GENERAL INFORMATION CU800 Service Manual
23
1.11 BASIC SERVICE METHODS
Most of the procedures in this manual are straightforward and can be performed by anyone
reasonably competent with tools. However, consider personal capabilities carefully before attempting
any operation involving major disassembly.
1. Front, in this manual, riders to the front of the EV, The front of any component is the end closest to
the front the EV. The left and right sides refer to the position of the parts as viewed by the rider
sitting on the seat facing forward.
2. Whenever servicing an engine or suspension component, secure the EV in a safe manner.
3. Tag all similar parts for location and mark all mating parts for position. Record the number and
thickness of any shims when removing them. Identify parts by placing them in sealed and labeled
plastic sandwich bags.
4. Tag disconnected wires and connectors with masking tape and a marking pen. Do not rely on
memory alone.
5. Protect finished surfaces from physical damage or corrosion. Keep gasoline and other chemicals
off painted surfaces.
6. Use penetrating oil on frozen or tight bolts. Avoid using heat where possible. Heat can warp, melt
or affect the temper of parts. Heat also damages the finish of paint and plastics.
7. When a part is a press fit or requires a special tool to remove, the information or type of tool is
identified in the text. Otherwise, if a part is difficult to remove or install, determine the cause
before proceeding.
8. To prevent objects or debris from falling into the engine, cover all openings.
9. Read each procedure thoroughly and compare the illustrations to the actual components before
starting the procedure. Perform the procedure in.
10. Recommendations are occasionally made to refer service to a dealership or specialist. In these
cases, the work can be performed more economically by the specialist than by the home
mechanic.
11. The term replaces means to discard a defective part and replace it with a new part. Overhaul
means to remove, disassemble, inspect, measure, repair and/or replace parts as required to
recondition an assembly.
12. Some operations require using a hydraulic press. If a press is not available, have these
operations performed by a shop equipped with the necessary equipment. Do not use makeshift
equipment that may damage the motorcycle.
13. Repairs are much faster and easier if the EV is clean before starting work. Degrease the
motorcycle with a commercial degreaser; follow the directions on the container for the best results.
Clean all parts with cleaning solvent when removing them.
CAUTION
Do not direct high-pressure water at steering bearings, battery, wheel bearings,
suspension and electrical components. Water may force grease out of the bearings
and possibly damage the seals.
14. If special tools are required, have them available before starting the procedure. When special
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