Here we go with day 2.

Remove horn. 10mm nut


Upper Front Stabalizer Link and Bracket Removal
1. Remove 2bolts (T-45)and take the link out. You will need a piece of pipe to give you some leverage because the bolts ore in there tight


2. Remove 2 bolts from the front of the cylinder head. (5/8" closed end wrench) and remove bracket.


1. Remove 4 bolts (each head..2 each side for each head) 3/16 allen wrench


2. Pull covers off. May take a little work but they will come off. Remove seals from where bolts were. 2 removed in pic.


3 Remove screw for breather valve and remove the valve. Black one is for the front and the Brown one is for the back.


I removed the back head first.
1. Close valves. Put bike in first gear and turn the back wheel till the valve closes. Make sure spark plugs are removed before you do this.

2.Remove bolts in this order.
2 each 3/16 allen wrench


3. 3 each...7/16 socket


3. WARNING>>>Take these 4 bolts out in 1/4 -1/2 turn increments using a cross pattern. You will know when they are free and are able to take them out by hand. 1/2" socket.



4. Remove pushrods. They have to go back in the same holes. Mine were already marked. For the back head it was red..front and white back. For the front head it was reversed...White front and red back.


Repeat these steps for the front head.
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1. WARNING>>>>> Loosen head bolts. They MUST be done in this order and only in 1/8" increments. Use ONLY a 12pt 1/2" socket. You will have to use a bar to get enough leverage to break them loose. Notice the different pattern on the heads.

Back head.
1. RED
2. BLUE
3. PINK
4.GREEN


Front head.
1.RED
2. BLUE
3. PINK
4. GREEN


2. Pull top heads off. Then pull ouff the pushrod covers.




3. To pull the jugs off make sure the piston is at the bottom stroke. Then just pull it off. Make sure you cover the hole so nothing falls into the motor.


After removal. Put pieces of rubber over each cylinder stud so no damage occurs to them.

Here is both jugs removed.


Here is how it look as of now. The beer was getting cold agian so I called it a day. I had to order the too from HD to be able to remove the piston. Note..I probably could have gotten by without it but I would rather be safe than sorry. Personnal preference here.





Next weekend I will remove the pistons and rejet the carb while I am waiting for the parts

 

Great pics. keep 'em comming!

 

Are you sure they will be going back together? Just kiddn'
You should write your own repair manual lol. Thanks for the heads up!

 

You are the best for sharing all this with us. Thanks pal.

 

You are a great and patient man to take the time to post all of this info to share with the forum.

 

awesome job keep up the great work. can't wait to do mine next winter. Thanks again

 

i will be printing all of this off when its complete, to refer to when i do mine. thanks for taking the trouble top document everything.

 

AWESOME man!

Thanks so much for sharing this 411. I was sort of planning this project in the Spring. I'm feeling more confident I can do it with these great instructions and pics.