,transcrib]'s note3 ,italic text is d5ot$ by und]scores1 bold text is d5ot$ ?us4 ,! orig9al spell+1 punctuation & hyph5ation has be5 reta9$ except = app>5t pr9t]'s errors :i* h be5 sil5tly correct$4 ,see fur!r notes at ! end ( ! book4 ,illu/ration3 ,cov] #a,,tm #i-hgi ,,re/rict$ ,,te*nical ,,manual ,,w> ,,dep>tm5t ,no4 #i-hgi ,wa%+ton1 #ah ,octob] #aidc ,,motorcycle1 ,,solo 7,h>ley,davidson ,model ,,wla7 ,dissem9ation ( re/rict$ matt]4--,! in=mation conta9$ 9 re/rict$ docum5ts1 & ! ess5tial *>act]i/ics ( re/rict$ mat]iel1 may be giv5 to any p]son kn[n to be 9 ! s]vice ( ! ,unit$ ,/ates1 & to p]sons ( und\bt$ loyalty & discretion :o are coop]at+ 9 ,gov]nm5t "w1 b w n be communicat$ to ! public or to ! press except by au?oriz$ milit>y public relations ag5cies4 7,see also p>agraph #ah;b1 ,,ar #chj-e1 #bh ,septemb] #aidb47 ,,cont5ts ,,"p ,,"o--,,vehicle ,,op]at+ ,,in/ructions ,p>agraphs ,pages ,,section ,i ,introduction #a-b #c-f ,,ii ,description & tabulat$ data #c-d #g-h ,,iii ,controls & op]ation #e-ac #i-ai ,,iv ,fir/ e*elon1 prev5tive ma9t5ance s]vices #ad-ah #bj-bi ,v ,lubrication #ai-bj #cj-cd ,,vi ,tools & equipm5t /[age on ! vehicle #ba-bc #ce-ch ,,"p ,,two--,,organizational ,,ma9t5ance ,,section ,,vii ,ma9t5ance allocation #bd-be #ci-dd ,,viii ,second e*elon prev5tive ma9t5ance s]vices #bf #de-ei ,,ix ,organization tools & equipm5t #bg #fj ,x ,tr\ble %oot+ #bh-ch #fa-ga ,,xi ,eng9e #ci-dd #gb-gg ,,xii ,eng9e--removal & in/allation #de-df #gh-hd ,,xiii ,clut* #dg-eb #he-ie ,,xiv ,transmission #ec-eh #if-ajd ,,xv ,*a9s & sprockets #ei-ff #aje-aad ,,xvi ,fuel sy/em #fg-gd #aae-aba ,,xvii ,intake & exhau/ sy/em #ge-ha #abb-abh ,,xviii ,ignition sy/em #hb-hi #abi-ada ,,xix ,g5]at+ sy/em #ij-ie #adb-adh ,,xx ,brake sy/em #if-ig #adi-aec ,,xxi ,/e]+ control #ih-aja #aed-aff ,,xxii ,%eet metal & equipm5t #ajb-aaa #afg-ahj ,,xxiii ,batt]y1 light+ sy/em1 horn #aab-aah #aha-aij ,,xxiv ,in/rum5t panel #aai-aba #aia-aib ,,xxv ,tires1 :eels1 & hubs #abb-abg #aic-aii ,,ref]5ces #bjj ,,index #bja ,footnote #a3 ,= sup]session ( qu>t]ma/] manuals1 ref] to p>agraph #b4 ,,"p ,,"o--,,op]at+ ,,in/ructions ,section ,i ,,introduction ,p>agraph ,scope #a ,sup]session ( qu>t]ma/] manuals #b #a4 ,,scope4 a4 ,?is te*nical manual#b is publi%$ = ! in=mation & guidance ( ! us+ arm p]sonnel *>g$ ) ! op]ation1 ma9t5ance1 & m9or repair ( ?is mat]iel4 b4 ,9 addition to a description ( ! ,h>ley,davidson motorcycle1 ?is manual conta9s te*nical in=mation requir$ = ! id5tification1 use1 & c>e ( ! mat]iel4 ,! manual is divid$ into two p>ts4 ,"p ,"o1 section ,i ?r\gh section ,,vi1 gives vehicle op]at+ in/ructions4 ,"p ,two1 section ,,vii ?r\gh section ,,xxv1 gives vehicle ma9t5ance in/ructions to us+ arm p]sonnel *>g$ ) ! responsibility ( do+ ma9t5ance "w )9 _! jurisdiction4 c4 ,9 all cases :]e ! nature ( ! repair1 modifications1 or adju/m5t is beyond ! scope or facilities ( ! unit1 ! responsible ordnance s]vice %\ld be in=m$ s t tra9$ p]sonnel ) suitable tools & equipm5t may be provid$1 or prop] in/ructions issu$4 #b4 ,,sup]session ,,( ,,qu>t]ma/] ,,manuals4 a4 ,?is te*nical manual1 toge!r ) ,,tm #i-ahgi1 sup]s$es & replaces ! foll[+ ,qu>t]ma/] ,corps publications3 7#a7 ,,tm #aj-aage--,ma9t5ance manual1 motorcycle1 solo1 ,h>ley,davidson 7,model #db-,,wla71 #aa ,septemb] #aida4 7#b7 ,,tm #aj-aagg--,ma9t5ance manual1 motorcycle1 solo1 ,h>ley,davidson 7,models #aidj-da-db71 #aa ,septemb] #aida4 7#c7 ,,tm #aj-acca--,ma9t5ance manual1 motorcycle1 *a9 drive ,h>ley,davidson 7,model #db ,,wla1 solo74 7#d7 ,,tm #aj-acei--;,in/ruction fold] 7#de-;,a7 motorcycles1 solo1 ,h>ley,davidson 7,model #aida ,,wla #de71 #be ,novemb] #aida4 7#e7 ,,tm #aj-acfa--;,in/ruction fold] 7#de-;,b7 motorcycle1 solo1 ,h>ley,davidson 7,model #aida ,,wla #de71 #be ,novemb] #aida4 ,illu/ration3 ,,ra ,,pd #caegjh ,figure #a--,top ,view ( ,motorcycle ,illu/ration3 ,,ra ,,pd #caegji ,figure #b--,left ,side ,view ( ,motorcycle ,illu/ration3 ,,ra ,,pd #caegaj ,figure #c--,"r ,side ,view ( ,motorcycle ,footnote #b3 ,to provide op]at+ in/ructions ) ! mat]iel1 ?is te*nical manual has be5 publi%$ 9 advance ( complete te*nical review4 ,any errors or omissions w be correct$ by *anges or1 if ext5sive1 by an e>ly revision4 ,section ,,ii ,,description ,,& ,,tabulat$ ,,data ,p>agraph ,description #c ,data #d #c4 ,,description 7figs4 #a1 #b1 & #c74 a4 ,?is #b;cyl9d] solo motorcycle is p[]$ by a ,vtype1 aircool$ gasol9e eng9e1 op]at+ on conv5tional #d/roke1 #d;cycle pr9ciples4 ,aircool$ eng9es rely ^u movem5t ( air ov] cyl9d] & head radiat+ f9s1 & ^u circulation ( oil = dissipation ( excessive heat4 ,motorcycle eng9es1 !re=e1 "u no conditions %\ld be op]at$ = m ?an #a m9ute :5 motorcycle is n 9 motion4 #d4 ,,data4 a4 ,vehicle ,specifications4 ,type ( eng9e #b;cyl9d]1 ,vtype ,lhead1 aircool$ ,cyl9d] bore #b-c_/d 94 ,/roke #c-ac_/af 94 ,eng9e numb] 7s]ial7 left side eng9e base1 bel[ front cyl9d]4 ,:eelbase #d ft #aa-a_/b 94 ,l5g? ov]all #g ft #d 94 ,wid? ov]all 7h&le b>s7 #c ft #e 94 ,:eel size #ah 94 ,tire size #d4jj #ah 94 ,tire type ,drop c5t] ,weight ( vehicle 7)\t rid] or armam5t7 #edj lb4 ,gr\nd cle>ance 7skid plate7 #d 94 ,k9d & grade ( fuel ,gasol9e3 #gb octane or high] ,high ge> ratio #d4ei3a ,eng9e sprocket #catoo? ,c\nt]%aft sprocket #agtoo? ,re> :eel sprocket #datoo? b4 ,p]=mance4 ,maximum all[able spe$ #fe mph ,miles p] gallon 7h>d surface7 #ce ,cruis+ range 7)\t refill7 #ajj miles ,=d+ dep? 7c>buretor7 #ah 94 c4 ,capacities4 ,fuel capacity 7left tank7 #c-c_/h ,u4,s4 gal ,oil tank capacity 7"r tank7 #a-a_/h ,u4,s4 gal ,transmission capacity #c_/d pt ,section ,,iii ,,controls ,,& ,,op]ation ,p>agraph ,controls #e ,eng9e pre/>t+ in/ructions #f ,/>t+ ! eng9e #g ,/opp+ ! eng9e #h ,op]ation ( vehicle #i ,driv+ precautions #aj ,/opp+ & p>k+ vehicle #aa ,t[+ vehicle to />t eng9e #ab ,runn+9 new eng9e 7or vehicle7 #ac ,illu/ration3 ,,ra ,,pd #cajbja ,figure #d--;,controls #e4 ,,controls 7fig4 #d74 a4 ,controls are peculi> to ! motorcycle4 ,! rid] mu/ become ?or\ghly famili> ) ! location & use ( all control devices be=e attempt+ to op]ate vehicle4 b4 ,gasol9e ,valve 7figs4 #e & #f74 ,gasol9e valve is locat$ 9 left tank1 =w>d4 ,valve is clos$ by turn+ to ! "r1 f+] tight4 ,turn+ to left op5s valve4 ,valve is 9 normal op]at+ position :5 turn$ to left1 ) valve head d[n4 ,lift+ valve head releases em]g5cy supply ( fuel 7#c qu>ts74 ,illu/ration3 ,,ra ,,pd #cajbjb ,figure #e--;,fuel ,supply ,valve ,illu/ration3 ,,ra ,,pd #cajbic ,figure #f--;,fuel ,supply ,valve ,positions c4 ,?rottle4 ,! ?rottle is controll$ by "r h&le b> grip4 ,turn+ grip inw>d op5s ?rottle1 turn+ x outw>d closes ?rottle4 d4 ,sp>k4 ,sp>k is controll$ by left h&le b> grip4 ,turn+ grip inw>d advances sp>k1 turn+ x outw>d ret>ds sp>k4 e4 ,clut* 7fig4 #g74 ,clut* is op]at$ by left foot 7rock]type7 p$al1 connect+ ) /eel cable1 :i* actuates clut* release lev]4 ,p$al is locat$ on left side ( motorcycle above footbo>d4 ,=w>d d[nw>d 7toe7 position ( p$al engages clut*4 ,re> d[nw>d 7heel7 position ( p$al dis5gages clut*4 ,foot p$al provid$ ) friction device to reta9 x 9 ei!r engag$ or dis5gag$ position4 ,illu/ration3 ,,ra ,,pd #cajbjd ,figure #g--;,clut* ,p$al ,positions ,illu/ration3 ,,ra ,,pd #cajbje ,figure #h--;,ge> ,%ift] ,lev] ,positions f4 ,s]vice ,brake 7,re> ,:eel74 ,foot p$al is locat$ on "r side ( motorcycle at =w>d end ( footbo>d4 g4 ,auxili>y ,brake 7,front ,:eel74 ,auxili>y brake is op]at$ by h& lev] locat$ on left h&le b>4 ,x is us$ 9 conjunction ) s]vice brake1 z an em]g5cy brake1 or = hold+ vehicle :ile />t+ eng9e on grade4 ,,caution3 ,brake is to be appli$ lightly & cauti\sly on wet & slipp]y roads4 h4 ,ge> ,%ift] 7fig4 #h74 ,%ift] lev] is locat$ on left tank1 =w>d position1 & op]ates )9 a guide4 ,%ift] lev] guide is not*$ = positive location ( ge>s & ea* position is id5tifi$1 front to re>3 8#a0--l[ ge>2 8,n0--neutral2 8#b0--second ge>2 8#c0--;direct high ge>4 ,illu/ration3 ,,ra ,,pd #cajbjf ,figure #i--;,c>buretor ,*oke ,lev] ,positions i4 ,/e]+ ,damp]4 ,/e]+ damp] is an adju/able friction device to damp] turn+ action ( =ks1 /eady front :eel1 & prev5t wobble 9 r\gh t]ra9 or at high spe$s1 & is locat$ on top ( /e]+ head 9 c5t] ( h&le b>s4 ,move h&le to "r to apply desir$ friction4 j4 ,foot ,/>t] ,crank 7fig4 #a74 ,! foot />t] crank is locat$ on "r side ( motorcycle4 ,ge> %ift] lev] mu/ be 9 neutral position1 & clut* foot p$al 9 =w>d engag$ position1 be=e us+ foot />t] crank4 ,/>t] crank normally is 9 upw>d position4 ,/raddle motorcycle1 place "r foot on />t] crank1 & %ift weight ( body = =ceful d[nw>d crank op]ation to />t eng9e4 k4 ,ignition & ,light ,swit*4 ,e>li] models are provid$ ) swit* lock1 lat] models are nonlock+4 ,swit* is (f 9 /raight=w>d position4 ,fir/ position to "r is = eng9e ignition only4 ,second position to "r is = ignition & black\t lights4 ,to use vehicle s]vice lights1 depress button to turn swit* to ?ird "r position4 l4 ,in/rum5t ,panel ,signal ,lights4 ,in/ead ( an ammet] & oil pressure gage1 signal lights indicate g5]ator *>g+1 & eng9e oil pressure4 7#a7 ,gre5 light is locat$ on left side ( in/rum5t panel4 ,:5 eng9e is runn+1 & light is out1 x indicates g5]ator is *>g+4 7#b7 ,r$ light is locat$ on "r side ( in/rum5t panel4 ,:5 eng9e is runn+1 & light is out1 x indicates eng9e oil is circulat+4 m4 ,c>buretor ,*oke 7fig4 #i74 ,*oke lev] is 9 full prime position :5 all ! way up1 & 9 normal runn+ position :5 all ! way d[n4 #f4 ,,eng9e ,,pre/>t+ ,,in/ructions4 a4 ,be=e ! eng9e is />t$1 p]=m ! ,be=eop]ation ,s]vice outl9$ 9 p>agraph #ae4 ,special c>e mu/ be tak5 dur+ />t+ & w>m+up p]iod to avoid unnecess>y eng9e we>4 b4 ,! rid] mu/ acquire correct motorcycle eng9e />t+ habits1 & le>n to d ! job ! quicke/1 easie/1 & mo/ dep5dable way4 ,! foll[+ po9t]s w be helpful to ! beg9n] z well z to a season$ rid]3 7#a7 ,m\nt 7/raddle7 motorcycle to obta9 firm grip on h&le b>s4 7#b7 ,leave side /& 7jiffy /&7 outw>d to support vehicle :ile op]at+ foot />t] crank ) "r foot4 7#c7 ,eng9e />t+ w be b5efit$ by use ( front :eel1 h&op]at$ brake1 to prev5t vehicle f roll+ or %ift+ dur+ />t+ kicks4 ,?is is especially helpful if vehicle is p>k$ on an incl9e or on s(t1 unev5 surface4 c4 ,! proc$ure outl9$ bel[ is prep>atory to />t+ ei!r cold1 w>m1 or hot eng9e3 7#a7 ,place ge> %ift] lev] 9 8,n0 7neutral7 position 7fig4 #h74 7#b7 ,see t gasol9e %ut(f valve is op5 7fig4 #e74 7#c7 ,engage clut* 7fig4 #g74 7#d7 ,sp>k control 7left7 grip mu/ be turn$ inw>d to fully advanc$ position1 or ne>ly s4 7#e7 ,foot />t] crank may travel #a_/b way d[nw>d be=e />t+ eng9e4 ,see t a full vigor\s />t] /roke is us$4 ,a vigor\s kick1 us+ a full sw+ 7n a jab7 ( "r leg & hip1 is correct eng9e />t+ practice4 #g4 ,,/>t+ ,,! ,,eng9e4 a4 ,proc$ure = />t+ cold1 w>m1 or hot motorcycle eng9es diff]s4 ,!re=e1 foll[+ in/ructions are us$ ) p>agraph #f c to cov] correct proc$ure 9 all ?ree cases4 b4 ,/>t+ ,cold ,eng9e4 ,:5 vehicle has n be5 op]at$ = "s "t1 & eng9e is normally cold1 foll[ progressive proc$ure = easie/ />t+4 7#a7 ,set c>buretor *oke lev] 9 full upw>d 7clos$7 position4 7#b7 ,op5 ?rottle wide by turn+ "r grip inw>d z f> z x w g4 7#c7 ,prime cyl9d]s by op]at+ foot />t] crank "o or two /rokes4 7#d7 ,set c>buretor *oke lev] 9 #a_/d to #a_/b clos$ position = mild wea!r />t+3 #c_/d clos$ 7or leave fully *ok$7 = extremely cold wea!r />t+4 ,,caution3 ,x is only 9 extremely cold wea!r t eng9e may />t be/ ) *oke fully clos$1 & ev5 !n x w h to be mov$ f ?is position imm$iately aft] eng9e is />t$4 7#e7 ,set ?rottle 7"r7 grip to slightly op5 position4 7#f7 ,turn ignition swit* on1 fir/ "r position4 7#g7 ,/>t eng9e ) vigor\s /rokes ( foot />t] crank4 7#h7 ,:5 eng9e />ts1 set ?rottle = mod]ate idl+ spe$ = w>m+ up1 or until ready to set vehicle 9 motion4 ,d n race eng9e unnecess>ily4 7#i7 ,aft] eng9e w>ms up1 & misfires due to an ov]ri* mixture1 gradually move *oke lev] d[nw>d4 ,aft] eng9e has ?or\ghly w>m$ up1 move *oke lev] to fully op5 7d[nw>d7 position4 c4 ,/>t+ ,w>m ,eng9e4 ,foll[+ in/ructions apply to eng9e :5 halfway betwe5 hot & cold4 ,) eng9e 9 ?is condition1 c>buretor *ok+ mu/ be h&l$ cauti\sly4 7#a7 ,lift *oke lev] to fir/ upw>d position f normal 7#a_/d clos$74 7#b7 ,set ?rottle 7"r7 grip to fully clos$ 7outw>d7 position4 7#c7 ,op]ate foot />t] crank "o or two /rokes4 7#d7 ,set ?rottle grip to betwe5 #a_/d & #a_/c op5 position4 7#e7 ,turn ignition swit* on4 7#f7 ,/>t eng9e ) vigor\s /rokes ( foot />t] crank4 7#g7 ,soon aft] eng9e />ts1 *oke lev] mu/ be mov$ to fully op5 7d[nw>d7 position4 7#h7 ,turn ?rottle grip to control idl+ spe$ ( eng9e4 d4 ,/>t+ ,hot ,eng9e4 ,if eng9e has be5 %ut (f = only a brief p]iod & is ne> normal op]at+ temp]ature1 x is n necess>y to use c>buretor *oke lev]4 ,) "s eng9es1 dep5d+ ^u c>buretor condition & adju/m5t1 hot />t+ is easi] & m dep5dable if foot />t] crank is op]at$ "o /roke be=e turn+ ignition swit* on4 7#a7 ,close ?rottle grip by turn+ fully outw>d4 7#b7 ,turn ignition swit* on4 7#c7 ,op]ate foot />t] crank to />t eng9e4 7#d7 ,:5 hot eng9e does n />t readily aft] two or ?ree /rokes ( ! foot />t] crank1 x is usually due to an ov]ri* 7flood$7 condition1 & ! prop] proc$ure !n is to op5 ?rottle wide s t m air c ent]3 close ?rottle quickly aft] eng9e />ts4 ,,caution3 ,aft] eng9e has w>m$ up to a normal op]at+ temp]ature1 d n all[ eng9e to /& idl+ = long] ?an a #a m9ute int]val4 e4 ,/>t+ ,eng9e ) ,dead ,batt]y4 ,see p>agraph #ab4 f4 ,behavior ( ,in/rum5t ,panel ,signal ,lights4 ,function ( g5]ator 7gre57 signal light dep5ds ^u action ( cutout relay2 eng9e oil pressure 7r$7 signal light dep5ds ^u action ( oil fe$ pump4 ,rid] mu/1 !re=e1 ?or\ghly und]/& op]at+ *>act]i/ics ( bo? signal lights to judge condition ( g5]atorbatt]y circuit & pressure 9 eng9e oil circulat+ sy/em4 7#a7 ,:5 ignition light swit* is turn$ to fir/ 7"r7 position1 prep>atory to />t+ eng9e1 bo? gre5 & r$ signal lights %\ld g on4 ,,caution3 ,:5 swit* is turn$ on1 imm$iately aft] eng9e has be5 prim$ by crank+1 r$ 7oil pressure7 signal light may n light at once1 b w light aft] a few seconds1 due to oil pressure built up by crank+1 & is mo/ likely to be notic$ 9 cold wea!r4 7#b7 ,) eng9e />t$ & runn+ at m$ium idl+ spe$1 bo? signal lights %\ld g (f4 ,,caution3 ,%\ld oil pressure 7r$7 signal light fail to g (f at spe$s above idl+1 conditions mu/ be br\ght to att5tion ( unit me*anic4 7#c7 ,at sl[ idle spe$1 or "u approximately #bj miles p] h\r road spe$ 79 high ge>71 g5]ator 7gre57 signal light w normally fla% on & (f1 because at t spe$ g5]ator voltage output is v l[ & un/eady4 ,,caution3 ,%\ld g5]ator 7gre57 signal light fail to g (f at spe$ above approximately #bj miles p] h\r1 g5]ator is ei!r n *>g+ at all1 or its curr5t output is n up to normal1 & g5]ator %\ld be giv5 att5tion at once4 #h4 ,,/opp+ ,,! ,,eng9e4 a4 ,/op eng9e only by turn+ ignition & light swit* to (f 7/raightahead7 position1 to prev5t dis*>ge ( batt]y ?r\gh sp>k coil prim>y circuit4 #i4 ,,op]ation ,,( ,,vehicle4 a4 ,/>t+ on ,level ,gr\nd4 ,! eng9e hav+ be5 w>m$ up & *eck$ = satisfactory op]ation1 ! vehicle 7) op]ator 9 rid+ position7 is put 9 motion z foll[s3 7#a7 ,transf] body weight to "r leg4 7#b7 ,fold back side /& 7jiffy /&74 7#c7 ,dis5gage clut* by depress+ clut* foot p$al ) heel ( left foot4 7#d7 ,%ift ge> %ift] lev] into 8#a0 7l[7 ge> position4 7#e7 ,sl[ly engage clut* by depress+ clut* foot p$al ) toe ( left foot4 7#f7 ,:5 clut* />ts to 8take hold10 op5 ?rottle suffici5tly to ma9ta9 eng9e spe$4 7#g7 ,accel]ate gradually to betwe5 #ab & #ae miles p] h\r 9 l[ ge>4 7#h7 ,close ?rottle quickly4 7#i7 ,dis5gage clut*4 7#aj7 ,%ift ?r\gh 8,n0 7neutral7 position into 8#b0 7second7 ge>4 7#aa7 ,re5gage clut* & accel]ate to ab\t #be miles p] h\r4 7#ab7 ,close ?rottle quickly4 7#ac7 ,dis5gage clut*4 7#ad7 ,%ift into 8#c0 7high7 ge>4 7#ae7 ,re5gage clut* & accel]ate to desir$ spe$4 b4 ,/>t+ on ,unev5 or ,s(t ,gr\nd4 7#a7 ,if /&+ on an incl9e or 9 loose1 heavy gr\nd1 m eng9e p[] w be requir$ to />t vehicle )\t /all+ eng9e4 7#b7 ,x may be necess>y to keep vehicle f roll+ by keep+ pressure on front brake h& lev]4 ,brake pressure is releas$ aft] vehicle />ts 9 =w>d motion4 7#c7 ,op5 ?rottle & engage clut* at same "t to provide p[] ne$$ = />t+1 )\t rac+ eng9e unnecess>ily4 7#d7 ,motorcycle />ts %\ld be made )\t excessive application ( p[]1 ) consequ5t unnecess>y sp9n+ ( re> :eel4 #aj4 ,,driv+ ,,precautions4 a4 ,practice w enable a rid] to judge at :at rate ( spe$ ! motorcycle %\ld be mov+ be=e he %ifts f a l[] to high] ge>1 & eng9e %\ld nev] be p]mitt$ to labor unduly1 :5 a %ift ( ge>s1 high] to l[]1 w\ld improve op]ation4 7#a7 ,op]ator mu/ n look d[n at ge> %ift] :5 %ift+ ge>s1 b keep 8 eyes on ! road ahead4 ,d n ride ! clut*4 ,! op]ator's foot %\ld re/ on clut* foot p$al only :5 he is op]at+ x4 ,:5 %ift+ ge>s1 dis5gage clut* fully to avoid ge> damage & %ift+ difficulties4 ,,caution3 ,_m transmissions are ru9$ ?r\gh failure to dis5gage clut* fully :5 %ift+ ge>s4 b4 ,brak+4 ,re> :eel s]vice brake mu/ be 9 su* condition t m$iumh>d application w cause re> :eel to lock4 ,application ( s]vice brake %\ld be gradual1 ) j en\gh =ce to accompli% desir$ result4 7#a7 ,auxili>y front :eel brake1 :5 us$ 9 conjunction ) s]vice brake1 mu/ be appli$ ) caution1 especially on wet1 muddy1 or slipp]y roads4 7#b7 ,aft] pass+ ?r\gh wat]1 ! brakes %\ld be set slightly1 & ! vehicle op]at$ = a %ort di/ance1 until suffici5t heat has be5 g5]at$ to dry ! brakes4 c4 ,avoid ,l[ ,ge> ,op]ation4 ,always op]ate vehicle 9 highe/ ge> possible1 consi/5t ) tactical situation1 spe$ requir$1 p[] requir$1 & k9d & nature ( road sub/ance1 to prev5t ov]heat+ ( eng9e4 d4 ,high ,spe$ ,tips4 ,only exp]i5c$ rid]s %\ld indulge 9 highspe$ rid+4 ,a motorcycle op]at$ = long di/ances at high spe$ mu/ be giv5 clos] ?an ord9>y att5tion to avoid s]i\s eng9e ov]heat+ ) consequ5t damage4 ,= bett] motorcycle s]vice1 apply ! foll[+ sugge/ions3 7#a7 ,develop habit ( frequ5tly snapp+ ?rottle %ut = an in/ant :5 runn+ at high spe$4 ,?is draws additional lubrication to pi/on & cyl9d] & assi/s 9 cool+ eng9e4 7#b7 ,9 cool wea!r1 op]ate eng9e sl[ly until x is ?or\ghly w>m$ up1 to avoid damage to pi/ons1 r+s1 cyl9d]s1 & o!r p>ts be=e oil is w>m en\gh to circulate freely4 7#c7 ,if h&le b> w9d%ield & leg %ields are us$1 eng9e is m likely to ov]heat ) cont9u$ highspe$ rid+4 ,wat* ?is c>efully4 7#d7 ,adju/ 8/e]+ damp]0 = be/ control ( motorcycle consi/5t ) rid+ spe$ & condition & nature ( road4 #aa4 ,,/opp+ ,,& ,,p>k+ ,,vehicle4 a4 ,/opp+ ,vehicle4 ,rid] w make a 8re/>t0 easi] & quick] if he w apply ! foll[+ in/ructions ^u /opp+ vehicle3 7#a7 ,close ?rottle4 7#b7 ,dis5gage clut*4 7#c7 ,apply brake 7or brakes7 to sl[ vehicle )\t slid+ re> tire4 7#d7 ,j be=e com+ to a complete /op1 %ift into 8,n0 7neutral7 position & engage clut*4 ,,caution3 ,if imm$iate re/>t is to be made1 %ift into 8#a0 7l[7 ge> & all[ clut* foot p$al to rema9 9 dis5gag$ position4 7,rid] w be m\nt$ on motorcycle ) eng9e runn+47 7#e7 ,cont9ue brake application to complete /op4 7#f7 ,aft] vehicle sl[s to po9t :]e x c no long] be balanc$ by /e]+1 place left foot on gr\nd to ma9ta9 balance until "r foot c be remov$ f brake op]at+ p$al4 ,,caution3 ,d n idle eng9e long] ?an #a m9ute4 7#g7 ,/op eng9e by turn+ ignition swit* (f4 b4 ,p>k+ ,vehicle4 7#a7 ,lean motorcycle on side 7jiffy7 /&4 7#b7 ,%ift into 8#a0 7l[7 ge>4 7#c7 ,engage clut* s vehicle _c roll4 7#d7 ,%ut (f gasol9e supply by turn+ valve 7to "r7 f+]tight aga9/ its seat4 #ab4 ,,t[+ ,,vehicle ,,to ,,/>t ,,eng9e4 a4 ,9 em]g5cies :5 eng9e _c be />t$ ) foot />t] crank1 x c be />t$ by t[+ ! motorcycle4 7#a7 ,set ge> %ift] lev] 9 8#b0 7second7 ge> position4 7#b7 ,dis5gage clut*4 7#c7 ,*oke c>buretor4 7#d7 ,turn ignition swit* on4 7#e7 ,aft] mom5tum ( ! t[$ motorcycle rea*es betwe5 #aj & #ae miles p] h\r1 engage clut*1 & cont9ue proc$ure until eng9e />ts4 b4 ,eng9e ,/>t+ ) ,dead ,batt]y4 ,em]g5cy eng9e />t+ ) dead batt]y c be effect$ by mak+ use ( fre%ly *>g$ batt]y1 or by t[+ z outl9$ above4 ,if vehicle ) dead batt]y is to be t[$ = eng9e />t+1 proce$ z foll[s3 7#a7 ,disconnect batt]y negative wire f gr\nd on "r side ( motorcycle4 7#b7 ,t[ motorcycle = eng9e />t+4 7#c7 ,aft] eng9e is />t$1 reconnect batt]y gr\nd wire to frame to prev5t damage to electrical sy/em4 #ac4 ,,runn+,,9 ,,new ,,eng9e 7,,or ,,vehicle74 a4 ,a new motorcycle eng9e or newly ov]haul$ eng9e mu/ be giv5 prop] 8break90 consid]ation = at lea/ ! fir/ #a1jjj to #a1bjj miles ( s]vice4 ,failure to d ?is may result 9 damage t w put eng9e out ( active s]vice )9 a %ort p]iod ( "t4 b4 ,at ! fir/ #bej miles1 *eck front & re> drive *a9s to make sure !y are receiv+ requir$ am\nt ( oil = ample lubrication4 ,if necess>y1 h *a9 oil]s adju/$ by unit me*anic4 ,drive *a9s mu/ be inspect$ = correct adju/m5t1 & be giv5 att5tion by unit me*anic z ne$$4 c4 ,at fir/ #ejj miles1 dra9 oil tank & refill ) fre% oil4 ,*eck front & re> *a9s 7/ep b above74 ,!reaft]1 foll[ in/ructions 9 ,ma9t5ance ,op]ation section4 d4 ,aft] a new motorcycle has be5 run #ejj to #a1jjj miles x ne$s to be ?or\ghly *eck$ ov] & any loose screws & nuts tight5$4 ,p>ticul> att5tion mu/ be giv5 eng9e & transmission m\nt+ bolts & nuts1 & to re> :eel m\nt+ socket screws4 e4 ,foll[+ po9t]s mu/ be obs]v$ :5 runn+9 new eng9e or newly ov]haul$ eng9e3 7#a7 ,d n exce$ #cj miles p] h\r dur+ fir/ #ajj miles4 7#b7 ,d n exce$ #ce miles p] h\r dur+ next #bjj miles4 7#c7 ,d n exce$ #dj miles p] h\r dur+ next #djj miles4 7#d7 ,d n exce$ #ej miles p] h\r dur+ next #ejj miles4 7#e7 ,avoid use ( l[ ge>s dur+ break9 op]ation z mu* z possible4 ,section ,,iv ,,fir/ ,,e*elon ,,prev5tive ,,ma9t5ance ,,s]vices ,p>agraph ,purpose #ad ,be=eop]ation s]vice #ae ,dur+op]ation s]vice #af ,athalt s]vice #ag ,aft]op]ation & weekly s]vice #ah #ad4 ,,purpose4 a4 ,to insure me*anical effici5cy x is necess>y t ! vehicle be sy/ematically inspect$ at int]vals ea* day x is op]at$ & weekly1 s t defects may be discov]$ & correct$ be=e !y result 9 s]i\s damage or failure4 ,c]ta9 s*$ul$ ma9t5ance s]vices w be p]=m$ at ^! designat$ int]vals4 ,! s]vices set =? 9 ?is section are ^? p]=m$ by driv] or crew be=e op]ation1 dur+ op]ation1 at halt1 aft] op]ation1 & weekly4 b4 ,driv] prev5tive ma9t5ance s]vices are li/$ on ! back ( 8,driv]'s ,trip ,ticket & ,prev5tive ,ma9t5ance ,s]vice ,record10 ,w4,d4 ,=m ,no4 #dh1 to cov] vehicles ( all types & models4 ,items peculi> to specific vehicles1 b n li/$ on ,w4,d4 ,=m ,no4 #dh1 are cov]$ 9 manual proc$ures "u ! items to :i* !y are relat$4 ,c]ta9 items li/$ on ! =m t d n p]ta9 to ! vehicle involv$ are elim9at$ f ! proc$ures z writt5 into ! manual4 ,e organization mu/ ?or\ghly s*ool ea* driv] 9 p]=m+ ! ma9t5ance proc$ures set =? 9 manuals1 :e!r or n !y are li/$ specifically on ,w4,d4 ,=m ,no4 #dh4 c4 ,! items li/$ on ,w4,d4 ,=m ,no4 #dh t apply to ?is vehicle are exp&$ 9 ?is manual to provide specific proc$ures = accompli%m5t ( ! inspections & s]vices4 ,^! s]vices are arrang$ to facilitate inspection & cons]ve ! "t ( ! driv]1 & are n necess>ily 9 ! same num]ical ord] z %[n on ,w4,d4 ,=m ,no4 #dh4 ,! item numb]s1 h[ev]1 are id5tical ) ^? %[n on t =m4 d4 ,! g5]al inspection ( ea* item applies also to any support+ memb] or connection1 & g5]ally includes a *eck to see :e!r ! item is 9 good condition1 correctly assembl$1 secure1 or excessively worn4 7#a7 ,! inspection = 8good condition0 is usually an ext]nal visual inspection to det]m9e :e!r ! unit is damag$ beyond safe or s]viceable limits4 ,! t]m 8good condition0 is expla9$ fur!r by ! foll[+3 n b5t or twi/$1 n *af$ or burn$1 n brok5 or crack$1 n b>e or fray$1 n d5t$ or collaps$1 n torn or cut4 7#b7 ,! inspection ( a unit to see t x is 8correctly assembl$0 is usually an ext]nal visual inspection to see :e!r x is 9 its normal assembl$ position 9 ! vehicle4 7#c7 ,! inspection ( a unit to det]m9e if x is 8secure0 is usually an ext]nal visual exam9ation1 a h&feel1 or a pryb> *eck = loos5ess4 ,su* an inspection %\ld include any brackets1 lock wa%]s1 lock nuts1 lock+ wires1 or cott] p9s us$ 9 assembly4 7#d7 8,excessively worn0 w be und]/ood to mean worn close to1 or beyond1 s]viceable limits1 & likely to result 9 a failure if n replac$ be=e ! next s*$ul$ inspection4 e4 ,any defects or unsatisfactory op]at+ *>act]i/ics beyond ! scope ( fir/ e*elon to correct mu/ be report$ at ! e>lie/ opportunity to ! designat$ individual 9 au?ority4 #ae4 ,,be=e,,op]ation ,,s]vice4 a4 ,?is inspection s*$ule is design$ prim>ily z a *eck to see t ! vehicle has n be5 tamp]$ )1 or sabotag$ s9ce ! ,aft]op]ation ,s]vice 0 p]=m$4 ,v>i\s combat conditions may h r5d]$ ! vehicle unsafe = op]ation & x is ! duty ( ! driv] to det]m9e :e!r or n ! vehicle is 9 condition to c>ry out any mission to :i* x is assign$4 ,?is op]ation w n be entirely omitt$1 ev5 9 extreme tactical situations4 b4 ,proc$ures4 ,be=eop]ation ,s]vice consi/s ( inspect+ items li/$ bel[ accord+ to ! proc$ure describ$1 & correct+ or report+ any defici5cies4 ,^u completion ( ! s]vice1 results %\ld be report$ promptly to ! designat$ individual 9 au?ority4 7#a7 ,,item #a1 ,,tamp]+ ,,& ,,damage4 ,look = any injury to vehicle 9 g5]al1 its accessories or equipm5t1 t may h be5 caus$ by tamp]+1 sabotage1 collision1 fall+ debris1 or %ell fire s9ce p>k+ vehicle4 ,look = loos5$ or damag$ accessories1 loose fuel or oil l9es1 or any disconnect$ l9kage4 7#b7 ,,item #c1 ,,fuel ,,& ,,oil4 ,inspect tanks = fuel & oil levels1 add oil & fuel z necess>y4 ,any appreciable *ange 9 levels s9ce p]=m+ ,aft]op]ation ,s]vice %\ld be inve/igat$ & report$ to designat$ au?ority4 7#c7 ,,item #d1 ,,accessories ,,& ,,drives4 ,exam9e all accessories su* z c>buretor1 air clean]1 g5]ator1 & cutout relay = loose connections1 loose m\nt+s1 or leaks4 ,exam9e re> *a9 7f9al drive7 = free up&d[n movem5t 7slack71 midway betwe5 sprockets4 ,total up&d[n movem5t mu/ n be m ?an #a in*1 nor less ?an #a_/b in*4 ,inspect re> *a9 = adequate lubrication4 7#d7 ,,item #f1 ,,leaks1 ,,g5]al4 ,exam9e vehicle & gr\nd "u vehicle = indications ( fuel or oil leaks4 ,normally a few drops ( wa/e oil f *a9s may be expect$ to drop f skid plate4 7#e7 ,,item #aa1 ,,glass4 ,clean glass on in/rum5ts2 clean & adju/ re> view mirror2 inspect glass = breakage4 7#f7 ,,item #ab1 ,,lamps4 ,if tactical situation p]mits1 obs]ve :e!r black\t & s]vice lights op]ate ) swit* 9 its respective positions1 & g out :5 swit*$ (f4 ,also see t lights are secure1 & t l5ses are clean & n brok54 ,obs]ve :e!r bo? filam5ts ( s]vice headlight op]ate :5 dimm] swit* on left h&le b> is mov$ to its respective positions4 7#g7 ,,item #ac1 ,,:eels1 ,,axle ,,nuts ,,& ,,screws4 ,exam9e re> :eel m\nt+ socket screws1 front & re> axle nuts1 & front =k rock] /ud nuts = tightness4 ,obs]ve re> *a9 adju/+ screws = secure lock+4 ,inspect spokes = good condition & tightness4 7#h7 ,,item #ad1 ,,tires4 ,exam9e tires = cuts or imb$d$ objects 9 treads or c>cass4 ,if "t p]mits1 *eck air pressure1 :i* %\ld be #ah p\nds front1 & #bj p\nds re> 7tires cold74 ,inspect valve caps = pres5ce & secure m\nt+4 7#i7 ,,item #ae1 ,,spr+s ,,& ,,susp5sion4 ,exam9e front =k spr+s = secure m\nt+ & good condition4 ,pu% d[n re> ( saddle to te/ = full action ( saddle po/ spr+4 7#aj7 ,,item #af1 ,,/e]+ ,,& ,,h&le ,,b> ,,controls4 ,te/ /e]+ head be>+ adju/m5t by ex]t+ /rong upw>d pull at h&le b> grips1 & obs]v+ :e!r or n !re is any noticeable play 9 be>+4 ,op]ate /e]+ damp] lev] & obs]ve t damp] is compress$ be=e lev] rea*es "rside position1 & is fully releas$ ) lev] 9 leftside position4 ,te/ h&le b> grip controls = full1 free action2 also te/ = complete op5+ & clos+ ( ?rottle1 & full advance & ret>d ( tim]4 7#aa7 ,,item #ag1 ,,f5d]s 7,,mudgu>ds71 ,,luggage ,,c>ri]1 ,,safety ,,gu>ds1 ,,& ,,/&s4 ,exam9e ^! items = good condition & secure m\nt+4 7#ab7 ,,item #ba1 ,,tools ,,& ,,equipm5t4 ,inspect tools & equipm5t = pres5ce1 s]viceability1 & prop] /[age4 7,see tool li/ 9 p>4 #ba47 7#ac7 ,,item #g1 ,,eng9e ,,w>m,,up4 ,/>t eng9e1 not+ any t5d5cy t[>d h>d />t+1 or improp] action ( foot />t] crank4 ,set ?rottle to mod]ate idle spe$4 ,li/5 = unusual noises4 ,wat* in/rum5t indications & eng9e p]=mance1 su* z misfir+4 ,,caution3 ,d n idle eng9e long] ?an #a m9ute ) vehicle /&+4 7#ad7 ,,item #h1 ,,*oke4 ,dur+ idl+ ( eng9e1 reset *oke z requir$ to prev5t excessive *ok+ & dilution ( eng9e oil4 7#ae7 ,,item #i1 ,,in/rum5ts4 ,:5 swit* is turn$ on & eng9e is idl+ at mod]ate spe$ bo? r$ light 7indicat+ oil pressure7 & gre5 light 7indicat+ g5]ator action7 %\ld be out4 ,at l[] op]at+ spe$s g5]atorindicat+ light may flick]4 ,,caution3 ,d n op]ate eng9e ) r$ light on 7no oil pressure74 7#af7 ,,item #aj1 ,,horn4 ,tactical situation p]mitt+1 te/ horn4 7#ag7 ,,item #bb1 ,,eng9e ,,op]ation4 ,eng9e %\ld idle smoo?ly4 ,accel]ate & decel]ate1 li/5+ = any unusual noises t may indicate compression or exhau/ leaks1 worn1 damag$1 loose1 or inadequately lubricat$ eng9e p>ts1 or accessories4 ,note any unusual smoke f exhau/4 7#ah7 ,,item #bc1 ,,driv]',s ,,p]mit1 ,,accid5t ,,report ,,=m ,,no4 #bf1 ,,& ,,vehicle ,,manual4 ,^! items mu/ be pres5t on vehicle & safely /[$4 7#ai7 ,,item #be1 ,,dur+,,op]ation ,,s]vice4 ,! ,dur+op]ation ,s]vice %\ld />t imm$iately aft] vehicle is put 9 motion1 9 ! nature ( a road te/4 #af4 ,,dur+,,op]ation ,,s]vice4 a4 ,:ile vehicle is 9 motion1 li/5 = any s\nds su* z rattles1 knocks1 squeals1 or hums t may indicate tr\ble4 ,be al]t to detect any odor ( ov]heat$ compon5ts or units su* z g5]ator1 brakes1 or clut*1 fuel vapor f a leak 9 fuel sy/em1 exhau/ gas1 or o!r signs ( tr\ble4 ,any "t ! brakes are us$1 ge>s %ift$1 or vehicle turn$1 consid] ?is a te/ & notice any unsatisfactory or unusual p]=mance4 ,wat* ! in/rum5ts con/antly4 ,notice promptly any unusual in/rum5t indication t may signify possible tr\ble 9 sy/em to :i* ! in/rum5t applies4 b4 ,proc$ures4 ,dur+op]ation ,s]vice consi/s ( obs]v+ items li/$ bel[ accord+ to ! proc$ures foll[+ ea* item1 & inve/igat+ any indications ( s]i\s tr\ble4 ,notice m9or defici5cies to be correct$ or report$ at e>lie/ opportunity1 usually at next s*$ul$ halt4 7#a7 ,,item #bg1 ,,foot ,,& ,,h& ,,brakes4 ,! foot brake %\ld op]ate smoo?ly & effectively1 leav+ res]ve p$al travel ( #a in*4 ,normal free play be=e op]ation is #a in*4 ,te/ h& brake lev] = free play1 :i* %\ld be #a_/d ( total h&le travel4 ,te/ = ease & smoo?ness ( op]ation4 7#b7 ,,item #bh1 ,,clut*4 ,inspect clut* = dis5gagem5t at ab\t #a_/b p$al travel4 ,clut* %\ld n *att]1 squeal1 or slip4 7#c7 ,,item #bi1 ,,transmission4 ,ge>s %\ld %ift smoo?ly1 op]ate quietly1 & n jump out ( me% dur+ op]ation4 ,if transmission jumps out ( me% 9 any ge>1 ?is indicates ne$ ( %ift] control adju/m5t4 7#d7 ,,item #ca1 ,,eng9e ,,& ,,controls4 ,be al]t = defici5cy 9 eng9e p]=mance su* z lack ( usual p[]1 misfir+1 unusual noise1 /all+1 indication ( eng9e ov]heat+1 or unusual exhau/ smoke4 ,notice :e!r eng9e responds to controls satisfactorily1 :e!r controls appe> to be 9 prop] adju/m5t & are suffici5tly tight4 7#e7 ,,item #cb1 ,,in/rum5ts4 ,obs]ve in/rum5ts = indication ( normal function+ ( sy/ems to :i* !y apply4 7a7 ,spe$omet] & ,odomet]4 ,spe$omet] %\ld indicate vehicle spe$ )\t excessive noise or fluctuation4 ,odomet] %\ld record trip & total mileage4 7b7 ,oil ,pressure ,signal ,light4 ,r$ light %\ld be (f dur+ op]ation4 ,if light goes on1 /op vehicle & inve/igate = oil pressure failure4 7c7 ,g5]ator ,signal ,light4 ,gre5 light %\ld be (f above #bj miles p] h\r4 ,batt]y dis*>ge is indicat$ by gre5 light be+ on4 7#f7 ,,item #cc1 ,,/e]+4 ,adju/ /e]+ damp] to desir$ /e]+ friction4 ,obs]ve vehicle /e]+ = w&]1 %immy1 lead+ to "o side1 or :eel hop4 7#g7 ,,item #cd1 ,,runn+ ,,ge>4 ,li/5 = any unusual noises f :eels1 axles1 or susp5sion p>ts t might indicate loos5ess or damage4 7#h7 ,,item #ce1 ,,*assis4 ,be al]t = noises t might indicate loose accessories1 controls1 atta*m5ts1 or equipm5t4 #ag4 ,,at,,halt ,,s]vice4 a4 ,athalt ,s]vice may be reg>d$ z m9imum ma9t5ance proc$ures & %\ld be p]=m$ "u all tactical conditions1 ev5 ?\gh m ext5sive ma9t5ance s]vices mu/ be slight$ or omitt$ altoge!r4 b4 ,proc$ures4 ,athalt ,s]vice consi/s ( inve/igat+ any defici5cies not$ dur+ op]ation1 inspect+ items li/$ bel[ accord+ to ! proc$ures foll[+ ! items1 & correct+ any defici5cies f\nd4 ,defici5cies n correct$ %\ld be report$ promptly to ! designat$ individual 9 au?ority4 7#a7 ,,item #ch1 ,,fuel ,,& ,,oil4 ,repl5i% fuel & oil z may be requir$ to rea* next refill+ po9t4 ,,caution3 ,left tank is = fuel2 "r tank is = oil4 ,fill] caps %\ld n be int]*ang$1 z only fuel tank cap is v5t$4 7#b7 ,,item #ci1 ,,temp]atures4 ,h&feel :eel hubs & brake drums = ov]heat+4 7#c7 ,,item #dj1 ,,v5ts4 ,make sure t crankcase brea!r outlet & re> *a9 oil fe$ pipe are cle>4 ,make sure grease dra9s 9 front & re> brake side cov]s are op5 & clean4 7#d7 ,,item #db1 ,,spr+s ,,& ,,susp5sions4 ,look = brok5 spr+s 9 =k4 7#e7 ,,item #dc1 ,,/e]+4 ,inve/igate any difficulty develop$ dur+ rid+4 7#f7 ,,item #dd1 ,,:eels ,,& ,,m\nt+ ,,screws4 ,inspect :eels = brok51 b5t1 or loose spokes4 ,also1 look = loose axle nuts or re> :eel m\nt+ screws4 ,inspect :eel rims = good condition4 7#g7 ,,item #de1 ,,tires4 ,exam9e tires = l[ pressure or damage4 ,remove =eign matt] f tire treads2 inspect = cuts4 7#h7 ,,item #df1 ,,leaks1 ,,g5]al4 ,inspect vehicle = indication ( fuel1 oil1 or batt]y leaks4 7#i7 ,,item #dg1 ,,accessories ,,& ,,*a94 ,exam9e accessories = loose connections1 loose m\nt+s1 or damage4 ,exam9e re> drive *a9 = brok5 roll]s1 brok5 l9k side plates1 & brok5 or miss+ connect+ l9k spr+ clips4 ,inspect *a9 = adequate lubrication4 7#aj7 ,,item #dh1 ,,air ,,clean]4 ,air clean] mu/ be secure1 ) air passages 9 good condition & clean4 ,:5 op]at+ "u extremely du/y or s&y conditions1 inspect air clean] frequ5tly & s]vice z requir$4 7#aa7 ,,item #di1 ,,f5d]s 7,,mudgu>ds71 ,,luggage ,,c>ri]1 ,,safety ,,gu>ds1 ,,& ,,/&s4 ,inspect ^! items = loos5ess or damage4 7#ab7 ,,item #eb1 ,,appe>ance ,,& ,,glass4 ,clean w9d%ield1 re> view mirror1 & light l5ses2 inspect = good condition1 secure atta*m5t1 & brok5 glass4 #ah4 ,,aft],,op]ation ,,& ,,weekly ,,s]vice4 a4 ,aft]op]ation ,s]vice is p>ticul>ly important1 because at ?is "t ! driv] inspects 8 vehicle to detect any defici5cies t may h develop$1 & corrects ^? he is p]mitt$ to h&le4 ,he %\ld report promptly1 to ! designat$ individual 9 au?ority1 ! results ( 8 inspection4 ,if ?is s*$ule is p]=m$ ?or\ghly1 ! vehicle %\ld be ready to roll aga9 on a mom5t's notice4 ,! ,be=eop]ation ,s]vice1 ) a few exceptions1 is !n necess>y only to asc]ta9 :e!r ! vehicle is 9 ! same condition 9 :i* x 0 left ^u completion ( ! ,aft]op]ation ,s]vice4 ,! ,aft]op]ation ,s]vice %\ld nev] be entirely omitt$1 ev5 9 extreme tactical situations1 b may be r$uc$ to ! b>e fundam5tal s]vices outl9$ = ! ,athalt ,s]vice1 if necess>y4 b4 ,proc$ures4 ,:5 p]=m+ ! ,aft]op]ation ,s]vice1 ! driv] mu/ rememb] & consid] any irregul>ities notic$ dur+ ! day 9 ! ,be=eop]ation4 ,dur+op]ation1 & ,athalt ,s]vices4 ,! ,aft]op]ation ,s]vice consi/s ( inspect+ & s]vic+ ! foll[+ items4 ,^? items ( ! ,aft]op]ation ,s]vices t are m>k$ ) an a/]isk 7997 require additional ,weekly s]vices1 ! proc$ures = :i* are indicat$ 9 /ep 7b7 ( ea* applicable item4 7#a7 ,,item #ed1 ,,fuel ,,& ,,oil4 ,fill fuel & oil tanks2 fill oil tank )9 #a in* ( top2 be sure to put oil 9 "r tank & fuel 9 left tank2 d n int]*ange caps4 ,,caution3 ,:5 op]at+ "u extremely du/y conditions1 dra9 eng9e oil tank & refill ) fre% oil z frequ5tly z excessive contam9ation ( ! oil occurs4 7#b7 ,,item #ee1 ,,eng9e ,,op]ation4 ,te/ = satisfactory eng9e idle )\t /all+4 ,accel]ate & decel]ate eng9e1 not+ any t5d5cy to miss or backfire1 unusual noises1 or vibration t may indicate worn p>ts1 loose m\nt+1 incorrect fuel mixture1 or faulty ignition4 ,inve/igate any unsatisfactory eng9e op]at+ *>act]i/ics not$ dur+ op]ation4 ,le>n to recognize noise caus$ by loose prim>y 7front7 drive *a94 ,slack 9 excess ( #a_/b in* total up&d[n motion c cause excessive noise :i* s\nds l eng9e knock4 ,remove inspection cov] = exam9ation ( *a94 7#c7 ,,item #eg1 ,,horn4 ,if tactical situation p]mits1 te/ horn4 7#d7 ,,item #ei1 ,,lights4 ,if tactical situation p]mits1 obs]ve :e!r black\t & s]vice lights op]ate ) swit* 9 its respective positions1 & g out :5 swit*$ (f4 ,also see t lights are secure1 & l5ses clean & n brok54 ,obs]ve :e!r bo? filam5ts ( s]vice headlight op]ate :5 dimm] swit* on left h&le b> is mov$ to its respective positions4 7#e7 ,,item #ef1 ,,in/rum5ts4 ,be=e /opp+ eng9e1 inspect in/rum5ts to see t indicator lights are /ill out4 ,/op eng9e4 ,aft] #cj seconds1 turn on swit* to see t oil pressure & g5]ator signal lights turn on4 ,,caution3 ,be sure to turn (f ignition swit* aft] ?is te/4 7#f7 ,,item #eh1 ,,glass4 ,clean re> view mirror1 w9d%ield1 in/rum5t1 & light glass4 ,exam9e = secure m\nt+ & breakage4 7#g7 ,,item #fb1 99,,batt]y4 7a7 ,inspect batt]y c>ri] = good condition & secure m\nt+4 ,inspect electrolyte level 7%\ld be #e_/af in* above plates74 ,inspect = any signs ( leakage ( electrolyte indicat+ batt]y has be5 ov]fill$1 poorly seal$1 or damag$4 ,,caution3 ,d n add wat] unless actually ne$$4 7b7 ,weekly4 ,clean dirt f top ( batt]y1 remove batt]y caps1 br+ electrolyte level to #e_/af in* above plates1 us+ clean1 dr9kable wat]4 ,clean t]m9als or po/s if corrod$2 be sure felt wa%]s are on t]m9als & prop]ly oil$2 tight5 t]m9al bolts cauti\sly1 if loose4 ,clean & pa9t batt]y c>ri] if corrod$4 7#h7 ,,item #fc1 99,,accessories ,,& ,,*a94 7a7 ,inspect c>buretor1 air clean]1 g5]ator1 & cutout relay = loose connections1 m\nt+s1 or damage4 ,exam9e re> drive *a9 = brok5 roll]s1 brok5 l9k side plates1 & brok5 or miss+ connect+ l9k spr+ clips4 ,exam9e re> *a9 7f9al drive7 = free up&d[n movem5t 7slack7 midway betwe5 sprockets2 maximum total all[able deflection is #a in*1 m9imum1 #a_/b in*4 7b7 ,weekly4 ,tight5 any accessory connections f\nd loose4 ,wipe excess dirt f re> *a94 ,*eck front *a9 = adju/m5t1 & inspect = prop] lubrication4 7#i7 ,,item #fe1 99,,air ,,clean]4 7a7 ,exam9e oil cup = excessive dirt & correct oil level4 ,if air clean] is excessively dirty1 clean elem5ts 9 dryclean+ solv5t1 refill cup ) fre% oil4 ,dip elem5ts 9 oil 9 oil cup1 replac+ elem5ts & atta*+ oil cup imm$iately4 ,if gaskets are damag$1 replace4 ,"u extremely du/y or s&y conditions x may be necess>y to clean & refill ! air clean] m ?an once daily4 ,inspect hose = leaks4 7b7 ,weekly4 ,inspect air clean] = prop] oil level & excessively dirty oil4 ,clean & s]vice air clean]1 tight5 m\nt+ & hose clamps4 ,,note3 ,e>lytype1 r\nd air clean] does n h removable filt] elem5ts4 ,complete clean] mu/ be remov$ to wa% elem5t4 7#aj7 ,,item #ff1 99,,fuel ,,filt] 7,,gasol9e ,,/ra9]74 7a7 ,clean cap & scre5 ( fuel filt]4 7b7 ,weekly4 ,clean cap & scre5 ( fuel filt]1 remove c>buretor b[l dra9 plug1 & dra9 (f wat] & dirt4 ,be sure to replace plug1 be+ c>eful to avoid cross ?read+4 7#aa7 ,,item #fg1 ,,eng9e ,,controls4 ,exam9e ?rottle & sp>k controls = damage to wires or = disconnect$ l9kage4 ,obs]ve = lack ( lubrication4 7#ab7 ,,item #fh1 99,,tires4 7a7 ,remove =eign matt] su* z nails1 glass1 or /ones f tire treads4 ,inspect tires = abnormal tread we>1 cuts1 or bruises3 also = pres5ce & tightness ( valve caps4 ,inflate tires to #ah p\nds front1 #bj p\nds re>1 ) tires cool4 7b7 ,weekly4 ,replace badly worn or o!rwise uns]viceable tires4 7#ac7 ,,item #fi1 99,,spr+s ,,& ,,susp5sion4 7a7 ,inspect front =k = brok5 or sagg$ spr+s1 loose bolts1 /uds1 & nuts4 7b7 ,weekly4 ,tight5 :eel axle nuts & re> brake sleeve nut4 ,also tight5 re> :eel m\nt+ socket screws v securely4 7#ad7 ,,item #gj1 ,,/e]+4 ,inspect /e]+ head = prop] adju/m5t ( be>+s4 ,exam9e /e]+ damp] = correct adju/m5t4 7#ae7 ,,item #gb1 99,,v5ts4 7a7 ,make sure t crankcase brea!r outlet & re> *a9 oil supply pipe are cle>4 ,make sure grease dra9s 9 front & re> brake side cov]s are op5 & clean4 7b7 ,weekly4 ,clean crankcase brea!r outlet1 re> *a9 oil supply pipe1 & grease dra9s 9 front & re> brake side cov]s4 7#af7 ,,item #gc1 ,,leaks1 ,,g5]al4 ,look ar\nd me*anism & b5ea? vehicle = indication ( fuel1 oil1 & grease leaks4 ,exam9e ar\nd brake drums = evid5ce ( grease 9 drums or on l9+s4 ,normally a few drops ( oil may be expect$ to drip f skid plate4 7#ag7 ,,item #gd1 ,,ge> ,,oil ,,levels4 ,inspect transmission oil level ) vehicle /&+ on re> /& 7n jiffy /&72 refill1 if requir$1 to level ( fill] plug op5+ ) eng9e oil4 ,,caution3 ,d n use ge> oil4 7#ah7 ,,item #gf1 ,,f5d]s 7,,mudgu>ds71 ,,luggage ,,c>ri]1 ,,safety ,,gu>ds1 ,,& ,,/&s4 ,exam9e ^! items = good condition & secure m\nt+4 7#ai7 ,,item #hb1 99,,tight54 7a7 ,inspect all frame & assembly nuts1 bolts1 & cap screws = tightness4 7b7 ,weekly4 ,tight5 all vehicle assembly or m\nt+ nuts4 ,driv] is caution$ n to tamp] ) or tight5 screws or nuts ab\t ! circuit break]1 z do+ s may di/urb ignition tim+4 7#bj7 ,,item #hc1 99,,lubricate ,,z ,,ne$$4 7a7 ,lubricate all p>ts :]e inspection reveals ne$ = lubrication3 wipe all dirt f fitt+s be=e apply+ lubricant4 ,report any miss+ fitt+s4 7b7 ,weekly4 ,:5 vehicle has be5 driv5 a suffici5t numb] ( miles s t x is due = a regul>ly s*$ul$ lubrication1 lubricate accord+ to ,lubrication ,guide 9 manual & curr5t lubrication directives4 ,refra9 f ov]lubricat+ :eel be>+s1 front brake side cov] bu%+1 & front & re> brake op]at+ lev] cam%afts4 7#ba7 ,,item #hd1 99,,clean ,,eng9e ,,& ,,vehicle4 7a7 ,clean dirt & tra% f vehicle & remove excess grease4 7b7 ,weekly4 ,wa% vehicle if possible4 ,if n1 wipe (f ?or\ghly4 ,d n rub lu/reless pa9t en\gh to cause %9e4 ,if vehicle is wa%$ 9 a /ream1 c>e %\ld be tak5 t wat] or dirt does n get into be>+s1 brea!r valve1 or brakes4 ,,caution3 ,x is extremely important t highpressure /reams or /eam %\ld n be direct$ aga9/ :eel hubs1 brakes1 c>buretor1 air clean]1 or electrical units4 7#ab7 ,,item #fd1 99,,electrical ,,wir+4 7a7 ,inspect all ignition wir+ to see t x is securely connect$1 clean1 & n damag$4 7b7 ,weekly4 ,inspect all wir+ to see t x is securely connect$ & support$1 t insulation is n crack$ or *af$1 t loom1 %ield+1 & cond5s]s are 9 good condition & securely atta*$4 ,clean z requir$4 ,tight5 any loose connections c>efully4 ,radio %ield+ or bond+ defects1 except clean+ or tight5+1 mu/ be ref]r$ to signal corps p]sonnel4 7#bc7 ,,item #he1 99,,tools ,,& ,,equipm5t4 7a7 ,see t all tools & equipm5t assign$ to vehicle are pres5t1 9 good condition1 & prop]ly /[$4 7b7 ,weekly4 ,*eck tools & equipm5t assign$ to vehicle ) vehicle /[age li/ 7p>4 #ba7 to see t !y are pres5t4 ,inspect tools = good condition & prop] /[age4 ,report miss+ or uns]viceable items to designat$ au?ority4 ,section ,v ,,lubrication ,p>agraph ,introduction #ai ,lubrication guide #bj #ai4 ,,introduction4 a4 ,lubrication is an ess5tial "p ( prev5tive ma9t5ance1 det]m9+ to a great ext5t s]viceability ( p>ts & assemblies4 #bj4 ,,lubrication ,,guide 7fig4 #aj74 a4 ,g5]al4 ,lubrication in/ructions = ?is mat]iel are consolidat$ 9 a ,lubrication ,guide 7fig4 #aj74 ,^! specify ! po9ts to be lubricat$1 ! p]iods ( lubrication1 & ! lubricant to be us$4 ,int]vals indicat$ on ! guide are = normal s]vice4 ,= extreme conditions1 high spe$1 heat1 mud1 sn[1 r\gh roads1 du/1 etc41 *ange eng9e oil & lubricate m frequ5tly4 ,9 addition to ! items on ! guide1 brake1 ge> %ift]1 clut* control l9kage1 & h+es mu/ be lubricat$ at frequ5t int]vals4 b4 ,supplies4 ,9 ! field x may n be possible to supply a complete assortm5t ( lubricants call$ = by ! ,lubrication ,guide to meet ! recomm5dations4 ,x w be necess>y to make ! be/ use ( ^? available1 subject to inspection by ! (fic] conc]n$1 9 consultation ) responsible ordnance p]sonnel4 c4 ,lubrication ,notes4 ,! foll[+ notes apply to ! ,lubrication ,guide 7fig4 #aj74 ,all note ref]5ces 9 ! guide itself are to ! /eps bel[ hav+ ! correspond+ numb]3 7#a7 ,,brake ,,fitt+s4 ,ex]cise caution :5 lubricat+ brake op]at+ cams & front brake cov] bu%+1 z excess grease work+ out ( ^! be>+s is likely to get onto brake l9+1 r$uc+ brake effici5cy4 ,,caution3 ,:5 us+ airop]at$ grease gun1 make sure n to ov]lubricate brake fitt+s4 7#b7 ,,brake ,,h& ,,lev] ,,oilcan ,,po9ts4 ,oil h& lev] fitt+s & 8oil]0 m\nt$ on cable h\s+4 ,oil front brake control cable at ends ( control cable h\s+4 7#c7 ,,g5]ator ,,commutator ,,end ,,be>+4 ,h&pack ) g5]al purpose grease1 ,no4 #b1 at temp]atures above z]o4 ,bel[ z]o1 use light] grease4 ,?is op]ation requires removal ( g5]ator end cov]4 ,be>+ out] grease reta9] mu/ be loos5$ & swung aside = access to be>+4 ,if n conv5i5t to grease be>+ at specifi$ int]vals1 at lea/ lubricate ) a few drops ( eng9e oil appli$ to hole 9 out] grease reta9]4 ,d n ov]lubricate4 ,,caution3 ,g5]ator regulat+ bru% plate mu/ n be %ift$ :ile be>+ out] grease reta9] is loose 7p>4 #ib74 ,g5]ator drive end be>+ requires no att5tion1 s9ce x is lubricat$ by oil circulat+ ?r\gh eng9e4 ,illu/ration3 ,,key ------------------------------------- ,,lubricants ,,oe--,,oil1 ,,eng9e 7,,crankcase ,,grade7 ,,cg--,,grease1 ,,g5]al ,,purpose ,no4 #a 7,,above #cb7 ,no4 #a ,,or ,no4 #j 7#cb ,,to #aj7 ,no4 #j 7,,bel[ #aj7 ,,wb--,,grease1 ,,g5]al ,,purpose 7,no4 #b7 ------------------------------------- -------------------------- ,,int]vals #a_/d--bej ,,miles #a_/b--ejj ,,miles #a--ajjj ,,miles #f--fjjj ,,miles 99 ,l--,,special ,,lubrication -------------------------- ,,*eck ,,daily ----------- ,air ,clean] ,eng9e ,oil ,tank -------------------------- ,,table ,,( ,,capacities ,,) ,,recomm5dations ,,at ,,temp]atures ,,%[n ---------------------------------------- ---------------------- ,,unit ,,capacity ,,above #cb #cb ,,to #aj ,,bel[ #aj ---------------------------------------- ---------------------- ,,oil ,,tank #a ,,gallon ,,oe ,,oe ,,oe ,s4,a4,e4 #ej ,s4,a4,e4 #cj ,s4,a4,e4 #aj ---------------------------------------- ---------------------- ,,transmission #c_/d p9t ,,oe ,,oe ,,oe ,s4,a4,e4 #ej ,s4,a4,e4 #cj ,s4,a4,e4 #aj ---------------------------------------- ---------------------- ,,ra ,,pd #cajbjg ,figure #aj--,lubrication ,guide 7#d7 ,,sp>k ,,& ,,?rottle ,,control ,,grips4 ,^! grips require disassembly4 ,twice a ye>1 or :5ev] grips d n turn freely1 indicat+ ne$ ( lubrication1 remove grips1 clean p>ts1 apply grease1 & reassemble 7p>4 #aja74 7#e7 ,,air ,,clean]4 ,exam9e oil cup daily = excessive dirt & correct oil level4 ,"u extremely du/y or s&y conditions x may be necess>y to clean & refill ! air clean] m ?an once daily4 ,refill oil cup to indicat$ level ) eng9e oil4 ,dra91 clean1 & refill oil cup e #bej miles1 dep5d+ ^u op]at+ conditions4 ,e #a1jjj miles 7(t5] if necess>y71 remove air clean] filt] units1 wa% 9 dryclean+ solv5t1 lubricate1 & reassemble 7p>4 #gf74 ,,note3 ,e>ly type r\nd clean] did n h removable filt] elem5t4 ,complete clean] mu/ be remov$ to wa% elem5t4 7#f7 ,,:eel ,,be>+s4 ,:5 :eel hubs are lubricat$ at regul> #ejjmile int]val1 #a_/h ounce ( grease ) ea* greas+ is suffici5t4 ,?is am\nts to ab\t #ae %ots ( ! /&>d #ap\nd air gun1 or f\r /rokes ) a #ap\nd1 h&op]at$ gun4 ,if vehicle has be5 op]at$ 9 wat]1 :eel hubs subm]g$1 apply hub greas+ s]vice imm$iately aft]w>d 7or soon z situation p]mits74 ,d n ov]lubricate :eel hub be>+s1 z excess grease may "w into brake l9+s1 r$uc+ brake effici5cy4 ,:5 us+ airop]at$ grease gun1 x is easy to ov]lubricate :eel hub be>+s4 7#g7 ,,/e]+ ,,head ,,be>+s4 ,e #ej1jjj miles1 repack upp] & l[] be>+s1 or :5ev] !re is occasion to remove rigid =k = repair or replacem5t 7p>4 #ih74 7#h7 ,,tank1 ,,eng9e ,,oil4 ,oil tank is locat$ on "r side ( motorcycle4 ,empty tank holds #a ,u4 ,s4 gallon4 ,*eck daily & add eng9e oil z necess>y to refill tank )9 #a in* ( top4 ,oil level gage rod 7dip /ick7 is locat$ directly bel[ tank cap4 ,:5 oil level is d[n to 8,,refill0 m>k on gage rod1 #b ,u4 ,s4 qu>ts may be add$4 ,dra9 oil tank e #a1jjj miles & refill ) fre% eng9e oil4 ,dra9 plug locat$ on und]side ( tank 9 =w>d position4 ,9 extremely du/y s]vice1 & 9 w9t] wea!r1 *ange oil (t5]4 7a7 ,w9t] ,caution4 ,wat] is a byproduct ( combu/ion 9 any int]nal combu/ion eng9e4 ,9 a cond5s$ /ate1 ! wat] vapor =m$ w\ld equal approximately ! quantity ( gasol9e burn$4 ,"s ( ?is wat] vapor escapes pa/ ! r+s into ! crankcase4 ,:5 />t+ & w>m+ up 9 cold wea!r1 consid]able vapor gett+ into crankcase cond5ses to wat] be=e crankcase is hot en\gh to exhau/ ! vapor1 )\t inside cond5sation1 ?r\gh outside brea!r4 ,if eng9e is driv5 en\gh to get crankcase ?or\ghly w>m$ up frequ5tly1 mo/ ( ?is wat] is aga9 vaporiz$ & bl[n out ?r\gh outside brea!r4 ,h[ev]1 a mod]ately driv5 eng9e1 mak+ only %ort runs n[ & !n1 & seldom ?or\ghly w>m$ up1 is likely to accumulate an increas+ am\nt ( wat] 9 oil tank4 ,?is wat] w1 9 freez+ wea!r1 become slu% or ice &1 if all[$ to accumulate too long1 may block oil l9es ) result+ damage to eng9e4 ,also1 wat] mix$ ) oil = "s "t1 =ms a heavy sludge ( consid]able acid cont5t t is v h>mful to be>+s & o!r int]nal eng9e p>ts4 ,to sum x up briefly1 an eng9e t is us$ only = %ort runs dur+ freez+ wea!r requires frequ5t oil *anges along ) ?or\gh flu%+ ( tank to remove any accumulat$ sludge4 7#i7 ,,transmission ,,fill] ,,op5+4 ,*eck oil level 9 transmission case e #bej miles & add eng9e oil z necess>y to br+ level up to fill] op5+4 ,if motorcycle is run unusually long di/ances1 inspect m frequ5tly4 ,motorcycle mu/ be on re> /& 9 /raight upright position :5 *eck+ oil level or fill+ transmission case4 ,use same grade ( oil us$ 9 eng9e1 summ]1 & w9t]4 ,if ge> %ift+ difficulty is caus$ by oil congeal+ 9 extremely cold wea!r1 ?9 oil ) small am\nt ( k]os5e or dryclean+ solv5t4 ,e #a1jjj miles1 dra9 & refill transmission to level ( transmission fill] plug op5+ ) specifi$ grade ( eng9e oil4 ,transmission holds #c_/d p9t ( oil4 ,to dra9 transmission case remove fill] plug & lay motorcycle on "r side4 ,,caution3 ,d n leave motorcycle on side long] ?an two m9utes4 7#aj7 ,,drive ,,*a9s4 7a7 ,front & re> drive *a9s are automatically suppli$ ) lubrication by eng9e oil pumps4 ,*a9 oil]s are adju/able & may ne$ occasional readju/m5t to meet lubrication requirem5ts ( v>i$ op]at+ conditions4 ,e #a1jjj miles 7or m (t5 if op]at+ conditions are extremely sev]e7 inspect front prim>y drive *a9 = adequate lubrication 7fig4 #cf74 7b7 ,at e #a1jjjmile p]iod re> drive *a9 %\ld h additional lubrication z foll[s3 ,remove *a91 wa% ?or\ghly 9 dryclean+ solv5t & hang x up to dry4 ,!n soak *a9 9 ,,sae #aj eng9e oil = a %ort p]iod ( "t to all[ oil to p5etrate into all *a9 be>+s4 ,dra9 *a9 & wipe (f excess oil4 ,in/all re> *a9 7p>4 #fc74 7,?is att5tion is n requir$ by front *a947 ,readju/m5t ( *a9 oil]s mu/ be made only by organization me*anic 7p>4 #fa74 ,,caution3 ,inspect frequ5tly & make sure t re> *a9 oil] supply pipe is cle>1 n b5t or damag$4 d4 ,be=e ,apply+ ,lubricant4 ,always wipe dirt f ! lubrication fitt+s or plugs s t dirt w n ent] ) ! lubricant4 ,lubricate all *assis po9ts aft] wa%+ vehicle or aft] vehicle has be5 op]at$ 9 /reams or extremely muddy or slu%y roads4 ,,caution3 ,x is extremely important t highpressure clean+ /reams or /eam %\ld n be direct$ aga9/ ends ( :eel hubs1 brake side cov] be>+s1 air clean]1 h&le b> grips1 or electrical sy/em4 ,to d s w s]i\sly affect correct lubrication & function+ ( ^! p>ts4 e4 ,oilcan ,po9ts4 ,all brake1 transmission1 & clut* control po9ts n fitt$ ) grease connections %\ld be lubricat$ ) eng9e oil4 ,front brake control cable1 sp>k1 & ?rottle control wires mu/ be oil$ at ! ends ( _! respective h\s+s1 especially aft] wa%+ vehicle1 or aft] op]at+ x 9 wet wea!r4 ,keep batt]y t]m9al felt wa%]s saturat$ ) eng9e oil to prev5t corrosion ( connections4 f4 ,w>n+ ,light4 ,action ( ! eng9e oil fe$ pump is indicat$ by r$ signal light 9 in/rum5t panel4 ,rid] mu/ be ?or\ghly famili> ) op]at+ *>act]i/ics ( ?is signal light1 to judge condition ( eng9e oil circulat+ sy/em 7p>4 #g f74 ,section ,,vi ,,tools ,,& ,,equipm5t ,,/[age ,,on ,,! ,,vehicle ,p>agraph ,vehicle tools #ba ,vehicle equipm5t #bb ,vehicle sp>e p>ts #bc ,illu/ration3 ,,ra ,,pd #cajbjh ,figure #aa--,vehicle ,tools #ba4 ,,vehicle ,,tools 7fig4 #aa74 a4 ,kits4 ,includ$ 9 ! tool kit assembly are ! foll[+3 ,leg5d ,lett] = ,numb] ,mfr's ,f$]al ,/ock ,:]e ,fig4 #aa ,tool ,c>ri$ ,numb] ,numb] ,c>ri$ ,a ,tool roll #a #aahai-dd -- ,9 saddle bag ,b ,irons1 tire #b #aaeea-,x #da-;,i-#ggc-ge ,9 tool roll 99,c ,h&le1 *a9 tool #a #aahag-dj #da-;,h-#aeaj-djj ,9 tool roll ,d ,wr5*1 #e_/h-;94 by #c_/d-;94 #a #aahjd-dd;,c -- ,9 tool roll ,e ,wr5*1 #a_/b-;94 by #i_/af-;94 #a #aahjd-dd;,b -- ,9 tool roll ,f ,wr5*1 #g_/af-;94 by #a_/b-;94 #a #aahjd-dd;,a -- ,9 tool roll ,g ,wr5*1 #e_/af-;94 by #c_/h-;94 #a #aahjd-dd -- ,9 tool roll ,h ,wr5*1 #c_/h-;94 by #g_/af-;94 7valve tappet7 #a #aaije-,x -- ,9 tool roll ,i ,wr5*1 adju/able #a #aahac-dd -- ,9 tool roll 99,j ,wr5*1 #c_/d-;94 by #a-c_/d-;94 7re> axle nut & trans47 #a #aahad-ce #da-,w-#aihi-hej ,9 tool roll ,k ,gage1 tire #a #aaefb-dc ---- ,9 tool roll 99,l ,tool1 *a9 repair #a #abjci-ch ---- ,9 tool roll 99,m ,wa%]s1 #j4jjb-;94 ?ick 7*a9 oil] adj47 #d #fgd-cb ---- ,9 tool roll 99,n ,wr5*1 #g_/af-;94 by #a-c_/h-;94 7valve cov]7 #a #aahjf-ca #da-,w-#cfag ,9 tool roll 99,o ,wr5*1 #g_/af-;94 by #a-a_/h-;94 7use ) sp>k plug socket7 #a #aaibi-ci ---- ,9 tool roll 99,p ,pli]s1 adju/able #a #aahab-dd ---- ,9 tool roll 99,q ,screwdriv] #a #aahaa-,x ---- ,9 tool roll ,r ,wr5*1 #i_/af-;94 socket 7cyl4 head bolt7 #a #abjdg-cj;,a #da-,w#jaebe ,9 tool roll 99,s ,wr5*1 :eel m\nt+ #a #aahae-ce #da-,w-#chbe-djj ,9 tool roll 99,t ,wr5*1 socket 7sp>k plug2 use ) ,o7 #a #aahje-dj #da-,w-#cccb ,9 tool roll ,pump1 tire #a #aaeec-da,m #h-,p-#dijj ,on frame1 left side ,grease gun 79 case7 #a #aaffa-ch;,a ---- ,9 saddle bag 99,,exception3 ,e>li] models furni%$ ) small] tool roll & kit conta9 ! items m>k$ by a/]isk4 #bb4 ,,vehicle ,,equipm5t 7figs4 #ab & #ac74 a4 ,atta*$ to ,vehicle4 ,numb] ,:]e ,item ,c>ri$ ,c>ri$ ,saddlebags #b ,on luggage c>ri] ,mirror1 re> view #a ,on left h&le b> ,box1 subma*9e gun ammunition #a ,front f5d]1 left side ,bracket1 subma*9e gun c>ri] #a ,front f5d]1 "r side ,gu>d1 front safety #a ,atta*$ to frame ,gu>d1 re> safety #a ,atta*$ to frame ,w9d%ield1 cpt #a ,on h&le b> ,leg %ields1 cpt 7"r & left7 #b ,atta*$ to frame ,illu/ration3 ,,ra ,,pd #cajbaf ,figure #ab--,vehicle ,equipm5t1 ,left ,side ,illu/ration3 ,,ra ,,pd #cajbag ,figure #ac--,vehicle ,equipm5t1 ,"r ,side ,illu/ration3 ,,ra ,,pd #cajbji ,figure #ad--,vehicle ,sp>e ,p>ts #bc4 ,,vehicle ,,sp>e ,,p>ts 7fig4 #ad74 #c;a4 ,sp>e ,p>ts4 ,numb] ,:]e ,item ,c>ri$ ,c>ri$ ,a ,roll1 p>ts kit #a ,9 saddlebag ,h ,plug1 sp>k 7& gasket7 #a ,9 kit roll ,f ,l9k1 re> *a9 repair #a ,9 kit roll ,g ,l9k1 front *a9 repair #a ,9 kit roll ,k ,lampunit1 tail black\t #a ,9 kit roll ,j ,lampunit1 /op black\t #a ,9 kit roll ,l ,lampunit1 tail & /op #a ,9 kit roll ,b ,lamp bulk kit1 head lamps1 #e bulbs #a ,9 kit roll ,c ,kit1 tire repair #a ,9 kit roll ,i ,tape1 friction #a ,9 kit roll ,d ,caps1 tire valve 7#e 9 box7 #a ,9 kit roll ,e ,cores1 tire valve 7#e 9 box7 #a ,9 kit roll ,footnote #c3 ,,exception3 ,no sp>e p>ts kit suppli$ ) e>li] models4 ,re> *a9 repair l9k only sp>e "p furni%$4 ,,"p ,,two--,,vehicle ,,ma9t5ance ,,in/ructions ,section ,,vii ,,ma9t5ance ,,allocation ,p>agraph ,scope #bd ,allocation ( ma9t5ance #be #bd4 ,,scope4 a4 ,! scope ( ma9t5ance & repair by ! crew & o!r units ( ! us+ arms is det]m9$ by ! availability ( suitable tools1 availability ( necess>y p>ts1 capabilities ( ! me*anics1 "t available1 & ! tactical situation4 ,all ( ^! are v>iable & no exact sy/em ( proc$ure c be prescrib$4 #be4 ,,allocation ,,( ,,ma9t5ance4 a4 ,indicat$ bel[ are ! ma9t5ance duties = :i* tools & p>ts h be5 provid$ = ! us+ arm & ma9t5ance p]sonnel4 ,replacem5ts & repairs :i* are ! responsibility ( ordnance ma9t5ance p]sonnel may be p]=m$ by us+ arm p]sonnel :5 circum/ances p]mit1 )9 ! discretion ( ! comm&] conc]n$4 ,e*elons & words z us$ 9 ?is li/ ( ma9t5ance allocations are def9$ z foll[s3 ,,fir/ ,,& ,,op]at+ ,,organization ,,driv]1 ,,op]ator ,,second ,,e*elon3 or crew1 companies & deta*m5ts1 ,table ,,iii battalions1 squadrons1 regim5ts1 & ,,ar #hej-ae sep>ate companies & deta*m5ts 7fir/ & second e*elons1 respectively74 ,,?ird ,,e*elon3 ,te*nical light & m$ium ma9t5ance ,table ,,iii units1 includ+ po/ & port %ops4 ,,ar #hej-ae ,,f\r? ,,e*elon3 ,te*nical heavy ma9t5ance & field ,table ,,iii depot units includ+ designat$ po/ ,,ar #hej-ae & s]vice comm& %ops4 ,,fif? ,,e*elon3 ,te*nical base units4 ,table ,,iii ,,ar #hej-ae ,,s]vice3 ,*eck+ & repl5i%+ fuel1 oil1 7,includ+ prev5tive grease1 wat] & antifreeze1 air1 & ma9t5ance7 p>4 #bd a batt]y liquid2 *eck+ & tight5+ 7#b7 & 7#c7 9 "p nuts & bolts2 clean+4 ,,ar #hej-ae ,,replace3 ,to remove an uns]viceable "p1 assembly1 ,p>4 #bd a 7#e7 or subassembly f a vehicle & ,,ar #hej-ae replace x ) a s]viceable "o4 ,,repair3 ,to re/ore to a s]viceable condition1 ,p>4 #bd a 7#f7 9 "p su* p>ts1 assemblies or subassemblies ,,ar #hej-ae z c be accompli%$ )\t completely disassembl+ ! assembly or subassembly1 & :]e heavy rivet+1 or precision ma*9+1 fitt+1 balanc+1 or al9+ is n requir$4 ,,rebuild3 ,consi/s ( /ripp+ & completely ,p>4 #bd a 7#f7 recondition+ & replac+ 9 s]viceable ,,ar #hej-ae condition any vehicle or uns]viceable "p1 subassembly1 or assembly ( ! vehicle1 includ+ weld+1 rivet+1 ma*9+1 fitt+1 al9+1 balanc+1 assembl+1 & te/+4 ,,reclamation3 ,salvage ( s]viceable or economically ,,ar #hej-ae repairable units & p>ts remov$ f ,p>4 #d 7c7 9 "p ,,cir4 vehicles1 & _! return to /ock4 ,?is #ge1 dat$ #af ,m>* '#dc includes ! process :i* recov]s &_/or reclaims unusable articles or compon5t p>ts !re( & places !m 9 a s]viceable condition4 ,,notes3 7#a7 ,op]ations allocat$ w normally be p]=m$ 9 ! e*elon indicat$ by ,x4 7#b7 ,op]ations allocat$ to ! ?ird e*elon z indicat$ by ,e may be p]=m$ by ^! units 9 em]g5cies only4 7#c7 ,op]ations allocat$ to ! f\r? e*elon by ,e are normally fif? e*elon op]ations4 ,!y w n be p]=m$ by ! f\r? e*elon1 unless ! unit is expressly au?oriz$ to d s by ! *ief ( ! s]vice conc]n$4 ,,e*elons ,,clut* #bnd #crd #d? #e? ,be>+s1 clut* release--replace ,x ,clut*--replace &_/or repair 7rel9e7 ,x ,hub1 clut*--replace ,x ,hub1 clut*--repair ,x ,sprocket assembly1 clut*--replace ,x ,sprocket assembly1 clut*--repair ,x ,,controls ,,& ,,l9kage ,controls & l9kage--s]vice &_/or replace ,x ,controls & l9kage--repair ,x ,,electrical ,,gr\p ,batt]y--s]vice 7re*>ge7 &_/or replace ,x ,batt]y--repair ,x ,batt]y--rebuild ,e ,x ,cables1 batt]y--replace &_/or repair ,x ,coil1 ignition--replace ,x ,head1 spe$omet]--replace ,x ,head1 spe$omet]--repair ,x ,head1 spe$omet]--rebuild ,x ,horn assembly--replace ,x ,horn assembly--repair ,x ,light assemblies--s]vice &_/or replace ,x ,light assemblies--repair ,x ,panel1 in/rum5t--replace ,x ,panel1 in/rum5t--repair ,x ,swit* assemblies--replace ,x ,swit* assemblies--repair ,x ,wir+--replace ,x ,,eng9e 7,v-#de-,tw9 ,eng9e7 ,be>+s1 ma9--replace ,e ,x ,be>+s1 connect+ rod--replace ,e ,x ,break] assembly1 circuit--replace ,x ,break] assembly1 circuit--repair ,x ,break] assembly1 circuit--rebuild ,x ,c>buretor--replace ,x ,c>buretor--repair ,x ,c>buretor--rebuild ,x ,clean]1 air--s]vice &_/or replace ,x ,clean]1 air--repair ,x ,clean]1 air--rebuild ,x ,cyl9d] assembly--replace ,x ,cyl9d] assembly--repair ,x ,cyl9d] assembly--rebuild 7recondition7 ,e ,x ,cond5s]--replace ,x ,eng9e assembly--replace 99#d ,x ,eng9e assembly--repair ,x ,eng9e assembly--rebuild ,e ,x ,gasket1 cyl9d] head--replace ,x ,ge>s1 tim+--replace ,e ,x ,g5]ator assembly--replace ,x ,g5]ator assembly--repair ,x ,g5]ator assembly--rebuild ,x ,head1 cyl9d]--replace &_/or repair ,x ,l9es & connections--replace ,x ,l9es & connections--repair ,x ,pi/ons1 r+s & p9s assembly--replace ,e ,e ,x ,plug1 sp>k--replace ,x ,po9ts1 circuit break]--s]vice &_/or replace ,x ,pump assembly1 fe$--replace ,x ,pump assembly1 fe$--repair ,x ,pump assembly1 fe$--rebuild ,x ,pump assembly1 oil--replace ,x ,pump assembly1 oil--repair ,x ,pump assembly1 oil--rebuild ,x ,pump assembly1 oil scav5g]--replace &_/or repair ,x ,pump assembly1 oil scav5g]--rebuild ,x ,rod1 connect+--replace &_/or rebuild 7recondition7 ,x ,x ,sprocket1 eng9e--replace ,x ,/ra9$ gasol9e--replace &_/or repair ,x ,valves--s]vice ,x ,,exhau/ ,,gr\p ,muffl] & exhau/ pipe--replace ,x ,muffl] & exhau/ pipe--repair ,x ,,miscellane\s ,b>s1 safety--replace ,x ,b>s1 safety--repair ,x ,boxes1 ammunition1 batt]y & tool--replace ,x ,boxes1 ammunition1 batt]y & tool--repair ,x ,c>ri]s1 luggage & scabb>d--replace ,x ,c>ri]s1 luggage & scabb>d--repair ,x ,frame--replace &_/or rebuild ,e ,x ,gu>ds1 mud--replace ,x ,gu>ds1 mud--repair ,x ,plate1 skid--replace ,x ,plate1 skid--repair ,x ,saddle--replace ,x ,saddle--repair ,x ,saddle--rebuild ,x ,spr+s1 saddle po/--replace ,x ,tank1 fuel--replace ,x ,tank1 fuel--repair ,x ,tank1 oil--replace ,x ,tank1 oil--repair ,x ,,susp5sion 7,,front7 ,b>s1 h&le--replace ,x ,b>s1 h&le--repair ,x ,damp]1 /e]+--replace ,x ,drum1 brake--replace ,x ,=k1 front assembly--replace ,x ,=k1 front assembly--repair ,x ,=k1 front assembly--rebuild ,x ,=k1 spr+--replace ,x ,=k1 spr+--repair ,x ,=k1 spr+--rebuild ,x ,plate1 rock]--replace ,x ,plate1 rock]--repair ,x ,%oe assembly1 brake--s]vice &_/or replace ,x ,%oe assembly1 brake--repair 7rel9e7 ,x ,spr+s1 cu%ion & reb\nd--replace ,x ,,susp5sion 7,,re>7 ,*a9s1 all--replace &_/or repair ,x ,drum1 brake1 re>--replace ,x ,gu>ds1 *a9s--replace ,x ,gu>ds1 *a9s--repair ,x ,%oe assemblies1 brake--s]vice &_/or replace ,x ,%oe assemblies1 brake--repair 7rel9e7 ,x ,sprocket1 re>--replace ,x ,:eels--replace ,x ,:eels--repair ,x ,:eels--rebuild ,e ,x ,,tires ,cas+s & tubes--replace ,x ,cas+s--repair ,e ,x ,tubes1 inn]--repair ,x ,,transmission ,spr+1 kick />t]--replace ,x ,sprocket1 transmission c\nt]%aft--replace ,x ,/>t]1 kick--replace ,x ,/>t]1 kick--repair ,x ,transmission--replace 99#d ,x ,transmission--repair ,x ,transmission--rebuild ,e ,x ,,vehicle ,,assembly ,motorcycle--s]vice ,x ,motorcycle--rebuild 7) s]viceable unit assemblies7 ,x ,e ,footnote #d3 ,! second e*elon is au?oriz$ to remove & re9/all items m>k$ by an a/]isk4 ,h[ev]1 :5 x is necess>y to replace an item m>k$ by an a/]isk ) a new or rebuilt "p1 subassembly or unit assembly1 ! assembly m>k$ by an a/]isk may be remov$ f ! vehicle by ! second e*elon only aft] au?ority has be5 obta9$ f a high] e*elon ( ma9t5ance4 ,section ,,viii ,,second ,,e*elon ,,prev5tive ,,ma9t5ance ,p>agraph ,second e*elon prev5tive ma9t5ance s]vices #bf #bf4 ,,second ,,e*elon ,,prev5tive ,,ma9t5ance ,,s]vices4 a4 ,regul> s*$ul$ ma9t5ance inspections & s]vices are a prev5tive ma9t5ance function ( ! us+ arms1 & are ! responsibility ( comm&]s ( op]at+ organizations4 7#a7 ,,frequ5cy4 ,! frequ5cies ( ! prev5tive ma9t5ance s]vices outl9$ h]e9 are consid]$ a m9imum requirem5t = normal op]ation ( vehicles4 ,"u unusual op]at+ conditions su* z extreme temp]atures1 & du/y or s&y t]ra91 x may be necess>y to p]=m c]ta9 ma9t5ance s]vices m frequ5tly4 7#b7 ,,fir/ ,,e*elon ,,p>ticipation4 ,! driv]s %\ld accompany _! vehicles & assi/ ! me*anics :ile p]iodic second e*elon prev5tive ma9t5ance s]vices are p]=m$4 ,ord9>ily ! driv] %\ld pres5t ! vehicle = a s*$ul$ prev5tive ma9t5ance s]vice 9 a reasonably clean condition2 t is1 x %\ld be dry1 & n cak$ ) mud or grease to su* an ext5t t inspection & s]vic+ w be s]i\sly hamp]$4 ,h[ev]1 ! vehicle %\ld n be wa%$ or wip$ ?or\ghly clean1 s9ce c]ta9 types ( defects1 su* z cracks1 leaks1 & loose or %ift$ p>ts or assemblies are m evid5t if ! surfaces are slightly soil$ or du/y4 7#c7 ,if in/ructions o!r ?an ^? conta9$ 9 ! g5]al proc$ures 9 p>agraph 7#d7 or ! specific proc$ures 9 p>agraph 7#e7 :i* foll[1 are requir$ = ! correct p]=mance ( a prev5tive ma9t5ance s]vice1 or = correction ( a defici5cy1 o!r sections ( ! vehicle op]ator's manual p]ta9+ to ! item involv$1 or a designat$ individual 9 au?ority1 %\ld be consult$4 7#d7 ,,g5]al ,,proc$ures4 ,^! g5]al proc$ures are basic in/ructions :i* are to be foll[$ :5 p]=m+ ! s]vices on ! items li/$ 9 ! specific proc$ures4 ,! second e*elon p]sonnel mu/ be ?or\ghly tra9$ 9 ^! proc$ures s t !y w apply !m automatically4 7a7 ,:5 new or ov]haul$ subassemblies are in/all$ to correct defici5cies1 c>e %\ld be tak5 to see t !y are clean1 correctly in/all$1 prop]ly lubricat$1 & adju/$4 7b7 ,:5 in/all+ new lubricant reta9] seals1 a coat+ ( ! lubricant %\ld be wip$ ov] ! seal+ surface ( ! lip ( ! seal4 7c7 ,! g5]al inspection ( ea* item applies also to any support+ memb] or connection1 & usually includes a *eck to see :e!r ! item is 9 good condition1 correctly assembl$1 secure1 or excessively worn4 ,! me*anics mu/ be ?or\ghly tra9$ 9 ! foll[+ explanations ( ^! t]ms3 #a4 ,! inspection = 8good condition0 is usually an ext]nal visual inspection to det]m9e :e!r or n ! unit is damag$ beyond safe or s]viceable limits4 ,! t]m 8good condition0 is expla9$ fur!r by ! foll[+3 n b5t or twi/$1 n *af$ or burn$1 n brok5 or crack$1 n b>e or fray$1 n d5t$ or collaps$1 n torn or cut4 #b4 ,! inspection ( a unit to see t x is 8correctly assembl$0 is usually an ext]nal visual inspection to see :e!r or n x is 9 its normal assembl$ position 9 ! vehicle4 #c4 ,! inspection ( a unit to det]m9e if x is 8secure0 is usually an ext]nal visual exam9ation1 a h&feel1 or a pryb> *eck = loos5ess2 su* an inspection %\ld include any brackets1 lock wa%]s1 lock nuts1 lock+ wires1 or cott] p9s us$ 9 assembly4 #d4 8,excessively worn0 w be und]/ood to mean worn1 close to or beyond s]viceable limits1 & likely to result 9 a failure if n replac$ be=e ! next s*$ul$ inspection4 7d7 ,special ,s]vices4 ,^! are indicat$ by repeat+ ! item numb]s 9 ! columns :i* %[ ! int]val at :i* ! s]vices are to be p]=m$1 & %[ t ! p>ts1 or assemblies1 are to receive c]ta9 m&atory s]vices4 ,= example1 an item numb] 9 "o or bo? columns opposite a ,tight5 proc$ure1 means t ! actual tight5+ ( ! object mu/ be p]=m$4 ,! special s]vices include3 #a4 ,adju/4 ,make all necess>y adju/m5ts 9 accordance ) ! p]t95t section ( ! vehicle op]ator's manual1 special bullet9s1 or o!r curr5t directives4 #b4 ,clean4 ,clean units ( ! vehicle ) dryclean+ solv5t to remove excess lubricant1 dirt1 & o!r =eign mat]ial4 ,aft] ! p>ts are clean$1 r9se !m 9 clean dryclean+ solv5t1 & dry !m ?or\ghly4 ,take c>e to keep ! p>ts clean until reassembl$1 & be c]ta9 to keep dryclean+ solv5t away f rubb] or o!r mat]ial :i* x w damage4 ,clean ! protective grease coat+ f new p>ts1 s9ce ?is mat]ial is n a good lubricant4 #c4 ,special lubrication4 ,?is applies bo? to lubrication op]ations t d n appe> on ! vehicle ,lubrication ,guide1 & to items t d appe> on su* guides1 b %\ld be p]=m$ 9 connection ) ! ma9t5ance op]ations1 if p>ts h to be disassembl$ = inspection or s]vice4 #d4 ,s]ve4 ,?is usually consi/s ( p]=m+ special op]ations1 su* z repl5i%+ batt]y wat]1 & dra9+ & refill+ units ) oil4 #e4 ,tight54 ,all tight5+ op]ations %\ld be p]=m$ ) suffici5t wr5*torque 7=ce on ! wr5* h&le7 to tight5 ! nut accord+ to good me*anical practice4 ,use torqueindicat+ wr5* :]e specifi$4 ,d n ov]tight51 z ?is may /rip ?reads1 or cause di/ortion4 ,tight5+ w always be und]/ood to include ! correct in/allation ( lock wa%]s1 lock nuts1 & cott] p9s provid$ to secure ! tight5+4 7e7 ,:5 conditions make x difficult to p]=m ! complete prev5tive ma9t5ance proc$ures at "o "t1 ^! c sometimes be h&l$ 9 sections1 plann+ to complete all op]ations )9 ! task if possible4 ,all available "t at halts & 9 biv\ac areas mu/ be utiliz$1 if necess>y1 to assure t ma9t5ance op]ations are complet$4 ,:5 limit$ by ! tactical situation1 items ) special s]vices 9 ! columns %\ld be giv5 fir/ consid]ation4 7f7 ,! numb]s ( ! prev5tive ma9t5ance proc$ures t foll[ are id5tical ) ^? outl9$ on ,w4,d4 ,,ago ,=m ,no4 #dfc1 :i* is ! ,prev5tive ,ma9t5ance ,s]vice ,"w ,%eet = ,motorcycles4 ,c]ta9 items on ! "w %eet t d n apply to ?is vehicle are n includ$ 9 ! proc$ures 9 ?is manual4 ,9 g5]al1 ! num]ical sequ5ce ( items on ! "w %eet is foll[$ 9 ! manual proc$ures1 b 9 "s in/ances !re is deviation = cons]vation ( ! me*anic's "t & ef=t4 7#e7 ,,specific ,,proc$ures4 ,! proc$ures = p]=m+ ea* item 9 ! #a1jjjmile ma9t5ance proc$ures are describ$ 9 ! foll[+ *>t4 ,ea* page ( ! *>t has a column at its left edge correspond+ to ! #a1jjjmile ma9t5ance4 ,,road ,,te/ ,sid5ote3 #ajjj ,mile ,ma9t5ance ,,note3 ,if tactical situation does n p]mit a full road te/1 p]=m items #b1 #c1 #d1 #e1 #f1 #g1 #h1 #i1 #ab1 & #ad1 :i* require slight or no movem5t ( ! vehicle4 ,:5 a road te/ is possible1 x %\ld be = pref]ably #e1 & n ov] #aj miles4 ,sid5ote3 #a ,be=eop]ation ,inspection4 ,p]=m ,be=eop]ation ,s]vice li/$ on ,w4,d4 ,=m ,no4 #dah4 8,driv]'s ,trip ,ticket & ,prev5tive ,ma9t5ance ,s]vice ,record0 7describ$ 9 p>4 #ae71 to det]m9e if vehicle is 9 a satisfactory condition to make ! road te/ safely4 ,sid5ote3 #b ,ease ( ,/>t+4 ,/>t eng9e & obs]ve action ( />t]4 ,note if eng9e responds readily4 ,sid5ote3 #c ,oil ,circulation4 ,oil circulation is normally indicat$ by oil signal light 7r$ light7 9 in/rum5t panel be+ out4 ,:5 r$ light is on1 oil is n circulat+4 ,obs]ve = excess smoke 9 exhau/4 ,,caution3 ,if r$ light fails to g out aft] eng9e has be5 />t$1 /op eng9e at once4 ,ref] to p>agraph #cj = possible causes4 ,sid5ote3 #d ,in/rum5ts4 ,obs]ve in/rum5ts = prop] or normal indication & function+ ( sy/em to :i* !y apply4 ,,spe$omet] ,,& ,,odomet]4 ,spe$omet] mu/ indicate vehicle spe$ )\t excessive noise or fluctuation2 odomet] mu/ record trip & total mileage4 ,,oil ,,pressure ,,signal ,,light4 ,note :e!r oil signal light 7r$ light7 indicates correctly4 ,aft] ignition swit* is turn$ on1 & be=e />t+ eng9e1 ! r$ light %\ld g on1 indicat+ no oil circulation4 ,:5 eng9e is />t$1 light %\ld g out4 ,,g5]ator ,,signal ,,light4 ,) swit* on1 & be=e />t+ eng9e1 ! gre5 signal light %\ld g on1 indicat+ dis*>ge ( batt]y4 ,aft] />t+ eng9e1 increase eng9e spe$ to a m$ium fa/ idle2 gre5 signal light %\ld !n g out1 indicat+ g5]ator is *>g+ batt]y4 ,,caution3 ,cont9ue obs]vation ( signal lights dur+ road te/1 & if lights %\ld fail to op]ate z indicat$ above1 /op eng9e1 inve/igate cause1 & correct or report tr\ble to prop] au?ority4 ,sid5ote3 #e ,brake ,op]ation4 ,te/ foot brake = safe /op )9 reasonable di/ance4 ,note squeaks or *att] t might indicate wet1 oily1 dirty1 or loose l9+1 damag$ drum1 or improp] adju/m5t4 ,apply h&op]at$ front brake only 9 conjunction ) re> brake & obs]ve :e!r x op]ates effectively 9 assi/+ to make a quick] /op4 ,sid5ote3 #f ,clut* ,op]ation4 ,be=e mov+ vehicle1 make sure t clut* p$al has satisfactory free travel be=e x beg9s to dis5gage clut*2 t x releases clut* completely be=e rea*+ end ( travel2 & t !re are no unusual noises 9 clut*release me*anism4 ,:5 />t+ vehicle1 obs]ve :e!r clut* grabs1 *att]s1 or slips :5 fully engag$4 ,sid5ote3 #g ,ge>%ift4 ,%ift ?r\gh entire ge> range ( transmission & obs]ve :e!r me*anism op]ates freely )\t cla%+ or jump+ out ( ge>4 ,note any unusual vibration t might indicate loose eng9e or transmission m\nt+s4 ,sid5ote3 #h ,unusual ,noises4 ,dur+ entire road te/1 li/5 = unusual noises t might indicate worn1 loose1 damag$1 or insuffici5tly lubricat$ p>ts 9 ! entire motorcycle1 p>ticul>ly 9 eng9e & accessories1 or 9 ! p[] tra94 ,,caution3 ,loose prim>y 7front7 drive *a91 ) slack 9 excess ( #a_/b in* total up&d[n motion1 c cause excessive noise :i* s\nds l eng9e knock4 ,remove inspection cov] = exam9ation ( *a94 ,sid5ote3 #i ,/e]+4 ,obs]ve /e]+ me*anism = indication ( loos5ess or excessive b9d+ ?r\gh full turn+ range4 ,) h&s re/+ lightly on h&le b>s & vehicle 9 v]tical position1 obs]ve :e!r !re is any t5d5cy to pull to "o side :5 op]at+ at a reasonable spe$4 ,note any indication ( /e]+ in/ability at high] spe$s4 ,sid5ote3 #aj ,balance4 ,if vehicle does n balance prop]ly 9 op]ation1 inspect = misal9em5t ( re> :eel4 ,sid5ote3 #aa ,spe$omet] & ,odomet]4 ,inspect spe$omet] = prop] op]ation1 excessive fluctuation1 or unusual noise4 ,obs]ve odomet] = correct record+ ( trip & total mileage4 ,sid5ote3 #ab ,?rottle & ,sp>k ,controls4 ,set ?rottle /op screw & l[ spe$ ne$le adju/m5t s t eng9e w op]ate smoo?ly & w n /all at idl+ spe$4 ,) vehicle runn+ at a spe$ ( #cj miles p] h\r1 or fa/]1 9 high ge>1 turn ?rottle control grip to 8,,op50 & 8,,clos$0 positions & note :e!r eng9e responds in/antly to ?rottle *anges4 ,turn sp>k control grip & note :e!r x fully advances & ret>ds ignition tim]4 ,sid5ote3 #ac ,p[] & ,op]ation4 ,obs]ve eng9e = normal pull+ p[]1 & good op]at+ *>act]i/ics 9 ea* spe$1 f fir/ to high ge>4 ,also obs]ve :e!r eng9e misses1 /alls1 knocks excessively1 or makes any o!r unusual noise4 ,sid5ote3 #ad ,c>buretor ,adju/m5t4 ,no c>buretor adju/m5t1 o!r ?an idle adju/m5t z p]=m$ 9 item #ab1 is requir$ on ?is vehicle4 ,sid5ote3 #ae ,brake ,drum & ,hub ,temp]ature4 ,imm$iately aft] complet+ road te/1 feel front & re> brake drums & :eel hubs = ov]heat+4 ,sid5ote3 #af ,p[] ,tra9 ,temp]atures4 ,feel transmission = ov]heat+4 ,,ma9t5ance ,,op]ation ,sid5ote3 #ag ,compression ,te/4 ,) ?rottle wideop51 te/ compression ) />t]4 ,if eng9e lacks compression1 inspect = leaks4 ,sid5ote3 #ah ,transmission4 ,inspect transmission = good condition1 secure m\nt+1 & leaks4 ,inspect oil level4 ,dra9 & refill transmission to level ( transmission fill] plug op5+ ) specifi$ grade ( eng9e oil4 ,,caution3 ,always dra9 transmission imm$iately aft] x has be5 w>m$ & agitat$ by op]ation ( eng9e4 ,refill z soon z dra9+ is complet$ to avoid haz>d ( op]at+ )\t lubricant4 ,tight5 all m\nt+ & assembly bolts securely4 ,sid5ote3 #bj ,eng9e ,oil4 ,inspect oil tank = oil level3 dra9 & refill tank4 ,,caution3 ,fill to )9 #a in* ( fill] op5+ & fill] cap ) specifi$ weight ( oil4 ,always dra9 imm$iately aft] eng9e op]ation & refill z soon z dra9+ is complet$1 to avoid haz>d ( op]at+ )\t lubricant4 ,sid5ote3 #ba ,batt]y & ,c>ri]4 ,clean top ( batt]y4 ,see t batt]y & c>ri] are 9 good condition1 & t c>ri] is securely m\nt$4 ,remove cell caps3 make sure t v5ts are op54 ,te/ specific gravity ) hydromet] & record read+s on "w %eet1 ,w4,d4 ,,ago ,=m ,no4 #dfc4 ,read+s bel[ #a4bbe indicate ne$ = re*>ge1 or batt]y failure4 ,v>iation betwe5 cells ( m !n #j4jbe mu/ be report$4 ,read & record voltage ( batt]y 7#fvolt read+ is normal74 ,br+ electrolyte to #e_/af in* above tops ( plates1 us+ clean1 dr9kable wat]4 ,if excessive loos5ess ( batt]y 9 case is not$1 *eck = pres5ce ( rubb] pad 9 bottom ( case1 & make sure rubb] pad is in/all$ on top ( batt]y1 :5 batt]y s]vice is complet$4 ,sid5ote3 #bb ,batt]y ,wires & ,t]m9als4 ,inspect batt]y = good condition & secure connections4 ,look = worn spots 9 wire insulation4 ,oil ! felt wa%]s on batt]y t]m9als4 ,sid5ote3 #bc ,electrical ,wir+4 ,inspect all electric wir+ to see t x is 9 good condition1 securely atta*$1 & connect$4 ,look = worn spots 9 insulation4 ,sid5ote3 #bd ,g5]ator ,drive & ,m\nt+1 & ,relay4 ,inspect g5]ator = secure m\nt+4 ,aft] remov+ left footbo>d assembly1 remove g5]ator & cov]4 ,exam9e commutator = cleanl9ess1 good condition1 or excessive we>4 ,if commutator is dirty1 x mu/ be clean$ ) ,no4 #jj s&pap]4 ,bl[ out ) compress$ air4 ,if commutator is 9 bad condition or excessively worn1 replace g5]ator4 ,remove relay cov]1 be+ c>eful to avoid damage to me*anism1 & inspect = cleanl9ess4 ,bl[ out ) air if wet or dirty4 ,,caution3 ,d n attempt to adju/ relay1 or to clean x 9 any o!r mann]4 ,sid5ote3 #be ,tim] 7,circuit ,break]74 ,clean & remove tim] cov]4 ,see t wir+ leads are securely connect$ & t inside ( ! tim] is clean4 ,inspect break] po9ts to see t !y are clean1 welll9$1 engag+ squ>ely1 & are n excessively pitt$1 burn$1 or worn4 ,see t cond5s] m\nt+ screw is tight4 ,break] lev] %\ld be free on its pivot & well insulat$ f ! pivot p94 ,det]m9e if break] arm spr+ ex]ts normal =ce aga9/ arm4 ,exam9e cam%aft by h&feel to see :e!r x is excessively worn 9 its bu%+s2 if cam%aft bu%+s are worn excessively1 in/all new tim]4 ,if po9ts are slightly burn$ or pitt$1 dress !m ) a f9e file4 ,if break] po9ts are uns]viceable1 in/all a new set1 tak+ c>e to al9e !m & to adju/ gap to #j4jbb in*4 ,apply "o drop ( oil to break] arm pivot p94 ,use clean clo? to wipe cam & !n coat ) a v light film ( light grease4 ,,caution3 ,be c>eful to avoid gett+ oil or grease on break] po9ts4 ,sid5ote3 #bf ,sp>k ,plugs4 ,remove sp>k plugs1 clean ) s&bla/ clean]1 & inspect = crack$ insulators3 inspect electrodes = good condition & adju/ gap to #j4jbe to #j4jcj in*2 replace faulty plugs4 ,be sure to in/all new gasket ) new plug4 ,inspect radio suppressors on plug cables = good condition & secure atta*m5t4 ,sid5ote3 #bg ,ignition & ,light ,swit*4 ,make sure t ! swit* is 9 good condition & op]at+ prop]ly 9 all positions4 ,sid5ote3 #bh ,lights1 ,s]vice & ,black\t4 ,see t all lights are clean1 9 good condition1 prop]ly aim$1 & securely m\nt$4 ,tactical situation p]mitt+1 turn swit* to ea* ( its positions & obs]ve :e!r s]vice & black\t lights op]ate prop]ly1 & :e!r !y g out :5 swit*$ (f4 ,op]ate dimm] swit* on left h&le b> to see :e!r x depresses beam ( s]vice headlight4 ,apply foot brake = *eck ( bo? black\t & s]vice /op light op]ation4 ,inspect l5ses = breakage1 & headlight reflector = discoloration4 ,clean all l5ses4 ,sid5ote3 #bi ,horn4 ,tactical situation p]mitt+1 s\nd horn to te/ = normal signal4 ,exam9e horn = good condition1 secure m\nt+1 & tight wir+ connections4 ,sid5ote3 #cj ,cyl9d] ,heads4 ,if cyl9d] head gaskets %[ signs ( leakage1 tight5 head bolts3 if leakage p]si/s1 new gaskets %\ld be in/all$4 ,a head bolt wr5* 7,f$,/ock ,no4 #da-,w-#aebe7 is available ) :i* head bolts c be tight5$ )\t remov+ tanks = wr5* cle>ance4 ,if tanks are remov$ to p]mit tak+ (f heads & in/all+ new gaskets1 bolts %\ld !n be tight5$ ev5ly ) a torque wr5* to a t5sion ( #fj footp\nds m9imum1 or #fe footp\nds maximum1 :5 eng9e is cold4 ,sid5ote3 #ca ,cyl9d] ,holdd[n ,nuts4 ,if ^! nuts are loose1 or !re is excessive oil leakage ar\nd cyl9d] bases1 tight5 nuts ev5ly :5 eng9e is cold4 ,if excessive leakage p]si/s1 new gaskets %\ld be in/all$4 ,,caution3 ,if cyl9d] base nuts are loose1 p]=m item #cf be=e />t+ eng9e4 ,sid5ote3 #cb ,eng9e ,m\nt+s4 ,inspect top eng9e m\nt+ bracket & bolt = good condition & security4 ,,caution3 ,tight seat+ ( ! eng9e bracket m\nt+ bolt is a necessity = effective radio bond+4 ,inspect f\r l[] eng9e m\nt+ bolts = signs ( loos5ess4 ,tight5 z requir$4 ,sid5ote3 #cc ,eng9e ,crankcase4 ,exam9e eng9e crankcase = good condition & = leaks4 ,make sure tim+ ge> cov] screws1 & oil fe$ & scav5g] pump nuts1 are tight4 ,sid5ote3 #cd ,intake ,manifold4 ,exam9e manifold = good condition & secure m\nt+4 ,make sure manifold nuts are tight4 ,sid5ote3 #ce ,muffl] & ,exhau/ ,pipes4 ,inspect muffl] & exhau/ pipes = good condition1 secure m\nt+1 & = leaks4 ,be sure tail pipe op5+ is n re/rict$4 ,sid5ote3 #cf ,valve ,me*anism4 ,:5 eng9e is cold1 adju/ valve tappet cle>ance to #j4jjd-;in* m9imum1 #j4jje-;in* maximum on intake valve2 #j4jjf-;in* m9imum1 #j4jjg-;in* maximum on exhau/ valve4 ,see t valve spr+s are 9 good condition & prop]ly secur$2 t valve tappet adju/+ screws & lock nuts are 9 good condition2 & t valve cov]s are 9 good condition1 secure1 & n leak+ oil4 ,sid5ote3 #cg ,/>t]4 ,exam9e p$al1 crank1 & return spr+ = good condition1 correct assembly1 & secure m\nt+4 ,/>t] %\ld op]ate )\t b9d+1 & return spr+ %\ld br+ />t] crank to its dis5gag$ position :5 foot pressure is remov$4 ,,caution3 ,make sure t />t] crank p9* bolt is in/all$ ) head ( bolt t[>d re> ( vehicle :5 crank is 9 upright position4 ,sid5ote3 #ch ,eng9e ,cool+ ,f9s4 ,inspect eng9e cool+ f9s = good condition & cleanl9ess4 ,remove all dirt or =eign matt]4 ,d n apply pa9t to cool+ f9s4 ,sid5ote3 #ci ,fill] ,caps & ,v5ts4 ,wipe dirt & du/ f fill] caps ( fuel & oil tanks4 ,inspect caps & gaskets to see t !y are 9 good condition4 ,note :e!r v5t 9 fuel fill] cap is op54 ,re9/all caps1 obs]v+ t ea* locks prop]ly on fill] neck4 ,d n int]*ange fuel & oil tank fill] caps4 ,sid5ote3 #dj ,fuel ,tank ,valves & ,l9es4 ,see t valves & l9es are 9 good condition1 secure1 & n leak+4 ,te/ fuel %ut(f valve = ample friction to hold valve 9 res]ve position4 ,see t valve lifts freely en\gh to op]ate satisfactorily4 ,sid5ote3 #da ,oil ,sy/em ,leaks4 ,exam9e oil tank1 oil l9es1 v5t l9e1 & connections = good condition1 secure atta*m5t1 & = leaks4 ,sid5ote3 #db ,c>buretor & ,fuel ,filt] 7,gasol9e ,/ra9]74 ,exam9e c>buretor & fuel filt] = good condition1 secure connections1 & = leaks4 ,%ut (f fuel tank valve & remove filt] 7/ra9]7 cap & scre54 ,wa% cap & scre5 9 dryclean+ solv5t1 & op5 %ut(f valve slightly to flu% filt] body4 ,reassemble scre51 gaskets1 & cap1 be+ c>eful n to damage gaskets4 ,use new gaskets if necess>y4 ,dra9 wat] & =eign matt] f c>buretor b[l by remov+ b[l dra9 plug4 ,op5 %ut(f valve slightly to flu% c>buretor b[l :ile plug is out4 ,replace plug1 be+ c>eful to avoid cross+ ?reads4 ,op5 fuel tank %ut(f valve & *eck = leaks4 ,sid5ote3 #dc ,air ,clean]4 ,remove oil cup2 inspect condition ( oil1 & am\nt ( s$im5t4 ,if s]vice is requir$1 remove filt] elem5ts1 clean & fill cup to ,,normal level4 ,wa% elem5ts 9 dryclean+ solv5t1 dry ?or\ghly ) compress$ air1 imm]se ea* elem5t 9 oil 9 cup1 & reassemble elem5ts & oil cup to air clean] body imm$iately4 ,make sure gaskets are 9 good condition4 ,,note3 ,e>ly type r\nd clean] does n h removable filt] elem5t2 !re=e1 ! complete clean] body mu/ be remov$ to wa% elem5t4 ,sid5ote3 #dd ,ge>%ift ,lev] & ,l9kage4 ,see t ge>%ift lev] & l9kage are 9 good condition1 secure1 & n excessively worn4 ,lubricate all jo9ts ) a few drops ( eng9e oil4 ,adju/ %ift] lev] s t :5 mov$ to any ge> position 9 %ift] guide on tank1 ! transmission is %ift$ to full engagem5t 9 correspond+ ge>4 ,sid5ote3 #de ,prim>y ,drive4 ,remove inspection hole cov] f front *a9 gu>d4 ,) clut* engag$ & transmission 9 neutral1 rotate prim>y *a9 to position ( lea/ slack4 ,*eck *a9 = #a_/b-;in* deflection4 ,deflection measurem5t %\ld be total up&d[n free movem5t4 ,inspect *a9 = adequate lubrication4 ,loos5 front & re> *a9 oil] adju/+ screws two turns ea*4 ,d n remove screws4 ,idle eng9e #a m9ute1 !n tight5 screws firmly1 b d n =ce4 ,?is op]ation s]ves to flu% control valves & re> *a9 oil] pipe4 ,sid5ote3 #df ,clut* ,p$al & ,l9kage4 ,inspect clut* p$al clevis connections & cable to see t !y are 9 good condition & n excessively worn4 ,*eck free travel ( clut* p$al to make sure x is )9 specifi$ limits4 ,) foot p$al 9 fully dis5gag$ position 7heel aga9/ footbo>d7 clut* release lev] mu/ cle> sprocket cov] /ud & nut by ab\t #a_/af in*3 ) foot p$al 9 fully engag$ position1 clut* release lev] mu/ h betwe5 #a_/h- & #a_/d-;in* ( free movem5t on end ( foot p$al cable4 ,lubricate all jo9ts ) a few drops ( eng9e oil1 includ+ cable at ea* end ( cable h\s+4 ,sid5ote3 #dg ,re> ,*a9 & ,gu>d4 ,inspect re> *a9 gu>d = good condition & secure m\nt+4 ,remove *a91 wa% ?or\ghly 9 dryclean+ solv5t1 & hang x up to dry4 ,see t *a9 is 9 good condition1 n excessively worn1 & has no brok5 roll]s on side plates4 ,soak *a9 9 ,,sae #aj eng9e oil = a %ort p]iod ( "t to all[ oil to p5etrate into all roll]s2 dra9 *a91 & wipe (f excess oil4 ,inspect c\nt]%aft sprocket1 & re> :eel sprocket to see t !y are 9 good condition1 n excessively worn1 & t re> sprocket rivets are tight4 ,d n re9/all *a9 until item #ga has be5 p]=m$4 ,:5 re9/all+ *a91 make sure t connect+ l9k is 9 good condition & securely lock$4 ,see t op5 end ( connect+ l9k spr+ clip is trail+ 9 direction ( *a9 travel4 ,adju/ *a9 7p>agraph #fj74 ,sid5ote3 #dh ,f9al ,drive ,sprockets4 ,inspection ( f9al drive sprockets is made :5 p]=m+ item #dg4 ,sid5ote3 #ej ,pa9t & ,m>k+s4 ,exam9e vehicle = good condition & see t pa9t is n rubb$ to a poli%1 & has no b>e spots t might ru/ or reflect light4 ,see t vehicle m>k+s are legible4 ,sid5ote3 #ea ,frame4 ,exam9e frame = good condition2 obs]ve :e!r x seems to be sprung out ( al9em5t4 ,sid5ote3 #eb ,/e]+ ,head & ,=k ,/em4 ,raise front end ( vehicle by plac+ blocks "u skid plate4 ,complete all foll[+ items to & includ+ item #ga1 be=e l[]+ vehicle to gr\nd4 ,exam9e /e]+ head & =k /ems = good condition4 ,note :e!r !re is up&d[n play caus$ by loose be>+s4 ,move h&le b>s ?r\gh complete range & obs]ve if !re is any b9d+ :i* might indicate improp]ly adju/$ or defective be>+s4 ,sid5ote3 #ec ,h&le ,b>s4 ,exam9e h&le b>s = good condition & secure m\nt+4 ,sid5ote3 #ed ,?rottle ,control4 ,see t grip is 9 good condition1 t ?rottle op5s & closes completely z grip is turn$ to its extreme positions1 & t control wire & h\s+ are 9 good condition & secure4 ,lubricate lightly ?r\gh hole 9 re> ( grip to avoid ru/+ & 8freez+40 ,if grip does n rotate freely1 disassemble grip1 clean1 & lubricate spiral control p>ts4 ,sid5ote3 #ee ,sp>k ,control4 ,see t grip is 9 good condition1 t sp>k is fully advanc$ & ret>d$ z ! grip is turn$ to its extreme positions2 t ! control wire & h\s+ are 9 good condition & secure4 ,lubricate lightly ?r\gh hole 9 re> ( grip to avoid ru/+ & 8freez+40 ,if grip does n rotate freely1 disassemble grip1 clean1 & lubricate spiral control p>ts4 ,sid5ote3 #eg ,re> ,view ,mirror4 ,clean re> view mirror & exam9e = good condition & secure m\nt+4 ,sid5ote3 #eh ,front ,f5d] 7,mudgu>d74 ,exam9e front f5d] = good condition & secure m\nt+2 see t f5d] does n scrape tire4 ,sid5ote3 #ei ,weapon ,c>ri]4 ,inspect weapon c>ri] = good condition & secure m\nt+4 ,sid5ote3 #fj ,ammunition ,box4 ,see t ammunition box & cov] are 9 good condition & securely atta*$4 ,sid5ote3 #fa ,front ,spr+s4 ,see t front spr+s & _! m\nt+s are 9 good condition1 correctly assembl$1 & secure4 ,sid5ote3 #fb ,front ,=ks4 ,see t front =ks are 9 good condition & securely m\nt$4 ,sid5ote3 #fc ,front ,=k ,rock] ,plates 7,rock] ,arms74 ,see t front =k rocket plates are 9 good condition1 secure1 & n excessively worn4 ,tight5 rock] plate /ud nuts securely4 ,sid5ote3 #fd ,front ,=k ,damp]4 ,inspect /e]+ damp] = good condition & to see t x op]ates freely4 ,obs]ve :e!r friction disks are glaz$1 coat$ ) grease1 or excessively worn4 ,sid5ote3 #fe ,front ,brake & ,control ,l9kage4 ,see t control l9kage op]ates freely1 t all connections are tight1 & t brake is adju/$ s t end ( h& lev] has #a_/d free travel be=e meet+ resi/ance4 ,look = any indications ( a crack$ or excessively worn brake drum3 badly worn1 loose1 or greasesaturat$ l9+s4 ,if !re are any su* indications1 remove :eel = clos] inspection4 ,look = badly worn brake side cov] bu%+1 %ackle bu%+s & /uds1 or brake op]at+ /ud be>+4 ,apply a few drops ( eng9e oil to control cable1 especially at control h\s+ oil] at left h&le b>1 & to p9 jo9ts4 ,sid5ote3 #ff ,front ,:eel ,al9em5t & ,spokes4 ,exam9e front :eel spokes = pres5ce1 good condition1 & tightness4 ,if loose spokes are f\nd1 tight5 ev5ly1 tak+ c>e n to di/ort rim out(r\nd1 or to cause runout4 ,exam9e rim = good condition1 & sp9 :eel to see t x has no appreciable runout4 ,sid5ote3 #fg ,front ,:eel ,be>+s4 ,inspect :eel to see :e!r be>+s are excessively loose4 ,:eel %\ld h slight am\nt ( side play at rim4 ,sp9 :eel & li/5 = unusual noises :i* might indicate dry or defective be>+s or races4 ,obs]ve = excessive grease leak4 ,if :eel is f\nd to ne$ only slight cone readju/m5t to correct excessive be>+ play1 remove :eel & make ?is adju/m5t 7p>4 #abf74 ,if indications are f\nd t hub is o!rwise 9 bad ord]1 replace :eel4 ,,ea* ,,six? #a1jjj-,,mile ,,ma9t5ance ,,s]vice4 ,remove front :eel1 axle sleeve & be>+1 &1 toge!r ) :eel hub1 clean ?or\ghly 9 dryclean+ solv5t4 ,inspect p>ts = good condition3 inspect brake drum4 ,inspect l9+ = good condition & secure atta*m5t1 & see t x is nei!r excessively worn nor soak$ ) grease4 ,repack be>+s1 hub1 & axle sleeve ) specifi$ lubricant4 ,,caution3 ,make sure t h&s & grease are p]fectly clean1 & t grease is =c$ betwe5 balls onto ! cone4 ,reassemble & adju/ be>+s accord+ to in/ructions 9 p>agraph #abf1 tak+ c>e to see t :eel is prop]ly al9$4 ,if unusual op]at+ conditions1 su* z =d+ /reams1 h indicat$ probable contam9ation ( lubricant1 ?is s]vice %\ld be p]=m$ m frequ5tly4 ,sid5ote3 #fh ,front ,:eel ,axle ,nuts4 ,tight5 axle nuts1 mak+ sure t cott] p9s are in/all$4 ,slot 9 /abiliz] plate mu/ be an*or$ on ext5d$ end ( leftfront rock] plate /ud4 ,sid5ote3 #fi ,tires1 ,front & ,re>4 ,gage tires & inflate to #ah p\nds front1 & #bj p\nds re> 7cold74 ,make sure t valve /ems are 9 good condition & correctly in/all$1 & t valve caps are pres5t & secure4 ,exam9e tires = cuts1 bruises1 breaks1 & bli/]s3 remove imb$d$ glass1 nails1 or o!r =eign matt] f tire treads2 obs]ve treads = excessive or irregul> tire we>4 ,at any inspection :5 unusual or irregul> tire we> becomes evid5t1 int]*ange front & re> tires4 ,sid5ote3 #gj ,re> ,:eel ,al9em5t & ,spokes4 ,) vehicle on re> /&1 inspect 9 same mann] z front :eel 7item #ff74 ,if x is necess>y to al9e :eel 9 frame1 make sure sprockets & *a9s are 9 correct al9em5t4 ,sid5ote3 #ga ,re> ,:eel ,be>+s & ,seals4 ,inspect :eel to see :e!r be>+s are excessively loose 7:eel %\ld h a slight am\nt ( play at rim74 ,sp9 :eel & li/5 = unusual noise :i* might indicate dry or defective be>+s4 ,also obs]ve :e!r !re is excessive grease leak4 ,te/ = excessive end play4 ,if :eel is f\nd to h consid]able side play at rim1 indicat+ excessively worn be>+s1 or !re is evid5ce ( hub assembly be+ 9 bad ord] o!rwise1 replace :eel4 ,if :eel mu/ be replac$1 inspect brake drum & l9+ = good condition1 z indicat$ 9 item #ge1 be=e re9/all+ :eel4 ,,caution3 ,make sure t :eel m\nt+ socket screws are tight4 ,sid5ote3 #gb ,re> ,:eel ,axle ,nut4 ,see t re> :eel axle nut is 9 good condition & securely tight5$4 ,sid5ote3 #gd ,re> ,f5d] 7,mudgu>d74 ,inspect re> f5d] = good condition & secure atta*m5t4 ,sid5ote3 #ge ,re> ,brake & ,control ,l9kage4 ,see t brake control l9kage op]ates freely1 & t all connections are secure4 ,look = indications ( badly worn or greasesaturat$ l9+s4 ,if brake op]at+ lev] /&s consid]ably ahead ( v]tical1 excessive l9+ we> is indicat$4 ,if grease has work$ out betwe5 brake drum & brake cov]1 greasesaturat$ l9+s are indicat$4 ,9 ei!r case ! :eel %\ld be remov$ = clos] inspection4 ,inspect drum = cracks or excessive we>4 ,make sure :eel m\nt+ socket screws are tight4 ,exam9e l9kage = loose or worn p9 or clevis1 & = miss+ wa%]s or cott] p9s4 ,apply a few drops ( eng9e oil to all l9kage jo9ts4 ,brake p$al %\ld h #a-;in* free travel be=e brake beg9s to meet resi/ance4 ,adju/ l5g? ( brake rod at brake op]at+ lev] to provide #a-;in* free p$al travel4 ,sid5ote3 #gg ,footbo>d & ,re/4 ,exam9e footbo>d & re/ = good condition & secure atta*m5t4 ,sid5ote3 #gh ,saddle ,spr+ & ,h+e4 ,exam9e saddle = good condition & secure m\nt+1 pay+ p>ticul> att5tion to torn lea!r1 ripp$ seams1 sagg+ or brok5 spr+ 9 seat po/1 & excessive we> 9 front h+e4 ,,caution3 ,make sure t spr+ wire clip prop]ly locks ! saddle re> h+e clevis p94 ,sid5ote3 #gi ,luggage ,c>ri]4 ,exam9e luggage c>ri] = good condition & secure m\nt+4 ,sid5ote3 #hj ,saddle ,bags4 ,exam9e saddle bags = good condition1 cleanl9ess1 & secure fa/5+ to luggage c>ri]4 ,note p>ticul>ly :e!r lea!r is torn1 seams ripp$1 or /raps & buckles miss+ or damag$4 ,sid5ote3 #ha ,tools1 ,tire ,pump1 & ,equipm5t4 ,inspect tool kit1 tools1 tire pump1 & o!r equipm5t = good condition1 cleanl9ess1 s]viceability1 & prop] /[age4 ,make sure t tire pump is securely clamp$ to motorcycle frame4 ,*eck all items ) /[age li/ 7p>s4 #ba1 #bb & #bc74 ,make sure t vehicle manuals & ,accid5t ,report ,=m ,no4 #bf are pres5t on vehicle & legible4 ,sid5ote3 #hb ,safety ,gu>ds4 ,inspect safety gu>ds = good condition & secure m\nt+4 ,sid5ote3 #hc ,leg ,%ields4 ,inspect leg %ields = good condition & secure m\nt+4 ,,note3 ,motorcycles op]at+ 9 w>m wea!r %\ld n be equipp$ ) leg %ields1 z !y s]i\sly hamp] eng9e cool+4 ,sid5ote3 #hd ,skid ,plate4 ,exam9e skid plate = good condition & secure m\nt+4 ,,caution3 ,skid plate mu/ be pres5t4 ,sid5ote3 #he ,vehicle ,lubrication4 ,lubricate all po9ts ( vehicle 9 accordance ) in/ructions 9 ?is manual1 ,lubrication ,guide1 curr5t lubrication bullet9s or directives1 & ! foll[+ in/ructions3 ,any unit t requir$ disassembly = inspection purposes mu/ be lubricat$ correctly unless ! vehicle is to be deadl9$ = ! repair ( t unit4 ,use only clean lubricant4 ,keep all lubricant conta9]s cov]$ except :5 us$ dur+ lubrication4 ,be=e apply+ lubricant1 always wipe dirt f ! lubrication fitt+ or plug s t dirt w n ent] ) ! lubricant4 ,if lubricant fitt+s or plugs are miss+ or damag$1 replace !m4 ,clean ! hole 9 :i* ! fitt+ is to be in/all$1 & lubricate aft] ! new fitt+ has be5 in/all$4 ,lubricant mu/ be appli$ prop]ly4 ,on unseal$ jo9ts or bu%+s1 apply lubricant until x appe>s at op5+s4 ,h[ev]1 lubricate sp>+ly ! front :eel hub1 re> :eel hub1 front brake side cov] bu%+1 front brake op]at+ lev] /ud1 & re> brake op]at+ lev] /ud1 to prev5t grease rea*+ brake l9+s4 ,rid] %\ld be advis$ :5ev] :eel be>+s are s]vic$ or adju/$1 s t dur+ ! next road op]ation he may det]m9e :e!r be>+s or brake drums are runn+ hot1 due to ov]tight adju/m5t ( be>+s1 or a dragg+ brake4 ,d n apply m ?an specifi$ am\nt ( lubricant to g5]ator or tim] 7circuit break]74 ,to d s may cause failure ( ! unit4 ,wipe (f excess appli$ lubricant t may drip onto brake or op]at+ surfaces1 soil clo!s1 or detract f vehicle's appe>ance4 ,p>ts or assemblies t h already be5 lubricat$ :ile disassembl$ = inspection1 ge> cases t h be5 dra9$ & refill$ z m&atory items 9 ! proc$ure1 & ^? p>ts t h be5 indicat$ = special lubrication1 w be omitt$ f ! g5]al lubrication ( ! vehicle4 ,sid5ote3 #hf ,f9al ,road ,te/4 ,make a f9al road te/1 re9spect+ items #b to #af1 inclusive4 ,be sure to re*eck transmission to see t lubricant is at correct level & n leak+4 ,conf9e ?is road te/ to ! m9imum di/ance necess>y to make satisfactory obs]vation4 ,correct or report all defici5cies f\nd dur+ f9al road te/ to designat$ au?ority4 ,section ,,ix ,,organization ,,tools ,,& ,,equipm5t ,p>agraph ,tools & equipm5t #bg #bg4 ,,tools ,,& ,,equipm5t4 a4 ,ref] to ,,snl-,n #ai = common h& tools available to second e*elon4 b4 ,ref] to li/ giv5 bel[ = all special tools available to second e*elon4 ,special ,tool ,manufactur]'s ,f$]al ,/ock ,description ,numb] ,numb] ,hydromet]1 batt]y1 special ,,hrd #aahca-,x #ah-;,h-#abdb ,tool1 repair1 drive *a91 motorcycle univ]sal ,,hrd #abjci-,x #da-,t-#ccbj ,tool1 spoke tight5+1 special1 #c_/d-;in*1 = small diamet] spokes ,,imc #g-,t-#cbei #da-,t-#ccfh-bj ,wr5*1 cyl4 base nut1 tw9 ,,hrd #abfej-bi #bida-,w-#hgb-aj ,wr5*1 head bolt ,,hrd #abjdg-cj;,a #da-,w-#aebe ,wr5*1 manifold1 #de-;94 tw9 ,,hrd #abjjc-,x #da-,w-#aegj-aj ,wr5*1 sp>k plug ,,hrd #aaibi-dj #da-,w-#cccd ,wr5*1 spoke nipple1 front :eel ,,hrd #abjcb-,x #da-,w-#ccci ,wr5*1 spoke nipple1 heavy duty re> :eel ,,hrd #abjcc-ci #da-,w-#ccdj ,wr5*1 tappet & dbl-head op5-end #g_/af- & #a-c_/h-;9 ,,hrd #aahjf-ca #da-,w-#cfag ,section ,x ,,tr\ble ,,%oot+ ,p>agraph ,introduction #bh ,eng9e #bi ,eng9e lubricat+ sy/em #cj ,fuel sy/em #ca ,ignition sy/em #cb ,g5]at+ sy/em #cc ,electrical sy/em #cd ,transmission & clut* #ce ,:eels & *a9s #cf ,brakes #cg ,/e]+ #ch #bh4 ,,introduction4 a4 ,tr\ble %oot+ = ! entire vehicle is giv5 9 ?is section4 ,! eng9e tr\ble %oot+ p>agraph traces tr\ble to a sy/em affect+ eng9e p]=mance3 = example1 fuel or ignition4 ,to trace tr\ble to "o or m defective compon5ts ( a sy/em1 x is necess>y to ref] to ! p]t95t p>agraph ( ?is section :5 ! defective sy/em or sy/ems h be5 locat$ 9 ! eng9e tr\ble %oot+ p>agraph4 b4 ,! mat]ial giv5 9 ?is section applies to ! op]ation ( ! vehicle "u normal conditions4 ,if extreme conditions ( temp]ature occur1 x is assum$ ! op]ator ( ! vehicle has prep>$ 8 vehicle = use = ! conditions enc\nt]$4 #bi4 ,,eng9e4 a4 ,in/ruction4 ,?is subp>agraph traces tr\bles to a sy/em affect+ eng9e p]=mance4 ,/ep b bel[ gives simple eng9e te/s to det]m9e ! me*anical condition ( ! eng9e4 ,ref]5ces 9 /ep b ref] to /ep c = eng9e me*anical tr\bles1 or to p]t95t p>agraphs 9 ?is section = sy/em tr\bles1 or :5 a te/ indicates a special unit is faulty1 to ! p]t95t p>agraph 9 ?is manual4 7#a7 ,,eng9e ,,does ,,n ,,turn ,,ov] ,,:5 ,,foot ,,/>t] ,,is ,,op]at$4 7a7 ,clut* slipp+4 ,*eck adju/m5t 7p>4 #dh74 7b7 ,%e>$ eng9e sprocket key4 ,replace 7p>4 #fe74 7c7 ,/>t] clut* /uck by congeal$ oil4 ,free />t] clut*4 ,use prop] grade ( oil4 7d7 ,/>t] clut* worn4 ,ref] to ma9t5ance p]sonnel4 7e7 ,eng9e lock$ 7seiz$74 ,ref] to organization me*anic4 7#b7 ,,eng9e ,,turns ,,ov] ,,:5 ,,crank$ ,,b ,,does ,,n ,,/>t4 7a7 ,fuel supply valve clos$4 ,op5 valve4 7b7 ,empty fuel tank4 ,fill tank4 7c7 ,fuel sy/em faulty4 ,ref] to p>agraph #ca4 7d7 ,ignition sy/em faulty4 ,ref] to p>agraph #cb4 7e7 ,batt]y weak or dead4 ,ref] to p>agraph #cd4 7f7 ,insuffici5t compression4 ,ref] to /ep b1 bel[4 7#c7 ,,weak ,,compression4 ,ref] to /ep b bel[ = te/4 7a7 ,improp] valve tappet adju/m5t4 ,adju/ 7p>4 #dc74 7b7 ,valves /ick+4 ,use dryclean+ solv5t to free valve /ems 9 guides4 7c7 ,faulty lubrication4 ,ref] to p>agraph #bj4 7d7 ,loose cyl9d] head bolts &_/or faulty gasket4 ,tight5 head bolts or replace gasket 7p>4 #da74 7#d7 ,,ov]heat+4 7a7 ,faulty fuel sy/em4 ,ref] to p>agraph #ca4 7b7 ,dirt on cyl9d]s4 ,clean f9s on cyl9d]1 especially ! f9s on cyl9d] head4 7c7 ,defective lubrication sy/em4 ,ref] to p>agraph #cj4 7d7 ,defective ignition sy/em4 ,ref] to p>agraph #cb4 7e7 ,idl+ eng9e )\t hav+ vehicle 9 motion4 ,d n idle eng9e long] ?an #a m9ute4 7f7 ,valve tappet adju/m5t incorrect4 ,ref] to /ep b 7#a7 bel[ = te/1 to p>agraph #dc = adju/m5t4 7g7 ,drive *a9s too tight4 ,adju/ 7p>s4 #ei & #fj74 7h7 ,excessive c>bon deposits4 ,ref] to organization me*anic4 7#e7 ,,lack ,,( ,,p[]4 7a7 ,defective fuel sy/em4 ,ref] to p>agraph #ca4 7b7 ,defective ignition sy/em4 ,ref] to p>agraph #cb4 7c7 ,ov]heat+4 ,ref] to /ep 7#d7 above4 7d7 ,defective lubricat+ sy/em4 ,ref] to p>agraph #cj4 7e7 ,poor compression4 ,ref] to /ep 7#c7 above4 7f7 ,drive *a9s too tight4 ,adju/ 7p>s4 #ei & #fj74 7g7 ,brakes dragg+4 ,adju/ 7p>s4 #if & #ig74 7#f7 ,,popp+ ,,& ,,spitt+ ,,?r\gh ,,c>buretor4 7a7 ,wat] 9 fuel4 ,wat] may be pres5t 9 fuel tank & c>buretor4 ,dra9 & refill fuel tank & c>buretor b[l4 7b7 ,incorrect valve tappet adju/m5t or /icky valves4 ,te/ 7/ep b 7#a7 bel[74 ,adju/ tappets 7p>4 #dc74 7c7 ,defective ignition sy/em4 ,ref] to p>agraph #cb4 7d7 ,defective fuel sy/em4 ,ref] to p>agraph #ca4 7e7 ,weak &_/or brok5 valve spr+s4 ,ref] to high] au?ority4 7#g7 ,,sp>k ,,knock4 7a7 ,defective ignition sy/em4 ,ref] to p>agraph #cb4 7b7 ,excessive c>bon deposits4 ,ref] to /ep b 7#b7 bel[4 7c7 ,defective fuel sy/em4 ,ref] to p>agraph #ca4 7d7 ,defective lubrication sy/em4 ,ref] to p>agraph #cj4 7#h7 ,,p\nd+ ,,& ,,excessive ,,metallic ,,noise4 7a7 ,front drive *a9 too loose4 ,ref] to p>agraph #cf4 7b7 ,eng9e sprocket loose on %aft4 7c7 ,excessively loose valve tappets4 ,adju/ 7p>4 #dc74 7d7 ,eng9e m\nt+ bolts loose4 ,tight54 7e7 ,transmission m\nt+ /ud nuts loose4 ,tight5 7p>4 #fj74 7f7 ,sp>k tim+ incorrect4 ,adju/4 7g7 ,int]nal p>ts ( eng9e worn or brok54 ,notify organization me*anic4 b4 ,te/s to ,det]m9e ,me*anical ,condition ( ,eng9e4 7#a7 ,,r+s ,,& ,,valves4 ,?is is a simple compression te/4 ,if possible1 make ?is te/ ) ! eng9e w>m4 ,ignition swit* mu/ be (f4 ,crank eng9e sl[ly1 plac+ entire weight ( body on />t] crank4 ,eng9e compression %\ld su/a9 ! weight ( an av]age size rid] sev]al seconds be=e crank passes ?r\gh complete range ( its travel4 ,if eng9e (f]s little resi/ance to />t] crank 9 te/+ ei!r or bo? cyl9d]s1 x is an indication t compression is n adequate 9 "o or bo? cyl9d]s4 ,no cle>ance or insuffici5t cle>ance at valve tappets2 valves /ick+ 9 guides2 valves seat+ poorly2 cyl9d] heads leak+2 sp>k plugs loose 9 heads2 pi/on r+s badly worn &_/or brok52 cyl9d] & pi/ons badly worn1 or lack ( lubrication c\ld cause ! above condition4 ,make ext]nal *ecks fir/3 ,see t oil is 9 tank1 t sp>k plugs are tight1 & exam9e ar\nd cyl9d] heads = signs ( leak+ oil deposits4 ,9 extremely cold wea!r1 resi/ance to ! />t] crank is increas$ by 8/iff0 oil 9 eng9e & transmission4 ,!re=e1 d n mi/ake ?is condition to indicate actual eng9e compression4 7#b7 ,,abnormal ,,eng9e ,,noise4 ,ow+ to con/ructional design ( ! motorcycle1 correct adju/m5t ( ! sev]al units & compon5ts is necess>y = smoo? & normally quiet eng9e op]ation4 ,_m motorcycles h be5 8deadl9$0 & eng9es ex*ang$ because simple tuneup s]vice & correct adju/m5t ( compon5ts h be5 neglect$4 ,r\gh1 j]ky1 & noisy eng9e action at l[ spe$ rid+ is usually caus$ by excessively loose front & re> drive *a9s1 or by a transmission be+ loose 9 its frame m\nt+4 ,fa/ idl+ ( eng9e ) ! front drive *a9 too loose1 may give ! false impression t ! eng9e be>+s & pi/ons ne$ replacem5t s]vice4 ,eng9e sprocket loose on its %aft w cause a p\nd+ noise simil> to t ( badly worn eng9e be>+s4 ,if front drive *a9 is too tight1 or eng9e sprocket & *a9 are badly worn1 a gr9d+ noise results1 seem+ to come f ! eng9e4 ,excessively loose valve tappets w cause abnormal metallic noise 9 ! valve tim+ ge> tra9 & eng9e crankcase4 ,sp>k advanc$ too f> w cause r\gh eng9e p]=mance at l[ spe$s z well z sp>k knock1 p\nd+1 & ov]heat+4 ,eng9e p\nd+ & r\gh op]ation ) consequ5t noise1 result f loose m\nt+ bolts4 ,g5]ator m\nt$ to give insuffici5t ge>too? cle>ance w cause 8h[l0 9 ge> case4 #cj4 ,,eng9e ,,lubricat+ ,,sy/em4 a4 ,action ( ! oil fe$ pump is indicat$ by ! r$ signal light locat$ 9 "r side ( in/rum5t panel4 7,r$ signal light is normally gr\nd$ by ! oil pressure swit*4 ,:5 oil pump pressure is built up sev]al p\nds1 diaphragm op5s ! signal light circuit47 ,action ( ! scav5g] 7oil return7 pump is indicat$ 7eng9e runn+7 by oil dripp+ f #a_/h-;in* hole 9 oil return tube 7l>ge tube7 inside oil tank1 j back ( oil gage rod 7dip /ick7 tube4 ,s9ce ! oil fe$ pump & scav5g] pump are sep>ate units1 op]at$ individually1 x is possible 7due to faulty unit7 = ei!r to function alone1 ?us affect+ eng9e oil pressure & return ( oil to ! tank4 ,action ( ! v5t pipe 7small pipe7 locat$ )9 ! oil tank is ( a 8brea!r0 nature2 its function n be+ indicat$ 9 any mann]4 ,be=e attempt+ to diagnose tr\ble 9 eng9e lubricat+ sy/em1 rid] mu/ be famili> ) & und]/& indications by in/rum5t panel signal lights 7p>4 #g f74 b4 ,r$ ,signal ,light ,fails to ,burn ,:5 ,ignition & ,light ,swit* is ,turn$ ,on4 7#a7 ,*eck o!r lights to det]m9e if batt]y is 8up0 & t swit* & wir+ connections betwe5 batt]y & swit* are 9 good ord]4 ,see t wire connection is secure & screw is tight on oil pressure swit* t]m9al4 ,failure ( light to burn aft] ^! *ecks indicates t ei!r ! lamp is burn$ out or oil pressure swit* is faulty4 7#b7 ,te/ to elim9ate ! oil pressure swit* by remov+ wire f swit* t]m9al2 gr\nd wire on swit* body & note if r$ light burns ) ignition & light swit* 9 8,,on0 position4 ,if light burns1 x indicates t oil pressure swit* is faulty1 & mu/ be replac$4 ,if light does n burn 9 mak+ ?is te/1 x indicates t lamp is burn$ out4 ,remove panel cov] 7p>4 #aai7 & replace lamp4 c4 ,r$ ,signal ,light ,cont9ues to ,burn ,aft] ,eng9e ,is ,op]at$ ,above ,idl+ ,spe$s4 7#a7 ,*eck oil supply 9 tank4 ,if light fails to g out aft] eng9e is w>m1 or aft] #a m9ute ( op]ation1 fur!r *ecks mu/ be made to locate tr\ble1 z indication po9ts to faulty eng9e lubrication sy/em1 or fault 9 signal circuit4 ,elim9ate ! signal sy/em fir/4 7#b7 ,te/ oil pressure signal swit* to panel signal light circuit4 ,remove wire f oil pressure swit* t]m9al by turn+ on ignition & light swit* & obs]v+ r$ signal light4 ,if light burns1 %ort circuit 9 wir+ exi/s4 ,if light does n burn1 x indicates normal condition1 leav+ oil pressure swit* ( ! signal circuit to be te/$4 7#c7 ,in/all new oil pressure swit* & />t eng9e4 ,if r$ signal light goes out aft] eng9e is op]at$ above idl+ spe$s1 x indicates tr\ble 9 oil pressure signal swit*4 ,if r$ signal light cont9ues to burn1 x indicates tr\ble 9 oil fe$ pump4 ,replace pump 7p>4 #dd74 d4 ,excessive ,smoke ,issues f ,exhau/ & ,oil ,spray ,issues f ,ge> ,case ,brea!r ,outlet4 ,?is is an indication t ! scav5g] pump is n dra9+ eng9e crankcase & return+ oil to tank4 ,) eng9e runn+ at idle spe$1 exam9e oil return 9 tank4 ,remove tank oil cap1 & ) a small fla%light 7tactical situation p]mitt+71 obs]ve :e!r or n oil is dripp+ f #a_/h-;in* hole 9 oil return tube4 ,hole is on "u side ( tube & is locat$ j back ( oil gage rod tube4 ,if obs]vation is poor1 place f+] ov] hole & feel = pulsation ( oil pressure4 ,if oil does n return to tank1 scav5g] pump is faulty4 ,%\ld ! crankcase brea!r valve be incorrectly tim$1 smoke w issue f ! exhau/1 b n z noticeably z :5 scav5g] pump is n work+4 ,ref] to /ep e bel[ = ?is condition4 e4 ,smoke ,issues f ,exhau/ & ,excessive ,oil ,condition ,exi/s ,ar\nd ,cyl9d] ,exhau/ ,ports 7:]e exhau/ pipes ent] cyl9d]s74 ,eng9e scav5g] pump & crankcase brea!r valve are "o unit1 op]at$ by worm ge> locat$ beh9d eng9e %aft p9ion ge>4 ,al?\gh scav5g] pump is n 8tim$10 ! brea!r valve sleeve :i* drives x mu/ be tim$ to balance ! eng9e lubricat+ sy/em4 ,if = any reason ! scav5g] pump unit is remov$ f eng9e base1 ! brea!r valve mu/ be retim$ 7)9 ! ge> case7 :5 pump assembly is replac$4 ,incorrectly tim$ brea!r valve w =ce oil pa/ pi/on r+s1 caus+ "s smoke1 besides =c+ oil out ?r\gh exhau/ ports1 caus+ excessive oily condition ar\nd exhau/ pipes :]e !y ent] cyl9d] ports4 #ca4 ,,fuel ,,sy/em4 a4 ,_m symptoms :i* might be attribut$ to ! airfuel sy/em are1 9 reality1 due to faulty ignition4 ,be=e attempt+ any b ! obvi\sly requir$ adju/m5ts1 *eck ! ignition sy/em ?or\ghly4 ,gasol9e tank supply valve is a dual purpose valve1 & its op]ation is expla9$ 9 p>agraph #e b4 b4 ,%ut (f gasol9e supply valve4 ,disconnect fuel l9e at /ra9]1 op5 valve1 & obs]ve free fl[ ( fuel f pipe4 ,if l9e is plugg$1 remove1 clean out1 & replace4 c4 ,remove1 disassemble1 clean1 & in/all fuel /ra9] 7p>4 #gb74 d4 ,h>d ,/>t+1 ,spitt+1 & ,misfir+ ,caus$ by ,wat] 9 ,fuel4 ,remove dra9 screw f c>buretor b[l1 dra9 b[l1 & replace screw4 ,take c>e n to cross dra9 screw ?reads :5 replac+4 ,if !re is /ill evid5ce ( wat]1 dirt1 or o!r =eign matt] aft] b[l is dra9$1 replace c>buretor 7p>s4 #gj & #ga74 ,remove air clean] oil cup & inspect = evid5ce ( wat] 9 oil4 ,dra91 clean1 refill to correct level m>k1 & replace cup4 ,%\ld above proc$ure fail to elim9ate tr\ble1 dra9 fuel tank by remov+ dra9 plug locat$ "u tank 9 =w>d position4 ,replace dra9 plug & refill tank ) fuel4 e4 ,h>d ,/>t+1 or ,miss+ at ,idl+ & ,l[ ,spe$s4 ,c>buretor l[ spe$ circuit 9 ne$ ( adju/m5t 7p>4 #fh74 ,c>buretor high spe$ circuit is controll$ by a fix$ jet4 f4 ,impossible to ,obta9 ,satisfactory ,c>buretor ,adju/m5t3 ,lean ,spot ,betwe5 ,idl+ & ,up to #cj ,miles p] ,h\r ,spe$s4 ,c>buretors 9 s]vice = "s "t become dirty & cru/ =ms 9 ! ?rottle b>rel1 mak+ satisfactory l[ spe$ adju/m5t difficult1 if n impossible4 ,replace c>buretor 7p>s4 #gj & #ga74 g4 ,fuel ,leak+ f ,c>buretor4 ,evid5ce ( dirt 9 float valve1 incorrect float level1 or faulty float4 ,replace c>buretor 7p>s4 #gj & #ga74 h4 ,difficult ,/>t+1 ,fuel ,mixture ,too ,ri*4 ,air clean] oil cup ov]fill$1 or clean] elem5ts exceptionally dirty1 *ok+ (f adequate air supply to c>buretor4 ,*eck ! oil cup level4 ,if oil cup level is correct1 remove1 clean1 & in/all clean] elem5ts 7p>4 #gf74 #cb4 ,,ignition ,,sy/em4 a4 ,:5 *eck+ ignition sy/em = tr\ble1 make ! mo/ obvi\s & simple *ecks fir/4 ,= example3 ,turn on ignition & light swit*1 obs]ve lights to asc]ta9 batt]y curr5t supply2 !n *eck to see t curr5t is rea*+ sp>k coil1 circuit break]1 etc4 ,faulty sp>k plugs are responsible = ! great majority ( eng9e ignition tr\bles4 ,!re is no s]vice = sp>k plugs o!r ?an s&bla/ clean+ & correct adju/m5t ( electrodes4 ,que/ionable sp>k plugs mu/ be replac$ 7p>4 #hc74 b4 ,rem$y all poor connections 9 ignition wir+ sy/em 7fig4 #dh74 c4 ,remove circuit break] cov]1 op]ate eng9e ) />t] p$al1 & obs]ve op5+ & clos+ ( circuit break] po9ts4 ,correct po9t gap :5 break] lev] fib] is on highe/ po9t ( cam is #j4jbb in*4 ,= adju/m5t ref] to p>agraph #hd4 d4 ,te/+ = ,high ,t5sion ,sp>k4 ,sp>k at plug gaps dep5ds ^u condition & op]ation ( circuit break] po9ts1 condition ( cond5s]1 & condition ( sp>k coil & hight5sion cables4 ,te/+ ! ignition sy/em is be/ done by means ( elim9ation1 te/+ ea* unit by replacem5t until tr\ble is locat$2 !n replac+ s]viceable units :i* 7 remov$4 7#a7 ,remove sp>k plug cable t]m9al f ei!r plug1 leav+ o!r cable & plug connect$ 7to effect gr\nd return ( hight5sion curr5t72 turn eng9e until circuit break] po9ts are clos$2 turn ignition & light swit* on2 hold high t5sion cable t]m9al #a_/d in* f cyl9d]2 op5 & close circuit break] po9ts ) f+] & obs]ve sp>k jump at gap4 ,if sp>k jumps gap1 x indicates ignition prim>y & second>y circuits are complete4 7#b7 ,no sp>k at hight5sion gap calls = te/+ ( prim>y & second>y circuits4 ,turn eng9e until break] po9ts are held op52 hold cable end #a_/d in* f cyl9d]2 turn ignition swit* on & ) ! bit ( a screwdriv]1 make a good gr\nd connection betwe5 break] movable 7lev]7 po9t1 & ! gr\nd4 ,if a good sp>k is obta9$ at hight5sion cable t]m9al gap :5 gr\nd connection made by screwdriv] is brok51 clean or replace faulty break] po9ts 7p>4 #hd74 7#c7 ,if circuit break] po9ts are 9 good condition1 b no sp>k 7or a v weak sp>k7 occurs at hight5sion gap1 replace cond5s] 7p>4 #he7 & repeat te/ "u /ep 7#a7 above4 ,if replacem5t ( cond5s] does n rem$y tr\ble1 replace sp>k coil 7p>4 #hi74 7#d7 ,if te/s made "u /eps d 7#a71 7#b71 & 7#c7 above %[ ignition sy/em to be 9 good ord] 7no units hav+ be5 replac$71 & ignition tr\ble /ill exi/s1 x means t break] po9ts1 cond5s]1 & sp>k coil mu/ be replac$ ) new units & eng9e road te/ made ) ea* replacem5t until tr\ble has be5 locat$ & rem$i$4 e4 ,ignition ,sy/em ,te/s ,satisfactory b ,eng9e ,/>ts ,h>d1 ,ov]heats or ,misses4 ,cle>ly an indication t sp>k plugs are faulty4 ,remove sp>k plugs1 clean ) s&bla/1 regap po9ts betwe5 #j4jbh in* to #j4jcj in* & re9/all4 ,replace defective plugs ) new ones ( correct 7,no4 #b7 heat range 7p>4 #hc74 f4 ,eng9e ,misses ,aft] ,w>mup1 or ,:5 ,q ,hot4 ,replacem5t ( sp>k plugs %\ld rem$y ?is tr\ble4 ,if x does n1 !n ei!r ! cond5s] or sp>k coil is at fault4 ,replace cond5s] fir/ 7p>4 #he74 ,if new cond5s] fails to correct tr\ble1 replace sp>k coil 7p>4 #hi74 #cc4 ,,g5]at+ ,,sy/em4 a4 ,panel ,gre5 ,signal ,light ,cont9ues to ,burn ,above #bj ,miles p] ,h\r4 ,correct faulty wir+ & connections betwe5 batt]y & g5]ator4 ,ref] to figure #ee4 ,inspect condition ( relay &1 if necess>y1 replace 7p>4 #ie74 ,inspect bru%es & commutator ( g5]ator4 ,clean commutator if necess>y 7p>4 #ia74 ,if bru%es are /ick+ 9 hold]s or badly worn1 replace g5]ator 7p>s4 #ic & #id74 b4 ,g5]ator ,output ,fails to ,keep ,batt]y ,*>g$ ,al?\gh ,gre5 ,signal ,light ,behavior ,is ,satisfactory4 ,te/ batt]y3 if x w n hold *>ge1 or is defective1 replace 7p>4 #aac74 ,if ! ma*9e is us$ mo/ ( ! "t = night op]ation1 h a high] e*elon increase ! g5]at+ *>g+ rate4 ,inspect bru%es & commutator ( g5]ator4 ,clean commutator if necess>y 7p>4 #ia74 ,if bru%es are badly worn or /ick+ 9 hold]s1 replace g5]ator 7p>s4 #ic & #id74 #cd4 ,,electrical ,,sy/em4 a4 ,panel ,lamps ,d ,n ,light ,:5 ,swit* ,is ,turn$ ,on4 ,exam9e ea* lamp & if burn$ out1 replace 7p>4 #abj74 ,exam9e batt]y2 if dis*>g$1 replace 7p>4 #aac74 ,rem$y defective wir+ & connections 7fig4 #ga74 ,te/ light swit*3 if defective1 replace 7p>4 #aaf74 ,te/ black\t light swit* 79 lamp body73 if defective1 replace lamp 7p>4 #aad74 b4 ,lights ,burn ,dim b ,bright5 ,up ,consid]ably ,:5 ,eng9e ,is ,accel]at$4 ,te/ batt]y ) hydromet]4 ,if x is n fully *>g$1 replace 7p>4 #aac74 ,rem$y defective wir+1 connections1 & swit*es 9 circuit 7fig4 #gc74 ,if ! batt]y runs d[n aga9 aft] a %ort p]iod ( op]ation1 h ! g5]ator output increas$ 7ref] to a high] e*elon74 c4 ,lights ,exce$ ,normal ,brilliancy ,:5 ,accel]at+ ,eng9e4 ,exam9e batt]y3 if defective1 replace 7p>4 #aac74 ,rem$y faulty wir+ & connections 7fig4 #gc74 ,d n =get ! gr\nd connection ( ! lamp body4 d4 ,black\t ,/op ,lamp &_/or ,s]vice ,/op ,lamp ,fail to ,light4 ,if ! unit is burn$ out1 replace x 7p>4 #aae74 ,if ! brake p$al is n op]at+ swit*1 rem$y ! faulty op]ation4 ,rem$y all faulty wir+ & connections 7fig4 #gc74 e4 ,horn ,does ,n ,s\nd ,:5 ,ignition & ,light ,swit* ,is ,turn$ ,on & ,horn ,button ,is ,press$4 ,te/ batt]y by turn+ on lights4 ,if lights are dim1 replace batt]y 7p>4 #aac74 ,rem$y defective wir+ & connections 7fig4 #gc74 ,if ! horn does n respond to adju/m5t1 replace 7p>4 #aag74 #ce4 ,,transmission ,,& ,,clut*4 a4 ,ne$ = att5tion to clut* & controls is indicat$ by clut* slipp+ "u load or dragg+ 7transmission ge>s w %ift h>d & cla%7 :5 9 dis5gag$ position4 ,9 ei!r case1 ! fir/ ?+ to be *eck$ is adju/m5t ( controls2 ?is be+ ! att5tion usually ne$$4 ,indication t ge> %ift] controls are 9 ne$ ( adju/m5t is :5 transmission ge>s 8jump0 out ( engagem5t :5 accel]at+ vehicle or :5 "u heavy pull4 ,,caution3 ,?is w>n+ mu/ n be disreg>d$4 7#a7 ,,clut* ,,slips ,,:5 ,,fully ,,engag$4 ,adju/ clut* control 7p>4 #dh74 ,adju/ clut* spr+ t5sion 7p>4 #dh74 ,if ! clut* /ill slips1 replace ei!r ! disks1 spr+s1 or bo? 7p>4 #dh74 7#b7 ,,clut* ,,drags ,,:5 ,,fully ,,dis5gag$4 ,adju/ control 7p>4 #dh74 ,adju/ spr+ t5sion 7p>4 #dh74 7#c7 ,,clut* ,,rattles ,,:5 ,,9 ,,dis5gag$ ,,position1 ,,eng9e ,,idl+4 ,9 ?is case1 ! clut* probably 0 n prop]ly assembl$4 ,ref] to p>agraph #ea a4 7#d7 ,,transmission 8,,jumps0 ,,out ,,( ,,ge> ,,^u ,,accel]at+ ,,vehicle1 ,,or ,,:5 ,,"u ,,heavy ,,pull4 ,adju/ %ift] lev] control l9kage 7p>4 #ed74 7#e7 ,,transmission ,,ge>s ,,%ift ,,h>d ,,or ,,cla% ,,:5 ,,clut* ,,is ,,fully ,,dis5gag$4 ,adju/ clut* control l9kage & spr+ t5sion 7p>4 #dh74 ,make sure ! transmission m\nt+ bolts & units are tight 7p>s4 #eg & #eh74 ,dra9 & fill transmission ) correct lubricant 7fig4 #aj74 ,if ! above me?ods fail to cure ! symptom1 ref] to a high] au?ority4 #cf4 ,,:eels ,,& ,,*a9s4 a4 ,transmission ,c\nt]%aft & ,re> ,:eel ,sprockets ,%[ ,excessive ,we> on ,"o ,side ( ,tee?4 ,adju/ ! position ( ! re> :eel axle to al9e ! re> :eel sprocket ) ! transmission sprocket 7p>4 #fj74 ,if !y _c be al9$1 ! frame is out ( al9em5t1 & ! tr\ble mu/ be ref]r$ to a high] au?ority4 b4 ,*a9s ,produce ,gr9d+ ,noise ) ,eng9e ,idl+ & ,vehicle on ,re> ,/&4 ,if ei!r *a9 is adju/$ too tight1 adju/ to prop] t5sion 7p>s4 #ei & #fj74 ,exam9e bo? *a9s = pres5ce ( dirt & grit4 ,if dirty1 clean & lubricate !m 7p>4 #bj c 7#aj774 ,if ei!r *a9 is dry1 adju/ *a9 oil]s 7p>4 #fa74 ,badly worn *a9s & sprockets w cause ?is symptom2 ! worn p>ts mu/ be replac$ 7p>s4 #fb & #fc74 c4 ,front ,*a9 ,dry &_/or ,r$ 7,ru/y7 9 ,appe>ance4 ,! *a9 9 ?is condition has n be5 receiv+ en\gh lubrication4 ,adju/ *a9 oil] 7p>4 #fa74 ,if ! *a9 is damag$ f lack ( oil1 replace 7p>4 #fb74 d4 ,r\gh or ,j]ky ,vehicle ,op]ation at ,l[ ,spe$4 ,*a9s are too loose4 ,adju/ 7p>s4 #ei & #fj74 e4 ,excessive ,side ,play at ,rim ( ,front ,:eel4 ,adju/ be>+ cones 7p>4 #abf74 ,if ! cones & or hub races are badly worn1 replace :eel 7p>4 #abe74 f4 ,front ,:eel ,sp9n+ ,te/ ,produces ,gr9d+1 ,grat+ ,noise 7n 9 brake74 ,! :eel be>+s are defective4 ,replace :eel 7p>4 #abe74 g4 ,re> ,:eel ,has ,excessive ,side ,play at ,rim ( ,:eel4 ,! hub be>+s are defective4 ,replace :eel 7p>4 #abg74 h4 ,re> ,:eel ,has ,side ,play 9 ,excess ( #j4jaj in* on ,axle4 ,! ?ru/ wa%]s ( hub are worn or damag$4 ,replace :eel 7p>4 #abg74 i4 ,re> ,:eel ,sp9n+ ,te/ ,produces ,gr9d+1 ,grat+ ,noise 7*a9 remov$74 ,tight5 :eel m\nt+ screws4 ,if ?is does n correct noise1 replace :eel 7p>4 #abg74 #cg4 ,,brakes4 a4 ,re> ,brake ,does ,n ,hold ,:5 ,foot ,p$al ,is ,depress$4 ,if ! brake l9+s are wet1 op]ate ! vehicle & apply a slight pressure to ! brake p$al to dry out l9+s4 ,aft] dry+ ! l9+s adju/ brake rod l5g? 7p>4 #if b74 ,if ! brake op]at+ lev] /&s ahead ( ! v]tical position ) brake appli$1 or ! brake does n hold1 replace ! defective brake %oes 7p>4 #if74 b4 ,re> ,brake ,squeaks or ,*att]s ,:5 ,us$4 ,tight5 side plate sleeve nut1 if x is loose4 ,adju/ %oe position 7p>4 #if74 ,if ! op]at+ cam%aft &_/or side cov] be>+ is worn1 replace ! assembly 7p>4 #if74 ,if ! brake %oe spr+ is defective1 replace 7p>4 #if74 ,if ! l9+ on ! brake %oes is loose1 worn1 or defective1 replace %oes 7p>4 #if74 ,if ! brake drum is worn or damag$1 replace ! brake drum & sprocket assembly 7p>4 #if74 c4 ,re> ,brake ,drags 7vehicle on re> /&74 ,adju/ l9kage 7p>4 #if74 ,if x /ill drags1 equalize %oe assemblies1 & adju/ l9kage 7p>4 #if74 d4 ,front ,brake ,does ,n ,hold ,:5 ,h& ,lev] ,is ,op]at$4 ,adju/ brake control 7p>4 #ig74 ,if brakes are wet1 op]ate vehicle a %ort di/ance ) slight pressure on brake lev] to dry out l9+s4 ,if brake does n hold1 replace %oes 7p>4 #ig74 e4 ,front ,brake ,drags4 ,adju/ control l9kage 7p>4 #ig74 ,if brake /ill drags1 equalize %oes & readju/ control l9kage 7p>4 #ig74 f4 ,front ,brake ,action ,r\gh &_/or ,*att]s4 ,adju/ control l9kage assembly 7p>4 #ig74 ,if malfunction cont9ues1 exam9e brake %oes1 %oe spr+1 cam%aft be>+ & side cov] be>+4 ,replace any defective p>ts or assemblies 7p>4 #ig74 #ch4 ,,/e]+4 a4 ,motorcycle ,pulls to ,"o ,side4 ,inspect & correct al9em5t ( re> :eel 7p>4 #fj74 ,if ! front =ks are b5t or twi/$1 replace 7p>4 #ih74 ,if tr\ble p]si/s1 ref] to high] au?ority4 b4 ,motorcycle ,weaves f ,side to ,side4 ,adju/ /e]+ damp] to suit spe$ & road conditions4 ,if ?is fails1 inflate tires to correct pressure4 ,make sure re> :eel m\nt+ screws are tight4 ,if ! /e]+ head be>+s are too tight1 weav+ w result4 ,*eck ! /e]+ head be>+s 7p>4 #ih71 & adju/ if necess>y4 c4 ,motorcycle ,%immies at ,high ,spe$4 ,inflate tires to correct pressure4 ,adju/ /e]+ damp] to suit spe$ & road conditions4 ,if ! tire tread is unev5ly worn1 & %ift+ tires does n correct ! condition1 replace ! defective cas+s4 ,make sure ! axle nuts are tight4 ,if ! rock] plate /uds & bu%+s are badly worn1 or ! =k spr+s are brok51 replace 7p>4 #ih74 ,section ,,xi ,,eng9e ,p>agraph ,description & data #ci ,tuneup #dj ,replacem5t ( head gasket #da ,c>bon removal #db ,valve tappet adju/m5t #dc ,replacem5t ( oil fe$ pump #dd #ci4 ,,description ,,& ,,data4 a4 ,description4 ,?is #b;cyl9d]1 ,vtype1 aircool$ gasol9e eng9e ( ,lhead design op]ates on ! #d/roke1 #d;cycle pr9ciple4 ,fly:eel & connect+ rod assemblies op]ate on roll] be>+s4 ,eng9e is fitt$ ) l[expansion alum9um alloy1 camgr\nd1 horizontally slott$ pi/ons & ) deepf9n$ alum9um cyl9d] heads4 ,z view$ f left side ( vehicle 7drive *a9 side71 rotation ( eng9e is c\nt]clockwise4 b4 ,lubrication sy/em is ( drysump type1 9 :i* oil supply is ma9ta9$ 9 a tank away f eng9e4 ,oil is circulat$ by a supply fe$ pump & a scav5g]1 return pump4 ,?is oil circulat+ sy/em plays a mo/ important "p 9 cool+ ! eng9e z well z lubricat+ x4 c4 ,data4 ,type ( eng9e #b;cyl9d]1 ,vtype1 ,lhead1 aircool$ ,cyl9d] bore #b-c_/d 94 ,/roke #c-acaf 94 ,pi/on displacem5t #de4ab cu 94 ,compression ratio #e4j3a ,horsep[] 7,n4,a4,c4,c4 ,rat+7 #f4je ,eng9e numb] 7s]ial71 left side ( eng9e base1 j bel[ front cyl9d]4 #dj4 ,,tune,,up4 a4 ,tuneup consi/s ( mak+ correct adju/m5t to valve tappets1 circuit break] ignition po9ts1 sp>k plug electrodes3 *eck+ & correct+ ignition tim+2 dra9+ & flu%+ c>buretor b[l2 clean+ & flu%+ gasol9e /ra9]2 clean+ muffl] outlet1 s]vic+ air clean]1 & adju/+ c>buretor4 7#a7 ,valve tappet adju/m5t 7p>4 #dc74 7#b7 ,circuit break] po9t adju/m5t 7p>4 #hd74 7#c7 ,sp>k plug s]vice 7p>4 #hc74 7#d7 ,tim+ ignition 7p>4 #hf74 7#e7 ,dra9+ c>buretor b[l 7p>4 #gc74 7#f7 ,clean+ fuel /ra9] 7p>4 #gb74 7#g7 ,clean+ muffl] outlet requires free+ outlet ( c>bon deposits1 cak$ dirt1 oil1 etc41 ) blade ( screwdriv]1 or o!r suitable tool4 ,d n enl>ge outlet size :5 clean+4 7#h7 ,s]vic+ air clean] 7p>4 #gf74 7#i7 ,adju/+ c>buretor 7p>4 #fh74 ,illu/ration3 ,a--,,cyl9d] ,,bracket ,,spac]s ,,& ,,wa%]s ,b--,,cyl9d] ,,bracket ,,& ,,frame ,,bolt ,c--,,cyl9d] ,,upp] ,,m\nt+ ,,bracket ,d--,,sp>k ,,cable ,,clip ,e--,,cyl9d] ,,bracket ,,bolts ,f--,,oil ,,return ,,pipe ,,connection ,,holl[ ,,bolt ,,& ,,wa%]s ,,ra ,,pd #caegaa ,figure #ae--;,disassembly = ,head ,gasket ,replacem5t #da4 ,,replacem5t ,,( ,,head ,,gasket 7fig4 #ae74 a4 ,removal4 ,ref] to figure #ae1 illu/rat+ necess>y p>ts & units to be remov$ to p]=m ?is op]ation4 7#a7 ,remove in/rum5t panel cov] 7p>4 #aai74 7#b7 ,remove gasol9e tank & oil tank 7p>4 #ajg74 7#c7 ,remove cyl9d] head bracket to frame lug bolt3 ?is w free clamp :i* secures front sp>k plug cable4 ,pay p>ticul> att5tion to %im wa%]s plac$ betwe5 cyl9d] head bracket & frame lug1 z ^! wa%]s mu/ be replac$ :5 in/all+ cyl9d] head4 7#d7 ,remove sp>k plug1 or plugs4 7#e7 ,remove cyl9d] head bolts1 us+ head bolt wr5* #da-,w-#aebe4 ,,note3 ,on "s #db ,,wla models1 pla9 wa%]s 7#j4jie-;in* ?ick71 9 addition to regul> 7heavy7 cyl9d] head bolt wa%]s1 7 us$ to prev5t cyl9d] head bolts f bottom+4 7#f7 ,p]=m c>bon removal 7head only74 ,ref] to p>agraph #db4 b4 ,in/all+ ,gasket & ,head 7fig4 #ae74 7#a7 ,clean top ( cyl9d]4 ,apply a light application ( grease or oil to bo? sides ( gasket be=e locat+ on cyl9d] head4 ,place head on cyl9d]4 7#b7 ,in/all head bolts1 us+ heavy wa%]s 7also #j4jie-;in* ?ick pla9 wa%]s1 if any 7 remov$74 ,if 9 d\bt z to use ( #j4jie-;in* ?ick wa%]s 9 addition to regul> wa%]s1 measure dep? ( bolt holes 9 cyl9d] head4 ,head hav+ hole dep? ( #ca_/cb in* mu/ use ! #j4jie-;in* ?ick wa%]s 9 addition to regul> wa%]s4 ,head hav+ bolt hole dep? ( #a-a_/af in* does n require ! #j4jie-;in* ?ick wa%]s4 7#c7 ,in/all cyl9d] frame bracket ) ! two long bolts1 special 7spool%ap$7 spac]s1 & flat wa%]s4 ,! spac]s g betwe5 cyl9d] heads & frame bracket4 ,a flat wa%] goes "u ! head ( ea* long cyl9d] bolt1 above ! bracket2 "s eng9es may h flat wa%]s betwe5 ! spac]s & ! bracket4 7#d7 ,tight5 head bolts ev5ly to ensure a tight cyl9d] head jo9t4 ,use head bolt wr5* #da-,w-#aebe1 fir/ turn+ d[n bolts j snug1 !n tight5+ ea* bolt #a_/h to #a_/d turn at a "t1 until all are securely tight5$4 ,if torque wr5* is available1 tight5 head bolts to #fj footp\nds m9imum1 #fe footp\nds maximum t5sion :5 eng9e is cold4 #db4 ,,c>bon ,,removal4 a4 ,at "t cyl9d] head is remov$ = gasket replacem5t1 c>bon mu/ be remov$ f head only4 #dc4 ,,valve ,,tappet ,,adju/m5t 7fig4 #af74 a4 ,adju/ ,tappets ) ,eng9e ,cold4 ,be=e loos5+ valve spr+ cov]s1 a light application ( oil ar\nd top edge ( ea* cov] w facilitate rais+ cov] )\t damage to seal pack+4 7#a7 ,loos5 valve spr+ cov]s2 use tappet & valve cov] wr5* #da-,w-#cfag4 7#b7 ,be=e *eck+ or adju/+ tappet cle>ance1 make sure valve is seat$ & t tappet is at l[e/ position1 by turn+ eng9e ahead until l tappet 7inlet or exhau/1 :i*ev] "o is be+ adju/$7 9 ! o!r cyl9d] is at highe/ position 7valve fully op574 ,inlet valves are locat$ ne>e/ ! c>buretor manifold4 ,illu/ration3 ,,ra ,,pd #cajbaa ,figure #af--,valve ,tappet ,adju/m5t 7#d7 ,loos5 adju/+ screw lock nut 78#b10 fig4 #af7 slightly be=e turn+ adju/+ screw 7fig4 #af74 7#e7 ,adju/ inlet valve tappets to #j4jjd-;in* m9imum1 & #j4jje-;in* maximum cle>ance betwe5 valve /ems & tappet 78#a0 & 8#d10 fig4 #af74 ,use ?ickness gage to det]m9e cle>ance2 re*eck 7correct+ if necess>y7 cle>ance aft] lock nut has be5 securely tight5$4 7#f7 ,adju/ exhau/ valve tappets to #j4jjf-;in* m9imum1 & #j4jjg-;in* maximum cle>ance betwe5 valve /ems & tappet4 ,use ?ickness gage to det]m9e cle>ance2 re*eck 7correct+ if necess>y7 cle>ance aft] lock nut has be5 securely tight5$4 7#g7 ,be=e turn+ d[n valve spr+ cov]s1 inspect pap] gasket betwe5 ea* cov] & tappet guide4 ,if brok5 or damag$1 fit a new gasket to prev5t oil leak4 ,turn d[n & securely tight5 valve spr+ cov]s4 ,illu/ration3 ,,ra ,,pd #caegab ,figure #ag--,oil ,pump ,remov$ #dd4 ,,replacem5t ,,( ,,oil ,,fe$ ,,pump 7fig4 #ag74 a4 ,removal4 7#a7 ,disconnect oil tank fe$ pipe at oil tank4 ,in/all nipple cap on tank nipple to prev5t oil f runn+ out1 or dra9 tank4 ,disconnect oil fe$ pipe f oil pump nipple4 7#b7 ,oil pump is secur$ to eng9e ge> case cov] by "o hexagon head bolt & ?ree nuts4 ,two ( ! nuts are extra long to provide wr5* cle>ance1 & _! location %\ld be not$ s !y w be put back :]e !y belong :5 re9/all+ pump4 ,aft] remov+ screw & nuts1 remove pump4 ,unless a new pump gasket is available1 take c>e n to damage or break ! old "o1 z ?is is a v special gasket conc]n+ bo? ?ickness & holes provid$ = oil *annels4 ,a 8homemade0 gasket may put oil+ sy/em completely out ( commission4 b4 ,in/all+ ,oil ,pump4 7#a7 ,clean surface ( pump body m\nt+ on ge> case cov] & see t gasket is 9 good condition4 ,clean face ( oil pump body4 7#b7 ,/>t pump on m\nt+ /uds1 turn eng9e sl[ly & press lightly aga9/ pump until driv+ dogs on end ( cam ge> %aft l9e up ) & drop into driv+ slot 9 oil pump rotor4 7#c7 ,ins]t hexagonhead bolt & lock wa%]1 & in/all ! ?ree lock wa%]s & nuts 7two are long ext5sion nuts7 on pump m\nt+ /uds4 ,make sure to replace ! two extra long nuts on ! /uds f :i* !y 7 orig9ally remov$4 7#d7 ,tight5 m\nt+ bolt & ?ree nuts securely4 7#e7 ,connect oil fe$ pipe to oil pump nipple4 ,remove nipple cap f tank nipple & connect upp] end ( oil fe$ pipe to ?is nipple4 ,tight5 nipple nuts securely4 ,section ,,xii ,,eng9e--,,removal ,,& ,,in/allation ,p>agraph ,remove eng9e #de ,in/all eng9e #df #de4 ,,remove ,,eng9e 7figs4 #ah1 #ai1 & #bj74 a4 ,a /udy ( figures #ah & #ai w provide a good picture ( ! /eps necess>y = eng9e removal4 ,d n attempt any %ort cut me?ods1 z ?is w\ld consume m "t & possibly cause damage to p>ts or unit assemblies4 7#a7 ,disconnect batt]y gr\nd wire at frame lug connection on "r side ( vehicle4 7#b7 ,to disconnect brake front rod f bell crank 7locat$ on "r side ( re> support rod71 remove cott] p9 & pla9 wa%]4 7#c7 ,loos5 footbo>d re> support /ud nut & remove footbo>d front /ud nut1 !n pull footbo>d outw>d to free "r front end ( safety gu>d4 ,disconnect brake front rod at bell crank4 ,remove bolt :i* secures front exhau/ pipe clamp4 ,remove nut f re> support rod1 free+ /op light swit* & re> end ( side b>4 ,remove nut f front support rod1 free+ footbo>d & brake assembly = removal4 7#d7 ,remove ! two re> m\nt+ bolts & drop re> end ( skid plate 7fig4 #cg74 7#e7 ,remove muffl] 7p>4 #ha74 7#f7 ,disconnect oil pipe f tank & in/all nipple cap on oil tank fe$ pipe nipple to prev5t oil f runn+ out1 or dra9 tank4 ,disconnect pipe f oil pump & remove oil pipe4 7#g7 ,disconnect sp>k control wire at circuit break] lev]1 & free control h\s+ clamp at cyl9d] base4 7#h7 ,disconnect brake re> rod f bell crank4 7#i7 ,disconnect r$ wire & black wire f front end ( relay2 also gre5 wire f g5]ator t]m9al4 7#aj7 ,remove sp>k plugs4 7#aa7 ,remove eng9e top m\nt+ 7cyl9d] head bracket7 bracket to frame lug bolt3 ?is also frees front sp>k plug cable clamp4 ,pay p>ticul> att5tion to %im wa%]s 7if any7 betwe5 cyl9d] head bracket & frame lug2 ^! w h to be in/all$ 9 ! orig9al position4 7#ab7 ,remove lev] bottom bolt1 free+ ge> %ift] lev] f %ift] rod4 ,illu/ration3 ,,ra ,,pd #caegac ,a--,,left ,,footbo>d1 ,,clut* ,,p$al ,,& ,,sideb> ,,assembly ,,& ,,m\nt+ ,,nuts ,,& ,,wa%]s ,b--,,sp>k ,,control ,,wire ,,& ,,h\s+ ,c--,,eng9e ,,sprocket1 ,,key1 ,,nut ,,& ,,front ,,drive ,,*a9 ,d--,,eng9e ,,sprocket ,,%aft ,e--,,re> ,,support ,,rod ,f--,,inn] ,,*a9 ,,gu>d ,g--,,air ,,clean] ,,& ,,bracket ,,assembly ,h--,,out] ,,*a9 ,,gu>d ,,re> ,,m\nt+ ,,bolt1 ,,wa%]1 ,,spr+1 ,,nut ,,& ,,cott] ,,p9 ,j--,,sp>k ,,coil ,,re> ,,t]m9al ,,nut1 ,,wa%] ,,& ,,screw ,k--,,out] ,,*a9 ,,gu>d ,l--,,air ,,clean] ,,bracket ,,upp] ,,m\nt+ ,,bolt ,,nuts ,,& ,,wa%]s ,m--,,air ,,clean] ,,hose ,,& ,,c>buretor ,,fitt+ ,,assembly ,,& ,,m\nt+ ,,screws ,n--,,eng9e ,,left ,,re> ,,base ,,m\nt+ ,,bolt ,,ca/le ,,nut1 ,,wa%]s ,,& ,,cott] ,,p9 ,o--,,re> ,,support ,,rod ,,ext5d$ ,,nut ,p--,,inn] ,,*a9 ,,gu>d ,,m\nt+ ,,screws ,,& ,,locks ,q--,,fuel ,,pipe ,,& ,,/ra9] ,,assembly ,r--,,eng9e ,,left ,,front ,,base ,,m\nt+ ,,bolt1 ,,wa%]s1 ,,ca/le ,,nut ,,& ,,cott] ,,p9 ,s--,,ge> ,,%ift] ,,& ,,rod ,,atta*+ ,,bolt1 ,,wa%] ,,& ,,nut ,t--,,tank1 ,,l[] ,,front ,,m\nt+ ,,bolt1 ,,wa%]s ,,& ,,nut ,u--,,eng9e ,,sprocket ,,nut ,,wr5* ,,ra ,,pd #caegac;,b ,figure #ah--;,disassembly = ,eng9e ,removal--,left ,side ,illu/ration3 ,,ra ,,pd #caegad ,a--,,muffl] ,,assembly ,,& ,,m\nt+ ,,bolts ,,& ,,nuts ,b--,,skid ,,plate ,c--,,/op ,,light ,,swit* ,d--,,re> ,,brake ,,rod ,,front ,,end ,e--,,cyl9d] ,,bracket ,,& ,,frame ,,m\nt+ ,,bolt1 ,,spac+ ,,wa%]s1 ,,sp>k ,,cable ,,clip ,,& ,,nut ,f--,,eng9e ,,"r ,,front ,,base ,,m\nt+ ,,bolt1 ,,ca/le ,,nut1 ,,wa%]s ,,& ,,cott] ,,p9 ,g--,,relay ,,t]m9al ,,screws ,,& ,,wa%]s ,h--,,safety ,,gu>d ,,end ,j--,,"r ,,footbo>d1 ,,brake ,,p$al ,,& ,,sideb> ,,assembly ,,& ,,m\nt+ ,,nuts ,,& ,,wa%]s ,k--,,front ,,exhau/ ,,pipe ,,clamp1 ,,bolt1 ,,wa%] ,,& ,,nut ,l--,,exhau/ ,,pipe ,,assembly ,m--,,sp>k ,,plugs ,,& ,,gaskets ,n--,,re> ,,support ,,rod1 ,,wa%] ,,& ,,nut ,o--,,brake ,,rod ,,bellcrank ,p--,,eng9e ,,re> ,,base ,,m\nt+ ,,bolts1 ,,wa%]s1 ,,ca/le ,,nut ,,& ,,cott] ,,p9 ,q--,,oil ,,fe$ ,,pipe ,r--,,v5t ,,pipe ,,holl[ ,,bolt ,,& ,,wa%] ,s--,,v5t ,,pipe ,t--,,oil ,,return ,,pipe ,,ra ,,pd #caegad;,b ,figure #ai--;,disassembly = ,eng9e ,removal--,"r ,side 7#ac7 ,close fuel tank valve4 ,remove gasol9e pipe f tank nipple & fuel filt] nipple4 7#ad7 ,disconnect ?rottle control wire at c>buretor lev]4 7#ae7 ,disconnect air intake hose connection fitt+ f c>buretor 7f\r screws7 & leave atta*$ to hose4 ,remove air clean] f m\nt+ bracket 7p>4 #gh74 ,illu/ration3 ,,ra ,,pd #cajbae ,figure #bj--,remov+ ,eng9e 7#af7 ,remove front *a9 gu>d 7p>4 #ajb74 7#ag7 ,remove eng9e sprocket 7p>4 #fe74 7#ah7 ,remove two screws & locks secur+ inn] *a9 gu>d to crankcase4 7#ai7 ,) #ac_/af-;in* deep socket wr5* slipp$ ov] re> footbo>d support rod /ud1 remove ext5d$ nut1 & )draw support rod f "r side ( vehicle4 7#bj7 ,to disconnect ! circuit break] to coil wire & %ield+ gr\nd f coil re> t]m9als1 disconnect oil pressure signal light wire f oil pressure swit* t]m9al4 ,x w be necess>y to free air clean] m\nt+ bracket & sw+ x outw>d1 to ga9 access to coil re> %ield+ gr\nd t]m9al4 7#ba7 ,eng9e m\nt+ bolts are secur$ by cott] p9s & ca/le nuts4 ,remove all eng9e m\nt+ bolts1 except ! "o "u g5]ator2 ?is bolt _c be remov$ )\t remov+ g5]ator2 m]ely pu% x up f> en\gh to cle> frame eng9e lug :5 eng9e is remov$ f frame4 7#bb7 ,lift & remove eng9e f "r side ( frame4 #df4 ,,in/all ,,eng9e 7figs4 #ah1 #ai1 & #bj74 a4 ,in/all+ ! eng9e is g5]ally ! rev]se ( ! proc$ure foll[$ 9 eng9e removal4 ,pay close att5tion to ! foll[+ proc$ure because *eck+ & adju/m5t ( controls & o!r items is necess>y to satisfactory vehicle op]ation4 7#a7 ,lift eng9e into frame f "r side ( vehicle4 ,make sure t m\nt+ bolt "u g5]ator is rais$ to cle> frame eng9e lug4 7#b7 ,pass rema9+ ?ree eng9e m\nt+ bolts up f "u side ( frame lugs ?r\gh crankcase lugs3 in/all pla9 wa%]s & ca/le nuts4 ,fit pla9 wa%] & ca/le nut on m\nt+ bolt "u g5]ator4 ,securely tight5 all f\r ca/le nuts & lock ) cott] p9s4 7#c7 ,connect circuit break] to coil wire4 ,connect wire to coil re> t]m9al & gr\nd %ield+ on coil case t]m9al4 7#d7 ,connect oil pressure swit* wire to swit* t]m9al4 7#e7 ,pass re> footbo>d support rod ?r\gh frame lug f "r side ( vehicle & in/all ! ext5d$ #ac_/af-;in* nut4 7#f7 ,secure inn] *a9 gu>d by atta*+ ! two screws & locks m\nt+ inn] *a9 gu>d to eng9e base4 ,drift edge ( locks into screw slots = security4 7#g7 ,in/all eng9e sprocket & front drive *a9 toge!r4 ,see t eng9e %aft is clean1 sprocket tap] clean1 & t key is 9 place be=e tight5+ sprocket nut4 ,drift nut tight1 us+ hamm] on wr5*4 7#h7 ,in/all out] front *a9 gu>d 7p>4 #ajb74 7#i7 ,connect hose & fitt+ assembly by in/all+ two bolts1 wa%]s1 & nuts secur+ air clean] to frame bracket2 !n in/all f\r screws secur+ hose fitt+ to c>buretor4 ,,note3 ,if clean] frame bracket 0 loos5$ & %ift$ to ga9 access to coil re> t]m9als1 securely m\nt bracket be=e in/all+ air clean] assembly4 7#aj7 ,connect ?rottle control wire to c>buretor lev]4 ,make sure t ?rottle closes fully :5 "r grip is turn$ outw>d2 & t ?rottle op5s fully :5 grip is turn$ inw>d4 7#aa7 ,in/all fuel pipe4 ,securely tight5 union nuts on tank & fuel /ra9] nipples4 ,op5 fuel supply valve & *eck connections = leaks4 7#ab7 ,connect ge> %ift] lev] end to ge> %ift] rod by tight5+ bolt & nut4 7#ac7 ,atta* eng9e top m\nt+ bracket 7cyl9d] head bracket7 to frame lug1 ex]cis+ c>e 9 in/all+ requir$ numb] ( ?9 %ims1 toge!r ) clamp = front sp>k plug cable1 to fill space betwe5 bracket & frame lug be=e tight5+ bolt nut4 ,,note3 ,frame lug mu/ be free f pa9t or grease to make clean 8electrical0 connection ) plat$ %ims & m\nt+ bracket = adequate radio bond+4 7#ad7 ,be=e in/all+ sp>k plugs1 inspect = cleanl9ess & correct electrode adju/m5t4 ,s]vice if necess>y 7p>4 #hc74 ,replace gaskets to ensure tight jo9ts4 7#ae7 ,connect r$ & black wires to relay3 connect gre5 wire to g5]ator t]m9al m>k$ 8,,swit*40 ,ref] to wir+ diagram 7fig4 #gc74 7#af7 ,atta* re> brake rod to bell crank4 ,in/all pla9 wa%] & secure ) cott] p94 7#ag7 ,connect sp>k control wire to circuit break] lev] & secure control wire h\s+ clamp "u cyl9d] base nut4 ,make sure t sp>k advances fully 7lev] inw>d7 :5 control grip 7left h&le b>7 is turn$ inw>d1 & t sp>k ret>ds fully :5 control grip is turn$ outw>d4 ,make ne$$ adju/m5t at control wire & lev] connection4 7#ah7 ,remove nipple cap f tank oil pipe nipple 7if "o 0 us$7 & connect oil fe$ pipe1 securely tight5+ union nuts at tank & oil pump4 7#ai7 ,position exhau/ pipe & muffl] assembly & atta* re> hang] frame bolt1 wa%]1 & nut4 ,secure muffl] front m\nt+ bracket bolt1 b d n tight5 nut until skid plate re> bracket is locat$ on ?is bolt4 7#bj7 ,lift re> end ( skid plate1 secure re> m\nt+ bracket & muffl] front m\nt+ bracket ) bolt1 wa%]1 & nut4 ,atta* skid plate left side bracket1 tight5+ support rod nut & bracket bolt & nut4 7#ba7 ,in/all "r side footbo>d1 sideb>1 & brake p$al assembly4 ,in/all /op light swit* bracket on re> support rod be=e plac+ lock wa%] & tight5+ nut4 ,atta* front exhau/ pipe clamp to sideb>4 ,in/all lock wa%]1 & tight5 sideb> front support rod nut4 ,atta* "r end ( front safety gu>d to sideb> ) footbo>d front support /ud4 ,replace lock wa%]1 & tight5 nut4 ,also tight5 footbo>d re> support /ud nut4 ,connect /op light swit* control to brake foot p$al4 7#bb7 ,atta* brake front rod to bell crank2 fit pla9 wa%] & secure ) cott] p94 7#bc7 ,connect batt]y gr\nd wire to frame lug on "r side ( vehicle4 b4 ,*eck in/rum5t panel signal lights = normal indications1 & see t oil is 9 tank be=e />t+ eng9e4 ,section ,,xiii ,,clut* ,p>agraph ,description #dg ,ma9t5ance & adju/m5t #dh ,removal ( disks #di ,inspection ( disks & spr+s #ej ,in/allation ( disks #ea ,replacem5t ( clut* release be>+ #eb #dg4 ,,description 7fig4 #ba74 a4 ,clut* is ( simple multipledrydisk type1 hav+ two /eel disks & ?ree l9$ disks1 "o ( :i* provides spr+ action )9 disk pack to 8cu%ion0 clut* op]ation4 #dh4 ,,ma9t5ance ,,& ,,adju/m5t 7figs4 #bb1 #bc1 #bd1 & #be74 a4 ,if clut* adju/m5t is correctly ma9ta9$1 clut* w cause v little tr\ble4 ,ease ( ge> %ift+ & s]vice life ( transmission ge> %ift] clut* dogs dep5d l>gely ^u full dis5gagem5t ( ! clut*4 ,clut* adju/m5t is 9 two p>ts2 namely1 control l9kage & spr+ t5sion4 ,d n adju/ clut* spr+ t5sion be=e correct+ control adju/m5t4 b4 ,clut* ,control ,l9kage 7fig4 #bb74 ,op]ation ( foot p$al1 control cable1 & clut* release lev] actuates ! pu% rod ?r\gh holl[ transmission %aft1 dis5gag+ or engag+ clut* at w4 ,correct adju/m5t to control cable & release lev] mu/ be made be=e pu% rod adju/m5t is made4 c4 ,clut* ,control ,adju/m5t 7figs4 #bc1 #bd1 #be1 & #bf74 7#a7 ,,adju/+ ,,cable ,,l5g?4 ,) clut* 9 fully dis5gag$ position 7foot p$al heel d[n7 ! clut* release lev] mu/ cle> ! c\nt]%aft sprocket cov] /ud &_/or nut by #a_/af in*4 ,%\ld clut* release lev] /rike sprocket cov] & nut1 clut* pu% rod movem5t is re/rict$1 & clut* _c be fully dis5gag$4 ,l5g? ( control cable mu/ be adju/$ to obta9 #a_/af-;in* clut* release lev] & sprocket cov] /ud &_/or nut cle>ance4 ,to l5g!n or %ort5 clut* control cable1 cable adju/able end mu/ be remov$ f foot p$al /ud 7figs4 #bc & #bd74 ,) foot p$al 9 =w>d 7toe d[n7 position1 remove cott] p9 & wa%] reta9+ cable end4 ,release o!r end ( cable f not* 9 clut* release lev] by press+ release lev] inw>d & lift+ cable end out ( not*4 ,rock ! foot p$al to re> 7heel d[n7 position & "w cable adju/able end (f foot p$al /ud4 ,loos5 lock nut & turn cable end to "r 7clockwise7 to %ort5 cable2 turn to left 7c\nt]clockwise7 to l5g!n cable4 ,tight5 lock nut1 in/all cable end on foot p$al /ud2 in/all wa%] & cott] p91 & in/all o!r end ( cable 9 clut* release lev] not*4 ,illu/ration3 ,a--,,clut* ,,hub ,,complete1 ,,) ,,l9]1 ,,be>+1 ,,/uds1 ,,etc4 ,b--,,hub ,,disk ,,l9+4 ,c--,,l9+ ,,rivet 7#f ,,us$74 ,d--,,p9 7#g ,,us$74 ,e--,,/ud4 ,f--,,sprocket ,,complete ,,) ,,disk ,,spl9e ,,r+4 ,g--,,l9$ ,,disks 7#b ,,us$74 ,h--,,pla9 ,,/eel ,,disks 7#b ,,us$74 ,j--,,sprung ,,/eel ,,disk ,,) ,,"o ,,l9+4 ,k--,,releas+ ,,disk 7,,) ,,pu% ,,rod ,,adju/+ ,,screw ,,& ,,adju/+ ,,screw74 ,l--,,clut* ,,spr+s 7#aj ,,us$74 ,m--,,/ud ,,nut ,,lock+ ,,wa%] 7#c ,,us$74 ,n--,,/ud ,,nut 7#c ,,us$74 ,o--,,spr+ ,,compression ,,coll>4 ,p--,,pu% ,,rod ,,adju/+ ,,screw4 ,q--,,adju/+ ,,screw ,,lock ,,nut4 ,r--,,reta9+ ,,plate ,,lock ,,r+ 7#c ,,us$74 ,s--,,be>+ ,,reta9+ ,,plate4 ,t--#fj #g_/cb-;,,in* ,,/eel ,,balls4 ,u--,,ball ,,be>+ ,,reta9]4 ,,ra ,,pd #cajbah ,figure #ba--;,clut*1 ,disassembl$ ,illu/ration3 ,,ra ,,pd #cajbai ,figure #bb--;,clut* ,control ,l9kage ,illu/ration3 ,,ra ,,pd #cajbbj ,figure #bc--;,clut* ,lev] & ,/ud ,nut ,cle>ance ,illu/ration3 ,,ra ,,pd #cajbba ,figure #bd--;,control ,cable ,l5g? ,adju/m5t ,illu/ration3 ,,ra ,,pd #caegae ,figure #be--;,clut* ,adju/m5ts 7#b7 ,,adju/+ ,,cle>ance ,,( ,,clut* ,,release ,,lev] ,,& ,,pu% ,,rod 7fig4 #be74 ,) clut* release lev] & sprocket cov] /ud cle>ance correctly adju/$ 7/ep 7#a7 above71 clut* release lev] mu/ h betwe5 #a_/h-;in* & #a_/d-;in* free play at end :]e control cable engages lev] not* 7fig4 #be74 ,?is free play ensures a fully engag$ clut* )\t pressure on clut* release be>+4 ,adju/m5t is made by means ( pu% rod adju/+ screw locat$ 9 clut* out] disk4 ,remove two screws :i* secure inspection hole cov] to *a9 gu>d 7fig4 #be74 ,if clut* release lev] has less ?an #a_/h-;in* free play at end ( cable1 loos5 pu% rod adju/+ screw lock nut & turn pu% rod adju/+ screw to ! left 7c\nt]clockwise7 to increase am\nt ( free play4 ,if clut* release lev] has m ?an #a_/d-;in* free play at end ( cable1 turn adju/+ screw to ! "r 7clockwise7 to decrease am\nt ( free play4 ,tight5 lock nut aft] correct adju/m5t is obta9$4 ,replace inspection hole cov]4 ,,caution3 ,if end ( clut* release lev] has no free play z expla9$ above1 clut* w n hold :5 fully engag$4 ,if too mu* free play is all[$1 clut* w drag :5 dis5gag$2 consequ5tly1 transmission ge>s w %ift h>d1 cla%1 & ev5tually become damag$4 ,illu/ration3 ,,ra ,,pd #cajbbc ,figure #bf--;,adju/+ ,clut* ,spr+ ,t5sion d4 ,adju/+ ,clut* ,spr+ ,t5sion 7fig4 #bf74 ,if clut* slips 7does n hold :5 />t+ eng9e or ) vehicle 9 op]ation7 aft] controls h be5 correctly adju/$ 7/ep c 7#a7 & 7#c7 above71 spr+ t5sion mu/ be increas$4 ,,note3 ,d n increase spr+ t5sion any m ?an actually requir$ to make clut* hold4 7#a7 ,remove front out] *a9 gu>d 7p>4 #ajb74 7#b7 ,b5d d[n lock lips to free ! ?ree clut* adju/+ nuts4 7#c7 ,turn+ nuts to "r 7clockwise7 increases clut* spr+ t5sion4 ,tight5 7turn to "r7 all ?ree adju/+ nuts1 "ohalf turn at a "t1 until clut* holds4 ,te/ clut* aft] ea* halfturn ( ! ?ree adju/+ nuts by crank+ eng9e4 ,usually a clut* t holds )\t any noticeable slippage :5 crank+ eng9e1 also holds on ! road4 7#d7 ,aft] clut* spr+ t5sion adju/m5t is made1 b5d up nut lock lips to secure adju/+ nuts4 ,replace any brok5 or badly damag$ locks4 7#e7 ,:5 a new clut* is orig9ally assembl$ & adju/$1 ! di/ance f ! inn] edge ( %\ld] on spr+ coll> to face ( out] 7releas+7 disk is #a-c_/cb in*es 7fig4 #bg74 ,9 any case1 d n tight5 ! ?ree adju/+ nuts to ! po9t :]e inn] edge ( %\ld] ( spr+ coll> is clos] ?an in* to face ( out] 7releas+7 disk4 ,if compress$ m1 clut* probably _c be fully dis5gag$4 ,illu/ration3 ,,ra ,,pd #cajbbd ,figure #bg--,measur+ ,di/ance ,betwe5 ,spr+ ,coll> & ,disk 7#g7 ,if clut* /ill does n hold1 aft] correct control & spr+ t5sion adju/m5ts h be5 made1 clut* 8pack0 assembly mu/ be replac$ 7p>4 #di74 7#h7 ,aft] mak+ clut* spr+ t5sion adju/m5t1 replace out] front *a9 gu>d 7p>4 #ajb74 #di4 ,,removal ,,( ,,disks 7figs4 #bh1 #bi1 & #cj74 a4 ,clut* disks c be remov$ = inspection1 clean+1 &_/or replac+4 ,spr+s c be remov$ = *eck+ &_/or replac+ )\t di/urb+ sprocket1 :i* is integral ) clut* %ell4 ,x is advisable to remove releas+ 7out]7 disk1 spr+s1 & coll> z an assembly because x is difficult to correctly al9e1 hold 9 place1 & reassemble spr+s 9 ?is unit4 ,if spr+s %[ signs ( ov]heat+1 & appe> to be 8set10 !y %\ld be remov$1 measur$1 & replac$ if necess>y 7p>4 #ej74 ,illu/ration3 ,,ra ,,pd #caegaf ,figure #bh--,remov+ ,spr+ & ,out] ,disk ,assembly 7#a7 ,remove out] front *a9 gu>d 7p>4 #ajb74 7#b7 ,remove pu% rod adju/+ screw lock nut4 ,place a l>ge flat wa%]1 approximately #a_/h-;in* ?ick1 #a-c_/d-;in* 9 diamet] ) a #c_/h-;in* c5t] hole1 ov] pu% rod adju/+ screw1 & replace adju/+ screw lock nut j remov$ 7fig4 #bh74 ,tight5 adju/+ screw lock nut aga9/ l>ge wa%] until ! ?ree clut* spr+ adju/+ nuts are free4 ,b5d nut lock d[n1 remove ! ?ree adju/+ nuts1 & )draw releas+ 7out]7 disk & spr+ assembly z "o unit4 ,rema9+ l9$ & pla9 /eel disks c n[ be remov$ f sprocket & clut* %ell unit )\t fur!r disassembly 7fig4 #cj74 ,,note3 ,at "t l9$ & pla9 disks are remov$ f %ell1 obs]ve relative position ( ea* disk 9 ord] ( correct assembly4 #ej4 ,,inspection ,,( ,,disks ,,& ,,spr+s4 a4 ,worn ,disk ,l9]s4 ,:5 disk l9]s are worn d[n flu% 7or ne>ly flu%7 ) rivet heads1 disk & l9] assembly mu/ be replac$4 ,illu/ration3 ,,ra ,,pd #caegag ,figure #bi--,out] ,assembly ,remov$1 ,expos+ ,clut* ,disks ,illu/ration3 ,,ra ,,pd #caegah ,figure #cj--;,clut* ,disks1 ,remov$ b4 ,loose ,l9] ,rivets4 ,if disk l9] rivets are loose1 replace disk & l9] assembly ) l assembly 9 new or good ord]4 c4 ,oilsoak$ ,disk ,l9]s4 ,if l9$ disks are n badly worn1 b are oilsoak$1 wa% !m ?or\ghly 9 clean gasol9e & dry ) air or heat4 d4 ,%runk5 or ,weak ,spr+s4 ,if clut* has be5 badly ov]heat$ z a result ( slippage1 spr+s may be f\nd 9 %runk5 or weak5$ condition4 ,assum+ disk l9]s are n badly worn1 weak5$ spr+s are indicat$ :5 ! ?ree spr+ t5sion nuts h be5 tight5$ to make ! clut* hold until ! di/ance betwe5 spr+ coll> & releas+ 7out]7 disk is in*4 ,if %runk5 or weak spr+s are suspect$1 remove !m = inspection4 7#a7 ,to remove spr+s1 remove pu% rod adju/+ screw lock nut1 free+ spr+ coll> & ! #aj spr+s f ! releas+ 7out]7 disk assembly4 7#b7 ,measure spr+s = free l5g?4 ,free l5g? ( new clut* spr+s is approximately #a-a_/b in*es 7!y may v>y plus or m9us #a_/cb in*74 ,old spr+s f\nd to be %runk #a_/h in* 7total free l5g? ( spr+ is #a-c_/h in* or less7 mu/ be replac$ ) new spr+s4 ,,note3 ,be=e replac+ spr+s1 select #aj spr+s t d n v>y m ?an #a_/cb in* to make up ! assembly4 7#c7 ,,assembl+ ,,releas+ ,,disk1 ,,spr+s1 ,,& ,,spr+ ,,coll>4 ,place ! #aj spr+s upright on releas+ disk to c5trally locate ea* ( ! #aj /ud holes4 ,place spr+ coll> 7flang$ edge d[n7 ov] ends ( spr+s1 locat+ ! coll> plate 8dimples0 9 ends ( #g ( ! spr+s4 ,place ! l>ge wa%] ov] pu% rod adju/+ screw2 tight5 adju/+ screw nut1 & compress spr+s lightly4 ,turn assembly ov] & obs]ve al9em5t ( spr+s & disk holes4 ,if necess>y1 ins]t a #c_/h-;in* rod ?r\gh holes to al9e spr+s4 ,tight5 d[n adju/+ screw nut2 assembly is n[ ready = complete clut* assembly4 #ea4 ,,in/allation ,,( ,,disks 7figs4 #cj1 #bi1 & #bh74 a4 ,x is important :5 assembl+ a clut* to />t ) a l9$ disk4 ,in/all ! two /eel disks s t ! antirattle devices are /agg]$ on spl9es 9 ! %ell1 & ! 8sprung0 disk 7l9$ on "o side7 is ! la/ ( ! pack1 its l9$ side fac+ ! /eel disk4 ,be=e in/all+ disks1 see t be>+ reta9+ plate lock r+s 78,r10 fig4 #ba7 are 9 place on ! %ort /uds1 & are tight aga9/ ! reta9+ plate4 ,?is is to prev5t noise 9 ! clut*4 7#a7 ,in/all "o ( ! two l9$ disks on clut* hub /uds fir/4 7#b7 ,next1 engage "o ( ! two /eel disks ) ! spl9es )9 ! clut* %ell1 ) side /amp$ 8,,out0 fac+ outw>d4 7#c7 ,in/all ! rema9+ l9$ disk on ! clut* hub /uds4 7#d7 ,engage rema9+ /eel disk ) %ell spl9es ) 8,,out0 side fac+ outw>d4 7#e7 ,in/all 8sprung0 7"o side l9$7 /eel disk1 l9$ side inw>d1 on clut* hub /uds4 7#f7 ,x w be not$ t ! ?ree long1 ?read$end1 clut* hub /uds are n spac$ an equal di/ance ap>t4 ,x w also be not$ t ! ?ree holes 7keyhole %ap$7 9 ! spr+ coll> are n spac$ equidi/antly4 ,!re=e1 :5 in/all+ releas+ disk & spr+ assembly on clut* hub /uds1 ! ?ree ?read$ /uds & holes 9 spr+ coll> mu/ be al9$4 ,in/all assembly on /uds1 replace ! ?ree nut locks1 replace ! ?ree adju/+ nuts1 & tight5 all ?ree ev5ly until ! di/ance betwe5 %\ld] ( spr+ coll> & face ( releas+ disk is #a-a_/cb in* 7fig4 #bg74 7#g7 ,remove ! l>ge wa%] & replace pu% rod adju/+ screw lock nut4 ,d n attempt adju/m5t ( clut* release lev] & pu% rod adju/+ screw until out] front *a9 gu>d & footbo>d h be5 in/all$4 ,illu/ration3 ,,ra ,,pd #caegai ,figure #ca--,remov+ ,clut* ,releas+ ,be>+ ,assembly 7#h7 ,in/all out] front *a9 gu>d 7p>4 #ajb74 7#i7 ,*eck controls & clut* adju/m5t4 ,if necess>y1 correct accord+ to p>agraph #dh4 #eb4 ,,replacem5t ,,( ,,clut* ,,release ,,be>+ 7fig4 #ca74 a4 ,clut* release lev] acts aga9/ a ?ru/ be>+ & pu% rod assembly :i* actuates clut* releas+ disk4 b4 ,remove ,clut* ,release ,be>+4 ,engage clut* fully 7foot p$al toe d[n7 & dis5gage clut* control cable end f slott$ end ( clut* release lev]4 7#a7 ,loos5 re> *a9 gu>d by remov+ cap screw :i* reta9s re> *a9 oil pipe & secures front end ( re> drive *a9 gu>d to transmission c\nt]%aft sprocket cov]4 7#b7 ,remove ! f\r nuts :i* secure sprocket cov] to transmission4 7#c7 ,remove fill] plug4 7#d7 ,hold d[n />t] crank ) screwdriv]4 7#e7 ,remove sprocket cov] & clut* release lev] assembly4 ,x may be necess>y to pry cov] (f /uds4 ,) cov] remov$1 clut* release be>+ is expos$4 7#f7 ,)draw clut* release be>+ & pu% rod assembly f transmission %aft4 c4 ,in/all ,clut* ,release ,be>+4 7#a7 ,ins]t pu% rod ) clut* release be>+ assembly into transmission %aft hole1 z f> z rod w g4 ,see t be>+ is clean & well greas$4 7#b7 ,in/all sprocket cov]4 ,securely tight5 ! f\r nuts4 7#c7 ,in/all cap screw :i* secures re> *a9 gu>d end & *a9 oil] pipe clamp to sprocket cov]4 7#d7 ,engage clut* control cable end 9 slott$ end ( clut* release lev]4 7#e7 ,*eck clut* release lev] = free play at end ( cable4 ,section ,,xiv ,,transmission ,p>agraph ,description #ec ,control l9kage #ed ,replacem5t ( foot />t] crank #ee ,replacem5t ( />t] crank spr+ #ef ,remove transmission #eg ,in/all transmission #eh #ec4 ,,description4 a4 ,transmission has ?ree spe$s3 l[1 second1 & high1 & is ( ! con/antme%1 nonselective type4 ,high ge> is direct drive4 ,s9ce 8dogs0 on ge> %ift] clut*es are us$ to engage transmission ge>s1 x is ( great importance t vehicle clut* is correctly adju/$4 ,clut* mu/ be fully dis5gag$ :5 %ift+ ge>s1 to prev5t cla%+ ( ge>s1 & possible damage to ! %ift] clut* 8dogs0 & transmission ge>s4 ,x is also important t ge> %ift] control l9kage be kept 9 correct adju/m5t to ensure full engagem5t ( %ift] clut* driv+ dogs 9 all positions1 ?us prev5t+ possible damage caus$ by dogs jump+ out ( engagem5t "u driv+ load4 ,close fitt+ & ne$le roll] be>+s1 )9 ! transmission1 necessitate use ( eng9e oil 7seasonal grade7 9 transmission case = adequate lubrication4 #ed4 ,,control ,,l9kage 7fig4 #cb74 a4 ,transmission ,%ift$ to ,adju/ ,front ,drive ,*a94 ,! transmission is locat$ to receive p[] f front 7eng9e7 drive *a9 & transmit p[] ?r\gh re> drive *a9 to re> :eel1 & is movable on its m\nt+ = adju/m5t ( ! front 7eng9e7 drive *a94 ,:5 front 7eng9e7 drive *a9 is adju/$1 transmission ge> %ift] control l9kage is affect$4 ,!re=e1 aft] ea* front drive *a9 adju/m5t1 ge> %ift] control l9kage mu/ be *eck$1 &1 if necess>y1 correctly adju/$ to ensure prop] ge> %ift+ ) full engagem5t ( ! ge> %ift] clut* driv+ 8dogs0 z well z prev5t transmission f jump+ out ( ge> "u load4 b4 ,*eck+ ,ge> ,%ift] ,control ,l9kage4 ,be=e mak+ adju/m5t to ge> %ift] control l9kage1 make ! foll[+ *ecks3 ,see t all l9kage po9ts f transmission ge> %ift] lev] to ge> %ift] h& lev] are well oil$ & freework+4 ,*eck h& lev] pivot bolt nut = tightness4 ,obs]ve :e!r !re is b9d+ or int]f]5ce ) %ift] rod at any po9t 9 ! %ift+ range2 ?is sometimes results f a b5t snift] rod4 ,*eck :e!r or n %ift] rod is correctly adju/$ s t :5 h& lev] is mov$ to any ge> position 9 tank %ift] guide1 transmission lev] moves to ! prop] position to fully engage %ift] clut* dogs & %ift] cam spr+ plung] 9 camlocat+ not* 7inside transmission74 ,illu/ration3 ,,ra ,,pd #cajbbi ,figure #cb--;,adju/+ ,ge> ,%ift] ,rod c4 ,adju/+ ,ge> ,%ift] ,control ,l9kage 7fig4 #cb74 7#a7 ,set h& lev] 9 8,n0 7neutral7 position 9 %ift] guide4 7#b7 ,remove nut & bolt to disconnect %ift] rod f h& lev]4 7#c7 ,) slight backw>d & =w>d movem5t ( %ift] rod1 c>efully 8feel0 transmission lev] into exact position :]e %ift] cam spr+ plung] 7inside transmission7 seats fully 9 camlocat+ not*4 7#d7 ,next1 see t h& lev] is 9 exact 8,n0 7neutral7 position 9 tank %ift] guide4 7#e7 ,readju/ l5g? ( %ift] rod by loos5+ rod end lock nut1 & turn+ rod end 7onto or (f rod z necess>y7 until its bolt hole l9es up ) bolt hole 9 h& lev]4 7#f7 ,replace bolt & tight5 nut4 7#g7 ,,*eck ,,adju/m5t4 ,x is advisable to %ift h& lev] into 8,l0 7l[7 & 8,s0 7second7 ge> positions & *eck %ift] rod adju/m5t to be sure ( hav+ be/ allr\nd adju/m5t4 7#h7 ,:5 %ift] clut*es become worn or damag$ to ! ext5t ( jump+ out ( engagem5t "u driv+ load1 ev5 ?\gh %ift] control l9kage is correctly adju/$1 transmission mu/ be remov$ & ref]r$ to high] au?ority = s]vice4 #ee4 ,,replacem5t ,,( ,,foot ,,/>t] ,,crank4 a4 ,remove4 7#a7 ,remove />t] crank clamp bolt nut & remove bolt f crank4 7#b7 ,pull />t] crank (f squ>$ %aft4 b4 ,in/all4 ,9 in/all+ foot />t] crank1 not* 7= clampbolt cle>ance7 mu/ be 9 upw>d position 9 squ>$ %aft to put return spr+ t5sion on crank4 7#a7 ,use a -in*1 op5end wr5* & turn squ>e %aft c\nt]clockwise until bolt slot is upw>d4 ,hold %aft 9 ?is position & press />t] crank onto %aft until clamp+ bolt c be ins]t$4 7#b7 ,ins]t clamp bolt ) bolt head t[>d re> :eel 7crank 9 upw>d position7 to provide cle>ance :5 />t] crank is op]at$4 7#c7 ,fit lock wa%] & nut & tight5 nut securely4 #ef4 ,,replacem5t ,,( ,,/>t] ,,crank ,,spr+ 7fig4 #cc74 a4 ,/>t] crank spr+ fits r snugly beh9d re> edge ( c\nt]%aft sprocket cov]2 h[ev]1 x c be remov$ & in/all$ )\t remov+ sprocket cov]4 b4 ,remove4 7#a7 ,remove foot />t] crank 7p>4 #ee74 7#b7 ,) ! blade ( a screwdriv] or ) pli]s1 pry hook$ end ( spr+ (f /ud4 ,,note3 ,if spr+ is brok51 ?is op]ation w n be necess>y4 ,pull on spr+ end1 at same "t pry+ spr+ free ( sprocket cov] s z to pull spr+ (f squ>e %aft4 c4 ,in/all4 7#a7 ,turn squ>$ %aft s t clamp bolt not* is 9 bottom position4 ,engage squ>e hole 9 spr+ on %aft ) ! hook$ spr+ end to re>1 9 l9e ) />t] spr+ /ud4 ,"w spr+ onto %aft1 pry+ x to re> to cle> sprocket cov]4 ,press all ! way on squ>$ %aft4 ,illu/ration3 ,,ra ,,pd #caegbj ,figure #cc--,remov+ ,/>t] ,crank ,spr+ 7#b7 ,hook end ( spr+ 9 place on spr+ /ud4 7#c7 ,in/all foot />t] crank 7p>4 #ee74 #eg4 ,,remove ,,transmission 7figs4 #cd & #ce74 a4 ,transmission & clut* are assembl$ 9 "o unit & mu/ be remov$ & in/all$ toge!r4 ,to make sure tr\ble is 9 transmission1 *eck clut* adju/m5t 7p>4 #dh7 & transmission control l9kage 7p>4 #ed7 be=e replac+ a faulty unit4 ,illu/ration3 ,,ra ,,pd #caegba ,a--,,tool ,,box ,,& ,,bracket ,,assembly ,,& ,,m\nt+ ,,bolt1 ,,wa%] ,,& ,,nut ,b--,,batt]y ,c--,,batt]y ,,box ,,re> ,,m\nt+ ,,bolts1 ,,wa%]s1 ,,fitt+s ,,& ,,nuts ,d--,,batt]y ,,box ,,assembly ,,& ,,cov] ,e--,,batt]y ,,box ,,front ,,m\nt+ ,,bolt1 ,,wa%]s ,,& ,,nut ,f--,,transmission ,,& ,,clut* ,,assembly ,g--,,front ,,*a9 ,,adju/+ ,,screw ,h--,,transmission ,,m\nt+ ,,/ud ,,nuts ,,& ,,wa%]s ,j--,,re> ,,*a9 ,,oil] ,,pipe ,k--,,re> ,,*a9 ,,gu>d ,,front ,,m\nt+ ,,bolt ,,& ,,wa%]s ,l--,,muffl] ,,assembly ,,& ,,atta*+ ,,bolt1 ,,wa%]s ,,& ,,nuts ,m--,,re> ,,brake ,,rod ,,assembly1 ,,wa%] ,,& ,,cott] ,,p9 ,n--,,re> ,,*a9 ,,gu>d ,o--,,re> ,,brake ,,clevis ,,p91 ,,wa%]s ,,& ,,cott] ,,p9 ,,ra ,,pd #caegba;,b ,figure #cd--;,disassembly = ,transmission ,removal f ,"r ,side b4 ,remove4 7#a7 ,drop re> end ( skid plate 7p>4 #aaa74 7#b7 ,remove front *a9 gu>d 7p>4 #ajb74 7#c7 ,remove oil ba? air clean] & m\nt+ bracket 7p>4 #hj74 ,l[] bracket bolt also secures clut* cable tube to frame tube bracket on left side4 7#d7 ,remove eng9e sprocket & front drive *a9 7p>4 #fe74 7#e7 ,remove ! two m\nt+ screws & locks 9 eng9e case to free inn] front *a9 gu>d4 7#f7 ,remove tool box f m\nt+ bracket 7p>4 #ajf74 ,remove bracket f frame4 7#g7 ,remove re> brake rod 7p>4 #if74 7#h7 ,remove re> drive *a9 7p>4 #fc74 7#i7 ,remove re> drive *a9 gu>d 7p>4 #ajb74 ,remove re> *a9 oil] pipe aft] disconnect+ at oil pump4 7#aj7 ,remove batt]y box 7p>4 #aje74 7#aa7 ,remove nut1 wa%]1 & bolt secur+ clut* tube assembly bracket to frame bracket on "r side ( vehicle4 ,dis5gage clut* op]at+ cable end f end ( clut* release lev] & remove cable & tube assembly4 7#ab7 ,remove ge> %ift] rod by disconnect+ at h& %ift] lev] & at transmission ge> %ift] lev]4 7#ac7 ,remove ! ?ree transmission m\nt+ /ud nuts1 !n remove lock wa%]s & l>ge pla9 wa%]s 7locat$ "u frame bracket71 & lift transmission suffici5tly to p]mit removal ( front *a9 adju/+ screw4 7#ad7 ,loos5 upp] ,ubolts on ignition coil m\nt+1 !n remove ! l[] ,ubolt nuts & %ift coil on frame tube z f> z possible t[>d ! front4 7#ae7 ,remove transmission & clut* assembly f vehicle by lift+ complete unit suffici5tly to free m\nt+ /uds f frame bracket2 !n rotate top ( transmission backw>d ab\t #a_/d turn 7fig4 #cd7 & remove unit f left side ( frame 7fig4 #ce74 #eh4 ,,in/all ,,transmission 7figs4 #cd & #ce74 a4 ,in/all f ,left ,side4 ,work+ f left side ( frame1 tilt top ( transmission backw>d1 & z unit passes into position1 rotate top =w>d1 until unit is squ>ely 9 position & m\nt+ /uds pass ?r\gh slots 9 frame m\nt+ bracket4 7#a7 ,%ift ignition coil m\nt+ back into correct position & tight5 ,ubolt nuts4 ,illu/ration3 ,,ra ,,pd #caegbb ,figure #ce--;,disassembly = ,transmission ,removal f ,left ,side ( ,vehicle ,a--,,left ,,footbo>d1 ,,clut* ,,p$al ,,& ,,sideb> ,,assembly ,,& ,,m\nt+ ,,nuts ,,& ,,wa%]s ,b--,,eng9e ,,sprocket1 ,,nut1 ,,key ,,& ,,front ,,*a9 ,c--,,inn] ,,*a9 ,,gu>d ,,m\nt+ ,,screws ,,& ,,locks ,d--,,inn] ,,*a9 ,,gu>d ,e--,,transmission ,,& ,,clut* ,,assembly ,f--,,out] ,,*a9 ,,gu>d ,g--,,out] ,,*a9 ,,gu>d ,,re> ,,m\nt+ ,,bolt1 ,,wa%]1 ,,spr+1 ,,nut ,,& ,,cott] ,,p9 ,h--,,air ,,clean] ,,& ,,bracket ,,assembly ,j--,,air ,,clean] ,,bracket ,,upp] ,,m\nt+ ,,bolt ,,nuts ,,& ,,wa%]s ,k--,,sp>k ,,coil ,,l[] ,,m\nt+ ,u,,bolt ,,nuts ,,& ,,wa%]s ,l--,,clut* ,,cable ,,& ,,h\s+ ,,assembly ,,& ,,m\nt+ ,,bolts1 ,,wa%]s ,,& ,,nuts ,m--,,ge> ,,%ift] ,,rod ,,assembly ,,) ,,atta*+ ,,bolt1 ,,wa%]s1 ,,p9 ,,& ,,nut ,,ra ,,pd #caegbb;,b ,leg5d = ,figure #ce--;,disassembly = ,transmission ,removal f ,left ,side ( ,vehicle 7#b7 ,in/all front *a9 adju/+ screw4 ,lift transmission to engage screw 9 frame not*4 7#c7 ,in/all l>ge pla9 wa%]s1 lock wa%]s1 & nuts on ! ?ree transmission m\nt+ /uds4 ,d n tight54 7#d7 ,in/all ge> %ift] rod by connect+ to h& %ift] lev] & transmission ge> %ift] lev]4 7#e7 ,in/all clut* op]at+ cable & tube assembly4 ,connect cable end to clut* release lev]4 ,position tube assembly bracket to frame bracket & in/all bolt1 wa%]1 & nut to hold 9 place4 7#f7 ,in/all batt]y box 7p>4 #aje74 7#g7 ,in/all re> drive *a9 gu>d 7p>4 #ajb74 7#h7 ,in/all re> drive *a9 7p>4 #fc74 7#i7 ,in/all re> brake rod 7p>4 #if74 7#aj7 ,in/all tool box bracket & tool box 7p>4 #ajf74 7#aa7 ,secure inn] front *a9 gu>d to eng9e base by in/all+ screw locks & screws4 ,aft] screws are tight5$1 drift edge ( ea* lock into screw slot = security4 7#ab7 ,in/all eng9e sprocket & front drive *a9 7p>4 #fe74 7#ac7 ,if necess>y1 adju/ front drive *a9 7p>4 #ei74 7#ad7 ,securely tight5 transmission m\nt+ /ud nuts4 7#ae7 ,in/all out] front *a9 gu>d cov] 7p>4 #ajb74 ,connect re> *a9 oil] pipe to oil pump4 7#af7 ,in/all air clean] & m\nt+ bracket1 air hose1 & connections 7p>4 #gi74 7#ag7 ,lift skid plate into position & in/all two m\nt+ bolts1 lock wa%]s1 & nuts4 7#ah7 ,*eck ge> %ift] control1 &1 if necess>y1 adju/ l9kage 7p>4 #ed74 7#ai7 ,*eck re> drive *a9 adju/m5t & adju/ if necess>y 7p>4 #fj74 7#bj7 ,*eck re> brake adju/m5t4 ,if necess>y1 adju/ re> brake l9kage 7p>4 #if74 7#ba7 ,*eck clut* controls & adju/ if necess>y 7p>4 #dh74 7#bb7 ,be=e op]at+ vehicle1 see t transmission oil level is up to fill] op5+ 7vehicle /&+ upright74 ,section ,,xv ,,*a9s ,,& ,,sprockets ,p>agraph ,adju/ front *a9 #ei ,adju/ re> *a9 & al9e re> :eel #fj ,*a9 oil]s #fa ,replacem5t ( front *a9 #fb ,replacem5t ( re> *a9 #fc ,*a9 repair tool #fd ,replacem5t ( eng9e sprocket #fe ,replacem5t ( c\nt]%aft sprocket #ff #ei4 ,,adju/ ,,front ,,*a9 7figs4 #cf1 #cg1 & #ch74 a4 ,at ! "t front *a9 adju/m5t is made1 inspect *a9 = correct lubrication &1 if necess>y1 adju/ front *a9 oil] 7p>4 #fa74 b4 ,*a9s we> unev5ly & "s /ret* may result1 mak+ tight & loose sections4 ,= ?is reason1 eng9e mu/ be turn$ & *a9 rotat$ to position ( lea/ slack at ! "t adju/m5t is made4 c4 ,a correctly adju/$ front *a9 has #a_/b-;in*1 or slightly m1 free up&d[n movem5t midway betwe5 sprockets1 at inspection hole4 ,*a9 mu/ nev] be run taut 7no slack at tighte/ po9t74 ,*a9 mu/ nev] be all[$ to run loose en\gh to cause j]ky1 noisy action &_/or /rike ! *a9 gu>d4 d4 ,adju/m5t ( front *a9 is made by %ift+ transmission on its m\nt+ base4 ,?is w affect adju/m5t ( ge> %ift] control l9kage1 clut* control l9kage1 & re> *a94 e4 ,h[ to ,adju/ ,front ,*a94 7#a7 ,remove inspection hole cov] by remov+ screws & lift+ cov] f front out] *a9 gu>d1 expos+ *a9 7fig4 #cf74 7#b7 ,obta9 tighte/ *a9 position by rotat+ *a9 to position ( lea/ slack4 ,te/ am\nt ( slack by lift+ & depress+ *a9 ) f+]4 ,use a free up&d[n motion ( ! f+] to make ?is te/4 7#c7 ,loos5 ! ?ree transmission m\nt+ /ud nuts und]nea? transmission m\nt+ base4 7,x is n necess>y to drop skid plate to rea* /ud nuts 7fig4 #cg747 ,transmission c n[ be %ift$ on its m\nt+ base by means ( adju/+ screw1 head ( :i* protrudes ?r\gh not* ( frame fitt+1 locat$ at re> ( transmission 7fig4 #ch74 ,illu/ration3 ,,ra ,,pd #cajbcc ,figure #cf--;,front ,*a9 ,inspection ,hole ,cov] ,remov$ 7#d7 ,turn adju/+ screw clockwise 7to ! "r7 to move transmission backw>d & tight5 front *a94 ,turn adju/+ screw c\nt]clockwise 7to ! left7 to move transmission =w>d & loos5 front *a94 7#e7 ,aft] mov+ transmission by means ( adju/+ screw1 *eck front *a9 adju/m5t2 !n securely tight5 ! ?ree transmission m\nt+ /ud nuts & aga9 *eck *a9 adju/m5t1 z tight5+ /ud nuts sometimes *anges *a9 adju/m5t4 7#f7 ,aft] front *a9 adju/m5t has be5 made1 securely tight5 ! ?ree transmission m\nt+ /ud nuts4 7#g7 ,in/all front *a9 inspection hole cov] & tight5 screws4 7#h7 ,*eck %ift] lev] control l9kage adju/m5t 7p>4 #ed74 7#i7 ,*eck clut* control l9kage adju/m5t 7p>4 #dh74 ,illu/ration3 ,,ra ,,pd #cajbcd ,figure #cg--,skid ,plate ,dropp$ to ,%[ ,location ( ,transmission ,m\nt+ ,nuts ,illu/ration3 ,,ra ,,pd #cajbce ,figure #ch--,transmission ,m\nt+ ,nuts & ,*a9 ,adju/+ ,screw #fj4 ,,adju/ ,,re> ,,*a9 ,,& ,,al9e ,,re> ,,:eel 7fig4 #ci74 a4 ,9 mov+ transmission backw>d on its m\nt+ to tight5 front *a91 ! re> *a9 w be loos5$4 ,re> *a9 mu/ !n be adju/$ by mov+ re> :eel backw>d4 ,:5 re> :eel is mov$ ei!r =w>d or backw>d1 adju/m5t ( ! re> :eel brake is affect$4 b4 ,:5 *eck+ re> *a9 = slack midway betwe5 ! sprockets1 turn :eel & rotate *a9 to position ( lea/ slack4 ,use free up&d[n movem5t ( f+] to lift *a9 & depress x to det]m9e tighte/ position4 ,illu/ration3 ,,ra ,,pd #cajbcf ,figure #ci--;,brake ,sleeve ,nut c4 ,at position ( lea/ slack1 a correctly adju/$ re> *a9 has #a_/b-;in*1 or slightly m1 free up&d[n movem5t midway betwe5 sprockets4 ,*a9 mu/ nev] be run taut 7no slack at tighte/ po9t74 ,*a9 mu/ nev] be all[$ to run loose en\gh to cause j]ky op]ation &_/or /rike ! *a9 gu>d or o!r *assis p>ts4 d4 ,at ! "t re> *a9 adju/m5t is made1 inspect *a9 = correct lubrication & if necess>y1 adju/ re> *a9 oil] 7p>4 #fa74 e4 ,re> *a9 adju/m5t & re> :eel al9em5t are bo? made by means ( ! re> :eel adju/+ screws4 ,!re=e1 adju/m5t ( ei!r ! *a9 or ! :eel al9em5t c affect adju/m5t ( ! o!r1 mak+ x necess>y to consid] bo? adju/m5ts at ! same "t4 7#a7 ,remove re> axle nut & lock wa%] 7"r side ( vehicle74 7#b7 ,loos5 brake sleeve nut en\gh to all[ brake assembly to slide backw>d or =w>d 9 frame m\nt+ 7fig4 #ci74 7#c7 ,loos5 ! two 7"r & left side7 re> :eel adju/+ screw lock nuts4 7#d7 ,turn :eel adju/+ screws clockwise 7to "r7 to move :eel & sprocket backw>d4 ,?is tight5s *a94 ,,note3 ,if *a9 is too tight1 turn :eel adju/+ screws c\nt]clockwise 7to left7 s t :eel c be %ift$ =w>d4 ,?is w loos5 *a94 ,always turn ! two :eel adju/+ screws an equal numb] ( turns 9 ord] to keep :eel al9$4 7#e7 ,*eck correct al9em5t ( :eel by not+ t tire 7n tire rim7 runs approximately midway betwe5 l[] re> frame tubes at ! po9t :]e tubes jo9 transmission m\nt+4 ,x is desirable to h tire run slightly clos] 7n m ?an #a_/af 947 to "r ?an to left side l[] tube4 ,a fur!r *eck ( al9em5t is obs]v+ t re> sprocket runs c5trally 9 *a94 ,,caution3 ,if re> :eel is n correctly al9$1 vehicle /e]+ w be affect$1 & sprockets w we> excessively on "o side4 7#f7 ,) adju/m5t ( *a9 & :eel al9em5t complet$1 securely tight5 :eel adju/+ screw lock nuts1 & brake sleeve nut3 replace axle lock wa%] & nut1 tight5+ nut4 7#g7 ,re*eck adju/m5t ( *a9 z tight5+ brake sleeve nut & axle nut sometimes *anges ! *a9 adju/m5t4 7#h7 ,aft] tight5+ re> *a91 re> brake may be f\nd too tight4 ,*eck & correct brake adju/m5t 7p>4 #if74 #fa4 ,,*a9 ,,oil]s 7fig4 #dj74 a4 ,bo? front & re> *a9s are automatically lubricat$ by eng9e oil pumps4 ,*a9 oil]s are adju/able & may ne$ occasional readju/m5t to meet lubrication requirem5ts ( v>i$ op]at+ conditions4 ,*a9s "u mo/ op]at+ conditions require a v small am\nt ( oil2 !re=e1 *a9 oil]s require v f9e adju/m5t to supply j en\gh oil )\t wa/e4 b4 ,:5 adju/+ *a9 oil]s1 x is advisable to add or remove only "o ?9 wa%] at a "t & inspect *a9 aga9 aft] vehicle has run approximately #ajj miles1 to det]m9e :e!r or n fur!r adju/m5t is necess>y4 c4 ,if inspection ( front *a9 ?r\gh inspection hole reveals t *a9 is n gett+ en\gh oil1 adju/ front *a9 oil] z foll[s3 7#a7 ,add ?9 7#j4jjb-;in* ?ick7 wa%] "u head ( front *a9 oil] adju/+ screw 7fig4 #dj74 ,d n remove any wa%]s already "u head ( screw4 7#b7 ,to *eck results1 ref] to /ep b above4 d4 ,evid5ce ( too mu* oil on front *a9 requires cutt+ d[n on *a9 oil]4 ,illu/ration3 ,,ra ,,pd #cajbcg ,figure #dj--;,*a9 ,oil]s 7#a7 ,to adju/ oil]1 remove ?9 7#j4jjb-;in* ?ick7 wa%] f "u head ( front *a9 oil] adju/+ screw 7fig4 #dj74 7#b7 ,to *eck results1 ref] to /ep b above4 e4 ,if inspection reveals t re> *a9 is n gett+ en\gh oil1 & t oil pipe end is op51 is n b5t1 & is direct$ on *a92 !n ! re> *a9 oil] mu/ be adju/$4 7#a7 ,adju/ oil] by add+ ?9 7#j4jjb-;in* ?ick7 wa%] "u head ( re> *a9 oil] adju/+ screw 7fig4 #dj74 ,d n remove any wa%]s already "u head ( screw4 7#b7 ,to *eck results1 ref] to /ep b above4 f4 ,evid5ce ( too mu* oil on re> *a9 7suppli$ by oil]7 requires cutt+ d[n on *a9 oil]4 7#a7 ,to adju/ oil]1 remove ?9 7#j4jjb-;in* ?ick7 wa%] f "u head ( re> *a9 oil] adju/+ screw 7fig4 #dj74 7#b7 ,to *eck results1 ref] to /ep b above4 g4 ,at #ajjj-mile int]vals1 loos5 bo? front & re> *a9 oil] adju/+ screws 7fig4 #dj7 two turns ea*4 ,d n remove screws4 ,/>t & idle eng9e #a m9ute1 !n tight5 screws firmly1 b d n =ce4 ,?is op]ation s]ves to flu% oil] control valves & re> *a9 oil] pipe4 #fb4 ,,replacem5t ,,( ,,front ,,*a94 a4 ,a new or orig9al duplex front *a9 is endless1 n provid$ ) connect+ l9k1 & eng9e sprocket mu/ be remov$ 9 ord] to remove or replace *a94 b4 ,remove4 7#a7 ,remove out] front *a9 gu>d 7p>4 #ajb74 7#b7 ,remove eng9e sprocket 7p>4 #fe74 ,*a9 c n[ be lift$ (f clut* sprocket4 c4 ,in/all4 ,:5 in/all+ a new front *a9 &_/or sprocket1 x may be necess>y to %ift transmission ahead 9 ord] to get *a9 on 7p>4 #ei e74 7#a7 ,clean eng9e %aft tap] & sprocket hole4 7#b7 ,place *a9 on clut* sprocket tee? & in/all sprocket 7p>4 #fe74 7#c7 ,*eck *a9 adju/m5t 7p>4 #ei74 7#d7 ,in/all out] front *a9 gu>d 7p>4 #ajb74 #fc4 ,,replacem5t ,,( ,,re> ,,*a9 7fig4 #da74 a4 ,remove4 ,support vehicle on re> /&4 ,) transmission 9 8,n0 7neutral7 position1 turn re> :eel until *a9 connect+ l9k is locat$ on re> sprocket tee?1 ab\t /raight back f axle4 7#a7 ,us+ pli]s1 lift split end ( connect+ l9k spr+ clip out ( l9k p9 not*1 tak+ c>e n to damage spr+ clip4 ,remove spr+ clip f o!r l9k p9 not*4 7#b7 ,pull (f l9k side plate & pu% l9k out ( *a9 ends4 ,replace connect+ l9k & spr+ clip 9 "o end ( *a9 to prev5t its loss4 ,illu/ration3 ,,ra ,,pd #cajbch ,figure #da--,re> ,drive ,*a9 & ,connect+ ,l9k 7#c7 ,pull on l[] half ( *a91 guid+ upp] "p :ile x rotates ar\nd c\nt]%aft sprocket1 until remov$4 ,if a new re> *a9 is to be in/all$1 "o end c be l9k$ to ! upp] half end ( old *a9 & c be pull$ onto c\nt]%aft sprocket z old *a9 is remov$4 b4 ,in/all4 ,:5 in/all+ a new re> *a9 &_/or c\nt]%aft sprocket1 x may be necess>y to set re> :eel ahead 9 ord] to get *a9 on 7p>4 #fj74 7#a7 ,/>t end ( *a9 ov] c\nt]%aft sprocket tee?1 us+ />t] crank to turn sprocket4 ,aft] *a9 end has rea*$ front half ( sprocket1 x w be necess>y to guide end "u sprocket & out ( sprocket cov]4 ,c5t] *a9 s t ends engage re> sprocket tee?1 back ( ! axle4 7#b7 ,in/all connect+ l9k1 side plate & spr+ clip4 ,see t op5 end ( spr+ clip is to ! re> ) reg>d to *a9 travel 7l ! end ( an arr[74 ,if orig9al spr+ clip is b5t or damag$1 use a new "o4 7#c7 ,adju/ re> *a9 7p>4 #fj74 7#d7 ,*eck re> brake adju/m5t 7p>4 #if74 #fd4 ,,*a9 ,,repair ,,tool 7fig #db74 a4 ,damag$ or brok5 *a9 l9ks c be replac$ ) connect+ 7repair7 l9ks aft] bad l9ks h be5 remov$4 ,to remove damag$ or brok5 l9k1 pu% out *a9 side plate p9s ) ! *a9 repair tool 7#da-,t-#ccbj74 ,front *a9 is a d\ble r[ ( duplex *a92 re> *a9 is a s+le r[ *a94 ,! *a9 tool furni%$ 9 ! tool kit is design$ to accommodate bo?4 ,to put a connect+ l9k 9 ! front *a91 x w be necess>y to remove front *a9 gu>d 7p>4 #ajb74 ,illu/ration3 ,,ra ,,pd #cajbci ,figure #db--;,*a9 ,repair ,tool 9 ,use b4 ,:5 connect+ 7repair7 l9ks h be5 fitt$ to *a91 make sure t spr+ clips are correctly & securely lock$ on l9k p9 ends4 #fe4 ,,replacem5t ,,( ,,eng9e ,,sprocket4 a4 ,remove4 7#a7 ,remove front out] *a9 gu>d 7p>4 #ajb74 7#b7 ,remove eng9e sprocket nut 7"rh& ?read74 ,x w be necess>y to /rike wr5* ) a hamm] to loos5 nut4 7#c7 ,give flat surface ( eng9e sprocket1 ne> out] edge1 a light b %>p rap ) a hamm]1 be+ c>eful n to /rike & damage sprocket tee?4 ,take c>e n to lose sprocket %aft key4 b4 ,in/all4 ,if new sprocket is be+ in/all$1 x may be necess>y to %ift transmission =w>d to get *a9 to fit on sprockets 7p>4 #ei74 7#a7 ,?or\ghly clean eng9e %aft tap] & see t key is 9 place4 ,clean sprocket tap] hole1 fit front *a9 on sprocket tee?1 & rotate *a9 until keyway 9 sprocket l9es up ) key 9 eng9e %aft4 ,slip sprocket onto eng9e %aft1 in/all nut1 & tight5 securely4 ,/rike wr5* ) a hamm] to make sure sprocket nut is v tight4 7#b7 ,in/all front out] *a9 gu>d 7p>4 #ajb74 #ff4 ,,replacem5t ,,( ,,c\nt]%aft ,,sprocket4 a4 ,remove4 7#a7 ,remove foot />t] crank 7p>4 #ee74 7#b7 ,remove />t] crank spr+ 7p>4 #ef74 7#c7 ,remove c\nt]%aft sprocket cov] 7p>4 #eb74 7#d7 ,b5d back ext5sion ( sprocket nut lock4 7#e7 ,remove sprocket reta9+ nut4 ,x w be necess>y to /rike wr5* ) a hamm] to loos5 nut4 7#f7 ,give sprocket a light b %>p rap ) a hamm] ne> out] edge1 be+ c>eful n to /rike ! sprocket tee?1 & remove sprocket f %aft tap]4 ,d n lose ! two sprocket %aft keys4 b4 ,in/all4 7#a7 ,clean %aft tap] & tap] hole 9 c\nt]%aft sprocket4 ,in/all ! two keys4 7#b7 ,in/all sprocket on %aft4 ,place re> *a9 on sprocket be=e in/all+ sprocket cov]4 7#c7 ,exam9e nut lock &1 if badly damag$1 use a new "o4 7#d7 ,in/all sprocket reta9+ nut4 ,tight5 by /rik+ wr5* ) a hamm]4 ,,note3 ,?is nut mu/ be tight4 ,b5d up ext5sion ( nut lock aga9/ side ( nut4 7#e7 ,x w be easi] to in/all />t] crank spr+ at ?is /ep to avoid int]f]5ce ) sprocket cov]4 7#f7 ,in/all sprocket cov]4 7#g7 ,in/all />t] crank4 ,section ,,xvi ,,fuel ,,sy/em ,p>agraph ,g5]al #fg ,c>buretor adju/m5t #fh ,?rottle control wire adju/m5t #fi ,c>buretor removal #gj ,c>buretor in/allation #ga ,fuel /ra9] #gb ,c>buretor b[l clean+ #gc ,fuel pipe #gd #fg4 ,,g5]al4 a4 ,c>buretor is ( ! sideoutlet1 pla9tube type ) a fix$ v5turi4 ,fuel fe$ is by gravity f tank above4 ,c>buretor has two manual controls3 ! ?rottle1 :i* is op]at$ by ! "r h&le b> grip1 & ! *oke1 :i* is op]at$ by a lev] on ! c>buretor itself4 ,! high spe$ fuel supply is gov]n$ by a fix$ 7nonadju/able7 jet4 ,! idl+ to m$ium spe$ 7#cj mph7 fuel supply is gov]n$ by an adju/able 7l[ spe$7 ne$le valve locat$ on re> side ( c>buretor body4 #fh4 ,,c>buretor ,,adju/m5t 7fig4 #dc74 a4 ,be=e attempt+ to adju/ c>buretor to correct faulty eng9e p]=mance1 att5tion %\ld be giv5 o!r items :i* h a direct be>+ on & c affect c>buretor adju/m5t z well z eng9e p]=mance4 7#a7 ,inspect fuel tank cap & make sure air v5t is n plugg$4 7#b7 ,see t ?rottle control adju/m5t is correct 7p>4 #fi74 7#c7 ,see t sp>k control adju/m5t is correct 7p>4 #hh74 7#d7 ,dra9 & flu% c>buretor b[l 7p>4 #gc74 7#e7 ,dra9 & flu% fuel /ra9] 7p>4 #gb74 7#f7 ,inspect air clean] to see t passage ( air ?r\gh clean] is n re/rict$ by oil level be+ too high 9 oil cup1 or by an excessive accumulation ( dirt 9 filt] elem5ts 7p>4 #gf74 7#g7 ,*eck manifold pack+ nuts & c>buretor m\nt+ screws = tightness4 7#h7 ,see t sp>k plugs are clean & t gaps are adju/$ betwe5 #j4jbe in* to #j4jcj in*4 ,if condition ( sp>k plugs is que/ionable1 in/all new ones4 7#i7 ,*eck adju/m5t ( valve tappets 7p>4 #dc74 7#aj7 ,*eck compression ( bo? cyl9d]s 7p>4 #bi b47 7#a7 7#aa7 ,*eck condition & adju/m5t ( circuit break] po9ts 7p>4 #hd74 7#ab7 ,*eck ignition to batt]y wir+ connections 7diagram fig4 #dh74 7#ac7 ,see t batt]y is n entirely dis*>g$ by turn+ on lights 7tactical situation p]mitt+7 & obs]v+ brilliancy4 b4 ,a c>buretor1 once correctly adju/$1 %\ld require little1 if any1 readju/+4 ,at mo/1 x %\ld n be necess>y to adju/ ! l[ spe$ ne$le m ?an "o or two not*es ei!r way to correct mixture to meet *anges 9 wea!r conditions4 c4 ,l[ ,spe$ ,adju/+ ,ne$le 7figs4 #dc & #dd74 ,adju/m5t ( ?is ne$le valve controls only idl+ & l[ spe$ 7up to approximately #cj mph7 fuel mixture4 ,turn ne$le valve d[n 7to "r7 to make mixture lean]4 ,back out 7to left7 ne$le valve to make mixture ri*]4 ,ne$le valve is held 9 any desir$ position by a spr+&ball plung] :i* engages not*es 9 ! ne$le adju/+ screw4 d4 ,complete ,readju/m5t ( ,c>buretor4 ,a c>buretor t is badly out ( adju/m5t1 &_/or a new c>buretor j in/all$1 mu/ be adju/$ z foll[s3 7#a7 ,turn ! l[ spe$ ne$le valve all ! way d[n 7to "r74 7#b7 ,back ne$le valve out 7to left7 ab\t ?ree full turns4 ,) ne$le valve 9 ?is position1 eng9e w />t1 b mixture w probably be too ri*4 7#c7 ,/>t eng9e z foll[s3 ,aft] *oke lev] has be5 mov$ to normal op5 runn+ position & eng9e is normally hot1 correct adju/m5t ( ne$le valve by turn+ ne$le valve d[n 7to "r7 "o not* at a "t until mixture becomes s lean t eng9e misses1 & is incl9$ to /op3 !n back out 7to left7 ne$le valve #e to #aj not*es1 or until eng9e fires regul>ly ) sp>k advanc$ & ?rottle clos$ 7or z ne>ly clos$ z x c be set & /ill h eng9e runn+ at idl+ spe$74 7#d7 ,adju/ ?rottle lev] /op screw 7fig4 #dc7 z necess>y to make eng9e idle at prop] spe$ ) ?rottle 9 fully clos$ position4 ,turn+ /op screw to ! "r makes eng9e idle fa/]4 ,turn+ /op screw to ! left makes eng9e idle sl[]4 ,d n idle eng9e at ! sl[e/ possible spe$1 because an extremely sl[ idl+ adju/m5t causes h>d eng9e />t+4 ,*ang+ idl+ spe$ ) ?rottle /op screw is likely to *ange ! l[ spe$ fuel mixture to "s ext5t3 !re=e1 x w be necess>y to aga9 *eck & correct ! l[ spe$ ne$le valve adju/m5t 7/ep 7#c7 above74 7#e7 ,eng9e />t+ & allr\nd c>buretion w be improv$ ) l[ spe$ fuel adju/m5t slightly ri*1 r ?an extremely lean4 ,illu/ration3 ,,ra ,,pd #cajbdj ,figure #dc--,?rottle 9 ,fully ,clos$ ,position ,illu/ration3 ,,ra ,,pd #cajbda ,figure #dd--,?rottle 9 ,fully ,op5 ,position #fi4 ,,?rottle ,,control ,,wire ,,adju/m5t 7figs4 #dc & #dd74 a4 ,c>buretor ?rottle is op5$ & clos$ by means ( ! "r h&le b> grip1 op]at+ a control wire 7)9 a h\s+7 :i* connects to ! ?rottle lev]4 ,adju/m5t = full op5+ & clos+ ( ! ?rottle to correspond ) full inw>d & outw>d motion ( ! h&le b> grip is made at ! junction ( ! control wire end & ! ?rottle lev] connection4 b4 ,adju/ ,fully ,clos$ ,?rottle 7fig4 #dc74 ,see t !re is ab\t #a in* di/ance betwe5 end ( control wire h\s+ & ?rottle lev] :5 9 fully clos$ position1 s t h\s+ end does n int]f]e ) =w>d movem5t ( ?rottle lev]4 ,if adju/m5t ( control wire h\s+ is necess>y1 ref] to p>agraph #aja4 ,proce$ ) clos$ ?rottle adju/m5t4 7#a7 ,loos5 control wire clamp screw 9 connector block4 7#b7 ,turn "r h&le b> grip outw>d z f> z x w g3 !n turn x inw>d slightly4 ,hold+ ?rottle grip 9 ?is position1 move ?rottle lev] =w>d aga9/ its /op 7clos$ position7 & secure control wire 9 connector block ) clamp screw4 ,*eck clos+ ( ?rottle aft] tight5+ control wire set screw4 ,if necess>y1 reset ! control wire 9 ! connector block until ?rottle is clos$ ) full outw>d grip movem5t4 c4 ,adju/ ,fully ,op5 ,?rottle 7fig4 #dd74 ,foll[ in/ructions "u /ep b above1 !n3 7#a7 ,turn "r h&le b> grip inw>d z f> z x w g & see t ?rottle lev] is aga9/ its /op 9 fully op5 position4 ,if ?rottle does n op5 fully :5 grip is turn$ inw>d1 reset ! control wire 9 ! connector block to correct ! adju/m5t4 #gj4 ,,c>buretor ,,removal4 a4 ,remove ,c>buretor = ,replacem5t ,only4 7#a7 ,%ut (f fuel supply valve4 7#b7 ,loos5 connector block clamp screw & disconnect ?rottle control wire at ?rottle lev]4 7#c7 ,disconnect fuel fe$ pipe at /ra9] nipple4 7#d7 ,loos5 air clean] hose clamp at c>buretor air intake fitt+1 & remove f\r screws & air intake fitt+ f c>buretor4 7#e7 ,remove ! ?ree m\nt+ bolts 7f "r side ( vehicle7 :i* secure c>buretor to manifold flange4 ,,caution3 ,take c>e n to damage or lose gaskets f\nd betwe5 c>buretor flange & manifold flange1 &_/or #a_/b-;in* ?ick /eel spac] fitt$ betwe5 c>buretor & manifold on "s models4 7#f7 ,remove c>buretor4 7#g7 ,remove fuel /ra9] assembly f c>buretor b[l nipple4 #ga4 ,,c>buretor ,,in/allation a4 ,:5 in/all+ c>buretor be sure to fit ! #a_/b-;in* ?ick /eel spac] 7if "o 0 orig9ally fitt$7 betwe5 c>buretor & manifold flanges1 ) two gaskets on "o side & "o gasket on ! o!r side4 ,lat] models h a long] manifold neck1 ext5d+ c>buretor f>!r to ! left1 away f cyl9d]s1 & d n ne$ ! spac]4 7#a7 ,in/all fuel /ra9] assembly on b[l nipple4 ,leave c\pl+ nut loose until aft] fuel pipe is connect$4 ,illu/ration3 ,,ra ,,pd #cajbdb ,figure #de--,remov+ ,fuel ,/ra9] 7#b7 ,to in/all c>buretor on manifold1 locate c>buretor flange & two gaskets 7#a_/b-;in* /eel spac] & gaskets if orig9ally fitt$7 to al9e ) holes 9 manifold flange1 & ins]t & securely tight5 ! ?ree c>buretor m\nt+ screws4 ,use a #g_/af-;in* socket wr5*1 or a l>ge screwdriv]1 to securely tight5 ^! screws4 ,,note3 ,if c>buretor manifold is loose 9 manifold pack+ nuts 7c>buretor c be lift$ & manifold turns 9 pack+ nuts71 tight5 manifold nuts securely1 us+ manifold wr5* 7#da-,w-#aegj-aj74 7#c7 ,ins]t c>buretor air intake fitt+ into end ( air hose & m\nt fitt+ on c>buretor ) ! f\r screws4 ,tight5 air hose clamp4 7#d7 ,connect fuel pipe to fuel /ra9] nipple by tight5+ ! union nut & also ! /ra9] union nut on b[l nipple4 7#e7 ,atta* ?rottle control wire to ?rottle lev] connector block & adju/ 7p>4 #fi74 7#f7 ,op5 fuel supply valve & obs]ve = leaks4 7#g7 ,adju/ c>buretor 7p>4 #fh74 #gb4 ,,fuel ,,/ra9] 7fig4 #de74 a4 ,clean+4 7#a7 ,%ut (f fuel supply valve4 7#b7 ,unscrew cap f bottom ( /ra9] body4 7#c7 ,lift /ra9] scre5 elem5t ) cork wa%] out ( cap & clean ?or\ghly4 ,remove any dirt or s$im5t collect$ 9 cap4 ,,note3 ,if compress$ air is n available = clean+1 gasol9e f ! fuel pipe c be us$ = clean+ scre5 & cap4 7#d7 ,in/all "o cork wa%] 9 bottom ( cap1 set /ra9] scre5 elem5t 9 place1 & locate ! o!r cork wa%] ov] scre5 elem5t4 ,turn cap ) scre5 elem5t & wa%]s onto bottom ( /ra9] body1 h&tight4 b4 ,remove ,/ra9] ,assembly4 7#a7 ,%ut (f fuel supply valve4 7#b7 ,disconnect fuel fe$ pipe at /ra9] body nipple4 7#c7 ,remove filt] assembly f c>buretor b[l nipple4 ,x w be not$ t c\pl+ nut is an integral "p ( ! filt] body assembly4 c4 ,in/all ,/ra9] ,assembly4 7#a7 ,in/all fuel /ra9] assembly on c>buretor b[l nipple4 ,leave c\pl+ nut loose until aft] fuel pipe is connect$4 7#b7 ,connect fuel pipe to /ra9] body nipple & tight5 union nut4 ,/ra9] c\pl+ nut c n[ be tight5$ on b[l nipple4 7#c7 ,op5 fuel supply valve4 ,inspect fuel pipe & c\pl+ nuts = leaks4 #gc4 ,,c>buretor ,,b[l ,,clean+4 a4 ,wat] f fuel1 wat] moi/ure1 & dirt ent]+ air clean] w settle 9 bottom ( c>buretor b[l & w int]f]e ) eng9e />t+ & c>buretion4 ,at p]iodic int]vals b[l mu/ be dra9$4 ,,note3 ,be=e dra9+ & flu%+ b[l1 clean fuel /ra9] 7p>4 #gb74 7#a7 ,support vehicle on jiffy 7side7 /&4 7#b7 ,%ut (f fuel supply valve4 7#c7 ,remove b[l dra9 screw4 ,let fuel1 wat]1 & dirt run out ( b[l4 ,) dra9 screw /ill remov$1 op5 fuel supply valve 7turn to left7 & leave op5 only a few seconds1 to all[ fre% gasol9e to flu% out b[l4 7#d7 ,replace b[l dra9 screw1 tak+ c>e to avoid ?read cross+4 ,set screw snug1 b n tight en\gh to /rip ! ?reads4 #gd4 ,,fuel ,,pipe4 a4 ,remove4 7#a7 ,%ut (f fuel supply valve4 7#b7 ,remove pipe union nut f tank nipple4 ,remove pipe aft] disconnect+ union nut f fuel /ra9] body nipple4 b4 ,in/all4 ,fuel pipe mu/ be in/all$ )\t putt+ undue twi/ or /ra9 on pipe or end fitt+s4 ,!re=e1 b5d &_/or %ape pipe to 8fit0 betwe5 nipple connections be=e replac+ & draw+ up on union nuts4 7#a7 ,connect l[] end ( pipe to fuel filt] body nipple4 ,d n tight5 nut4 7#b7 ,connect upp] end ( pipe to tank nipple4 ,securely tight5 ?is nut4 ,next1 tight5 union nut on /ra9] body nipple4 ,section ,,xvii ,,intake ,,& ,,exhau/ ,,sy/em ,p>agraph ,description #ge ,air clean] #gf ,hose & c>buretor fitt+ #gg ,remove air clean] #gh ,in/all air clean] #gi ,replacem5t ( air clean] m\nt+ bracket #hj ,exhau/ sy/em #ha #ge4 ,,description4 a4 ,intake ,sy/em4 ,! air intake sy/em consi/s ( oil ba? air clean]1 connect+ air hose1 & c>buretor intake hose fitt+4 ,?is sy/em is locat$ on left side ( vehicle4 b4 ,exhau/ ,sy/em4 ,! exhau/ sy/em consi/s ( muffl] & tailpiece assembly1 front exhau/ pipe assembly1 & re> exhau/ pipe4 ,exhau/ pipe ends are a slip fit 9 cyl9d] exhau/ ports4 #gf4 ,,air ,,clean] 7figs4 #df & #dg74 a4 ,g5]al4 ,air clean] %\ld n be subm]g$ 9 wat]1 nor %\ld highpressure /ream be direct$ into clean] l\v]s 7:]e air ent]s on re> ( body7 :5 clean+ vehicle4 ,ei!r wat] or dirt ent]+ air clean] 9 excessive quantities w raise ! oil level 9 oil cup & *oke (f prop] air supply to c>buretor4 b4 ,s]vice4 ,) vehicle 9 normal use on h>dsurfac$ roads1 clean & refill air clean] oil cup ) eng9e oil 7seasonal grade7 at lea/ ea* "t eng9e oil tank is dra9$ & refill$4 ,,caution3 ,s]vice m frequ5tly "u du/y conditions2 daily "u extremely du/y conditions4 ,*eck oil supply daily4 7#a7 ,hold oil cup ) "o h& & release 7unlat*7 oil cup reta9+ spr+ clips to remove oil cup4 7#b7 ,if oil 9 cup is clean1 ) no signs ( dirt & grit 9 oil or cup1 b ! oil level is bel[ ! indicat$ level m>k1 add eng9e oil 7seasonal grade7 to br+ level up to m>k4 ,,note3 ,if oil & cup are dirty1 empty out oil & wa% out cup ) dryclean+ solv5t4 ,refill ) clean eng9e oil 7seasonal grade7 to indicat$ level m>k4 7#c7 ,be=e in/all+ oil cup make sure t ! oil cup gasket is 9 place & 9 good condition4 7#d7 ,*eck baffle plate ?umb screw = tightness4 ,illu/ration3 ,,ra ,,pd #cajbdc ,figure #df--;,air ,clean] ,oil ,cup ,remov$ 7#e7 ,in/all oil cup1 mak+ sure t reta9+ spr+ clips are fully engag$ 9 lip ( oil cup & hold oil cup securely to clean] body4 7#f7 ,oil ba? air clean]s on e>li] models are ( 8r\nd0 type1 oil cup be+ secur$ to body ) a metal clamp b& & ?umb screw4 ,:5 oil cup is remov$ on ?is type ( clean]1 ! baffle plate w come out ) ! cup4 ,make sure t baffle plate is correctly in/all$ & t gasket is 9 place :5 in/all+ cup4 c4 ,ma9t5ance 7fig4 #dg74 ,! rectangul>type oil ba? air clean] is provid$ ) two filt] elem5ts1 reta9$ 9 filt] body by means ( ! baffle plate4 ,if daily *eck reveals excessive accumulation ( dirt & grit 9 oil & cup1 filt] elem5ts mu/ be remov$ & clean$4 ,,note3 ,*eck sev]al times daily "u extremely du/y or s&y conditions4 7#a7 ,hold oil cup ) "o h& & release 7unlat*7 oil cup reta9+ spr+ clips2 remove cup4 7#b7 ,unscrew baffle plate ?umb screw & remove baffle plate4 7#c7 ,filt] elem5ts may 8b9d0 9 clean] body4 ,if s1 rap side ( body ) h& to loos5 !m2 or1 if necess>y1 )draw elem5ts f body ) pli]s or a hook$ wire4 7#d7 ,*eck = pres5ce & condition ( gasket above ! two filt] elem5ts 79 filt] body72 also = oil cup gasket4 ,illu/ration3 ,,ra ,,pd #cajbdd ,figure #dg--;,air ,clean]1 ,disassembl$ 7#e7 ,clean bo? filt] elem5ts ?or\ghly 9 dryclean+ solv5t4 ,all[ elem5ts to dry out 7use air hose if available74 7#f7 ,clean oil cup & refill to indicat$ level m>k4 ,use clean eng9e oil 7seasonal grade74 7#g7 ,dip "o scre5 surface ( ea* filt] elem5t ab\t #a_/b in* into oil 9 ! oil cup 7to 8oil wet0 filt] pack74 ,in/all ! two filt] elem5ts1 baffle plate1 & oil cup imm$iately aft] 8oil wett+0 ! filt] elem5ts4 ,make sure gaskets are 9 place4 ,,note3 ,d n add m oil to oil cup aft] elem5ts h be5 dipp$ into x1 because excess oil absorb$ by elem5ts w drip back into oil cup1 br++ level back to normal4 7#h7 ,r\ndtype oil ba? air clean] us$ on e>li] models does n h removable filt] elem5t4 ,complete clean] body mu/ be remov$ f vehicle1 imm]s$ & agitat$ 9 clean+ solv5t to wa% out dirt4 ,aft] clean+1 all[ filt] elem5t to dry 7use air hose if available71 !n apply a few squirts ( eng9e oil to inside ( clean] elem5t1 us+ oilcan4 ,refill cup1 replace baffle plate & cup1 securely tight5+ clamp b& ?umb screw4 #gg4 ,,hose ,,& ,,c>buretor ,,fitt+4 a4 ,remove4 ,c>buretor intake & hose connection mu/ be remov$ f c>buretor to remove &_/or in/all air hose4 7#a7 ,loos5 screws 9 ! two hose clamps4 7#b7 ,remove f\r screws reta9+ c>buretor air intake fitt+4 ,remove c>buretor fitt+ f end ( hose1 & pull hose (f air clean] body connection4 b4 ,in/all4 ,be=e in/all+ air hose1 inspect = breaks or faulty condition t might prev5t airtight seal betwe5 air clean] & c>buretor fitt+4 7#a7 ,in/all "o end ( hose on c>buretor fitt+4 ,d n tight5 clamp screw4 7#b7 ,in/all o!r end ( hose on air clean] connection4 ,d n tight5 clamp screw4 7#c7 ,in/all c>buretor fitt+4 ,securely tight5 ! f\r screws4 ,next1 c5t] air hose betwe5 c>buretor fitt+ & air clean] connection & securely tight5 hose clamp screws4 #gh4 ,,remove ,,air ,,clean]4 a4 ,loos5 hose clamp screw at air clean] body connection & remove two nuts & ge>too!d wa%]s f bolts secur+ air clean] assembly to frame bracket4 ,,note3 ,ge>too!d lock wa%]s are also us$ "u heads ( ! two m\nt+ bolts4 ,)draw clean] f end ( air hose4 b4 ,! same proc$ure applies to r\ndtype air clean]s us$ on e>li] models4 #gi4 ,,in/all ,,air ,,clean]4 a4 ,engage air clean] hose connection 9 end ( hose & m\nt clean] assembly on frame bracket ) two bolts1 ge>too!d lock wa%]s1 & nuts4 ,securely tight5 m\nt+ nuts4 ,,note3 ,! plat$ 7:it5$7 m\nt+ bolts1 f\r ge>too!d lock wa%]s1 & bolt nuts mu/ effect a gr\nd connection betwe5 bracket & filt] m\nt+ to insure adequate radio bond+4 ,tight5 air hose clamp screw at clean] body connection4 b4 ,! same proc$ure applies to r\ndtype air clean]s us$ on e>li] models4 #hj4 ,,replacem5t ,,( ,,air ,,clean] ,,m\nt+ ,,bracket4 a4 ,air clean] m\nt+ bracket & air clean] c be remov$ or in/all$ z an assembly4 b4 ,remove4 7#a7 ,loos5 hose clamp connection at air clean] body4 7#b7 ,disconnect batt]y gr\nd wire4 ,?is prev5ts %ort+ batt]y :5 remov+ clean] bracket clamp bolt4 7#c7 ,remove ! two upp] clean] bracket frame clamp bolts4 7#d7 ,remove l[] m\nt+ bolt4 ,clean] l[] bracket m\nt+ & clut* cable tube m\nt+ are secur$ to frame bracket by ! same :it5$ radio bond+ bolt1 ge>too!d lock wa%]s1 & nut4 ,remove nut & drop bolt to free clean] bracket4 c4 ,in/all4 7#a7 ,engage air hose & clean] body connection4 7#b7 ,atta* l[] bracket fir/4 ,locate clean] bracket s t hole l9es up ) bolt holes 9 frame bracket & clut* cable tube m\nt+4 ,pass :it5$ radio bond+ bolt upw>d ?r\gh bracket hole1 in/all %akepro( lock wa%]1 & securely tight5 nut4 7#c7 ,atta* bracket to ! two upp] frame clips4 ,tight5 ! clamp bolt nuts4 7#d7 ,connect batt]y gr\nd wire4 7#e7 ,tight5 air hose clamp screw at clean] connection4 #ha4 ,,exhau/ ,,sy/em4 a4 ,remove ,muffl] ,assembly4 7#a7 ,support vehicle on re> /&4 7#b7 ,remove bolt f end ( hang] bracket on left side ( vehicle1 & remove bolt f muffl] clamp & skid plate bracket on "r side ( vehicle4 ,drop skid plate4 7#c7 ,loos5 nut & bolt on clamp :i* secures front end ( muffl] at exhau/ pipe connection 7clamp is atta*$ to muffl]74 7#d7 ,remove muffl] re> hang] bracket bolt nut4 ,pull muffl] assembly free f exhau/ pipe connection4 b4 ,in/all ,muffl] ,assembly4 7#a7 ,engage muffl] pipe & exhau/ pipe at muffl] pipe clamp connection4 ,d n tight5 clamp bolt nut z yet4 7#b7 ,atta* muffl] re> hang] bracket to frame bracket bolt1 in/all+ lock wa%]1 & tight5+ nut4 ,,note3 ,x may be advisable to loos5 hang] bracket on muffl] s t muffl] c be l9$ up = front end connection4 7#c7 ,tight5 muffl] & exhau/ pipe clamp bolt nut & re> hang] nut4 7#d7 ,raise skid plate into position & in/all "r side m\nt+ bolt :i* secures muffl] front bracket & skid plate bracket to frame clip4 ,tight5 all m\nt+ nuts4 c4 ,remove ,exhau/ ,pipes4 7#a7 ,ref] to /ep a 7#a71 7#b71 7#c7 above4 7#b7 ,remove "r side footbo>d & brake p$al assembly z foll[s3 ,loos5 footbo>d re> support /ud nut1 remove front support /ud nut1 & pull footbo>d outw>d to free end ( safety gu>d4 ,remove bolt :i* secures front exhau/ pipe clamp1 & remove nut f re> support rod1 free+ /op light swit* & re> end ( footbo>d sideb>4 ,remove nut f front support rod1 & drop footbo>d & brake foot p$al assembly to provide cle>ance = exhau/ pipe removal4 ,dis5gage re> exhau/ pipe at cyl9d] port1 at same "t pry+ & pull+ front exhau/ pipe =w>d & d[nw>d to free f cyl9d] port4 ,bo? exhau/ pipes c n[ be work$ d[nw>d & remov$ f vehicle z an assembly4 d4 ,in/all ,exhau/ ,pipes4 7#a7 ,position exhau/ pipe 7front & re>7 assembly1 work+ x into position s t front pipe end slips into cyl9d] port2 !n1 pry & =ce re> pipe end into re> cyl9d] port4 7#b7 ,m\nt footbo>d1 brake foot p$al1 & sideb> assembly on support rods1 in/all+ wa%] & nut on front support rod4 7#c7 ,position & m\nt /op light swit* on re> support rod4 ,see t spr+ & op]at+ control wire ex]t a /raight pull on swit* plung] :5 foot p$al is op]at$4 7#d7 ,in/all bolt1 wa%]1 & nut :i* secure front exhau/ pipe clamp to footbo>d sideb>4 7#e7 ,to atta* safety gu>d to sideb>1 pull front end ( footbo>d away f sideb>1 l9e up holes 9 sideb> & safety gu>d end1 !n pass footbo>d support /ud ?r\gh bo? pieces1 & secure ) wa%] & nut4 7#f7 ,tight5 footbo>d re> support /ud nut4 7#g7 ,to complete in/allation1 foll[ proc$ure outl9$ 9 /ep b 7#a7 ?r\gh 7#d7 above4 ,illu/ration3 #aj--;,,in/rum5t ,,panel ,,t]m9al4 #ab--;,,batt]y ,,positive4 #ac--;,,batt]y ,,negative 7,,gr\nd74 #ah--,,t]m9al ,,junction ,,on ,,frame4 #bf--;,,ignition--,,light ,,swit*4 #bh--,,sp>k ,,coil4 #cc--;,,circuit ,,break]4 #cd--;,,coil ,,to ,,tim] ,,wire4 99,a--,,radio ,,bond1 ,,coil ,,to ,,tim] ,,wire4 99,b--,,radio ,,bond1 ,,coil ,,to ,,eng9e4 99,c--,,noise ,,suppression ,,cond5s]4 99,d--,,%ield$ ,,coil ,,to ,,tim] ,,wire4 99,e--,,sp>k ,,plug ,,suppressors4 ,,ra ,,pd #caegbc ,figure #dh--;,ignition to ,batt]y ,wir+ ,diagram ,section ,,xviii ,,ignition ,,sy/em ,p>agraph ,description #hb ,sp>k plugs #hc ,circuit break] po9ts #hd ,cond5s] #he ,circuit break] & tim] assembly #hf ,coil to tim] wire #hg ,adju/ sp>k control #hh ,sp>k coil #hi #hb4 ,,description4 a4 ,! ignition sy/em diff]s f t ( ! conv5tional automotive types 9 t x has no di/ributor4 ,a circuit break] alone is us$4 ,bo? coil hight5sion w9d+ ends lead directly to bo? sp>k plugs4 ,?us bo? plugs sp>k at ! same "t1 "o cyl9d] be+ on compression /roke :ile ! o!r cyl9d] is on exhau/ /roke4 #hc4 ,,sp>k ,,plugs4 a4 ,defective sp>k plugs are indicat$ by eng9e miss+1 ov]heat+1 knock+ excessively1 & lack+ normal p[]4 b4 ,type4 ,sp>k plugs are m$ium heat range1 manufactur]'s 7,h-,d7 ,no4 #c4 c4 ,clean+4 ,d n take plugs ap>t = clean+4 ,use ! s&bla/ clean] me?od4 d4 ,po9t ,adju/m5t4 ,b5d electrode locat$ 9 plug base to adju/ po9t gap #j4jbe in* to #j4jcj in*4 e4 ,replacem5t4 ,use sp>k plug wr5* 7#da-,w-#cccd7 to in/all plugs1 us+ new gaskets4 ,nev] draw a cool plug up tight 9 a hot cyl9d] head1 r turn d[n snug & wait l_/#b m9ute until plug base is w>m3 !n tight5 securely4 ,,caution3 ,take c>e n to cross?read :5 in/all+ sp>k plug4 #hd4 ,,circuit ,,break] ,,po9ts 7fig4 #di74 a4 ,circuit break] lev] is insulat$ f gr\nd & connects to prim>y wire b9d+ po/ by means ( a 8pigtail0 wire4 ,/ation>y po9t is gr\nd$ to tim] base & is movable 9 ord] to adju/ circuit break] po9ts4 ,circuit break] po9ts t are burn$ or pitt$ %\ld be r5ew$ or dress$ ) a clean f9ecut1 contact po9t file4 ,! file %\ld n be us$ on o!r metals & %\ld n be all[$ to become greasy or dirty4 ,,caution3 ,nev] use em]y clo? to clean po9ts4 ,contact surfaces1 aft] consid]able use1 may n appe> bright & smoo?1 b ?is is n necess>ily an indication t !y are n function+ satisfactorily4 b4 ,remove ,break] ,lev]4 7#a7 ,to disconnect cond5s] t]m9al1 remove nut f end ( cond5s] & remove ge>too!d wa%]1 pla9 wa%]1 & ! brass t]m9al /rip4 ,d n remove fib] wa%] & pla9 wa%] locat$ back ( brass t]m9al /rip on cond5s] t]m9al po/4 ,illu/ration3 ,,ra ,,pd #cajbdh ,figure #di--;,circuit ,break] ,po9ts ,remov$ 7#b7 ,b5d brass t]m9al /rip d[n & remove b9d+ nut :i* secures brass t]m9al /rip & break] lev] 8pigtail0 to prim>y wire b9d+ po/4 7#c7 ,compress break] lev] spr+ at end ( lev]1 dis5gag+ spr+4 ,,caution3 ,d n lose spr+4 ,release & remove lev] f insulat$ pivot po/4 c4 ,remove ,adju/able ,contact ,po9t4 7#a7 ,remove ! two lock screws & wa%] plate1 secur+ adju/able contact po9t assembly to tim] base4 ,po9t assembly is free to be lift$ (f lev] pivot /ud4 d4 ,in/all ,adju/able ,contact ,po9t4 7#a7 ,in/all contact po9t assembly1 replac+ wa%] plate & ! two lock screws4 ,d n tight5 lock screws until circuit break] po9ts are adju/$ 7/ep f bel[74 e4 ,in/all ,break] ,lev]4 7#a7 ,in/all brass t]m9al /rip on prim>y wire b9d+ po/4 7#b7 ,connect end ( brass t]m9al /rip to cond5s] t]m9al po/4 ,in/all flat wa%]1 ge>too!d wa%]1 & nut4 7#c7 ,in/all break] lev] on pivot po/ insulat$ be>+4 7#d7 ,in/all break] lev] spr+4 ,make sure t ends ( spr+ are reta9$ correctly4 7#e7 ,,note3 ,keep break] lev] cam v lightly greas$4 f4 ,adju/+ ,circuit ,break] ,po9ts 7fig4 #ea74 7#a7 ,correct po9t gap is #j4jbb in*4 ,circuit break] po9t faces mu/ seat squ>ely aga9/ ea* o!r4 ,if b5t1 squ>e up & al9e by b5d+ contact plate4 ,turn tim] break] cam until break] lev] fib] is locat$ on highe/ po9t ( cam4 7#b7 ,) ! adju/able po9t lock screws loose1 %ift ! adju/able po9t plate to obta9 a #j4jbb-;in* gap betwe5 ! circuit break] po9ts4 ,measure gap ) an accurate ?ickness gage be=e retight5+ lock screws1 & aga9 re*eck po9t gap aft] tight5+ ! lock screws4 ,,note3 ,wrong circuit break] po9t gap affects ignition tim+4 #he4 ,,cond5s]4 a4 ,! cond5s] is connect$ 9 p>allel ) ! circuit break] po9ts1 "o ( its t]m9als be+ gr\nd$ 7= ! adju/able po9t7 to ! tim] base by means ( ! m\nt+ screw1 ! o!r t]m9al mak+ connection ) ! circuit break] lev] 7= ! lev] po9t7 by means ( ! lev] 8pigtail40 b4 ,remove4 7#a7 ,unlat* circuit break] cov] reta9] & remove cov]4 7#b7 ,remove nut f end ( cond5s] & remove ge>too!d wa%]1 pla9 wa%]1 & ! brass t]m9al /rip4 ,,note3 ,a small pla9 wa%] & a l>ge fib] wa%] are locat$ beh9d brass t]m9al /rip4 7#c7 ,remove screw :i* secures cond5s] to tim] base4 ,remove cond5s]4 ,illu/ration3 ,,ra ,,pd #cajbdi ,figure #ej--;,circuit ,break] 7,tim]71 ,disassembl$ c4 ,in/all4 7#a7 ,m\nt cond5s] on tim] h\s+4 ,in/all lock wa%] & screw4 ,make sure small pla9 wa%] & l>ge fib] wa%] are 9 place on cond5s] end t]m9al screw be=e connect+ ! brass t]m9al /rip4 7#b7 ,connect brass t]m9al /rip to cond5s]4 ,replace pla9 wa%]1 ge>too!d wa%] & t]m9al nut4 7#c7 ,in/all circuit break] cov]4 #hf4 ,,circuit ,,break] ,,& ,,tim] ,,assembly 7figs4 #ej & #ea74 a4 ,:5 ! circuit break] tim] %aft & base assembly mu/ be replac$ due to excessive we> 9 tim] %aft be>+1 %e>$ worm ge> p91 &_/or worn or damag$ worm ge>1 eng9e ignition mu/ be retim$4 ,ignition tim+ = ! ,vtype tw9 eng9e is difficult & %\ld be attempt$ only by exp]i5c$ p]sonnel4 b4 ,remove 7fig4 #ej74 ,be=e ! tim] %aft & base assembly c be remov$1 ! circuit break] tim] head assembly mu/ be remov$4 ,,note3 ,if ! tim] head only1 or tim] wire1 is to be replac$1 x is n necess>y to remove tim] %aft & base assembly1 & ?us ?r[ eng9e ignition out ( "t4 7#a7 ,remove tim] head cov]4 7#b7 ,unlat* cov] reta9] ends f holes 9 ! tim] head & remove4 7#c7 ,disconnect sp>k control wire at tim] lev]4 7#d7 ,lift ! tim] head assembly (f base4 ,! head seat+ t5sion 7gr\nd7 spr+ 7und]nea? %aft base7 is also free1 & c n[ be remov$4 ,,note3 ,x is n necess>y to disconnect tim] to coil wire f tim] head t]m9al po/1 unless head or wire is be+ replac$4 7#e7 ,remove ! two tim] base m\nt+ screws & lock wa%]s4 ,x w be not$ t "o screw gr\nds ! tim] to coil wire %ield+4 7#f7 ,tim] %aft & base assembly c n[ be lift$ out ( eng9e ge> case cov]4 ,take c>e n to damage or misplace base gasket4 c4 ,in/all ,tim] ,%aft & ,base ,assembly & ,tim+ ,ignition 7fig4 #ea74 ,?is calls = retim+ eng9e ignition z foll[s3 7,,note3 ,circuit break] cam turns 9 clockwise direction73 7#a7 ,unscrew & raise front cyl9d] inlet valve spr+ cov]1 us+ tappet wr5* 7#da-,w-#cfag74 7#b7 ,turn eng9e 9 direction 9 :i* x runs until valve tappet indicates front cyl9d] is on compression /roke 7directly aft] front cyl9d] intake valve closes74 ,illu/ration3 ,a--,,fly:eel ,,tim+ ,,m>k ,,9 ,,crankcase ,,inspection ,,hole4 ,b--,,cov] ,,reta9]4 ,c--,,circuit ,,break] ,,lev]4 ,d--,,circuit ,,break] ,,cam4 ,e--,,cond5s]4 ,f--,,sp>k ,,control ,,wire ,,h\s+4 ,g--,,sp>k ,,control ,,wire4 ,h--,,sp>k ,,lev] ,,quadrant4 ,j--,,sp>k ,,lev]4 ,k--,,tim] ,,head ,,adju/+ ,,b& ,,screw4 ,l--,,tim] ,,head ,,adju/+ ,,b&4 ,m--,,m>k ,,on ,,break] ,,cam ,,& ,,m>ks ,,on ,,tim] ,,head ,,& ,,h& ,,indicat+ ,,orig9al ,,factory ,,tim+4 ,n--,,circuit ,,break] ,,po9ts4 ,o--,,adju/able ,,contact ,,po9t ,,plate4 ,p--,,adju/able ,,contact ,,po9t ,,lock ,,screws4 ,q--,,circuit ,,break] ,,lev] ,,pivot 7,,insulat$74 ,r--,,break] ,,lev] ,,spr+4 ,,ra ,,pd #cajbha ,figure #ea--;,circuit ,break] ,m>ks & ,fly:eel ,m>k ,correctly ,al9$ 7#c7 ,remove plug f tim+ inspection hole 9 leftside crankcase4 7#d7 ,cont9ue turn+ eng9e sl[ly until fly:eel tim+ m>k is 9 c5t] ( inspection hole 7fig4 #ea74 ,d n turn eng9e fur!r4 7#e7 ,in/all pap] gasket & tim] head t5sion 7gr\nd7 spr+ on tim] %aft base assembly4 ,make sure b5t ends ( t5sion spr+ are fac+ d[nw>d 7away f tim] base74 7#f7 ,ins]t tim] %aft & base assembly all ! way d[n into place 9 tim+ ge> case cov]1 try+ to locate m>k on small end ( break] cam 9 position %[n 9 figure #ea4 ,d n in/all base m\nt+ screws z yet4 7#g7 ,in/all tim] head assembly s t sp>k control lev] is )9 ! advance & ret>d quadrant 7fig4 #ea74 ,,note3 ,d n in/all cov] reta9] until lat]4 7#h7 ,fully advance sp>k lev] 7pu% inw>d t[>d eng9e7 & obs]ve h[ closely m>k on break] cam l9es up ) break] lev] fib]4 ,if m>k does n l9e up1 lift tim] base & turn %aft ge> s its engagem5t ) its driv+ ge> is *ang$ "o too?4 ,*eck aga9 accord+ to break] cam m>k & break] lev] fib]4 ,repeat ?is proc$ure until ge> engagem5t is obta9$ :i* closely al9es cam m>k & break] lev] fib]4 7#i7 ,see t tim] base is turn$ s t tim] to coil wire is t[>d re> ( eng9e4 7#aj7 ,in/all tim] base screws & lock wa%]s4 ,make sure t tim] to coil wire %ield+ is gr\nd$ "u head ( screw f>!/ away f eng9e 7fig4 #eb74 ,securely tight5 screws4 7#aa7 ,in/all tim] head on base & secure ) gr\nd spr+ & cov] reta9]4 ,be sure gr\nd spr+ is 9 its prop] place s t :5 cov] reta9] ends are fitt$ ?r\gh holes 9 ! tim] head1 !y w also fit into spr+ locat+ not*es4 ,x w be necess>y to press gr\nd spr+ upw>d "u tim] base to engage reta9] ends 9 ! spr+ not*es4 ,,note3 ,if cov] reta9] ends d n engage gr\nd spr+ not*es1 spr+ w h no t5sion & tim] head w be loose on its base4 ,circuit break] po9ts & cond5s] are electrically gr\nd$ ?r\gh tim] base1 & gr\nd spr+ holds ! head & base 9 close contact1 ?us assur+ a good gr\nd4 7#ab7 ,connect sp>k control wire & tim] lev] & adju/ 7p>4 #hh74 7#ac7 ,eng9e is n[ tim$ accord+ to orig9al factory sett+1 provid+ m>k on side ( tim] head & hole 9 head adju/+ b& are /ill 9 al9em5t1 & circuit break] po9t gap is #j4jbb in*4 ,ev5 ?\gh all ignition tim+ m>ks are 9 p]fect al9em5t1 z outl9$ 9 ! =ego+ in/ructions1 x is advisable to accurately *eck ignition tim+ 7/ep d foll[+74 d4 ,recomm5d$ ,re*eck ( ,ignition ,tim+ 7fig4 #ea74 ,ev5 ?\gh all ignition tim+ m>ks are 9 p]fect al9em5t1 z :5 eng9e 0 orig9ally tim$1 ignition tim+ may *ange some:at aft] eng9e has be5 9 s]vice = a :ile1 due to normal we> & seat+ ( ! v>i\s mov+ p>ts t c affect ignition tim+4 ,s9ce accurate ignition tim+ is ! fir/ ess5tial to good eng9e p]=mance1 x is advisable to *eck ignition tim+ on new vehicle aft] fir/ #a1ejj miles ( s]vice1 & at ea* #b1jjj miles !reaft]4 7#a7 ,see t circuit break] po9ts are adju/$ = correct gap ( #j4jbb in* 7p>4 #hd f74 7#b7 ,advance tim] lev] fully 7t[>d eng9e74 7#c7 ,turn eng9e 9 direction 9 :i* x runs until front cyl9d] is on compression /roke1 & cont9ue to turn x ahead sl[ly until n>r[ tim] cam 7! end ) ! tim+ m>k71 j />ts to op5 ! circuit break] po9ts4 ,illu/ration3 ,,ra ,,pd #cahbje ,figure #eb--,%ield+ ( ,coil to ,tim] ,wire ,gr\nd$ on ,base 7#d7 ,an accurate te/ light *eck z to :5 po9ts j />t to break c be made1 us+ ! in/rum5t panel r$ light = ! purpose4 ,disconnect panel light wire f ! oil pressure swit*1 atta*+ ?is wire to ! insulat$ t]m9al po/ on tim] head4 ,turn ignition & light swit* on4 ,z long z circuit break] po9ts are clos$1 lamp w rema9 lit2 z po9ts />t to op51 lamp w g out4 ,,note3 ,aft] mak+ use ( in/rum5t panel r$ light = above purpose1 reconnect wire to oil pressure swit*4 7#e7 ,:5 exact position is f\nd1 :]e po9ts j />t to op51 fly:eel m>k %\ld be 9 ! c5t] ( ! inspection hole4 7#f7 ,if fly:eel m>k is n 9 c5t] ( hole :5 po9ts op51 readju/ ignition tim+ z necess>y 7sl[] or fa/]7 by means ( ! tim] head & b& adju/m5t4 ,illu/ration3 ,,ra ,,pd #cahbjc ,figure #ec--,%ield$ ,coil to ,tim] ,wire ,correctly ,connect$ at ,coil 7#g7 ,to readju/ tim] head1 loos5 adju/+ b& screw & %ift tim] head 9 b&4 ,if fly:eel tim+ m>k %[s =w>d ( c5t] 9 inspection hole1 ! tim+ is sl[4 ,to correct1 %ift tim] head c\nt]clockwise aga9/ rotation ( break] cam4 ,if fly:eel m>k is to re> ( c5t] ( inspection hole1 tim+ is fa/ & tim] head mu/ be %ift$ ) rotation 7clockwise7 ( break] cam1 to correct tim+4 7#h7 ,) ignition tim+ correct1 front cyl9d] pi/on is #i_/cb in* be=e top dead c5t]1 on compression /roke1 :5 circuit break] po9ts j />t to op54 ,at ?is po9t sp>k occurs1 ignit+ front cyl9d] fuel *>ge4 7#i7 ,in/all fly:eel inspection hole plug 9 left crankcase4 #hg4 ,,coil ,,to ,,tim] ,,wire 7figs4 #eb & #ec74 a4 ,models provid$ ) radio %ield+ are id5tifi$ by 8,s0 on ei!r side ( in/rum5t panel4 ,! coil to tim] wire 7l[t5sion wire7 on ^! models is %ield$ = radio noise suppression4 b4 ,remove4 7#a7 ,disconnect batt]y negative gr\nd wire at frame connection4 7#b7 ,remove ! two bolts :i* secure upp] end ( air clean] bracket to frame tube4 ,sw+ air clean] & bracket outw>d & =w>d to ga9 access to sp>k coil re> t]m9al4 7#c7 ,disconnect coil to tim] wire t]m9al f coil re> connection4 ,disconnect wire %ield+ f coil re> gr\nd connection4 7#d7 ,ref] to p>agraph #hf b 7#a7 to 7#d7 = tim] head removal4 7#e7 ,remove tim] base m\nt+ screw :i* secures wire %ield+ 7fig4 #eb74 7#f7 ,note position ( coil to tim] wire inside ( tim] head2 !n remove nut wa%] connect+ wire to insulat$ contact /ud4 7#g7 ,"w old wire & loom out ( tim] head hole & free f vehicle4 7#h7 ,on e>li] models1 ! coil to tim] wire 0 sold]$ to end ( insulat$ /ud4 ,removal ( /ud is necess>y to remove ?is wire1 or replace x ) a %ield$ wire4 ,note location ( /ud insulations on inside & outside ( tim] head1 = correct in/allation :5 reassembl+4 c4 ,in/all4 7#a7 ,pass end ( wire1 %ield t]m9al1 & loom up ?r\gh hole 9 tim] base4 7#b7 ,gr\nd ! wire %ield t]m9al "u head ( tim] base m\nt+ screw 7fig4 #eb74 7#c7 ,connect wire end t]m9al to insulat$ /ud s t wire leads away f /ud 9 direction %[n 7fig4 #eb74 7#d7 ,pass coil to tim] wire up alongside & to re> ( frame saddle po/ tube to rea* re> ( sp>k coil4 7#e7 ,gr\nd ! wire %ield t]m9al to coil re> gr\nd connection 7fig4 #ec74 7#f7 ,connect wire t]m9al to coil re> prim>y connection 7fig4 #ec74 7#g7 ,in/all tim] head on base 7p>4 #hf c 7#aa774 7#h7 ,connect sp>k control wire to tim] lev] & adju/ 7p>4 #hh74 7#i7 ,connect batt]y negative po/ wire to frame gr\nd t]m9al4 7#aj7 ,sw+ air clean] bracket back into place & in/all two bolts1 wa%]s1 & nuts secur+ bracket to frame clips4 7#aa7 ,replace tim] cov] & *eck eng9e = />t+4 #hh4 ,,adju/ ,,sp>k ,,control4 a4 ,sp>k advance & ret>d is controll$ by left h&le b> grip4 ,sp>k lev] op]ates )9 a quadrant m\nt$ on eng9e4 ,sp>k mu/ be fully advanc$ 7lev] inw>d t[>d eng9e7 :5 h&le b> grip is turn$ inw>d to full ext5t ( its travel4 ,:5 h&le b> grip is turn$ outw>d1 sp>k lev] ret>ds 7lev] outw>d away f eng9e74 7#a7 ,) control wire 9 lev] /ud & clamp screw loose1 turn left grip fully inw>d2 !n back x out j a little4 7#b7 ,%ift sp>k lev] inw>d t[>d eng9e z f> z x w g2 !n tight5 control wire clamp screw4 ,te/ by turn+ left grip fully inw>d & not+ position ( sp>k lev]4 ,x %\ld be aga9/ inn] side ( quadrant 7fig4 #ea74 ,ret>d sp>k & *eck position ( lev] )9 quadrant2 x %\ld be aga9/ out] side ( quadrant4 7#c7 ,*eck f9al adju/m5t4 ,readju/ full advance & ret>d tim] lev] positions z necess>y :5 left grip is turn$ inw>d1 & outw>d1 respectively4 #hi4 ,,sp>k ,,coil 7fig4 #ed74 a4 ,sp>k coil hight5sion cables g directly to ! sp>k plugs1 no di/ributor be+ us$4 ,:5 ! coil is faulty1 x mu/ be replac$1 s9ce int]nal repairs are n possible4 ,! hight5sion cables c be replac$1 h[ev]4 ,coil is provid$ ) a cond5s] = radio noise suppression1 & metal coil case is gr\nd$ to eng9e by bond+4 b4 ,remove4 7#a7 ,disconnect batt]y negative gr\nd wire f frame connection4 7#b7 ,free hight5sion cable ends 7) radio noise suppressors7 f sp>k plugs4 ,free front cyl9d] hight5sion cable f clip at upp] eng9e frame m\nt+4 7#c7 ,loos5 air intake hose connection at c>buretor fitt+4 7#d7 ,remove two nuts1 wa%]s1 & bolts secur+ upp] end ( air clean] m\nt+ bracket to frame clamps4 ,illu/ration3 ,,ra ,,pd #cahbjd ,figure #ed--;,coil ,front ,connections ,%[+ ,radio ,bond+ & ,noise ,suppression ,cond5s] 7#e7 ,sw+ air clean] & bracket assembly outw>d to ga9 access to coil re> t]m9als4 7#f7 ,disconnect coil to tim] wire f coil re> t]m9al screw4 ,disconnect wire %ield+ f coil re> gr\nd t]m9al 7fig4 #ec74 7#g7 ,sw+ clean] back & remove wire connections f coil front t]m9al screw 7fig4 #ed74 7#h7 ,disconnect radio bond+ at coil front gr\nd t]m9al 7fig4 #ed74 7#i7 ,remove nuts & bolts :i* m\nt coil to bracket4 ,coil is n[ free = removal4 c4 ,in/all4 7#a7 ,m\nt coil on frame bracket ) hight5sion cables upw>d1 & re9/all m\nt+ bolts1 lock wa%]s1 & nuts4 ,tight5 nuts4 7#b7 ,connect t]m9als ( ! two gre5 wires to coil front t]m9al screw4 ,ref] to wir+ diagram1 figure #dh4 7#c7 ,connect radio bond+ to coil front gr\nd t]m9al4 ,tight5 nut securely4 7#d7 ,connect coil to tim] wire t]m9al to coil re> t]m9al screw4 ,connect wire %ield+ to coil re> gr\nd t]m9al4 ,tight5 nut securely4 7#e7 ,sw+ air clean] & bracket assembly back 9 place & in/all two bolts1 lock wa%]s1 & nuts secur+ bracket to frame clamps4 ,tight5 nuts securely4 7#f7 ,connect batt]y negative gr\nd wire to frame connection4 7#g7 ,pass front cyl9d] hight5sion wire "u tank1 secure 9 cable clip at upp] eng9e frame m\nt+1 & atta* cable end 7radio noise suppressor7 to front sp>k plug4 ,atta* re> hight5sion cable end 7radio noise suppressor7 to re> sp>k plug4 7#h7 ,*eck wir+ connections 7fig4 #dh7 & te/ coil by eng9e />t+4 ,section ,,xix ,,g5]at+ ,,sy/em ,p>agraph ,description #ij ,clean commutator #ia ,armature be>+ special lubrication #ib ,remove g5]ator #ic ,in/all g5]ator #id ,cutout relay #ie ,illu/ration3 #h--;,,g5]ator ,,signal ,,light #ab--;,,batt]y ,,positive ,,t]m9al #ac--;,,batt]y ,,negative ,,t]m9al 7,,gr\nd7 #ad--8,,swit*0 ,,t]m9al ,,( ,,g5]ator #ae--8,,relay0 ,,t]m9al ,,( ,,g5]ator #ah--;,,front ,,junction ,,t]m9al #bf--;,,ignition ,,& ,,light ,,swit* #cb--;,,cut,,out ,,relay 99,h--,,noise ,,suppression ,,cond5s] ,,ra ,,pd #cagbjj ,figure #ee--;,g5]ator to ,batt]y ,wir+ ,diagram #ij4 ,,description 7fig4 #ee74 a4 ,! g5]ator is %unt connect$4 ,! two field coils1 regulat+ coil1 & %unt coil are n connect$ 9 s]ies 9 ! conv5tional mann]4 ,! regulat+ field coil provides adequate curr5t output 7approx4 #d amp]es7 = daytime op]ation4 ,! %unt field coil is controll$ ?r\gh ! ignition & light swit* to increase curr5t output 7approx4 #h amp]es7 :5 vehicle lights are 9 use4 ,g5]ator uses ! ?ird 7regulat+7 bru% sy/em ( curr5t regulation4 ,a cutout relay s]ves z a magnetic swit* 9 ! g5]atorbatt]y circuit1 also op]at+ ! in/rum5t panel gre5 signal light to indicate g5]ator *>ge4 ,illu/ration3 ,,ra ,,pd #cajbei ,figure #ef--;,g5]ator ,cov] ,remov$ = ,commutator ,clean+ #ia4 ,,clean ,,commutator 7fig4 #ef74 a4 ,if batt]y is 9 good condition1 cutout relay is function+1 & wir+ connections are made accord+ to diagram 7fig4 #ee71 yet g5]ator does n *>ge or *>ge rate is l[1 proce$ to clean ! commutator4 7#a7 ,remove left footbo>d1 sideb>1 & clut* foot p$al assembly1 foll[+ proc$ure outl9$ "u p>agraph #ajb a 7#a7 to 7#f71 to p]mit g5]ator cov] removal4 7#b7 ,remove ! two end cov] screws & pull end cov] (f g5]ator4 7#c7 ,clean armature commutator ) ,no4 #jj s&pap] until bright & clean4 ,bl[ out ) air4 ,,caution3 ,d n remove or di/urb bru%es 9 _! hold]s4 ,nev] use em]y clo? to clean ! commutator4 ,illu/ration3 ,,ra ,,pd #cajbfj ,figure #eg--;,g5]ator ,end ,cov] & ,grease ,reta9] ,remov$ 7#d7 ,tempor>ily in/all footbo>d assembly & op]ate eng9e1 to obs]ve :e!r or n g5]ator is *>g+ 7gre5 signal light goes (f at above #bj mph74 ,if clean+ commutator does n rem$y g5]ator *>ge1 &_/or commutator is badly worn1 !n g5]ator mu/ be replac$ 7p>4 #ic74 ,if clean+ ( commutator rem$i$ g5]ator *>ge1 re9/all g5]ator end cov]1 & ! footbo>d & clut* p$al assembly 7p>4 #ajb b74 #ib4 ,,armature ,,be>+ ,,special ,,lubrication 7fig4 #eg74 a4 ,at ! #f1jjj-mile second e*elon prev5tive ma9t5ance s]vice p]iod1 ! commutator end be>+ mu/ be h&pack$4 ,9 p]=m+ ?is op]ation1 c>e mu/ be tak5 n to %ift or move ! g5]ator ?ird 7regulat+7 bru%1 ?us di/urb+ g5]ator curr5t regulation4 ,g5]ator drive end be>+ is adequately lubricat$ by oil circulat+ ?r\gh eng9e4 b4 ,to ,lubricate ,commutator ,end ,be>+4 7#a7 ,remove left footbo>d1 sideb>1 & clut* p$al assembly1 foll[+ proc$ure outl9$ 9 p>agraph #ajb a 7#a7 to 7#f74 7#b7 ,remove ! two end cov] screws & pull end cov] (f g5]ator4 7#c7 ,remove two ( ! ?ree screws :i* secure ! out] grease reta9] plate to end ( g5]ator 7fig4 #eg74 7#d7 ,loos5 ! o!r grease reta9] plate screw slightly to p]mit %ift+ plate to "o side4 7#e7 ,pack ball be>+ ) g5]al purpose grease ,no4 #b1 press+ lubricant into be>+ ) f+]4 7#f7 ,%ift ! out] grease reta9] plate back into position4 ,in/all ! two screws remov$1 & securely tight5 all ?ree screws4 7#g7 ,in/all g5]ator end cov] & ! two reta9+ screws4 7#h7 ,in/all left footbo>d1 sideb>1 & clut* foot p$al assembly1 foll[+ proc$ure outl9$ 9 p>agraph #ajb b4 #ic4 ,,remove ,,g5]ator 7figs4 #eh & #ei74 a4 ,g5]ator is ge> driv5 ?r\gh eng9e tim+ ge> tra94 ,g5]ator c be remov$ & in/all$ )\t remov+ tim+ ge> case cov]1 or affect+ al9em5t ( tim+ ge>s4 b4 ,be=e replac+ g5]ator because ( failure ( in/rum5t panel gre5 signal light to indicate *>ge1 *eck panel light wir+ & bulb = good condition 7p>4 #abj74 c4 ,:5 x has be5 det]m9$ t g5]ator mu/ be remov$ = replacem5t1 proce$ z foll[s3 7#a7 ,disconnect wires f ! two g5]ator t]m9als m>k$ ,,swit* & ,,relay4 7#b7 ,remove ! two long screws1 ?r\gh tim+ ge> case cov]1 t secure end ( g5]ator aga9/ ge> case 7fig4 #eh74 7#c7 ,remove /rap nut1 lock wa%]1 & curv$ wa%] f end ( /rap t clamps g5]ator 9 its cradle on eng9e crankcase 7fig4 #ei74 ,illu/ration3 ,,ra ,,pd #cajbfa ,figure #eh--,remov+ ,g5]ator ,end ,m\nt+ ,screws ,illu/ration3 ,,ra ,,pd #cajbfb ,figure #ei--,remov+ ,g5]ator ,/rap ,nut 7#d7 ,lift /rap high en\gh to p]mit rais+ g5]ator s t oil sl+] 7on end ( g5]ator ge>7 w cle> adjac5t ge>1 & all[ g5]ator to be remov$ f eng9e4 ,be sure to obs]ve & c\nt numb] ( pap] %ims betwe5 g5]ator & cradle4 ,lay ^! %ims aside to be us$ aga9 :5 g5]ator is re9/all$4 ,also1 note location ( hole 9 %ims = oil dra94 ,^! %ims 7 requir$ 9 orig9al assembly to adju/ driv+ ge>s = prop] me% &1 if left out1 ge>s may me% too deeply & 8h[l10 ev5 ?\gh consid]ably worn4 ,unless a new g5]ator gasket is available1 to be us$ :5 g5]ator is re9/all$1 be c>eful n to damage ! old "o4 #id4 ,,in/all ,,g5]ator4 a4 ,:5 in/all+ g5]ator1 ! important po9t to consid] is correct %imm+ ( g5]ator 9 its cradle to provide correct me% ( driv+ ge> ) int]m$iate tim+ ge>4 ,make sure same numb] ( pap] %ims are us$ 9 reassembl+ z 7 f\nd und]nea? g5]ator :5 x 0 remov$4 ,aft] an eng9e has be5 run a consid]able l5g? ( "t & ge>s h worn to "s ext5t1 !y h possibly develop$ suffici5t la% or play to safely remove "o or m ( ! orig9al %ims1 & ?us affect clos] me%+ & quiet] op]ation4 ,h[ev]1 ?is %\ld n be done unless tim+ ge> case cov] is remov$ s t ge> me% & la% c be c>efully *eck$4 7#a7 ,pass g5]ator drive ge> end ?r\gh ge> case hole1 lift+ g5]ator s t oil sl+] cle>s int]m$iate tim+ ge>4 ,turn g5]ator 9 its cradle s t end holes l9e up ) long m\nt+ screws :i* pass ?r\gh ge> case cov]4 ,tight5 m\nt+ screws securely4 7#b7 ,in/all curv$ wa%]1 lock wa%]1 & nut on end ( clamp /rap2 tight5 nut securely4 7#c7 ,connect r$black wire to g5]ator t]m9al m>k$ ,,relay1 & gre5 wire to g5]ator t]m9al m>k$ ,,swit*4 ,ref] to wir+ diagram 7fig4 #ee74 7#d7 ,op]ate eng9e & *eck g5]ator = curr5t output1 z well z *eck = ge> noise4 ,if %imm+ "u g5]ator is prop]1 g5]ator & tim+ ge>s w run quietly4 ,if necess>y1 readju/ %imm+ until ge>s op]ate quietly4 #ie4 ,,cut,,out ,,relay4 a4 ,op]ation ( ! in/rum5t panel gre5 signal light1 indicat+ g5]ator *>ge1 is controll$ by ! cutout relay4 ,!re=e1 if relay is faulty ! signal light w n op]ate prop]ly1 falsely indicat+ g5]ator tr\ble4 ,ru/ ar\nd ! contact po9ts1 burn$ po9ts1 & loss ( armature spr+ t5sion are s\rces ( mo/ relay tr\ble4 ,,note3 ,be=e condemn+ a relay because ( failure ( gre5 signal light1 make light te/ 7p>4 #abj74 b4 ,correct adju/m5t ( relay po9t gaps & t5sion+ ( armature spr+s require use ( precision electric met]s & exp]t k on ! subject4 ,a faulty relay1 o!r ?an remov+ cov] & clean+ ) air1 %\ld be replac$4 ,no adju/m5t ( po9ts %\ld be attempt$4 c4 ,remove4 7#a7 ,disconnect ! ?ree wires f relay t]m9al screws4 7#b7 ,remove ! two m\nt+ screws & lock wa%]s4 ,remove relay f eng9e base4 d4 ,in/all4 7#a7 ,m\nt relay on eng9e base ) two screws & lock wa%]s4 ,make sure t m\nt+ is clean to make good electrical gr\nd contact betwe5 relay & eng9e4 7#b7 ,reconnect ! ?ree wire t]m9als to relay t]m9al screws4 ,foll[ wir+ diagram1 figure #ee4 7#c7 ,op]ate eng9e & obs]ve action ( relay1 also action ( in/rum5t panel gre5 signal light to indicate g5]ator *>ge4 ,section ,,xx ,,brake ,,sy/em ,p>agraph ,re> :eel brake #if ,front :eel brake #ig #if4 ,,re> ,,:eel ,,brake 7figs4 #fj1 #fa1 & #fb74 a4 ,l9kage4 ,brake foot p$al on "r side ( vehicle is connect$ to bell crank 7locat$ on re> footbo>d support rod7 by means ( ! front brake rod 7nonadju/able74 ,! bell crank is connect$ to re> brake op]at+ lev] by means ( ! re> brake rod ) adju/able clevis end4 ,illu/ration3 ,,ra ,,pd #cajbgg ,figure #fj--,re> ,brake ,adju/m5t b4 ,adju/+ ,re> ,:eel ,brake 7fig4 #fj74 ,if brake op]at+ lev] /&s ahead ( v]tical position1 excessive l9+ we> is indicat$4 ,brake %oes mu/ be replac$ 7/eps c & d bel[74 ,normal free play ( brake foot p$al be=e brake op]ation is #a in*4 ,aft] brake takes effect 9 vehicle op]ation1 brake foot p$al %\ld h #a-;in* res]ve travel be=e bottom+ on footbo>d4 ,if brake foot p$al op]ation does n come )9 ^! limits1 adju/ re> brake rod z foll[s3 7#a7 ,remove cott] p91 pla9 wa%]1 & clevis p9 f end ( re> brake rod clevis4 7#b7 ,loos5 clevis lock nut on brake rod4 7#c7 ,turn clevis onto 7clockwise7 brake rod to %ort5 rod & take up foot p$al free play4 7#d7 ,turn clevis (f 7c\nt]clockwise7 brake rod to l5g!n rod & increase foot p$al free play4 7#e7 ,aft] mak+ brake adju/m5t1 sp9 re> :eel & make sure brake is n dragg+4 ,:5 correct brake adju/m5t is atta9$1 in/all clevis p9 9 clevis & brake op]at+ lev] ) pla9 wa%]1 & reta9 ) cott] p94 ,,note3 ,cott] p9 mu/ be 9 good condition4 ,illu/ration3 ,,ra ,,pd #cajbgc ,figure #fa--,re> ,brake ,assembly c4 ,remove ,brake ,%oes 7fig4 #fa74 7#a7 ,remove re> :eel 7p>4 #abg74 7#b7 ,remove brake drum & sprocket assembly4 ,brake %oes are n[ accessible4 ,d n remove side cov] assembly f frame4 7#c7 ,disconnect brake rod clevis at brake op]at+ lev]4 7#d7 ,place end ( l>ge screwdriv] blade betwe5 ends ( brake %oes at pivot /ud4 ,move brakeop]at+ lev] =w>d to hold brake %oes 9 fully exp&$ position1 & pry ends ( %oes (f pivot /ud )\t remov+ brake %oe spr+s4 d4 ,in/all ,brake ,%oes4 ,obs]ve t brake %oes are made = upp] & l[] positions & are n int]*angeable4 ,recess 9 end ( %oe = pivot /ud head det]m9es position ( %oe 9 assembly4 7#a7 ,engage ends ( spr+s 9 %oe assembly holes f ! inside be=e in/all+ %oes on side cov] 7fig4 #fa74 7#b7 ,) brake %oes & spr+s assembl$1 in/all s t ends ( %oes w slip ov] pivot /ud & %aftop]at+ cam4 7#c7 ,connect brake rod clevis to brake op]at+ lev]4 7#d7 ,in/all brake drum & sprocket assembly4 ,lock brake to hold drum 9 place :ile in/all+ :eel 7fig4 #hd74 7#e7 ,in/all re> :eel 7p>4 #abg74 ,,note3 ,if re> *a9 is 9 ne$ ( adju/m5t1 x %\ld be done at ?is "t4 7#f7 ,to equalize brake %oes1 loos5 nut on brake %oe adju/able pivot /ud 7on outside ( brake side plate71 & :ile apply+ pressure on brake foot p$al 7to 8c5t]0 ! brake %oes )9 ! drum71 retight5 ! pivot /ud nut4 7#g7 ,aft] new or rel9$ %oes h be5 in/all$1 *eck foot p$al = free play 7/ep b above74 #ig4 ,,front ,,:eel ,,brake 7fig4 #fb74 a4 ,l9kage 7control74 ,h&le b> h& lev] control wire :i* op]ates front :eel brake c be adju/$ & or replac$4 ,keep brake control wire lubricat$ 7?r\gh oil] 9 h\s+ & at ends ( h\s+7 ) eng9e oil4 b4 ,remove ,control ,wire4 ,remove control wire clamp nut f brake lev] clevis1 & free l[] end ( control wire f clevis4 7#a7 ,remove cott] p9 & flat wa%] f holl[ p91 p]mitt+ holl[ p9 to be pull$ out ( h& lev]4 ,control wire c n[ be pull$ out ( h\s+ ?r\gh ! hole 9 h& lev]4 c4 ,in/all ,control ,wire4 ,apply grease or eng9e oil to new control wire & ins]t1 ?r\gh h& lev]1 into control wire h\s+4 ,use caution :5 ins]t+ a new control wire into h\s+1 to prev5t wire end f fray+4 ,a fray$ wire ) loose end /r&s w n fe$ ?r\gh ! h\s+4 7#a7 ,) control wire 9 h\s+1 ins]t h& lev] holl[ p9 s t n>r[ slot /raddles control wire3 !n fit flat wa%] ov] end ( holl[ p91 reta9+ bo? ) cott] p94 7#b7 ,ins]t l[] end ( control wire ?r\gh clamp nut1 !n ?r\gh clevis & back ?r\gh clamp nut aga94 ,grasp end ( wire ) pli]s & pull until all slack is tak5 up4 ,!n1 :ile pull+ wire snug1 tight5 clamp nut securely4 ,cut (f excess wire4 7#c7 ,adju/ brake control 7ref] to /ep d bel[74 ,illu/ration3 ,,ra ,,pd #cajbgd ,figure #fb--;,front ,brake ,control & ,adju/+ ,memb]s d4 ,adju/+ ,front ,:eel ,brake4 ,end ( brake h& lev] mu/ move freely ab\t #a_/d ( its travel be=e meet+ resi/ance ( brake op]ation4 7#a7 ,loos5 adju/+ sleeve lock nut & turn adju/+ sleeve z necess>y to atta9 correct free movem5t ( h& lev]4 7#b7 ,aft] correct h& lev] adju/m5t is made1 tight5 adju/+ sleeve lock nut4 e4 ,remove ,brake ,%oes4 7#a7 ,remove front :eel 7p>4 #abe74 ,aft] front :eel is remov$1 brake side cov] & %oe assembly is accessible = %oe replacem5t4 7#b7 ,remove brake %oes4 ,brake %oes & spr+s c be pri$ (f pivot /ud & fre$ f op]at+ cam )\t remov+ spr+s4 f4 ,in/all ,brake ,%oes4 ,obs]ve t brake %oes are made = upp] & l[] positions & are n int]*angeable4 ,recess 9 end ( %oe = pivot /ud head det]m9es position ( %oe 9 assembly4 7#a7 ,engage ends ( spr+s 9 %oe holes f ! inside be=e in/all+ %oes 9 brake side plate4 7#b7 ,) %oes & spr+s assembl$1 in/all ! %oes s t ends ( %oes w slip ov] pivot /ud & %aft op]at+ cam4 7#c7 ,in/all front :eel & brake assembly 7p>4 #abe74 7#d7 ,loos5 nut on brake %oe adju/able pivot /ud & :ile apply+ pressure on brake h& lev]1 retight5 pivot /ud nut4 ,?is is to c5t] brake %oes )9 ! brake drum4 7#e7 ,aft] new or rel9$ %oes h be5 in/all$1 *eck brake h& lev] &1 if necess>y1 adju/ ! control wire 7/ep d above74 ,section ,,xxi ,,/e]+ ,,control ,p>agraph ,=ks #ih ,/e]+ damp] #ii ,h&le b>s #ajj ,h&le b> controls #aja #ih4 ,,=ks 7figs4 #fc & #fd74 a4 ,ei!r ! spr+ =k c be remov$ & replac$1 or ! complete =k assembly 7spr+ =k & rigid7 c be replac$4 b4 ,remove ,spr+ ,=k 7fig4 #fc74 7#a7 ,support vehicle on re> /&4 7#b7 ,remove ! =k spr+ rod lock nuts 7acorntype74 7#c7 ,sit on front mudgu>d1 or o!rwise provide weight1 to compress =k cu%ion 7l[]7 spr+s4 ,! spr+ rod l>ge nuts c !n be easily remov$1 free+ ! upp] recoil & upp] bump] spr+s = removal4 7#d7 ,remove front :eel 7p>4 #abe74 7#e7 ,remove front mudgu>d 7p>4 #ajd74 7#f7 ,remove spr+ =k "r & left side rock] plate /uds4 ,,note3 ,leave rigid =k rock] /uds1 ) rock]s1 atta*$4 7#g7 ,remove spr+ =k f vehicle4 c4 ,in/all ,spr+ ,=k4 7#a7 ,place buff] spr+s & l[] cu%ion spr+s on =k rods4 ,apply grease to rods4 ,pass =k rods up ?r\gh rigid =k bracket4 ,b9d l[] end ( spr+ =k to l[] end ( rigid =k ) a /rap or piece ( heavy wire 7fig4 #fd71 to prev5t =ks f sep>at+ :ile compress+ cu%ion spr+s4 7#b7 ,in/all two bolts 9 ! rigid =k brackets :i* m\nt ! mudgu>d2 !n place a rod ab\t #h in*es long on ! brackets to provide a pry base = ! lev]age b> :5 compress+ cu%ion spr+s 7fig4 #fd74 ,) a lev]age b> ab\t #ah in*es long1 an*or$ on top ( ! pry base rod & "u ! spr+ =k1 lift upw>d to compress cu%ion spr+s suffici5tly to in/all "o ( ! rock] plates4 ,!n in/all ! o!r rock] plate 7fig4 #fd74 ,,note3 ,left side spr+ =k rock] plate /ud has a button end :i* fits into not* 9 brake /abiliz] plate4 7#c7 ,in/all mudgu>d 7p>4 #ajd74 7#d7 ,in/all front :eel 7p>4 #abe74 7#e7 ,in/all ! two spr+ rod bu%+s4 ,in/all upp] bump] spr+s & upp] recoil spr+s on ! =k rods1 apply+ grease to rods4 7#f7 ,remove blocks f "u vehicle4 7#g7 ,sit on mudgu>d to compress =k cu%ion 7l[]7 spr+s4 ,tight5 ! two l>ge spr+ rod nuts suffici5tly to provide full ?read = ! spr+ rod lock nuts 7acorntype74 ,in/all spr+ rod lock nuts & tight54 7#h7 ,see t all nuts1 bolts1 & screws secur+ lamp bracket1 mudgu>d1 scabb>d c>ri]1 & ammunition c>ri] are tight5$ securely4 7#i7 ,*eck front :eel brake = op]ation4 d4 ,remove ,upp] ,recoil ,spr+s &_/or ,upp] ,bump] ,spr+s4 7#a7 ,support vehicle on re> /&4 ,remove ! =k spr+ rod lock nuts 7acorntype74 7#b7 ,sit on front mudgu>d1 or o!rwise provide weight1 to compress =k cu%ion 7l[]7 spr+s4 ,! spr+ rod l>ge nuts c !n be easily remov$1 free+ ! upp] recoil & upp] bump] spr+s = removal4 e4 ,in/all ,upp] ,recoil ,spr+s &_/or ,upp] ,bump] ,spr+s4 7#a7 ,apply grease to =k spr+ rods & in/all upp] bump] spr+s4 7#b7 ,in/all upp] recoil spr+s ov] bump] spr+s on =k spr+ rods4 7#c7 ,sit on front mudgu>d to compress cu%ion 7l[]7 spr+s suffici5tly to />t on spr+ rod l>ge nuts4 7#d7 ,tight5 bo? spr+ rod l>ge nuts4 ,in/all & tight5 ! two spr+ rod 7acorntype7 lock nuts4 f4 ,remove & ,in/all ,l[] ,cu%ion ,spr+s &_/or ,l[] ,buff] ,spr+s4 ,?is op]ation calls = same proc$ure foll[$ 9 remov+ & in/all+ spr+ =k 7/eps b & c above74 g4 ,remove ,complete ,=k ,assembly4 7#a7 ,remove ammunition box c>ri] 7p>4 #ajc74 7#b7 ,remove scabb>d c>ri] 7p>4 #ajc74 7#c7 ,remove front :eel 7p>4 #abe74 7#d7 ,remove /e]+ damp] 7p>4 #ii74 ,illu/ration3 ,,ra ,,pd #caegbh ,figure #fc--,spr+ ,=k ,disassembl$ ,a--,,upp] 7,,recoil7 ,,spr+s ,b--,,upp] ,,bump] ,,spr+s ,c--,,spr+ ,,rod ,,lock ,,nuts 7,,acorn,,type7 ,d--,,spr+ ,,rod ,,bu%+s ,e--,,l>ge ,,spr+ ,,rod ,,nuts ,f--,,l[] ,,cu%ion ,,spr+s ,g--,,spr+ ,,rods ,h--,,l[] ,,buff] ,,spr+s ,j--,,spr+ ,,=k ,,assembly ,k--,,rock] ,,plate ,,/ud ,,nuts ,,& ,,locks ,l--,,"r ,,side ,,rock] ,,plate ,,/ud ,,& ,,wa%] ,m--,,left ,,side ,,rock] ,,plate ,,/ud 7,,has ,,button ,,end7 ,,& ,,wa%] ,n--,,ammunition ,,box ,,c>ri] ,,m\nt+ ,,bolt1 ,,wa%]s ,,& ,,nut ,o--,,headlight ,,bracket ,,& ,,mudgu>d ,,bolt1 ,,wa%] ,,& ,,nut 7,,left ,,side7 ,p--,,front ,,axle1 ,,ca/le ,,nut ,,& ,,cott] ,,p9 ,q--,,scabb>d ,,c>ri] ,,m\nt+ ,,bolt1 ,,wa%]s ,,& ,,nut ,r--,,headlight ,,bracket ,,& ,,mudgu>d ,,bolt1 ,,m>k] ,,light ,,gable ,,clip1 ,,wa%] ,,& ,,nut 7,,"r ,,side7 ,s--,,brake ,,%ackle ,,bolt1 ,,lock ,,& ,,nut ,t--,,brake ,,& ,,side ,,cov] ,,assembly ,u--,,mudgu>d ,,bracket ,,m\nt+ ,,lock1 ,,wa%] ,,& ,,nuts 7,,"r ,,side7 ,v--,,mudgu>d ,,& ,,rigid ,,=k ,,m\nt+ ,,screws1 ,,wa%]s ,,& ,,nuts ,w--,,mudgu>d ,,bracket ,,m\nt+ ,,lock1 ,,wa%] ,,& ,,nuts 7,,left ,,side7 ,x--,,not*es ,,9 ,,mudgu>d ,,brackets ,,= ,,special ,,locks ,,ra ,,pd #caegbhh ,leg5d = ,figure #fc--,spr+ ,=k ,disassembl$ 7#e7 ,remove front mudgu>d1 aft] remov+ nuts & locks f re> rock] plate /uds1 two screws & nuts secur+ mudgu>d to rigid =k1 & ! two bolts m\nt+ headlight bracket to mudgu>d4 ,,note3 ,front mudgu>d black\t light wire connects to ignition & light swit* & c>e mu/ be ex]cis$ n to break ?is wire if x is n disconnect$ f ! swit*4 7#f7 ,disconnect batt]y negative gr\nd wire at frame connection4 ,remove black\t light 7p>4 #aad74 ,remove headlight1 horn1 & bracket assembly z "o unit4 7#g7 ,remove h&le b> brake fitt+s & brake control wire h\s+ f side ( =k4 ,remove h&le b>s aft] remov+ h&le b> bracket lock nut & cone lock plate4 ,x is n necess>y to disconnect sp>k & ?rottle control wire h\s+s f frame4 ,unscrew =k upp] adju/+ cone f =k /em1 free+ =k assembly to be remov$ f frame head4 ,,note3 ,/e]+ head ball be>+s are loose 7n 9 reta9]s7 9 upp] & l[] frame head be>+ cups4 ,take c>e n to lose balls4 h4 ,in/all ,=k ,assembly4 ,) vehicle on re> /&1 & front end up by block+ "u frame loop or skid plate1 proce$ ) in/all+ =k assembly1 z foll[s3 7#a7 ,?or\ghly clean upp] & l[] frame head be>+ cups & pack ) g5]al purpose grease ,no4 #b1 in/all+ fifte5 #e_/af-;in* ball be>+s 9 ea* cup4 ,"w grease ?or\ghly 9 betwe5 balls4 7#b7 ,see t l[] =k /em cone is clean & 9 place1 pass =k /em up ?r\gh frame head1 turn+ on upp] adju/+ cone4 ,d n try to adju/ be>+ cone z yet4 7#c7 ,in/all h&le b>s by locat+ m\nt+ bracket on ends ( =k sides & c5t] /em1 mak+ sure t sp>k & ?rottle control wire h\s+s are 9 place4 7#d7 ,adju/ upp] =k /em adju/+ cone s t !re is no p]ceptible %ake 9 head be>+s :5 h&le b>s are work$ up & d[n1 & =k does n b9d :5 turn$ to "r & left extremes4 7#e7 ,in/all cone lock plate by engag+ p9 9 "o ( ! cone not*es4 7#f7 ,in/all lock nut on /em & tight5 securely4 ,,note3 ,*eck head be>+ play1 z tight5+ lock nut sometimes makes head be>+ too tight4 ,readju/ if necess>y4 7#g7 ,atta* h&le b> brake fitt+s & brake control wire h\s+ to side ( =k4 7#h7 ,re9/all headlight1 horn1 & bracket assembly4 ,connect wires 7p] wir+ diagram fig4 #gc7 be=e front mudgu>d is re9/all$4 ,in/all black\t light 7p>4 #aad74 ,reconnect batt]y negative gr\nd wire to frame gr\nd connection4 7#i7 ,in/all /e]+ damp] 7p>4 #ii74 ,illu/ration3 ,,ra ,,pd #cajbff ,figure #fd--;,compress+ ,cu%ion ,spr+s = ,spr+ ,=k ,assembly 7#aj7 ,in/all front mudgu>d4 ,atta* two screws1 wa%]s1 & nuts = rigid =k m\nt+ & two bolts1 wa%]s1 & nuts = headlight bracket m\nt+4 ,fit "r & left mudgu>d brace clip locks to "r & left side rock] plate /uds respectively4 ,d n put on nuts until aft] in/all+ ammunition box c>ri] & scabb>d c>ri]4 7#aa7 ,in/all front :eel 7p>4 #abe74 7#ab7 ,in/all scabb>d c>ri] & ammunition box c>ri] 7p>4 #ajc74 7#ac7 ,*eck lights1 horn1 sp>k control1 ?rottle control1 front brake control1 /e]+ damp] control1 & /e]+ head be>+ = fre$om )\t b9d+4 i4 ,remove ,rock] ,plate ,/uds4 ,/uds &_/or rock] plates c be remov$ & in/all$ 9 ! same op]ation4 ,9 remov+ & in/all+ /uds1 remove only "o =k rock] plate at a "t1 leav+ ! o!r plate atta*$ to opposite side =k ends to hold =k spr+s 9 compress$ position4 ,?is w elim9ate necessity ( compress+ =k spr+s to fit rock] plates on /uds4 7#a7 ,remove front :eel 7p>4 #abe74 7#b7 ,remove nuts & locks f rock] plate /uds on "r side ( vehicle4 ,?is releases gun scabb>d c>ri] & mudgu>d /ay clip4 ,,note3 ,remove ! l>ge nut :i* secures ! long /ud to rigid =k4 7#c7 ,drive out /uds f =k ends1 releas+ rock] plate4 7#d7 ,in/all /uds & rock] plate be=e remov+ /uds f left side ( vehicle4 j4 ,in/all ,rock] ,plate ,/uds4 ,apply grease to /uds & ins]t 9 rock] plate1 !n in/all l>ge flat wa%]s on /uds be=e m\nt+ ?is assembly on =k ends4 ,make sure t %ort /ud is 9 front position1 & t long /ud is 9 re> position = ! rigid =k4 7#a7 ,drift /uds 7) plate assembly7 into =k end holes f ! inside4 7#b7 ,in/all special nut lock 7) half r\nd hole7 on front /ud & turn /ud z necess>y to make lock 8cup0 ov] end ( =k4 ,in/all & tight5 /ud nut & b5d up end ( lock = security4 ,place lock wa%] ov] long /ud & in/all ?ick nut1 securely tight5+ x4 7#c7 ,atta* end ( gun scabb>d c>ri] & mudgu>d brace clip ) special lock to long /ud1 replac+ wa%] & nut4 7#d7 ,aft] "r side rock] plate &_/or /uds h be5 in/all$1 remove & in/all /uds &_/or plate on left side ( vehicle foll[+ same /epby/ep proc$ure z above4 ,! exceptions w be ammunition box c>ri] in/ead ( scabb>d c>ri]2 also1 ! left side front /ud is special1 hav+ a 8button0 end4 7#e7 ,in/all front :eel 7p>4 #abe74 ,illu/ration3 ,,ra ,,pd #cajbgf ,figure #fe--,/e]+ ,damp] ,assembly #ii4 ,,/e]+ ,,damp] 7fig4 #fe74 a4 ,remove 7fig4 #fe74 7#a7 ,remove front :eel 7p>4 #abe74 7#b7 ,remove front mudgu>d 7p>4 #ajd74 7#c7 ,remove lock nut f /e]+ damp] rod1 !n remove upp] end p>ts 9 ! foll[+ ord]3 adju/+ nut1 key$ /eel wa%]1 fib] wa%]1 op]at+ lev]1 & actuat+ sleeve4 ,?is entire assembly is locat$ 9 ! c5tral "p ( ! h&le b> m\nt+ bracket4 7#d7 ,/e]+ damp] rod1 cu%ion spr+1 pressure disk1 fib] disk1 & /eel disk assembly c n[ be )drawn 7d[nw>d7 f =k /em hole4 b4 ,in/all 7fig4 #fe74 ,be=e in/all+ /e]+ damp]1 make sure t ! p>ts are 9 correct ord] on ! l[] end ( ! rod be=e pass+ rod up ?r\gh hole 9 =k /em4 ,*eck p>ts & ord] ( assembly4 7#a7 ,assemble p>ts on rod end 7fig4 #fe71 mak+ sure t ! b5t d[n lip ( ! /eel pressure disk engages ) not* 9 end ( ! rod lock plate4 7#b7 ,pass rod ) its l[] end assembly up ?r\gh hole 9 =k /em1 turn+ /eel pressure disk to front position s t 8b5tup0 lip engages ) not* 9 front side ( rigid =k cr[n1 at ! same "t engag+ curv$ end ( /eel disk torque arm 9 slot 9 und]side ( frame head4 ,ma9ta9 pressure aga9/ end ( rod to keep l[] disks 9 ord] :ile assembl+ upp] rod end p>ts4 7#c7 ,in/all upp] rod end assembly 9 ! foll[+ ord]3 ,small pla9 wa%]1 releas+ spr+1 adju/+ sleeve screws into end ( =k /em1 op]at+ lev] regi/]s on ! adju/+ sleeve1 fib] wa%]1 key$ /eel wa%] regi/]s 9 rod slot1 l>ge adju/+ nut1 & lock nut4 7#d7 ,turn actuat+ sleeve all ! way into =k /em & !n back x out 7up7 #a_/b turn or m4 ,regi/] ! op]at+ lev] on flat ( actuat+ sleeve1 & see t lev] has full movem5t to ! left )\t bottom+ sleeve 9 ! =k /em4 7#e7 ,adju/ /e]+ damp] by sett+ adju/+ 7l>ge7 nut s t op]at+ lev] mu/ be mov$ ne>ly /raight back f ! free 7leftside7 position1 be=e damp] takes noticeable effect 7applies friction to movem5t ( ! h&le b>s74 ,hold l>ge adju/+ nut & tight5 ! small lock nut4 7#f7 ,in/all front mudgu>d 7p>4 #ajd74 7#g7 ,in/all front :eel 7p>4 #abe74 #ajj4 ,,h&le ,,b>s4 a4 ,remove ,complete ,assembly4 ,if vehicle is equipp$ ) h&le b> w9d%ield & re> view mirror1 remove ^! accessories be=e />t+ to remove h&le b> assembly4 7#a7 ,disconnect ?rottle control wire at c>buretor lev]1 & sp>k control wire at tim] lev]4 7#b7 ,release sp>k control wire h\s+ clip at front cyl9d] base bolt 7ne> tim]74 ,also release h\s+ f frame clip on left side ( vehicle4 ,release ?rottle control wire h\s+ clip1 locat$ at tank1 l[] front connection bolt4 7#c7 ,remove front brake h& lev] fitt+s f h&le b>s4 ,also release brake control wire h\s+ at h&le b> clamp4 7#d7 ,disconnect batt]y negative gr\nd wire at frame connection & wires at headlight4 ,headlight mu/ be remov$ = access to ! two t]m9al screws 7fig4 #gc74 7#e7 ,disconnect horn wire lead+ to h&le b>s & r$ wire 7t]m9al ,no4 #ag1 fig4 #gc7 lead+ to h&le b>s4 7#f7 ,remove /e]+ damp] rod upp] end fitt+s 9 ! foll[+ ord]3 ,lock nut1 adju/+ nut1 key$ /eel wa%]1 fib] wa%]1 op]at+ lev]1 & op]at+ sleeve 7screws into end ( =k /em74 ,removal ( ^! p>ts gives access to h&le b> lock nut4 ,remove h&le b> lock nut & cone lock plate4 7#g7 ,loos5 h&le b> bracket=k end p9* bolts4 ,h&le b>s are n[ free to be drift$ (f ends ( =k sides & c5t] /em4 7#h7 ,remove h&le b> w9d%ield apron spr+ gu>d aft] h&le b>s are remov$ f vehicle4 b4 ,in/all ,complete ,assembly4 ,if vehicle is equipp$ ) h&le b> w9d%ield & re> view mirror1 atta* ^! accessories aft] h&le b> assembly is in/all$4 7#a7 ,atta* w9d%ield apron spr+ gu>d to h&le b> bracket4 ,d n tight5 bolt nut until aft] h&le b>s are in/all$4 7#b7 ,/>t h&le b> bracket holes ov] ends ( =k1 see+ t sp>k control wire h\s+ is on "r side ( frame head3 !n drive h&le b>s onto =k ends1 us+ a ra:ide mallet1 or a hamm] & wood block4 7#c7 ,to in/all cone lock plate1 ent] regi/]+ p9 ?r\gh hole 9 h&le b>s & engage not* 9 ! adju/+ cone4 ,in/all & tight5 h&le b> lock nut securely4 ,,caution3 ,:5 tight5+ ?is nut1 always make sure t regi/] 7%\ld]7 ( nut ent]s hole 9 lock plate & h&le b>s4 7#d7 ,*eck adju/m5t ( head be>+4 ,! =k mu/ turn freely b )\t p]ceptible %ake4 ,readju/ head cone to obta9 prop] be>+ adju/m5t if necess>y4 7#e7 ,tight5 h&le b> bracket=k end p9* bolts4 7#f7 ,position w9d%ield apron gu>d s t x cle>s =k spr+s4 ,securely tight5 m\nt+ bolt nut4 7#g7 ,in/all /e]+ damp] upp] end fitt+s 7fig4 #fe74 ,make sure t l[] end disks & plates are prop]ly engag$4 ,adju/ 7p>4 #ii74 7#h7 ,connect h&le b> wires to t]m9al plate1 horn1 & headlight4 ,consult wir+ diagram 7fig4 #gc74 ,in/all headlight4 ,adju/ beam & secure m\nt+ nut 7p>4 #aad74 ,connect batt]y negative gr\nd wire to frame connection4 7#i7 ,*eck op]ation ( lights & horn1 tactical situation p]mitt+4 7#aj7 ,atta* front brake h& lev] fitt+s to left h&le b>4 ,secure control wire h\s+ 9 h&le b> clamp1 j ahead ( h\s+ oil]4 ,*eck front brake = correct op]ation &1 if necess>y1 adju/ 7p>4 #ig74 7#aa7 ,pass sp>k control wire h\s+ along left side ( frame front tube1 betwe5 cyl9d]s 7"u c>buretor7 to position h\s+ end clamp on cyl9d] /ud ne> tim]4 ,secure clamp "u cyl9d] /ud nut4 ,secure wire cable "u clamp on left side ( frame front tube1 ) :ite pa9t m>k slightly ahead ( clamp front edge4 ,engage end ( sp>k control wire 9 tim] lev] & adju/ sp>k control 7p>4 #hh74 7#ab7 ,pass ?rottle control wire h\s+ along "r side ( frame front tube & ov] top ( front cyl9d] head to rea* c>buretor connection4 ,in/all tank 7l[] front7 m\nt+ bolt to secure wire h\s+ clamp4 ,see t :ite pa9t m>k on wire h\s+ is slightly ahead ( clamp1 !n secure bolt nut on left side ( vehicle4 ,engage end ( ?rottle control wire 9 ?rottle lev] & adju/ 7p>4 #fi74 ,illu/ration3 ,,ra ,,pd #cajbhb ,figure #ff--,remov+ ,h&le ,b> ,grip ,sleeve ,reta9+ ,nut #aja4 ,,h&le ,,b> ,,controls 7figs4 #ff & #fg74 a4 ,con/ruction ( ! ?rottle & sp>k controls is ! same1 ?us replac+ a control wire or wire h\s+ foll[s ! same g5]al proc$ure up to ! po9t :]e control adju/m5t is made4 ,h&le b> grip sleeves 7spirals7 are int]*angeable4 b4 ,remove ,?rottle ,control ,wire 7fig4 #fg74 7#a7 ,disconnect control wire at ?rottle lev] connection4 7#b7 ,ins]t blade ( a l>ge1 squ>e%ank screwdriv] ?r\gh hole 9 end ( grip & turn out end nut by us+ a wr5* on ! %ank ( ! screwdriv] 7fig4 #ff74 ,sometimes ?is nut is difficult to remove4 ,9 ?is case1 ins]t pun* into ! slot 9 ! nut & /rike pun* two or ?ree %>p bl[s to 8free0 nut 9 h&le b> end ?reads4 ,remove nut z above4 ,,note3 ,nut rema9s inside ! grip & is remov$ ) ! grip & spiral sleeve assembly4 7#c7 ,remove grip & spiral assembly f h&le b>s4 ,control wire & work+ p>ts are n[ accessible4 7#d7 ,remove pla9 roll] f p94 ,remove roll] block f p94 ,remove p9 f plung]4 7#e7 ,pull plung] ) wire atta*$ out ( h&le b> end4 ,remove hexagon head screw :i* secures wire to plung]4 ,,note3 ,if wire is brok51 remove o!r half f h\s+ at c>buretor connection end4 7#f7 ,remove any ru/1 dirt1 or gum f grip spiral1 h&le b> end1 wire plung]1 & inside ( h&le b> :]e plung] op]ates4 ,illu/ration3 ,a--,,end ,,nut4 ,b--,,grip4 ,c--,,grip ,,sleeve ,,assembly4 ,d--,,roll] ,,p94 ,e--,,roll]4 ,f--,,roll] ,,block4 ,g--,,plung]4 ,h--,,control ,,wire4 ,i--,,wire ,,reta9+ ,,nut4 ,,ra ,,pd #cajbfc ,figure #fg--;,h&le ,b> ,grip & ,wire ,control1 ,disassembl$ c4 ,in/all ,?rottle ,control ,wire 7fig4 #fg74 7#a7 ,pass holl[ screw ov] control wire ) ?read$ end ( holl[ screw fac+ button on end ( wire4 ,in/all screw 9 end ( plung]4 ,securely tight5 screw4 7#b7 ,apply grease or eng9e oil to control wire & ins]t end into control wire h\s+4 7#c7 ,apply grease to plung] & pu% plung] & wire into h&le b> until plung] p9 hole is expos$ 9 h&le b> slot4 ,"w plung] or turn x )9 h&le b> s t p9 hole & flat side are upw>d & are c5t]$ 9 slot2 !n ins]t roll] p9 into plung] hole1 roll] block 7) flat sides71 & roll] 9 ord] nam$4 ,apply grease to plung] p9 & roll] & to outside ( h&le b> end4 7#d7 ,in/all grip & spiral assembly by engag+ plung] roll] 9 spiral op5+ 9 end ( grip sleeve4 ,grip spiral sleeve nut c be/ be />t$ )\t dang] ( cross ?read+1 by hold+ grip assembly back slightly :ile />t+ nut 9 h&le b> end4 ,?is squ>es nut ) end ( grip sleeve1 al9+ ?reads4 ,securely tight5 nut ) screwdriv] & wr5*4 7#e7 ,connect control wire at ?rottle lev] connection4 ,adju/ control 7p>4 #fi74 d4 ,remove ,sp>k ,control ,wire 7fig4 #fg74 ,disconnect control wire at tim] lev] & foll[ proc$ure outl9$ "u /ep b above4 e4 ,in/all ,sp>k ,control ,wire 7fig4 #fg74 ,foll[ proc$ure outl9$ "u /ep c above1 !n connect control wire at tim] lev] & adju/ control 7p>4 #hh74 f4 ,remove & ,in/all ,control ,wire ,h\s+s4 ,remove ei!r control wire h\s+ aft] foll[+ proc$ure outl9$ above 7/ep b71 !n remove set screw on "u side ( h&le b>1 j ahead ( grip sleeve %\ld]4 ,,note3 ,set screw = sp>k control wire h\s+ is locat$ "u headlight dimm] swit*4 ,aft] set screw is remov$ & h\s+ fre$ f atta*+ clamps1 h\s+ c be pu%$ out ?r\gh end ( h&le b>4 7#a7 ,:5 in/all+ control wire h\s+s1 see t h\s+ end is secur$ 9 h&le b> ) set screw1 & t h\s+ is correctly atta*$ to vehicle clamps4 7#b7 ,in/all control wire & grip 7/ep c above7 & adju/ controls3 sp>k 7p>4 #hh71 ?rottle 7p>4 #fi74 ,section ,,xxii ,,%eet ,,metal ,,& ,,equipm5t ,p>agraph ,*a9 gu>ds #ajb ,c>ri]s #ajc ,mudgu>ds #ajd ,batt]y box #aje ,tool box #ajf ,tanks #ajg ,/&s #ajh ,saddle po/ #aji ,safety gu>ds #aaj ,skid plate #aaa #ajb4 ,,*a9 ,,gu>ds4 a4 ,remove ,out] ,front ,*a9 ,gu>d 7figs4 #fh & #fi74 7#a7 ,remove nut & wa%] :i* secures c5t] ( *a9 gu>d & skid plate leftside support bracket4 7#b7 ,loos5 skid plate support bracket l[] bolt & nut & remove bracket f /ud4 7#c7 ,loos5 ! nut :i* secures footbo>d re> /ud to sideb>1 !n remove nut :i* secures footbo>d front /ud to sideb>4 ,pull front end ( footbo>d away f sideb> s t /ud w cle> end ( safety gu>d4 7#d7 ,remove ext5d$ nut :i* secures sideb> to frame front support rod4 7#e7 ,disconnect clut* control cable end at clut* foot p$al by remov+ cott] p9 & pla9 wa%] f /ud4 7#f7 ,left side footbo>d1 sideb>1 & clut* foot p$al assembly c n[ be remov$4 ,if re> end ( sideb> is l[]$1 ! front end w cle> end ( safety gu>d4 7#g7 ,remove cott] p91 nut1 spr+1 wa%]1 & bolt f *a9 gu>d re> m\nt+4 ,out] front *a9 gu>d c n[ be remov$1 expos+ eng9e sprocket1 front drive *a91 & clut* assembly4 b4 ,in/all ,out] ,front ,*a9 ,gu>d4 7#a7 ,locate out] front *a9 gu>d on c5t] support /ud 7frame re> support rod end74 ,l9e up re> m\nt+ bracket ) frame bracket4 7#b7 ,in/all bolt1 wa%]1 spr+1 nut1 & cott] p9 to secure re> m\nt+4 7#c7 ,in/all footbo>d1 sideb>1 & clut* foot p$al assembly on frame support rod ends4 ,illu/ration3 ,,ra ,,pd #cajbfd ,figure #fh--,left ,footbo>d ,assembly ,remov$ ,illu/ration3 ,,ra ,,pd #caegbi ,figure #fi--,out] ,front ,*a9 ,gu>d ,remov$ 7#d7 ,atta* front end ( sideb>4 ,in/all ext5d$ nut & lock wa%] to secure front sideb> & support rod m\nt+4 7#e7 ,in/all skid plate support bracket on support rod 79 c5t] ( *a9 gu>d71 tight5+ nut on bolt4 ,in/all nut & lock wa%] :i* secure skid plate bracket & *a9 gu>d on re> support rod4 ,tight5 nut4 7#f7 ,pull front end ( footbo>d away f sideb> s t hole 9 end ( safety gu>d l9es up ) hole 9 sideb>1 !n pass footbo>d /ud ?r\gh bo? pieces1 in/all+ wa%] & secur+ /ud nut4 ,tight5 footbo>d re> /ud nut4 7#g7 ,atta* brake control cable end to foot p$al /ud4 c4 ,remove ,re> ,*a9 ,gu>d4 7#a7 ,remove cap screw :i* secures re> *a9 oil pipe clamp1 & provides m\nt+ = front end ( *a9 gu>d on transmission sprocket cov]4 ,remove *a9 gu>d4 7#b7 ,remove *a9 gu>d f re> m\nt+ by pu%+ ! gu>d back s t /ud 7) wa%]s & spr+7 slips out ( m\nt+ clip not*4 d4 ,in/all ,re> ,*a9 ,gu>d4 7#a7 ,locate re> *a9 gu>d 9 position = m\nt+4 ,spread ! l>ge wa%] on ! re> /ud to engage clip not*4 ,pu% gu>d =w>d until front end hole l9es up ) *a9 oil] pipe clamp1 !n in/all cap screw & wa%]1 secur+ gu>d & clip to sprocket cov]4 #ajc4 ,,c>ri]s4 a4 ,remove ,ammunition ,box ,c>ri]4 7#a7 ,remove nut & screw :i* secures c>ri] bracket to front mudgu>d4 7#b7 ,remove nut & lock wa%] f rock] plate re> /ud4 ,?is frees l[] end ( c>ri]4 7#c7 ,remove nut1 wa%]1 cable clip1 & pla9 wa%] f rigid =k /ud4 ,remove c>ri] & box4 b4 ,in/all ,ammunition ,box ,c>ri]4 7#a7 ,locate hole 9 l[] end ( bracket on rock] plate re> /ud4 ,atta* upp] end ( bracket to rigid =k /ud4 ,replace lock wa%]s & nuts4 ,tight5 nuts4 7#b7 ,atta* c>ri] bracket to front mudgu>d ) screw1 wa%]1 & nut4 ,tight5 nut4 c4 ,remove & ,in/all ,scabb>d ,c>ri]4 ,! proc$ure = remov+ & in/all+ scabb>d c>ri] is ! same z outl9$ = ammunition box c>ri]1 except t scabb>d c>ri] is on left side ( vehicle4 ,foll[ proc$ure outl9$ "u /eps a & b above4 d4 ,remove ,luggage ,c>ri]4 7#a7 ,loos5 /raps ( bo? saddlebags1 & remove saddlebags f keyhole not*es 9 luggage c>ri] side plates4 ,remove nuts f "r & left side m\nt+ /uds1 :i* secure luggage c>ri] to frame clips4 ,deflate re> :eel tire s t a piece ( wood or suitable object c be us$ to depress top "p ( tire "u mudgu>d1 to provide cle>ance1 & access to ! ?ree nuts :i* secure screws = luggage c>ri] mudgu>d m\nt+4 ,,note3 ,if re> :eel is remov$1 m\nt+ screws are accessible4 7#b7 ,remove ! ?ree luggage c>ri] c5t] m\nt+ screws4 ,remove luggage c>ri] f vehicle4 e4 ,in/all ,luggage ,c>ri]4 7#a7 ,m\nt luggage c>ri] on frame clip /uds4 ,in/all wa%]s & nuts4 ,) re> tire deflat$ & depress$ = cle>ance "u mudgu>d1 in/all ! ?ree screws1 lock wa%]s1 & nuts = c>ri]mudgu>d m\nt+4 ,,note3 ,if re> :eel is remov$1 m\nt+ screws are accessible4 7#b7 ,tight5 frame /ud nuts to secure bo? sides ( c>ri]4 7#c7 ,atta* saddlebags & securely /rap to frame /ays4 7#d7 ,inflate tire to #bj p\nds4 #ajd4 ,,mudgu>ds4 a4 ,remove ,front ,mudgu>d4 7#a7 ,remove front :eel 7p>4 #abe74 7#b7 ,remove in/rum5t panel cov] 7p>4 #aai71 disconnect front mudgu>d black\t m>k] light wire at swit*4 ,pull wire out1 free f tanks4 7#c7 ,remove ! two screws & nuts f rigid =k & mudgu>d m\nt+4 ,remove ! two screws & nuts secur+ lamp bracket to mudgu>d4 7#d7 ,remove bolt & nut :i* secure ammunition box c>ri] to mudgu>d4 7#e7 ,remove bolt & nut :i* secure gun scabb>d c>ri] to mudgu>d4 7#f7 ,remove nuts f =k left rock] plate /ud4 ,^! nuts secure ammunition box l[] bracket1 & mudgu>d /ay clip4 ,remove nuts f =k "r rock] plate /ud4 ,^! nuts secure gun scabb>d c>ri] l[] bracket1 & mudgu>d /ay clip4 7#g7 ,pull c>ri] brackets (f rock] plate /uds4 ,remove mudgu>d brace clip locks f slots 9 clips s t mudgu>d c be dropp$4 ,:5 remov+ mudgu>d f vehicle1 take c>e n to break &_/or damage black\t light wire4 b4 ,in/all ,front ,mudgu>d4 7#a7 ,locate mudgu>d 9 m\nt+ position4 ,engage slots 9 /ay clips on rock] plate /uds1 in/all+ ! special locks 9 ! clip slots4 ,,note3 ,brace clip locks are made = "r & left side in/allation4 ,secure bo? clip locks ) /ud nuts4 7#b7 ,atta* ends ( ammunition & scabb>d c>ri]s to rock] plate /uds4 ,secure ) lock wa%]s & nuts4 7#c7 ,m\nt mudgu>d to rigid =k bracket4 ,tight5 ! two screws1 wa%]s1 & nuts4 7#d7 ,atta* l[] end ( headlight bracket to mudgu>d ) two bolts1 wa%]s1 & nuts4 7#e7 ,atta* ammunition box c>ri] bracket to mudgu>d4 ,tight5 bolt1 wa%]1 & nut4 7#f7 ,atta* gun scabb>d c>ri] bracket to mudgu>d4 ,tight5 bolt1 wa%]1 & nut4 7#g7 ,re9/all front :eel & brake assembly 7p>4 #abe74 7#h7 ,connect mudgu>d black\t light wire to swit* t]m9al4 ,ref] to wir+ diagram1 figure #gc4 7#i7 ,in/all in/rum5t panel cov] 7p>4 #aai74 c4 ,remove ,re> ,mudgu>d4 7#a7 ,support vehicle on re> /&4 ,remove re> :eel 7p>4 #abg74 7#b7 ,remove luggage c>ri] 7p>4 #ajc74 7#c7 ,remove re> *a9 gu>d 7p>4 #ajb74 7#d7 ,remove ! two ,ubolt nuts :i* m\nt safety gu>d at upp] frame bracket4 ,!n pull safety gu>d away f /uds & remove /uds f frame bracket1 free+ mudgu>d at ?is po9t4 ,,note3 ,^! two /uds screw into a 8plate0 nut4 7#e7 ,remove bolt & nut :i* secure batt]y box leftside bracket to mudgu>d4 7#f7 ,remove bolt & nut :i* secure batt]y box "rside bracket4 ,?is bolt also secures l[] tool box bracket & spe$omet] cable clip to mudgu>d4 7#g7 ,remove nut & wa%]s f bolt :i* secures l[] end ( mudgu>d to frame 7beh9d transmission74 7#h7 ,remove taillight connector plugs f sockets & remove cable f mudgu>d spr+ clips4 7#i7 ,remove nuts f /uds :i* secure "r & leftside mudgu>d brace clips to frame axle clips4 ,mudgu>d c n[ be remov$ f vehicle4 d4 ,in/all ,re> ,mudgu>d4 7#a7 ,locate mudgu>d 9 position = m\nt+4 ,in/all ! two /uds1 wa%]s1 & nuts :i* secure "r & leftside brace clips to frame axle clips4 ,,note3 ,if brake side cov] int]f]es ) locat+ nut on "r side1 loos5 ! brake sleeve nut & pu% brake side cov] assembly inw>d = cle>ance4 ,be sure to retight5 brake sleeve nut4 7#b7 ,atta* front l[] end ( mudgu>d4 ,in/all flat wa%]1 lock wa%]1 & nut on bolt to secure l[] end ( mudgu>d to frame 79 back ( transmission74 7#c7 ,in/all ! two /uds :i* m\nt mudgu>d & upp] batt]y box bracket on frame bracket4 ,^! two /uds screw into a plate nut locat$ und]nea? ! batt]y box bracket4 ,remov+ ! batt]y box cov] w give m access to plate nut 9 ?is /ep4 ,in/all batt]y box cov] if x is remov$ = ?is job4 7#d7 ,atta* re> safety gu>d to ! two frame bracket /uds4 ,in/all wa%]s & nuts4 ,securely tight5 nuts & tight5 ,ubolt nuts1 :i* secure ends ( safety gu>d to frame /ays4 7#e7 ,atta* batt]y box bracket to mudgu>d bracket4 ,in/all bolt1 wa%]1 & nut :i* secure batt]y box "rside bracket1 tool box bracket l[] end1 & spe$omet] cable clip to mudgu>d bracket4 ,bolt is ins]t$ f front side1 head t[>d eng9e4 ,,note3 ,spe$omet] cable clip is "u head ( bolt4 7#f7 ,atta* leftside mudgu>d bracket & batt]y box bracket4 ,in/all bolt1 wa%]1 & nut :i* secure batt]y box leftside bracket to mudgu>d bracket4 ,bolt is ins]t$ f front side1 head t[>d eng9e4 7#g7 ,in/all re> *a9 gu>d 7p>4 #ajb74 7#h7 ,locate & reta9 taillight cable 9 mudgu>d spr+ clips4 ,atta* connector plugs to taillights 7wir+ diagram1 fig4 #gc74 7#i7 ,in/all luggage c>ri] 7p>4 #ajc74 7#aj7 ,in/all re> :eel 7p>4 #abg74 7#aa7 ,securely tight5 all bolts & nuts4 #aje4 ,,batt]y ,,box4 a4 ,remove ,batt]y ,box4 7#a7 ,remove batt]y 7p>4 #aac74 7#b7 ,to remove re> brake rod1 disconnect clevis f brake lev]1 & free front end ( rod at brake %aft bell crank4 7#c7 ,remove re> *a9 gu>d 7p>4 #ajb74 7#d7 ,remove tool box & bracket 9 "o piece 7p>4 #ajf74 7#e7 ,remove nut & bolt secur+ left side l[] batt]y box m\nt+ to mudgu>d bracket4 ,remove nut & bolt secur+ batt]y front m\nt+ to frame saddle po/ tube bracket4 7#f7 ,remove ! two nuts secur+ re> safety gu>d c5t] connection to m\nt+ /uds4 ,unscrew m\nt+ /uds to free ! plate nut :i* clamps ! batt]y box bracket to frame cross memb]4 7#g7 ,remove batt]y box f "r side ( vehicle4 b4 ,in/all ,batt]y ,box4 ,locate batt]y box 9 vehicle f left side & secure upp] re> m\nt+ bracket ) ! two frame cross memb] /uds & ! plate nut4 ,in/all wa%]s & nuts :i* secure safety gu>d to ^! same two /uds4 7#a7 ,in/all bolt to secure batt]y box front m\nt+ to frame tube4 ,make sure t bolt passes ?r\gh frame tube bracket f left side1 & t l>ge pla9 wa%] be>s aga9/ batt]y box front bracket 7bracket has op5 end74 ,tight5 nut to secure box bracket to frame tube bracket4 7#b7 ,in/all tool box & bracket 7p>4 #ajf74 7#c7 ,in/all bolt1 wa%]1 & nut :i* secure batt]y box leftside m\nt+ to mudgu>d4 ,ins]t bolt f ! front4 7#d7 ,in/all re> *a9 gu>d 7p>4 #ajb74 7#e7 ,connect re> brake rod end to bell crank fitt+4 ,atta* clevis to brake op]at+ lev]1 in/all+ pla9 wa%]1 clevis p91 & cott] p94 7#f7 ,in/all batt]y 7p>4 #aac74 #ajf4 ,,tool ,,box4 a4 ,g5]al4 ,:5 tool box only is to be remov$ &_/or in/all$1 x is a simple matt] to op5 box & remove &_/or in/all ! ?ree l>ge screws4 ,ge>too!d lock wa%]s & l>ge recess$ wa%]s fit "u screw heads4 b4 ,remove ,box & ,bracket ,assembly4 ,remove bolt & nut :i* secure tool box upp] m\nt+ bracket to frame clip4 ,l[] end ( m\nt+ bracket1 batt]y box bracket1 & spe$omet] cable are all secur$ to ! mudgu>d bracket by ! same bolt & nut4 ,remove spe$omet] cable f clip & remove bolt & nut1 free+ tool box & bracket assembly = removal4 ,,note3 ,removal ( re> brake rod w make bracket l[] m\nt+ bolt & nut m accessible4 c4 ,in/all ,box & ,bracket ,assembly4 ,locate box & bracket assembly on vehicle & in/all bolt1 wa%]1 & nut at ! upp] frame clip m\nt+4 ,to atta* bracket l[] end to mudgu>d bracket1 place bolt ?r\gh spe$omet] cable clip1 !n ?r\gh box m\nt+ bracket1 batt]y box bracket1 & mudgu>d bracket1 secur+ assembly ) lock wa%] & nut4 ,illu/ration3 ,,ra ,,pd #cajbde ,figure #gj--;,fuel & ,oil ,tanks ,remov$ #ajg4 ,,tanks 7fig4 #gj74 a4 ,g5]al4 ,fuel & oil tanks are sep>ate1 fitt+ toge!r1 saddletype1 9 upp] frame tubes1 & are reta9$ 9 position ) ?ree m\nt+ bolts4 ,ei!r tank c be remov$ &_/or in/all$ )\t di/urb+ l9e connections ( ! o!r tank4 b4 ,fuel ,tank4 ,fuel tank is locat$ on left side ( vehicle & holds slightly ov] #c ,u4,s4 gallons4 ,x provides m\nt+ = %ift] lev] & %ift] lev] guide4 ,dra9 is locat$ 9 =w>d position on "u side ( tank4 c4 ,oil ,tank4 ,oil tank is locat$ on "r side ( vehicle & holds #a ,u4,s4 gallon4 ,oil fe$ pipe1 scav5g] 7return7 pipe1 & brea!r pipe connections are on "u side ( tank4 ,dra9 is locat$ 9 =w>d position on "u side ( tank4 d4 ,remove ,fuel ,tank4 7#a7 ,disconnect batt]y negative gr\nd wire at frame connection4 7#b7 ,loos5 ! two cap screws :i* secure caution plate & tank top /rip4 7#c7 ,remove in/rum5t panel cov] 7p>4 #aai74 7#d7 ,disconnect ge> %ift] lev] & %ift] rod by remov+ bolt4 7#e7 ,%ut (f fuel supply4 ,disconnect fuel pipe at tank union nipple4 7#f7 ,remove nuts1 lock wa%]s1 & flat wa%]s f ! two front 7"o upp] & "o l[]7 m\nt+ bolts1 & nut1 lock wa%]1 & flat wa%] f ! re> m\nt+ bolt4 ,leave bolts 9 place s t oil tank w /ay 9 position aft] fuel tank is remov$4 ,remove fuel tank f vehicle4 e4 ,in/all ,fuel ,tank4 7#a7 ,position fuel tank on vehicle4 ,pass ! ?ree m\nt+ bolts ?r\gh tank brackets f "r side ( vehicle4 ,x w be necess>y to pry up on tank top /rip 9 ord] to slip top edge ( tank "u /rip4 ,in/all l>ge flat wa%]s1 lock wa%]s1 & nuts on m\nt+ bolts & securely tight5 ! nuts4 7#b7 ,tight5 ! two cap screws1 secur+ caution plate & tank top /rip4 7#c7 ,connect fuel pipe at tank nipple union4 ,op5 supply valve4 7#d7 ,in/all in/rum5t panel cov] 7p>4 #aai74 7#e7 ,connect ge> %ift] lev] & %ift] rod by in/all+ bolt1 lock wa%]1 & nut4 7#f7 ,connect batt]y negative gr\nd wire to frame connection4 7#g7 ,aft] fuel tank has be5 fill$1 *eck pipe connection & dra9 plug = leaks4 f4 ,remove ,oil ,tank4 7#a7 ,disconnect batt]y negative gr\nd wire at frame connection4 7#b7 ,loos5 ! two cap screws :i* secure caution plate & tank top /rip4 7#c7 ,remove in/rum5t panel cov] 7p>4 #aai74 7#d7 ,dra9 oil f tank by remov+ dra9 plug4 ,use a tr\gh 7( c>dbo>d or t97 to keep oil f dra9+ on eng9e4 ,,note3 ,if oil fe$ pipe nipple cap 7manufactur]'s 7,h-,d7 ,no4 #cehc-ae7 is available1 x c be screw$ on to tank nipple1 ?us elim9at+ dra9+ ( oil4 7#e7 ,disconnect oil fe$ pipe at re> nipple union4 7#f7 ,disconnect scav5g] 7return7 pipe at nipple union4 7#g7 ,disconnect brea!r pipe banjotype connection by tak+ out bolt4 7#h7 ,remove nuts1 lock wa%]s1 & flat wa%]s f ! two front 7"o upp] & "o l[]7 m\nt+ bolts1 & nut1 lock wa%]1 & flat wa%] f re> m\nt+ bolt4 ,,note3 ,to prev5t fuel tank f fall+ out ( frame1 remove upp] front m\nt+ bolt & re> m\nt+ bolt & pass bo? back ?r\gh fuel tank m\nt+ brackets f ! left side ( vehicle4 ,oil tank c !n be remov$1 & fuel tank w /ay 9 place4 g4 ,in/all ,oil ,tank4 7#a7 ,position oil tank on vehicle4 ,make sure t composition buff] is 9 place be=e in/all+ m\nt+ bolts f "r side ( vehicle4 ,pry up on tank top /rip 9 ord] to slip top edge ( tank "u /rip4 7#b7 ,in/all l>ge flat wa%]s1 lock wa%]s1 & nuts on m\nt+ bolts4 ,securely tight5 ! nuts4 7#c7 ,tight5 ! two cap screws secur+ caution plate & tank top /rip4 7#d7 ,connect oil fe$ pipe to tank nipple4 ,tank nipple is locat$ at l[] re> end ( tank4 7#e7 ,connect scav5g] 7return7 pipe to tank nipple4 ,nipple is locat$ und]nea? tank1 ne> c5t]4 7#f7 ,connect brea!r pipe ) banjotype fitt+ to tank4 ,use holl[ bolt1 mak+ sure flat wa%]s are 9 place on bo? sides ( banjo fitt+ & t m\nt+ bolt is tight4 7#g7 ,in/all in/rum5t panel cov] 7p>4 #aai74 7#h7 ,see t oil tank dra9 plug & wa%] are 9 place1 & t ! plug is tight4 7#i7 ,connect batt]y negative gr\nd wire to frame connection4 7#aj7 ,aft] fill+ oil tank1 *eck all pipe fitt+s = leaks4 #ajh4 ,,/&s4 a4 ,remove ,re> ,/&4 ,remove nuts :i* secure re> /& m\nt+ bolts4 ,drift bolts out ( frame clip holes1 free+ /&4 b4 ,in/all ,re> ,/&4 ,locate /& 9 position s t bracket /op is d[nw>d & w be> aga9/ frame axle clips to support vehicle :5 /& is 9 use4 ,see t cupp$ spr+ wa%]s are on m\nt+ bolts be=e atta*+ /& to frame4 ,drift m\nt+ bolts into frame axle clips & secure ) lock wa%]s & nuts4 c4 ,remove ,jiffy ,/&4 7#a7 ,support vehicle on re> /&4 7#b7 ,loos5 footbo>d re> support /ud nut4 ,remove footbo>d front support rod nut & pull footbo>d outw>d to release end ( safety gu>d4 ,remove ext5d$ nut f footbo>d sideb> front m\nt+4 ,remove nut secur+ upp] end ( skid plate hang] & sideb> re> m\nt+ 7locat$ 9 c5t] ( *a9 gu>d cov]74 ,loos5 nut & bolt :i* secure skid plate hang] bracket to skid plate3 drop bracket4 ,disconnect clut* control cable f foot p$al /ud to prev5t damage to cable end piece4 ,remove left footbo>d1 clut* foot p$al1 & sideb> assembly f support rod ends4 ,illu/ration3 ,,ra ,,pd #cajbfi ,figure #ga--,saddle & ,susp5sion 7#c7 ,remove ! two nuts f ,ubolt :i* secure safety gu>d bracket to frame tube1 remove bracket f ,ubolt1 & slide safety gu>d assembly out ( support rod4 d4 ,in/all ,jiffy ,/&4 7#a7 ,in/all safety gu>d assembly on support rod & secure m\nt+ bracket to frame tube ) ,ubolt1 wa%]s1 & nuts4 7#b7 ,in/all footbo>d1 clut* foot p$al1 & sideb> assembly4 ,atta* skid plate hang] bracket & secure to support rod4 ,atta* clut* control cable end to foot p$al /ud1 in/all+ pla9 wa%] & cott] p94 ,in/all wa%] & ext5d$ nut on end ( front support rod4 ,securely tight5 nut4 ,atta* front end ( sideb> to end ( safety gu>d by pull+ front ( footbo>d outw>d1 al9+ hole 9 safety gu>d end ) hole 9 sideb>1 & pass+ footbo>d front support /ud ?r\gh bo? p>ts1 secur+ ) wa%] & nut4 ,tight5 footbo>d re> support /ud nut4 7#c7 ,return vehicle to op]at+ position4 #aji4 ,,saddle ,,po/ 7fig4 #ga74 a4 ,saddle is m\nt$ on saddle b> by means ( ?ree m\nt+ bolts & c be %ift$ =w>d or backw>d to provide ?ree positions on saddle b>4 ,spac] coll>s c be add$ & or remov$ f ! two re> m\nt+s to raise or l[] re> ( saddle to alt] rid+ position4 ,saddle b> h+es on frame bracket & is clevisconnect$ to saddle spr+ po/4 ,saddle & saddle b> c be lift$ upw>d & =w>d aft] releas+ spr+ lat* 7on left side7 f groove 9 clevis p9 end & remov+ clevis p9 f saddle b>4 b4 ,remove ,saddle ,spr+ ,po/4 ,support vehicle on re> /&4 ,raise saddle & saddle b> aft] remov+ saddle po/ clevis p94 ,remove bolt & nut f leftside skid plate bracket & remove nut to free "rside skid plate bracket at muffl] pipe clamp & frame connection4 ,drop skid plate4 ,remove saddle spr+ po/ clamp nut1 :i* is locat$ und]nea? frame at bottom end ( saddle po/ frame tube4 ,saddle spr+ po/ assembly c be pull$ upw>d out ( frame tube4 c4 ,in/all ,saddle ,spr+ ,po/4 ,:5 saddle spr+ po/ assembly is ins]t$ 9 frame tube1 see t flat side ma*9$ on po/ rod end nut regi/]s 9 flat side ( hole 9 bottom ( frame tube4 ,in/all & securely tight5 saddle spr+ po/ clamp nut at bottom end ( frame tube4 ,lift skid plate & secure 9 position ) leftside bracket bolt1 wa%]1 & nut & ) "r bracket bolt1 wa%]1 & nut 7?is also secures muffl] pipe clamp to frame clip74 ,l[] saddle & saddle b> into position4 ,ins]t clevis p9 f "r side & secure ) spr+ lat*1 mak+ sure t spr+ is 9 p9 groove4 #aaj4 ,,safety ,,gu>ds4 a4 ,remove ,front ,safely ,gu>d4 7#a7 ,loos5 nuts :i* secure "r & left footbo>d re> support /uds to sideb>s4 ,remove nuts :i* secure "r & left footbo>d front support /uds 7& m\nt ends ( safety gu>d7 to sideb>s4 ,pull front end ( ea* footbo>d outw>d s t support /ud w free end ( safety gu>d4 ,remove f\r nuts f ! two ,ubolts :i* m\nt safety gu>d upp] bracket to frame tube4 ,remove safety gu>d4 b4 ,in/all ,front ,safety ,gu>d4 ,locate safety gu>d & m\nt upp] bracket to frame tube ) ! two ,ubolts1 wa%]s1 & nuts1 b d n tight5 nuts z yet4 ,pull front end ( "r footbo>d outw>d1 l9e up hole 9 safety gu>d end ) hole 9 sideb>1 & pass footbo>d front support /ud ?r\gh bo? p>ts1 secur+ ) wa%] & nut4 ,foll[ same proc$ure to m\nt left end ( safety gu>d4 ,tight5 ,ubolt nuts securely4 c4 ,remove ,re> ,safety ,gu>d4 ,remove nuts f ,ubolts :i* m\nt ends ( safety gu>d to l[] frame /ays4 ,remove ! two nuts f upp] safety gu>d m\nt+4 ,aft] remov+ ,ubolts1 safety gu>d c be remov$ f vehicle4 d4 ,in/all ,re> ,safety ,gu>d4 ,position safety gu>d on vehicle4 ,in/all ,ubolts1 wa%]s1 & nuts = l[] end m\nt+ on frame /ays4 ,d n tight5 nuts4 ,engage upp] m\nt+ holes on /uds & replace wa%]s & nuts4 ,tight5 all m\nt+ nuts4 ,illu/ration3 ,,ra ,,pd #cajbcd ,figure #gb--,%[+ ,skid ,plate ,dropp$ #aaa4 ,,skid ,,plate4 a4 ,re> end ( skid plate mu/ be dropp$ :5 remov+ & or replac+ muffl] assembly1 saddle spr+ po/1 transmission1 & eng9e4 b4 ,drop ,skid ,plate 7fig4 #gb74 7#a7 ,remove nut f bolt :i* secures skid plate side m\nt+ bracket to frame clip4 ,?is bolt also m\nts muffl] tube clamp to frame clip4 7#b7 ,remove left side m\nt+4 ,remove nut & bolt :i* secures l[] end ( hang] bracket to skid plate on left side ( vehicle4 ,drop re> end ( skid plate4 c4 ,in/all ,dropp$ ,skid ,plate4 7#a7 ,lift re> end ( skid plate into position4 ,atta* "rside bracket at frame clip bolt4 ,secure m\nt+ ) wa%] & nut4 7#b7 ,atta* l[] end ( leftside hang] bracket to skid plate4 ,in/all bolt1 wa%]1 & nut4 ,tight5 nut4 d4 ,remove &_/or ,in/all ,skid ,plate4 7#a7 ,to remove skid plate f vehicle1 foll[ in/ructions 9 /ep b above2 !n remove nut & bolt f ,uclamp :i* secures skid plate to frame bracket1 & remove nut & belt f clamp :i* secures "r front end to support rod4 7#b7 ,to in/all skid plate1 m\nt "r front end to support rod clamp1 & in/all bolt & nut to secure ,uclamp "u frame bracket4 ,!n foll[ in/ructions 9 /ep c above4 ,section ,,xxiii ,,batt]y1 ,,light+ ,,sy/em1 ,,horn ,p>agraph ,description #aab ,batt]y #aac ,headlights #aad ,taillights #aae ,ignition & light swit* #aaf ,horn #aag ,wir+ #aah #aab4 ,,description4 a4 ,light+ sy/em & horn are suppli$ #fvolt curr5t f ! #bb;amp]eh\r batt]y4 ,negative side ( batt]y & sy/em is gr\nd$4 ,black\t lights & s]vice lights are controll$ by ! same swit* 7ignition & light swit*7 :i* also controls ignition4 ,black\t headlight has auxili>y control swit* 9 body4 ,s]vice headlight upp] & l[] beam is controll$ by toggle swit* on left h&le b>4 ,horn is op]at$ by button on left h&le b> aft] ignition & light swit* is 9 8,,on0 position4 ,black\t /op light & s]vice /op light are op]at$ by brake foot p$al swit*4 #aac4 ,,batt]y4 a4 ,! #c;cell1 #aeplate1 #fvolt1 #bb;amp]eh\r batt]y is locat$ 9 batt]y box back ( frame seat po/ tube1 & is accessible = inspection & or s]vice aft] remov+ box cov]4 ,normally *>g$ batt]y has specific gravity read+ ( #a4bge4 ,normally dis*>g$ batt]y has specific gravity ( #a4aej4 b4 ,*eck ,electrolyte ,level 7fig4 #gd74 7#a7 ,raise saddle & b> assembly aft] releas+ & remov+ swivel p94 7#b7 ,loos5 w+ ?umb nuts on box top holdd[n /uds suffici5tly to dis5gage bracket slots1 !n lift (f box cov]4 7#c7 ,remove ! ?ree fill] plugs4 ,*eck & or adju/ electrolyte level4 ,see t electrolyte level is #e_/af in* above plates4 ,if necess>y1 br+ electrolyte to t level1 us+ clean1 dr9kable wat]4 7#d7 ,clean top ( batt]y be=e in/all+ box cov]4 7#e7 ,clean t]m9als or po/s1 if corrod$4 ,make sure t ! felt wa%]s are on po/s & are saturat$ ) eng9e oil4 c4 ,remove ,batt]y4 ,raise saddle & b> assembly4 ,release & remove swivel p94 ,loos5 w+ ?umb nuts on box top holdd[n /uds suffici5tly to dis5gage bracket slots1 !n lift (f box cov]4 ,disconnect positive & negative wires f batt]y t]m9als4 ,lift batt]y upw>d out ( batt]y box4 ,illu/ration3 ,,ra ,,pd #cajbgh ,figure #gc--;,complete ,wir+ ,diagram #a4 ,,swit* ,,t]m9al 7,?ree ,wires connect$7--,black wire f black\t m>k] light #bd2 taillight cable gre5 wire f black\t taillight #bb2 s+le wire direct f black\t headlight z %[n by dott$ l9e 9 illu/ration #dc1 or horn & headlight cable black wire f junction t]m9al #ce z %[n 9 illu/ration #dd4 #b4 ,,swit* ,,t]m9al 7,f\r wires connect$7--,g5]ator & relay cable gre5 wire f 8swit*0 t]m9al 7#ad7 ( g5]ator2 taillight cable black wire f s]vice /op & taillight 7#bc72 horn & headlight cable r$ wire f junction t]m9al #ag2 black wire f spe$omet] light 7#aa74 #c4 ,,swit* ,,t]m9al 7,two wires connect$7--,g5]ator & relay cable r$ wire f t]m9al m>k$ 8,,bat0 on relay2 coil & batt]y cable r$ wire f junction t]m9al #ah4 #d4 ,,swit* ,,t]m9al 7,"o wire connect$7--,black wire f oil signal light t]m9al 7#aj74 #e4 ,,swit* ,,t]m9al 7,"o wire connect$7--,taillight cable yell[ wire f black\t /op lamp 7#ba74 #f4 ,,swit* ,,t]m9al 7,"o wire connect$7--,batt]y & coil cable black wire f junction t]m9al #ai4 #g4 ,,swit* ,,t]m9al 7,"o wire connect$7--,taillight cable r$ wire f s]vice /op & taillight 7#bc74 #h4 ,,g5]ator ,,signal ,,light ,,t]m9al 7,"o wire connect$7--,g5]ator & relay cable black wire f relay "r front t]m9al4 #i4 ,,oil ,,pressure ,,signal ,,light ,,t]m9al 7,"o wire connect$7--,black wire f oil pressure swit* 7#af74 #aj4 ,,signal ,,light ,,t]m9al 7,f\r wires connect$7--,black wire 7"u swit* panel7 f g5]ator signal light t]m9al 7#h72 black wire f swit* t]m9al 7#d72 batt]y & coil cable gre5 wire f coil front t]m9al2 horn & headlight cable gre5 wire f horn4 #aa4 ,,spe$omet] ,,light--,black wire f swit* t]m9al #b4 #ab4 ,,batt]y ,,positive ,,t]m9al 7,,left ,,side7--,r$ wire ) black trac] f junction t]m9al #ah4 #ac4 ,,batt]y ,,negative ,,t]m9al 7,,"r ,,side7--,black wire f gr\nd clamp on frame4 #ad4 8,,swit*0 ,,t]m9al ,,( ,,g5]ator--,g5]ator & relay cable gre5 wire f swit* t]m9al #b4 #ae4 8,,relay0 ,,t]m9al ,,( ,,g5]ator--,r$ wire ) black trac] f relay re> t]m9al4 #af4 ,,oil ,,pressure ,,signal ,,swit*--,black wire f signal light t]m9al #i4 #ag4 ,,junction ,,t]m9al 7,,bakelite ,,t]m9al ,,plate ,,on ,,horn ,,m\nt+7--,horn & headlight cable r$ wire f swit* t]m9al #b1--r$ wire ) black trac] f h&leb> toggle swit* 7#ca74 #ah4 ,,front ,,junction ,,t]m9al 79 motorcycle frame1 "u saddle7--,coil & batt]y cable r$ wire f swit* t]m9al #c2 r$ wire ) black trac] f batt]y positive t]m9al 7#ab74 #ai4 ,,re> ,,junction ,,t]m9al 79 motorcycle frame1 "u saddle7--,coil & batt]y cable black wire f swit* t]m9al #f2 r$ wire f /op light swit* 7#bj74 ,,ra ,,pd #cajbgh;,b #bj4 ,,/op ,,light ,,swit*--,r$ wire f junction t]m9al #ai2 gre5 wire f coil t]m9al4 #ba4 ,,black\t ,,/op ,,light 7,top socket 9 "r taillight7--,taillight cable yell[ wire f swit* t]m9al #e4 #bb4 ,,black\t ,,taillights--,taillight cable gre5 wire f swit* t]m9al #a4 #bc4 ,,s]vice ,,tail ,,& ,,/op ,,light 7top socket 9 left taillight--two wires 9 "o plug7--,taillight cable black wire f swit* t]m9al #b is = s]vice taillight1 & taillight cable r$ wire f swit* t]m9al #g is = s]vice /op light4 #bd4 ,,black\t ,,m>k] ,,light 7,,on ,,front ,,mudgu>d7--,black wire f swit* t]m9al #a4 #be4 ,,s]vice ,,headlight--,black wire ) r$ trac] f h&leb> toggle swit* 7#ca7 to l>ge t]m9al screw2 r$ wire ) yell[ trac] f h&leb> toggle swit* to small t]m9al screw4 #bf4 ,,ignition ,,& ,,light ,,swit* 7,,top ,,view7--,swit* 8,,(f0 9 /raightahead position4 #bg4 ,,black\t ,,headlight--,black\t headlight is fitt$ ) indep5d5t swit* 9 lamp body4 #bh4 ,,sp>k ,,coil--,coil & batt]y cable gre5 wire f t]m9al #aj to coil front t]m9al2 gre5 wire f /op light swit* 7#bj7 to coil front t]m9al2 l[ t5sion wire 7#cd7 f circuit break] 7#cc7 to coil re> t]m9al4 #bi4 ,,horn--,horn & headlight cable gre5 wire f t]m9al #aj2 black wire f horn swit* 7#cj74 #cj4 ,,horn ,,swit*--,black wire f horn4 #ca4 ,,h&leb> ,,toggle ,,swit*--,black wire ) r$ trac] f s]vice headlight t]m9al ) l>ge t]m9al screw2 r$ wire ) yell[ trac] to s]vice headlight t]m9al ) small t]m9al screw2 r$ wire ) black trac] f junction t]m9al #ag4 #cb4 ,,cut,,out ,,relay--,r$ wire ) black trac] f 8relay0 t]m9al ( g5]ator to relay re> t]m9al2 g5]ator & relay cable r$ wire f swit* t]m9al #c to relay t]m9al m>k$ 8,,bat02 g5]ator & relay cable black wire f t]m9al #h1 to relay "r front t]m9al4 #cc4 ,,ignition ,,circuit ,,break] ,,& ,,tim]--,l[ t5sion wire 7#cd7 f coil re> t]m9al4 #cd4 ,,circuit ,,break],,to,,coil ,,l[ ,,t5sion ,,wire--,see ,description #cc4 #ce4 ,,junction ,,t]m9al ,,on ,,bakelite ,,t]m9al ,,plate--,horn & headlight cable black wire f swit* t]m9al #a2 wire f black\t headlight 7#bg74 ,all ,,wla model motorcycles orig9ally equipp$ ) radio int]f]5ce suppressiondevices1 or to :i* suppressiondevices h be5 add$1 c be id5tifi$ by a l>ge lett] ,s /5cil$ on left & "r sides ( in/rum5t panel cov]4 99,a ,,gr\nd ,,t]m9als ,,on ,,coil ,,h\s+4 99,b ,,flexible ,,braid ,,conductor4 99,c ,,cond5s]4 99,d ,,%ield$ ,,circuit ,,break],,to,,coil ,,l[ ,,t5sion ,,wire4 99,e ,,sp>k ,,plug ,,suppressors4 99,h ,,cond5s]4 ,,ra ,,pd #cajbgh;,c ,leg5d = ,figure #gc--;,complete ,wir+ ,diagram ,illu/ration3 ,,ra ,,pd #cajbdg ,figure #gd--;,batt]y ,box ,op5 & ,fill] ,plugs ,remov$ = ,s]vice d4 ,in/all ,batt]y4 ,see t rubb] mat is 9 place 9 bottom ( batt]y box & in/all batt]y 9 box s t positive po/ is on left side ( vehicle1 & negative po/ is on "r side ( vehicle4 ,connect wires to batt]y positive & negative po/s4 ,fit rubb] mat on top ( batt]y4 ,in/all cov] & securely tight5 ?umb w+ nuts4 ,l[] saddle & b> assembly4 ,in/all swivel p9 on "r side ( vehicle s t reta9+ spr+ fits 9 groove 9 end ( swivel p94 #aad4 ,,headlights4 a4 ,s]vice ,headlight4 7#a7 ,remove nut :i* secures light body to bracket1 obs]v+ t conical wa%] be>s aga9/ cup ( bracket = secure light m\nt+4 ,disconnect wires f light body t]m9als4 7#b7 ,be=e in/all+ s]vice headlight1 connect wires to light body t]m9als1 not+ t black wire ) r$ trac] connects ) ! l>g] t]m9al screw4 ,m\nt light on bracket4 ,position conical%ap$ wa%] & lock wa%] & in/all m\nt+ /ud nut4 ,d n tight5 m\nt+ nut4 b4 ,adju/ ,s]vice ,headlight4 ,adju/m5t %\ld be made 9 d>k5$ area or at night1 tactical situation p]mitt+4 ,vehicle mu/ be /&+ on a level surface ab\t #be feet away f & head$ t[>d a wall or scre5 ^u :i* a horizontal l9e has be5 drawn at exactly ! same height z s]vice headlight c5t]4 ,set h&le b> toggle swit* 9 8,,bright0 position & *eck light beam = height & direction4 ,! top ( ma9 beam ( light %\ld regi/] on wall or scre5 ev5 )1 b n high] ?an1 ! horizontal l9e m5tion$4 ,tilt light body 9 bracket up or d[n to correctly aim x 9 relation to ! horizontal l9e1 mak+ sure t light body is n turn$ ei!r to "r or left4 ,securely tight5 m\nt+ /ud nut4 ,illu/ration3 ,,ra ,,pd #cajbge ,figure #ge--;,black\t ,headlight ,in/allation c4 ,black\t ,headlight4 ,black\t headlight is m\nt$ on bracket :i* atta*es to left upp] side ( front =k4 ,black\t headlight op]ates :5 ignition & light swit* is turn$ to ! second "r position4 ,h[ev]1 black\t headlight is fitt$ ) an indep5d5t swit* 9 light body to p]mit turn+ x (f :ile o!r black\t lights are 9 use4 ,black\t headlight body is secur$ to m\nt+ bracket by means ( a conical wa%]1 lock wa%]1 & m\nt+ nut1 provid+ a swivel m\nt+ to p]mit light adju/m5t4 d4 ,black\t ,m>k] ,light4 ,! black\t m>k] light is secur$ to front mudgu>d by means ( a holl[ m\nt+ /ud1 ) pla9 wa%]1 lock wa%]1 & nut4 ,light wire passes ?r\gh holl[ /ud & is protect$ by tub+ on "u side ( mudgu>d4 ,black\t m>k] light wire connects ) ,no4 #a po/ on ignition & light swit*4 ,lamp is on ) ignition & light swit* 9 second "r position4 #aae4 ,,taillights4 a4 ,black\t ,/op & ,taillight4 ,black\t /op & taillight is m\nt$ on "r side ( taillight bracket4 ,light is provid$ ) top unit to provide black\t /op light controll$ by brakeop]at$ /op light swit*4 ,bottom unit 9 ! black\t /op & taillight is regul>ly us$ z s]vice black\t taillight & is controll$ by ignition & light swit*4 ,illu/ration3 ,,ra ,,pd #cajbgb ,figure #gf--;,ignition & ,light ,swit*1 ,front & ,back ,positions b4 ,s]vice ,/op & ,taillight4 ,light is locat$ on left side ( light m\nt+ bracket4 ,top unit is us$ = s]vice /op & taillight 7d\ble filam5t lamp74 ,taillight filam5t is controll$ by ignition & light swit*2 /op lamp filam5t is controll$ by brakeop]at$ /op light swit*4 ,/op light does n op]ate 9 daytime :5 ignition only is turn$ on4 ,bottom unit s]ves z a sp>e black\t taillight4 ,9 case ! regul>ly us$ 7"rside7 black\t taillamp fails1 its socket plug c be transf]r$ to ?is taillight socket4 c4 ,/op & ,taillight ,swit*4 ,?is swit* is op]at$ by brake p$al & is locat$ on end ( re> support rod on "r side ( vehicle4 ,ref] to wir+ diagram 7fig4 #gc7 & p>agraph #aah = wir+ connections4 #aaf4 ,,ignition ,,& ,,light ,,swit*4 a4 ,e>li] models are provid$ ) lock1 lat] models are nonlock+4 ,illu/ration3 #h--;,,g5]ator ,,signal ,,light4 #ad--;,,g5]ator ,,t]m9al ,,to ,,swit*4 #ae--;,,g5]ator ,,t]m9al ,,to ,,relay4 #bf--;,,ignition,,light ,,swit*4 #cb--,,relay4 #ce--,,t]m9al ,,/rip ,,b9d+ ,,po/4 #cf--,,magnetic ,,swit* ,,= ,,black\t ,,light4 ,h--,,noise ,,suppression ,,cond5s]4 ,,ra ,,pd #cajbgi ,figure #gg--;,black\t ,headlight ,magnetic ,swit* on ,lat] ,models b4 ,remove4 ,disconnect batt]y gr\nd wire4 ,remove in/rum5t panel cov] 7p>4 #aai74 ,disconnect all wires f swit*4 ,remove ! f\r swit* m\nt+ screws & spac]s4 ,swit* is n[ free = removal4 c4 ,in/all4 ,m\nt swit* on in/rum5t panel base4 ,in/all f\r screws & spac]s4 ,connect wires 7fig4 #gc74 ,connect batt]y negative gr\nd wire to frame4 ,turn swit* on4 ,*eck lights & horn1 tactical situation p]mitt+4 ,in/all in/rum5t panel cov] 7p>4 #aai74 ,illu/ration3 ,,ra ,,pd #cajbgj ,figure #gh--,wir+ ,cables1 ,left ,side ,illu/ration3 ,,ra ,,pd #cajbga ,figure #gi--,wir+ ,cables1 ,"r ,side #aag4 ,,horn4 a4 ,description4 ,horn is m\nt$ to headlight bracket by means ( f\r bolts1 lock wa%]s1 & nuts4 ,"o horn t]m9al is connect$ ) op]at+ button1 & o!r t]m9al is connect$ to ,no4 #d ignition & light swit* t]m9al 7fig4 #gc74 b4 ,adju/4 ,tone adju/+ screw is locat$ 9 re> side ( horn4 ,if horn fails to op]ate & mov+ ! adju/+ screw does n rem$y ! tr\ble1 horn mu/ be replac$4 ,,note3 ,d n *ange position ( ! adju/+ screw locat$ 9 c5t] ( diaphragm4 #aah4 ,,wir+4 a4 ,cable ,sy/em4 ,s9ce ignition & lights are controll$ by ! ignition & light swit*1 all wires t]m9ate at ! ignition & light swit*4 ,cables = wire protection are us$1 mak+ x necess>y to replace cables r ?an individual wires4 ,a /udy ( figure #gc w be helpful :5 remov+ or in/all+ any ( ! wir+ cables4 ,also /udy figures #gh & #gi & note h[ cables are arrang$ on frame1 & h[ !y lead to ! swit* panel4 b4 ,remove & ,in/all ,cables4 ,:5 x becomes necess>y to replace wir+ cables lead+ to ! ignition & light swit*1 bo? fuel & oil tanks mu/ be remov$ 7p>4 #ajg7 & in/rum5t panel cov] remov$ 7p>4 #aai7 = accessibility4 ,section ,,xxiv ,,in/rum5t ,,panel ,p>agraph ,panel cov] #aai ,indicator lights #abj ,spe$omet] head #aba #aai4 ,,panel ,,cov] 7fig4 #hj74 a4 ,remove4 ,remove spe$omet] light swit* knob & remove screw4 ,remove hexagonhead screw on front ( cov]4 ,remove two screws f side ( cov]4 ,remove two screws & wa%]s :i* fa/5 plate to "r side ( cov]4 ,lift cov] (f panel4 ,illu/ration3 ,,ra ,,pd #caegca ,figure #hj--,panel ,cov] ,remov$ b4 ,in/all4 ,position cov] on panel4 ,in/all two side m\nt+ screws & wa%]s & in/all hexagonhead screw1 pla9 wa%]1 & lock wa%] 9 front end ( cov]4 ,atta* cov] side plate1 in/all+ two screws & wa%]s4 ,in/all spe$omet] light swit* knob & screw4 #abj4 ,,indicator ,,lights4 a4 ,?ree #b-;c4p4 s+lecontact lamps are locat$ on in/rum5t panel4 ,"o = oil pressure 7r$7 indicator light3 "o = g5]ator*>ge 7gre57 indicator light1 & "o = spe$omet] illum9ation4 b4 ,remove &_/or ,in/all4 ,remove &_/or in/all panel cov] 7p>4 #aai74 c4 ,te/ ,g5]ator,*>ge 7,gre57 ,indicator ,lamp4 ,disconnect black wire f relay t]m9al 7top t]m9al at front end ( relay7 & gr\nd on relay base4 ,turn ignition & light swit* on4 ,lamp %\ld light4 ,if x does n light1 *eck wire = condition &_/or replace lamp aft] remov+ panel cov] 7p>4 #aai74 d4 ,te/ ,oil ,pressure 7,r$7 ,indicator ,lamp4 ,disconnect wire f oil pressure swit*4 ,gr\nd ! wire on eng9e4 ,turn ignition & light swit* on4 ,lamp %\ld light4 ,if x does n light1 *eck wire = condition &_/or replace lamp aft] remov+ panel cov] 7p>4 #aai74 ,if lamp & wir+ are satisfactory1 replace oil pressure swit*4 #aba4 ,,spe$omet] ,,head4 a4 ,remove4 ,remove in/rum5t panel cov] 7p>4 #aai74 ,loos5 ! two tank front m\nt+ bolts & remove re> m\nt+ bolt to free spe$omet] cable clamp4 ,disconnect spe$omet] cable at drive unit4 ,free cable f clip locat$ bel[ tool box4 ,remove two screws :i* m\nt head to frame4 ,pull head upw>d1 work+ cable =w>d "u tank1 until head & cable connection nut is cle> ( frame4 ,unscrew cable nut4 ,,note3 ,cable may be secur$ to frame tube1 betwe5 tanks1 ) friction tape4 ,if s1 cut tape4 b4 ,in/all4 ,atta* spe$omet] head to cable end & tight5 nut4 ,pass cable d[n into frame hole1 pull+ on re> ( cable at same "t4 ,m\nt spe$omet] head to frame ) two screws & lock wa%]s4 ,in/all panel cov] 7p>4 #aai74 ,secure cable clamp "u head ( tank re> m\nt+ bolt4 ,secure cable 9 clip1 locat$ "u tool box4 ,atta* end ( cable to drive unit4 ,tight5 ! two tank front m\nt+ bolts4 ,section ,,xxv ,,tires1 ,,:eels1 ,,& ,,hubs ,p>agraph ,description #abb ,tires #abc ,rims & spokes #abd ,front :eel replacem5t #abe ,front :eel hub adju/m5t #abf ,re> :eel replacem5t #abg #abb4 ,,description4 a4 ,:eels h drop c5t] rims to accommodate #d4jj x #ah tires4 ,front & re> :eels are n int]*angeable4 ,front :eel hub is ( ballbe>+ design1 hav+ cone adju/m5t simil> to t ( a bicycle hub4 ,re> :eel hub is ( roll]be>+ design & mu/ be tak5 ap>t = adju/m5t4 ,bo? :eels h 8knockout0 type axles4 #abc4 ,,tires4 a4 ,description4 ,:eel rims are ( ! dropc5t] type1 hav+ a depression1 or well1 9 c5t] ( rim4 ,! rim well1 be+ small] 9 circumf]5ce ?an ! re/ ( ! rim1 all[s "o cas+ bead to fit loosely 9 x :ile o!r bead is be+ work$ ov] edge ( rim4 ,be> 9 m9d ! importance ( keep+ "o bead 9 rim well :ile o!r bead is be+ work$ onto or (f rim4 ,,note3 ,x is n always necess>y to completely remove cas+ f rim4 ,remov+ "o side only all[s inn] tube to be remov$ & re9/all$1 & also all[s inside ( cas+ to be inspect$4 b4 ,remove4 7#a7 ,remove :eel f vehicle & lay :eel on its side4 ,to remove front :eel1 ref] to p>agraph #abe4 ,to remove re> :eel1 ref] to p>agraph #abg4 7#b7 ,remove valve cap & valve core to free all air f tube4 7#c7 ,press cas+ head into rim well to )9 a %ort di/ance ( ea* side ( valve4 7#d7 ,us+ tire iron 8,b0 9 vehicle kit 7fig4 #aa71 />t bead ov] edge ( rim at valve4 ,d n use =ce :5 />t+ bead ov] edge ( rim ) tire iron1 because bead wires may be brok5 or /ret*$1 & tire ru9$4 ,) fir/ bead 9 rim well1 bead on o!r side c be />t$ easily ov] edge ( rim4 ,aft] a portion ( second bead is />t$ ov] rim edge1 cas+ c be fur!r remov$ f :eel )\t aid ( tire iron4 ,illu/ration3 ,,ra ,,pd #cajbed ,figure #ha--;,disassembly = ,front ,:eel ,removal c4 ,in/all4 ,be=e apply+ cas+ to rim1 see t rubb] rim /rip is 9 place 9 rim well & t rim /rip valve hole al9es ) valve hole 9 rim4 7#a7 ,/>t ei!r bead ( cas+ ov] rim edge4 ,"w ar\nd :eel until entire bead is on rim4 7#b7 ,place inn] tube 9 cas+4 ,,note3 ,inn] tube may be plac$ 9 cas+ be=e or aft] fir/ bead ( cas+ is on rim4 ,ins]t valve /em ?r\gh hole 9 rim & />t valve /em lock nut4 ,:ile press+ fir/ bead into rim well1 "w rema9+ bead ov] edge ( rim1 />t+ directly opposite valve /em4 ,"w bo? ways ar\nd :eel t[>d valve4 7#c7 ,inflate front tire to #ah p\nds1 & re> tire to #bj p\nds4 7#d7 ,re9/all front :eel 7p>4 #abe73 re9/all :eel 7p>4 #abg74 ,,caution3 ,tire cas+s are balanc$ & mu/ be appli$ to rim ) balance m>k locat$ at valve /em4 ,on ,fire/one tires ! balance m>k is a r$ triangle1 & on ,goodye> tires a r$ dot4 #abd4 ,,rims ,,& ,,spokes4 a4 ,:eels ) brok5 & or miss+ spokes1 ) rims 9 badly k9k$ & or di/ort$ condition1 or hav+ consid]able runout1 mu/ be replac$4 b4 ,loose :eel spokes mu/ be tight5$ ev5ly1 be+ c>eful n to di/ort rim out(r\nd or cause runout4 ,use spoke nipple wr5* 7#da-,w-#ccci7 = front :eel spokes1 & wr5* 7#da-,w-#ccdj7 = re> :eel spokes4 #abe4 ,,front ,,:eel ,,replacem5t 7fig4 #ha74 a4 ,remove4 7#a7 ,support vehicle on re> /&4 ,raise front end ( vehicle by block+ up "u frame loop on skid plate4 7#b7 ,remove brake %ackle bolt f rigid =k on left side ( vehicle4 7#c7 ,front axle is knockout type4 ,remove cott] p9 & axle ca/le nut & pull out axle4 ,:eel is free = removal4 ,,caution3 ,be=e remov+ axle note h[ slot 9 brake /abiliz] plate is fitt$ ov] ! ext5d$ 7button7 end ( ! leftfront rock] plate /ud4 ,x is necess>y t ?is be correctly assembl$ :5 replac+ front :eel4 7#d7 ,roll :eel =w>d & remove brake assembly f brake drum1 leav+ ! assembly atta*$ to brake control wire & control wire h\s+4 b4 ,in/all 7fig4 #ha74 ,,note3 ,at ! "t :eel & brake assembly is locat$ 9 front =k1 & be=e axle is in/all$1 make sure t ! curv$ slot 9 brake /abiliz] plate engages ) ! button end ( ! leftfront rock] plate /ud4 7#a7 ,in/all brake assembly 9 brake drum4 7#b7 ,roll :eel into position4 ,engage /abiliz] plate not* & rock] plate /ud button end1 & at same "t ins]t front axle4 7#c7 ,in/all ca/le nut 7no lock wa%] us$7 on axle & securely tight54 ,illu/ration3 ,,ra ,,pd #cajbeb ,figure #hb--;,front ,hub ,prep>$ = ,cone ,adju/m5t 7#d7 ,use good cott] p9 to secure nut4 7#e7 ,in/all brake %ackle bolt & special lock wa%] & nut4 ,tight5 nut4 7#f7 ,*eck front brake control wire & h\s+ to make sure ev]y?+ is 9 ord] & correctly adju/$ 7p>4 #ig74 7#g7 ,remove block+ f "u vehicle4 #abf4 ,,front ,,:eel ,,hub ,,adju/m5t4 a4 ,front :eel1 ballbe>+ hub1 is simil> to a bicycle front hub z f> z adju/m5t is conc]n$4 ,d n completely disassemble hub = adju/m5t z balls are n 9 reta9]s1 & w fall out :5 cone is remov$4 ,hub is provid$ ) grease deflector sleeve & felt reta9]4 ,,note3 ,e>li] models are n equipp$ ) grease deflector sleeve or felt reta9] wa%]4 ,front :eel %\ld h slight play or %ake on be>+s1 & %\ld turn freely4 ,illu/ration3 ,,ra ,,pd #caegcc ,figure #hc--;,disassembly = ,re> ,:eel ,removal 7#a7 ,remove front :eel 7p>4 #abe74 7#b7 ,back (f cone lock nut to end ( axle sleeve4 ,d n remove nut4 7#c7 ,turn cone on axle sleeve to ! "r 7clockwise7 to take up :eel play1 & to ! left 7c\nt]clockwise7 to give m :eel play4 ,adju/ s t :eel has slight play on be>+4 7#d7 ,tight5 cone lock nut4 ,aft] tight5+ nut1 aga9 try = slight :eel play on be>+4 ,sometimes tight5+ lock nut takes up on be>+ play4 ,if necess>y1 readju/ = desir$ results :5 cone lock nut is tight4 7#e7 ,in/all front :eel & brake assembly 7p>4 #abe74 7#f7 ,*eck adju/m5t ( front brake4 #abg4 ,,re> ,,:eel ,,replacem5t 7figs4 #hc & #hd74 a4 ,remove4 7#a7 ,support vehicle on re> /&4 7#b7 ,release mudgu>d re> /ays4 ,loos5 m\nt+ nuts1 & raise end ( mudgu>d = :eel cle>ance4 ,illu/ration3 ,,ra ,,pd #cajbec ,figure #hd--;,brake ,rod ,lock 7#c7 ,remove ! five :eel m\nt+ socket screws :i* secure :eel hub to brake %ell & sprocket assembly4 ,use vehicle kit wr5* 8,s0 & sleeve 7h&le7 8,c0 7fig4 #aa74 ,,note3 ,wr5* c be ins]t$ f left side ?r\gh holes 9 hub1 & :eel mu/ be turn$ to br+ ea* m\nt+ screw directly to ! re> ( axle = accessibility4 7#d7 ,use brake rod lock to set & lock brake to prev5t brake %ell & sprocket f com+ (f brake assembly :ile :eel is be+ remov$4 ,apply brake p$al & %ift brake rod lock aga9/ tool box bracket1 secur+ lock 9 ?is position ) w+ nut 7fig4 #hd74 7#e7 ,remove axle nut 7"r side ( vehicle71 us+ vehicle kit wr5* 8,j0 7fig4 #aa74 7#f7 ,pull out axle f left side ( vehicle4 7#g7 ,remove spac] f betwe5 :eel hub end & left side ( frame4 7#h7 ,:eel is n[ free to come out by pull+ & work+ x away f d[el p9s locat$ 9 brake %ell assembly4 ,a :eel be+ remov$ = ! fir/ "t may (f] "s resi/ance4 ,x w be obs]v$ t *a91 sprocket1 & brake assembly rema9 9 ! vehicle frame4 b4 ,in/all 7figs4 #hc & #hd74 7#a7 ,position :eel on brake %ell d[el p9s4 ,"w hub onto d[els z f> z x w g4 7#b7 ,in/all axle spac] at left end ( hub s t axle w pass ?r\gh x & ! hub4 7#c7 ,in/all axle f left side ( vehicle4 ,pass x ?r\gh sleeve & hub1 ) end ( axle engag+ ! frame left axle clip not*4 7#d7 ,see t lock wa%] is 9 place4 ,turn on & securely tight5 axle nut1 us+ vehicle kit wr5* 8,j0 7fig4 #aa74 7#e7 ,loos5 w+ nut clamp+ brake rod lock4 ,move brake rod lock =w>d s t x w n /rike any object :5 brake is op]at$2 tight5 w+ nut to reta9 9 position 7fig4 #hd74 7#f7 ,in/all & securely tight5 ! five :eel m\nt+ socket screws4 7#g7 ,l[] mudgu>d into position & atta* ends ( re> /ays4 ,securely tight5 ! clamp+ nuts4 ,,ref]5ces ,,/&>d ,,nom5clature ,,li/s ,motorcycle1 *a9 drive 7,h>ley,davidson7 ,,snl ,g-#ebc ,clean+1 pres]v+ & lubricat+ mat]ials1 recoil fluids1 special oils1 & miscellane\s relat$ items ,,snl ,k-#a ,sold]+1 braz+1 & weld+ mat]ials1 gases1 & relat$ items ,,snl ,k-#b ,tools1 ma9t5ance1 = ! repair ( automotive vehicles ,,snl ,g-#bg ,tool sets--motor transport ,,snl ,n-#ai ,tool sets = ordnance s]vice comm&1 automotive %ops ,,snl ,n-#cj ,curr5t ,/&>d ,nom5clature ,li/s are li/$ above4 ,an uptodate li/ ( ,,snl's is ma9ta9$ 9 ! ,index to ,ma9t5ance ,publications ,,(sb #a-a ,,explanatory ,,publications ,milit>y motor vehicles ,,ar #hej-ae ,automotive ,mat]iel ,automotive electricity ,,tm #aj-ehj ,electric fundam5tals ,,tm #aj-dee ,! motor vehicle ,,tm #aj-eaj ,*assis1 body1 & trail] units ,,tm #aj-eej ,ma9t5ance & ,repair ,automotive lubrication ,,tm #aj-edj ,motor transport inspections ,,tm #aj-ede ,tire repair & retread ,,tm #i-ahfh ,clean+1 pres]v+1 lubricat+ & weld+ mat]ials & simil> items issu$ by ! ordnance ,,tm #i-hej ,detail$ lubrication in/ructions = ordnance mat]iel ,,(sb #f-s]ies ,protection ( ,mat]iel ,explosives & demolitions ,,fm #e-be ,def5se aga9/ *emical attack ,,fm #ba-dj ,decontam9ation ( ,armor$ ,=ce vehicles ,,fm #ag-ei ,*emical decontam9ation1 mat]ials & equipm5t ,,tm #c-bbj ,li/ ( ,publications = ,tra9+ ,,fm #ba-f ,/orage & ,%ipm5t ,regi/ration ( motor vehicles ,,ar #hej-aj ,/orage ( motor vehicle equipm5t ,,ar #hej-ah ,ordnance /orage & %ipm5t *>t1 gr\p ,g--,major items ,,ossc-,g ,,index ,a ,page ,no4 ,air clean]1 #abb ,allocation ( ma9t5ance by e*elons1 #dj ,ammunition box c>ri]1 #afi ,armature be>+ special lubrication1 #ade ,auxili>y brake1 #ab ,b ,batt]y1 light+ sy/em1 horn batt]y *eck electrolyte level1 #aha in/allation1 #ahe removal1 #aha description1 #aha horn adju/m5t1 #aij description1 #aij ignition & light swit* in/allation1 #ahh removal1 #ahh s]vice headlights adju/m5t1 #ahe black\t1 #ahf m>k]1 #ahg taillights black\t /op & taillight1 #ahg s]vice /op & taillight1 #ahg wir+ cable sy/em1 #aij removal & in/allation1 #aij ,brake sy/em brake %oe in/allation1 #aea brake %oe removal1 #aej front :eel brake1 #aea re> :eel brake adju/m5t1 #adi l9kage1 #adi ,c ,c>buretor adju/m5t1 #aaf b[l clean+1 #abj in/allation1 #aah removal1 #aah ,*a9s & sprockets *a9 oil]s1 #aji *a9 repair tool1 #aac c\nt]%aft sprocket replacem5t1 #aad eng9e sprocket replacem5t1 #aac front *a9 adju/m5t1 #aje front *a9 replacem5t1 #aaa re> *a9 adju/m5t1 #ajg re> *a9 replacem5t1 #aaa re> :eel al9em5t1 #ajg ,clut* control adju/m5t1 #he description1 #hf disk & spr+ inspection1 #ia disk in/allation1 #ic disk removal1 #ij ma9t5ance & adju/m5t1 #hf release be>+ in/allation1 #ie removal1 #ie spr+ t5sion adju/m5t1 #hi ,controls & op]ation controls auxili>y brake 7front :eel71 #ab c>buretor *oke1 #ac clut*1 #aj foot />t] crank1 #ab gasol9e valve1 #i ge> %ift]1 #ab ignition & light swit*1 #ab in/rum5t panel signal lights1 #ac s]vice brake 7re> :eel71 #ab sp>k1 #aj /e]+ damp]1 #ab ?rottle1 #aj driv+ precautions avoid l[ ge> op]ation1 #ag brak+1 #ag highspe$ tips1 #ag eng9e pre/>t+ in/ructions1 #ac op]ation ( vehicle />t+ on level gr\nd1 #af />t+ on unev5 or s(t gr\nd1 #af runn+9 new eng9e 7or vehicle71 #ai />t+ eng9e behavior ( in/rum5t panel signal lights1 #ae cold eng9e1 #ad eng9e ) dead batt]y1 #ae hot eng9e1 #ae w>m eng9e1 #ad /opp+ & p>k+ vehicle p>k+ vehicle1 #ah /opp+ vehicle1 #ag /opp+ ! eng9e1 #af t[+ vehicle to />t eng9e eng9e />t+ ) dead batt]y1 #ah ,d ,data1 tabulat$ eng9e1 #gb vehicle specifications1 #g capacities1 #h p]=mance1 #g ,description batt]y1 light+ sy/em1 horn1 #aha clut*1 #hf eng9e1 #gb g5]at+ sy/em1 #adb ignition sy/em1 #abi intake & exhau/ sy/em1 #abb tires1 :eels & hubs1 #aic transmission1 #if ,description ( vehicle1 #g ,e ,e*elon sy/em ( ma9t5ance allocation1 #dj ,eng9e c>bon removal1 #gd data1 #gb description1 #gb head1 gasket replacem5t in/allation1 #gd removal1 #gc in/allation1 #hb oil fe$ pump replacem5t1 #gg removal1 #gh tuneup1 #gb valve tappet adju/m5t1 #gd ,exhau/ sy/em1 #abf ,f ,fir/ e*elon prev5tive ma9t5ance s]vices aft]op]ation & weekly s]vice1 #be athalt s]vice1 #bd be=eop]ation s]vice1 #ba dur+op]ation s]vice1 #bc purpose1 #bj ,fuel sy/em c>buretor in/allation1 #aah removal1 #aah c>buretor adju/m5t complete readju/m5t ( c>buretor1 #aaf l[ spe$ adju/+ ne$le1 #aaf c>buretor b[l clean+1 #abj fuel pipe in/allation1 #aba removal1 #aba fuel /ra9] clean+1 #abj in/all /ra9] assembly1 #abj remove /ra9] assembly1 #abj g5]al1 #aae ?rottle control wire adju/m5t clos$ ?rottle1 #aah op5 ?rottle1 #aah ,g ,g5]at+ sy/em armature be>+ special lubrication1 #ade commutator clean+1 #adc cutout relay1 #adg description1 #adb g5]ator in/allation1 #adg g5]ator removal1 #ade ,g5]ator removal & in/allation1 #ade1 #adg ,h ,horn1 #aij ,i ,ignition sy/em circuit break] & tim] assembly in/allation1 #acc recomm5d$ re*eck ( ignition tim+1 #ace removal1 #acc circuit break] po9ts adju/able contact po9t in/allation1 #aca adju/able contact po9t removal1 #aca adju/m5t1 #aca break] lev] in/allation1 #aca break] lev] removal1 #acj coil to tim] wire in/allation1 #ach removal1 #ach cond5s] in/allation1 #acc removal1 #aca description1 #abi sp>k coil in/allation1 #adj removal1 #aci sp>k control adju/m5t1 #aci sp>k plugs clean+1 #abi po9t adju/m5t1 #abi replacem5t1 #abi type1 #abi ,in/allation proc$ure air clean]1 #abf ammunition box c>ri]1 #afi batt]y1 #ahe batt]y box1 #agc c>buretor1 #aah circuit break] & tim] assembly1 #acc circuit break] lev]1 #aca circuit break] po9ts1 #aca clut* release be>+1 #ie coil to tim] wire1 #ach cond5s]1 #acc control wire h\s+s1 #aff eng9e1 #hb eng9e head gasket1 #gd exhau/ pipe1 #abg foot />t]1 #ih =k assembly1 #aeh front :eel1 #aif fuel pipe1 #aba fuel /ra9] assembly1 #abj fuel tank1 #age g5]ator1 #adg h&le b> assembly1 #afc ignition & light swit*1 #ahh in/rum5t panel cov]1 #aia jiffy /&1 #agg luggage c>ri]1 #agj mudgu>ds1 #aga muffl] assembly1 #abg oil tank1 #agf out] front *a9 gu>d1 #afg re> *a9 gu>d1 #afi re> /&1 #agf re> :eel1 #aii saddle po/1 #agh safety gu>ds1 #agh scabb>d c>ri]1 #afi skid plates1 #ahj sp>k coil1 #adj sp>k control wire1 #aff spe$omet]1 #aib spr+ =ks1 #aed />t] crank spr+s1 #aja /e]+ damp]1 #afa ?rottle control wire1 #afe tires1 #aie tool box & bracket assembly1 #agc upp] bump] spr+s1 #aee upp] coil spr+s1 #aee wir+1 #aij ,in/rum5t panel indicator lights1 #aia panel cov] in/allation1 #aia removal1 #aia spe$omet] in/allation1 #aib removal1 #aib ,intake & exhau/ sy/em air clean] g5]al1 #abb in/allation1 #abf ma9t5ance1 #abc removal1 #abe s]vice1 #abb air clean] m\nt+ bracket replacem5t1 #abf description exhau/1 #abb intake1 #abb exhau/ sy/em muffl] assembly in/allation1 #abg muffl] assembly removal1 #abf pipe in/allation1 #abg hose & c>buretor fitt+ in/allation1 #abe removal1 #abe ,introduction scope ( manual1 #c sup]session ( qu>t]ma/] manuals1 #c ,l ,light+ sy/em1 #aha ,lubrication introduction1 #cj lubrication guide1 #cj g5]al1 #cj lubrication notes1 #cj oilcan po9ts1 #cd supplies1 #cj w>n+ light1 #cd ,m ,ma9t5ance allocation allocation ( ma9t5ance by e*elons clut*1 #dj controls & l9kage1 #dj electrical gr\p1 #da eng9e 7,v#de tw9 eng9e71 #da exhau/ gr\p1 #db miscellane\s1 #db susp5sion 7front71 #dc susp5sion 7re>71 #dc tires1 #dd transmission1 #dd vehicle assembly1 #dd scope ( ma9t5ance1 #ci ,manual1 scope (1 #c ,o ,organization tools & equipm5t1 #fj ,p ,prev5tive ma9t5ance s]vices fir/ e*elon1 #bj second e*elon1 #de ,r ,ref]5ces explanatory publications automotive mat]iel1 #bjj li/ ( publications = tra9+1 #bjj ma9t5ance & repair1 #bjj protection ( mat]iel1 #bjj /orage & %ipm5t1 #bjj /&>d nom5clature li/s1 #bjj ,removal proc$ure air clean]1 #abe ammunition box c>ri]1 #afi batt]y1 #aha batt]y box1 #agb c>bon1 #gd c>buretor1 #aah circuit break] & tim] assembly1 #acc circuit break] lev]1 #acj cond5s]1 #aca control wire h\s+s1 #aff eng9e1 #gh eng9e head gasket1 #gc foot />t]1 #ih =k assembly1 #aee front :eel1 #aie fuel pipe1 #aba fuel /ra9] assembly1 #abj fuel tank1 #agd g5]ator1 #ade h&le b> assembly1 #afb ignition coil to tim] wire1 #ach in/rum5t panel cov]1 #aia jiffy /&1 #agf luggage c>ri]1 #agj mudgu>ds1 #agj1 #aga muffl] assembly1 #abf oil tank1 #age out] front *a9 gu>d1 #afg re> *a9 gu>d1 #afi re> /&1 #agf re> :eel1 #aih release be>+ 7clut*71 #ie saddle po/1 #agh safety gu>ds1 #agh scabb>d c>ri]1 #afi skid plates1 #ahj sp>k coil1 #aci sp>k control wire1 #aff spe$omet]1 #aib spr+ =ks1 #aed />t] crank spr+1 #ih /e]+ damp]1 #afa ?rottle control wire1 #afd tires1 #aic tool box & bracket assembly1 #agc upp] bump] spr+s1 #aee upp] coil spr+s1 #aee ,road te/ *>t ( ma9t5ance op]ations1 #di ,s ,second e*elon prev5tive ma9t5ance road te/ *>t1 #dg ma9t5ance op]ation1 #di s]vices fir/ e*elon p>ticipation1 #de frequ5cy1 #de g5]al proc$ures1 #de specific proc$ures1 #dg ,%eet metal & equipm5t batt]y box in/allation1 #agc removal1 #agb c>ri]s ammunition box c>ri] in/allation1 #afi ammunition box c>ri] removal1 #afi fuel tank in/allation1 #age removal1 #agd *a9 gu>ds out] front *a9 gu>d in/allation1 #afg out] front *a9 gu>d removal1 #afg re> *a9 gu>d in/allation1 #afi re> *a9 gu>d removal1 #afi jiffy /& in/allation1 #agg removal1 #agf luggage c>ri] in/allation1 #agj removal1 #agj mudgu>d 7front7 in/allation1 #aga removal1 #agj mudgu>d 7re>7 in/allation1 #aga removal1 #aga oil tank in/allation1 #agf removal1 #age re> /& in/allation1 #agf removal1 #agf saddle po/ description1 #agh in/allation1 #agh removal1 #agh safety gu>ds in/allation1 #agh removal1 #agh scabb>d c>ri] in/allation1 #afi removal1 #afi skid plates in/allation1 #ahj removal1 #ahj tanks fuel tank1 #agc g5]al1 #agc oil tank1 #agc tool box box & bracket assembly in/allation1 #agc box & bracket assembly removal1 #agc ,sp>k plugs1 #abi ,spe$omet] in/allation1 #aib removal1 #aib ,/e]+ control control wire h\s+s in/allation1 #aff removal1 #aff =k assembly 7complete7 in/allation1 #aeh removal1 #aee rock] plate /uds1 #afj =ks 7spr+s7 in/allation1 #aed removal1 #aed h&le b> controls in/all ?rottle control wire1 #afe remove ?rottle control wire1 #afd h&le b>s in/allation ( assembly1 #afc removal ( assembly1 #afb sp>k control wire in/allation1 #aff removal1 #aff /e]+ damp] in/allation1 #afa removal1 #afa upp] coil spr+s & upp] bump] spr+s in/allation1 #aee removal1 #aee ,/[age on vehicle 7tools & equipm5t71 #ce ,t ,tabulat$ data eng9e1 #gb vehicle specifications1 #g capacities1 #h p]=mance1 #g ,tires1 :eels1 & hubs description1 #aic front :eel hub adju/m5t1 #aig in/allation1 #aif removal1 #aie re> :eel in/allation1 #aii removal1 #aih rims & spokes1 #aie tires description1 #aic in/allation1 #aie removal1 #aic ,tools & equipm5t /[age on ! vehicle vehicle equipm5t1 #cf vehicle sp>e p>ts1 #ch vehicle tools1 #ce ,transmission control l9kage adju/m5t1 #ig *eck+ ge> %ift] control l9kage1 #if transmission %ift$ to adju/ front drive *a91 #if description1 #if foot />t] in/allation1 #ih removal1 #ih in/allation1 #aja removal1 #ii />t] crank spr+s in/allation1 #ih removal1 #ih ,tr\ble %oot+ brakes1 #gj electrical sy/em1 #fh eng9e in/ruction1 #fa te/s to det]m9e me*anical condition1 #fc eng9e lubricat+ sy/em1 #fd fuel sy/em1 #fe g5]at+ sy/em1 #fh ignition sy/em1 #ff introduction1 #fa /e]+1 #ga transmission & clut*1 #fi :eels & *a9s1 #fi ,w ,:eels & hubs1 #aie ,wir+1 #aij ,a4,g4 #cjj4g 7#ag ,aug4 #aidc7 ,,by ,,ord] ,,( ,,! ,,secret>y ,,( ,,w>3 ,g4 ,c4 ,,m>%all1 ,*ief ( ,/aff4 ,,(ficial3 ,j4 ,a4 ,,ulio1 ,major ,g5]al1 ,! ,adjutant ,g5]al4 ,,di/ribution3 ,r#i 7#d73 ,,ir #e1 #g & #ag 7#e73 ,bn #i 7#b73 ,i,bn #e1 #f1 #g & #ag 7#e73 ,c#i 7#h73 ,,ic #e1 #f1 #g & #ag 7#e7 7,= explanation ( symbols1 see ,,fm #ba-f7 ,,rapd#c,,oec#dc-ha,m ,,publications ,,dep>tm5t ,,r>itan ,,ars5al ,transcrib]'s notes3 ,9 ! ,fig4 #ea caption ,m--,,m>k ,,on ,,break] ,,cam ,,& ,,m>ks ,,on ,,tim] ,,head ,,& ,,h& - #8,,h&' %\ld possibly read #8,,b&'4 ,9 ! e*elon table1 section #be4 ,,allocation ,,( ,,ma9t5ance1 #8/ra9$ gasol9e' %\ld possibly read #8/ra9] gasol9e'4