Repair And Fix it

Drain the coolant from the radiator into a container, and store the coolant for later use.

Detach the radiator hose from the housing of the thermostat, and remove the bypass hose from the intake manifold. Disconnect the air cleaner and ducts from the the intake manifold with a socket wrench. Remove the distributor cap, and detach its electrical wiring from the engine.

Mark the distributor housing to indicate the rotors position, and detach the electrical primary wire from the ignition coil. Disconnect the hold-down bolt for the distributor, and remove the distributor from the intake manifold.

Detach the vacuum lines on the intake manifold, and disconnect the electrical wire for the temperature sending unit. Remove the vacuum lines and fuel line from the carburetor. Disconnect the linkages that attach the carburetor to the intake manifold.

Disconnect the valve covers with a socket wrench. Turn the four mounting bolts for the rocker shaft two turns counterclockwise, proceeding from front to back. Repeat this until you disconnect all of the mounting bolts for the rocker shaft.

Mount the new rocker shaft and fasten the mounting bolts with a socket wrench. Tighten each bolt two full turns at a time, proceeding from back to front.

Install the remaining components by performing steps two through four in reverse sequence. Use the mark that you made on the distributor housing in Step 3 to install the distributor in the correct position. Refill the radiator with coolant, and check the vehicle for fluid leaks.

Close the petcock. Ensure the motorcycle is cold.

Remove the seat bolt and washer from the tab on the rear of your seat. Remove the seat to access the battery. Loosen the negative battery cable from the terminal with a box wrench and remove the cable from the battery.

Remove the center console. Typically, the center console is attached to the center console bracket with three Allen head screws.

Remove the fuel line from the petcock. Typically the petcock and fuel supply are joined by a hose clamp. Loosen the hose clamp with a flat head screwdrivers.

Drain the gasoline in your tank into an adequately sized, sealable, gas can. On models with dual gas caps, disconnect the crossover and fuel venting hoses in the front, middle bottom of the tank.

Remove the front mounting bolt, flat washers and acorn nut with a box wrench and socket wrench. Remove the rear mounting bolt, flat washers and acorn nut.

Disconnect the fuel gauge connector on recent models. The fuel gauge connector is under the left side of the fuel tank.

Remove the gas tank from the motorcycle. Set the tank on a flat stable surface in a well vented place.

Remove the six Allen bolts and washers that connect the rocker cover to the rocker assembly. Begin with the front rocker box and work on one cylinder at a time.

Remove the metal D-ring if your motorcycle is equipped with an Evolution engine. Note the top, bottom and orientation of the D-ring. Completely remove the old gasket. Use a gasket scraper if necessary.

Examine your rocker arm housing. Rocker arm housings with only a partial inner lip require you to use an adhesive like high temperature rubber cement to properly install the new gasket. Rocker arm housings with a full inner lip do not require adhesive.

Apply adhesive if needed and properly place the gasket on the rocker arm. Replace the D-Ring on Evolution engines. Replace the rocker arm cover.

Tighten the Allen bolts in a cross pattern to 10 to 12 foot pounds of torque. Refer to the shop manual for your motorcycle and use the exact torque sequence and specifications described there.

Re-bolt the gas tank to your motorcycle. Reconnect the fuel gauge connector. Reinstall the fuel line to the petcock.

Reinstall the center console. Refuel the motorcycle.

Reconnect the negative battery cable to the battery. Reinstall the seat.