Table 3-26. Engine in chassis: cam compartment service
| 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 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. |
| Continue with 3.17 BOTTOM END OVERHAUL: DISASSEMBLY. | |
| Remove gear case cover and cam gears. See 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Gearcase Cover and Cam Gears: XL Models or 3.17 BOTTOM END OVERHAUL: DISASSEMBLY. Oil Pump Housing/Gearcase Cover and Cam Gears: XR 1200X. | *Inspect and repair as necessary. See 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Gearcase Cover and Cam Gears: XL Models or 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Oil Pump Housing/Gearcase Cover and Cam Gears: XR 1200X. |
| Remove oil pump components. See 3.20 OIL PUMP: XL MODELS or 3.21 OIL PUMP: XR 1200X. | Inspect and repair as necessary. See 3.20 OIL PUMP: XL MODELS or 3.21 OIL PUMP: XR 1200X. |
| Complete all appropriate steps under 3.22 BOTTOM 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 bottom end service, advance to 3.22 BOTTOM END OVERHAUL: ASSEMBLY if no other work is to be done.
Table 3-27. Engine removed from chassis: flywheel compartment service or complete engine overhaul
| 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 | Inspect and repair as necessary. See 3.14 CYLINDER HEAD. |
| Heads. | |
| Remove pushrods and pushrod covers. See 3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder Heads. Remove tappet covers and tappets. See 3.22 BOTTOM END OVERHAUL: ASSEMBLY, Tappets. | Inspect and repair as necessary. See 3.16 TOP END OVERHAUL: ASSEMBLY. Tappet Covers, Pushrod Covers and Pushrods. |
| 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. |
| Continue with 3.17 BOTTOM END OVERHAUL: DISASSEMBLY. Remove and repair subassembly components as necessary. | |
| Remove gearcase cover and cam gears. See 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Gearcase Cover and Cam Gears: XL Models or 3.17 BOTTOM END OVERHAUL: DISASSEMBLY. Oil Pump Housing/Gearcase Cover and Cam Gears: XR 1200X. | Inspect and repair as necessary. See 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Gearcase Cover and Cam Gears: XL Models or 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Oil Pump Housing/Gearcase Cover and Cam Gears: XR 1200X. |
| Remove oil pump. See 3.20 OIL PUMP: XL MODELS or 3.21 OIL PUMP: XR 1200X. | Inspect and repair as necessary. See 3.20 OIL PUMP: XL MODELS or 3.21 OIL PUMP: XR 1200X. |
| Complete all appropriate steps under 3.17 BOTTOM END OVERHAUL: DISASSEMBLY, Crankcase to split crankcases and remove flywheel assembly, piston jets, etc. | Inspect and repair as necessary. See 3.19 CRANKCASE. Inspect and repair transmission assembly as necessary. See 5.9 TRANSMISSION REMOVAL AND DISASSEMBLY, 5.10 TRANSMISSION ASSEMBLY, 5.14 TRANSMISSION INSTALLATION and related subjects. |
| Complete all appropriate steps under 3.22 BOTTOM END OVERHAUL: ASSEMBLY. | |
| 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. |