Clean parts thoroughly with a solution of baking soda and water. Measure the rocker arm shaft outside diameter Figure 19 where it rides in the rocker arm and in the lower rocker arm cover. Rear exhuast cam gear bushing 13. On California models, move the carbon canister purge hose out of the vapor valve bracket groove Chapter Ten or Chapter Eleven. On 1988-1991 models, align the rear muffler tab with the muffler support bracket and install the bolt, washer and nut finger-tight only. Install the snap ring into the groove next to countershaft fifth gear Figure 98. If excessive chain or sprocket wear is evident, replace the chain and both sprockets as a complete set Chapter Thirteen.Next
The whole assembly is constructed from aluminum alloy and the crankcase is divided vertically. Pull the choke knob to the second detent position. . Install the Nice bearing 3, Figure 162 , washer 4 and handle 5. Place a bearing driver C, Figure 87 over the inner countershaft bearing race.
Loosen the Allen bolt securing the retainer plate Figure 93 , then remove the pushrod cover assembly Figure 94. Remove each wire and the ring connector from the terminal stud. Allow the oil to drain completely. Rotate the engine so that the tappets for the cylinder Wire: 13-14 in. Rotate front tappet guides clockwise or rear tappet guides counterclockwise and remove the guides. Maintain this engine rpm when performing substep e.Next
There should be up procedures. The gauge adapter is either inserted or screwed into the spark plug hole to obtain the reading. On high-mileage motorcycles, the starter pinion gear A, Figure 8 can jam on a worn clutch ring gear B. Largest number visible on the sleeve line 0. This manual is not a scan copie of a book, this is the origanal factory service manual and it is by far the best you will find anywhere, thats to say if you can even find it.Next
Install the cylinder head onto the cylinder dowel pins and studs. Drain the engine oil tank Chapter Three. This circlip is located behind the main drive gear oil seal. If the motorcycle is ridden far enough, the water can- not buildup in the crankcase and should not be a problem. Remove all the spark plugs as described in this chapter. On 1999-2003 883C and 1200C models, remove the rear brake pedal assembly as described in Chapter Sixteen.Next
Oil pump drive gear 1986-1987 models 2B. Push the upper pushrod cover up Figure 89 and seat it in the cylinder head Figure 90. Operation Refer to Safety in Chapter One prior to working on the The carburetor atomizes fuel, and mixes it in correct pro-. Frame downtube alternator stator 4. Slide the gear Fig- ure 82 over the bearing. Check the shift forks Figure 31 for cracks, deep scor- Third ing or excessive wear.Next
If the voltage is correct, perform Step 3. Mark the pushrods so they can be installed in their origi- nal positions, then remove the pushrods Figure 92. Remove the drive chain as described in Chapter Thirteen. Do not remove the spark plugs from the cylinder heads. Bolt 1992-2003 models 1998-2003 1200S models 14. On 1991 models, remove the speedometer or tachometer if equipped. Install a new oil pump gasket.
At the handlebar, loosen both control cable adjuster jam nuts A, Figure 70 , then turn the cable adjusters B and C to increase cable slack. Disconnect the harness connector B, Figure 68 from the ignition coil. For access to the pushrods Figure 92 , remove the rocker covers as described in this chapter. If replacing a shift fork, be sure to replace it with one of the same length Figure 32. Installation is the reverse of the preceding steps while noting the following. Use diagonal pliers or other suitable tool to separate the clamp bands, then remove the clamp.