago ,form ,no4 #dfc1 which is the ,preventive ,maintenance ,service ,work ,sheet for ,motorcycles4 ,certain items on the work sheet that do not apply to this vehicle are not included in the procedures in this manual4 ,in general1 the numerical sequence of items on the work sheet is followed in the manual procedures1 but in some instances there is deviation for conservation of the mechanic's time and effort4 7#e7 ,,specific ,,procedures4 ,the procedures for performing each item in the #a1jjjmile maintenance procedures are described in the following chart4 ,each page of the chart has a column at its left edge corresponding to the #a1jjjmile maintenance4 ,,road ,,test ,sidenote3 #ajjj ,mile ,maintenance ,,note3 ,if tactical situation does not permit a full road test1 perform items #b1 #c1 #d1 #e1 #f1 #g1 #h1 #i1 #ab1 and #ad1 which require slight or no movement of the vehicle4 ,when a road test is possible1 it should be for preferably #e1 and not over #aj miles4 ,sidenote3 #a ,beforeoperation ,inspection4 ,perform ,beforeoperation ,service listed on ,w4,d4 ,form ,no4 #dah4 8,driver's ,trip ,ticket and ,preventive ,maintenance ,service ,record0 7described in par4 #ae71 to determine if vehicle is in a satisfactory condition to make the road test safely4 ,sidenote3 #b ,ease of ,starting4 ,start engine and observe action of starter4 ,note if engine responds readily4 ,sidenote3 #c ,oil ,circulation4 ,oil circulation is normally indicated by oil signal light 7red light7 in instrument panel being out4 ,when red light is on1 oil is not circulating4 ,observe for excess smoke in exhaust4 ,,caution3 ,if red light fails to go out after engine has been started1 stop engine at once4 ,refer to paragraph #cj for possible causes4 ,sidenote3 #d ,instruments4 ,observe instruments for proper or normal indication and functioning of system to which they apply4 ,,speedometer ,,and ,,odometer4 ,speedometer must indicate vehicle speed without excessive noise or fluctuation2 odometer must record trip and total mileage4 ,,oil ,,pressure ,,signal ,,light4 ,note whether oil signal light 7red light7 indicates correctly4 ,after ignition switch is turned on1 and before starting engine1 the red light should go on1 indicating no oil circulation4 ,when engine is started1 light should go out4 ,,generator ,,signal ,,light4 ,with switch on1 and before starting engine1 the green signal light should go on1 indicating discharge of battery4 ,after starting engine1 increase engine speed to a medium fast idle2 green signal light should then go out1 indicating generator is charging battery4 ,,caution3 ,continue observation of signal lights during road test1 and if lights should fail to operate as indicated above1 stop engine1 investigate cause1 and correct or report trouble to proper authority4 ,sidenote3 #e ,brake ,operation4 ,test foot brake for safe stop within reasonable distance4 ,note squeaks or chatter that might indicate wet1 oily1 dirty1 or loose lining1 damaged drum1 or improper adjustment4 ,apply handoperated front brake only in conjunction with rear brake and observe whether it operates effectively in assisting to make a quicker stop4 ,sidenote3 #f ,clutch ,operation4 ,before moving vehicle1 make sure that clutch pedal has satisfactory free travel before it begins to disengage clutch2 that it releases clutch completely before reaching end of travel2 and that there are no unusual noises in clutchrelease mechanism4 ,when starting vehicle1 observe whether clutch grabs1 chatters1 or slips when fully engaged4 ,sidenote3 #g ,gearshift4 ,shift through entire gear range of transmission and observe whether mechanism operates freely without clashing or jumping out of gear4 ,note any unusual vibration that might indicate loose engine or transmission mountings4 ,sidenote3 #h ,unusual ,noises4 ,during entire road test1 listen for unusual noises that might indicate worn1 loose1 damaged1 or insufficiently lubricated parts in the entire motorcycle1 particularly in engine and accessories1 or in the power train4 ,,caution3 ,loose primary 7front7 drive chain1 with slack in excess of #a_/b inch total upanddown motion1 can cause excessive noise which sounds like engine knock4 ,remove inspection cover for examination of chain4 ,sidenote3 #i ,steering4 ,observe steering mechanism for indication of looseness or excessive binding through full turning range4 ,with hands resting lightly on handle bars and vehicle in vertical position1 observe whether there is any tendency to pull to one side when operating at a reasonable speed4 ,note any indication of steering instability at higher speeds4 ,sidenote3 #aj ,balance4 ,if vehicle does not balance properly in operation1 inspect for misalinement of rear wheel4 ,sidenote3 #aa ,speedometer and ,odometer4 ,inspect speedometer for proper operation1 excessive fluctuation1 or unusual noise4 ,observe odometer for correct recording of trip and total mileage4 ,sidenote3 #ab ,throttle and ,spark ,controls4 ,set throttle stop screw and low speed needle adjustment so that engine will operate smoothly and will not stall at idling speed4 ,with vehicle running at a speed of #cj miles per hour1 or faster1 in high gear1 turn throttle control grip to 8,,open0 and 8,,closed0 positions and note whether engine responds instantly to throttle changes4 ,turn spark control grip and note whether it fully advances and retards ignition timer4 ,sidenote3 #ac ,power and ,operation4 ,observe engine for normal pulling power1 and good operating characteristics in each speed1 from first to high gear4 ,also observe whether engine misses1 stalls1 knocks excessively1 or makes any other unusual noise4 ,sidenote3 #ad ,carburetor ,adjustment4 ,no carburetor adjustment1 other than idle adjustment as performed in item #ab1 is required on this vehicle4 ,sidenote3 #ae ,brake ,drum and ,hub ,temperature4 ,immediately after completing road test1 feel front and rear brake drums and wheel hubs for overheating4 ,sidenote3 #af ,power ,train ,temperatures4 ,feel transmission for overheating4 ,,maintenance ,,operation ,sidenote3 #ag ,compression ,test4 ,with throttle wideopen1 test compression with starter4 ,if engine lacks compression1 inspect for leaks4 ,sidenote3 #ah ,transmission4 ,inspect transmission for good condition1 secure mounting1 and leaks4 ,inspect oil level4 ,drain and refill transmission to level of transmission filler plug opening with specified grade of engine oil4 ,,caution3 ,always drain transmission immediately after it has been warmed and agitated by operation of engine4 ,refill as soon as draining is completed to avoid hazard of operating without lubricant4 ,tighten all mounting and assembly bolts securely4 ,sidenote3 #bj ,engine ,oil4 ,inspect oil tank for oil level3 drain and refill tank4 ,,caution3 ,fill to within #a inch of filler opening and filler cap with specified weight of oil4 ,always drain immediately after engine operation and refill as soon as draining is completed1 to avoid hazard of operating without lubricant4 ,sidenote3 #ba ,battery and ,carrier4 ,clean top of battery4 ,see that battery and carrier are in good condition1 and that carrier is securely mounted4 ,remove cell caps3 make sure that vents are open4 ,test specific gravity with hydrometer and record readings on work sheet1 ,w4,d4 ,,ago ,form ,no4 #dfc4 ,readings below #a4bbe indicate need for recharge1 or battery failure4 ,variation between cells of more then #j4jbe must be reported4 ,read and record voltage of battery 7#fvolt reading is normal74 ,bring electrolyte to #e_/af inch above tops of plates1 using clean1 drinkable water4 ,if excessive looseness of battery in case is noted1 check for presence of rubber pad in bottom of case1 and make sure rubber pad is installed on top of battery1 when battery service is completed4 ,sidenote3 #bb ,battery ,wires and ,terminals4 ,inspect battery for good condition and secure connections4 ,look for worn spots in wire insulation4 ,oil the felt washers on battery terminals4 ,sidenote3 #bc ,electrical ,wiring4 ,inspect all electric wiring to see that it is in good condition1 securely attached1 and connected4 ,look for worn spots in insulation4 ,sidenote3 #bd ,generator ,drive and ,mounting1 and ,relay4 ,inspect generator for secure mounting4 ,after removing left footboard assembly1 remove generator and cover4 ,examine commutator for cleanliness1 good condition1 or excessive wear4 ,if commutator is dirty1 it must be cleaned with ,no4 #jj sandpaper4 ,blow out with compressed air4 ,if commutator is in bad condition or excessively worn1 replace generator4 ,remove relay cover1 being careful to avoid damage to mechanism1 and inspect for cleanliness4 ,blow out with air if wet or dirty4 ,,caution3 ,do not attempt to adjust relay1 or to clean it in any other manner4 ,sidenote3 #be ,timer 7,circuit ,breaker74 ,clean and remove timer cover4 ,see that wiring leads are securely connected and that inside of the timer is clean4 ,inspect breaker points to see that they are clean1 welllined1 engaging squarely1 and are not excessively pitted1 burned1 or worn4 ,see that condenser mounting screw is tight4 ,breaker lever should be free on its pivot and well insulated from the pivot pin4 ,determine if breaker arm spring exerts normal force against arm4 ,examine camshaft by handfeel to see whether it is excessively worn in its bushings2 if camshaft bushings are worn excessively1 install new timer4 ,if points are slightly burned or pitted1 dress them with a fine file4 ,if breaker points are unserviceable1 install a new set1 taking care to aline them and to adjust gap to #j4jbb inch4 ,apply one drop of oil to breaker arm pivot pin4 ,use clean cloth to wipe cam and then coat with a very light film of light grease4 ,,caution3 ,be careful to avoid getting oil or grease on breaker points4 ,sidenote3 #bf ,spark ,plugs4 ,remove spark plugs1 clean with sandblast cleaner1 and inspect for cracked insulators3 inspect electrodes for good condition and adjust gap to #j4jbe to #j4jcj inch2 replace faulty plugs4 ,be sure to install new gasket with new plug4 ,inspect radio suppressors on plug cables for good condition and secure attachment4 ,sidenote3 #bg ,ignition and ,light ,switch4 ,make sure that the switch is in good condition and operating properly in all positions4 ,sidenote3 #bh ,lights1 ,service and ,blackout4 ,see that all lights are clean1 in good condition1 properly aimed1 and securely mounted4 ,tactical situation permitting1 turn switch to each of its positions and observe whether service and blackout lights operate properly1 and whether they go out when switched off4 ,operate dimmer switch on left handle bar to see whether it depresses beam of service headlight4 ,apply foot brake for check of both blackout and service stop light operation4 ,inspect lenses for breakage1 and headlight reflector for discoloration4 ,clean all lenses4 ,sidenote3 #bi ,horn4 ,tactical situation permitting1 sound horn to test for normal signal4 ,examine horn for good condition1 secure mounting1 and tight wiring connections4 ,sidenote3 #cj ,cylinder ,heads4 ,if cylinder head gaskets show signs of leakage1 tighten head bolts3 if leakage persists1 new gaskets should be installed4 ,a head bolt wrench 7,fed,stock ,no4 #da-,w-#aebe7 is available with which head bolts can be tightened without removing tanks for wrench clearance4 ,if tanks are removed to permit taking off heads and installing new gaskets1 bolts should then be tightened evenly with a torque wrench to a tension of #fj footpounds minimum1 or #fe footpounds maximum1 when engine is cold4 ,sidenote3 #ca ,cylinder ,holddown ,nuts4 ,if these nuts are loose1 or there is excessive oil leakage around cylinder bases1 tighten nuts evenly when engine is cold4 ,if excessive leakage persists1 new gaskets should be installed4 ,,caution3 ,if cylinder base nuts are loose1 perform item #cf before starting engine4 ,sidenote3 #cb ,engine ,mountings4 ,inspect top engine mounting bracket and bolt for good condition and security4 ,,caution3 ,tight seating of the engine bracket mounting bolt is a necessity for effective radio bonding4 ,inspect four lower engine mounting bolts for signs of looseness4 ,tighten as required4 ,sidenote3 #cc ,engine ,crankcase4 ,examine engine crankcase for good condition and for leaks4 ,make sure timing gear cover screws1 and oil feed and scavenger pump nuts1 are tight4 ,sidenote3 #cd ,intake ,manifold4 ,examine manifold for good condition and secure mounting4 ,make sure manifold nuts are tight4 ,sidenote3 #ce ,muffler and ,exhaust ,pipes4 ,inspect muffler and exhaust pipes for good condition1 secure mounting1 and for leaks4 ,be sure tail pipe opening is not restricted4 ,sidenote3 #cf ,valve ,mechanism4 ,when engine is cold1 adjust valve tappet clearance to #j4jjd-;inch minimum1 #j4jje-;inch maximum on intake valve2 #j4jjf-;inch minimum1 #j4jjg-;inch maximum on exhaust valve4 ,see that valve springs are in good condition and properly secured2 that valve tappet adjusting screws and lock nuts are in good condition2 and that valve covers are in good condition1 secure1 and not leaking oil4 ,sidenote3 #cg ,starter4 ,examine pedal1 crank1 and return spring for good condition1 correct assembly1 and secure mounting4 ,starter should operate without binding1 and return spring should bring starter crank to its disengaged position when foot pressure is removed4 ,,caution3 ,make sure that starter crank pinch bolt is installed with head of bolt toward rear of vehicle when crank is in upright position4 ,sidenote3 #ch ,engine ,cooling ,fins4 ,inspect engine cooling fins for good condition and cleanliness4 ,remove all dirt or foreign matter4 ,do not apply paint to cooling fins4 ,sidenote3 #ci ,filler ,caps and ,vents4 ,wipe dirt and dust from filler caps of fuel and oil tanks4 ,inspect caps and gaskets to see that they are in good condition4 ,note whether vent in fuel filler cap is open4 ,reinstall caps1 observing that each locks properly on filler neck4 ,do not interchange fuel and oil tank filler caps4 ,sidenote3 #dj ,fuel ,tank ,valves and ,lines4 ,see that valves and lines are in good condition1 secure1 and not leaking4 ,test fuel shutoff valve for ample friction to hold valve in reserve position4 ,see that valve lifts freely enough to operate satisfactorily4 ,sidenote3 #da ,oil ,system ,leaks4 ,examine oil tank1 oil lines1 vent line1 and connections for good condition1 secure attachment1 and for leaks4 ,sidenote3 #db ,carburetor and ,fuel ,filter 7,gasoline ,strainer74 ,examine carburetor and fuel filter for good condition1 secure connections1 and for leaks4 ,shut off fuel tank valve and remove filter 7strainer7 cap and screen4 ,wash cap and screen in drycleaning solvent1 and open shutoff valve slightly to flush filter body4 ,reassemble screen1 gaskets1 and cap1 being careful not to damage gaskets4 ,use new gaskets if necessary4 ,drain water and foreign matter from carburetor bowl by removing bowl drain plug4 ,open shutoff valve slightly to flush carburetor bowl while plug is out4 ,replace plug1 being careful to avoid crossing threads4 ,open fuel tank shutoff valve and check for leaks4 ,sidenote3 #dc ,air ,cleaner4 ,remove oil cup2 inspect condition of oil1 and amount of sediment4 ,if service is required1 remove filter elements1 clean and fill cup to ,,normal level4 ,wash elements in drycleaning solvent1 dry thoroughly with compressed air1 immerse each element in oil in cup1 and reassemble elements and oil cup to air cleaner body immediately4 ,make sure gaskets are in good condition4 ,,note3 ,early type round cleaner does not have removable filter element2 therefore1 the complete cleaner body must be removed to wash element4 ,sidenote3 #dd ,gearshift ,lever and ,linkage4 ,see that gearshift lever and linkage are in good condition1 secure1 and not excessively worn4 ,lubricate all joints with a few drops of engine oil4 ,adjust shifter lever so that when moved to any gear position in shifter guide on tank1 the transmission is shifted to full engagement in corresponding gear4 ,sidenote3 #de ,primary ,drive4 ,remove inspection hole cover from front chain guard4 ,with clutch engaged and transmission in neutral1 rotate primary chain to position of least slack4 ,check chain for #a_/b-;inch deflection4 ,deflection measurement should be total upanddown free movement4 ,inspect chain for adequate lubrication4 ,loosen front and rear chain oiler adjusting screws two turns each4 ,do not remove screws4 ,idle engine #a minute1 then tighten screws firmly1 but do not force4 ,this operation serves to flush control valves and rear chain oiler pipe4 ,sidenote3 #df ,clutch ,pedal and ,linkage4 ,inspect clutch pedal clevis connections and cable to see that they are in good condition and not excessively worn4 ,check free travel of clutch pedal to make sure it is within specified limits4 ,with foot pedal in fully disengaged position 7heel against footboard7 clutch release lever must clear sprocket cover stud and nut by about #a_/af inch3 with foot pedal in fully engaged position1 clutch release lever must have between #a_/h- and #a_/d-;inch of free movement on end of foot pedal cable4 ,lubricate all joints with a few drops of engine oil1 including cable at each end of cable housing4 ,sidenote3 #dg ,rear ,chain and ,guard4 ,inspect rear chain guard for good condition and secure mounting4 ,remove chain1 wash thoroughly in drycleaning solvent1 and hang it up to dry4 ,see that chain is in good condition1 not excessively worn1 and has no broken rollers on side plates4 ,soak chain in ,,sae #aj engine oil for a short period of time to allow oil to penetrate into all rollers2 drain chain1 and wipe off excess oil4 ,inspect countershaft sprocket1 and rear wheel sprocket to see that they are in good condition1 not excessively worn1 and that rear sprocket rivets are tight4 ,do not reinstall chain until item #ga has been performed4 ,when reinstalling chain1 make sure that connecting link is in good condition and securely locked4 ,see that open end of connecting link spring clip is trailing in direction of chain travel4 ,adjust chain 7paragraph #fj74 ,sidenote3 #dh ,final ,drive ,sprockets4 ,inspection of final drive sprockets is made when performing item #dg4 ,sidenote3 #ej ,paint and ,markings4 ,examine vehicle for good condition and see that paint is not rubbed to a polish1 and has no bare spots that might rust or reflect light4 ,see that vehicle markings are legible4 ,sidenote3 #ea ,frame4 ,examine frame for good condition2 observe whether it seems to be sprung out of alinement4 ,sidenote3 #eb ,steering ,head and ,fork ,stem4 ,raise front end of vehicle by placing blocks under skid plate4 ,complete all following items to and including item #ga1 before lowering vehicle to ground4 ,examine steering head and fork stems for good condition4 ,note whether there is upanddown play caused by loose bearings4 ,move handle bars through complete range and observe if there is any binding which might indicate improperly adjusted or defective bearings4 ,sidenote3 #ec ,handle ,bars4 ,examine handle bars for good condition and secure mounting4 ,sidenote3 #ed ,throttle ,control4 ,see that grip is in good condition1 that throttle opens and closes completely as grip is turned to its extreme positions1 and that control wire and housing are in good condition and secure4 ,lubricate lightly through hole in rear of grip to avoid rusting and 8freezing40 ,if grip does not rotate freely1 disassemble grip1 clean1 and lubricate spiral control parts4 ,sidenote3 #ee ,spark ,control4 ,see that grip is in good condition1 that spark is fully advanced and retarded as the grip is turned to its extreme positions2 that the control wire and housing are in good condition and secure4 ,lubricate lightly through hole in rear of grip to avoid rusting and 8freezing40 ,if grip does not rotate freely1 disassemble grip1 clean1 and lubricate spiral control parts4 ,sidenote3 #eg ,rear ,view ,mirror4 ,clean rear view mirror and examine for good condition and secure mounting4 ,sidenote3 #eh ,front ,fender 7,mudguard74 ,examine front fender for good condition and secure mounting2 see that fender does not scrape tire4 ,sidenote3 #ei ,weapon ,carrier4 ,inspect weapon carrier for good condition and secure mounting4 ,sidenote3 #fj ,ammunition ,box4 ,see that ammunition box and cover are in good condition and securely attached4 ,sidenote3 #fa ,front ,springs4 ,see that front springs and their mountings are in good condition1 correctly assembled1 and secure4 ,sidenote3 #fb ,front ,forks4 ,see that front forks are in good condition and securely mounted4 ,sidenote3 #fc ,front ,fork ,rocker ,plates 7,rocker ,arms74 ,see that front fork rocket plates are in good condition1 secure1 and not excessively worn4 ,tighten rocker plate stud nuts securely4 ,sidenote3 #fd ,front ,fork ,damper4 ,inspect steering damper for good condition and to see that it operates freely4 ,observe whether friction disks are glazed1 coated with grease1 or excessively worn4 ,sidenote3 #fe ,front ,brake and ,control ,linkage4 ,see that control linkage operates freely1 that all connections are tight1 and that brake is adjusted so that end of hand lever has #a_/d free travel before meeting resistance4 ,look for any indications of a cracked or excessively worn brake drum3 badly worn1 loose1 or greasesaturated linings4 ,if there are any such indications1 remove wheel for closer inspection4 ,look for badly worn brake side cover bushing1 shackle bushings and studs1 or brake operating stud bearing4 ,apply a few drops of engine oil to control cable1 especially at control housing oiler at left handle bar1 and to pin joints4 ,sidenote3 #ff ,front ,wheel ,alinement and ,spokes4 ,examine front wheel spokes for presence1 good condition1 and tightness4 ,if loose spokes are found1 tighten evenly1 taking care not to distort rim outofround1 or to cause runout4 ,examine rim for good condition1 and spin wheel to see that it has no appreciable runout4 ,sidenote3 #fg ,front ,wheel ,bearings4 ,inspect wheel to see whether bearings are excessively loose4 ,wheel should have slight amount of side play at rim4 ,spin wheel and listen for unusual noises which might indicate dry or defective bearings or races4 ,observe for excessive grease leak4 ,if wheel is found to need only slight cone readjustment to correct excessive bearing play1 remove wheel and make this adjustment 7par4 #abf74 ,if indications are found that hub is otherwise in bad order1 replace wheel4 ,,each ,,sixth #a1jjj-,,mile ,,maintenance ,,service4 ,remove front wheel1 axle sleeve and bearing1 and1 together with wheel hub1 clean thoroughly in drycleaning solvent4 ,inspect parts for good condition3 inspect brake drum4 ,inspect lining for good condition and secure attachment1 and see that it is neither excessively worn nor soaked with grease4 ,repack bearings1 hub1 and axle sleeve with specified lubricant4 ,,caution3 ,make sure that hands and grease are perfectly clean1 and that grease is forced between balls onto the cone4 ,reassemble and adjust bearings according to instructions in paragraph #abf1 taking care to see that wheel is properly alined4 ,if unusual operating conditions1 such as fording streams1 have indicated probable contamination of lubricant1 this service should be performed more frequently4 ,sidenote3 #fh ,front ,wheel ,axle ,nuts4 ,tighten axle nuts1 making sure that cotter pins are installed4 ,slot in stabilizer plate must be anchored on extended end of leftfront rocker plate stud4 ,sidenote3 #fi ,tires1 ,front and ,rear4 ,gage tires and inflate to #ah pounds front1 and #bj pounds rear 7cold74 ,make sure that valve stems are in good condition and correctly installed1 and that valve caps are present and secure4 ,examine tires for cuts1 bruises1 breaks1 and blisters3 remove imbedded glass1 nails1 or other foreign matter from tire treads2 observe treads for excessive or irregular tire wear4 ,at any inspection when unusual or irregular tire wear becomes evident1 interchange front and rear tires4 ,sidenote3 #gj ,rear ,wheel ,alinement and ,spokes4 ,with vehicle on rear stand1 inspect in same manner as front wheel 7item #ff74 ,if it is necessary to aline wheel in frame1 make sure sprockets and chains are in correct alinement4 ,sidenote3 #ga ,rear ,wheel ,bearings and ,seals4 ,inspect wheel to see whether bearings are excessively loose 7wheel should have a slight amount of play at rim74 ,spin wheel and listen for unusual noise which might indicate dry or defective bearings4 ,also observe whether there is excessive grease leak4 ,test for excessive end play4 ,if wheel is found to have considerable side play at rim1 indicating excessively worn bearings1 or there is evidence of hub assembly being in bad order otherwise1 replace wheel4 ,if wheel must be replaced1 inspect brake drum and lining for good condition1 as indicated in item #ge1 before reinstalling wheel4 ,,caution3 ,make sure that wheel mounting socket screws are tight4 ,sidenote3 #gb ,rear ,wheel ,axle ,nut4 ,see that rear wheel axle nut is in good condition and securely tightened4 ,sidenote3 #gd ,rear ,fender 7,mudguard74 ,inspect rear fender for good condition and secure attachment4 ,sidenote3 #ge ,rear ,brake and ,control ,linkage4 ,see that brake control linkage operates freely1 and that all connections are secure4 ,look for indications of badly worn or greasesaturated linings4 ,if brake operating lever stands considerably ahead of vertical1 excessive lining wear is indicated4 ,if grease has worked out between brake drum and brake cover1 greasesaturated linings are indicated4 ,in either case the wheel should be removed for closer inspection4 ,inspect drum for cracks or excessive wear4 ,make sure wheel mounting socket screws are tight4 ,examine linkage for loose or worn pin or clevis1 and for missing washers or cotter pins4 ,apply a few drops of engine oil to all linkage joints4 ,brake pedal should have #a-;inch free travel before brake begins to meet resistance4 ,adjust length of brake rod at brake operating lever to provide #a-;inch free pedal travel4 ,sidenote3 #gg ,footboard and ,rest4 ,examine footboard and rest for good condition and secure attachment4 ,sidenote3 #gh ,saddle ,spring and ,hinge4 ,examine saddle for good condition and secure mounting1 paying particular attention to torn leather1 ripped seams1 sagging or broken spring in seat post1 and excessive wear in front hinge4 ,,caution3 ,make sure that spring wire clip properly locks the saddle rear hinge clevis pin4 ,sidenote3 #gi ,luggage ,carrier4 ,examine luggage carrier for good condition and secure mounting4 ,sidenote3 #hj ,saddle ,bags4 ,examine saddle bags for good condition1 cleanliness1 and secure fastening to luggage carrier4 ,note particularly whether leather is torn1 seams ripped1 or straps and buckles missing or damaged4 ,sidenote3 #ha ,tools1 ,tire ,pump1 and ,equipment4 ,inspect tool kit1 tools1 tire pump1 and other equipment for good condition1 cleanliness1 serviceability1 and proper stowage4 ,make sure that tire pump is securely clamped to motorcycle frame4 ,check all items with stowage list 7pars4 #ba1 #bb and #bc74 ,make sure that vehicle manuals and ,accident ,report ,form ,no4 #bf are present on vehicle and legible4 ,sidenote3 #hb ,safety ,guards4 ,inspect safety guards for good condition and secure mounting4 ,sidenote3 #hc ,leg ,shields4 ,inspect leg shields for good condition and secure mounting4 ,,note3 ,motorcycles operating in warm weather should not be equipped with leg shields1 as they seriously hamper engine cooling4 ,sidenote3 #hd ,skid ,plate4 ,examine skid plate for good condition and secure mounting4 ,,caution3 ,skid plate must be present4 ,sidenote3 #he ,vehicle ,lubrication4 ,lubricate all points of vehicle in accordance with instructions in this manual1 ,lubrication ,guide1 current lubrication bulletins or directives1 and the following instructions3 ,any unit that required disassembly for inspection purposes must be lubricated correctly unless the vehicle is to be deadlined for the repair of that unit4 ,use only clean lubricant4 ,keep all lubricant containers covered except when used during lubrication4 ,before applying lubricant1 always wipe dirt from the lubrication fitting or plug so that dirt will not enter with the lubricant4 ,if lubricant fittings or plugs are missing or damaged1 replace them4 ,clean the hole in which the fitting is to be installed1 and lubricate after the new fitting has been installed4 ,lubricant must be applied properly4 ,on unsealed joints or bushings1 apply lubricant until it appears at openings4 ,however1 lubricate sparingly the front wheel hub1 rear wheel hub1 front brake side cover bushing1 front brake operating lever stud1 and rear brake operating lever stud1 to prevent grease reaching brake linings4 ,rider should be advised whenever wheel bearings are serviced or adjusted1 so that during the next road operation he may determine whether bearings or brake drums are running hot1 due to overtight adjustment of bearings1 or a dragging brake4 ,do not apply more than specified amount of lubricant to generator or timer 7circuit breaker74 ,to do so may cause failure of the unit4 ,wipe off excess applied lubricant that may drip onto brake or operating surfaces1 soil clothes1 or detract from vehicle's appearance4 ,parts or assemblies that have already been lubricated while disassembled for inspection1 gear cases that have been drained and refilled as mandatory items in the procedure1 and those parts that have been indicated for special lubrication1 will be omitted from the general lubrication of the vehicle4 ,sidenote3 #hf ,final ,road ,test4 ,make a final road test1 reinspecting items #b to #af1 inclusive4 ,be sure to recheck transmission to see that lubricant is at correct level and not leaking4 ,confine this road test to the minimum distance necessary to make satisfactory observation4 ,correct or report all deficiencies found during final road test to designated authority4 ,section ,,ix ,,organization ,,tools ,,and ,,equipment ,paragraph ,tools and equipment #bg #bg4 ,,tools ,,and ,,equipment4 a4 ,refer to ,,snl-,n #ai for common hand tools available to second echelon4 b4 ,refer to list given below for all special tools available to second echelon4 ,special ,tool ,manufacturer's ,federal ,stock ,description ,number ,number ,hydrometer1 battery1 special ,,hrd #aahca-,x #ah-;,h-#abdb ,tool1 repair1 drive chain1 motorcycle universal ,,hrd #abjci-,x #da-,t-#ccbj ,tool1 spoke tightening1 special1 #c_/d-;inch1 for small diameter spokes ,,imc #g-,t-#cbei #da-,t-#ccfh-bj ,wrench1 cyl4 base nut1 twin ,,hrd #abfej-bi #bida-,w-#hgb-aj ,wrench1 head bolt ,,hrd #abjdg-cj;,a #da-,w-#aebe ,wrench1 manifold1 #de-;in4 twin ,,hrd #abjjc-,x #da-,w-#aegj-aj ,wrench1 spark plug ,,hrd #aaibi-dj #da-,w-#cccd ,wrench1 spoke nipple1 front wheel ,,hrd #abjcb-,x #da-,w-#ccci ,wrench1 spoke nipple1 heavy duty rear wheel ,,hrd #abjcc-ci #da-,w-#ccdj ,wrench1 tappet and dbl-head open-end #g_/af- and #a-c_/h-;in ,,hrd #aahjf-ca #da-,w-#cfag ,section ,x ,,trouble ,,shooting ,paragraph ,introduction #bh ,engine #bi ,engine lubricating system #cj ,fuel system #ca ,ignition system #cb ,generating system #cc ,electrical system #cd ,transmission and clutch #ce ,wheels and chains #cf ,brakes #cg ,steering #ch #bh4 ,,introduction4 a4 ,trouble shooting for the entire vehicle is given in this section4 ,the engine trouble shooting paragraph traces trouble to a system affecting engine performance3 for example1 fuel or ignition4 ,to trace trouble to one or more defective components of a system1 it is necessary to refer to the pertinent paragraph of this section when the defective system or systems have been located in the engine trouble shooting paragraph4 b4 ,the material given in this section applies to the operation of the vehicle under normal conditions4 ,if extreme conditions of temperature occur1 it is assumed the operator of the vehicle has prepared his vehicle for use for the conditions encountered4 #bi4 ,,engine4 a4 ,instruction4 ,this subparagraph traces troubles to a system affecting engine performance4 ,step b below gives simple engine tests to determine the mechanical condition of the engine4 ,references in step b refer to step c for engine mechanical troubles1 or to pertinent paragraphs in this section for system troubles1 or when a test indicates a special unit is faulty1 to the pertinent paragraph in this manual4 7#a7 ,,engine ,,does ,,not ,,turn ,,over ,,when ,,foot ,,starter ,,is ,,operated4 7a7 ,clutch slipping4 ,check adjustment 7par4 #dh74 7b7 ,sheared engine sprocket key4 ,replace 7par4 #fe74 7c7 ,starter clutch stuck by congealed oil4 ,free starter clutch4 ,use proper grade of oil4 7d7 ,starter clutch worn4 ,refer to maintenance personnel4 7e7 ,engine locked 7seized74 ,refer to organization mechanic4 7#b7 ,,engine ,,turns ,,over ,,when ,,cranked ,,but ,,does ,,not ,,start4 7a7 ,fuel supply valve closed4 ,open valve4 7b7 ,empty fuel tank4 ,fill tank4 7c7 ,fuel system faulty4 ,refer to paragraph #ca4 7d7 ,ignition system faulty4 ,refer to paragraph #cb4 7e7 ,battery weak or dead4 ,refer to paragraph #cd4 7f7 ,insufficient compression4 ,refer to step b1 below4 7#c7 ,,weak ,,compression4 ,refer to step b below for test4 7a7 ,improper valve tappet adjustment4 ,adjust 7par4 #dc74 7b7 ,valves sticking4 ,use drycleaning solvent to free valve stems in guides4 7c7 ,faulty lubrication4 ,refer to paragraph #bj4 7d7 ,loose cylinder head bolts and_/or faulty gasket4 ,tighten head bolts or replace gasket 7par4 #da74 7#d7 ,,overheating4 7a7 ,faulty fuel system4 ,refer to paragraph #ca4 7b7 ,dirt on cylinders4 ,clean fins on cylinder1 especially the fins on cylinder head4 7c7 ,defective lubrication system4 ,refer to paragraph #cj4 7d7 ,defective ignition system4 ,refer to paragraph #cb4 7e7 ,idling engine without having vehicle in motion4 ,do not idle engine longer than #a minute4 7f7 ,valve tappet adjustment incorrect4 ,refer to step b 7#a7 below for test1 to paragraph #dc for adjustment4 7g7 ,drive chains too tight4 ,adjust 7pars4 #ei and #fj74 7h7 ,excessive carbon deposits4 ,refer to organization mechanic4 7#e7 ,,lack ,,of ,,power4 7a7 ,defective fuel system4 ,refer to paragraph #ca4 7b7 ,defective ignition system4 ,refer to paragraph #cb4 7c7 ,overheating4 ,refer to step 7#d7 above4 7d7 ,defective lubricating system4 ,refer to paragraph #cj4 7e7 ,poor compression4 ,refer to step 7#c7 above4 7f7 ,drive chains too tight4 ,adjust 7pars4 #ei and #fj74 7g7 ,brakes dragging4 ,adjust 7pars4 #if and #ig74 7#f7 ,,popping ,,and ,,spitting ,,through ,,carburetor4 7a7 ,water in fuel4 ,water may be present in fuel tank and carburetor4 ,drain and refill fuel tank and carburetor bowl4 7b7 ,incorrect valve tappet adjustment or sticky valves4 ,test 7step b 7#a7 below74 ,adjust tappets 7par4 #dc74 7c7 ,defective ignition system4 ,refer to paragraph #cb4 7d7 ,defective fuel system4 ,refer to paragraph #ca4 7e7 ,weak and_/or broken valve springs4 ,refer to higher authority4 7#g7 ,,spark ,,knock4 7a7 ,defective ignition system4 ,refer to paragraph #cb4 7b7 ,excessive carbon deposits4 ,refer to step b 7#b7 below4 7c7 ,defective fuel system4 ,refer to paragraph #ca4 7d7 ,defective lubrication system4 ,refer to paragraph #cj4 7#h7 ,,pounding ,,and ,,excessive ,,metallic ,,noise4 7a7 ,front drive chain too loose4 ,refer to paragraph #cf4 7b7 ,engine sprocket loose on shaft4 7c7 ,excessively loose valve tappets4 ,adjust 7par4 #dc74 7d7 ,engine mounting bolts loose4 ,tighten4 7e7 ,transmission mounting stud nuts loose4 ,tighten 7par4 #fj74 7f7 ,spark timing incorrect4 ,adjust4 7g7 ,internal parts of engine worn or broken4 ,notify organization mechanic4 b4 ,tests to ,determine ,mechanical ,condition of ,engine4 7#a7 ,,rings ,,and ,,valves4 ,this is a simple compression test4 ,if possible1 make this test with the engine warm4 ,ignition switch must be off4 ,crank engine slowly1 placing entire weight of body on starter crank4 ,engine compression should sustain the weight of an average size rider several seconds before crank passes through complete range of its travel4 ,if engine offers little resistance to starter crank in testing either or both cylinders1 it is an indication that compression is not adequate in one or both cylinders4 ,no clearance or insufficient clearance at valve tappets2 valves sticking in guides2 valves seating poorly2 cylinder heads leaking2 spark plugs loose in heads2 piston rings badly worn and_/or broken2 cylinder and pistons badly worn1 or lack of lubrication could cause the above condition4 ,make external checks first3 ,see that oil is in tank1 that spark plugs are tight1 and examine around cylinder heads for signs of leaking oil deposits4 ,in extremely cold weather1 resistance to the starter crank is increased by 8stiff0 oil in engine and transmission4 ,therefore1 do not mistake this condition to indicate actual engine compression4 7#b7 ,,abnormal ,,engine ,,noise4 ,owing to constructional design of the motorcycle1 correct adjustment of the several units and components is necessary for smooth and normally quiet engine operation4 ,many motorcycles have been 8deadlined0 and engines exchanged because simple tuneup service and correct adjustment of components have been neglected4 ,rough1 jerky1 and noisy engine action at low speed riding is usually caused by excessively loose front and rear drive chains1 or by a transmission being loose in its frame mounting4 ,fast idling of engine with the front drive chain too loose1 may give the false impression that the engine bearings and pistons need replacement service4 ,engine sprocket loose on its shaft will cause a pounding noise similar to that of badly worn engine bearings4 ,if front drive chain is too tight1 or engine sprocket and chain are badly worn1 a grinding noise results1 seeming to come from the engine4 ,excessively loose valve tappets will cause abnormal metallic noise in the valve timing gear train and engine crankcase4 ,spark advanced too far will cause rough engine performance at low speeds as well as spark knock1 pounding1 and overheating4 ,engine pounding and rough operation with consequent noise1 result from loose mounting bolts4 ,generator mounted to give insufficient geartooth clearance will cause 8howl0 in gear case4 #cj4 ,,engine ,,lubricating ,,system4 a4 ,action of the oil feed pump is indicated by the red signal light located in right side of instrument panel4 7,red signal light is normally grounded by the oil pressure switch4 ,when oil pump pressure is built up several pounds1 diaphragm opens the signal light circuit47 ,action of the scavenger 7oil return7 pump is indicated 7engine running7 by oil dripping from #a_/h-;inch hole in oil return tube 7large tube7 inside oil tank1 just back of oil gage rod 7dip stick7 tube4 ,since the oil feed pump and scavenger pump are separate units1 operated individually1 it is possible 7due to faulty unit7 for either to function alone1 thus affecting engine oil pressure and return of oil to the tank4 ,action of the vent pipe 7small pipe7 located within the oil tank is of a 8breather0 nature2 its function not being indicated in any manner4 ,before attempting to diagnose trouble in engine lubricating system1 rider must be familiar with and understand indications by instrument panel signal lights 7par4 #g f74 b4 ,red ,signal ,light ,fails to ,burn ,when ,ignition and ,light ,switch is ,turned ,on4 7#a7 ,check other lights to determine if battery is 8up0 and that switch and wiring connections between battery and switch are in good order4 ,see that wire connection is secure and screw is tight on oil pressure switch terminal4 ,failure of light to burn after these checks indicates that either the lamp is burned out or oil pressure switch is faulty4 7#b7 ,test to eliminate the oil pressure switch by removing wire from switch terminal2 ground wire on switch body and note if red light burns with ignition and light switch in 8,,on0 position4 ,if light burns1 it indicates that oil pressure switch is faulty1 and must be replaced4 ,if light does not burn in making this test1 it indicates that lamp is burned out4 ,remove panel cover 7par4 #aai7 and replace lamp4 c4 ,red ,signal ,light ,continues to ,burn ,after ,engine ,is ,operated ,above ,idling ,speeds4 7#a7 ,check oil supply in tank4 ,if light fails to go out after engine is warm1 or after #a minute of operation1 further checks must be made to locate trouble1 as indication points to faulty engine lubrication system1 or fault in signal circuit4 ,eliminate the signal system first4 7#b7 ,test oil pressure signal switch to panel signal light circuit4 ,remove wire from oil pressure switch terminal by turning on ignition and light switch and observing red signal light4 ,if light burns1 short circuit in wiring exists4 ,if light does not burn1 it indicates normal condition1 leaving oil pressure switch of the signal circuit to be tested4 7#c7 ,install new oil pressure switch and start engine4 ,if red signal light goes out after engine is operated above idling speeds1 it indicates trouble in oil pressure signal switch4 ,if red signal light continues to burn1 it indicates trouble in oil feed pump4 ,replace pump 7par4 #dd74 d4 ,excessive ,smoke ,issues from ,exhaust and ,oil ,spray ,issues from ,gear ,case ,breather ,outlet4 ,this is an indication that the scavenger pump is not draining engine crankcase and returning oil to tank4 ,with engine running at idle speed1 examine oil return in tank4 ,remove tank oil cap1 and with a small flashlight 7tactical situation permitting71 observe whether or not oil is dripping from #a_/h-;inch hole in oil return tube4 ,hole is on under side of tube and is located just back of oil gage rod tube4 ,if observation is poor1 place finger over hole and feel for pulsation of oil pressure4 ,if oil does not return to tank1 scavenger pump is faulty4 ,should the crankcase breather valve be incorrectly timed1 smoke will issue from the exhaust1 but not as noticeably as when scavenger pump is not working4 ,refer to step e below for this condition4 e4 ,smoke ,issues from ,exhaust and ,excessive ,oil ,condition ,exists ,around ,cylinder ,exhaust ,ports 7where exhaust pipes enter cylinders74 ,engine scavenger pump and crankcase breather valve are one unit1 operated by worm gear located behind engine shaft pinion gear4 ,although scavenger pump is not 8timed10 the breather valve sleeve which drives it must be timed to balance the engine lubricating system4 ,if for any reason the scavenger pump unit is removed from engine base1 the breather valve must be retimed 7within the gear case7 when pump assembly is replaced4 ,incorrectly timed breather valve will force oil past piston rings1 causing some smoke1 besides forcing oil out through exhaust ports1 causing excessive oily condition around exhaust pipes where they enter cylinder ports4 #ca4 ,,fuel ,,system4 a4 ,many symptoms which might be attributed to the airfuel system are1 in reality1 due to faulty ignition4 ,before attempting any but the obviously required adjustments1 check the ignition system thoroughly4 ,gasoline tank supply valve is a dual purpose valve1 and its operation is explained in paragraph #e b4 b4 ,shut off gasoline supply valve4 ,disconnect fuel line at strainer1 open valve1 and observe free flow of fuel from pipe4 ,if line is plugged1 remove1 clean out1 and replace4 c4 ,remove1 disassemble1 clean1 and install fuel strainer 7par4 #gb74 d4 ,hard ,starting1 ,spitting1 and ,misfiring ,caused by ,water in ,fuel4 ,remove drain screw from carburetor bowl1 drain bowl1 and replace screw4 ,take care not to cross drain screw threads when replacing4 ,if there is still evidence of water1 dirt1 or other foreign matter after bowl is drained1 replace carburetor 7pars4 #gj and #ga74 ,remove air cleaner oil cup and inspect for evidence of water in oil4 ,drain1 clean1 refill to correct level mark1 and replace cup4 ,should above procedure fail to eliminate trouble1 drain fuel tank by removing drain plug located under tank in forward position4 ,replace drain plug and refill tank with fuel4 e4 ,hard ,starting1 or ,missing at ,idling and ,low ,speeds4 ,carburetor low speed circuit in need of adjustment 7par4 #fh74 ,carburetor high speed circuit is controlled by a fixed jet4 f4 ,impossible to ,obtain ,satisfactory ,carburetor ,adjustment3 ,lean ,spot ,between ,idling and ,up to #cj ,miles per ,hour ,speeds4 ,carburetors in service for some time become dirty and crust forms in the throttle barrel1 making satisfactory low speed adjustment difficult1 if not impossible4 ,replace carburetor 7pars4 #gj and #ga74 g4 ,fuel ,leaking from ,carburetor4 ,evidence of dirt in float valve1 incorrect float level1 or faulty float4 ,replace carburetor 7pars4 #gj and #ga74 h4 ,difficult ,starting1 ,fuel ,mixture ,too ,rich4 ,air cleaner oil cup overfilled1 or cleaner elements exceptionally dirty1 choking off adequate air supply to carburetor4 ,check the oil cup level4 ,if oil cup level is correct1 remove1 clean1 and install cleaner elements 7par4 #gf74 #cb4 ,,ignition ,,system4 a4 ,when checking ignition system for trouble1 make the most obvious and simple checks first4 ,for example3 ,turn on ignition and light switch1 observe lights to ascertain battery current supply2 then check to see that current is reaching spark coil1 circuit breaker1 etc4 ,faulty spark plugs are responsible for the great majority of engine ignition troubles4 ,there is no service for spark plugs other than sandblast cleaning and correct adjustment of electrodes4 ,questionable spark plugs must be replaced 7par4 #hc74 b4 ,remedy all poor connections in ignition wiring system 7fig4 #dh74 c4 ,remove circuit breaker cover1 operate engine with starter pedal1 and observe opening and closing of circuit breaker points4 ,correct point gap when breaker lever fiber is on highest point of cam is #j4jbb inch4 ,for adjustment refer to paragraph #hd4 d4 ,testing for ,high ,tension ,spark4 ,spark at plug gaps depends upon condition and operation of circuit breaker points1 condition of condenser1 and condition of spark coil and hightension cables4 ,testing the ignition system is best done by means of elimination1 testing each unit by replacement until trouble is located2 then replacing serviceable units which were removed4 7#a7 ,remove spark plug cable terminal from either plug1 leaving other cable and plug connected 7to effect ground return of hightension current72 turn engine until circuit breaker points are closed2 turn ignition and light switch on2 hold high tension cable terminal #a_/d inch from cylinder2 open and close circuit breaker points with finger and observe spark jump at gap4 ,if spark jumps gap1 it indicates ignition primary and secondary circuits are complete4 7#b7 ,no spark at hightension gap calls for testing of primary and secondary circuits4 ,turn engine until breaker points are held open2 hold cable end #a_/d inch from cylinder2 turn ignition switch on and with the bit of a screwdriver1 make a good ground connection between breaker movable 7lever7 point1 and the ground4 ,if a good spark is obtained at hightension cable terminal gap when ground connection made by screwdriver is broken1 clean or replace faulty breaker points 7par4 #hd74 7#c7 ,if circuit breaker points are in good condition1 but no spark 7or a very weak spark7 occurs at hightension gap1 replace condenser 7par4 #he7 and repeat test under step 7#a7 above4 ,if replacement of condenser does not remedy trouble1 replace spark coil 7par4 #hi74 7#d7 ,if tests made under steps d 7#a71 7#b71 and 7#c7 above show ignition system to be in good order 7no units having been replaced71 and ignition trouble still exists1 it means that breaker points1 condenser1 and spark coil must be replaced with new units and engine road test made with each replacement until trouble has been located and remedied4 e4 ,ignition ,system ,tests ,satisfactory but ,engine ,starts ,hard1 ,overheats or ,misses4 ,clearly an indication that spark plugs are faulty4 ,remove spark plugs1 clean with sandblast1 regap points between #j4jbh inch to #j4jcj inch and reinstall4 ,replace defective plugs with new ones of correct 7,no4 #b7 heat range 7par4 #hc74 f4 ,engine ,misses ,after ,warmup1 or ,when ,quite ,hot4 ,replacement of spark plugs should remedy this trouble4 ,if it does not1 then either the condenser or spark coil is at fault4 ,replace condenser first 7par4 #he74 ,if new condenser fails to correct trouble1 replace spark coil 7par4 #hi74 #cc4 ,,generating ,,system4 a4 ,panel ,green ,signal ,light ,continues to ,burn ,above #bj ,miles per ,hour4 ,correct faulty wiring and connections between battery and generator4 ,refer to figure #ee4 ,inspect condition of relay and1 if necessary1 replace 7par4 #ie74 ,inspect brushes and commutator of generator4 ,clean commutator if necessary 7par4 #ia74 ,if brushes are sticking in holders or badly worn1 replace generator 7pars4 #ic and #id74 b4 ,generator ,output ,fails to ,keep ,battery ,charged ,although ,green ,signal ,light ,behavior ,is ,satisfactory4 ,test battery3 if it will not hold charge1 or is defective1 replace 7par4 #aac74 ,if the machine is used most of the time for night operation1 have a higher echelon increase the generating charging rate4 ,inspect brushes and commutator of generator4 ,clean commutator if necessary 7par4 #ia74 ,if brushes are badly worn or sticking in holders1 replace generator 7pars4 #ic and #id74 #cd4 ,,electrical ,,system4 a4 ,panel ,lamps ,do ,not ,light ,when ,switch ,is ,turned ,on4 ,examine each lamp and if burned out1 replace 7par4 #abj74 ,examine battery2 if discharged1 replace 7par4 #aac74 ,remedy defective wiring and connections 7fig4 #ga74 ,test light switch3 if defective1 replace 7par4 #aaf74 ,test blackout light switch 7in lamp body73 if defective1 replace lamp 7par4 #aad74 b4 ,lights ,burn ,dim but ,brighten ,up ,considerably ,when ,engine ,is ,accelerated4 ,test battery with hydrometer4 ,if it is not fully charged1 replace 7par4 #aac74 ,remedy defective wiring1 connections1 and switches in circuit 7fig4 #gc74 ,if the battery runs down again after a short period of operation1 have the generator output increased 7refer to a higher echelon74 c4 ,lights ,exceed ,normal ,brilliancy ,when ,accelerating ,engine4 ,examine battery3 if defective1 replace 7par4 #aac74 ,remedy faulty wiring and connections 7fig4 #gc74 ,do not forget the ground connection of the lamp body4 d4 ,blackout ,stop ,lamp and_/or ,service ,stop ,lamp ,fail to ,light4 ,if the unit is burned out1 replace it 7par4 #aae74 ,if the brake pedal is not operating switch1 remedy the faulty operation4 ,remedy all faulty wiring and connections 7fig4 #gc74 e4 ,horn ,does ,not ,sound ,when ,ignition and ,light ,switch ,is ,turned ,on and ,horn ,button ,is ,pressed4 ,test battery by turning on lights4 ,if lights are dim1 replace battery 7par4 #aac74 ,remedy defective wiring and connections 7fig4 #gc74 ,if the horn does not respond to adjustment1 replace 7par4 #aag74 #ce4 ,,transmission ,,and ,,clutch4 a4 ,need for attention to clutch and controls is indicated by clutch slipping under load or dragging 7transmission gears will shift hard and clash7 when in disengaged position4 ,in either case1 the first thing to be checked is adjustment of controls2 this being the attention usually needed4 ,indication that gear shifter controls are in need of adjustment is when transmission gears 8jump0 out of engagement when accelerating vehicle or when under heavy pull4 ,,caution3 ,this warning must not be disregarded4 7#a7 ,,clutch ,,slips ,,when ,,fully ,,engaged4 ,adjust clutch control 7par4 #dh74 ,adjust clutch spring tension 7par4 #dh74 ,if the clutch still slips1 replace either the disks1 springs1 or both 7par4 #dh74 7#b7 ,,clutch ,,drags ,,when ,,fully ,,disengaged4 ,adjust control 7par4 #dh74 ,adjust spring tension 7par4 #dh74 7#c7 ,,clutch ,,rattles ,,when ,,in ,,disengaged ,,position1 ,,engine ,,idling4 ,in this case1 the clutch probably was not properly assembled4 ,refer to paragraph #ea a4 7#d7 ,,transmission 8,,jumps0 ,,out ,,of ,,gear ,,upon ,,accelerating ,,vehicle1 ,,or ,,when ,,under ,,heavy ,,pull4 ,adjust shifter lever control linkage 7par4 #ed74 7#e7 ,,transmission ,,gears ,,shift ,,hard ,,or ,,clash ,,when ,,clutch ,,is ,,fully ,,disengaged4 ,adjust clutch control linkage and spring tension 7par4 #dh74 ,make sure the transmission mounting bolts and units are tight 7pars4 #eg and #eh74 ,drain and fill transmission with correct lubricant 7fig4 #aj74 ,if the above methods fail to cure the symptom1 refer to a higher authority4 #cf4 ,,wheels ,,and ,,chains4 a4 ,transmission ,countershaft and ,rear ,wheel ,sprockets ,show ,excessive ,wear on ,one ,side of ,teeth4 ,adjust the position of the rear wheel axle to aline the rear wheel sprocket with the transmission sprocket 7par4 #fj74 ,if they cannot be alined1 the frame is out of alinement1 and the trouble must be referred to a higher authority4 b4 ,chains ,produce ,grinding ,noise with ,engine ,idling and ,vehicle on ,rear ,stand4 ,if either chain is adjusted too tight1 adjust to proper tension 7pars4 #ei and #fj74 ,examine both chains for presence of dirt and grit4 ,if dirty1 clean and lubricate them 7par4 #bj c 7#aj774 ,if either chain is dry1 adjust chain oilers 7par4 #fa74 ,badly worn chains and sprockets will cause this symptom2 the worn parts must be replaced 7pars4 #fb and #fc74 c4 ,front ,chain ,dry and_/or ,red 7,rusty7 in ,appearance4 ,the chain in this condition has not been receiving enough lubrication4 ,adjust chain oiler 7par4 #fa74 ,if the chain is damaged from lack of oil1 replace 7par4 #fb74 d4 ,rough or ,jerky ,vehicle ,operation at ,low ,speed4 ,chains are too loose4 ,adjust 7pars4 #ei and #fj74 e4 ,excessive ,side ,play at ,rim of ,front ,wheel4 ,adjust bearing cones 7par4 #abf74 ,if the cones and or hub races are badly worn1 replace wheel 7par4 #abe74 f4 ,front ,wheel ,spinning ,test ,produces ,grinding1 ,grating ,noise 7not in brake74 ,the wheel bearings are defective4 ,replace wheel 7par4 #abe74 g4 ,rear ,wheel ,has ,excessive ,side ,play at ,rim of ,wheel4 ,the hub bearings are defective4 ,replace wheel 7par4 #abg74 h4 ,rear ,wheel ,has ,side ,play in ,excess of #j4jaj inch on ,axle4 ,the thrust washers of hub are worn or damaged4 ,replace wheel 7par4 #abg74 i4 ,rear ,wheel ,spinning ,test ,produces ,grinding1 ,grating ,noise 7chain removed74 ,tighten wheel mounting screws4 ,if this does not correct noise1 replace wheel 7par4 #abg74 #cg4 ,,brakes4 a4 ,rear ,brake ,does ,not ,hold ,when ,foot ,pedal ,is ,depressed4 ,if the brake linings are wet1 operate the vehicle and apply a slight pressure to the brake pedal to dry out linings4 ,after drying the linings adjust brake rod length 7par4 #if b74 ,if the brake operating lever stands ahead of the vertical position with brake applied1 or the brake does not hold1 replace the defective brake shoes 7par4 #if74 b4 ,rear ,brake ,squeaks or ,chatters ,when ,used4 ,tighten side plate sleeve nut1 if it is loose4 ,adjust shoe position 7par4 #if74 ,if the operating camshaft and_/or side cover bearing is worn1 replace the assembly 7par4 #if74 ,if the brake shoe spring is defective1 replace 7par4 #if74 ,if the lining on the brake shoes is loose1 worn1 or defective1 replace shoes 7par4 #if74 ,if the brake drum is worn or damaged1 replace the brake drum and sprocket assembly 7par4 #if74 c4 ,rear ,brake ,drags 7vehicle on rear stand74 ,adjust linkage 7par4 #if74 ,if it still drags1 equalize shoe assemblies1 and adjust linkage 7par4 #if74 d4 ,front ,brake ,does ,not ,hold ,when ,hand ,lever ,is ,operated4 ,adjust brake control 7par4 #ig74 ,if brakes are wet1 operate vehicle a short distance with slight pressure on brake lever to dry out linings4 ,if brake does not hold1 replace shoes 7par4 #ig74 e4 ,front ,brake ,drags4 ,adjust control linkage 7par4 #ig74 ,if brake still drags1 equalize shoes and readjust control linkage 7par4 #ig74 f4 ,front ,brake ,action ,rough and_/or ,chatters4 ,adjust control linkage assembly 7par4 #ig74 ,if malfunction continues1 examine brake shoes1 shoe spring1 camshaft bearing and side cover bearing4 ,replace any defective parts or assemblies 7par4 #ig74 #ch4 ,,steering4 a4 ,motorcycle ,pulls to ,one ,side4 ,inspect and correct alinement of rear wheel 7par4 #fj74 ,if the front forks are bent or twisted1 replace 7par4 #ih74 ,if trouble persists1 refer to higher authority4 b4 ,motorcycle ,weaves from ,side to ,side4 ,adjust steering damper to suit speed and road conditions4 ,if this fails1 inflate tires to correct pressure4 ,make sure rear wheel mounting screws are tight4 ,if the steering head bearings are too tight1 weaving will result4 ,check the steering head bearings 7par4 #ih71 and adjust if necessary4 c4 ,motorcycle ,shimmies at ,high ,speed4 ,inflate tires to correct pressure4 ,adjust steering damper to suit speed and road conditions4 ,if the tire tread is unevenly worn1 and shifting tires does not correct the condition1 replace the defective casings4 ,make sure the axle nuts are tight4 ,if the rocker plate studs and bushings are badly worn1 or the fork springs are broken1 replace 7par4 #ih74 ,section ,,xi ,,engine ,paragraph ,description and data #ci ,tuneup #dj ,replacement of head gasket #da ,carbon removal #db ,valve tappet adjustment #dc ,replacement of oil feed pump #dd #ci4 ,,description ,,and ,,data4 a4 ,description4 ,this #b;cylinder1 ,vtype1 aircooled gasoline engine of ,lhead design operates on the #dstroke1 #d;cycle principle4 ,flywheel and connecting rod assemblies operate on roller bearings4 ,engine is fitted with lowexpansion aluminum alloy1 camground1 horizontally slotted pistons and with deepfinned aluminum cylinder heads4 ,as viewed from left side of vehicle 7drive chain side71 rotation of engine is counterclockwise4 b4 ,lubrication system is of drysump type1 in which oil supply is maintained in a tank away from engine4 ,oil is circulated by a supply feed pump and a scavenger1 return pump4 ,this oil circulating system plays a most important part in cooling the engine as well as lubricating it4 c4 ,data4 ,type of engine #b;cylinder1 ,vtype1 ,lhead1 aircooled ,cylinder bore #b-c_/d in4 ,stroke #c-acaf in4 ,piston displacement #de4ab cu in4 ,compression ratio #e4j3a ,horsepower 7,n4,a4,c4,c4 ,rating7 #f4je ,engine number 7serial71 left side of engine base1 just below front cylinder4 #dj4 ,,tune,,up4 a4 ,tuneup consists of making correct adjustment to valve tappets1 circuit breaker ignition points1 spark plug electrodes3 checking and correcting ignition timing2 draining and flushing carburetor bowl2 cleaning and flushing gasoline strainer2 cleaning muffler outlet1 servicing air cleaner1 and adjusting carburetor4 7#a7 ,valve tappet adjustment 7par4 #dc74 7#b7 ,circuit breaker point adjustment 7par4 #hd74 7#c7 ,spark plug service 7par4 #hc74 7#d7 ,timing ignition 7par4 #hf74 7#e7 ,draining carburetor bowl 7par4 #gc74 7#f7 ,cleaning fuel strainer 7par4 #gb74 7#g7 ,cleaning muffler outlet requires freeing outlet of carbon deposits1 caked dirt1 oil1 etc41 with blade of screwdriver1 or other suitable tool4 ,do not enlarge outlet size when cleaning4 7#h7 ,servicing air cleaner 7par4 #gf74 7#i7 ,adjusting carburetor 7par4 #fh74 ,illustration3 ,a--,,cylinder ,,bracket ,,spacers ,,and ,,washers ,b--,,cylinder ,,bracket ,,and ,,frame ,,bolt ,c--,,cylinder ,,upper ,,mounting ,,bracket ,d--,,spark ,,cable ,,clip ,e--,,cylinder ,,bracket ,,bolts ,f--,,oil ,,return ,,pipe ,,connection ,,hollow ,,bolt ,,and ,,washers ,,ra ,,pd #caegaa ,figure #ae--;,disassembly for ,head ,gasket ,replacement #da4 ,,replacement ,,of ,,head ,,gasket 7fig4 #ae74 a4 ,removal4 ,refer to figure #ae1 illustrating necessary parts and units to be removed to perform this operation4 7#a7 ,remove instrument panel cover 7par4 #aai74 7#b7 ,remove gasoline tank and oil tank 7par4 #ajg74 7#c7 ,remove cylinder head bracket to frame lug bolt3 this will free clamp which secures front spark plug cable4 ,pay particular attention to shim washers placed between cylinder head bracket and frame lug1 as these washers must be replaced when installing cylinder head4 7#d7 ,remove spark plug1 or plugs4 7#e7 ,remove cylinder head bolts1 using head bolt wrench #da-,w-#aebe4 ,,note3 ,on some #db ,,wla models1 plain washers 7#j4jie-;inch thick71 in addition to regular 7heavy7 cylinder head bolt washers1 were used to prevent cylinder head bolts from bottoming4 7#f7 ,perform carbon removal 7head only74 ,refer to paragraph #db4 b4 ,installing ,gasket and ,head 7fig4 #ae74 7#a7 ,clean top of cylinder4 ,apply a light application of grease or oil to both sides of gasket before locating on cylinder head4 ,place head on cylinder4 7#b7 ,install head bolts1 using heavy washers 7also #j4jie-;inch thick plain washers1 if any were removed74 ,if in doubt as to use of #j4jie-;inch thick washers in addition to regular washers1 measure depth of bolt holes in cylinder head4 ,head having hole depth of #ca_/cb inch must use the #j4jie-;inch thick washers in addition to regular washers4 ,head having bolt hole depth of #a-a_/af inch does not require the #j4jie-;inch thick washers4 7#c7 ,install cylinder frame bracket with the two long bolts1 special 7spoolshaped7 spacers1 and flat washers4 ,the spacers go between cylinder heads and frame bracket4 ,a flat washer goes under the head of each long cylinder bolt1 above the bracket2 some engines may have flat washers between the spacers and the bracket4 7#d7 ,tighten head bolts evenly to ensure a tight cylinder head joint4 ,use head bolt wrench #da-,w-#aebe1 first turning down bolts just snug1 then tightening each bolt #a_/h to #a_/d turn at a time1 until all are securely tightened4 ,if torque wrench is available1 tighten head bolts to #fj footpounds minimum1 #fe footpounds maximum tension when engine is cold4 #db4 ,,carbon ,,removal4 a4 ,at time cylinder head is removed for gasket replacement1 carbon must be removed from head only4 #dc4 ,,valve ,,tappet ,,adjustment 7fig4 #af74 a4 ,adjust ,tappets with ,engine ,cold4 ,before loosening valve spring covers1 a light application of oil around top edge of each cover will facilitate raising cover without damage to seal packing4 7#a7 ,loosen valve spring covers2 use tappet and valve cover wrench #da-,w-#cfag4 7#b7 ,before checking or adjusting tappet clearance1 make sure valve is seated and that tappet is at lowest position1 by turning engine ahead until like tappet 7inlet or exhaust1 whichever one is being adjusted7 in the other cylinder is at highest position 7valve fully open74 ,inlet valves are located nearest the carburetor manifold4 ,illustration3 ,,ra ,,pd #cajbaa ,figure #af--,valve ,tappet ,adjustment 7#d7 ,loosen adjusting screw lock nut 78#b10 fig4 #af7 slightly before turning adjusting screw 7fig4 #af74 7#e7 ,adjust inlet valve tappets to #j4jjd-;inch minimum1 and #j4jje-;inch maximum clearance between valve stems and tappet 78#a0 and 8#d10 fig4 #af74 ,use thickness gage to determine clearance2 recheck 7correcting if necessary7 clearance after lock nut has been securely tightened4 7#f7 ,adjust exhaust valve tappets to #j4jjf-;inch minimum1 and #j4jjg-;inch maximum clearance between valve stems and tappet4 ,use thickness gage to determine clearance2 recheck 7correcting if necessary7 clearance after lock nut has been securely tightened4 7#g7 ,before turning down valve spring covers1 inspect paper gasket between each cover and tappet guide4 ,if broken or damaged1 fit a new gasket to prevent oil leak4 ,turn down and securely tighten valve spring covers4 ,illustration3 ,,ra ,,pd #caegab ,figure #ag--,oil ,pump ,removed #dd4 ,,replacement ,,of ,,oil ,,feed ,,pump 7fig4 #ag74 a4 ,removal4 7#a7 ,disconnect oil tank feed pipe at oil tank4 ,install nipple cap on tank nipple to prevent oil from running out1 or drain tank4 ,disconnect oil feed pipe from oil pump nipple4 7#b7 ,oil pump is secured to engine gear case cover by one hexagon head bolt and three nuts4 ,two of the nuts are extra long to provide wrench clearance1 and their location should be noted so they will be put back where they belong when reinstalling pump4 ,after removing screw and nuts1 remove pump4 ,unless a new pump gasket is available1 take care not to damage or break the old one1 as this is a very special gasket concerning both thickness and holes provided for oil channels4 ,a 8homemade0 gasket may put oiling system completely out of commission4 b4 ,installing ,oil ,pump4 7#a7 ,clean surface of pump body mounting on gear case cover and see that gasket is in good condition4 ,clean face of oil pump body4 7#b7 ,start pump on mounting studs1 turn engine slowly and press lightly against pump until driving dogs on end of cam gear shaft line up with and drop into driving slot in oil pump rotor4 7#c7 ,insert hexagonhead bolt and lock washer1 and install the three lock washers and nuts 7two are long extension nuts7 on pump mounting studs4 ,make sure to replace the two extra long nuts on the studs from which they were originally removed4 7#d7 ,tighten mounting bolt and three nuts securely4 7#e7 ,connect oil feed pipe to oil pump nipple4 ,remove nipple cap from tank nipple and connect upper end of oil feed pipe to this nipple4 ,tighten nipple nuts securely4 ,section ,,xii ,,engine--,,removal ,,and ,,installation ,paragraph ,remove engine #de ,install engine #df #de4 ,,remove ,,engine 7figs4 #ah1 #ai1 and #bj74 a4 ,a study of figures #ah and #ai will provide a good picture of the steps necessary for engine removal4 ,do not attempt any short cut methods1 as this would consume more time and possibly cause damage to parts or unit assemblies4 7#a7 ,disconnect battery ground wire at frame lug connection on right side of vehicle4 7#b7 ,to disconnect brake front rod from bell crank 7located on right side of rear support rod71 remove cotter pin and plain washer4 7#c7 ,loosen footboard rear support stud nut and remove footboard front stud nut1 then pull footboard outward to free right front end of safety guard4 ,disconnect brake front rod at bell crank4 ,remove bolt which secures front exhaust pipe clamp4 ,remove nut from rear support rod1 freeing stop light switch and rear end of side bar4 ,remove nut from front support rod1 freeing footboard and brake assembly for removal4 7#d7 ,remove the two rear mounting bolts and drop rear end of skid plate 7fig4 #cg74 7#e7 ,remove muffler 7par4 #ha74 7#f7 ,disconnect oil pipe from tank and install nipple cap on oil tank feed pipe nipple to prevent oil from running out1 or drain tank4 ,disconnect pipe from oil pump and remove oil pipe4 7#g7 ,disconnect spark control wire at circuit breaker lever1 and free control housing clamp at cylinder base4 7#h7 ,disconnect brake rear rod from bell crank4 7#i7 ,disconnect red wire and black wire from front end of relay2 also green wire from generator terminal4 7#aj7 ,remove spark plugs4 7#aa7 ,remove engine top mounting 7cylinder head bracket7 bracket to frame lug bolt3 this also frees front spark plug cable clamp4 ,pay particular attention to shim washers 7if any7 between cylinder head bracket and frame lug2 these will have to be installed in the original position4 7#ab7 ,remove lever bottom bolt1 freeing gear shifter lever from shifter rod4 ,illustration3 ,,ra ,,pd #caegac ,a--,,left ,,footboard1 ,,clutch ,,pedal ,,and ,,sidebar ,,assembly ,,and ,,mounting ,,nuts ,,and ,,washers ,b--,,spark ,,control ,,wire ,,and ,,housing ,c--,,engine ,,sprocket1 ,,key1 ,,nut ,,and ,,front ,,drive ,,chain ,d--,,engine ,,sprocket ,,shaft ,e--,,rear ,,support ,,rod ,f--,,inner ,,chain ,,guard ,g--,,air ,,cleaner ,,and ,,bracket ,,assembly ,h--,,outer ,,chain ,,guard ,,rear ,,mounting ,,bolt1 ,,washer1 ,,spring1 ,,nut ,,and ,,cotter ,,pin ,j--,,spark ,,coil ,,rear ,,terminal ,,nut1 ,,washer ,,and ,,screw ,k--,,outer ,,chain ,,guard ,l--,,air ,,cleaner ,,bracket ,,upper ,,mounting ,,bolt ,,nuts ,,and ,,washers ,m--,,air ,,cleaner ,,hose ,,and ,,carburetor ,,fitting ,,assembly ,,and ,,mounting ,,screws ,n--,,engine ,,left ,,rear ,,base ,,mounting ,,bolt ,,castle ,,nut1 ,,washers ,,and ,,cotter ,,pin ,o--,,rear ,,support ,,rod ,,extended ,,nut ,p--,,inner ,,chain ,,guard ,,mounting ,,screws ,,and ,,locks ,q--,,fuel ,,pipe ,,and ,,strainer ,,assembly ,r--,,engine ,,left ,,front ,,base ,,mounting ,,bolt1 ,,washers1 ,,castle ,,nut ,,and ,,cotter ,,pin ,s--,,gear ,,shifter ,,and ,,rod ,,attaching ,,bolt1 ,,washer ,,and ,,nut ,t--,,tank1 ,,lower ,,front ,,mounting ,,bolt1 ,,washers ,,and ,,nut ,u--,,engine ,,sprocket ,,nut ,,wrench ,,ra ,,pd #caegac;,b ,figure #ah--;,disassembly for ,engine ,removal--,left ,side ,illustration3 ,,ra ,,pd #caegad ,a--,,muffler ,,assembly ,,and ,,mounting ,,bolts ,,and ,,nuts ,b--,,skid ,,plate ,c--,,stop ,,light ,,switch ,d--,,rear ,,brake ,,rod ,,front ,,end ,e--,,cylinder ,,bracket ,,and ,,frame ,,mounting ,,bolt1 ,,spacing ,,washers1 ,,spark ,,cable ,,clip ,,and ,,nut ,f--,,engine ,,right ,,front ,,base ,,mounting ,,bolt1 ,,castle ,,nut1 ,,washers ,,and ,,cotter ,,pin ,g--,,relay ,,terminal ,,screws ,,and ,,washers ,h--,,safety ,,guard ,,end ,j--,,right ,,footboard1 ,,brake ,,pedal ,,and ,,sidebar ,,assembly ,,and ,,mounting ,,nuts ,,and ,,washers ,k--,,front ,,exhaust ,,pipe ,,clamp1 ,,bolt1 ,,washer ,,and ,,nut ,l--,,exhaust ,,pipe ,,assembly ,m--,,spark ,,plugs ,,and ,,gaskets ,n--,,rear ,,support ,,rod1 ,,washer ,,and ,,nut ,o--,,brake ,,rod ,,bellcrank ,p--,,engine ,,rear ,,base ,,mounting ,,bolts1 ,,washers1 ,,castle ,,nut ,,and ,,cotter ,,pin ,q--,,oil ,,feed ,,pipe ,r--,,vent ,,pipe ,,hollow ,,bolt ,,and ,,washer ,s--,,vent ,,pipe ,t--,,oil ,,return ,,pipe ,,ra ,,pd #caegad;,b ,figure #ai--;,disassembly for ,engine ,removal--,right ,side 7#ac7 ,close fuel tank valve4 ,remove gasoline pipe from tank nipple and fuel filter nipple4 7#ad7 ,disconnect throttle control wire at carburetor lever4 7#ae7 ,disconnect air intake hose connection fitting from carburetor 7four screws7 and leave attached to hose4 ,remove air cleaner from mounting bracket 7par4 #gh74 ,illustration3 ,,ra ,,pd #cajbae ,figure #bj--,removing ,engine 7#af7 ,remove front chain guard 7par4 #ajb74 7#ag7 ,remove engine sprocket 7par4 #fe74 7#ah7 ,remove two screws and locks securing inner chain guard to crankcase4 7#ai7 ,with #ac_/af-;inch deep socket wrench slipped over rear footboard support rod stud1 remove extended nut1 and withdraw support rod from right side of vehicle4 7#bj7 ,to disconnect the circuit breaker to coil wire and shielding ground from coil rear terminals1 disconnect oil pressure signal light wire from oil pressure switch terminal4 ,it will be necessary to free air cleaner mounting bracket and swing it outward1 to gain access to coil rear shielding ground terminal4 7#ba7 ,engine mounting bolts are secured by cotter pins and castle nuts4 ,remove all engine mounting bolts1 except the one under generator2 this bolt cannot be removed without removing generator2 merely push it up far enough to clear frame engine lug when engine is removed from frame4 7#bb7 ,lift and remove engine from right side of frame4 #df4 ,,install ,,engine 7figs4 #ah1 #ai1 and #bj74 a4 ,installing the engine is generally the reverse of the procedure followed in engine removal4 ,pay close attention to the following procedure because checking and adjustment of controls and other items is necessary to satisfactory vehicle operation4 7#a7 ,lift engine into frame from right side of vehicle4 ,make sure that mounting bolt under generator is raised to clear frame engine lug4 7#b7 ,pass remaining three engine mounting bolts up from under side of frame lugs through crankcase lugs3 install plain washers and castle nuts4 ,fit plain washer and castle nut on mounting bolt under generator4 ,securely tighten all four castle nuts and lock with cotter pins4 7#c7 ,connect circuit breaker to coil wire4 ,connect wire to coil rear terminal and ground shielding on coil case terminal4 7#d7 ,connect oil pressure switch wire to switch terminal4 7#e7 ,pass rear footboard support rod through frame lug from right side of vehicle and install the extended #ac_/af-;inch nut4 7#f7 ,secure inner chain guard by attaching the two screws and locks mounting inner chain guard to engine base4 ,drift edge of locks into screw slots for security4 7#g7 ,install engine sprocket and front drive chain together4 ,see that engine shaft is clean1 sprocket taper clean1 and that key is in place before tightening sprocket nut4 ,drift nut tight1 using hammer on wrench4 7#h7 ,install outer front chain guard 7par4 #ajb74 7#i7 ,connect hose and fitting assembly by installing two bolts1 washers1 and nuts securing air cleaner to frame bracket2 then install four screws securing hose fitting to carburetor4 ,,note3 ,if cleaner frame bracket was loosened and shifted to gain access to coil rear terminals1 securely mount bracket before installing air cleaner assembly4 7#aj7 ,connect throttle control wire to carburetor lever4 ,make sure that throttle closes fully when right grip is turned outward2 and that throttle opens fully when grip is turned inward4 7#aa7 ,install fuel pipe4 ,securely tighten union nuts on tank and fuel strainer nipples4 ,open fuel supply valve and check connections for leaks4 7#ab7 ,connect gear shifter lever end to gear shifter rod by tightening bolt and nut4 7#ac7 ,attach engine top mounting bracket 7cylinder head bracket7 to frame lug1 exercising care in installing required number of thin shims1 together with clamp for front spark plug cable1 to fill space between bracket and frame lug before tightening bolt nut4 ,,note3 ,frame lug must be free from paint or grease to make clean 8electrical0 connection with plated shims and mounting bracket for adequate radio bonding4 7#ad7 ,before installing spark plugs1 inspect for cleanliness and correct electrode adjustment4 ,service if necessary 7par4 #hc74 ,replace gaskets to ensure tight joints4 7#ae7 ,connect red and black wires to relay3 connect green wire to generator terminal marked 8,,switch40 ,refer to wiring diagram 7fig4 #gc74 7#af7 ,attach rear brake rod to bell crank4 ,install plain washer and secure with cotter pin4 7#ag7 ,connect spark control wire to circuit breaker lever and secure control wire housing clamp under cylinder base nut4 ,make sure that spark advances fully 7lever inward7 when control grip 7left handle bar7 is turned inward1 and that spark retards fully when control grip is turned outward4 ,make needed adjustment at control wire and lever connection4 7#ah7 ,remove nipple cap from tank oil pipe nipple 7if one was used7 and connect oil feed pipe1 securely tightening union nuts at tank and oil pump4 7#ai7 ,position exhaust pipe and muffler assembly and attach rear hanger frame bolt1 washer1 and nut4 ,secure muffler front mounting bracket bolt1 but do not tighten nut until skid plate rear bracket is located on this bolt4 7#bj7 ,lift rear end of skid plate1 secure rear mounting bracket and muffler front mounting bracket with bolt1 washer1 and nut4 ,attach skid plate left side bracket1 tightening support rod nut and bracket bolt and nut4 7#ba7 ,install right side footboard1 sidebar1 and brake pedal assembly4 ,install stop light switch bracket on rear support rod before placing lock washer and tightening nut4 ,attach front exhaust pipe clamp to sidebar4 ,install lock washer1 and tighten sidebar front support rod nut4 ,attach right end of front safety guard to sidebar with footboard front support stud4 ,replace lock washer1 and tighten nut4 ,also tighten footboard rear support stud nut4 ,connect stop light switch control to brake foot pedal4 7#bb7 ,attach brake front rod to bell crank2 fit plain washer and secure with cotter pin4 7#bc7 ,connect battery ground wire to frame lug on right side of vehicle4 b4 ,check instrument panel signal lights for normal indications1 and see that oil is in tank before starting engine4 ,section ,,xiii ,,clutch ,paragraph ,description #dg ,maintenance and adjustment #dh ,removal of disks #di ,inspection of disks and springs #ej ,installation of disks #ea ,replacement of clutch release bearing #eb #dg4 ,,description 7fig4 #ba74 a4 ,clutch is of simple multipledrydisk type1 having two steel disks and three lined disks1 one of which provides spring action within disk pack to 8cushion0 clutch operation4 #dh4 ,,maintenance ,,and ,,adjustment 7figs4 #bb1 #bc1 #bd1 and #be74 a4 ,if clutch adjustment is correctly maintained1 clutch will cause very little trouble4 ,ease of gear shifting and service life of transmission gear shifter clutch dogs depend largely upon full disengagement of the clutch4 ,clutch adjustment is in two parts2 namely1 control linkage and spring tension4 ,do not adjust clutch spring tension before correcting control adjustment4 b4 ,clutch ,control ,linkage 7fig4 #bb74 ,operation of foot pedal1 control cable1 and clutch release lever actuates the push rod through hollow transmission shaft1 disengaging or engaging clutch at will4 ,correct adjustment to control cable and release lever must be made before push rod adjustment is made4 c4 ,clutch ,control ,adjustment 7figs4 #bc1 #bd1 #be1 and #bf74 7#a7 ,,adjusting ,,cable ,,length4 ,with clutch in fully disengaged position 7foot pedal heel down7 the clutch release lever must clear the countershaft sprocket cover stud and_/or nut by #a_/af inch4 ,should clutch release lever strike sprocket cover and nut1 clutch push rod movement is restricted1 and clutch cannot be fully disengaged4 ,length of control cable must be adjusted to obtain #a_/af-;inch clutch release lever and sprocket cover stud and_/or nut clearance4 ,to lengthen or shorten clutch control cable1 cable adjustable end must be removed from foot pedal stud 7figs4 #bc and #bd74 ,with foot pedal in forward 7toe down7 position1 remove cotter pin and washer retaining cable end4 ,release other end of cable from notch in clutch release lever by pressing release lever inward and lifting cable end out of notch4 ,rock the foot pedal to rear 7heel down7 position and work cable adjustable end off foot pedal stud4 ,loosen lock nut and turn cable end to right 7clockwise7 to shorten cable2 turn to left 7counterclockwise7 to lengthen cable4 ,tighten lock nut1 install cable end on foot pedal stud2 install washer and cotter pin1 and install other end of cable in clutch release lever notch4 ,illustration3 ,a--,,clutch ,,hub ,,complete1 ,,with ,,liner1 ,,bearing1 ,,studs1 ,,etc4 ,b--,,hub ,,disk ,,lining4 ,c--,,lining ,,rivet 7#f ,,used74 ,d--,,pin 7#g ,,used74 ,e--,,stud4 ,f--,,sprocket ,,complete ,,with ,,disk ,,spline ,,ring4 ,g--,,lined ,,disks 7#b ,,used74 ,h--,,plain ,,steel ,,disks 7#b ,,used74 ,j--,,sprung ,,steel ,,disk ,,with ,,one ,,lining4 ,k--,,releasing ,,disk 7,,with ,,push ,,rod ,,adjusting ,,screw ,,and ,,adjusting ,,screw74 ,l--,,clutch ,,springs 7#aj ,,used74 ,m--,,stud ,,nut ,,locking ,,washer 7#c ,,used74 ,n--,,stud ,,nut 7#c ,,used74 ,o--,,spring ,,compression ,,collar4 ,p--,,push ,,rod ,,adjusting ,,screw4 ,q--,,adjusting ,,screw ,,lock ,,nut4 ,r--,,retaining ,,plate ,,lock ,,ring 7#c ,,used74 ,s--,,bearing ,,retaining ,,plate4 ,t--#fj #g_/cb-;,,inch ,,steel ,,balls4 ,u--,,ball ,,bearing ,,retainer4 ,,ra ,,pd #cajbah ,figure #ba--;,clutch1 ,disassembled ,illustration3 ,,ra ,,pd #cajbai ,figure #bb--;,clutch ,control ,linkage ,illustration3 ,,ra ,,pd #cajbbj ,figure #bc--;,clutch ,lever and ,stud ,nut ,clearance ,illustration3 ,,ra ,,pd #cajbba ,figure #bd--;,control ,cable ,length ,adjustment ,illustration3 ,,ra ,,pd #caegae ,figure #be--;,clutch ,adjustments 7#b7 ,,adjusting ,,clearance ,,of ,,clutch ,,release ,,lever ,,and ,,push ,,rod 7fig4 #be74 ,with clutch release lever and sprocket cover stud clearance correctly adjusted 7step 7#a7 above71 clutch release lever must have between #a_/h-;inch and #a_/d-;inch free play at end where control cable engages lever notch 7fig4 #be74 ,this free play ensures a fully engaged clutch without pressure on clutch release bearing4 ,adjustment is made by means of push rod adjusting screw located in clutch outer disk4 ,remove two screws which secure inspection hole cover to chain guard 7fig4 #be74 ,if clutch release lever has less than #a_/h-;inch free play at end of cable1 loosen push rod adjusting screw lock nut and turn push rod adjusting screw to the left 7counterclockwise7 to increase amount of free play4 ,if clutch release lever has more than #a_/d-;inch free play at end of cable1 turn adjusting screw to the right 7clockwise7 to decrease amount of free play4 ,tighten lock nut after correct adjustment is obtained4 ,replace inspection hole cover4 ,,caution3 ,if end of clutch release lever has no free play as explained above1 clutch will not hold when fully engaged4 ,if too much free play is allowed1 clutch will drag when disengaged2 consequently1 transmission gears will shift hard1 clash1 and eventually become damaged4 ,illustration3 ,,ra ,,pd #cajbbc ,figure #bf--;,adjusting ,clutch ,spring ,tension d4 ,adjusting ,clutch ,spring ,tension 7fig4 #bf74 ,if clutch slips 7does not hold when starting engine or with vehicle in operation7 after controls have been correctly adjusted 7step c 7#a7 and 7#c7 above71 spring tension must be increased4 ,,note3 ,do not increase spring tension any more than actually required to make clutch hold4 7#a7 ,remove front outer chain guard 7par4 #ajb74 7#b7 ,bend down lock lips to free the three clutch adjusting nuts4 7#c7 ,turning nuts to right 7clockwise7 increases clutch spring tension4 ,tighten 7turn to right7 all three adjusting nuts1 onehalf turn at a time1 until clutch holds4 ,test clutch after each halfturn of the three adjusting nuts by cranking engine4 ,usually a clutch that holds without any noticeable slippage when cranking engine1 also holds on the road4 7#d7 ,after clutch spring tension adjustment is made1 bend up nut lock lips to secure adjusting nuts4 ,replace any broken or badly damaged locks4 7#e7 ,when a new clutch is originally assembled and adjusted1 the distance from the inner edge of shoulder on spring collar to face of outer 7releasing7 disk is #a-c_/cb inches 7fig4 #bg74 ,in any case1 do not tighten the three adjusting nuts to the point where inner edge of shoulder of spring collar is closer than inch to face of outer 7releasing7 disk4 ,if compressed more1 clutch probably cannot be fully disengaged4 ,illustration3 ,,ra ,,pd #cajbbd ,figure #bg--,measuring ,distance ,between ,spring ,collar and ,disk 7#g7 ,if clutch still does not hold1 after correct control and spring tension adjustments have been made1 clutch 8pack0 assembly must be replaced 7par4 #di74 7#h7 ,after making clutch spring tension adjustment1 replace outer front chain guard 7par4 #ajb74 #di4 ,,removal ,,of ,,disks 7figs4 #bh1 #bi1 and #cj74 a4 ,clutch disks can be removed for inspection1 cleaning1 and_/or replacing4 ,springs can be removed for checking and_/or replacing without disturbing sprocket1 which is integral with clutch shell4 ,it is advisable to remove releasing 7outer7 disk1 springs1 and collar as an assembly because it is difficult to correctly aline1 hold in place1 and reassemble springs in this unit4 ,if springs show signs of overheating1 and appear to be 8set10 they should be removed1 measured1 and replaced if necessary 7par4 #ej74 ,illustration3 ,,ra ,,pd #caegaf ,figure #bh--,removing ,spring and ,outer ,disk ,assembly 7#a7 ,remove outer front chain guard 7par4 #ajb74 7#b7 ,remove push rod adjusting screw lock nut4 ,place a large flat washer1 approximately #a_/h-;inch thick1 #a-c_/d-;inch in diameter with a #c_/h-;inch center hole1 over push rod adjusting screw1 and replace adjusting screw lock nut just removed 7fig4 #bh74 ,tighten adjusting screw lock nut against large washer until the three clutch spring adjusting nuts are free4 ,bend nut lock down1 remove the three adjusting nuts1 and withdraw releasing 7outer7 disk and spring assembly as one unit4 ,remaining lined and plain steel disks can now be removed from sprocket and clutch shell unit without further disassembly 7fig4 #cj74 ,,note3 ,at time lined and plain disks are removed from shell1 observe relative position of each disk in order of correct assembly4 #ej4 ,,inspection ,,of ,,disks ,,and ,,springs4 a4 ,worn ,disk ,liners4 ,when disk liners are worn down flush 7or nearly flush7 with rivet heads1 disk and liner assembly must be replaced4 ,illustration3 ,,ra ,,pd #caegag ,figure #bi--,outer ,assembly ,removed1 ,exposing ,clutch ,disks ,illustration3 ,,ra ,,pd #caegah ,figure #cj--;,clutch ,disks1 ,removed b4 ,loose ,liner ,rivets4 ,if disk liner rivets are loose1 replace disk and liner assembly with like assembly in new or good order4 c4 ,oilsoaked ,disk ,liners4 ,if lined disks are not badly worn1 but are oilsoaked1 wash them thoroughly in clean gasoline and dry with air or heat4 d4 ,shrunken or ,weak ,springs4 ,if clutch has been badly overheated as a result of slippage1 springs may be found in shrunken or weakened condition4 ,assuming disk liners are not badly worn1 weakened springs are indicated when the three spring tension nuts have been tightened to make the clutch hold until the distance between spring collar and releasing 7outer7 disk is inch4 ,if shrunken or weak springs are suspected1 remove them for inspection4 7#a7 ,to remove springs1 remove push rod adjusting screw lock nut1 freeing spring collar and the #aj springs from the releasing 7outer7 disk assembly4 7#b7 ,measure springs for free length4 ,free length of new clutch springs is approximately #a-a_/b inches 7they may vary plus or minus #a_/cb inch74 ,old springs found to be shrunk #a_/h inch 7total free length of spring is #a-c_/h inch or less7 must be replaced with new springs4 ,,note3 ,before replacing springs1 select #aj springs that do not vary more than #a_/cb inch to make up the assembly4 7#c7 ,,assembling ,,releasing ,,disk1 ,,springs1 ,,and ,,spring ,,collar4 ,place the #aj springs upright on releasing disk to centrally locate each of the #aj stud holes4 ,place spring collar 7flanged edge down7 over ends of springs1 locating the collar plate 8dimples0 in ends of #g of the springs4 ,place the large washer over push rod adjusting screw2 tighten adjusting screw nut1 and compress springs lightly4 ,turn assembly over and observe alinement of springs and disk holes4 ,if necessary1 insert a #c_/h-;inch rod through holes to aline springs4 ,tighten down adjusting screw nut2 assembly is now ready for complete clutch assembly4 #ea4 ,,installation ,,of ,,disks 7figs4 #cj1 #bi1 and #bh74 a4 ,it is important when assembling a clutch to start with a lined disk4 ,install the two steel disks so that the antirattle devices are staggered on splines in the shell1 and the 8sprung0 disk 7lined on one side7 is the last of the pack1 its lined side facing the steel disk4 ,before installing disks1 see that bearing retaining plate lock rings 78,r10 fig4 #ba7 are in place on the short studs1 and are tight against the retaining plate4 ,this is to prevent noise in the clutch4 7#a7 ,install one of the two lined disks on clutch hub studs first4 7#b7 ,next1 engage one of the two steel disks with the splines within the clutch shell1 with side stamped 8,,out0 facing outward4 7#c7 ,install the remaining lined disk on the clutch hub studs4 7#d7 ,engage remaining steel disk with shell splines with 8,,out0 side facing outward4 7#e7 ,install 8sprung0 7one side lined7 steel disk1 lined side inward1 on clutch hub studs4 7#f7 ,it will be noted that the three long1 threadedend1 clutch hub studs are not spaced an equal distance apart4 ,it will also be noted that the three holes 7keyhole shaped7 in the spring collar are not spaced equidistantly4 ,therefore1 when installing releasing disk and spring assembly on clutch hub studs1 the three threaded studs and holes in spring collar must be alined4 ,install assembly on studs1 replace the three nut locks1 replace the three adjusting nuts1 and tighten all three evenly until the distance between shoulder of spring collar and face of releasing disk is #a-a_/cb inch 7fig4 #bg74 7#g7 ,remove the large washer and replace push rod adjusting screw lock nut4 ,do not attempt adjustment of clutch release lever and push rod adjusting screw until outer front chain guard and footboard have been installed4 ,illustration3 ,,ra ,,pd #caegai ,figure #ca--,removing ,clutch ,releasing ,bearing ,assembly 7#h7 ,install outer front chain guard 7par4 #ajb74 7#i7 ,check controls and clutch adjustment4 ,if necessary1 correct according to paragraph #dh4 #eb4 ,,replacement ,,of ,,clutch ,,release ,,bearing 7fig4 #ca74 a4 ,clutch release lever acts against a thrust bearing and push rod assembly which actuates clutch releasing disk4 b4 ,remove ,clutch ,release ,bearing4 ,engage clutch fully 7foot pedal toe down7 and disengage clutch control cable end from slotted end of clutch release lever4 7#a7 ,loosen rear chain guard by removing cap screw which retains rear chain oil pipe and secures front end of rear drive chain guard to transmission countershaft sprocket cover4 7#b7 ,remove the four nuts which secure sprocket cover to transmission4 7#c7 ,remove filler plug4 7#d7 ,hold down starter crank with screwdriver4 7#e7 ,remove sprocket cover and clutch release lever assembly4 ,it may be necessary to pry cover off studs4 ,with cover removed1 clutch release bearing is exposed4 7#f7 ,withdraw clutch release bearing and push rod assembly from transmission shaft4 c4 ,install ,clutch ,release ,bearing4 7#a7 ,insert push rod with clutch release bearing assembly into transmission shaft hole1 as far as rod will go4 ,see that bearing is clean and well greased4 7#b7 ,install sprocket cover4 ,securely tighten the four nuts4 7#c7 ,install cap screw which secures rear chain guard end and chain oiler pipe clamp to sprocket cover4 7#d7 ,engage clutch control cable end in slotted end of clutch release lever4 7#e7 ,check clutch release lever for free play at end of cable4 ,section ,,xiv ,,transmission ,paragraph ,description #ec ,control linkage #ed ,replacement of foot starter crank #ee ,replacement of starter crank spring #ef ,remove transmission #eg ,install transmission #eh #ec4 ,,description4 a4 ,transmission has three speeds3 low1 second1 and high1 and is of the constantmesh1 nonselective type4 ,high gear is direct drive4 ,since 8dogs0 on gear shifter clutches are used to engage transmission gears1 it is of great importance that vehicle clutch is correctly adjusted4 ,clutch must be fully disengaged when shifting gears1 to prevent clashing of gears1 and possible damage to the shifter clutch 8dogs0 and transmission gears4 ,it is also important that gear shifter control linkage be kept in correct adjustment to ensure full engagement of shifter clutch driving dogs in all positions1 thus preventing possible damage caused by dogs jumping out of engagement under driving load4 ,close fitting and needle roller bearings1 within the transmission1 necessitate use of engine oil 7seasonal grade7 in transmission case for adequate lubrication4 #ed4 ,,control ,,linkage 7fig4 #cb74 a4 ,transmission ,shifted to ,adjust ,front ,drive ,chain4 ,the transmission is located to receive power from front 7engine7 drive chain and transmit power through rear drive chain to rear wheel1 and is movable on its mounting for adjustment of the front 7engine7 drive chain4 ,when front 7engine7 drive chain is adjusted1 transmission gear shifter control linkage is affected4 ,therefore1 after each front drive chain adjustment1 gear shifter control linkage must be checked1 and1 if necessary1 correctly adjusted to ensure proper gear shifting with full engagement of the gear shifter clutch driving 8dogs0 as well as prevent transmission from jumping out of gear under load4 b4 ,checking ,gear ,shifter ,control ,linkage4 ,before making adjustment to gear shifter control linkage1 make the following checks3 ,see that all linkage points from transmission gear shifter lever to gear shifter hand lever are well oiled and freeworking4 ,check hand lever pivot bolt nut for tightness4 ,observe whether there is binding or interference with shifter rod at any point in the shifting range2 this sometimes results from a bent snifter rod4 ,check whether or not shifter rod is correctly adjusted so that when hand lever is moved to any gear position in tank shifter guide1 transmission lever moves to the proper position to fully engage shifter clutch dogs and shifter cam spring plunger in camlocating notch 7inside transmission74 ,illustration3 ,,ra ,,pd #cajbbi ,figure #cb--;,adjusting ,gear ,shifter ,rod c4 ,adjusting ,gear ,shifter ,control ,linkage 7fig4 #cb74 7#a7 ,set hand lever in 8,n0 7neutral7 position in shifter guide4 7#b7 ,remove nut and bolt to disconnect shifter rod from hand lever4 7#c7 ,with slight backward and forward movement of shifter rod1 carefully 8feel0 transmission lever into exact position where shifter cam spring plunger 7inside transmission7 seats fully in camlocating notch4 7#d7 ,next1 see that hand lever is in exact 8,n0 7neutral7 position in tank shifter guide4 7#e7 ,readjust length of shifter rod by loosening rod end lock nut1 and turning rod end 7onto or off rod as necessary7 until its bolt hole lines up with bolt hole in hand lever4 7#f7 ,replace bolt and tighten nut4 7#g7 ,,check ,,adjustment4 ,it is advisable to shift hand lever into 8,l0 7low7 and 8,s0 7second7 gear positions and check shifter rod adjustment to be sure of having best allround adjustment4 7#h7 ,when shifter clutches become worn or damaged to the extent of jumping out of engagement under driving load1 even though shifter control linkage is correctly adjusted1 transmission must be removed and referred to higher authority for service4 #ee4 ,,replacement ,,of ,,foot ,,starter ,,crank4 a4 ,remove4 7#a7 ,remove starter crank clamp bolt nut and remove bolt from crank4 7#b7 ,pull starter crank off squared shaft4 b4 ,install4 ,in installing foot starter crank1 notch 7for clampbolt clearance7 must be in upward position in squared shaft to put return spring tension on crank4 7#a7 ,use a -inch1 openend wrench and turn square shaft counterclockwise until bolt slot is upward4 ,hold shaft in this position and press starter crank onto shaft until clamping bolt can be inserted4 7#b7 ,insert clamp bolt with bolt head toward rear wheel 7crank in upward position7 to provide clearance when starter crank is operated4 7#c7 ,fit lock washer and nut and tighten nut securely4 #ef4 ,,replacement ,,of ,,starter ,,crank ,,spring 7fig4 #cc74 a4 ,starter crank spring fits rather snugly behind rear edge of countershaft sprocket cover2 however1 it can be removed and installed without removing sprocket cover4 b4 ,remove4 7#a7 ,remove foot starter crank 7par4 #ee74 7#b7 ,with the blade of a screwdriver or with pliers1 pry hooked end of spring off stud4 ,,note3 ,if spring is broken1 this operation will not be necessary4 ,pull on spring end1 at same time prying spring free of sprocket cover so as to pull spring off square shaft4 c4 ,install4 7#a7 ,turn squared shaft so that clamp bolt notch is in bottom position4 ,engage square hole in spring on shaft with the hooked spring end to rear1 in line with starter spring stud4 ,work spring onto shaft1 prying it to rear to clear sprocket cover4 ,press all the way on squared shaft4 ,illustration3 ,,ra ,,pd #caegbj ,figure #cc--,removing ,starter ,crank ,spring 7#b7 ,hook end of spring in place on spring stud4 7#c7 ,install foot starter crank 7par4 #ee74 #eg4 ,,remove ,,transmission 7figs4 #cd and #ce74 a4 ,transmission and clutch are assembled in one unit and must be removed and installed together4 ,to make sure trouble is in transmission1 check clutch adjustment 7par4 #dh7 and transmission control linkage 7par4 #ed7 before replacing a faulty unit4 ,illustration3 ,,ra ,,pd #caegba ,a--,,tool ,,box ,,and ,,bracket ,,assembly ,,and ,,mounting ,,bolt1 ,,washer ,,and ,,nut ,b--,,battery ,c--,,battery ,,box ,,rear ,,mounting ,,bolts1 ,,washers1 ,,fittings ,,and ,,nuts ,d--,,battery ,,box ,,assembly ,,and ,,cover ,e--,,battery ,,box ,,front ,,mounting ,,bolt1 ,,washers ,,and ,,nut ,f--,,transmission ,,and ,,clutch ,,assembly ,g--,,front ,,chain ,,adjusting ,,screw ,h--,,transmission ,,mounting ,,stud ,,nuts ,,and ,,washers ,j--,,rear ,,chain ,,oiler ,,pipe ,k--,,rear ,,chain ,,guard ,,front ,,mounting ,,bolt ,,and ,,washers ,l--,,muffler ,,assembly ,,and ,,attaching ,,bolt1 ,,washers ,,and ,,nuts ,m--,,rear ,,brake ,,rod ,,assembly1 ,,washer ,,and ,,cotter ,,pin ,n--,,rear ,,chain ,,guard ,o--,,rear ,,brake ,,clevis ,,pin1 ,,washers ,,and ,,cotter ,,pin ,,ra ,,pd #caegba;,b ,figure #cd--;,disassembly for ,transmission ,removal from ,right ,side b4 ,remove4 7#a7 ,drop rear end of skid plate 7par4 #aaa74 7#b7 ,remove front chain guard 7par4 #ajb74 7#c7 ,remove oil bath air cleaner and mounting bracket 7par4 #hj74 ,lower bracket bolt also secures clutch cable tube to frame tube bracket on left side4 7#d7 ,remove engine sprocket and front drive chain 7par4 #fe74 7#e7 ,remove the two mounting screws and locks in engine case to free inner front chain guard4 7#f7 ,remove tool box from mounting bracket 7par4 #ajf74 ,remove bracket from frame4 7#g7 ,remove rear brake rod 7par4 #if74 7#h7 ,remove rear drive chain 7par4 #fc74 7#i7 ,remove rear drive chain guard 7par4 #ajb74 ,remove rear chain oiler pipe after disconnecting at oil pump4 7#aj7 ,remove battery box 7par4 #aje74 7#aa7 ,remove nut1 washer1 and bolt securing clutch tube assembly bracket to frame bracket on right side of vehicle4 ,disengage clutch operating cable end from end of clutch release lever and remove cable and tube assembly4 7#ab7 ,remove gear shifter rod by disconnecting at hand shifter lever and at transmission gear shifter lever4 7#ac7 ,remove the three transmission mounting stud nuts1 then remove lock washers and large plain washers 7located under frame bracket71 and lift transmission sufficiently to permit removal of front chain adjusting screw4 7#ad7 ,loosen upper ,ubolts on ignition coil mounting1 then remove the lower ,ubolt nuts and shift coil on frame tube as far as possible toward the front4 7#ae7 ,remove transmission and clutch assembly from vehicle by lifting complete unit sufficiently to free mounting studs from frame bracket2 then rotate top of transmission backward about #a_/d turn 7fig4 #cd7 and remove unit from left side of frame 7fig4 #ce74 #eh4 ,,install ,,transmission 7figs4 #cd and #ce74 a4 ,install from ,left ,side4 ,working from left side of frame1 tilt top of transmission backward1 and as unit passes into position1 rotate top forward1 until unit is squarely in position and mounting studs pass through slots in frame mounting bracket4 7#a7 ,shift ignition coil mounting back into correct position and tighten ,ubolt nuts4 ,illustration3 ,,ra ,,pd #caegbb ,figure #ce--;,disassembly for ,transmission ,removal from ,left ,side of ,vehicle ,a--,,left ,,footboard1 ,,clutch ,,pedal ,,and ,,sidebar ,,assembly ,,and ,,mounting ,,nuts ,,and ,,washers ,b--,,engine ,,sprocket1 ,,nut1 ,,key ,,and ,,front ,,chain ,c--,,inner ,,chain ,,guard ,,mounting ,,screws ,,and ,,locks ,d--,,inner ,,chain ,,guard ,e--,,transmission ,,and ,,clutch ,,assembly ,f--,,outer ,,chain ,,guard ,g--,,outer ,,chain ,,guard ,,rear ,,mounting ,,bolt1 ,,washer1 ,,spring1 ,,nut ,,and ,,cotter ,,pin ,h--,,air ,,cleaner ,,and ,,bracket ,,assembly ,j--,,air ,,cleaner ,,bracket ,,upper ,,mounting ,,bolt ,,nuts ,,and ,,washers ,k--,,spark ,,coil ,,lower ,,mounting ,u,,bolt ,,nuts ,,and ,,washers ,l--,,clutch ,,cable ,,and ,,housing ,,assembly ,,and ,,mounting ,,bolts1 ,,washers ,,and ,,nuts ,m--,,gear ,,shifter ,,rod ,,assembly ,,with ,,attaching ,,bolt1 ,,washers1 ,,pin ,,and ,,nut ,,ra ,,pd #caegbb;,b ,legend for ,figure #ce--;,disassembly for ,transmission ,removal from ,left ,side of ,vehicle 7#b7 ,install front chain adjusting screw4 ,lift transmission to engage screw in frame notch4 7#c7 ,install large plain washers1 lock washers1 and nuts on the three transmission mounting studs4 ,do not tighten4 7#d7 ,install gear shifter rod by connecting to hand shifter lever and transmission gear shifter lever4 7#e7 ,install clutch operating cable and tube assembly4 ,connect cable end to clutch release lever4 ,position tube assembly bracket to frame bracket and install bolt1 washer1 and nut to hold in place4 7#f7 ,install battery box 7par4 #aje74 7#g7 ,install rear drive chain guard 7par4 #ajb74 7#h7 ,install rear drive chain 7par4 #fc74 7#i7 ,install rear brake rod 7par4 #if74 7#aj7 ,install tool box bracket and tool box 7par4 #ajf74 7#aa7 ,secure inner front chain guard to engine base by installing screw locks and screws4 ,after screws are tightened1 drift edge of each lock into screw slot for security4 7#ab7 ,install engine sprocket and front drive chain 7par4 #fe74 7#ac7 ,if necessary1 adjust front drive chain 7par4 #ei74 7#ad7 ,securely tighten transmission mounting stud nuts4 7#ae7 ,install outer front chain guard cover 7par4 #ajb74 ,connect rear chain oiler pipe to oil pump4 7#af7 ,install air cleaner and mounting bracket1 air hose1 and connections 7par4 #gi74 7#ag7 ,lift skid plate into position and install two mounting bolts1 lock washers1 and nuts4 7#ah7 ,check gear shifter control1 and1 if necessary1 adjust linkage 7par4 #ed74 7#ai7 ,check rear drive chain adjustment and adjust if necessary 7par4 #fj74 7#bj7 ,check rear brake adjustment4 ,if necessary1 adjust rear brake linkage 7par4 #if74 7#ba7 ,check clutch controls and adjust if necessary 7par4 #dh74 7#bb7 ,before operating vehicle1 see that transmission oil level is up to filler opening 7vehicle standing upright74 ,section ,,xv ,,chains ,,and ,,sprockets ,paragraph ,adjust front chain #ei ,adjust rear chain and aline rear wheel #fj ,chain oilers #fa ,replacement of front chain #fb ,replacement of rear chain #fc ,chain repair tool #fd ,replacement of engine sprocket #fe ,replacement of countershaft sprocket #ff #ei4 ,,adjust ,,front ,,chain 7figs4 #cf1 #cg1 and #ch74 a4 ,at the time front chain adjustment is made1 inspect chain for correct lubrication and1 if necessary1 adjust front chain oiler 7par4 #fa74 b4 ,chains wear unevenly and some stretch may result1 making tight and loose sections4 ,for this reason1 engine must be turned and chain rotated to position of least slack at the time adjustment is made4 c4 ,a correctly adjusted front chain has #a_/b-;inch1 or slightly more1 free upanddown movement midway between sprockets1 at inspection hole4 ,chain must never be run taut 7no slack at tightest point74 ,chain must never be allowed to run loose enough to cause jerky1 noisy action and_/or strike the chain guard4 d4 ,adjustment of front chain is made by shifting transmission on its mounting base4 ,this will affect adjustment of gear shifter control linkage1 clutch control linkage1 and rear chain4 e4 ,how to ,adjust ,front ,chain4 7#a7 ,remove inspection hole cover by removing screws and lifting cover from front outer chain guard1 exposing chain 7fig4 #cf74 7#b7 ,obtain tightest chain position by rotating chain to position of least slack4 ,test amount of slack by lifting and depressing chain with finger4 ,use a free upanddown motion of the finger to make this test4 7#c7 ,loosen the three transmission mounting stud nuts underneath transmission mounting base4 7,it is not necessary to drop skid plate to reach stud nuts 7fig4 #cg747 ,transmission can now be shifted on its mounting base by means of adjusting screw1 head of which protrudes through notch of frame fitting1 located at rear of transmission 7fig4 #ch74 ,illustration3 ,,ra ,,pd #cajbcc ,figure #cf--;,front ,chain ,inspection ,hole ,cover ,removed 7#d7 ,turn adjusting screw clockwise 7to the right7 to move transmission backward and tighten front chain4 ,turn adjusting screw counterclockwise 7to the left7 to move transmission forward and loosen front chain4 7#e7 ,after moving transmission by means of adjusting screw1 check front chain adjustment2 then securely tighten the three transmission mounting stud nuts and again check chain adjustment1 as tightening stud nuts sometimes changes chain adjustment4 7#f7 ,after front chain adjustment has been made1 securely tighten the three transmission mounting stud nuts4 7#g7 ,install front chain inspection hole cover and tighten screws4 7#h7 ,check shifter lever control linkage adjustment 7par4 #ed74 7#i7 ,check clutch control linkage adjustment 7par4 #dh74 ,illustration3 ,,ra ,,pd #cajbcd ,figure #cg--,skid ,plate ,dropped to ,show ,location of ,transmission ,mounting ,nuts ,illustration3 ,,ra ,,pd #cajbce ,figure #ch--,transmission ,mounting ,nuts and ,chain ,adjusting ,screw #fj4 ,,adjust ,,rear ,,chain ,,and ,,aline ,,rear ,,wheel 7fig4 #ci74 a4 ,in moving transmission backward on its mounting to tighten front chain1 the rear chain will be loosened4 ,rear chain must then be adjusted by moving rear wheel backward4 ,when rear wheel is moved either forward or backward1 adjustment of the rear wheel brake is affected4 b4 ,when checking rear chain for slack midway between the sprockets1 turn wheel and rotate chain to position of least slack4 ,use free upanddown movement of finger to lift chain and depress it to determine tightest position4 ,illustration3 ,,ra ,,pd #cajbcf ,figure #ci--;,brake ,sleeve ,nut c4 ,at position of least slack1 a correctly adjusted rear chain has #a_/b-;inch1 or slightly more1 free upanddown movement midway between sprockets4 ,chain must never be run taut 7no slack at tightest point74 ,chain must never be allowed to run loose enough to cause jerky operation and_/or strike the chain guard or other chassis parts4 d4 ,at the time rear chain adjustment is made1 inspect chain for correct lubrication and if necessary1 adjust rear chain oiler 7par4 #fa74 e4 ,rear chain adjustment and rear wheel alinement are both made by means of the rear wheel adjusting screws4 ,therefore1 adjustment of either the chain or the wheel alinement can affect adjustment of the other1 making it necessary to consider both adjustments at the same time4 7#a7 ,remove rear axle nut and lock washer 7right side of vehicle74 7#b7 ,loosen brake sleeve nut enough to allow brake assembly to slide backward or forward in frame mounting 7fig4 #ci74 7#c7 ,loosen the two 7right and left side7 rear wheel adjusting screw lock nuts4 7#d7 ,turn wheel adjusting screws clockwise 7to right7 to move wheel and sprocket backward4 ,this tightens chain4 ,,note3 ,if chain is too tight1 turn wheel adjusting screws counterclockwise 7to left7 so that wheel can be shifted forward4 ,this will loosen chain4 ,always turn the two wheel adjusting screws an equal number of turns in order to keep wheel alined4 7#e7 ,check correct alinement of wheel by noting that tire 7not tire rim7 runs approximately midway between lower rear frame tubes at the point where tubes join transmission mounting4 ,it is desirable to have tire run slightly closer 7not more than #a_/af in47 to right than to left side lower tube4 ,a further check of alinement is observing that rear sprocket runs centrally in chain4 ,,caution3 ,if rear wheel is not correctly alined1 vehicle steering will be affected1 and sprockets will wear excessively on one side4 7#f7 ,with adjustment of chain and wheel alinement completed1 securely tighten wheel adjusting screw lock nuts1 and brake sleeve nut3 replace axle lock washer and nut1 tightening nut4 7#g7 ,recheck adjustment of chain as tightening brake sleeve nut and axle nut sometimes changes the chain adjustment4 7#h7 ,after tightening rear chain1 rear brake may be found too tight4 ,check and correct brake adjustment 7par4 #if74 #fa4 ,,chain ,,oilers 7fig4 #dj74 a4 ,both front and rear chains are automatically lubricated by engine oil pumps4 ,chain oilers are adjustable and may need occasional readjustment to meet lubrication requirements of varied operating conditions4 ,chains under most operating conditions require a very small amount of oil2 therefore1 chain oilers require very fine adjustment to supply just enough oil without waste4 b4 ,when adjusting chain oilers1 it is advisable to add or remove only one thin washer at a time and inspect chain again after vehicle has run approximately #ajj miles1 to determine whether or not further adjustment is necessary4 c4 ,if inspection of front chain through inspection hole reveals that chain is not getting enough oil1 adjust front chain oiler as follows3 7#a7 ,add thin 7#j4jjb-;inch thick7 washer under head of front chain oiler adjusting screw 7fig4 #dj74 ,do not remove any washers already under head of screw4 7#b7 ,to check results1 refer to step b above4 d4 ,evidence of too much oil on front chain requires cutting down on chain oiler4 ,illustration3 ,,ra ,,pd #cajbcg ,figure #dj--;,chain ,oilers 7#a7 ,to adjust oiler1 remove thin 7#j4jjb-;inch thick7 washer from under head of front chain oiler adjusting screw 7fig4 #dj74 7#b7 ,to check results1 refer to step b above4 e4 ,if inspection reveals that rear chain is not getting enough oil1 and that oil pipe end is open1 is not bent1 and is directed on chain2 then the rear chain oiler must be adjusted4 7#a7 ,adjust oiler by adding thin 7#j4jjb-;inch thick7 washer under head of rear chain oiler adjusting screw 7fig4 #dj74 ,do not remove any washers already under head of screw4 7#b7 ,to check results1 refer to step b above4 f4 ,evidence of too much oil on rear chain 7supplied by oiler7 requires cutting down on chain oiler4 7#a7 ,to adjust oiler1 remove thin 7#j4jjb-;inch thick7 washer from under head of rear chain oiler adjusting screw 7fig4 #dj74 7#b7 ,to check results1 refer to step b above4 g4 ,at #ajjj-mile intervals1 loosen both front and rear chain oiler adjusting screws 7fig4 #dj7 two turns each4 ,do not remove screws4 ,start and idle engine #a minute1 then tighten screws firmly1 but do not force4 ,this operation serves to flush oiler control valves and rear chain oiler pipe4 #fb4 ,,replacement ,,of ,,front ,,chain4 a4 ,a new or original duplex front chain is endless1 not provided with connecting link1 and engine sprocket must be removed in order to remove or replace chain4 b4 ,remove4 7#a7 ,remove outer front chain guard 7par4 #ajb74 7#b7 ,remove engine sprocket 7par4 #fe74 ,chain can now be lifted off clutch sprocket4 c4 ,install4 ,when installing a new front chain and_/or sprocket1 it may be necessary to shift transmission ahead in order to get chain on 7par4 #ei e74 7#a7 ,clean engine shaft taper and sprocket hole4 7#b7 ,place chain on clutch sprocket teeth and install sprocket 7par4 #fe74 7#c7 ,check chain adjustment 7par4 #ei74 7#d7 ,install outer front chain guard 7par4 #ajb74 #fc4 ,,replacement ,,of ,,rear ,,chain 7fig4 #da74 a4 ,remove4 ,support vehicle on rear stand4 ,with transmission in 8,n0 7neutral7 position1 turn rear wheel until chain connecting link is located on rear sprocket teeth1 about straight back from axle4 7#a7 ,using pliers1 lift split end of connecting link spring clip out of link pin notch1 taking care not to damage spring clip4 ,remove spring clip from other link pin notch4 7#b7 ,pull off link side plate and push link out of chain ends4 ,replace connecting link and spring clip in one end of chain to prevent its loss4 ,illustration3 ,,ra ,,pd #cajbch ,figure #da--,rear ,drive ,chain and ,connecting ,link 7#c7 ,pull on lower half of chain1 guiding upper part while it rotates around countershaft sprocket1 until removed4 ,if a new rear chain is to be installed1 one end can be linked to the upper half end of old chain and can be pulled onto countershaft sprocket as old chain is removed4 b4 ,install4 ,when installing a new rear chain and_/or countershaft sprocket1 it may be necessary to set rear wheel ahead in order to get chain on 7par4 #fj74 7#a7 ,start end of chain over countershaft sprocket teeth1 using starter crank to turn sprocket4 ,after chain end has reached front half of sprocket1 it will be necessary to guide end under sprocket and out of sprocket cover4 ,center chain so that ends engage rear sprocket teeth1 back of the axle4 7#b7 ,install connecting link1 side plate and spring clip4 ,see that open end of spring clip is to the rear with regard to chain travel 7like the end of an arrow74 ,if original spring clip is bent or damaged1 use a new one4 7#c7 ,adjust rear chain 7par4 #fj74 7#d7 ,check rear brake adjustment 7par4 #if74 #fd4 ,,chain ,,repair ,,tool 7fig #db74 a4 ,damaged or broken chain links can be replaced with connecting 7repair7 links after bad links have been removed4 ,to remove damaged or broken link1 push out chain side plate pins with the chain repair tool 7#da-,t-#ccbj74 ,front chain is a double row of duplex chain2 rear chain is a single row chain4 ,the chain tool furnished in the tool kit is designed to accommodate both4 ,to put a connecting link in the front chain1 it will be necessary to remove front chain guard 7par4 #ajb74 ,illustration3 ,,ra ,,pd #cajbci ,figure #db--;,chain ,repair ,tool in ,use b4 ,when connecting 7repair7 links have been fitted to chain1 make sure that spring clips are correctly and securely locked on link pin ends4 #fe4 ,,replacement ,,of ,,engine ,,sprocket4 a4 ,remove4 7#a7 ,remove front outer chain guard 7par4 #ajb74 7#b7 ,remove engine sprocket nut 7righthand thread74 ,it will be necessary to strike wrench with a hammer to loosen nut4 7#c7 ,give flat surface of engine sprocket1 near outer edge1 a light but sharp rap with a hammer1 being careful not to strike and damage sprocket teeth4 ,take care not to lose sprocket shaft key4 b4 ,install4 ,if new sprocket is being installed1 it may be necessary to shift transmission forward to get chain to fit on sprockets 7par4 #ei74 7#a7 ,thoroughly clean engine shaft taper and see that key is in place4 ,clean sprocket taper hole1 fit front chain on sprocket teeth1 and rotate chain until keyway in sprocket lines up with key in engine shaft4 ,slip sprocket onto engine shaft1 install nut1 and tighten securely4 ,strike wrench with a hammer to make sure sprocket nut is very tight4 7#b7 ,install front outer chain guard 7par4 #ajb74 #ff4 ,,replacement ,,of ,,countershaft ,,sprocket4 a4 ,remove4 7#a7 ,remove foot starter crank 7par4 #ee74 7#b7 ,remove starter crank spring 7par4 #ef74 7#c7 ,remove countershaft sprocket cover 7par4 #eb74 7#d7 ,bend back extension of sprocket nut lock4 7#e7 ,remove sprocket retaining nut4 ,it will be necessary to strike wrench with a hammer to loosen nut4 7#f7 ,give sprocket a light but sharp rap with a hammer near outer edge1 being careful not to strike the sprocket teeth1 and remove sprocket from shaft taper4 ,do not lose the two sprocket shaft keys4 b4 ,install4 7#a7 ,clean shaft taper and taper hole in countershaft sprocket4 ,install the two keys4 7#b7 ,install sprocket on shaft4 ,place rear chain on sprocket before installing sprocket cover4 7#c7 ,examine nut lock and1 if badly damaged1 use a new one4 7#d7 ,install sprocket retaining nut4 ,tighten by striking wrench with a hammer4 ,,note3 ,this nut must be tight4 ,bend up extension of nut lock against side of nut4 7#e7 ,it will be easier to install starter crank spring at this step to avoid interference with sprocket cover4 7#f7 ,install sprocket cover4 7#g7 ,install starter crank4 ,section ,,xvi ,,fuel ,,system ,paragraph ,general #fg ,carburetor adjustment #fh ,throttle control wire adjustment #fi ,carburetor removal #gj ,carburetor installation #ga ,fuel strainer #gb ,carburetor bowl cleaning #gc ,fuel pipe #gd #fg4 ,,general4 a4 ,carburetor is of the sideoutlet1 plaintube type with a fixed venturi4 ,fuel feed is by gravity from tank above4 ,carburetor has two manual controls3 the throttle1 which is operated by the right handle bar grip1 and the choke1 which is operated by a lever on the carburetor itself4 ,the high speed fuel supply is governed by a fixed 7nonadjustable7 jet4 ,the idling to medium speed 7#cj mph7 fuel supply is governed by an adjustable 7low speed7 needle valve located on rear side of carburetor body4 #fh4 ,,carburetor ,,adjustment 7fig4 #dc74 a4 ,before attempting to adjust carburetor to correct faulty engine performance1 attention should be given other items which have a direct bearing on and can affect carburetor adjustment as well as engine performance4 7#a7 ,inspect fuel tank cap and make sure air vent is not plugged4 7#b7 ,see that throttle control adjustment is correct 7par4 #fi74 7#c7 ,see that spark control adjustment is correct 7par4 #hh74 7#d7 ,drain and flush carburetor bowl 7par4 #gc74 7#e7 ,drain and flush fuel strainer 7par4 #gb74 7#f7 ,inspect air cleaner to see that passage of air through cleaner is not restricted by oil level being too high in oil cup1 or by an excessive accumulation of dirt in filter elements 7par4 #gf74 7#g7 ,check manifold packing nuts and carburetor mounting screws for tightness4 7#h7 ,see that spark plugs are clean and that gaps are adjusted between #j4jbe inch to #j4jcj inch4 ,if condition of spark plugs is questionable1 install new ones4 7#i7 ,check adjustment of valve tappets 7par4 #dc74 7#aj7 ,check compression of both cylinders 7par4 #bi b47 7#a7 7#aa7 ,check condition and adjustment of circuit breaker points 7par4 #hd74 7#ab7 ,check ignition to battery wiring connections 7diagram fig4 #dh74 7#ac7 ,see that battery is not entirely discharged by turning on lights 7tactical situation permitting7 and observing brilliancy4 b4 ,a carburetor1 once correctly adjusted1 should require little1 if any1 readjusting4 ,at most1 it should not be necessary to adjust the low speed needle more than one or two notches either way to correct mixture to meet changes in weather conditions4 c4 ,low ,speed ,adjusting ,needle 7figs4 #dc and #dd74 ,adjustment of this needle valve controls only idling and low speed 7up to approximately #cj mph7 fuel mixture4 ,turn needle valve down 7to right7 to make mixture leaner4 ,back out 7to left7 needle valve to make mixture richer4 ,needle valve is held in any desired position by a springandball plunger which engages notches in the needle adjusting screw4 d4 ,complete ,readjustment of ,carburetor4 ,a carburetor that is badly out of adjustment1 and_/or a new carburetor just installed1 must be adjusted as follows3 7#a7 ,turn the low speed needle valve all the way down 7to right74 7#b7 ,back needle valve out 7to left7 about three full turns4 ,with needle valve in this position1 engine will start1 but mixture will probably be too rich4 7#c7 ,start engine as follows3 ,after choke lever has been moved to normal open running position and engine is normally hot1 correct adjustment of needle valve by turning needle valve down 7to right7 one notch at a time until mixture becomes so lean that engine misses1 and is inclined to stop3 then back out 7to left7 needle valve #e to #aj notches1 or until engine fires regularly with spark advanced and throttle closed 7or as nearly closed as it can be set and still have engine running at idling speed74 7#d7 ,adjust throttle lever stop screw 7fig4 #dc7 as necessary to make engine idle at proper speed with throttle in fully closed position4 ,turning stop screw to the right makes engine idle faster4 ,turning stop screw to the left makes engine idle slower4 ,do not idle engine at the slowest possible speed1 because an extremely slow idling adjustment causes hard engine starting4 ,changing idling speed with throttle stop screw is likely to change the low speed fuel mixture to some extent3 therefore1 it will be necessary to again check and correct the low speed needle valve adjustment 7step 7#c7 above74 7#e7 ,engine starting and allround carburetion will be improved with low speed fuel adjustment slightly rich1 rather than extremely lean4 ,illustration3 ,,ra ,,pd #cajbdj ,figure #dc--,throttle in ,fully ,closed ,position ,illustration3 ,,ra ,,pd #cajbda ,figure #dd--,throttle in ,fully ,open ,position #fi4 ,,throttle ,,control ,,wire ,,adjustment 7figs4 #dc and #dd74 a4 ,carburetor throttle is opened and closed by means of the right handle bar grip1 operating a control wire 7within a housing7 which connects to the throttle lever4 ,adjustment for full opening and closing of the throttle to correspond with full inward and outward motion of the handle bar grip is made at the junction of the control wire end and the throttle lever connection4 b4 ,adjust ,fully ,closed ,throttle 7fig4 #dc74 ,see that there is about #a inch distance between end of control wire housing and throttle lever when in fully closed position1 so that housing end does not interfere with forward movement of throttle lever4 ,if adjustment of control wire housing is necessary1 refer to paragraph #aja4 ,proceed with closed throttle adjustment4 7#a7 ,loosen control wire clamp screw in connector block4 7#b7 ,turn right handle bar grip outward as far as it will go3 then turn it inward slightly4 ,holding throttle grip in this position1 move throttle lever forward against its stop 7closed position7 and secure control wire in connector block with clamp screw4 ,check closing of throttle after tightening control wire set screw4 ,if necessary1 reset the control wire in the connector block until throttle is closed with full outward grip movement4 c4 ,adjust ,fully ,open ,throttle 7fig4 #dd74 ,follow instructions under step b above1 then3 7#a7 ,turn right handle bar grip inward as far as it will go and see that throttle lever is against its stop in fully open position4 ,if throttle does not open fully when grip is turned inward1 reset the control wire in the connector block to correct the adjustment4 #gj4 ,,carburetor ,,removal4 a4 ,remove ,carburetor for ,replacement ,only4 7#a7 ,shut off fuel supply valve4 7#b7 ,loosen connector block clamp screw and disconnect throttle control wire at throttle lever4 7#c7 ,disconnect fuel feed pipe at strainer nipple4 7#d7 ,loosen air cleaner hose clamp at carburetor air intake fitting1 and remove four screws and air intake fitting from carburetor4 7#e7 ,remove the three mounting bolts 7from right side of vehicle7 which secure carburetor to manifold flange4 ,,caution3 ,take care not to damage or lose gaskets found between carburetor flange and manifold flange1 and_/or #a_/b-;inch thick steel spacer fitted between carburetor and manifold on some models4 7#f7 ,remove carburetor4 7#g7 ,remove fuel strainer assembly from carburetor bowl nipple4 #ga4 ,,carburetor ,,installation a4 ,when installing carburetor be sure to fit the #a_/b-;inch thick steel spacer 7if one was originally fitted7 between carburetor and manifold flanges1 with two gaskets on one side and one gasket on the other side4 ,later models have a longer manifold neck1 extending carburetor farther to the left1 away from cylinders1 and do not need the spacer4 7#a7 ,install fuel strainer assembly on bowl nipple4 ,leave coupling nut loose until after fuel pipe is connected4 ,illustration3 ,,ra ,,pd #cajbdb ,figure #de--,removing ,fuel ,strainer 7#b7 ,to install carburetor on manifold1 locate carburetor flange and two gaskets 7#a_/b-;inch steel spacer and gaskets if originally fitted7 to aline with holes in manifold flange1 and insert and securely tighten the three carburetor mounting screws4 ,use a #g_/af-;inch socket wrench1 or a large screwdriver1 to securely tighten these screws4 ,,note3 ,if carburetor manifold is loose in manifold packing nuts 7carburetor can be lifted and manifold turns in packing nuts71 tighten manifold nuts securely1 using manifold wrench 7#da-,w-#aegj-aj74 7#c7 ,insert carburetor air intake fitting into end of air hose and mount fitting on carburetor with the four screws4 ,tighten air hose clamp4 7#d7 ,connect fuel pipe to fuel strainer nipple by tightening the union nut and also the strainer union nut on bowl nipple4 7#e7 ,attach throttle control wire to throttle lever connector block and adjust 7par4 #fi74 7#f7 ,open fuel supply valve and observe for leaks4 7#g7 ,adjust carburetor 7par4 #fh74 #gb4 ,,fuel ,,strainer 7fig4 #de74 a4 ,cleaning4 7#a7 ,shut off fuel supply valve4 7#b7 ,unscrew cap from bottom of strainer body4 7#c7 ,lift strainer screen element with cork washer out of cap and clean thoroughly4 ,remove any dirt or sediment collected in cap4 ,,note3 ,if compressed air is not available for cleaning1 gasoline from the fuel pipe can be used for cleaning screen and cap4 7#d7 ,install one cork washer in bottom of cap1 set strainer screen element in place1 and locate the other cork washer over screen element4 ,turn cap with screen element and washers onto bottom of strainer body1 handtight4 b4 ,remove ,strainer ,assembly4 7#a7 ,shut off fuel supply valve4 7#b7 ,disconnect fuel feed pipe at strainer body nipple4 7#c7 ,remove filter assembly from carburetor bowl nipple4 ,it will be noted that coupling nut is an integral part of the filter body assembly4 c4 ,install ,strainer ,assembly4 7#a7 ,install fuel strainer assembly on carburetor bowl nipple4 ,leave coupling nut loose until after fuel pipe is connected4 7#b7 ,connect fuel pipe to strainer body nipple and tighten union nut4 ,strainer coupling nut can now be tightened on bowl nipple4 7#c7 ,open fuel supply valve4 ,inspect fuel pipe and coupling nuts for leaks4 #gc4 ,,carburetor ,,bowl ,,cleaning4 a4 ,water from fuel1 water moisture1 and dirt entering air cleaner will settle in bottom of carburetor bowl and will interfere with engine starting and carburetion4 ,at periodic intervals bowl must be drained4 ,,note3 ,before draining and flushing bowl1 clean fuel strainer 7par4 #gb74 7#a7 ,support vehicle on jiffy 7side7 stand4 7#b7 ,shut off fuel supply valve4 7#c7 ,remove bowl drain screw4 ,let fuel1 water1 and dirt run out of bowl4 ,with drain screw still removed1 open fuel supply valve 7turn to left7 and leave open only a few seconds1 to allow fresh gasoline to flush out bowl4 7#d7 ,replace bowl drain screw1 taking care to avoid thread crossing4 ,set screw snug1 but not tight enough to strip the threads4 #gd4 ,,fuel ,,pipe4 a4 ,remove4 7#a7 ,shut off fuel supply valve4 7#b7 ,remove pipe union nut from tank nipple4 ,remove pipe after disconnecting union nut from fuel strainer body nipple4 b4 ,install4 ,fuel pipe must be installed without putting undue twist or strain on pipe or end fittings4 ,therefore1 bend and_/or shape pipe to 8fit0 between nipple connections before replacing and drawing up on union nuts4 7#a7 ,connect lower end of pipe to fuel filter body nipple4 ,do not tighten nut4 7#b7 ,connect upper end of pipe to tank nipple4 ,securely tighten this nut4 ,next1 tighten union nut on strainer body nipple4 ,section ,,xvii ,,intake ,,and ,,exhaust ,,system ,paragraph ,description #ge ,air cleaner #gf ,hose and carburetor fitting #gg ,remove air cleaner #gh ,install air cleaner #gi ,replacement of air cleaner mounting bracket #hj ,exhaust system #ha #ge4 ,,description4 a4 ,intake ,system4 ,the air intake system consists of oil bath air cleaner1 connecting air hose1 and carburetor intake hose fitting4 ,this system is located on left side of vehicle4 b4 ,exhaust ,system4 ,the exhaust system consists of muffler and tailpiece assembly1 front exhaust pipe assembly1 and rear exhaust pipe4 ,exhaust pipe ends are a slip fit in cylinder exhaust ports4 #gf4 ,,air ,,cleaner 7figs4 #df and #dg74 a4 ,general4 ,air cleaner should not be submerged in water1 nor should highpressure stream be directed into cleaner louvers 7where air enters on rear of body7 when cleaning vehicle4 ,either water or dirt entering air cleaner in excessive quantities will raise the oil level in oil cup and choke off proper air supply to carburetor4 b4 ,service4 ,with vehicle in normal use on hardsurfaced roads1 clean and refill air cleaner oil cup with engine oil 7seasonal grade7 at least each time engine oil tank is drained and refilled4 ,,caution3 ,service more frequently under dusty conditions2 daily under extremely dusty conditions4 ,check oil supply daily4 7#a7 ,hold oil cup with one hand and release 7unlatch7 oil cup retaining spring clips to remove oil cup4 7#b7 ,if oil in cup is clean1 with no signs of dirt and grit in oil or cup1 but the oil level is below the indicated level mark1 add engine oil 7seasonal grade7 to bring level up to mark4 ,,note3 ,if oil and cup are dirty1 empty out oil and wash out cup with drycleaning solvent4 ,refill with clean engine oil 7seasonal grade7 to indicated level mark4 7#c7 ,before installing oil cup make sure that the oil cup gasket is in place and in good condition4 7#d7 ,check baffle plate thumb screw for tightness4 ,illustration3 ,,ra ,,pd #cajbdc ,figure #df--;,air ,cleaner ,oil ,cup ,removed 7#e7 ,install oil cup1 making sure that retaining spring clips are fully engaged in lip of oil cup and hold oil cup securely to cleaner body4 7#f7 ,oil bath air cleaners on earlier models are of 8round0 type1 oil cup being secured to body with a metal clamp band and thumb screw4 ,when oil cup is removed on this type of cleaner1 the baffle plate will come out with the cup4 ,make sure that baffle plate is correctly installed and that gasket is in place when installing cup4 c4 ,maintenance 7fig4 #dg74 ,the rectangulartype oil bath air cleaner is provided with two filter elements1 retained in filter body by means of the baffle plate4 ,if daily check reveals excessive accumulation of dirt and grit in oil and cup1 filter elements must be removed and cleaned4 ,,note3 ,check several times daily under extremely dusty or sandy conditions4 7#a7 ,hold oil cup with one hand and release 7unlatch7 oil cup retaining spring clips2 remove cup4 7#b7 ,unscrew baffle plate thumb screw and remove baffle plate4 7#c7 ,filter elements may 8bind0 in cleaner body4 ,if so1 rap side of body with hand to loosen them2 or1 if necessary1 withdraw elements from body with pliers or a hooked wire4 7#d7 ,check for presence and condition of gasket above the two filter elements 7in filter body72 also for oil cup gasket4 ,illustration3 ,,ra ,,pd #cajbdd ,figure #dg--;,air ,cleaner1 ,disassembled 7#e7 ,clean both filter elements thoroughly in drycleaning solvent4 ,allow elements to dry out 7use air hose if available74 7#f7 ,clean oil cup and refill to indicated level mark4 ,use clean engine oil 7seasonal grade74 7#g7 ,dip one screen surface of each filter element about #a_/b inch into oil in the oil cup 7to 8oil wet0 filter pack74 ,install the two filter elements1 baffle plate1 and oil cup immediately after 8oil wetting0 the filter elements4 ,make sure gaskets are in place4 ,,note3 ,do not add more oil to oil cup after elements have been dipped into it1 because excess oil absorbed by elements will drip back into oil cup1 bringing level back to normal4 7#h7 ,roundtype oil bath air cleaner used on earlier models does not have removable filter element4 ,complete cleaner body must be removed from vehicle1 immersed and agitated in cleaning solvent to wash out dirt4 ,after cleaning1 allow filter element to dry 7use air hose if available71 then apply a few squirts of engine oil to inside of cleaner element1 using oilcan4 ,refill cup1 replace baffle plate and cup1 securely tightening clamp band thumb screw4 #gg4 ,,hose ,,and ,,carburetor ,,fitting4 a4 ,remove4 ,carburetor intake and hose connection must be removed from carburetor to remove and_/or install air hose4 7#a7 ,loosen screws in the two hose clamps4 7#b7 ,remove four screws retaining carburetor air intake fitting4 ,remove carburetor fitting from end of hose1 and pull hose off air cleaner body connection4 b4 ,install4 ,before installing air hose1 inspect for breaks or faulty condition that might prevent airtight seal between air cleaner and carburetor fitting4 7#a7 ,install one end of hose on carburetor fitting4 ,do not tighten clamp screw4 7#b7 ,install other end of hose on air cleaner connection4 ,do not tighten clamp screw4 7#c7 ,install carburetor fitting4 ,securely tighten the four screws4 ,next1 center air hose between carburetor fitting and air cleaner connection and securely tighten hose clamp screws4 #gh4 ,,remove ,,air ,,cleaner4 a4 ,loosen hose clamp screw at air cleaner body connection and remove two nuts and geartoothed washers from bolts securing air cleaner assembly to frame bracket4 ,,note3 ,geartoothed lock washers are also used under heads of the two mounting bolts4 ,withdraw cleaner from end of air hose4 b4 ,the same procedure applies to roundtype air cleaners used on earlier models4 #gi4 ,,install ,,air ,,cleaner4 a4 ,engage air cleaner hose connection in end of hose and mount cleaner assembly on frame bracket with two bolts1 geartoothed lock washers1 and nuts4 ,securely tighten mounting nuts4 ,,note3 ,the plated 7whitened7 mounting bolts1 four geartoothed lock washers1 and bolt nuts must effect a ground connection between bracket and filter mounting to insure adequate radio bonding4 ,tighten air hose clamp screw at cleaner body connection4 b4 ,the same procedure applies to roundtype air cleaners used on earlier models4 #hj4 ,,replacement ,,of ,,air ,,cleaner ,,mounting ,,bracket4 a4 ,air cleaner mounting bracket and air cleaner can be removed or installed as an assembly4 b4 ,remove4 7#a7 ,loosen hose clamp connection at air cleaner body4 7#b7 ,disconnect battery ground wire4 ,this prevents shorting battery when removing cleaner bracket clamp bolt4 7#c7 ,remove the two upper cleaner bracket frame clamp bolts4 7#d7 ,remove lower mounting bolt4 ,cleaner lower bracket mounting and clutch cable tube mounting are secured to frame bracket by the same whitened radio bonding bolt1 geartoothed lock washers1 and nut4 ,remove nut and drop bolt to free cleaner bracket4 c4 ,install4 7#a7 ,engage air hose and cleaner body connection4 7#b7 ,attach lower bracket first4 ,locate cleaner bracket so that hole lines up with bolt holes in frame bracket and clutch cable tube mounting4 ,pass whitened radio bonding bolt upward through bracket hole1 install shakeproof lock washer1 and securely tighten nut4 7#c7 ,attach bracket to the two upper frame clips4 ,tighten the clamp bolt nuts4 7#d7 ,connect battery ground wire4 7#e7 ,tighten air hose clamp screw at cleaner connection4 #ha4 ,,exhaust ,,system4 a4 ,remove ,muffler ,assembly4 7#a7 ,support vehicle on rear stand4 7#b7 ,remove bolt from end of hanger bracket on left side of vehicle1 and remove bolt from muffler clamp and skid plate bracket on right side of vehicle4 ,drop skid plate4 7#c7 ,loosen nut and bolt on clamp which secures front end of muffler at exhaust pipe connection 7clamp is attached to muffler74 7#d7 ,remove muffler rear hanger bracket bolt nut4 ,pull muffler assembly free from exhaust pipe connection4 b4 ,install ,muffler ,assembly4 7#a7 ,engage muffler pipe and exhaust pipe at muffler pipe clamp connection4 ,do not tighten clamp bolt nut as yet4 7#b7 ,attach muffler rear hanger bracket to frame bracket bolt1 installing lock washer1 and tightening nut4 ,,note3 ,it may be advisable to loosen hanger bracket on muffler so that muffler can be lined up for front end connection4 7#c7 ,tighten muffler and exhaust pipe clamp bolt nut and rear hanger nut4 7#d7 ,raise skid plate into position and install right side mounting bolt which secures muffler front bracket and skid plate bracket to frame clip4 ,tighten all mounting nuts4 c4 ,remove ,exhaust ,pipes4 7#a7 ,refer to step a 7#a71 7#b71 7#c7 above4 7#b7 ,remove right side footboard and brake pedal assembly as follows3 ,loosen footboard rear support stud nut1 remove front support stud nut1 and pull footboard outward to free end of safety guard4 ,remove bolt which secures front exhaust pipe clamp1 and remove nut from rear support rod1 freeing stop light switch and rear end of footboard sidebar4 ,remove nut from front support rod1 and drop footboard and brake foot pedal assembly to provide clearance for exhaust pipe removal4 ,disengage rear exhaust pipe at cylinder port1 at same time prying and pulling front exhaust pipe forward and downward to free from cylinder port4 ,both exhaust pipes can now be worked downward and removed from vehicle as an assembly4 d4 ,install ,exhaust ,pipes4 7#a7 ,position exhaust pipe 7front and rear7 assembly1 working it into position so that front pipe end slips into cylinder port2 then1 pry and force rear pipe end into rear cylinder port4 7#b7 ,mount footboard1 brake foot pedal1 and sidebar assembly on support rods1 installing washer and nut on front support rod4 7#c7 ,position and mount stop light switch on rear support rod4 ,see that spring and operating control wire exert a straight pull on switch plunger when foot pedal is operated4 7#d7 ,install bolt1 washer1 and nut which secure front exhaust pipe clamp to footboard sidebar4 7#e7 ,to attach safety guard to sidebar1 pull front end of footboard away from sidebar1 line up holes in sidebar and safety guard end1 then pass footboard support stud through both pieces1 and secure with washer and nut4 7#f7 ,tighten footboard rear support stud nut4 7#g7 ,to complete installation1 follow procedure outlined in step b 7#a7 through 7#d7 above4 ,illustration3 #aj--;,,instrument ,,panel ,,terminal4 #ab--;,,battery ,,positive4 #ac--;,,battery ,,negative 7,,ground74 #ah--,,terminal ,,junction ,,on ,,frame4 #bf--;,,ignition--,,light ,,switch4 #bh--,,spark ,,coil4 #cc--;,,circuit ,,breaker4 #cd--;,,coil ,,to ,,timer ,,wire4 99,a--,,radio ,,bond1 ,,coil ,,to ,,timer ,,wire4 99,b--,,radio ,,bond1 ,,coil ,,to ,,engine4 99,c--,,noise ,,suppression ,,condenser4 99,d--,,shielded ,,coil ,,to ,,timer ,,wire4 99,e--,,spark ,,plug ,,suppressors4 ,,ra ,,pd #caegbc ,figure #dh--;,ignition to ,battery ,wiring ,diagram ,section ,,xviii ,,ignition ,,system ,paragraph ,description #hb ,spark plugs #hc ,circuit breaker points #hd ,condenser #he ,circuit breaker and timer assembly #hf ,coil to timer wire #hg ,adjust spark control #hh ,spark coil #hi #hb4 ,,description4 a4 ,the ignition system differs from that of the conventional automotive types in that it has no distributor4 ,a circuit breaker alone is used4 ,both coil hightension winding ends lead directly to both spark plugs4 ,thus both plugs spark at the same time1 one cylinder being on compression stroke while the other cylinder is on exhaust stroke4 #hc4 ,,spark ,,plugs4 a4 ,defective spark plugs are indicated by engine missing1 overheating1 knocking excessively1 and lacking normal power4 b4 ,type4 ,spark plugs are medium heat range1 manufacturer's 7,h-,d7 ,no4 #c4 c4 ,cleaning4 ,do not take plugs apart for cleaning4 ,use the sandblast cleaner method4 d4 ,point ,adjustment4 ,bend electrode located in plug base to adjust point gap #j4jbe inch to #j4jcj inch4 e4 ,replacement4 ,use spark plug wrench 7#da-,w-#cccd7 to install plugs1 using new gaskets4 ,never draw a cool plug up tight in a hot cylinder head1 rather turn down snug and wait l_/#b minute until plug base is warm3 then tighten securely4 ,,caution3 ,take care not to crossthread when installing spark plug4 #hd4 ,,circuit ,,breaker ,,points 7fig4 #di74 a4 ,circuit breaker lever is insulated from ground and connects to primary wire binding post by means of a 8pigtail0 wire4 ,stationary point is grounded to timer base and is movable in order to adjust circuit breaker points4 ,circuit breaker points that are burned or pitted should be renewed or dressed with a clean finecut1 contact point file4 ,the file should not be used on other metals and should not be allowed to become greasy or dirty4 ,,caution3 ,never use emery cloth to clean points4 ,contact surfaces1 after considerable use1 may not appear bright and smooth1 but this is not necessarily an indication that they are not functioning satisfactorily4 b4 ,remove ,breaker ,lever4 7#a7 ,to disconnect condenser terminal1 remove nut from end of condenser and remove geartoothed washer1 plain washer1 and the brass terminal strip4 ,do not remove fiber washer and plain washer located back of brass terminal strip on condenser terminal post4 ,illustration3 ,,ra ,,pd #cajbdh ,figure #di--;,circuit ,breaker ,points ,removed 7#b7 ,bend brass terminal strip down and remove binding nut which secures brass terminal strip and breaker lever 8pigtail0 to primary wire binding post4 7#c7 ,compress breaker lever spring at end of lever1 disengaging spring4 ,,caution3 ,do not lose spring4 ,release and remove lever from insulated pivot post4 c4 ,remove ,adjustable ,contact ,point4 7#a7 ,remove the two lock screws and washer plate1 securing adjustable contact point assembly to timer base4 ,point assembly is free to be lifted off lever pivot stud4 d4 ,install ,adjustable ,contact ,point4 7#a7 ,install contact point assembly1 replacing washer plate and the two lock screws4 ,do not tighten lock screws until circuit breaker points are adjusted 7step f below74 e4 ,install ,breaker ,lever4 7#a7 ,install brass terminal strip on primary wire binding post4 7#b7 ,connect end of brass terminal strip to condenser terminal post4 ,install flat washer1 geartoothed washer1 and nut4 7#c7 ,install breaker lever on pivot post insulated bearing4 7#d7 ,install breaker lever spring4 ,make sure that ends of spring are retained correctly4 7#e7 ,,note3 ,keep breaker lever cam very lightly greased4 f4 ,adjusting ,circuit ,breaker ,points 7fig4 #ea74 7#a7 ,correct point gap is #j4jbb inch4 ,circuit breaker point faces must seat squarely against each other4 ,if bent1 square up and aline by bending contact plate4 ,turn timer breaker cam until breaker lever fiber is located on highest point of cam4 7#b7 ,with the adjustable point lock screws loose1 shift the adjustable point plate to obtain a #j4jbb-;inch gap between the circuit breaker points4 ,measure gap with an accurate thickness gage before retightening lock screws1 and again recheck point gap after tightening the lock screws4 ,,note3 ,wrong circuit breaker point gap affects ignition timing4 #he4 ,,condenser4 a4 ,the condenser is connected in parallel with the circuit breaker points1 one of its terminals being grounded 7for the adjustable point7 to the timer base by means of the mounting screw1 the other terminal making connection with the circuit breaker lever 7for the lever point7 by means of the lever 8pigtail40 b4 ,remove4 7#a7 ,unlatch circuit breaker cover retainer and remove cover4 7#b7 ,remove nut from end of condenser and remove geartoothed washer1 plain washer1 and the brass terminal strip4 ,,note3 ,a small plain washer and a large fiber washer are located behind brass terminal strip4 7#c7 ,remove screw which secures condenser to timer base4 ,remove condenser4 ,illustration3 ,,ra ,,pd #cajbdi ,figure #ej--;,circuit ,breaker 7,timer71 ,disassembled c4 ,install4 7#a7 ,mount condenser on timer housing4 ,install lock washer and screw4 ,make sure small plain washer and large fiber washer are in place on condenser end terminal screw before connecting the brass terminal strip4 7#b7 ,connect brass terminal strip to condenser4 ,replace plain washer1 geartoothed washer and terminal nut4 7#c7 ,install circuit breaker cover4 #hf4 ,,circuit ,,breaker ,,and ,,timer ,,assembly 7figs4 #ej and #ea74 a4 ,when the circuit breaker timer shaft and base assembly must be replaced due to excessive wear in timer shaft bearing1 sheared worm gear pin1 and_/or worn or damaged worm gear1 engine ignition must be retimed4 ,ignition timing for the ,vtype twin engine is difficult and should be attempted only by experienced personnel4 b4 ,remove 7fig4 #ej74 ,before the timer shaft and base assembly can be removed1 the circuit breaker timer head assembly must be removed4 ,,note3 ,if the timer head only1 or timer wire1 is to be replaced1 it is not necessary to remove timer shaft and base assembly1 and thus throw engine ignition out of time4 7#a7 ,remove timer head cover4 7#b7 ,unlatch cover retainer ends from holes in the timer head and remove4 7#c7 ,disconnect spark control wire at timer lever4 7#d7 ,lift the timer head assembly off base4 ,the head seating tension 7ground7 spring 7underneath shaft base7 is also free1 and can now be removed4 ,,note3 ,it is not necessary to disconnect timer to coil wire from timer head terminal post1 unless head or wire is being replaced4 7#e7 ,remove the two timer base mounting screws and lock washers4 ,it will be noted that one screw grounds the timer to coil wire shielding4 7#f7 ,timer shaft and base assembly can now be lifted out of engine gear case cover4 ,take care not to damage or misplace base gasket4 c4 ,install ,timer ,shaft and ,base ,assembly and ,timing ,ignition 7fig4 #ea74 ,this calls for retiming engine ignition as follows3 7,,note3 ,circuit breaker cam turns in clockwise direction73 7#a7 ,unscrew and raise front cylinder inlet valve spring cover1 using tappet wrench 7#da-,w-#cfag74 7#b7 ,turn engine in direction in which it runs until valve tappet indicates front cylinder is on compression stroke 7directly after front cylinder intake valve closes74 ,illustration3 ,a--,,flywheel ,,timing ,,mark ,,in ,,crankcase ,,inspection ,,hole4 ,b--,,cover ,,retainer4 ,c--,,circuit ,,breaker ,,lever4 ,d--,,circuit ,,breaker ,,cam4 ,e--,,condenser4 ,f--,,spark ,,control ,,wire ,,housing4 ,g--,,spark ,,control ,,wire4 ,h--,,spark ,,lever ,,quadrant4 ,j--,,spark ,,lever4 ,k--,,timer ,,head ,,adjusting ,,band ,,screw4 ,l--,,timer ,,head ,,adjusting ,,band4 ,m--,,mark ,,on ,,breaker ,,cam ,,and ,,marks ,,on ,,timer ,,head ,,and ,,hand ,,indicating ,,original ,,factory ,,timing4 ,n--,,circuit ,,breaker ,,points4 ,o--,,adjustable ,,contact ,,point ,,plate4 ,p--,,adjustable ,,contact ,,point ,,lock ,,screws4 ,q--,,circuit ,,breaker ,,lever ,,pivot 7,,insulated74 ,r--,,breaker ,,lever ,,spring4 ,,ra ,,pd #cajbha ,figure #ea--;,circuit ,breaker ,marks and ,flywheel ,mark ,correctly ,alined 7#c7 ,remove plug from timing inspection hole in leftside crankcase4 7#d7 ,continue turning engine slowly until flywheel timing mark is in center of inspection hole 7fig4 #ea74 ,do not turn engine further4 7#e7 ,install paper gasket and timer head tension 7ground7 spring on timer shaft base assembly4 ,make sure bent ends of tension spring are facing downward 7away from timer base74 7#f7 ,insert timer shaft and base assembly all the way down into place in timing gear case cover1 trying to locate mark on small end of breaker cam in position shown in figure #ea4 ,do not install base mounting screws as yet4 7#g7 ,install timer head assembly so that spark control lever is within the advance and retard quadrant 7fig4 #ea74 ,,note3 ,do not install cover retainer until later4 7#h7 ,fully advance spark lever 7push inward toward engine7 and observe how closely mark on breaker cam lines up with breaker lever fiber4 ,if mark does not line up1 lift timer base and turn shaft gear so its engagement with its driving gear is changed one tooth4 ,check again according to breaker cam mark and breaker lever fiber4 ,repeat this procedure until gear engagement is obtained which closely alines cam mark and breaker lever fiber4 7#i7 ,see that timer base is turned so that timer to coil wire is toward rear of engine4 7#aj7 ,install timer base screws and lock washers4 ,make sure that timer to coil wire shielding is grounded under head of screw farthest away from engine 7fig4 #eb74 ,securely tighten screws4 7#aa7 ,install timer head on base and secure with ground spring and cover retainer4 ,be sure ground spring is in its proper place so that when cover retainer ends are fitted through holes in the timer head1 they will also fit into spring locating notches4 ,it will be necessary to press ground spring upward under timer base to engage retainer ends in the spring notches4 ,,note3 ,if cover retainer ends do not engage ground spring notches1 spring will have no tension and timer head will be loose on its base4 ,circuit breaker points and condenser are electrically grounded through timer base1 and ground spring holds the head and base in close contact1 thus assuring a good ground4 7#ab7 ,connect spark control wire and timer lever and adjust 7par4 #hh74 7#ac7 ,engine is now timed according to original factory setting1 providing mark on side of timer head and hole in head adjusting band are still in alinement1 and circuit breaker point gap is #j4jbb inch4 ,even though all ignition timing marks are in perfect alinement1 as outlined in the foregoing instructions1 it is advisable to accurately check ignition timing 7step d following74 d4 ,recommended ,recheck of ,ignition ,timing 7fig4 #ea74 ,even though all ignition timing marks are in perfect alinement1 as when engine was originally timed1 ignition timing may change somewhat after engine has been in service for a while1 due to normal wear and seating of the various moving parts that can affect ignition timing4 ,since accurate ignition timing is the first essential to good engine performance1 it is advisable to check ignition timing on new vehicle after first #a1ejj miles of service1 and at each #b1jjj miles thereafter4 7#a7 ,see that circuit breaker points are adjusted for correct gap of #j4jbb inch 7par4 #hd f74 7#b7 ,advance timer lever fully 7toward engine74 7#c7 ,turn engine in direction in which it runs until front cylinder is on compression stroke1 and continue to turn it ahead slowly until narrow timer cam 7the end with the timing mark71 just starts to open the circuit breaker points4 ,illustration3 ,,ra ,,pd #cahbje ,figure #eb--,shielding of ,coil to ,timer ,wire ,grounded on ,base 7#d7 ,an accurate test light check as to when points just start to break can be made1 using the instrument panel red light for the purpose4 ,disconnect panel light wire from the oil pressure switch1 attaching this wire to the insulated terminal post on timer head4 ,turn ignition and light switch on4 ,as long as circuit breaker points are closed1 lamp will remain lit2 as points start to open1 lamp will go out4 ,,note3 ,after making use of instrument panel red light for above purpose1 reconnect wire to oil pressure switch4 7#e7 ,when exact position is found1 where points just start to open1 flywheel mark should be in the center of the inspection hole4 7#f7 ,if flywheel mark is not in center of hole when points open1 readjust ignition timing as necessary 7slower or faster7 by means of the timer head and band adjustment4 ,illustration3 ,,ra ,,pd #cahbjc ,figure #ec--,shielded ,coil to ,timer ,wire ,correctly ,connected at ,coil 7#g7 ,to readjust timer head1 loosen adjusting band screw and shift timer head in band4 ,if flywheel timing mark shows forward of center in inspection hole1 the timing is slow4 ,to correct1 shift timer head counterclockwise against rotation of breaker cam4 ,if flywheel mark is to rear of center of inspection hole1 timing is fast and timer head must be shifted with rotation 7clockwise7 of breaker cam1 to correct timing4 7#h7 ,with ignition timing correct1 front cylinder piston is #i_/cb inch before top dead center1 on compression stroke1 when circuit breaker points just start to open4 ,at this point spark occurs1 igniting front cylinder fuel charge4 7#i7 ,install flywheel inspection hole plug in left crankcase4 #hg4 ,,coil ,,to ,,timer ,,wire 7figs4 #eb and #ec74 a4 ,models provided with radio shielding are identified by 8,s0 on either side of instrument panel4 ,the coil to timer wire 7lowtension wire7 on these models is shielded for radio noise suppression4 b4 ,remove4 7#a7 ,disconnect battery negative ground wire at frame connection4 7#b7 ,remove the two bolts which secure upper end of air cleaner bracket to frame tube4 ,swing air cleaner and bracket outward and forward to gain access to spark coil rear terminal4 7#c7 ,disconnect coil to timer wire terminal from coil rear connection4 ,disconnect wire shielding from coil rear ground connection4 7#d7 ,refer to paragraph #hf b 7#a7 to 7#d7 for timer head removal4 7#e7 ,remove timer base mounting screw which secures wire shielding 7fig4 #eb74 7#f7 ,note position of coil to timer wire inside of timer head2 then remove nut washer connecting wire to insulated contact stud4 7#g7 ,work old wire and loom out of timer head hole and free from vehicle4 7#h7 ,on earlier models1 the coil to timer wire was soldered to end of insulated stud4 ,removal of stud is necessary to remove this wire1 or replace it with a shielded wire4 ,note location of stud insulations on inside and outside of timer head1 for correct installation when reassembling4 c4 ,install4 7#a7 ,pass end of wire1 shield terminal1 and loom up through hole in timer base4 7#b7 ,ground the wire shield terminal under head of timer base mounting screw 7fig4 #eb74 7#c7 ,connect wire end terminal to insulated stud so that wire leads away from stud in direction shown 7fig4 #eb74 7#d7 ,pass coil to timer wire up alongside and to rear of frame saddle post tube to reach rear of spark coil4 7#e7 ,ground the wire shield terminal to coil rear ground connection 7fig4 #ec74 7#f7 ,connect wire terminal to coil rear primary connection 7fig4 #ec74 7#g7 ,install timer head on base 7par4 #hf c 7#aa774 7#h7 ,connect spark control wire to timer lever and adjust 7par4 #hh74 7#i7 ,connect battery negative post wire to frame ground terminal4 7#aj7 ,swing air cleaner bracket back into place and install two bolts1 washers1 and nuts securing bracket to frame clips4 7#aa7 ,replace timer cover and check engine for starting4 #hh4 ,,adjust ,,spark ,,control4 a4 ,spark advance and retard is controlled by left handle bar grip4 ,spark lever operates within a quadrant mounted on engine4 ,spark must be fully advanced 7lever inward toward engine7 when handle bar grip is turned inward to full extent of its travel4 ,when handle bar grip is turned outward1 spark lever retards 7lever outward away from engine74 7#a7 ,with control wire in lever stud and clamp screw loose1 turn left grip fully inward2 then back it out just a little4 7#b7 ,shift spark lever inward toward engine as far as it will go2 then tighten control wire clamp screw4 ,test by turning left grip fully inward and noting position of spark lever4 ,it should be against inner side of quadrant 7fig4 #ea74 ,retard spark and check position of lever within quadrant2 it should be against outer side of quadrant4 7#c7 ,check final adjustment4 ,readjust full advance and retard timer lever positions as necessary when left grip is turned inward1 and outward1 respectively4 #hi4 ,,spark ,,coil 7fig4 #ed74 a4 ,spark coil hightension cables go directly to the spark plugs1 no distributor being used4 ,when the coil is faulty1 it must be replaced1 since internal repairs are not possible4 ,the hightension cables can be replaced1 however4 ,coil is provided with a condenser for radio noise suppression1 and metal coil case is grounded to engine by bonding4 b4 ,remove4 7#a7 ,disconnect battery negative ground wire from frame connection4 7#b7 ,free hightension cable ends 7with radio noise suppressors7 from spark plugs4 ,free front cylinder hightension cable from clip at upper engine frame mounting4 7#c7 ,loosen air intake hose connection at carburetor fitting4 7#d7 ,remove two nuts1 washers1 and bolts securing upper end of air cleaner mounting bracket to frame clamps4 ,illustration3 ,,ra ,,pd #cahbjd ,figure #ed--;,coil ,front ,connections ,showing ,radio ,bonding and ,noise ,suppression ,condenser 7#e7 ,swing air cleaner and bracket assembly outward to gain access to coil rear terminals4 7#f7 ,disconnect coil to timer wire from coil rear terminal screw4 ,disconnect wire shielding from coil rear ground terminal 7fig4 #ec74 7#g7 ,swing cleaner back and remove wire connections from coil front terminal screw 7fig4 #ed74 7#h7 ,disconnect radio bonding at coil front ground terminal 7fig4 #ed74 7#i7 ,remove nuts and bolts which mount coil to bracket4 ,coil is now free for removal4 c4 ,install4 7#a7 ,mount coil on frame bracket with hightension cables upward1 and reinstall mounting bolts1 lock washers1 and nuts4 ,tighten nuts4 7#b7 ,connect terminals of the two green wires to coil front terminal screw4 ,refer to wiring diagram1 figure #dh4 7#c7 ,connect radio bonding to coil front ground terminal4 ,tighten nut securely4 7#d7 ,connect coil to timer wire terminal to coil rear terminal screw4 ,connect wire shielding to coil rear ground terminal4 ,tighten nut securely4 7#e7 ,swing air cleaner and bracket assembly back in place and install two bolts1 lock washers1 and nuts securing bracket to frame clamps4 ,tighten nuts securely4 7#f7 ,connect battery negative ground wire to frame connection4 7#g7 ,pass front cylinder hightension wire under tank1 secure in cable clip at upper engine frame mounting1 and attach cable end 7radio noise suppressor7 to front spark plug4 ,attach rear hightension cable end 7radio noise suppressor7 to rear spark plug4 7#h7 ,check wiring connections 7fig4 #dh7 and test coil by engine starting4 ,section ,,xix ,,generating ,,system ,paragraph ,description #ij ,clean commutator #ia ,armature bearing special lubrication #ib ,remove generator #ic ,install generator #id ,cutout relay #ie ,illustration3 #h--;,,generator ,,signal ,,light #ab--;,,battery ,,positive ,,terminal #ac--;,,battery ,,negative ,,terminal 7,,ground7 #ad--8,,switch0 ,,terminal ,,of ,,generator #ae--8,,relay0 ,,terminal ,,of ,,generator #ah--;,,front ,,junction ,,terminal #bf--;,,ignition ,,and ,,light ,,switch #cb--;,,cut,,out ,,relay 99,h--,,noise ,,suppression ,,condenser ,,ra ,,pd #cagbjj ,figure #ee--;,generator to ,battery ,wiring ,diagram #ij4 ,,description 7fig4 #ee74 a4 ,the generator is shunt connected4 ,the two field coils1 regulating coil1 and shunt coil are not connected in series in the conventional manner4 ,the regulating field coil provides adequate current output 7approx4 #d amperes7 for daytime operation4 ,the shunt field coil is controlled through the ignition and light switch to increase current output 7approx4 #h amperes7 when vehicle lights are in use4 ,generator uses the third 7regulating7 brush system of current regulation4 ,a cutout relay serves as a magnetic switch in the generatorbattery circuit1 also operating the instrument panel green signal light to indicate generator charge4 ,illustration3 ,,ra ,,pd #cajbei ,figure #ef--;,generator ,cover ,removed for ,commutator ,cleaning #ia4 ,,clean ,,commutator 7fig4 #ef74 a4 ,if battery is in good condition1 cutout relay is functioning1 and wiring connections are made according to diagram 7fig4 #ee71 yet generator does not charge or charge rate is low1 proceed to clean the commutator4 7#a7 ,remove left footboard1 sidebar1 and clutch foot pedal assembly1 following procedure outlined under paragraph #ajb a 7#a7 to 7#f71 to permit generator cover removal4 7#b7 ,remove the two end cover screws and pull end cover off generator4 7#c7 ,clean armature commutator with ,no4 #jj sandpaper until bright and clean4 ,blow out with air4 ,,caution3 ,do not remove or disturb brushes in their holders4 ,never use emery cloth to clean the commutator4 ,illustration3 ,,ra ,,pd #cajbfj ,figure #eg--;,generator ,end ,cover and ,grease ,retainer ,removed 7#d7 ,temporarily install footboard assembly and operate engine1 to observe whether or not generator is charging 7green signal light goes off at above #bj mph74 ,if cleaning commutator does not remedy generator charge1 and_/or commutator is badly worn1 then generator must be replaced 7par4 #ic74 ,if cleaning of commutator remedied generator charge1 reinstall generator end cover1 and the footboard and clutch pedal assembly 7par4 #ajb b74 #ib4 ,,armature ,,bearing ,,special ,,lubrication 7fig4 #eg74 a4 ,at the #f1jjj-mile second echelon preventive maintenance service period1 the commutator end bearing must be handpacked4 ,in performing this operation1 care must be taken not to shift or move the generator third 7regulating7 brush1 thus disturbing generator current regulation4 ,generator drive end bearing is adequately lubricated by oil circulating through engine4 b4 ,to ,lubricate ,commutator ,end ,bearing4 7#a7 ,remove left footboard1 sidebar1 and clutch pedal assembly1 following procedure outlined in paragraph #ajb a 7#a7 to 7#f74 7#b7 ,remove the two end cover screws and pull end cover off generator4 7#c7 ,remove two of the three screws which secure the outer grease retainer plate to end of generator 7fig4 #eg74 7#d7 ,loosen the other grease retainer plate screw slightly to permit shifting plate to one side4 7#e7 ,pack ball bearing with general purpose grease ,no4 #b1 pressing lubricant into bearing with finger4 7#f7 ,shift the outer grease retainer plate back into position4 ,install the two screws removed1 and securely tighten all three screws4 7#g7 ,install generator end cover and the two retaining screws4 7#h7 ,install left footboard1 sidebar1 and clutch foot pedal assembly1 following procedure outlined in paragraph #ajb b4 #ic4 ,,remove ,,generator 7figs4 #eh and #ei74 a4 ,generator is gear driven through engine timing gear train4 ,generator can be removed and installed without removing timing gear case cover1 or affecting alinement of timing gears4 b4 ,before replacing generator because of failure of instrument panel green signal light to indicate charge1 check panel light wiring and bulb for good condition 7par4 #abj74 c4 ,when it has been determined that generator must be removed for replacement1 proceed as follows3 7#a7 ,disconnect wires from the two generator terminals marked ,,switch and ,,relay4 7#b7 ,remove the two long screws1 through timing gear case cover1 that secure end of generator against gear case 7fig4 #eh74 7#c7 ,remove strap nut1 lock washer1 and curved washer from end of strap that clamps generator in its cradle on engine crankcase 7fig4 #ei74 ,illustration3 ,,ra ,,pd #cajbfa ,figure #eh--,removing ,generator ,end ,mounting ,screws ,illustration3 ,,ra ,,pd #cajbfb ,figure #ei--,removing ,generator ,strap ,nut 7#d7 ,lift strap high enough to permit raising generator so that oil slinger 7on end of generator gear7 will clear adjacent gear1 and allow generator to be removed from engine4 ,be sure to observe and count number of paper shims between generator and cradle4 ,lay these shims aside to be used again when generator is reinstalled4 ,also1 note location of hole in shims for oil drain4 ,these shims were required in original assembly to adjust driving gears for proper mesh and1 if left out1 gears may mesh too deeply and 8howl10 even though considerably worn4 ,unless a new generator gasket is available1 to be used when generator is reinstalled1 be careful not to damage the old one4 #id4 ,,install ,,generator4 a4 ,when installing generator1 the important point to consider is correct shimming of generator in its cradle to provide correct mesh of driving gear with intermediate timing gear4 ,make sure same number of paper shims are used in reassembling as were found underneath generator when it was removed4 ,after an engine has been run a considerable length of time and gears have worn to some extent1 they have possibly developed sufficient lash or play to safely remove one or more of the original shims1 and thus affect closer meshing and quieter operation4 ,however1 this should not be done unless timing gear case cover is removed so that gear mesh and lash can be carefully checked4 7#a7 ,pass generator drive gear end through gear case hole1 lifting generator so that oil slinger clears intermediate timing gear4 ,turn generator in its cradle so that end holes line up with long mounting screws which pass through gear case cover4 ,tighten mounting screws securely4 7#b7 ,install curved washer1 lock washer1 and nut on end of clamp strap2 tighten nut securely4 7#c7 ,connect redblack wire to generator terminal marked ,,relay1 and green wire to generator terminal marked ,,switch4 ,refer to wiring diagram 7fig4 #ee74 7#d7 ,operate engine and check generator for current output1 as well as check for gear noise4 ,if shimming under generator is proper1 generator and timing gears will run quietly4 ,if necessary1 readjust shimming until gears operate quietly4 #ie4 ,,cut,,out ,,relay4 a4 ,operation of the instrument panel green signal light1 indicating generator charge1 is controlled by the cutout relay4 ,therefore1 if relay is faulty the signal light will not operate properly1 falsely indicating generator trouble4 ,rust around the contact points1 burned points1 and loss of armature spring tension are sources of most relay trouble4 ,,note3 ,before condemning a relay because of failure of green signal light1 make light test 7par4 #abj74 b4 ,correct adjustment of relay point gaps and tensioning of armature springs require use of precision electric meters and expert knowledge on the subject4 ,a faulty relay1 other than removing cover and cleaning with air1 should be replaced4 ,no adjustment of points should be attempted4 c4 ,remove4 7#a7 ,disconnect the three wires from relay terminal screws4 7#b7 ,remove the two mounting screws and lock washers4 ,remove relay from engine base4 d4 ,install4 7#a7 ,mount relay on engine base with two screws and lock washers4 ,make sure that mounting is clean to make good electrical ground contact between relay and engine4 7#b7 ,reconnect the three wire terminals to relay terminal screws4 ,follow wiring diagram1 figure #ee4 7#c7 ,operate engine and observe action of relay1 also action of instrument panel green signal light to indicate generator charge4 ,section ,,xx ,,brake ,,system ,paragraph ,rear wheel brake #if ,front wheel brake #ig #if4 ,,rear ,,wheel ,,brake 7figs4 #fj1 #fa1 and #fb74 a4 ,linkage4 ,brake foot pedal on right side of vehicle is connected to bell crank 7located on rear footboard support rod7 by means of the front brake rod 7nonadjustable74 ,the bell crank is connected to rear brake operating lever by means of the rear brake rod with adjustable clevis end4 ,illustration3 ,,ra ,,pd #cajbgg ,figure #fj--,rear ,brake ,adjustment b4 ,adjusting ,rear ,wheel ,brake 7fig4 #fj74 ,if brake operating lever stands ahead of vertical position1 excessive lining wear is indicated4 ,brake shoes must be replaced 7steps c and d below74 ,normal free play of brake foot pedal before brake operation is #a inch4 ,after brake takes effect in vehicle operation1 brake foot pedal should have #a-;inch reserve travel before bottoming on footboard4 ,if brake foot pedal operation does not come within these limits1 adjust rear brake rod as follows3 7#a7 ,remove cotter pin1 plain washer1 and clevis pin from end of rear brake rod clevis4 7#b7 ,loosen clevis lock nut on brake rod4 7#c7 ,turn clevis onto 7clockwise7 brake rod to shorten rod and take up foot pedal free play4 7#d7 ,turn clevis off 7counterclockwise7 brake rod to lengthen rod and increase foot pedal free play4 7#e7 ,after making brake adjustment1 spin rear wheel and make sure brake is not dragging4 ,when correct brake adjustment is attained1 install clevis pin in clevis and brake operating lever with plain washer1 and retain with cotter pin4 ,,note3 ,cotter pin must be in good condition4 ,illustration3 ,,ra ,,pd #cajbgc ,figure #fa--,rear ,brake ,assembly c4 ,remove ,brake ,shoes 7fig4 #fa74 7#a7 ,remove rear wheel 7par4 #abg74 7#b7 ,remove brake drum and sprocket assembly4 ,brake shoes are now accessible4 ,do not remove side cover assembly from frame4 7#c7 ,disconnect brake rod clevis at brake operating lever4 7#d7 ,place end of large screwdriver blade between ends of brake shoes at pivot stud4 ,move brakeoperating lever forward to hold brake shoes in fully expanded position1 and pry ends of shoes off pivot stud without removing brake shoe springs4 d4 ,install ,brake ,shoes4 ,observe that brake shoes are made for upper and lower positions and are not interchangeable4 ,recess in end of shoe for pivot stud head determines position of shoe in assembly4 7#a7 ,engage ends of springs in shoe assembly holes from the inside before installing shoes on side cover 7fig4 #fa74 7#b7 ,with brake shoes and springs assembled1 install so that ends of shoes will slip over pivot stud and shaftoperating cam4 7#c7 ,connect brake rod clevis to brake operating lever4 7#d7 ,install brake drum and sprocket assembly4 ,lock brake to hold drum in place while installing wheel 7fig4 #hd74 7#e7 ,install rear wheel 7par4 #abg74 ,,note3 ,if rear chain is in need of adjustment1 it should be done at this time4 7#f7 ,to equalize brake shoes1 loosen nut on brake shoe adjustable pivot stud 7on outside of brake side plate71 and while applying pressure on brake foot pedal 7to 8center0 the brake shoes within the drum71 retighten the pivot stud nut4 7#g7 ,after new or relined shoes have been installed1 check foot pedal for free play 7step b above74 #ig4 ,,front ,,wheel ,,brake 7fig4 #fb74 a4 ,linkage 7control74 ,handle bar hand lever control wire which operates front wheel brake can be adjusted and or replaced4 ,keep brake control wire lubricated 7through oiler in housing and at ends of housing7 with engine oil4 b4 ,remove ,control ,wire4 ,remove control wire clamp nut from brake lever clevis1 and free lower end of control wire from clevis4 7#a7 ,remove cotter pin and flat washer from hollow pin1 permitting hollow pin to be pulled out of hand lever4 ,control wire can now be pulled out of housing through the hole in hand lever4 c4 ,install ,control ,wire4 ,apply grease or engine oil to new control wire and insert1 through hand lever1 into control wire housing4 ,use caution when inserting a new control wire into housing1 to prevent wire end from fraying4 ,a frayed wire with loose end strands will not feed through the housing4 7#a7 ,with control wire in housing1 insert hand lever hollow pin so that narrow slot straddles control wire3 then fit flat washer over end of hollow pin1 retaining both with cotter pin4 7#b7 ,insert lower end of control wire through clamp nut1 then through clevis and back through clamp nut again4 ,grasp end of wire with pliers and pull until all slack is taken up4 ,then1 while pulling wire snug1 tighten clamp nut securely4 ,cut off excess wire4 7#c7 ,adjust brake control 7refer to step d below74 ,illustration3 ,,ra ,,pd #cajbgd ,figure #fb--;,front ,brake ,control and ,adjusting ,members d4 ,adjusting ,front ,wheel ,brake4 ,end of brake hand lever must move freely about #a_/d of its travel before meeting resistance of brake operation4 7#a7 ,loosen adjusting sleeve lock nut and turn adjusting sleeve as necessary to attain correct free movement of hand lever4 7#b7 ,after correct hand lever adjustment is made1 tighten adjusting sleeve lock nut4 e4 ,remove ,brake ,shoes4 7#a7 ,remove front wheel 7par4 #abe74 ,after front wheel is removed1 brake side cover and shoe assembly is accessible for shoe replacement4 7#b7 ,remove brake shoes4 ,brake shoes and springs can be pried off pivot stud and freed from operating cam without removing springs4 f4 ,install ,brake ,shoes4 ,observe that brake shoes are made for upper and lower positions and are not interchangeable4 ,recess in end of shoe for pivot stud head determines position of shoe in assembly4 7#a7 ,engage ends of springs in shoe holes from the inside before installing shoes in brake side plate4 7#b7 ,with shoes and springs assembled1 install the shoes so that ends of shoes will slip over pivot stud and shaft operating cam4 7#c7 ,install front wheel and brake assembly 7par4 #abe74 7#d7 ,loosen nut on brake shoe adjustable pivot stud and while applying pressure on brake hand lever1 retighten pivot stud nut4 ,this is to center brake shoes within the brake drum4 7#e7 ,after new or relined shoes have been installed1 check brake hand lever and1 if necessary1 adjust the control wire 7step d above74 ,section ,,xxi ,,steering ,,control ,paragraph ,forks #ih ,steering damper #ii ,handle bars #ajj ,handle bar controls #aja #ih4 ,,forks 7figs4 #fc and #fd74 a4 ,either the spring fork can be removed and replaced1 or the complete fork assembly 7spring fork and rigid7 can be replaced4 b4 ,remove ,spring ,fork 7fig4 #fc74 7#a7 ,support vehicle on rear stand4 7#b7 ,remove the fork spring rod lock nuts 7acorntype74 7#c7 ,sit on front mudguard1 or otherwise provide weight1 to compress fork cushion 7lower7 springs4 ,the spring rod large nuts can then be easily removed1 freeing the upper recoil and upper bumper springs for removal4 7#d7 ,remove front wheel 7par4 #abe74 7#e7 ,remove front mudguard 7par4 #ajd74 7#f7 ,remove spring fork right and left side rocker plate studs4 ,,note3 ,leave rigid fork rocker studs1 with rockers1 attached4 7#g7 ,remove spring fork from vehicle4 c4 ,install ,spring ,fork4 7#a7 ,place buffer springs and lower cushion springs on fork rods4 ,apply grease to rods4 ,pass fork rods up through rigid fork bracket4 ,bind lower end of spring fork to lower end of rigid fork with a strap or piece of heavy wire 7fig4 #fd71 to prevent forks from separating while compressing cushion springs4 7#b7 ,install two bolts in the rigid fork brackets which mount the mudguard2 then place a rod about #h inches long on the brackets to provide a pry base for the leverage bar when compressing cushion springs 7fig4 #fd74 ,with a leverage bar about #ah inches long1 anchored on top of the pry base rod and under the spring fork1 lift upward to compress cushion springs sufficiently to install one of the rocker plates4 ,then install the other rocker plate 7fig4 #fd74 ,,note3 ,left side spring fork rocker plate stud has a button end which fits into notch in brake stabilizer plate4 7#c7 ,install mudguard 7par4 #ajd74 7#d7 ,install front wheel 7par4 #abe74 7#e7 ,install the two spring rod bushings4 ,install upper bumper springs and upper recoil springs on the fork rods1 applying grease to rods4 7#f7 ,remove blocks from under vehicle4 7#g7 ,sit on mudguard to compress fork cushion 7lower7 springs4 ,tighten the two large spring rod nuts sufficiently to provide full thread for the spring rod lock nuts 7acorntype74 ,install spring rod lock nuts and tighten4 7#h7 ,see that all nuts1 bolts1 and screws securing lamp bracket1 mudguard1 scabbard carrier1 and ammunition carrier are tightened securely4 7#i7 ,check front wheel brake for operation4 d4 ,remove ,upper ,recoil ,springs and_/or ,upper ,bumper ,springs4 7#a7 ,support vehicle on rear stand4 ,remove the fork spring rod lock nuts 7acorntype74 7#b7 ,sit on front mudguard1 or otherwise provide weight1 to compress fork cushion 7lower7 springs4 ,the spring rod large nuts can then be easily removed1 freeing the upper recoil and upper bumper springs for removal4 e4 ,install ,upper ,recoil ,springs and_/or ,upper ,bumper ,springs4 7#a7 ,apply grease to fork spring rods and install upper bumper springs4 7#b7 ,install upper recoil springs over bumper springs on fork spring rods4 7#c7 ,sit on front mudguard to compress cushion 7lower7 springs sufficiently to start on spring rod large nuts4 7#d7 ,tighten both spring rod large nuts4 ,install and tighten the two spring rod 7acorntype7 lock nuts4 f4 ,remove and ,install ,lower ,cushion ,springs and_/or ,lower ,buffer ,springs4 ,this operation calls for same procedure followed in removing and installing spring fork 7steps b and c above74 g4 ,remove ,complete ,fork ,assembly4 7#a7 ,remove ammunition box carrier 7par4 #ajc74 7#b7 ,remove scabbard carrier 7par4 #ajc74 7#c7 ,remove front wheel 7par4 #abe74 7#d7 ,remove steering damper 7par4 #ii74 ,illustration3 ,,ra ,,pd #caegbh ,figure #fc--,spring ,fork ,disassembled ,a--,,upper 7,,recoil7 ,,springs ,b--,,upper ,,bumper ,,springs ,c--,,spring ,,rod ,,lock ,,nuts 7,,acorn,,type7 ,d--,,spring ,,rod ,,bushings ,e--,,large ,,spring ,,rod ,,nuts ,f--,,lower ,,cushion ,,springs ,g--,,spring ,,rods ,h--,,lower ,,buffer ,,springs ,j--,,spring ,,fork ,,assembly ,k--,,rocker ,,plate ,,stud ,,nuts ,,and ,,locks ,l--,,right ,,side ,,rocker ,,plate ,,stud ,,and ,,washer ,m--,,left ,,side ,,rocker ,,plate ,,stud 7,,has ,,button ,,end7 ,,and ,,washer ,n--,,ammunition ,,box ,,carrier ,,mounting ,,bolt1 ,,washers ,,and ,,nut ,o--,,headlight ,,bracket ,,and ,,mudguard ,,bolt1 ,,washer ,,and ,,nut 7,,left ,,side7 ,p--,,front ,,axle1 ,,castle ,,nut ,,and ,,cotter ,,pin ,q--,,scabbard ,,carrier ,,mounting ,,bolt1 ,,washers ,,and ,,nut ,r--,,headlight ,,bracket ,,and ,,mudguard ,,bolt1 ,,marker ,,light ,,gable ,,clip1 ,,washer ,,and ,,nut 7,,right ,,side7 ,s--,,brake ,,shackle ,,bolt1 ,,lock ,,and ,,nut ,t--,,brake ,,and ,,side ,,cover ,,assembly ,u--,,mudguard ,,bracket ,,mounting ,,lock1 ,,washer ,,and ,,nuts 7,,right ,,side7 ,v--,,mudguard ,,and ,,rigid ,,fork ,,mounting ,,screws1 ,,washers ,,and ,,nuts ,w--,,mudguard ,,bracket ,,mounting ,,lock1 ,,washer ,,and ,,nuts 7,,left ,,side7 ,x--,,notches ,,in ,,mudguard ,,brackets ,,for ,,special ,,locks ,,ra ,,pd #caegbhh ,legend for ,figure #fc--,spring ,fork ,disassembled 7#e7 ,remove front mudguard1 after removing nuts and locks from rear rocker plate studs1 two screws and nuts securing mudguard to rigid fork1 and the two bolts mounting headlight bracket to mudguard4 ,,note3 ,front mudguard blackout light wire connects to ignition and light switch and care must be exercised not to break this wire if it is not disconnected from the switch4 7#f7 ,disconnect battery negative ground wire at frame connection4 ,remove blackout light 7par4 #aad74 ,remove headlight1 horn1 and bracket assembly as one unit4 7#g7 ,remove handle bar brake fittings and brake control wire housing from side of fork4 ,remove handle bars after removing handle bar bracket lock nut and cone lock plate4 ,it is not necessary to disconnect spark and throttle control wire housings from frame4 ,unscrew fork upper adjusting cone from fork stem1 freeing fork assembly to be removed from frame head4 ,,note3 ,steering head ball bearings are loose 7not in retainers7 in upper and lower frame head bearing cups4 ,take care not to lose balls4 h4 ,install ,fork ,assembly4 ,with vehicle on rear stand1 and front end up by blocking under frame loop or skid plate1 proceed with installing fork assembly1 as follows3 7#a7 ,thoroughly clean upper and lower frame head bearing cups and pack with general purpose grease ,no4 #b1 installing fifteen #e_/af-;inch ball bearings in each cup4 ,work grease thoroughly in between balls4 7#b7 ,see that lower fork stem cone is clean and in place1 pass fork stem up through frame head1 turning on upper adjusting cone4 ,do not try to adjust bearing cone as yet4 7#c7 ,install handle bars by locating mounting bracket on ends of fork sides and center stem1 making sure that spark and throttle control wire housings are in place4 7#d7 ,adjust upper fork stem adjusting cone so that there is no perceptible shake in head bearings when handle bars are worked up and down1 and fork does not bind when turned to right and left extremes4 7#e7 ,install cone lock plate by engaging pin in one of the cone notches4 7#f7 ,install lock nut on stem and tighten securely4 ,,note3 ,check head bearing play1 as tightening lock nut sometimes makes head bearing too tight4 ,readjust if necessary4 7#g7 ,attach handle bar brake fittings and brake control wire housing to side of fork4 7#h7 ,reinstall headlight1 horn1 and bracket assembly4 ,connect wires 7per wiring diagram fig4 #gc7 before front mudguard is reinstalled4 ,install blackout light 7par4 #aad74 ,reconnect battery negative ground wire to frame ground connection4 7#i7 ,install steering damper 7par4 #ii74 ,illustration3 ,,ra ,,pd #cajbff ,figure #fd--;,compressing ,cushion ,springs for ,spring ,fork ,assembly 7#aj7 ,install front mudguard4 ,attach two screws1 washers1 and nuts for rigid fork mounting and two bolts1 washers1 and nuts for headlight bracket mounting4 ,fit right and left mudguard brace clip locks to right and left side rocker plate studs respectively4 ,do not put on nuts until after installing ammunition box carrier and scabbard carrier4 7#aa7 ,install front wheel 7par4 #abe74 7#ab7 ,install scabbard carrier and ammunition box carrier 7par4 #ajc74 7#ac7 ,check lights1 horn1 spark control1 throttle control1 front brake control1 steering damper control1 and steering head bearing for freedom without binding4 i4 ,remove ,rocker ,plate ,studs4 ,studs and_/or rocker plates can be removed and installed in the same operation4 ,in removing and installing studs1 remove only one fork rocker plate at a time1 leaving the other plate attached to opposite side fork ends to hold fork springs in compressed position4 ,this will eliminate necessity of compressing fork springs to fit rocker plates on studs4 7#a7 ,remove front wheel 7par4 #abe74 7#b7 ,remove nuts and locks from rocker plate studs on right side of vehicle4 ,this releases gun scabbard carrier and mudguard stay clip4 ,,note3 ,remove the large nut which secures the long stud to rigid fork4 7#c7 ,drive out studs from fork ends1 releasing rocker plate4 7#d7 ,install studs and rocker plate before removing studs from left side of vehicle4 j4 ,install ,rocker ,plate ,studs4 ,apply grease to studs and insert in rocker plate1 then install large flat washers on studs before mounting this assembly on fork ends4 ,make sure that short stud is in front position1 and that long stud is in rear position for the rigid fork4 7#a7 ,drift studs 7with plate assembly7 into fork end holes from the inside4 7#b7 ,install special nut lock 7with half round hole7 on front stud and turn stud as necessary to make lock 8cup0 over end of fork4 ,install and tighten stud nut and bend up end of lock for security4 ,place lock washer over long stud and install thick nut1 securely tightening it4 7#c7 ,attach end of gun scabbard carrier and mudguard brace clip with special lock to long stud1 replacing washer and nut4 7#d7 ,after right side rocker plate and_/or studs have been installed1 remove and install studs and_/or plate on left side of vehicle following same stepbystep procedure as above4 ,the exceptions will be ammunition box carrier instead of scabbard carrier2 also1 the left side front stud is special1 having a 8button0 end4 7#e7 ,install front wheel 7par4 #abe74 ,illustration3 ,,ra ,,pd #cajbgf ,figure #fe--,steering ,damper ,assembly #ii4 ,,steering ,,damper 7fig4 #fe74 a4 ,remove 7fig4 #fe74 7#a7 ,remove front wheel 7par4 #abe74 7#b7 ,remove front mudguard 7par4 #ajd74 7#c7 ,remove lock nut from steering damper rod1 then remove upper end parts in the following order3 adjusting nut1 keyed steel washer1 fiber washer1 operating lever1 and actuating sleeve4 ,this entire assembly is located in the central part of the handle bar mounting bracket4 7#d7 ,steering damper rod1 cushion spring1 pressure disk1 fiber disk1 and steel disk assembly can now be withdrawn 7downward7 from fork stem hole4 b4 ,install 7fig4 #fe74 ,before installing steering damper1 make sure that the parts are in correct order on the lower end of the rod before passing rod up through hole in fork stem4 ,check parts and order of assembly4 7#a7 ,assemble parts on rod end 7fig4 #fe71 making sure that the bent down lip of the steel pressure disk engages with notch in end of the rod lock plate4 7#b7 ,pass rod with its lower end assembly up through hole in fork stem1 turning steel pressure disk to front position so that 8bentup0 lip engages with notch in front side of rigid fork crown1 at the same time engaging curved end of steel disk torque arm in slot in underside of frame head4 ,maintain pressure against end of rod to keep lower disks in order while assembling upper rod end parts4 7#c7 ,install upper rod end assembly in the following order3 ,small plain washer1 releasing spring1 adjusting sleeve screws into end of fork stem1 operating lever registers on the adjusting sleeve1 fiber washer1 keyed steel washer registers in rod slot1 large adjusting nut1 and lock nut4 7#d7 ,turn actuating sleeve all the way into fork stem and then back it out 7up7 #a_/b turn or more4 ,register the operating lever on flat of actuating sleeve1 and see that lever has full movement to the left without bottoming sleeve in the fork stem4 7#e7 ,adjust steering damper by setting adjusting 7large7 nut so that operating lever must be moved nearly straight back from the free 7leftside7 position1 before damper takes noticeable effect 7applies friction to movement of the handle bars74 ,hold large adjusting nut and tighten the small lock nut4 7#f7 ,install front mudguard 7par4 #ajd74 7#g7 ,install front wheel 7par4 #abe74 #ajj4 ,,handle ,,bars4 a4 ,remove ,complete ,assembly4 ,if vehicle is equipped with handle bar windshield and rear view mirror1 remove these accessories before starting to remove handle bar assembly4 7#a7 ,disconnect throttle control wire at carburetor lever1 and spark control wire at timer lever4 7#b7 ,release spark control wire housing clip at front cylinder base bolt 7near timer74 ,also release housing from frame clip on left side of vehicle4 ,release throttle control wire housing clip1 located at tank1 lower front connection bolt4 7#c7 ,remove front brake hand lever fittings from handle bars4 ,also release brake control wire housing at handle bar clamp4 7#d7 ,disconnect battery negative ground wire at frame connection and wires at headlight4 ,headlight must be removed for access to the two terminal screws 7fig4 #gc74 7#e7 ,disconnect horn wire leading to handle bars and red wire 7terminal ,no4 #ag1 fig4 #gc7 leading to handle bars4 7#f7 ,remove steering damper rod upper end fittings in the following order3 ,lock nut1 adjusting nut1 keyed steel washer1 fiber washer1 operating lever1 and operating sleeve 7screws into end of fork stem74 ,removal of these parts gives access to handle bar lock nut4 ,remove handle bar lock nut and cone lock plate4 7#g7 ,loosen handle bar bracketfork end pinch bolts4 ,handle bars are now free to be drifted off ends of fork sides and center stem4 7#h7 ,remove handle bar windshield apron spring guard after handle bars are removed from vehicle4 b4 ,install ,complete ,assembly4 ,if vehicle is equipped with handle bar windshield and rear view mirror1 attach these accessories after handle bar assembly is installed4 7#a7 ,attach windshield apron spring guard to handle bar bracket4 ,do not tighten bolt nut until after handle bars are installed4 7#b7 ,start handle bar bracket holes over ends of fork1 seeing that spark control wire housing is on right side of frame head3 then drive handle bars onto fork ends1 using a rawhide mallet1 or a hammer and wood block4 7#c7 ,to install cone lock plate1 enter registering pin through hole in handle bars and engage notch in the adjusting cone4 ,install and tighten handle bar lock nut securely4 ,,caution3 ,when tightening this nut1 always make sure that register 7shoulder7 of nut enters hole in lock plate and handle bars4 7#d7 ,check adjustment of head bearing4 ,the fork must turn freely but without perceptible shake4 ,readjust head cone to obtain proper bearing adjustment if necessary4 7#e7 ,tighten handle bar bracketfork end pinch bolts4 7#f7 ,position windshield apron guard so that it clears fork springs4 ,securely tighten mounting bolt nut4 7#g7 ,install steering damper upper end fittings 7fig4 #fe74 ,make sure that lower end disks and plates are properly engaged4 ,adjust 7par4 #ii74 7#h7 ,connect handle bar wires to terminal plate1 horn1 and headlight4 ,consult wiring diagram 7fig4 #gc74 ,install headlight4 ,adjust beam and secure mounting nut 7par4 #aad74 ,connect battery negative ground wire to frame connection4 7#i7 ,check operation of lights and horn1 tactical situation permitting4 7#aj7 ,attach front brake hand lever fittings to left handle bar4 ,secure control wire housing in handle bar clamp1 just ahead of housing oiler4 ,check front brake for correct operation and1 if necessary1 adjust 7par4 #ig74 7#aa7 ,pass spark control wire housing along left side of frame front tube1 between cylinders 7under carburetor7 to position housing end clamp on cylinder stud near timer4 ,secure clamp under cylinder stud nut4 ,secure wire cable under clamp on left side of frame front tube1 with white paint mark slightly ahead of clamp front edge4 ,engage end of spark control wire in timer lever and adjust spark control 7par4 #hh74 7#ab7 ,pass throttle control wire housing along right side of frame front tube and over top of front cylinder head to reach carburetor connection4 ,install tank 7lower front7 mounting bolt to secure wire housing clamp4 ,see that white paint mark on wire housing is slightly ahead of clamp1 then secure bolt nut on left side of vehicle4 ,engage end of throttle control wire in throttle lever and adjust 7par4 #fi74 ,illustration3 ,,ra ,,pd #cajbhb ,figure #ff--,removing ,handle ,bar ,grip ,sleeve ,retaining ,nut #aja4 ,,handle ,,bar ,,controls 7figs4 #ff and #fg74 a4 ,construction of the throttle and spark controls is the same1 thus replacing a control wire or wire housing follows the same general procedure up to the point where control adjustment is made4 ,handle bar grip sleeves 7spirals7 are interchangeable4 b4 ,remove ,throttle ,control ,wire 7fig4 #fg74 7#a7 ,disconnect control wire at throttle lever connection4 7#b7 ,insert blade of a large1 squareshank screwdriver through hole in end of grip and turn out end nut by using a wrench on the shank of the screwdriver 7fig4 #ff74 ,sometimes this nut is difficult to remove4 ,in this case1 insert punch into the slot in the nut and strike punch two or three sharp blows to 8free0 nut in handle bar end threads4 ,remove nut as above4 ,,note3 ,nut remains inside the grip and is removed with the grip and spiral sleeve assembly4 7#c7 ,remove grip and spiral assembly from handle bars4 ,control wire and working parts are now accessible4 7#d7 ,remove plain roller from pin4 ,remove roller block from pin4 ,remove pin from plunger4 7#e7 ,pull plunger with wire attached out of handle bar end4 ,remove hexagon head screw which secures wire to plunger4 ,,note3 ,if wire is broken1 remove other half from housing at carburetor connection end4 7#f7 ,remove any rust1 dirt1 or gum from grip spiral1 handle bar end1 wire plunger1 and inside of handle bar where plunger operates4 ,illustration3 ,a--,,end ,,nut4 ,b--,,grip4 ,c--,,grip ,,sleeve ,,assembly4 ,d--,,roller ,,pin4 ,e--,,roller4 ,f--,,roller ,,block4 ,g--,,plunger4 ,h--,,control ,,wire4 ,i--,,wire ,,retaining ,,nut4 ,,ra ,,pd #cajbfc ,figure #fg--;,handle ,bar ,grip and ,wire ,control1 ,disassembled c4 ,install ,throttle ,control ,wire 7fig4 #fg74 7#a7 ,pass hollow screw over control wire with threaded end of hollow screw facing button on end of wire4 ,install screw in end of plunger4 ,securely tighten screw4 7#b7 ,apply grease or engine oil to control wire and insert end into control wire housing4 7#c7 ,apply grease to plunger and push plunger and wire into handle bar until plunger pin hole is exposed in handle bar slot4 ,work plunger or turn it within handle bar so that pin hole and flat side are upward and are centered in slot2 then insert roller pin into plunger hole1 roller block 7with flat sides71 and roller in order named4 ,apply grease to plunger pin and roller and to outside of handle bar end4 7#d7 ,install grip and spiral assembly by engaging plunger roller in spiral opening in end of grip sleeve4 ,grip spiral sleeve nut can best be started without danger of cross threading1 by holding grip assembly back slightly while starting nut in handle bar end4 ,this squares nut with end of grip sleeve1 alining threads4 ,securely tighten nut with screwdriver and wrench4 7#e7 ,connect control wire at throttle lever connection4 ,adjust control 7par4 #fi74 d4 ,remove ,spark ,control ,wire 7fig4 #fg74 ,disconnect control wire at timer lever and follow procedure outlined under step b above4 e4 ,install ,spark ,control ,wire 7fig4 #fg74 ,follow procedure outlined under step c above1 then connect control wire at timer lever and adjust control 7par4 #hh74 f4 ,remove and ,install ,control ,wire ,housings4 ,remove either control wire housing after following procedure outlined above 7step b71 then remove set screw on under side of handle bar1 just ahead of grip sleeve shoulder4 ,,note3 ,set screw for spark control wire housing is located under headlight dimmer switch4 ,after set screw is removed and housing freed from attaching clamps1 housing can be pushed out through end of handle bar4 7#a7 ,when installing control wire housings1 see that housing end is secured in handle bar with set screw1 and that housing is correctly attached to vehicle clamps4 7#b7 ,install control wire and grip 7step c above7 and adjust controls3 spark 7par4 #hh71 throttle 7par4 #fi74 ,section ,,xxii ,,sheet ,,metal ,,and ,,equipment ,paragraph ,chain guards #ajb ,carriers #ajc ,mudguards #ajd ,battery box #aje ,tool box #ajf ,tanks #ajg ,stands #ajh ,saddle post #aji ,safety guards #aaj ,skid plate #aaa #ajb4 ,,chain ,,guards4 a4 ,remove ,outer ,front ,chain ,guard 7figs4 #fh and #fi74 7#a7 ,remove nut and washer which secures center of chain guard and skid plate leftside support bracket4 7#b7 ,loosen skid plate support bracket lower bolt and nut and remove bracket from stud4 7#c7 ,loosen the nut which secures footboard rear stud to sidebar1 then remove nut which secures footboard front stud to sidebar4 ,pull front end of footboard away from sidebar so that stud will clear end of safety guard4 7#d7 ,remove extended nut which secures sidebar to frame front support rod4 7#e7 ,disconnect clutch control cable end at clutch foot pedal by removing cotter pin and plain washer from stud4 7#f7 ,left side footboard1 sidebar1 and clutch foot pedal assembly can now be removed4 ,if rear end of sidebar is lowered1 the front end will clear end of safety guard4 7#g7 ,remove cotter pin1 nut1 spring1 washer1 and bolt from chain guard rear mounting4 ,outer front chain guard can now be removed1 exposing engine sprocket1 front drive chain1 and clutch assembly4 b4 ,install ,outer ,front ,chain ,guard4 7#a7 ,locate outer front chain guard on center support stud 7frame rear support rod end74 ,line up rear mounting bracket with frame bracket4 7#b7 ,install bolt1 washer1 spring1 nut1 and cotter pin to secure rear mounting4 7#c7 ,install footboard1 sidebar1 and clutch foot pedal assembly on frame support rod ends4 ,illustration3 ,,ra ,,pd #cajbfd ,figure #fh--,left ,footboard ,assembly ,removed ,illustration3 ,,ra ,,pd #caegbi ,figure #fi--,outer ,front ,chain ,guard ,removed 7#d7 ,attach front end of sidebar4 ,install extended nut and lock washer to secure front sidebar and support rod mounting4 7#e7 ,install skid plate support bracket on support rod 7in center of chain guard71 tightening nut on bolt4 ,install nut and lock washer which secure skid plate bracket and chain guard on rear support rod4 ,tighten nut4 7#f7 ,pull front end of footboard away from sidebar so that hole in end of safety guard lines up with hole in sidebar1 then pass footboard stud through both pieces1 installing washer and securing stud nut4 ,tighten footboard rear stud nut4 7#g7 ,attach brake control cable end to foot pedal stud4 c4 ,remove ,rear ,chain ,guard4 7#a7 ,remove cap screw which secures rear chain oil pipe clamp1 and provides mounting for front end of chain guard on transmission sprocket cover4 ,remove chain guard4 7#b7 ,remove chain guard from rear mounting by pushing the guard back so that stud 7with washers and spring7 slips out of mounting clip notch4 d4 ,install ,rear ,chain ,guard4 7#a7 ,locate rear chain guard in position for mounting4 ,spread the large washer on the rear stud to engage clip notch4 ,push guard forward until front end hole lines up with chain oiler pipe clamp1 then install cap screw and washer1 securing guard and clip to sprocket cover4 #ajc4 ,,carriers4 a4 ,remove ,ammunition ,box ,carrier4 7#a7 ,remove nut and screw which secures carrier bracket to front mudguard4 7#b7 ,remove nut and lock washer from rocker plate rear stud4 ,this frees lower end of carrier4 7#c7 ,remove nut1 washer1 cable clip1 and plain washer from rigid fork stud4 ,remove carrier and box4 b4 ,install ,ammunition ,box ,carrier4 7#a7 ,locate hole in lower end of bracket on rocker plate rear stud4 ,attach upper end of bracket to rigid fork stud4 ,replace lock washers and nuts4 ,tighten nuts4 7#b7 ,attach carrier bracket to front mudguard with screw1 washer1 and nut4 ,tighten nut4 c4 ,remove and ,install ,scabbard ,carrier4 ,the procedure for removing and installing scabbard carrier is the same as outlined for ammunition box carrier1 except that scabbard carrier is on left side of vehicle4 ,follow procedure outlined under steps a and b above4 d4 ,remove ,luggage ,carrier4 7#a7 ,loosen straps of both saddlebags1 and remove saddlebags from keyhole notches in luggage carrier side plates4 ,remove nuts from right and left side mounting studs1 which secure luggage carrier to frame clips4 ,deflate rear wheel tire so that a piece of wood or suitable object can be used to depress top part of tire under mudguard1 to provide clearance1 and access to the three nuts which secure screws for luggage carrier mudguard mounting4 ,,note3 ,if rear wheel is removed1 mounting screws are accessible4 7#b7 ,remove the three luggage carrier center mounting screws4 ,remove luggage carrier from vehicle4 e4 ,install ,luggage ,carrier4 7#a7 ,mount luggage carrier on frame clip studs4 ,install washers and nuts4 ,with rear tire deflated and depressed for clearance under mudguard1 install the three screws1 lock washers1 and nuts for carriermudguard mounting4 ,,note3 ,if rear wheel is removed1 mounting screws are accessible4 7#b7 ,tighten frame stud nuts to secure both sides of carrier4 7#c7 ,attach saddlebags and securely strap to frame stays4 7#d7 ,inflate tire to #bj pounds4 #ajd4 ,,mudguards4 a4 ,remove ,front ,mudguard4 7#a7 ,remove front wheel 7par4 #abe74 7#b7 ,remove instrument panel cover 7par4 #aai71 disconnect front mudguard blackout marker light wire at switch4 ,pull wire out1 free from tanks4 7#c7 ,remove the two screws and nuts from rigid fork and mudguard mounting4 ,remove the two screws and nuts securing lamp bracket to mudguard4 7#d7 ,remove bolt and nut which secure ammunition box carrier to mudguard4 7#e7 ,remove bolt and nut which secure gun scabbard carrier to mudguard4 7#f7 ,remove nuts from fork left rocker plate stud4 ,these nuts secure ammunition box lower bracket1 and mudguard stay clip4 ,remove nuts from fork right rocker plate stud4 ,these nuts secure gun scabbard carrier lower bracket1 and mudguard stay clip4 7#g7 ,pull carrier brackets off rocker plate studs4 ,remove mudguard brace clip locks from slots in clips so that mudguard can be dropped4 ,when removing mudguard from vehicle1 take care not to break and_/or damage blackout light wire4 b4 ,install ,front ,mudguard4 7#a7 ,locate mudguard in mounting position4 ,engage slots in stay clips on rocker plate studs1 installing the special locks in the clip slots4 ,,note3 ,brace clip locks are made for right and left side installation4 ,secure both clip locks with stud nuts4 7#b7 ,attach ends of ammunition and scabbard carriers to rocker plate studs4 ,secure with lock washers and nuts4 7#c7 ,mount mudguard to rigid fork bracket4 ,tighten the two screws1 washers1 and nuts4 7#d7 ,attach lower end of headlight bracket to mudguard with two bolts1 washers1 and nuts4 7#e7 ,attach ammunition box carrier bracket to mudguard4 ,tighten bolt1 washer1 and nut4 7#f7 ,attach gun scabbard carrier bracket to mudguard4 ,tighten bolt1 washer1 and nut4 7#g7 ,reinstall front wheel and brake assembly 7par4 #abe74 7#h7 ,connect mudguard blackout light wire to switch terminal4 ,refer to wiring diagram1 figure #gc4 7#i7 ,install instrument panel cover 7par4 #aai74 c4 ,remove ,rear ,mudguard4 7#a7 ,support vehicle on rear stand4 ,remove rear wheel 7par4 #abg74 7#b7 ,remove luggage carrier 7par4 #ajc74 7#c7 ,remove rear chain guard 7par4 #ajb74 7#d7 ,remove the two ,ubolt nuts which mount safety guard at upper frame bracket4 ,then pull safety guard away from studs and remove studs from frame bracket1 freeing mudguard at this point4 ,,note3 ,these two studs screw into a 8plate0 nut4 7#e7 ,remove bolt and nut which secure battery box leftside bracket to mudguard4 7#f7 ,remove bolt and nut which secure battery box rightside bracket4 ,this bolt also secures lower tool box bracket and speedometer cable clip to mudguard4 7#g7 ,remove nut and washers from bolt which secures lower end of mudguard to frame 7behind transmission74 7#h7 ,remove taillight connector plugs from sockets and remove cable from mudguard spring clips4 7#i7 ,remove nuts from studs which secure right and leftside mudguard brace clips to frame axle clips4 ,mudguard can now be removed from vehicle4 d4 ,install ,rear ,mudguard4 7#a7 ,locate mudguard in position for mounting4 ,install the two studs1 washers1 and nuts which secure right and leftside brace clips to frame axle clips4 ,,note3 ,if brake side cover interferes with locating nut on right side1 loosen the brake sleeve nut and push brake side cover assembly inward for clearance4 ,be sure to retighten brake sleeve nut4 7#b7 ,attach front lower end of mudguard4 ,install flat washer1 lock washer1 and nut on bolt to secure lower end of mudguard to frame 7in back of transmission74 7#c7 ,install the two studs which mount mudguard and upper battery box bracket on frame bracket4 ,these two studs screw into a plate nut located underneath the battery box bracket4 ,removing the battery box cover will give more access to plate nut in this step4 ,install battery box cover if it is removed for this job4 7#d7 ,attach rear safety guard to the two frame bracket studs4 ,install washers and nuts4 ,securely tighten nuts and tighten ,ubolt nuts1 which secure ends of safety guard to frame stays4 7#e7 ,attach battery box bracket to mudguard bracket4 ,install bolt1 washer1 and nut which secure battery box rightside bracket1 tool box bracket lower end1 and speedometer cable clip to mudguard bracket4 ,bolt is inserted from front side1 head toward engine4 ,,note3 ,speedometer cable clip is under head of bolt4 7#f7 ,attach leftside mudguard bracket and battery box bracket4 ,install bolt1 washer1 and nut which secure battery box leftside bracket to mudguard bracket4 ,bolt is inserted from front side1 head toward engine4 7#g7 ,install rear chain guard 7par4 #ajb74 7#h7 ,locate and retain taillight cable in mudguard spring clips4 ,attach connector plugs to taillights 7wiring diagram1 fig4 #gc74 7#i7 ,install luggage carrier 7par4 #ajc74 7#aj7 ,install rear wheel 7par4 #abg74 7#aa7 ,securely tighten all bolts and nuts4 #aje4 ,,battery ,,box4 a4 ,remove ,battery ,box4 7#a7 ,remove battery 7par4 #aac74 7#b7 ,to remove rear brake rod1 disconnect clevis from brake lever1 and free front end of rod at brake shaft bell crank4 7#c7 ,remove rear chain guard 7par4 #ajb74 7#d7 ,remove tool box and bracket in one piece 7par4 #ajf74 7#e7 ,remove nut and bolt securing left side lower battery box mounting to mudguard bracket4 ,remove nut and bolt securing battery front mounting to frame saddle post tube bracket4 7#f7 ,remove the two nuts securing rear safety guard center connection to mounting studs4 ,unscrew mounting studs to free the plate nut which clamps the battery box bracket to frame cross member4 7#g7 ,remove battery box from right side of vehicle4 b4 ,install ,battery ,box4 ,locate battery box in vehicle from left side and secure upper rear mounting bracket with the two frame cross member studs and the plate nut4 ,install washers and nuts which secure safety guard to these same two studs4 7#a7 ,install bolt to secure battery box front mounting to frame tube4 ,make sure that bolt passes through frame tube bracket from left side1 and that large plain washer bears against battery box front bracket 7bracket has open end74 ,tighten nut to secure box bracket to frame tube bracket4 7#b7 ,install tool box and bracket 7par4 #ajf74 7#c7 ,install bolt1 washer1 and nut which secure battery box leftside mounting to mudguard4 ,insert bolt from the front4 7#d7 ,install rear chain guard 7par4 #ajb74 7#e7 ,connect rear brake rod end to bell crank fitting4 ,attach clevis to brake operating lever1 installing plain washer1 clevis pin1 and cotter pin4 7#f7 ,install battery 7par4 #aac74 #ajf4 ,,tool ,,box4 a4 ,general4 ,when tool box only is to be removed and_/or installed1 it is a simple matter to open box and remove and_/or install the three large screws4 ,geartoothed lock washers and large recessed washers fit under screw heads4 b4 ,remove ,box and ,bracket ,assembly4 ,remove bolt and nut which secure tool box upper mounting bracket to frame clip4 ,lower end of mounting bracket1 battery box bracket1 and speedometer cable are all secured to the mudguard bracket by the same bolt and nut4 ,remove speedometer cable from clip and remove bolt and nut1 freeing tool box and bracket assembly for removal4 ,,note3 ,removal of rear brake rod will make bracket lower mounting bolt and nut more accessible4 c4 ,install ,box and ,bracket ,assembly4 ,locate box and bracket assembly on vehicle and install bolt1 washer1 and nut at the upper frame clip mounting4 ,to attach bracket lower end to mudguard bracket1 place bolt through speedometer cable clip1 then through box mounting bracket1 battery box bracket1 and mudguard bracket1 securing assembly with lock washer and nut4 ,illustration3 ,,ra ,,pd #cajbde ,figure #gj--;,fuel and ,oil ,tanks ,removed #ajg4 ,,tanks 7fig4 #gj74 a4 ,general4 ,fuel and oil tanks are separate1 fitting together1 saddletype1 in upper frame tubes1 and are retained in position with three mounting bolts4 ,either tank can be removed and_/or installed without disturbing line connections of the other tank4 b4 ,fuel ,tank4 ,fuel tank is located on left side of vehicle and holds slightly over #c ,u4,s4 gallons4 ,it provides mounting for shifter lever and shifter lever guide4 ,drain is located in forward position on under side of tank4 c4 ,oil ,tank4 ,oil tank is located on right side of vehicle and holds #a ,u4,s4 gallon4 ,oil feed pipe1 scavenger 7return7 pipe1 and breather pipe connections are on under side of tank4 ,drain is located in forward position on under side of tank4 d4 ,remove ,fuel ,tank4 7#a7 ,disconnect battery negative ground wire at frame connection4 7#b7 ,loosen the two cap screws which secure caution plate and tank top strip4 7#c7 ,remove instrument panel cover 7par4 #aai74 7#d7 ,disconnect gear shifter lever and shifter rod by removing bolt4 7#e7 ,shut off fuel supply4 ,disconnect fuel pipe at tank union nipple4 7#f7 ,remove nuts1 lock washers1 and flat washers from the two front 7one upper and one lower7 mounting bolts1 and nut1 lock washer1 and flat washer from the rear mounting bolt4 ,leave bolts in place so that oil tank will stay in position after fuel tank is removed4 ,remove fuel tank from vehicle4 e4 ,install ,fuel ,tank4 7#a7 ,position fuel tank on vehicle4 ,pass the three mounting bolts through tank brackets from right side of vehicle4 ,it will be necessary to pry up on tank top strip in order to slip top edge of tank under strip4 ,install large flat washers1 lock washers1 and nuts on mounting bolts and securely tighten the nuts4 7#b7 ,tighten the two cap screws1 securing caution plate and tank top strip4 7#c7 ,connect fuel pipe at tank nipple union4 ,open supply valve4 7#d7 ,install instrument panel cover 7par4 #aai74 7#e7 ,connect gear shifter lever and shifter rod by installing bolt1 lock washer1 and nut4 7#f7 ,connect battery negative ground wire to frame connection4 7#g7 ,after fuel tank has been filled1 check pipe connection and drain plug for leaks4 f4 ,remove ,oil ,tank4 7#a7 ,disconnect battery negative ground wire at frame connection4 7#b7 ,loosen the two cap screws which secure caution plate and tank top strip4 7#c7 ,remove instrument panel cover 7par4 #aai74 7#d7 ,drain oil from tank by removing drain plug4 ,use a trough 7of cardboard or tin7 to keep oil from draining on engine4 ,,note3 ,if oil feed pipe nipple cap 7manufacturer's 7,h-,d7 ,no4 #cehc-ae7 is available1 it can be screwed on to tank nipple1 thus eliminating draining of oil4 7#e7 ,disconnect oil feed pipe at rear nipple union4 7#f7 ,disconnect scavenger 7return7 pipe at nipple union4 7#g7 ,disconnect breather pipe banjotype connection by taking out bolt4 7#h7 ,remove nuts1 lock washers1 and flat washers from the two front 7one upper and one lower7 mounting bolts1 and nut1 lock washer1 and flat washer from rear mounting bolt4 ,,note3 ,to prevent fuel tank from falling out of frame1 remove upper front mounting bolt and rear mounting bolt and pass both back through fuel tank mounting brackets from the left side of vehicle4 ,oil tank can then be removed1 and fuel tank will stay in place4 g4 ,install ,oil ,tank4 7#a7 ,position oil tank on vehicle4 ,make sure that composition buffer is in place before installing mounting bolts from right side of vehicle4 ,pry up on tank top strip in order to slip top edge of tank under strip4 7#b7 ,install large flat washers1 lock washers1 and nuts on mounting bolts4 ,securely tighten the nuts4 7#c7 ,tighten the two cap screws securing caution plate and tank top strip4 7#d7 ,connect oil feed pipe to tank nipple4 ,tank nipple is located at lower rear end of tank4 7#e7 ,connect scavenger 7return7 pipe to tank nipple4 ,nipple is located underneath tank1 near center4 7#f7 ,connect breather pipe with banjotype fitting to tank4 ,use hollow bolt1 making sure flat washers are in place on both sides of banjo fitting and that mounting bolt is tight4 7#g7 ,install instrument panel cover 7par4 #aai74 7#h7 ,see that oil tank drain plug and washer are in place1 and that the plug is tight4 7#i7 ,connect battery negative ground wire to frame connection4 7#aj7 ,after filling oil tank1 check all pipe fittings for leaks4 #ajh4 ,,stands4 a4 ,remove ,rear ,stand4 ,remove nuts which secure rear stand mounting bolts4 ,drift bolts out of frame clip holes1 freeing stand4 b4 ,install ,rear ,stand4 ,locate stand in position so that bracket stop is downward and will bear against frame axle clips to support vehicle when stand is in use4 ,see that cupped spring washers are on mounting bolts before attaching stand to frame4 ,drift mounting bolts into frame axle clips and secure with lock washers and nuts4 c4 ,remove ,jiffy ,stand4 7#a7 ,support vehicle on rear stand4 7#b7 ,loosen footboard rear support stud nut4 ,remove footboard front support rod nut and pull footboard outward to release end of safety guard4 ,remove extended nut from footboard sidebar front mounting4 ,remove nut securing upper end of skid plate hanger and sidebar rear mounting 7located in center of chain guard cover74 ,loosen nut and bolt which secure skid plate hanger bracket to skid plate3 drop bracket4 ,disconnect clutch control cable from foot pedal stud to prevent damage to cable end piece4 ,remove left footboard1 clutch foot pedal1 and sidebar assembly from support rod ends4 ,illustration3 ,,ra ,,pd #cajbfi ,figure #ga--,saddle and ,suspension 7#c7 ,remove the two nuts from ,ubolt which secure safety guard bracket to frame tube1 remove bracket from ,ubolt1 and slide safety guard assembly out of support rod4 d4 ,install ,jiffy ,stand4 7#a7 ,install safety guard assembly on support rod and secure mounting bracket to frame tube with ,ubolt1 washers1 and nuts4 7#b7 ,install footboard1 clutch foot pedal1 and sidebar assembly4 ,attach skid plate hanger bracket and secure to support rod4 ,attach clutch control cable end to foot pedal stud1 installing plain washer and cotter pin4 ,install washer and extended nut on end of front support rod4 ,securely tighten nut4 ,attach front end of sidebar to end of safety guard by pulling front of footboard outward1 alining hole in safety guard end with hole in sidebar1 and passing footboard front support stud through both parts1 securing with washer and nut4 ,tighten footboard rear support stud nut4 7#c7 ,return vehicle to operating position4 #aji4 ,,saddle ,,post 7fig4 #ga74 a4 ,saddle is mounted on saddle bar by means of three mounting bolts and can be shifted forward or backward to provide three positions on saddle bar4 ,spacer collars can be added and or removed from the two rear mountings to raise or lower rear of saddle to alter riding position4 ,saddle bar hinges on frame bracket and is clevisconnected to saddle spring post4 ,saddle and saddle bar can be lifted upward and forward after releasing spring latch 7on left side7 from groove in clevis pin end and removing clevis pin from saddle bar4 b4 ,remove ,saddle ,spring ,post4 ,support vehicle on rear stand4 ,raise saddle and saddle bar after removing saddle post clevis pin4 ,remove bolt and nut from leftside skid plate bracket and remove nut to free rightside skid plate bracket at muffler pipe clamp and frame connection4 ,drop skid plate4 ,remove saddle spring post clamp nut1 which is located underneath frame at bottom end of saddle post frame tube4 ,saddle spring post assembly can be pulled upward out of frame tube4 c4 ,install ,saddle ,spring ,post4 ,when saddle spring post assembly is inserted in frame tube1 see that flat side machined on post rod end nut registers in flat side of hole in bottom of frame tube4 ,install and securely tighten saddle spring post clamp nut at bottom end of frame tube4 ,lift skid plate and secure in position with leftside bracket bolt1 washer1 and nut and with right bracket bolt1 washer1 and nut 7this also secures muffler pipe clamp to frame clip74 ,lower saddle and saddle bar into position4 ,insert clevis pin from right side and secure with spring latch1 making sure that spring is in pin groove4 #aaj4 ,,safety ,,guards4 a4 ,remove ,front ,safely ,guard4 7#a7 ,loosen nuts which secure right and left footboard rear support studs to sidebars4 ,remove nuts which secure right and left footboard front support studs 7and mount ends of safety guard7 to sidebars4 ,pull front end of each footboard outward so that support stud will free end of safety guard4 ,remove four nuts from the two ,ubolts which mount safety guard upper bracket to frame tube4 ,remove safety guard4 b4 ,install ,front ,safety ,guard4 ,locate safety guard and mount upper bracket to frame tube with the two ,ubolts1 washers1 and nuts1 but do not tighten nuts as yet4 ,pull front end of right footboard outward1 line up hole in safety guard end with hole in sidebar1 and pass footboard front support stud through both parts1 securing with washer and nut4 ,follow same procedure to mount left end of safety guard4 ,tighten ,ubolt nuts securely4 c4 ,remove ,rear ,safety ,guard4 ,remove nuts from ,ubolts which mount ends of safety guard to lower frame stays4 ,remove the two nuts from upper safety guard mounting4 ,after removing ,ubolts1 safety guard can be removed from vehicle4 d4 ,install ,rear ,safety ,guard4 ,position safety guard on vehicle4 ,install ,ubolts1 washers1 and nuts for lower end mounting on frame stays4 ,do not tighten nuts4 ,engage upper mounting holes on studs and replace washers and nuts4 ,tighten all mounting nuts4 ,illustration3 ,,ra ,,pd #cajbcd ,figure #gb--,showing ,skid ,plate ,dropped #aaa4 ,,skid ,,plate4 a4 ,rear end of skid plate must be dropped when removing and or replacing muffler assembly1 saddle spring post1 transmission1 and engine4 b4 ,drop ,skid ,plate 7fig4 #gb74 7#a7 ,remove nut from bolt which secures skid plate side mounting bracket to frame clip4 ,this bolt also mounts muffler tube clamp to frame clip4 7#b7 ,remove left side mounting4 ,remove nut and bolt which secures lower end of hanger bracket to skid plate on left side of vehicle4 ,drop rear end of skid plate4 c4 ,install ,dropped ,skid ,plate4 7#a7 ,lift rear end of skid plate into position4 ,attach rightside bracket at frame clip bolt4 ,secure mounting with washer and nut4 7#b7 ,attach lower end of leftside hanger bracket to skid plate4 ,install bolt1 washer1 and nut4 ,tighten nut4 d4 ,remove and_/or ,install ,skid ,plate4 7#a7 ,to remove skid plate from vehicle1 follow instructions in step b above2 then remove nut and bolt from ,uclamp which secures skid plate to frame bracket1 and remove nut and belt from clamp which secures right front end to support rod4 7#b7 ,to install skid plate1 mount right front end to support rod clamp1 and install bolt and nut to secure ,uclamp under frame bracket4 ,then follow instructions in step c above4 ,section ,,xxiii ,,battery1 ,,lighting ,,system1 ,,horn ,paragraph ,description #aab ,battery #aac ,headlights #aad ,taillights #aae ,ignition and light switch #aaf ,horn #aag ,wiring #aah #aab4 ,,description4 a4 ,lighting system and horn are supplied #fvolt current from the #bb;amperehour battery4 ,negative side of battery and system is grounded4 ,blackout lights and service lights are controlled by the same switch 7ignition and light switch7 which also controls ignition4 ,blackout headlight has auxiliary control switch in body4 ,service headlight upper and lower beam is controlled by toggle switch on left handle bar4 ,horn is operated by button on left handle bar after ignition and light switch is in 8,,on0 position4 ,blackout stop light and service stop light are operated by brake foot pedal switch4 #aac4 ,,battery4 a4 ,the #c;cell1 #aeplate1 #fvolt1 #bb;amperehour battery is located in battery box back of frame seat post tube1 and is accessible for inspection and or service after removing box cover4 ,normally charged battery has specific gravity reading of #a4bge4 ,normally discharged battery has specific gravity of #a4aej4 b4 ,check ,electrolyte ,level 7fig4 #gd74 7#a7 ,raise saddle and bar assembly after releasing and removing swivel pin4 7#b7 ,loosen wing thumb nuts on box top holddown studs sufficiently to disengage bracket slots1 then lift off box cover4 7#c7 ,remove the three filler plugs4 ,check and or adjust electrolyte level4 ,see that electrolyte level is #e_/af inch above plates4 ,if necessary1 bring electrolyte to that level1 using clean1 drinkable water4 7#d7 ,clean top of battery before installing box cover4 7#e7 ,clean terminals or posts1 if corroded4 ,make sure that the felt washers are on posts and are saturated with engine oil4 c4 ,remove ,battery4 ,raise saddle and bar assembly4 ,release and remove swivel pin4 ,loosen wing thumb nuts on box top holddown studs sufficiently to disengage bracket slots1 then lift off box cover4 ,disconnect positive and negative wires from battery terminals4 ,lift battery upward out of battery box4 ,illustration3 ,,ra ,,pd #cajbgh ,figure #gc--;,complete ,wiring ,diagram #a4 ,,switch ,,terminal 7,three ,wires connected7--,black wire from blackout marker light #bd2 taillight cable green wire from blackout taillight #bb2 single wire direct from blackout headlight as shown by dotted line in illustration #dc1 or horn and headlight cable black wire from junction terminal #ce as shown in illustration #dd4 #b4 ,,switch ,,terminal 7,four wires connected7--,generator and relay cable green wire from 8switch0 terminal 7#ad7 of generator2 taillight cable black wire from service stop and taillight 7#bc72 horn and headlight cable red wire from junction terminal #ag2 black wire from speedometer light 7#aa74 #c4 ,,switch ,,terminal 7,two wires connected7--,generator and relay cable red wire from terminal marked 8,,bat0 on relay2 coil and battery cable red wire from junction terminal #ah4 #d4 ,,switch ,,terminal 7,one wire connected7--,black wire from oil signal light terminal 7#aj74 #e4 ,,switch ,,terminal 7,one wire connected7--,taillight cable yellow wire from blackout stop lamp 7#ba74 #f4 ,,switch ,,terminal 7,one wire connected7--,battery and coil cable black wire from junction terminal #ai4 #g4 ,,switch ,,terminal 7,one wire connected7--,taillight cable red wire from service stop and taillight 7#bc74 #h4 ,,generator ,,signal ,,light ,,terminal 7,one wire connected7--,generator and relay cable black wire from relay right front terminal4 #i4 ,,oil ,,pressure ,,signal ,,light ,,terminal 7,one wire connected7--,black wire from oil pressure switch 7#af74 #aj4 ,,signal ,,light ,,terminal 7,four wires connected7--,black wire 7under switch panel7 from generator signal light terminal 7#h72 black wire from switch terminal 7#d72 battery and coil cable green wire from coil front terminal2 horn and headlight cable green wire from horn4 #aa4 ,,speedometer ,,light--,black wire from switch terminal #b4 #ab4 ,,battery ,,positive ,,terminal 7,,left ,,side7--,red wire with black tracer from junction terminal #ah4 #ac4 ,,battery ,,negative ,,terminal 7,,right ,,side7--,black wire from ground clamp on frame4 #ad4 8,,switch0 ,,terminal ,,of ,,generator--,generator and relay cable green wire from switch terminal #b4 #ae4 8,,relay0 ,,terminal ,,of ,,generator--,red wire with black tracer from relay rear terminal4 #af4 ,,oil ,,pressure ,,signal ,,switch--,black wire from signal light terminal #i4 #ag4 ,,junction ,,terminal 7,,bakelite ,,terminal ,,plate ,,on ,,horn ,,mounting7--,horn and headlight cable red wire from switch terminal #b1--red wire with black tracer from handlebar toggle switch 7#ca74 #ah4 ,,front ,,junction ,,terminal 7in motorcycle frame1 under saddle7--,coil and battery cable red wire from switch terminal #c2 red wire with black tracer from battery positive terminal 7#ab74 #ai4 ,,rear ,,junction ,,terminal 7in motorcycle frame1 under saddle7--,coil and battery cable black wire from switch terminal #f2 red wire from stop light switch 7#bj74 ,,ra ,,pd #cajbgh;,b #bj4 ,,stop ,,light ,,switch--,red wire from junction terminal #ai2 green wire from coil terminal4 #ba4 ,,blackout ,,stop ,,light 7,top socket in right taillight7--,taillight cable yellow wire from switch terminal #e4 #bb4 ,,blackout ,,taillights--,taillight cable green wire from switch terminal #a4 #bc4 ,,service ,,tail ,,and ,,stop ,,light 7top socket in left taillight--two wires in one plug7--,taillight cable black wire from switch terminal #b is for service taillight1 and taillight cable red wire from switch terminal #g is for service stop light4 #bd4 ,,blackout ,,marker ,,light 7,,on ,,front ,,mudguard7--,black wire from switch terminal #a4 #be4 ,,service ,,headlight--,black wire with red tracer from handlebar toggle switch 7#ca7 to large terminal screw2 red wire with yellow tracer from handlebar toggle switch to small terminal screw4 #bf4 ,,ignition ,,and ,,light ,,switch 7,,top ,,view7--,switch 8,,off0 in straightahead position4 #bg4 ,,blackout ,,headlight--,blackout headlight is fitted with independent switch in lamp body4 #bh4 ,,spark ,,coil--,coil and battery cable green wire from terminal #aj to coil front terminal2 green wire from stop light switch 7#bj7 to coil front terminal2 low tension wire 7#cd7 from circuit breaker 7#cc7 to coil rear terminal4 #bi4 ,,horn--,horn and headlight cable green wire from terminal #aj2 black wire from horn switch 7#cj74 #cj4 ,,horn ,,switch--,black wire from horn4 #ca4 ,,handlebar ,,toggle ,,switch--,black wire with red tracer from service headlight terminal with large terminal screw2 red wire with yellow tracer to service headlight terminal with small terminal screw2 red wire with black tracer from junction terminal #ag4 #cb4 ,,cut,,out ,,relay--,red wire with black tracer from 8relay0 terminal of generator to relay rear terminal2 generator and relay cable red wire from switch terminal #c to relay terminal marked 8,,bat02 generator and relay cable black wire from terminal #h1 to relay right front terminal4 #cc4 ,,ignition ,,circuit ,,breaker ,,and ,,timer--,low tension wire 7#cd7 from coil rear terminal4 #cd4 ,,circuit ,,breaker,,to,,coil ,,low ,,tension ,,wire--,see ,description #cc4 #ce4 ,,junction ,,terminal ,,on ,,bakelite ,,terminal ,,plate--,horn and headlight cable black wire from switch terminal #a2 wire from blackout headlight 7#bg74 ,all ,,wla model motorcycles originally equipped with radio interference suppressiondevices1 or to which suppressiondevices have been added1 can be identified by a large letter ,s stenciled on left and right sides of instrument panel cover4 99,a ,,ground ,,terminals ,,on ,,coil ,,housing4 99,b ,,flexible ,,braid ,,conductor4 99,c ,,condenser4 99,d ,,shielded ,,circuit ,,breaker,,to,,coil ,,low ,,tension ,,wire4 99,e ,,spark ,,plug ,,suppressors4 99,h ,,condenser4 ,,ra ,,pd #cajbgh;,c ,legend for ,figure #gc--;,complete ,wiring ,diagram ,illustration3 ,,ra ,,pd #cajbdg ,figure #gd--;,battery ,box ,open and ,filler ,plugs ,removed for ,service d4 ,install ,battery4 ,see that rubber mat is in place in bottom of battery box and install battery in box so that positive post is on left side of vehicle1 and negative post is on right side of vehicle4 ,connect wires to battery positive and negative posts4 ,fit rubber mat on top of battery4 ,install cover and securely tighten thumb wing nuts4 ,lower saddle and bar assembly4 ,install swivel pin on right side of vehicle so that retaining spring fits in groove in end of swivel pin4 #aad4 ,,headlights4 a4 ,service ,headlight4 7#a7 ,remove nut which secures light body to bracket1 observing that conical washer bears against cup of bracket for secure light mounting4 ,disconnect wires from light body terminals4 7#b7 ,before installing service headlight1 connect wires to light body terminals1 noting that black wire with red tracer connects with the larger terminal screw4 ,mount light on bracket4 ,position conicalshaped washer and lock washer and install mounting stud nut4 ,do not tighten mounting nut4 b4 ,adjust ,service ,headlight4 ,adjustment should be made in darkened area or at night1 tactical situation permitting4 ,vehicle must be standing on a level surface about #be feet away from and headed toward a wall or screen upon which a horizontal line has been drawn at exactly the same height as service headlight center4 ,set handle bar toggle switch in 8,,bright0 position and check light beam for height and direction4 ,the top of main beam of light should register on wall or screen even with1 but not higher than1 the horizontal line mentioned4 ,tilt light body in bracket up or down to correctly aim it in relation to the horizontal line1 making sure that light body is not turned either to right or left4 ,securely tighten mounting stud nut4 ,illustration3 ,,ra ,,pd #cajbge ,figure #ge--;,blackout ,headlight ,installation c4 ,blackout ,headlight4 ,blackout headlight is mounted on bracket which attaches to left upper side of front fork4 ,blackout headlight operates when ignition and light switch is turned to the second right position4 ,however1 blackout headlight is fitted with an independent switch in light body to permit turning it off while other blackout lights are in use4 ,blackout headlight body is secured to mounting bracket by means of a conical washer1 lock washer1 and mounting nut1 providing a swivel mounting to permit light adjustment4 d4 ,blackout ,marker ,light4 ,the blackout marker light is secured to front mudguard by means of a hollow mounting stud1 with plain washer1 lock washer1 and nut4 ,light wire passes through hollow stud and is protected by tubing on under side of mudguard4 ,blackout marker light wire connects with ,no4 #a post on ignition and light switch4 ,lamp is on with ignition and light switch in second right position4 #aae4 ,,taillights4 a4 ,blackout ,stop and ,taillight4 ,blackout stop and taillight is mounted on right side of taillight bracket4 ,light is provided with top unit to provide blackout stop light controlled by brakeoperated stop light switch4 ,bottom unit in the blackout stop and taillight is regularly used as service blackout taillight and is controlled by ignition and light switch4 ,illustration3 ,,ra ,,pd #cajbgb ,figure #gf--;,ignition and ,light ,switch1 ,front and ,back ,positions b4 ,service ,stop and ,taillight4 ,light is located on left side of light mounting bracket4 ,top unit is used for service stop and taillight 7double filament lamp74 ,taillight filament is controlled by ignition and light switch2 stop lamp filament is controlled by brakeoperated stop light switch4 ,stop light does not operate in daytime when ignition only is turned on4 ,bottom unit serves as a spare blackout taillight4 ,in case the regularly used 7rightside7 blackout taillamp fails1 its socket plug can be transferred to this taillight socket4 c4 ,stop and ,taillight ,switch4 ,this switch is operated by brake pedal and is located on end of rear support rod on right side of vehicle4 ,refer to wiring diagram 7fig4 #gc7 and paragraph #aah for wiring connections4 #aaf4 ,,ignition ,,and ,,light ,,switch4 a4 ,earlier models are provided with lock1 later models are nonlocking4 ,illustration3 #h--;,,generator ,,signal ,,light4 #ad--;,,generator ,,terminal ,,to ,,switch4 #ae--;,,generator ,,terminal ,,to ,,relay4 #bf--;,,ignition,,light ,,switch4 #cb--,,relay4 #ce--,,terminal ,,strip ,,binding ,,post4 #cf--,,magnetic ,,switch ,,for ,,blackout ,,light4 ,h--,,noise ,,suppression ,,condenser4 ,,ra ,,pd #cajbgi ,figure #gg--;,blackout ,headlight ,magnetic ,switch on ,later ,models b4 ,remove4 ,disconnect battery ground wire4 ,remove instrument panel cover 7par4 #aai74 ,disconnect all wires from switch4 ,remove the four switch mounting screws and spacers4 ,switch is now free for removal4 c4 ,install4 ,mount switch on instrument panel base4 ,install four screws and spacers4 ,connect wires 7fig4 #gc74 ,connect battery negative ground wire to frame4 ,turn switch on4 ,check lights and horn1 tactical situation permitting4 ,install instrument panel cover 7par4 #aai74 ,illustration3 ,,ra ,,pd #cajbgj ,figure #gh--,wiring ,cables1 ,left ,side ,illustration3 ,,ra ,,pd #cajbga ,figure #gi--,wiring ,cables1 ,right ,side #aag4 ,,horn4 a4 ,description4 ,horn is mounted to headlight bracket by means of four bolts1 lock washers1 and nuts4 ,one horn terminal is connected with operating button1 and other terminal is connected to ,no4 #d ignition and light switch terminal 7fig4 #gc74 b4 ,adjust4 ,tone adjusting screw is located in rear side of horn4 ,if horn fails to operate and moving the adjusting screw does not remedy the trouble1 horn must be replaced4 ,,note3 ,do not change position of the adjusting screw located in center of diaphragm4 #aah4 ,,wiring4 a4 ,cable ,system4 ,since ignition and lights are controlled by the ignition and light switch1 all wires terminate at the ignition and light switch4 ,cables for wire protection are used1 making it necessary to replace cables rather than individual wires4 ,a study of figure #gc will be helpful when removing or installing any of the wiring cables4 ,also study figures #gh and #gi and note how cables are arranged on frame1 and how they lead to the switch panel4 b4 ,remove and ,install ,cables4 ,when it becomes necessary to replace wiring cables leading to the ignition and light switch1 both fuel and oil tanks must be removed 7par4 #ajg7 and instrument panel cover removed 7par4 #aai7 for accessibility4 ,section ,,xxiv ,,instrument ,,panel ,paragraph ,panel cover #aai ,indicator lights #abj ,speedometer head #aba #aai4 ,,panel ,,cover 7fig4 #hj74 a4 ,remove4 ,remove speedometer light switch knob and remove screw4 ,remove hexagonhead screw on front of cover4 ,remove two screws from side of cover4 ,remove two screws and washers which fasten plate to right side of cover4 ,lift cover off panel4 ,illustration3 ,,ra ,,pd #caegca ,figure #hj--,panel ,cover ,removed b4 ,install4 ,position cover on panel4 ,install two side mounting screws and washers and install hexagonhead screw1 plain washer1 and lock washer in front end of cover4 ,attach cover side plate1 installing two screws and washers4 ,install speedometer light switch knob and screw4 #abj4 ,,indicator ,,lights4 a4 ,three #b-;c4p4 singlecontact lamps are located on instrument panel4 ,one for oil pressure 7red7 indicator light3 one for generatorcharge 7green7 indicator light1 and one for speedometer illumination4 b4 ,remove and_/or ,install4 ,remove and_/or install panel cover 7par4 #aai74 c4 ,test ,generator,charge 7,green7 ,indicator ,lamp4 ,disconnect black wire from relay terminal 7top terminal at front end of relay7 and ground on relay base4 ,turn ignition and light switch on4 ,lamp should light4 ,if it does not light1 check wire for condition and_/or replace lamp after removing panel cover 7par4 #aai74 d4 ,test ,oil ,pressure 7,red7 ,indicator ,lamp4 ,disconnect wire from oil pressure switch4 ,ground the wire on engine4 ,turn ignition and light switch on4 ,lamp should light4 ,if it does not light1 check wire for condition and_/or replace lamp after removing panel cover 7par4 #aai74 ,if lamp and wiring are satisfactory1 replace oil pressure switch4 #aba4 ,,speedometer ,,head4 a4 ,remove4 ,remove instrument panel cover 7par4 #aai74 ,loosen the two tank front mounting bolts and remove rear mounting bolt to free speedometer cable clamp4 ,disconnect speedometer cable at drive unit4 ,free cable from clip located below tool box4 ,remove two screws which mount head to frame4 ,pull head upward1 working cable forward under tank1 until head and cable connection nut is clear of frame4 ,unscrew cable nut4 ,,note3 ,cable may be secured to frame tube1 between tanks1 with friction tape4 ,if so1 cut tape4 b4 ,install4 ,attach speedometer head to cable end and tighten nut4 ,pass cable down into frame hole1 pulling on rear of cable at same time4 ,mount speedometer head to frame with two screws and lock washers4 ,install panel cover 7par4 #aai74 ,secure cable clamp under head of tank rear mounting bolt4 ,secure cable in clip1 located under tool box4 ,attach end of cable to drive unit4 ,tighten the two tank front mounting bolts4 ,section ,,xxv ,,tires1 ,,wheels1 ,,and ,,hubs ,paragraph ,description #abb ,tires #abc ,rims and spokes #abd ,front wheel replacement #abe ,front wheel hub adjustment #abf ,rear wheel replacement #abg #abb4 ,,description4 a4 ,wheels have drop center rims to accommodate #d4jj x #ah tires4 ,front and rear wheels are not interchangeable4 ,front wheel hub is of ballbearing design1 having cone adjustment similar to that of a bicycle hub4 ,rear wheel hub is of rollerbearing design and must be taken apart for adjustment4 ,both wheels have 8knockout0 type axles4 #abc4 ,,tires4 a4 ,description4 ,wheel rims are of the dropcenter type1 having a depression1 or well1 in center of rim4 ,the rim well1 being smaller in circumference than the rest of the rim1 allows one casing bead to fit loosely in it while other bead is being worked over edge of rim4 ,bear in mind the importance of keeping one bead in rim well while other bead is being worked onto or off rim4 ,,note3 ,it is not always necessary to completely remove casing from rim4 ,removing one side only allows inner tube to be removed and reinstalled1 and also allows inside of casing to be inspected4 b4 ,remove4 7#a7 ,remove wheel from vehicle and lay wheel on its side4 ,to remove front wheel1 refer to paragraph #abe4 ,to remove rear wheel1 refer to paragraph #abg4 7#b7 ,remove valve cap and valve core to free all air from tube4 7#c7 ,press casing head into rim well to within a short distance of each side of valve4 7#d7 ,using tire iron 8,b0 in vehicle kit 7fig4 #aa71 start bead over edge of rim at valve4 ,do not use force when starting bead over edge of rim with tire iron1 because bead wires may be broken or stretched1 and tire ruined4 ,with first bead in rim well1 bead on other side can be started easily over edge of rim4 ,after a portion of second bead is started over rim edge1 casing can be further removed from wheel without aid of tire iron4 ,illustration3 ,,ra ,,pd #cajbed ,figure #ha--;,disassembly for ,front ,wheel ,removal c4 ,install4 ,before applying casing to rim1 see that rubber rim strip is in place in rim well and that rim strip valve hole alines with valve hole in rim4 7#a7 ,start either bead of casing over rim edge4 ,work around wheel until entire bead is on rim4 7#b7 ,place inner tube in casing4 ,,note3 ,inner tube may be placed in casing before or after first bead of casing is on rim4 ,insert valve stem through hole in rim and start valve stem lock nut4 ,while pressing first bead into rim well1 work remaining bead over edge of rim1 starting directly opposite valve stem4 ,work both ways around wheel toward valve4 7#c7 ,inflate front tire to #ah pounds1 and rear tire to #bj pounds4 7#d7 ,reinstall front wheel 7par4 #abe73 reinstall wheel 7par4 #abg74 ,,caution3 ,tire casings are balanced and must be applied to rim with balance mark located at valve stem4 ,on ,firestone tires the balance mark is a red triangle1 and on ,goodyear tires a red dot4 #abd4 ,,rims ,,and ,,spokes4 a4 ,wheels with broken and or missing spokes1 with rims in badly kinked and or distorted condition1 or having considerable runout1 must be replaced4 b4 ,loose wheel spokes must be tightened evenly1 being careful not to distort rim outofround or cause runout4 ,use spoke nipple wrench 7#da-,w-#ccci7 for front wheel spokes1 and wrench 7#da-,w-#ccdj7 for rear wheel spokes4 #abe4 ,,front ,,wheel ,,replacement 7fig4 #ha74 a4 ,remove4 7#a7 ,support vehicle on rear stand4 ,raise front end of vehicle by blocking up under frame loop on skid plate4 7#b7 ,remove brake shackle bolt from rigid fork on left side of vehicle4 7#c7 ,front axle is knockout type4 ,remove cotter pin and axle castle nut and pull out axle4 ,wheel is free for removal4 ,,caution3 ,before removing axle note how slot in brake stabilizer plate is fitted over the extended 7button7 end of the leftfront rocker plate stud4 ,it is necessary that this be correctly assembled when replacing front wheel4 7#d7 ,roll wheel forward and remove brake assembly from brake drum1 leaving the assembly attached to brake control wire and control wire housing4 b4 ,install 7fig4 #ha74 ,,note3 ,at the time wheel and brake assembly is located in front fork1 and before axle is installed1 make sure that the curved slot in brake stabilizer plate engages with the button end of the leftfront rocker plate stud4 7#a7 ,install brake assembly in brake drum4 7#b7 ,roll wheel into position4 ,engage stabilizer plate notch and rocker plate stud button end1 and at same time insert front axle4 7#c7 ,install castle nut 7no lock washer used7 on axle and securely tighten4 ,illustration3 ,,ra ,,pd #cajbeb ,figure #hb--;,front ,hub ,prepared for ,cone ,adjustment 7#d7 ,use good cotter pin to secure nut4 7#e7 ,install brake shackle bolt and special lock washer and nut4 ,tighten nut4 7#f7 ,check front brake control wire and housing to make sure everything is in order and correctly adjusted 7par4 #ig74 7#g7 ,remove blocking from under vehicle4 #abf4 ,,front ,,wheel ,,hub ,,adjustment4 a4 ,front wheel1 ballbearing hub1 is similar to a bicycle front hub as far as adjustment is concerned4 ,do not completely disassemble hub for adjustment as balls are not in retainers1 and will fall out when cone is removed4 ,hub is provided with grease deflector sleeve and felt retainer4 ,,note3 ,earlier models are not equipped with grease deflector sleeve or felt retainer washer4 ,front wheel should have slight play or shake on bearings1 and should turn freely4 ,illustration3 ,,ra ,,pd #caegcc ,figure #hc--;,disassembly for ,rear ,wheel ,removal 7#a7 ,remove front wheel 7par4 #abe74 7#b7 ,back off cone lock nut to end of axle sleeve4 ,do not remove nut4 7#c7 ,turn cone on axle sleeve to the right 7clockwise7 to take up wheel play1 and to the left 7counterclockwise7 to give more wheel play4 ,adjust so that wheel has slight play on bearing4 7#d7 ,tighten cone lock nut4 ,after tightening nut1 again try for slight wheel play on bearing4 ,sometimes tightening lock nut takes up on bearing play4 ,if necessary1 readjust for desired results when cone lock nut is tight4 7#e7 ,install front wheel and brake assembly 7par4 #abe74 7#f7 ,check adjustment of front brake4 #abg4 ,,rear ,,wheel ,,replacement 7figs4 #hc and #hd74 a4 ,remove4 7#a7 ,support vehicle on rear stand4 7#b7 ,release mudguard rear stays4 ,loosen mounting nuts1 and raise end of mudguard for wheel clearance4 ,illustration3 ,,ra ,,pd #cajbec ,figure #hd--;,brake ,rod ,lock 7#c7 ,remove the five wheel mounting socket screws which secure wheel hub to brake shell and sprocket assembly4 ,use vehicle kit wrench 8,s0 and sleeve 7handle7 8,c0 7fig4 #aa74 ,,note3 ,wrench can be inserted from left side through holes in hub1 and wheel must be turned to bring each mounting screw directly to the rear of axle for accessibility4 7#d7 ,use brake rod lock to set and lock brake to prevent brake shell and sprocket from coming off brake assembly while wheel is being removed4 ,apply brake pedal and shift brake rod lock against tool box bracket1 securing lock in this position with wing nut 7fig4 #hd74 7#e7 ,remove axle nut 7right side of vehicle71 using vehicle kit wrench 8,j0 7fig4 #aa74 7#f7 ,pull out axle from left side of vehicle4 7#g7 ,remove spacer from between wheel hub end and left side of frame4 7#h7 ,wheel is now free to come out by pulling and working it away from dowel pins located in brake shell assembly4 ,a wheel being removed for the first time may offer some resistance4 ,it will be observed that chain1 sprocket1 and brake assembly remain in the vehicle frame4 b4 ,install 7figs4 #hc and #hd74 7#a7 ,position wheel on brake shell dowel pins4 ,work hub onto dowels as far as it will go4 7#b7 ,install axle spacer at left end of hub so that axle will pass through it and the hub4 7#c7 ,install axle from left side of vehicle4 ,pass it through sleeve and hub1 with end of axle engaging the frame left axle clip notch4 7#d7 ,see that lock washer is in place4 ,turn on and securely tighten axle nut1 using vehicle kit wrench 8,j0 7fig4 #aa74 7#e7 ,loosen wing nut clamping brake rod lock4 ,move brake rod lock forward so that it will not strike any object when brake is operated2 tighten wing nut to retain in position 7fig4 #hd74 7#f7 ,install and securely tighten the five wheel mounting socket screws4 7#g7 ,lower mudguard into position and attach ends of rear stays4 ,securely tighten the clamping nuts4 ,,references ,,standard ,,nomenclature ,,lists ,motorcycle1 chain drive 7,harley,davidson7 ,,snl ,g-#ebc ,cleaning1 preserving and lubricating materials1 recoil fluids1 special oils1 and miscellaneous related items ,,snl ,k-#a ,soldering1 brazing1 and welding materials1 gases1 and related items ,,snl ,k-#b ,tools1 maintenance1 for the repair of automotive vehicles ,,snl ,g-#bg ,tool sets--motor transport ,,snl ,n-#ai ,tool sets for ordnance service command1 automotive shops ,,snl ,n-#cj ,current ,standard ,nomenclature ,lists are listed above4 ,an uptodate list of ,,snl's is maintained in the ,index to ,maintenance ,publications ,,ofsb #a-a ,,explanatory ,,publications ,military motor vehicles ,,ar #hej-ae ,automotive ,materiel ,automotive electricity ,,tm #aj-ehj ,electric fundamentals ,,tm #aj-dee ,the motor vehicle ,,tm #aj-eaj ,chassis1 body1 and trailer units ,,tm #aj-eej ,maintenance and ,repair ,automotive lubrication ,,tm #aj-edj ,motor transport inspections ,,tm #aj-ede ,tire repair and retread ,,tm #i-ahfh ,cleaning1 preserving1 lubricating and welding materials and similar items issued by the ordnance ,,tm #i-hej ,detailed lubrication instructions for ordnance materiel ,,ofsb #f-series ,protection of ,materiel ,explosives and demolitions ,,fm #e-be ,defense against chemical attack ,,fm #ba-dj ,decontamination of ,armored ,force vehicles ,,fm #ag-ei ,chemical decontamination1 materials and equipment ,,tm #c-bbj ,list of ,publications for ,training ,,fm #ba-f ,storage and ,shipment ,registration of motor vehicles ,,ar #hej-aj ,storage of motor vehicle equipment ,,ar #hej-ah ,ordnance storage and shipment chart1 group ,g--,major items ,,ossc-,g ,,index ,a ,page ,no4 ,air cleaner1 #abb ,allocation of maintenance by echelons1 #dj ,ammunition box carrier1 #afi ,armature bearing special lubrication1 #ade ,auxiliary brake1 #ab ,b ,battery1 lighting system1 horn battery check electrolyte level1 #aha installation1 #ahe removal1 #aha description1 #aha horn adjustment1 #aij description1 #aij ignition and light switch installation1 #ahh removal1 #ahh service headlights adjustment1 #ahe blackout1 #ahf marker1 #ahg taillights blackout stop and taillight1 #ahg service stop and taillight1 #ahg wiring cable system1 #aij removal and installation1 #aij ,brake system brake shoe installation1 #aea brake shoe removal1 #aej front wheel brake1 #aea rear wheel brake adjustment1 #adi linkage1 #adi ,c ,carburetor adjustment1 #aaf bowl cleaning1 #abj installation1 #aah removal1 #aah ,chains and sprockets chain oilers1 #aji chain repair tool1 #aac countershaft sprocket replacement1 #aad engine sprocket replacement1 #aac front chain adjustment1 #aje front chain replacement1 #aaa rear chain adjustment1 #ajg rear chain replacement1 #aaa rear wheel alinement1 #ajg ,clutch control adjustment1 #he description1 #hf disk and spring inspection1 #ia disk installation1 #ic disk removal1 #ij maintenance and adjustment1 #hf release bearing installation1 #ie removal1 #ie spring tension adjustment1 #hi ,controls and operation controls auxiliary brake 7front wheel71 #ab carburetor choke1 #ac clutch1 #aj foot starter crank1 #ab gasoline valve1 #i gear shifter1 #ab ignition and light switch1 #ab instrument panel signal lights1 #ac service brake 7rear wheel71 #ab spark1 #aj steering damper1 #ab throttle1 #aj driving precautions avoid low gear operation1 #ag braking1 #ag highspeed tips1 #ag engine prestarting instructions1 #ac operation of vehicle starting on level ground1 #af starting on uneven or soft ground1 #af runningin new engine 7or vehicle71 #ai starting engine behavior of instrument panel signal lights1 #ae cold engine1 #ad engine with dead battery1 #ae hot engine1 #ae warm engine1 #ad stopping and parking vehicle parking vehicle1 #ah stopping vehicle1 #ag stopping the engine1 #af towing vehicle to start engine engine starting with dead battery1 #ah ,d ,data1 tabulated engine1 #gb vehicle specifications1 #g capacities1 #h performance1 #g ,description battery1 lighting system1 horn1 #aha clutch1 #hf engine1 #gb generating system1 #adb ignition system1 #abi intake and exhaust system1 #abb tires1 wheels and hubs1 #aic transmission1 #if ,description of vehicle1 #g ,e ,echelon system of maintenance allocation1 #dj ,engine carbon removal1 #gd data1 #gb description1 #gb head1 gasket replacement installation1 #gd removal1 #gc installation1 #hb oil feed pump replacement1 #gg removal1 #gh tuneup1 #gb valve tappet adjustment1 #gd ,exhaust system1 #abf ,f ,first echelon preventive maintenance services afteroperation and weekly service1 #be athalt service1 #bd beforeoperation service1 #ba duringoperation service1 #bc purpose1 #bj ,fuel system carburetor installation1 #aah removal1 #aah carburetor adjustment complete readjustment of carburetor1 #aaf low speed adjusting needle1 #aaf carburetor bowl cleaning1 #abj fuel pipe installation1 #aba removal1 #aba fuel strainer cleaning1 #abj install strainer assembly1 #abj remove strainer assembly1 #abj general1 #aae throttle control wire adjustment closed throttle1 #aah open throttle1 #aah ,g ,generating system armature bearing special lubrication1 #ade commutator cleaning1 #adc cutout relay1 #adg description1 #adb generator installation1 #adg generator removal1 #ade ,generator removal and installation1 #ade1 #adg ,h ,horn1 #aij ,i ,ignition system circuit breaker and timer assembly installation1 #acc recommended recheck of ignition timing1 #ace removal1 #acc circuit breaker points adjustable contact point installation1 #aca adjustable contact point removal1 #aca adjustment1 #aca breaker lever installation1 #aca breaker lever removal1 #acj coil to timer wire installation1 #ach removal1 #ach condenser installation1 #acc removal1 #aca description1 #abi spark coil installation1 #adj removal1 #aci spark control adjustment1 #aci spark plugs cleaning1 #abi point adjustment1 #abi replacement1 #abi type1 #abi ,installation procedure air cleaner1 #abf ammunition box carrier1 #afi battery1 #ahe battery box1 #agc carburetor1 #aah circuit breaker and timer assembly1 #acc circuit breaker lever1 #aca circuit breaker points1 #aca clutch release bearing1 #ie coil to timer wire1 #ach condenser1 #acc control wire housings1 #aff engine1 #hb engine head gasket1 #gd exhaust pipe1 #abg foot starter1 #ih fork assembly1 #aeh front wheel1 #aif fuel pipe1 #aba fuel strainer assembly1 #abj fuel tank1 #age generator1 #adg handle bar assembly1 #afc ignition and light switch1 #ahh instrument panel cover1 #aia jiffy stand1 #agg luggage carrier1 #agj mudguards1 #aga muffler assembly1 #abg oil tank1 #agf outer front chain guard1 #afg rear chain guard1 #afi rear stand1 #agf rear wheel1 #aii saddle post1 #agh safety guards1 #agh scabbard carrier1 #afi skid plates1 #ahj spark coil1 #adj spark control wire1 #aff speedometer1 #aib spring forks1 #aed starter crank springs1 #aja steering damper1 #afa throttle control wire1 #afe tires1 #aie tool box and bracket assembly1 #agc upper bumper springs1 #aee upper coil springs1 #aee wiring1 #aij ,instrument panel indicator lights1 #aia panel cover installation1 #aia removal1 #aia speedometer installation1 #aib removal1 #aib ,intake and exhaust system air cleaner general1 #abb installation1 #abf maintenance1 #abc removal1 #abe service1 #abb air cleaner mounting bracket replacement1 #abf description exhaust1 #abb intake1 #abb exhaust system muffler assembly installation1 #abg muffler assembly removal1 #abf pipe installation1 #abg hose and carburetor fitting installation1 #abe removal1 #abe ,introduction scope of manual1 #c supersession of quartermaster manuals1 #c ,l ,lighting system1 #aha ,lubrication introduction1 #cj lubrication guide1 #cj general1 #cj lubrication notes1 #cj oilcan points1 #cd supplies1 #cj warning light1 #cd ,m ,maintenance allocation allocation of maintenance by echelons clutch1 #dj controls and linkage1 #dj electrical group1 #da engine 7,v#de twin engine71 #da exhaust group1 #db miscellaneous1 #db suspension 7front71 #dc suspension 7rear71 #dc tires1 #dd transmission1 #dd vehicle assembly1 #dd scope of maintenance1 #ci ,manual1 scope of1 #c ,o ,organization tools and equipment1 #fj ,p ,preventive maintenance services first echelon1 #bj second echelon1 #de ,r ,references explanatory publications automotive materiel1 #bjj list of publications for training1 #bjj maintenance and repair1 #bjj protection of materiel1 #bjj storage and shipment1 #bjj standard nomenclature lists1 #bjj ,removal procedure air cleaner1 #abe ammunition box carrier1 #afi battery1 #aha battery box1 #agb carbon1 #gd carburetor1 #aah circuit breaker and timer assembly1 #acc circuit breaker lever1 #acj condenser1 #aca control wire housings1 #aff engine1 #gh engine head gasket1 #gc foot starter1 #ih fork assembly1 #aee front wheel1 #aie fuel pipe1 #aba fuel strainer assembly1 #abj fuel tank1 #agd generator1 #ade handle bar assembly1 #afb ignition coil to timer wire1 #ach instrument panel cover1 #aia jiffy stand1 #agf luggage carrier1 #agj mudguards1 #agj1 #aga muffler assembly1 #abf oil tank1 #age outer front chain guard1 #afg rear chain guard1 #afi rear stand1 #agf rear wheel1 #aih release bearing 7clutch71 #ie saddle post1 #agh safety guards1 #agh scabbard carrier1 #afi skid plates1 #ahj spark coil1 #aci spark control wire1 #aff speedometer1 #aib spring forks1 #aed starter crank spring1 #ih steering damper1 #afa throttle control wire1 #afd tires1 #aic tool box and bracket assembly1 #agc upper bumper springs1 #aee upper coil springs1 #aee ,road test chart of maintenance operations1 #di ,s ,second echelon preventive maintenance road test chart1 #dg maintenance operation1 #di services first echelon participation1 #de frequency1 #de general procedures1 #de specific procedures1 #dg ,sheet metal and equipment battery box installation1 #agc removal1 #agb carriers ammunition box carrier installation1 #afi ammunition box carrier removal1 #afi fuel tank installation1 #age removal1 #agd chain guards outer front chain guard installation1 #afg outer front chain guard removal1 #afg rear chain guard installation1 #afi rear chain guard removal1 #afi jiffy stand installation1 #agg removal1 #agf luggage carrier installation1 #agj removal1 #agj mudguard 7front7 installation1 #aga removal1 #agj mudguard 7rear7 installation1 #aga removal1 #aga oil tank installation1 #agf removal1 #age rear stand installation1 #agf removal1 #agf saddle post description1 #agh installation1 #agh removal1 #agh safety guards installation1 #agh removal1 #agh scabbard carrier installation1 #afi removal1 #afi skid plates installation1 #ahj removal1 #ahj tanks fuel tank1 #agc general1 #agc oil tank1 #agc tool box box and bracket assembly installation1 #agc box and bracket assembly removal1 #agc ,spark plugs1 #abi ,speedometer installation1 #aib removal1 #aib ,steering control control wire housings installation1 #aff removal1 #aff fork assembly 7complete7 installation1 #aeh removal1 #aee rocker plate studs1 #afj forks 7springs7 installation1 #aed removal1 #aed handle bar controls install throttle control wire1 #afe remove throttle control wire1 #afd handle bars installation of assembly1 #afc removal of assembly1 #afb spark control wire installation1 #aff removal1 #aff steering damper installation1 #afa removal1 #afa upper coil springs and upper bumper springs installation1 #aee removal1 #aee ,stowage on vehicle 7tools and equipment71 #ce ,t ,tabulated data engine1 #gb vehicle specifications1 #g capacities1 #h performance1 #g ,tires1 wheels1 and hubs description1 #aic front wheel hub adjustment1 #aig installation1 #aif removal1 #aie rear wheel installation1 #aii removal1 #aih rims and spokes1 #aie tires description1 #aic installation1 #aie removal1 #aic ,tools and equipment stowage on the vehicle vehicle equipment1 #cf vehicle spare parts1 #ch vehicle tools1 #ce ,transmission control linkage adjustment1 #ig checking gear shifter control linkage1 #if transmission shifted to adjust front drive chain1 #if description1 #if foot starter installation1 #ih removal1 #ih installation1 #aja removal1 #ii starter crank springs installation1 #ih removal1 #ih ,trouble shooting brakes1 #gj electrical system1 #fh engine instruction1 #fa tests to determine mechanical condition1 #fc engine lubricating system1 #fd fuel system1 #fe generating system1 #fh ignition system1 #ff introduction1 #fa steering1 #ga transmission and clutch1 #fi wheels and chains1 #fi ,w ,wheels and hubs1 #aie ,wiring1 #aij ,a4,g4 #cjj4g 7#ag ,aug4 #aidc7 ,,by ,,order ,,of ,,the ,,secretary ,,of ,,war3 ,g4 ,c4 ,,marshall1 ,chief of ,staff4 ,,official3 ,j4 ,a4 ,,ulio1 ,major ,general1 ,the ,adjutant ,general4 ,,distribution3 ,r#i 7#d73 ,,ir #e1 #g and #ag 7#e73 ,bn #i 7#b73 ,i,bn #e1 #f1 #g and #ag 7#e73 ,c#i 7#h73 ,,ic #e1 #f1 #g and #ag 7#e7 7,for explanation of symbols1 see ,,fm #ba-f7 ,,rapd#c,,oec#dc-ha,m ,,publications ,,department ,,raritan ,,arsenal ,transcriber's notes3 ,in the ,fig4 #ea caption ,m--,,mark ,,on ,,breaker ,,cam ,,and ,,marks ,,on ,,timer ,,head ,,and ,,hand - #8,,hand' should possibly read #8,,band'4 ,in the echelon table1 section #be4 ,,allocation ,,of ,,maintenance1 #8strained gasoline' should possibly read #8strainer gasoline'4