INTAKE AND EXHAUST SYSTEM
Paragraph
Description 75
Air cleaner 76
Hose and carburetor fitting 77
Remove air cleaner 78
Install air cleaner 79
Replacement of air cleaner mounting bracket 80
Exhaust system 81
75. DESCRIPTION.
=a. Intake System.= The air intake system consists of oil bath air
cleaner, connecting air hose, and carburetor intake hose fitting. This
system is located on left side of vehicle.
=b. Exhaust System.= The exhaust system consists of muffler and
tailpiece assembly, front exhaust pipe assembly, and rear exhaust pipe.
Exhaust pipe ends are a slip fit in cylinder exhaust ports.
=76. AIR CLEANER= (figs. 46 and 47).
=a. General.= Air cleaner should not be submerged in water, nor
should high‐pressure stream be directed into cleaner louvers (where air
enters on rear of body) when cleaning vehicle. Either water or dirt
entering air cleaner in excessive quantities will raise the oil level
in oil cup and choke off proper air supply to carburetor.
=b. Service.= With vehicle in normal use on hard‐surfaced roads,
clean and refill air cleaner oil cup with engine oil (seasonal grade)
at least each time engine oil tank is drained and refilled. CAUTION:
_Service more frequently under dusty conditions; daily under extremely
dusty conditions. Check oil supply daily._
(1) Hold oil cup with one hand and release (unlatch) oil cup retaining
spring clips to remove oil cup.
(2) If oil in cup is clean, with no signs of dirt and grit in oil or
cup, but the oil level is below the indicated level mark, add engine
oil (seasonal grade) to bring level up to mark. NOTE: _If oil and cup
are dirty, empty out oil and wash out cup with dry‐cleaning solvent.
Refill with clean engine oil (seasonal grade) to indicated level mark._
(3) Before installing oil cup make sure that the oil cup gasket is in
place and in good condition.
(4) Check baffle plate thumb screw for tightness.
[Illustration: RA PD 310243
_Figure 46—Air Cleaner Oil Cup Removed_]
(5) Install oil cup, making sure that retaining spring clips are fully
engaged in lip of oil cup and hold oil cup securely to cleaner body.
(6) Oil bath air cleaners on earlier models are of “round” type, oil
cup being secured to body with a metal clamp band and thumb screw. When
oil cup is removed on this type of cleaner, the baffle plate will come
out with the cup. Make sure that baffle plate is correctly installed
and that gasket is in place when installing cup.
=c. Maintenance= (fig. 47). The rectangular‐type oil bath air cleaner
is provided with two filter elements, retained in filter body by means
of the baffle plate. If daily check reveals excessive accumulation
of dirt and grit in oil and cup, filter elements must be removed and
cleaned. NOTE: _Check several times daily under extremely dusty or
sandy conditions._
(1) Hold oil cup with one hand and release (unlatch) oil cup retaining
spring clips; remove cup.
(2) Unscrew baffle plate thumb screw and remove baffle plate.
(3) Filter elements may “bind” in cleaner body. If so, rap side of body
with hand to loosen them; or, if necessary, withdraw elements from body
with pliers or a hooked wire.
(4) Check for presence and condition of gasket above the two filter
elements (in filter body); also for oil cup gasket.
[Illustration: RA PD 310244
_Figure 47—Air Cleaner, Disassembled_]
(5) Clean both filter elements thoroughly in dry‐cleaning solvent.
Allow elements to dry out (use air hose if available).
(6) Clean oil cup and refill to indicated level mark. Use clean engine
oil (seasonal grade).
(7) Dip one screen surface of each filter element about 1/2 inch into
oil in the oil cup (to “oil wet” filter pack). Install the two filter
elements, baffle plate, and oil cup immediately after “oil wetting” the
filter elements. Make sure gaskets are in place. NOTE: _Do not add more
oil to oil cup after elements have been dipped into it, because excess
oil absorbed by elements will drip back into oil cup, bringing level
back to normal._
(8) Round‐type oil bath air cleaner used on earlier models does not
have removable filter element. Complete cleaner body must be removed
from vehicle, immersed and agitated in cleaning solvent to wash out
dirt. After cleaning, allow filter element to dry (use air hose if
available), then apply a few squirts of engine oil to inside of cleaner
element, using oilcan. Refill cup, replace baffle plate and cup,
securely tightening clamp band thumb screw.
77. HOSE AND CARBURETOR FITTING.
=a. Remove.= Carburetor intake and hose connection must be removed
from carburetor to remove and/or install air hose.
(1) Loosen screws in the two hose clamps.
(2) Remove four screws retaining carburetor air intake fitting. Remove
carburetor fitting from end of hose, and pull hose off air cleaner body
connection.
=b. Install.= Before installing air hose, inspect for
breaks or faulty condition that might prevent airtight seal between air
cleaner and carburetor fitting.
(1) Install one end of hose on carburetor fitting. Do not tighten clamp
screw.
(2) Install other end of hose on air cleaner connection. Do not tighten
clamp screw.
(3) Install carburetor fitting. Securely tighten the four screws. Next,
center air hose between carburetor fitting and air cleaner connection
and securely tighten hose clamp screws.
78. REMOVE AIR CLEANER.
=a.= Loosen hose clamp screw at air cleaner body connection and remove
two nuts and gear‐toothed washers from bolts securing air cleaner
assembly to frame bracket. NOTE: _Gear‐toothed lock washers are also
used under heads of the two mounting bolts. Withdraw cleaner from end
of air hose._
=b.= The same procedure applies to round‐type air cleaners used on
earlier models.
79. INSTALL AIR CLEANER.
=a.= Engage air cleaner hose connection in end of hose and mount
cleaner assembly on frame bracket with two bolts, gear‐toothed lock
washers, and nuts. Securely tighten mounting nuts. NOTE: _The plated
(whitened) mounting bolts, four gear‐toothed lock washers, and bolt
nuts must effect a ground connection between bracket and filter
mounting to insure adequate radio bonding._ Tighten air hose clamp
screw at cleaner body connection.
=b.= The same procedure applies to round‐type air cleaners used on
earlier models.
80. REPLACEMENT OF AIR CLEANER MOUNTING BRACKET.
=a.= Air cleaner mounting bracket and air cleaner can be removed or
installed as an assembly.
=b. Remove.=
(1) Loosen hose clamp connection at air cleaner body.
(2) Disconnect battery ground wire. This prevents shorting battery when
removing cleaner bracket clamp bolt.
(3) Remove the two upper cleaner bracket frame clamp bolts.
(4) Remove lower mounting bolt. Cleaner lower bracket mounting and
clutch cable tube mounting are secured to frame bracket by the same
whitened radio bonding bolt, gear‐toothed lock washers, and nut. Remove
nut and drop bolt to free cleaner bracket.
=c. Install.=
(1) Engage air hose and cleaner body connection.
(2) Attach lower bracket first. Locate cleaner bracket so that hole
lines up with bolt holes in frame bracket and clutch cable tube
mounting. Pass whitened radio bonding bolt upward through bracket hole,
install shakeproof lock washer, and securely tighten nut.
(3) Attach bracket to the two upper frame clips. Tighten the clamp bolt
nuts.
(4) Connect battery ground wire.
(5) Tighten air hose clamp screw at cleaner connection.
81. EXHAUST SYSTEM.
=a. Remove Muffler Assembly.=
(1) Support vehicle on rear stand.
(2) Remove bolt from end of hanger bracket on left side of vehicle, and
remove bolt from muffler clamp and skid plate bracket on right side of
vehicle. Drop skid plate.
(3) Loosen nut and bolt on clamp which secures front end of muffler at
exhaust pipe connection (clamp is attached to muffler).
(4) Remove muffler rear hanger bracket bolt nut. Pull muffler assembly
free from exhaust pipe connection.
=b. Install Muffler Assembly.=
(1) Engage muffler pipe and exhaust pipe at muffler pipe clamp
connection. Do not tighten clamp bolt nut as yet.
(2) Attach muffler rear hanger bracket to frame bracket bolt,
installing lock washer, and tightening nut. NOTE: _It may be advisable
to loosen hanger bracket on muffler so that muffler can be lined up for
front end connection._
(3) Tighten muffler and exhaust pipe clamp bolt nut and rear hanger nut.
(4) Raise skid plate into position and install right side mounting bolt
which secures muffler front bracket and skid plate bracket to frame
clip. Tighten all mounting nuts.
=c. Remove Exhaust Pipes.=
(1) Refer to step =a= (1), (2), (3) above.
(2) Remove right side footboard and brake pedal assembly as follows:
Loosen footboard rear support stud nut, remove front support stud
nut, and pull footboard outward to free end of safety guard. Remove
bolt which secures front exhaust pipe clamp, and remove nut from rear
support rod, freeing stop light switch and rear end of footboard
sidebar. Remove nut from front support rod, and drop footboard and
brake foot pedal assembly to provide clearance for exhaust pipe
removal. Disengage rear exhaust pipe at cylinder port, at same time
prying and pulling front exhaust pipe forward and downward to free
from cylinder port. Both exhaust pipes can now be worked downward and
removed from vehicle as an assembly.
=d. Install Exhaust Pipes.=
(1) Position exhaust pipe (front and rear) assembly, working it into
position so that front pipe end slips into cylinder port; then, pry and
force rear pipe end into rear cylinder port.
(2) Mount footboard, brake foot pedal, and sidebar assembly on support
rods, installing washer and nut on front support rod.
(3) Position and mount stop light switch on rear support rod. See that
spring and operating control wire exert a straight pull on switch
plunger when foot pedal is operated.
(4) Install bolt, washer, and nut which secure front exhaust pipe clamp
to footboard sidebar.
(5) To attach safety guard to sidebar, pull front end of footboard away
from sidebar, line up holes in sidebar and safety guard end, then pass
footboard support stud through both pieces, and secure with washer and
nut.
(6) Tighten footboard rear support stud nut.
(7) To complete installation, follow procedure outlined in step =b=
(1) through (4) above.
[Illustration:
=10=—INSTRUMENT PANEL TERMINAL.
=12=—BATTERY POSITIVE.
=13=—BATTERY NEGATIVE (GROUND).
=18=—TERMINAL JUNCTION ON FRAME.
=26=—IGNITION—LIGHT SWITCH.
=28=—SPARK COIL.
=33=—CIRCUIT BREAKER.
=34=—COIL TO TIMER WIRE.
=*A=—RADIO BOND, COIL TO TIMER WIRE.
=*B=—RADIO BOND, COIL TO ENGINE.
=*C=—NOISE SUPPRESSION CONDENSER.
=*D=—SHIELDED COIL TO TIMER WIRE.
=*E=—SPARK PLUG SUPPRESSORS.
RA PD 315723
_Figure 48—Ignition to Battery Wiring Diagram_]