2
Mechanical damage may also occur.
WARNI
NGS
arc
to be taken seriol/sly. In
so
me cases, se
ri
ous
injury
or
death has resulted from disregard
in
g
similar warning
s.
Thr
oughout this manual keep in mind 2
convent
io
n
s.
"Front"
refers
to
the front of
th
e bike.
Th
e front of any component, such as the en
gi
ne.
is the cnd which faces toward the front
of
the bike.
The "I
ef
t
-"
and "
ri
ght-hand" s
id
es refer to the
position of the p
arIS
as viewed by a
ri
der
silting
on
the
s
eal
facing forward. F
or
example. the
throttle control is on the right-hand side and the
clutch lever is on
th
e le
ft
-hand s
id
e.
These rules
are simple. but even
ex
p
erie
nced mechanics
occasionally become
di
so
riented.
SAFETY FIRST
Pr
ofessi
ona
l mechanics
can
work for years and
never sustain a serious inj
ur
y.
If
you observe a
few
rul
es
of eommon sense and safety. you can enjoy
many hours servicing your own machine. If you
ignore these rules. you
can
hurt yourse
lf
or dam-
age the bike.
I. Never use gasoline as a
clea
ning
so
lvent.
2. Never smoke
or
use a torch in the vici
ni
ty of
nammable liquids such as cleaning solve
nt
in open
co
ntainers.
3.
If welding or brazing is required on the ma-
chine. remove the fuel tank to a
sa
fe
distan
ce.
at
least
50
feet away.
4. Use the
proper
sized wrenches to avoid
dam-
age to nuts and injury to yo
ur
self.
5.
When loosening a tight
or
stuck nut . think about
what would happen
if
the wrench should slip. Be
car
ef
ul
; protect yourself accordingl
y.
6. K
eep
your work area clean and uncluttered.
7.
Wear safety goggl
es
during all
opera
ti
ons
in
volving drilling. grinding or the use of a cold
c
hi
se
l.
8.
Never use worn tool
s.
9.
Ke
ep a fire extinguisher handy and be sure it
is rated for gasoline and electrical fires.
SERVICE HINTS
Mo
st
of
the servi
ee
procedur
es
covered
are
s
tr
aightforward and can be pe
rf
ormed by anyone
reasonably handy with tools.
It
is
suggest
ed.
how-
ever.
th
at
you
cons
id
er your own capabilities
CHAPTER ONE
carefully before altempting any operation involving
ma
jo
r disassembly
of
the engine.
Take your time and
do
the
job
right. Do not
forget that a n
ew
ly rebuilt engine must be broken
in
the same as a new one. Ke
ep
the rpm within the
limits given
in
your owner's manual when you get
back on the road.
I. There are many items available that
ca
n be u
se
d
on your hands before and after working on your
bi
ke. A linlc preparation before getting
"a
ll greased
up" will help when cleaning up later. Before
starting out. work
Va
se
line. soap
or
a product such
as
In
visible Glove (
Figure
I) onto your
fo
re
arm
s.
i
nt
o your honds and und
er
yo
ur
fingernails and
cuticles.
Th
is
will make cleanup a lot easier. For
cleanup. use a waterless hand
so
ap such as 5ta-
Lube and
th
en finish up with powdered Boraxo and
a
fi
ngerna
il
brush (
Figure
2).
I
..
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