Page 16
I
I
I
Move radiators to side
- remove hose clamp (by prying end of clamp with flat-bladed screwdriv-
er) and hose attached to cylinder head. Loosen clamp on hose on top of left side radiator (where
hose goes through frame). Unhook rubber cord retaining radiator at top.
Pull top of radiator out of hose, then lift radiator up to disengage lower mounting pin from
frame mount. Hang radiator to side using rubber cord (see photo III-14)
Loosen clamp on hose at top of right side radiator. Pull hose off of radiator from left side of
frame, then remove clamp if it didn’t come out of frame cavity with hose. Pull top of radiator
away from frame, then lift up to remove. Clean front frame tube and frame tube over motor.
Remove spark plug
- using
13
⁄
16
˝ (21mm) wrench for NGK plugs,
5
⁄
8
˝ wrench for original
Champion plug.
Remove cylinder nuts
- Remove 4 nuts on top of cylinder head using a 10mm wrench. To pre-
vent warpage, loosen nuts
1
⁄
4
turn at a time using a criss-cross pattern until finger tight, then
remove.
Remove cylinder head
- Lift up on cylinder head to remove. Rock side to side to loosen if necessary. DO NOT insert a screw driver
or other implement between head and cylinder as damage will result! Small o-rings may stick to underside of head, take care not to
lose them. Lift up on combustion chamber to remove from cylinder. Do not lose o-rings on underside, remove from head to prevent
them from dropping into engine. Wipe up any coolant or dirt on cylinder or piston.
Rotate pipe outward and ease rear portion of pipe through
frame. Note position of front wheel.
lubricate hose with
soapy water
III
III
.1
.1
1
1
Remove exhaust extension using 5mm allen wrench.
Hang radiator to side using rubber o-ring
Remove radiator cap & drain coolant using bleed screw
Coolant drain screw
III
III
.12
.12
III
III
.13
.13
III
III
.14
.14
III
III
.15
.15
