1998 vulcan 1500 classic how to replace rubber cam plug

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Lilac LS-18 Motorcycle Maintenance Standards

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Filed Under (Lilac) by admin on 25-11-2010

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

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SUZUKI SV1000 PERIODIC MAINTENANCE

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Filed Under (Suzuki) by admin on 26-02-2011

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MAINTENANCE AND TUNE-UP PRO- CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER I Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months) . • * Remove the seat. (LF6-7) • * Lift and support the feul tank . (C-74-65) • * Remove the air cleaner box cap O. • * Remove the air cleaner element O. • * Carefully use air hose to blow the dust from the cleaner ele- ment. CAUTION Always use air pressure on the throttle body side of the air cleaner element . If air pressure is used on the other side, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element . PERIODIC MAINTENANCE 2-5 2-6PERIODIC MAINTENANCE • * Reinstall the cleaned or new air cleaner element in the reverse order of removal . CAUTION If driving under dusty condition, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner by removing the drain plug . SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months) . No. 1 (FRONT) SPARK PLUG REMOVAL • * Remove the radiator mounting bolt O. • * Move the radiator forward. • * Remove the spark plug cap O. NOTE: Be careful not to damage the radiator fins . A WARNING The hot radiator and the hot engine can burn you . Wait until the radiator and the engine are cool enough to touch . • * Remove the spark plug with a spark plug wrench. 1 6 I It No. 2 (REAR) SPARK PLUG REMOVAL • * Remove the seat. (r–,-6-7) • * Lift and support the fuel tank . (=4-65) 4-65) • * Disconnect the camshaft position sensor 1O and breather hose (Z. • * Remove the rubber heat shield ® . • * Remove the spark plug cap . • * Remove the spark plug with a spark plug wrench . HEAT RANGE • * Check to see the heat range of the plug . CARBON DEPOSIT •Check to see if there are carbon deposits on the plugs . If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end . SPARK PLUG GAP • * Measure the plug gap with a thickness gauge . If out of specification, adjust it to the following gap . 09900-20803 : Thickness gauge Spark plug gap OA Standard: 0.6 – 0 .7 mm (0.024 -0.028 in) ELECTRODES CONDITION •Check to see the worn or burnt condition of the electrodes . If it is extremely worn or burnt, replace the plug . And also replace the plug if it has a broken insulator, damaged thread . CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result

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HARLEY DAVIDSON HYBRID CAM PLATE AND HIGH FLOW OIL PUMP KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the service manual and follow the instructions to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. Gasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a) NOTES Installing this kit requires removal and installation of the cam support plate. Refer to the service manual for instructions with the following exception pertaining to cam compartment compo- nents: The crank and primary cam sprocket flange bolts are specially hardened, and the flat washers are of a special diameter and have ground surfaces. Use ONLY the parts provided in the Drive Gear Retention Kit (H-D Part Number 25533-99A, sold separately) when installing this kit. -J04804 1 of 7
The cr ank sprocket flange bolts and pr imary cam sproc ket flange bolts ARE NOT interchangeable. 2. Refer to the service manual to remove and discard the crank sprocket flange bolts and primary cam sprocket flange bolts and washers. 3. For 1999 models only: Refer to the service manual to remove and discard the currently installed cam drive sprocket. 4. Refer to the service manual to remove and disassemble the cams from the support plate and oil pump. Discard the support plate and oil pump. 5. For 1999 – 2000 Dyna, 2000 Softail, 1999 – 2000 Touring, and 2001 EFI Touring models only: Inspect the cams, chain, sprockets and chain tensioners for wear, and replace as needed. Refer to the service manual for inspection and replacement procedures. For 2001 – 2005 Dyna, 2001 – 2006 Softail, 2002 – 2006 Touring, and 2001 carbureted Touring models only: Inspect the cams and secondary cam chain for wear, and replace as needed. Refer to the service manual for inspection and replacement procedures. The primary cam chain, primary sprockets and both tensioners will be replaced by new components from the kit. For ALL models and years: Discard the guide, as it will not be used. INSTALLATION 1. ALL models: See Figure 1. Obtain the new Rear Cam Roller Bearing Kit (H-D Part Number 8983) from inside the Cam Service Kit (H-D Part Number 17045-99C, purchased separately), and install as indicated in Step 2. NOTE See Figure 2. If not enough of the splined shaft is exposed to install the sprocket, omit the spacer (4) and proceed to Step 2e. When the bearing inner race is started onto the machined area, remove the flange bolt (5), flat washer (6) and sprocket, then assemble using the spacer (4). Repeat Step 2e to fully install bearing inner race. To center thrust washer, be sure o-ring is installed in relief groove. Damage to bearing cage and engine can occur if thrust washer is not centered. (00473b) 2. See Figure 1. Install the O-ring (5), thrust washer (4) and bearing inner race (3) onto the rear camshaft as follows: a. See Figure 2. To properly locate the thrust washer (2), install the O-ring (3) in the grinding relief groove on the splined end of the rear camshaft between the machined area and the secondary cam sprocket.

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Yamaha YZ400/426F Camshafts REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 01-01-2012

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Cleanliness is always a good place to start. Make sure the motorcycle is cleaned thoroughly before you start. It would be advisable to use an engine degreaser on the frame and the engine. This will ensure a clean engine during the assembly process and less of a chance of thread damage and/or dirt contamination in the engine during reassembly. And as always, replace any fiber-based gasket that was moved in any way, i.e.: cam chain tensioner. You will need basic hand tools and a torque wrench, machine towels (rags), some cleaning solvent, and a cam chain tensioner gasket. And the Hot Cams’ Degree Wheel Kit if you so desire. We will start by removing the tank and seat, top engine mount, and the cam cover. Remove the crankshaft cap and timing hole cap on the left engine case cover. Remove the spark plug. Rotate the engine in a counter clockwise (CCW) direction. Position the engine on top dead center (TDC) using the mark on the flywheel or better yet a degree wheel using a positive stop. Be sure to notice that the intake valves were the last to move, this will ensure the engine of being on “true” TDC. True top dead center occurs when both the intake and exhaust valve are closed when the piston is at TDC. This is technically the end of the compression stroke and the Page 1
beginning of the power stroke. The “artificial” TDC is during the overlap when both the intake and exhaust valves would be open. Note the positioning of the cam lobes (their included angle will be close to 170 degrees), this will help during the installation of your new Hot Cams camshafts Remove the cap bolt on the end of the cam chain tensioner block, be aware of the copper washer. Release the spring tension on the cam chain tensioner by turning the flat blade screw slot inside the adjuster block in a clockwise (CW) direction; it will lock in the retracted position. Remove the two 8mm headed bolts that hold the cam chain tensioner to the cylinder block. Remove and discard the gasket. Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that secure the intake cam cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust camshaft out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft

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Yamaha YZ 250F Camshafts REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 30-12-2011

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Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that hold the intake camshaft cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust cam out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft. Fit the half moon shaped retainers in the grooves of the Hot Cams camshaft bearings to ensure good fit, set retainers aside for the time. Using assembly lube, lube the shim buckets, bearing surfaces for the camshafts in the cylinder head, and pack some in the camshaft bearings. Set the exhaust cam into the cylinder head casting while at the same time fitting the cam chain over the sprocket. Make sure that you keep all the cam chain slack to the back of the engine. The cam chain pulls the camshaft sprockets in a counter clockwise direction and the slack of the chain must be kept on the cam chain tensioner side of the engine. The exhaust cam has two timing marks on it. When correctly installed one mark will be at the 9 o’clock position and the other mark will be at the 12 o’clock position. When correctly timed the mark at 9 o’clock will be aligned with the valve cover gasket surface. Repeat the above process for the intake camshaft. Again, make sure you keep the chain slack to the cam chain tensioner side of the engine. Check to be sure the crankshaft is still at TDC. The intake cam has two timing marks also. One at 12 o’clock and the other at 3 o’clock. When both cams are installed correctly, the valve cover gasket surface will form a straight line through the exhaust timing mark at 9 o’clock and the intake timing mark at 3 o’clock

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Harley-Davidson Twin Cam Engines Cam Chain Drive System Installation and removal MANUAL

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Filed Under (Harley Davidson) by admin on 27-03-2012

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Removing the Cam Chain Drive System. NOTES Changing camshafts and cam drives in the 2006-up Harley-Davidson® Twin Cam 88® engines is different than in pervious engines. Procedures require use • of some special tools. Installation should be done by an experienced mechanic with access to factory service manual and required tools. Tighten all fasteners to the correct specifications and in order described. Always use an accurate torque wench. • Incorrect installation can cause engine damage not covered under warranty. CAUTION Failure to install components correctly can result in sudden engine seizure. Engine seizure may result in serous injury to motorcycle operator, passenger, or others. A- Disconnect the battery ground cable to eliminate potential sparks and inadvertently engagement of the starter while working on the motorcycle. B- Remove spark plugs and pushrod cover clips. Collapse the pushrod covers to expose the pushrods. C- Safely elevate and stabilize the rear of the motorcycle. Place the transmission in high gear. Turn the rear wheel to rotate the engine until both lifters and pushrods for either cylinder are at the lowest point on the camshaft (TDC of compression stroke). Both intake and exhaust pushrods for that cylinder will be under pressure from the valve springs and will rotate with light finger pressure. NOTE: 510G camshafts may use stock style non-adjustable pushrods instead of adjustable pushrods. If installing non-adjustable pushrods, disassemble and assemble rocker boxes per H-D® instructions. All other S&S® gear driven cams require installing adjustable pushrods. As a time-saving measure, the stock pushrods can be removed with bolt cutters. Be sure to head caution and warnings of these instructions. D- Cut the pushrods for the cylinder that is at TDC with the bolt cutter and remove the pushrod covers from the engine. Rotate the engine to place the pushrods for the other cylinder at their lowest point. Cut and remove the remaining pushrods. WARNING CAUTION Cutting pushrods with a saw or cutoff wheel may result in debris entering the engine, causing engine damage not covered under warranty. WARNING Cutting pushrods without releasing spring pressure, by rotating the engine until tappets are at the lowest point of travel can result in bodily injury. E- Remove the pushrod covers and lifters form the crankcase. F- Remove engine cam cover and gasket. Secure lifers with a tool made from a large binder clip

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BMW F 650 GS Repair Manual And Maintenance schedule

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Filed Under (BMW) by admin on 19-11-2010

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Replace oil in telescopic forks Check the coolant and restore to correct level if necessary *) Replace the coolant (every 2 years) every 2years Check valve clearances, adjust if necessary Replace the spark plug Drain the outlet hose from the air filter box Replace intake air filter If motorcycle is operated in very dirty or dusty conditions, clean or replace the intake air filter every 10,000 km (6,000 miles); check every 3,000 km (1,800 miles) Replace fuel filter (every 20,000 km/12,000 miles) 20,000 km Check clutch play, adjust if necessary Check wheel spoke tension and tighten if necessary more frequently if motorcycle is ridden in severe off-road conditions Examine brake pads and discs for wear, replace if necessary *) more frequently if motorcycle is ridden in severe off-road conditions Check brake fluid level at front and rear and top up if necessary *) Check for operation of brake system and freedom from leaks; repair/replace if necessary *) Replace the brake fluid at least once a year Replace the primary front/rear brake master cylinder cup (every 40,000 km/24,000 miles on a motorcycle with ABS ) 40,000 km Check wheel bearings and replace if necessary *) Check or, if necessary, replace chain, sprocket, chain guide rollers and pinion *) more frequently if motorcycle is ridden in severe off-road conditions Check chain tension and adjust if necessary *) Check battery acid level, add distilled water if necessary more frequently if motorcycle is ridden in severe off-road conditions Clean and grease the battery terminals, if necessary Check steering head bearings and adjust *) or replace if necessary *) Grease the side and main stands Grease the brake pedal Check bolts and nuts on engine mountings, frame connections, exhaust system mountings, swinging fork pivot, suspension levers, brake pedal, main and side stands and quick-release axles for tightness Final inspection with road safety and functional check

HARLEY DAVIDSON SCREAMIN' EAGLE BILLET CAM SUPPORT PLATE REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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REMOVAL NOTE For removal, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Remove the Maxi® fuse. 2. Remove the cam cover and gasket. 3. Remove and discard the crank and primary cam sprocket flange bolts and washers. 4. Release the oil pump, and remove the cam support plate and cams. Disassemble the cams from the support plate and discard the support plate. 5. Inspect cams, chain, sprockets, oil pump, chain tensioners and guide for wear and replace as needed. Refer to the Service Manual for inspection and replacement proce- dures. -J04503 INSTALLATION NOTES For installation, refer to the appropriate sections of the applicable Service Manual for detailed information on the following generalized steps. See Figure 1. When installing Screamin’ Eagle camshaft kits, install the O-ring included in this kit over the splined shaft of the rear camshaft as shown. 1. Using the Camshaft Assembly Tool (HD-47956) and assemble the camshafts, chains and tensioners to the billet cam support plate. 2. Install the cam support plate assembly into the crankcase. 3. Using the Crankshaft/Camshaft Locking Tool (HD-47941), install cam sprockets, chain and tensioner. 4. Install cam cover and gasket. 5. Install Maxi fuse.

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SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 10-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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Honda VT1100 Shadow Guide Plug Patch Repair Manual

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Filed Under (Honda) by admin on 24-04-2011

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Find the guide plug.bn The guide plug is shown in the shop manual with the engine removed from the frame and the left crankcase cover removed. (You’ll find this illustration in the “ELECTRIC STARTER/STARTER CLUTCH” chapter in the “STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL” section.) It’s a little bit harder to find it on the bike. Start by following the yardstick to see where the guide plug is on my bike. To find it on your bike, lie on the ground (or, preferably a mechanics creeper) next to the bike (without the yardstick) and peek under the shift lever and over the frame There it is, just barely visible from the side of the bike. Here’s what a new one looks like: 2. Clean the guide plug and crankcase. From the front of the bike, clean the guide plug and crankcase with brake cleaner in a VERY focused spray. Let the cleaner evaporate before moving to the next step. Page 4 Rev: Draft 5/20/2007 Page 4 of 5 3. Reposition the guide plug. a. From the side of the bike, use the yardstick (or a long screwdriver if you prefer) to gently push the guide plug back into the crankcase. (Note the JB Weld from the previous patch operation.) b. From the front of the bike, gently push upward on the bottom of the upper tab (as shown below) or the bottom of the forward tab to rotate the guide plug into the proper position while maintaining pressure with the yardstick

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