ENGINE—REMOVAL AND INSTALLATION
Paragraph
Remove engine 45
Install engine 46
=45. REMOVE ENGINE= (figs. 18, 19, and 20).
=a.= A study of figures 18 and 19 will provide a good picture of the
steps necessary for engine removal. Do not attempt any short cut
methods, as this would consume more time and possibly cause damage to
parts or unit assemblies.
(1) Disconnect battery ground wire at frame lug connection on right
side of vehicle.
(2) To disconnect brake front rod from bell crank (located on right
side of rear support rod), remove cotter pin and plain washer.
(3) Loosen footboard rear support stud nut and remove footboard front
stud nut, then pull footboard outward to free right front end of safety
guard. Disconnect brake front rod at bell crank. Remove bolt which
secures front exhaust pipe clamp. Remove nut from rear support rod,
freeing stop light switch and rear end of side bar. Remove nut from
front support rod, freeing footboard and brake assembly for removal.
(4) Remove the two rear mounting bolts and drop rear end of skid plate
(fig. 37).
(5) Remove muffler (par. 81).
(6) Disconnect oil pipe from tank and install nipple cap on oil tank
feed pipe nipple to prevent oil from running out, or drain tank.
Disconnect pipe from oil pump and remove oil pipe.
(7) Disconnect spark control wire at circuit breaker lever, and free
control housing clamp at cylinder base.
(8) Disconnect brake rear rod from bell crank.
(9) Disconnect red wire and black wire from front end of relay; also
green wire from generator terminal.
(10) Remove spark plugs.
(11) Remove engine top mounting (cylinder head bracket) bracket to
frame lug bolt: this also frees front spark plug cable clamp. Pay
particular attention to shim washers (if any) between cylinder head
bracket and frame lug; these will have to be installed in the original
position.
(12) Remove lever bottom bolt, freeing gear shifter lever from shifter
rod.
[Illustration: RA PD 315713
=A=—LEFT FOOTBOARD, CLUTCH PEDAL AND SIDEBAR ASSEMBLY AND MOUNTING
NUTS AND WASHERS
=B=—SPARK CONTROL WIRE AND HOUSING
=C=—ENGINE SPROCKET, KEY, NUT AND FRONT DRIVE CHAIN
=D=—ENGINE SPROCKET SHAFT
=E=—REAR SUPPORT ROD
=F=—INNER CHAIN GUARD
=G=—AIR CLEANER AND BRACKET ASSEMBLY
=H=—OUTER CHAIN GUARD REAR MOUNTING BOLT, WASHER, SPRING, NUT AND
COTTER PIN
=J=—SPARK COIL REAR TERMINAL NUT, WASHER AND SCREW
=K=—OUTER CHAIN GUARD
=L=—AIR CLEANER BRACKET UPPER MOUNTING BOLT NUTS AND WASHERS
=M=—AIR CLEANER HOSE AND CARBURETOR FITTING ASSEMBLY AND MOUNTING
SCREWS
=N=—ENGINE LEFT REAR BASE MOUNTING BOLT CASTLE NUT, WASHERS AND
COTTER PIN
=O=—REAR SUPPORT ROD EXTENDED NUT
=P=—INNER CHAIN GUARD MOUNTING SCREWS AND LOCKS
=Q=—FUEL PIPE AND STRAINER ASSEMBLY
=R=—ENGINE LEFT FRONT BASE MOUNTING BOLT, WASHERS, CASTLE NUT AND
COTTER PIN
=S=—GEAR SHIFTER AND ROD ATTACHING BOLT, WASHER AND NUT
=T=—TANK, LOWER FRONT MOUNTING BOLT, WASHERS AND NUT
=U=—ENGINE SPROCKET NUT WRENCH
RA PD 315713B
_Figure 18—Disassembly for Engine Removal—Left Side_]
[Illustration: RA PD 315714
=A=—MUFFLER ASSEMBLY AND MOUNTING BOLTS AND NUTS
=B=—SKID PLATE
=C=—STOP LIGHT SWITCH
=D=—REAR BRAKE ROD FRONT END
=E=—CYLINDER BRACKET AND FRAME MOUNTING BOLT, SPACING WASHERS,
SPARK CABLE CLIP AND NUT
=F=—ENGINE RIGHT FRONT BASE MOUNTING BOLT, CASTLE NUT, WASHERS AND
COTTER PIN
=G=—RELAY TERMINAL SCREWS AND WASHERS
=H=—SAFETY GUARD END
=J=—RIGHT FOOTBOARD, BRAKE PEDAL AND SIDEBAR ASSEMBLY AND MOUNTING
NUTS AND WASHERS
=K=—FRONT EXHAUST PIPE CLAMP, BOLT, WASHER AND NUT
=L=—EXHAUST PIPE ASSEMBLY
=M=—SPARK PLUGS AND GASKETS
=N=—REAR SUPPORT ROD, WASHER AND NUT
=O=—BRAKE ROD BELLCRANK
=P=—ENGINE REAR BASE MOUNTING BOLTS, WASHERS, CASTLE NUT AND
COTTER PIN
=Q=—OIL FEED PIPE
=R=—VENT PIPE HOLLOW BOLT AND WASHER
=S=—VENT PIPE
=T=—OIL RETURN PIPE
RA PD 315714B
_Figure 19—Disassembly for Engine Removal—Right Side_]
(13) Close fuel tank valve. Remove gasoline pipe from tank nipple and
fuel filter nipple.
(14) Disconnect throttle control wire at carburetor lever.
(15) Disconnect air intake hose connection fitting from carburetor
(four screws) and leave attached to hose. Remove air cleaner from
mounting bracket (par. 78).
[Illustration: RA PD 310215
_Figure 20—Removing Engine_]
(16) Remove front chain guard (par. 102).
(17) Remove engine sprocket (par. 65).
(18) Remove two screws and locks securing inner chain guard to
crankcase.
(19) With 13/16-inch deep socket wrench slipped over rear footboard
support rod stud, remove extended nut, and withdraw support rod from
right side of vehicle.
(20) To disconnect the circuit breaker to coil wire and shielding
ground from coil rear terminals, disconnect oil pressure signal light
wire from oil pressure switch terminal. It will be necessary to free
air cleaner mounting bracket and swing it outward, to gain access to
coil rear shielding ground terminal.
(21) Engine mounting bolts are secured by cotter pins and castle nuts.
Remove all engine mounting bolts, except the one under generator; this
bolt cannot be removed without removing generator; merely push it up
far enough to clear frame engine lug when engine is removed from frame.
(22) Lift and remove engine from right side of frame.
=46. INSTALL ENGINE= (figs. 18, 19, and 20).
a.= Installing the engine is generally the reverse of the procedure
=followed in engine removal. Pay close attention to the following
procedure because checking and adjustment of controls and other items
is necessary to satisfactory vehicle operation.
(1) Lift engine into frame from right side of vehicle. Make sure that
mounting bolt under generator is raised to clear frame engine lug.
(2) Pass remaining three engine mounting bolts up from under side of
frame lugs through crankcase lugs: install plain washers and castle
nuts. Fit plain washer and castle nut on mounting bolt under generator.
Securely tighten all four castle nuts and lock with cotter pins.
(3) Connect circuit breaker to coil wire. Connect wire to coil rear
terminal and ground shielding on coil case terminal.
(4) Connect oil pressure switch wire to switch terminal.
(5) Pass rear footboard support rod through frame lug from right side
of vehicle and install the extended 13/16-inch nut.
(6) Secure inner chain guard by attaching the two screws and locks
mounting inner chain guard to engine base. Drift edge of locks into
screw slots for security.
(7) Install engine sprocket and front drive chain together. See that
engine shaft is clean, sprocket taper clean, and that key is in place
before tightening sprocket nut. Drift nut tight, using hammer on wrench.
(8) Install outer front chain guard (par. 102).
(9) Connect hose and fitting assembly by installing two bolts, washers,
and nuts securing air cleaner to frame bracket; then install four
screws securing hose fitting to carburetor. NOTE: _If cleaner frame
bracket was loosened and shifted to gain access to coil rear terminals,
securely mount bracket before installing air cleaner assembly._
(10) Connect throttle control wire to carburetor lever. Make sure that
throttle closes fully when right grip is turned outward; and that
throttle opens fully when grip is turned inward.
(11) Install fuel pipe. Securely tighten union nuts on tank and fuel
strainer nipples. Open fuel supply valve and check connections for
leaks.
(12) Connect gear shifter lever end to gear shifter rod by tightening
bolt and nut.
(13) Attach engine top mounting bracket (cylinder head bracket) to
frame lug, exercising care in installing required number of thin shims,
together with clamp for front spark plug cable, to fill space between
bracket and frame lug before tightening bolt nut. NOTE: _Frame lug must
be free from paint or grease to make clean “electrical” connection with
plated shims and mounting bracket for adequate radio bonding._
(14) Before installing spark plugs, inspect for cleanliness and correct
electrode adjustment. Service if necessary (par. 83). Replace gaskets
to ensure tight joints.
(15) Connect red and black wires to relay: connect green wire to
generator terminal marked “SWITCH.” Refer to wiring diagram (fig. 73).
(16) Attach rear brake rod to bell crank. Install plain washer and
secure with cotter pin.
(17) Connect spark control wire to circuit breaker lever and secure
control wire housing clamp under cylinder base nut. Make sure that
spark advances fully (lever inward) when control grip (left handle
bar) is turned inward, and that spark retards fully when control grip
is turned outward. Make needed adjustment at control wire and lever
connection.
(18) Remove nipple cap from tank oil pipe nipple (if one was used) and
connect oil feed pipe, securely tightening union nuts at tank and oil
pump.
(19) Position exhaust pipe and muffler assembly and attach rear hanger
frame bolt, washer, and nut. Secure muffler front mounting bracket
bolt, but do not tighten nut until skid plate rear bracket is located
on this bolt.
(20) Lift rear end of skid plate, secure rear mounting bracket and
muffler front mounting bracket with bolt, washer, and nut. Attach skid
plate left side bracket, tightening support rod nut and bracket bolt
and nut.
(21) Install right side footboard, sidebar, and brake pedal assembly.
Install stop light switch bracket on rear support rod before placing
lock washer and tightening nut. Attach front exhaust pipe clamp to
sidebar. Install lock washer, and tighten sidebar front support rod
nut. Attach right end of front safety guard to sidebar with footboard
front support stud. Replace lock washer, and tighten nut. Also tighten
footboard rear support stud nut. Connect stop light switch control to
brake foot pedal.
(22) Attach brake front rod to bell crank; fit plain washer and secure
with cotter pin.
(23) Connect battery ground wire to frame lug on right side of vehicle.
=b.= Check instrument panel signal lights for normal indications, and
see that oil is in tank before starting engine.