Table 3-24. Engine in chassis
SERVICE PROCEDURE | COMPONENT REPAIR PROCEDURES |
Remove parts necessary to gain access to all components above cylinder deck. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End | |
Repair. | |
Continue with 3.13 TOP END OVERHAUL: DISASSEMBLY. Remove/repair subassembly components only if necessary. | |
Remove rocker arm outer covers. Remove crankcase breathers. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder Heads. | *Inspect and repair as necessary. See 3.4 CRANKCASE BREATHING SYSTEM, XL Models or 3.4 CRANKCASE BREATHING SYSTEM, XR 1200X. |
Remove cylinder heads. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder Heads. | *Inspect and repair as necessary. See 3.14 CYLINDER HEAD. |
Remove pushrods, pushrod covers and tappet covers. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder Heads. Remove tappets. See 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Tappets. | *Inspect and repair as necessary. See 3.22 BOTTOM END OVERHAUL: ASSEMBLY, Tappets. |
Remove cylinders and pistons. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder and Piston. | *Inspect and repair as necessary. See 3.15 CYLINDER AND PISTON. Inspect upper connecting rod and repair as necessary. See 3.15 CYLINDER AND PISTON, Connecting Rod Bushings. |
Complete all appropriate steps under 3.16 TOP END OVERHAUL: ASSEMBLY. | |
Complete motorcycle assembly. See 3.16 TOP END OVERHAUL: ASSEMBLY, Assembling Motorcycle After Top End Repair. |
* When this step is completed during top end service, advance to 3.16 TOP END OVERHAUL: ASSEMBLY if no other work is to be done.
Table 3-25. Engine removed from chassis
SERVICE PROCEDURE | COMPONENT REPAIR PROCEDURES |
Remove engine from chassis. See 3.10 REMOVING ENGINE FROM CHASSIS. | |
Start 3.13 TOP END OVERHAUL: DISASSEMBLY. Remove and repair subassembly components as necessary. | |
Remove rocker arm outer covers. Remove crankcase breathers. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder Heads. | *Inspect and repair as necessary. See 3.4 CRANKCASE BREATHING SYSTEM, XL Models or 3.4 CRANKCASE BREATHING SYSTEM, XR 1200X. |
Remove cylinder heads. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder Heads. | *Inspect and repair as necessary. See 3.14 CYLINDER HEAD. |
Remove pushrods, pushrod covers and tappet covers. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder Heads. Remove tappets. See 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Tappets. | *Inspect and repair as necessary. See 3.22 BOTTOM END OVERHAUL: ASSEMBLY, Tappets. |
Remove cylinders and pistons. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder and Piston. | *Inspect and repair as necessary. See 3.15 CYLINDER AND PISTON. Inspect upper connecting rod and repair as necessary. See 3.15 CYLINDER AND PISTON, Connecting Rod Bushings. |
Complete all appropriate steps under 3.16 TOP END OVERHAUL: ASSEMBLY. | |
Install engine in motorcycle. Complete all appropriate steps under 3.11 INSTALLING ENGINE IN CHASSIS. | |
Complete motorcycle assembly. See 3.16 TOP END OVERHAUL: ASSEMBLY, Assembling Motorcycle After Top End Repair. |
* When this step is completed during top end service, advance to 3.16 TOP END OVERHAUL: ASSEMBLY if no other work is to be done.