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.

(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).

(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.