1. | Remove main fuse following the instructions in the service manual. | |
2. | Remove the seat (if necessary) following the instructions in the service manual. Save all hardware for installation. NOTE Head gaskets provided in the 1690 conversion kit eliminate the need for original equipment (OE) O-rings. Do not install the two O-rings from the kit on the top cylinder dowels or severe engine damage can occur. | |
![]() When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) | ||
3. | Remove existing cylinder heads, cylinders and pistons following the instructions in the service manual. | |
4. | Remove existing primary chaincase cover, diaphragm spring retainer and clutch diaphragm spring following the instructions in the service manual. |
1. | Install main fuse following the instructions in the service manual. | |
![]() After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) | ||
2. | Install the seat (if removed) following the instructions in the service manual. |
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
---|---|---|---|---|---|---|
1 | Cylinder assembly (Silver) (2) | 16548-99A | 5 | Piston pin circlip (4) | 22097-99 | |
Cylinder assembly (Black) (2) | 16547-99A | 6 | Head gasket (2) | 16787-99A | ||
2 | Piston, 1690 standard (2) | Not Sold Separately (Available in Piston Kit 21966-07) | 7 | O-ring, cylinder deck ring dowel (2) | 11273 | |
3 | Piston ring set (2) | 21918-99 | 8 | O-ring, cylinder spigot (2) | 11256 | |
4 | Piston pin (2) | 22131-05 | Note: Do not install O-ring (item 7) to top cylinder dowels. |
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
---|---|---|---|---|---|---|
1 | Gasket, rocker cover base (2) | 16719-99B | 9 | Breather assembly | 17025-03A | |
2 | Gasket, rocker cover top (2) | 17386-99A | 10 | Baffle assembly | 26500002 | |
3 | Gasket, tappet cover (2) | 18635-99B | 11 | Seal, exhaust (not shown) | 17048-98 | |
4 | O-ring, middle push rod cover (4) | 11132A | 12 | Seal, EFI intake (2) (not shown) | 26995-86B | |
5 | O-ring, lower push rod cover (4) | 11145A | 13 | Spring, clutch diaphragm (not shown) | 37951-98 | |
6 | O-ring, upper push rod cover (4) | 11293 | 14 | Air cleaner kits (not shown) | ||
7 | O-ring, rocker arm support (2) | 11270 |
| 29440-99D 29260-08 29406-08 | ||
8 | Bolt (4) | 4400 | 15 | Product information label (not shown) | Not sold separately |