Ignition Spark plug (NGK type) ---- D-8ESL Electrode gap mm ---- 0.6-0.7 Inch ---- 0.024-0.

028 Point gap mm ---- 0.3-0.4 Inch ---- 0.012-0.016 Firing order ---- 1-3-2-4 Valve clearance (cold) mm ---- 0.1 Inch ---- 0.004 Electrical system voltage ---- 12 Battery specification ---- 12V-18AH Battery terminal grounded ---- Negative Tire size front ---- 3.50 x 19 Rear ---- 4.50 x 17 Tire pressure Front-kg/cm2 ---- 2.0 Psi ---- 28 Rear kg/cm2 ---- 2.3 Psi ----- 32 Number of speeds ----- 5

POINTS A battery and coil type ignition system is used. Ignition breaker points are mounted on aft end of left cylinder head. Left set of breaker points is for cylinders #1 and #2 (front cylinders) and right set of points is for #3 and #4 (rear cylinders). Maximum breaker point gap should be set to 0.35mm (0.014 inch). Left set of breaker points should just open as " F l " mark on crankshaft flywheel is aligned in timing hole. Timing hole is located above cyli nders on left side at rear of crankcase. Right set of breaker points should just open as "F2" mark on flywheel is aligned. A permanent magnet type alternator rotor is gear driven by crankshaft. Weight of alternator rotor is used to counteract crankshaft torque. Standard battery is 12V-18 AH unit mounted on left side of motorcycle.

COOLING SISTEM Cylinders and cylinder heads are liquid cooled. Cooling system should be service d with 3200cc of a 50/50 mixture of ethylene glycol based anti-freeze and water. Coolant should be maintained between level marks on overflow tank mounted on right, forward side, beneath cowl. Cool ing fan switches on at 210 degrees F.

VALVE SISTEM Valves are operated by two single overhead camshafts via rocker arms. Camshafts are driven by two Gilmer belts from pulleys on front of crankshaft, Gilmer belt tension is maintained by spring loaded tensioner pulley wheels. All valve clearances should be set to 0.10mm (0.004 inch) with engine cold. Remove cylinder head covers and timing mark inspection plug on crankcase. Remove kick starter access cover on left rear of engine. Insert kick lever, depress lever and secure in depressed position. Alternator rotor bolt may now be used to turn engine after removing plug in cover. Alternator rotor should onl y be turned in clockwise direction. Turn engine until "Tl" mark on flywheel is al igned in timing hole and valves of #1 (right, front) cylinder are closed. Adjust clea rance between rocker arm adjusting screws and valve systems of #1 cylinder to 0,10mm. Turn crankshaft 180 degrees to align "T2" mark in timing hole and adjust valves of # 3 (right, rear) cylinder. Turn crankshaft to align "Tl" mark again and adjust valves of #2 (lef t, front) cylinder. Align "T2" mark again and adjust valves of #4. CLUTCH Clutch cable should be adjusted to obtain 10-20mm (0.4-0,8 inch) free play measu red at ball on end of hand lever.

ENGINE AND TRANSMISSION UNIT Transmission output gear and cylinder heads may be removed for service without removing engine from frame. Engine must be removed from frame for the majority of remaining engine and transmission repair procedures. Drain crankcase lubricant and cooling system. Disconnect exhaust pipes from muffler and remove exhaust pipes from cylinder head. Disconnect and plug fuel line to fuel pump. Unbolt intake manifolds at cylinder heads. Carburetors and manifolds may be left as an assembly in motorcycle if secured to upper fram e tubes. Move rubber boot at forward end of drive shaft out of the way and remove snap ring retaining universal joint on transmission output shaft. Push drive shaft toward rear wheel until universal joint will clear output shaft. Disconne ct radiator hoses. Weight of engine should be well supported when mounting hardwar e is removed. Engine is removed out left side of frame after unbolting lower left frame rail. Crankshaft and transmission components remain in right crankcase half when case s are separated. Use caution to prevent damage to left side pistons as left case half is removed .

Piston pins are a tight fit in pistons. Connecting rods for left side of engine have holes drilled in them to aid in lubricating left cylinders. Upper and lower rocker arm shafts are not interchangeable parts. Install rocker arm shafts with oil holes pointing toward camshafts. Refer to the following standard specifications: Valve stem to guide clearances Intake 0.010-0.04mm (0.004-0,0016 inch) Wear limit - .0.08mm (0.0031 inch) Exhaust - 0.04-0.07mm (0.0016-0,0027 inch) Wear limit .. 0.1 mm (0.0039 inch) Recommended piston skirt to cylinder clearance - 0,03-0,07mm (0.0012-0.0027 inch ) Wear limit - 0.15mm (0.0059 inch) Position camshafts and crankshaft so that key slots are straight up (12 o*clock) for proper cam timing. Standard camshaft timing specifications are: Intake open - 5 BTDC Intake close - 50 ABDC Exhaust open - 50 BBDC Exhaust close - 5 ATDC REAR DRIVE UNIT AND SWING ARM. Remove drive unit and drain lubricant. Remove seal lock ring on left side of dri ve unit. A spanner wrench with four pins should be used to engage tabs on lock ring for removal. R emove eight screws securing ring gear cover. Pry at opposite sides of ring gear bearing support to raise ri ng gear and bearing assembly from housing. Remove spacer shim used to control ring gear depth from right sid e of housing. A special spline wrench should be used to hold pinion shaft while removing nut on forward end. Remove spline and oil seal in forward end of housing. Remove tapered roller bearing from front of housing. Pinion shaft may now be removed out rear of drive unit. Shims on each side of tapered roller bearing next to pinion gear are used to adjust gear engagement. Install swing arm pivot bolts evenly. Make sure that no binding exists in universal joint when pivot bolts are tight.

SPARK PLUG. Standard recommended spark plug is NGK type D-8ESL with an electrode gap of 0.60.7mm (0.024-0.028 inch). CARBURETORS. Four 32mm Keihin CV type carburetors are used. Initial sitting of pilot air scre w is 1% turns out from a lightly seated position. Engine idle speed should be set at 900 rpm. Standard size of primary main jet is #65 and of size secondary mainjet is #125. Float level should be 21mm (0.826 inch). Carburetor balance sho

uld be checked and adjusted with the aid of a vacuum gage set. Attach vacuum gages and bring engine to norm al operating temperature. Turn balance adjusting screw on left carburetors until vacuum of left carbureto rs is equal then use balance screw on right side carburetors to equalize them. Use balance adjusting screw i n linkage to match right side vacuum readings with those on left side. Fuel is supplied to carburetors by a mechanical fuel pump mounted aft of right c ylinder head. Fuel pump is driven by right camshaft. Fuel tank is mounted beneath seat. A drain plug is provided at bottom of fuel tank. Open fuel tank opening before removing drain plug. NOTE: Use caution when working around motorcycle with engine running. Thermostat ically controlled radiator fan may switch ON at any time.