GENERAL INFORMATION CU800 Service Manual
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tools are required, they are described at the beginning of the procedure.
15. Make diagrams of similar-appearing parts. For instance, crankcase bolts are often not the same
lengths. Do not rely on memory alone. Carefully laid out parts can become disturbed, making it
difficult to reassemble the comports correctly.
16. Make sure all shims and washers are reinstalled in the same location and position.
17. Whenever rotating parts contact a stationary part, look for a shim or washer.
18. Use new gaskets if there is any doubt about the condition of old ones.
19. If using self-locking fasteners, replace them with new ones. Do not install standard fasteners in
place of self-locking ones.
20. Use grease to hold small parts in place if they tend to fall out during assembly. Do not apply
grease to electrical or brake components.
1.11.1 Removing Frozen Fasteners
If a fastener cannot be removed, several methods may be used to loosen it. First, apply a
penetrating fluid. Apply it liberally and let it penetrate for 10-15 minutes. Rap the fastener several
times with a small hammer. Do not hit it hard enough to cause damage. Reapply the penetrating fluid
if necessary.
For frozen screws, apply penetrating fluid as
described, the insert a screwdriver in the slot and
rap the top of the screwdriver with a hammer. This
loosens the rust so the screw can be removed in
the normal way. If the screw head is too damaged
to use this method, grip the head with locking pliers
and twist the screw out.
Avoid applying heat unless specifically
instructed. Heat may melt, warp or remove the
temper from parts.
1.11.2 Removing Broken Fasteners
If the head breaks off a screw or bolt, several
methods are available for removing the remaining
portion. If a large portion of the remainder projects
out, try gripping it with locking pliers. If the
projecting portion is too small, file it to fit a wrench
of cut a slot in it to fit a screwdriver (Figure 37).
If the head breaks off flush, use a screw
extractor. To do this, center punch the exact center
of the remaining portion of the screw or bolt. Drill a
small hole in the screw and tap the extractor into
the hole. Back the screw out with a wrench on the
extractor (Figure 38).
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