REMOVE VALVE COVER

PRESS OUT STOCK PLASTIC INSERT FROM THE INSIDE, OR CAREFULLY PRY IT OUT FROM THE TOP SIDE

START THE SET SCREWS IN THE INSIDE (THREADED) PART OF THE NEW INSERT. THIS WILL MAKE IT EASIER TO TIGHTEN THESE LATER. WE RECOMMEND THE USE OF LOW OR MEDIUM STRENGTH (BLUE) LOCTITE, EITHER NO. 222 OR 243 ON THE SETSCREWS. EVEN WITHOUT LOCTITE, WHEN PROPERLY INSTALLED, IT IS IMPOSSIBLE FOR THE SET SCREWS TO FALL INTO THE ENGINE AS THEY ARE "TRAPPED" BY THE THREADED PLUG WHEN SEATED. HOWEVER, IF THE SETSCREWS ARE NOT SUFFICIENTLY TIGHTENED AND/OR LOCTITE’D, IT IS POSSIBLE FOR THEM TO LOOSEN ENOUGH TO ALLOW THE INSERT TO ROTATE IN THE VALVE COVER.

LUBE THE INSTALLED VITON O-RING ON THE NEW INSERT WITH ENGINE OIL OR GREASE.

PLACE THE INSERT LOOSELY IN THE TOP OF THE VALVE COVER AND ALIGN THE SET SCREWS TO BE PARALLEL WITH THE CENTERLINE OF THE BIKE. USING PRESSURE FROM TWO THUMBS, FIRMLY PRESS THE INSERT ALL THE WAY DOWN UNTIL THE O-RING FULLY SEATS IN ITS GROOVE IN THE VALVE COVER. IF YOU CANNOT GET THE O-RING FAR ENOUGH DOWN TO SEAT, PLACE THE VALVE COVER ON A BENCH, PLACE A SMALL BLOCK OF WOOD SQUARELY OVER THE INSERT AND CAREFULLY TAP INTO PLACE WITH A HAMMER. THE INSERT IS FULLY SEATED WHEN THE TOP OF THE INSERT IS FLUSH WITH THE TOP SURFACE OF THE VALVE COVER.

FROM THE BACKSIDE OF THE VALVE COVER, FIRMLY TIGHTEN THE SETSCREWS WITH THE ALLEN WRENCH. INSTALL THE FILLER PLUG AND TIGHTEN SECURELY WITH PROVIDED "MINI-WRENCH". THIS TEST ENSURES THE SETSCREWS ARE TIGHT ENOUGH TO PREVENT THE INSERT FROM TURNING. IF IT DOES SLIP, CAREFULLY TIGHTEN THE SETSCREWS A LITTLE MORE. RE-TEST.

REINSTALL THE VALVE COVER. BE SURE TO NOT DISTURB THE RUBBER-SEALING GASKET BETWEEN THE VALVE COVER AND THE HEAD.

GO RIDING…LEAK FREE!