REF-4 Maintenance Techniques
Basic maintenance spec~fictorque value, which is noted in the loosened by striking it with a soft-faced
. Specifications.Besuretofollowthetorquerec. hammernearthe matingsurfaces.A normal
techni q ues ommendatlons~losely:. hammer can be used if a block of wood is
Fasteners laId out In a pattem (Ie cylinder placed between the hamme d the art Dhead bolts engl b It )r an p. 0
Therearea numberof techniquesinvolvedin loosen d 'r h;e ~a~e 0 s, etc. must ~ not hammeron cast parts or parts that could be
maintenanceand repair that will be referred to Wine t~ c~ en In a.~equenceto avoId easilydamaged. With any particularlystubborn
throU~hout this manual. Application of these S~ldg go on ~:~~i I~~'allyitheNbo~~uts part, always recheck to make sure that every
techniqueswill enablethe amateurmechanicto should be tightened on~ fu~~~;n e:~h Ine~ fasten~r~ been remo~.
be more efficient,be~er organlsedand capable criss-cross or diagonal pattem. After each one Avoid uSInga scl9Wdnveror bar to pry apart
of.performIngthe varioustasks properly, which has been tightened one full tum retum to the components, as they can easily mark the
will ensure that the repair job is thorough and first one tightened and tighten th~m all half gasket sealing surfaces of the parts (which
complete. . one must . th) If . .
tum, followingthe samepattem. Finally,tighten remain smoo . prying ISabsolutely
each of them one quarter turn at a time until necessary, use a piece of wood, but keep In
Fastening systems each fastenerhas been tightened to the proper mindthat.extra clean-up will be necessaryIfthe
Fasteners basicall are nut I torque. To loosenand removethe fastenersthe wOOdsplInters.
screws used to hOI~'two ors~~etsp=~~ procedurewouldbe reversed. Afterthepartsareseparated,theoldgasket
together.Therearea few thingsto keep in mind must be carefully scraped off and the gasket
whenworking with fasteners.Almost allof them . surfacesC~ed. Stubbom gasketmaterialcan
usea locking device of some type (eithera lock Disassembly sequence be soaked with a gasket remover (available in
washer, locknut, locking tab or thread locking Component disassembly should be done aerosol cans) to soften it so it c~n be easily
compound). All threaded fasteners should be with care and purpose to help ensure that the sr:'aped off. A scraper ~anbe fashlon~ from a
clean, straight, have undamaged threads and parts go back together properly during piece ~f copper tubing by flattening and
undamagedcomers on the hex headwherethe reassembly.Alwayskeeptrack of the sequence sharpening.one end. Copper is recommended
spanner fits. Develop the habit of replacing all in which parts are removed. Take note of becauseIt ISusuallysofter than the surfacesto
damagednuts and bolts with newones. special characteristics or marks on parts that be scraped, which reduces the chance of
Rustednuts and bolts should be treated with can be installed more than one way (such as gouging the part. Some gaskets can be
a penetrating oil to ease removal and prevent convex washers and gear pinions). It's a good removed with a wire brush, but regardless of
breakage.After applying the rust penetrant, let Idea to lay the disassembled parts out on a the method used,the mating surfacesmust be
it work for a few minutes beforetrying to loosen clean surface in the order that they were left clean and smooth. If for some reason the
the nut or bolt. Badly rusted fasteners may removed. It may also be helpful to make gasketsurface isgouged, then a gasketsealant
have to be chiselled off or removed with a sketchesor take instant photos of components thick enough to fill scratches will have to be
specialnut breaker,availableat tool shops. beforeremoval. used during reassembly of the components.
If a bolt or stud breaks off in an assembly,it Whenremovingfastenersfrom acomponent, For most applications, a non-drying (or semi-
can be drilled out and removed with a special keep track of their locations. Sometimes drying)gasket sealantis best.
tool called an E-Zout (orscrew extractor). Most threading a bolt back in a part, or putting the
dealer service departments and motorcycle washers and nut back on a stud, can prevent
repair shops can perform this task, as well as mix-ups later. If nuts and bolts can't be Hose removal f
others (such asthe repairof threadedholes retumedto theiroriginallocations,theyshould IpS
that have been stripped out). be kept in a compartmented box or a series of Hose removal precautions closely parallel
Washers should always be replaced exactly small bo~es or la~led plastic bags. A box of gasket removal precautions. Avoid scratching
asremoved.Replaceanydamagedwashers thIS type IS especiallyhelpfulwhenworkingon or gougingthe surfacethat the hosemates
with new ones. Always use a flat washer assemblieswithverysmallparts(such asthe againstortheconnectionmayleak.Becauseof
betweena lock washerand any soft metal carburettors,tappets,shimsetc). variouschemicalreactions,the rubber in hoses
surface(suchasaluminium),thinsheetmetalor Whenever wiring looms, harnesses or canbonditselfto themetalunionthatthehose
plastic.Speciallocknuts can only be usedonce ~onn.ectorsare separated,it's a goodideato fits over.To removea hose, first loosenthe
or twicebefore they lose their locking ability Identitythetwohalveswithnumberedpiecesof hose clamps thatsecureit totheunion.Then,
and must be replaced. masking tape so they can be easily withslip joint pliers, grab the hoseat the clamp
reconnected. androtateitarolKldtheunion.WOI'kitbackand
forthuntilit is completely free, then pull it off
(silicone or other lubricants will ease removalIf
Tightening sequences and Gasket sealing surfaces they can be applied between the hose and the
procedures Gasketsare usedto sealthe mating surfaces outsid~ o~the union).Apply the same lubricant
between components and keep lubricants, to the InSIdeof the hoseand the outside of the
Whenthreaded fastenersare tightened, they fluids, vacuum or pressure contained in an unionto simplify installation.
are often tightened to a spe~ific torque value assembly. If the hose is particularly stubborn, slit the
(torqu~ IS basically a twisting force). Over- Many times these gaskets are coated with a hosewith a sharp knifeand peel it off the union.
~Ightenlng the fastener ca.n weakenit andcause liquid or paste type gasket seating compound The hose will obviously be destroyed uq this
It to break, while under-tighteningcan cause it before assembly. Age, heat and pressure can method.
to eventuallyco":e loose.Eachbolt, depending sometimes cause the two parts to stick If a hose clamp is broken or damaged, do
on the material it s made of, the diameter of its together so tightly that they are very difficult to not reuse it. Also do not reuse hoses that
shankandthematerialit isthreaded into, hasa separate. In most cases, the part can be cracked,split or t~m. are
