1. Remove the two phillips srews, followed by the four 4mm fan cover bolts. On engine shrouds. |
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2. Remove engine shrouds. |
3. Use a flat head srewdriver and pop off the first half of the air filter. |
4. With the same srewdriver, unbolt the second half of the air filter and the carb. |
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5. Use a 4mm Allen and unbolt the intake manifold. |
6. There are 2 bolt used to hold on the coil. use a 3mm alllen and remove those bolts. mind the spacers under the coil. |
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7. To take off the exhaust can, you will need to unbolt the 4mm exhaust bolts and one small phillips srew that is under the can |
8. Remove both 4mm cylinder bolts and then remove cylinder. Make sure to pull the cylinder strait up when bolts are out. |
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9. Next is the flywheel, remove the spark plug and repalce with a piston stop. remove the flywheel nut and install the flywheel puller. twist until you feel a pop. "mind the half moon flywheel key" |
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9. If you dont have a flywheel puller use a single bolt that threads into one of the side. it might take a minute to thread all the way. just wait for the pop. |
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10. To take the cases apart. you will have to remove the four 4mm long bolts that hold them together. "It might be a little tough due to the lock tight" |
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11. Your almost there. now its just the crank and the piston. to remove the piston there is a small C clip on the side. pop the C-Clip out with a small srewdriver. to take out the wrist pin. use a pillips srew driver and place pointing at the wrist pin. give it a couple hits. it should come out with little work. WHEN INSTALLING NEW C-CLIPS MAKE SURE THE GAP IS POINTING UP OR DOWN. IF C-CLIPS ARE INSTALLED WITH THE GAP ON THE LEFT OR RIGHT THEY CAN COME OUT. ALSO MAKE SURE THE C-CLIPS ARE ALL THE WAY IN!!!! |
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12. Reverse the strip down process and reassemble motor. |
Tips for reassembling motor
When installing ignition coil place a business card between the flywheel and coil (make sure magnets on flwyhweel are directly under the coil. Press down on the coil while tightening bolts. |
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When installing piston the arrow or circle will always face the exhaust port. When installing cylinder make sure to put a coat of oil in the cylinder. The gap in the piston ring will close on the intake port. When installing cylinder pinch the piston ring and slide the piston into the cylinder. The piston should go in the cylinder easily. If you feel resistance do not force piston into cylinder. This can cause damage to your cylinder and or piston. |