Engine Removal

ENGINE REMOVAL

NOTE:
It is not necessary to remove the engine in order to remove the following components:

•   Piston
•   Clutch
•  Carburetor
•  Oil pump

PREPARATION FOR REMOVAL

1.      Remove all dirt, mud, dust, and foreign material before removal and disassembly.

2.      Use proper tools and cleaning equipment. Refer to CHAPTER 1, "SPECIAL TOOL"

NOTE: 
When disassembling the engine, keep mated parts together. This includes gear, cylinders, pistons, and other parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.

3. During the engine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled in the engine.

SEAT AND FUEL TANK

1.     Remove:
•  Seat (1)
•  Fuel tank (2)
•  Left side cover (3)

2.     Drain:
•  Engine oil

BATTERY

1. Disconnect:
•  Battery leads (1),(2)
•  Breather hose (3)

NOTE:
Disconnect the negative lead first.

EXHAUST PIPE AND MUFFLER

1.     Remove:
•  Nuts

2.     Loosen:
•  Clamp bolts

3.     Remove:
•  Exhaust pipes (1)

4. Remove:
•  Chamber mount bolt (1)
•  Muffler mount bolts (2)
•  Muffler with chamber

CARBURETOR AND CABLES

1.      Loosen:
•  Clamp screws

2.      Remove:
•  Air cleaner case (1) mount bolts (2)

3.      Push the air cleaner case toward the rear to disconnect air outlet hoses from carburetors.

4.      Disconnect:
•  Choke cables (3)

5.      Remove:
•  Carburetors
•  Throttle cable (4)

NOTE: 
After removing the carburetors, cover the carburetors with a clean cloth to keep dust and dirt out.

7. Disconnect:
•  Crankcase ventilation hose (1) (from crankcase)
•  Clutch cable (2)

CONNECTOR

1.      Remove:
•  Plate

2.      Disconnect:
•  Pickup coil lead
•  Generator lead
•  Neutral switch lead
•  Oil level switch lead
•  Starter motor lead (1) (from starter motor)

SHIFT PEDAL BRAKE PEDAL, FOOTREST AND DRIVE SHAFT

1.      Remove:
•  Shift pedal (1)
•  Left footrest (2)

2.      Disconnect:
•  Rubber boot (3)

3.      Remove:
•  Joint bolts (4)

4. Remove:
•  Brake pedal (1)
•  Right footrest (2)

ENGINE REMOVAL

1.     Place a suitable stand under the engine.

2.     Remove:
•  Mounting bolts
•  Downtube frame (1)

3. Remove:
• Engine assembly (from chassis right side)