42
10.
Remove front engine mount bolt (13 mm socket, 6 mm hex key).
11.
To access the swingarm bolt, remove brake lever (13 mm wrench,
5 mm hex key).
12.
Remove the swingarm bolt (22mm socket & wrench).
NOTE:
Only drive the swingarm bolt far enough to clear the engine, leave it holding the
one side of the swingarm to the frame
13.
Remove the engine from the right side of the frame.
14.
Locate a suitable container for the engine coolant and remove
radiator hoses from engine (coolant will drain).
NOTE:
If the coolant looks to be free of contaminates it may be reused.
NOTE:
If you are merely performing a top end service skip ahead to
Top End
Disassembly Procedure
.
Complete Engine Disassembly Procedure
1.
Remove the magneto cover (9/64” hex key)
2.
Remove the bolt from the water pump shaft (4mm) and slide off the belt
cover and the water pump belt
3.
Using a flywheel holding tool and 14 mm socket remove the nut that
secures the flywheel.
4.
Using the Cobra flywheel / clutch puller (#MCMUTL68), remove the
flywheel from the crankshaft.
5.
Remove the stator (9/64” hex key).
6.
Remove the nut holding the large gear to the transmission input shaft (19
mm socket).
7.
Remove the special nut / starter gear that holds on the clutch (special tool
available, contact your local dealer).
8.
With the Cobra flywheel / clutch puller (#MCMUTL68), remove the clutch
from the crankshaft (details in Clutch Service portion of this manual).
Top End Disassembly Procedure
1. Remove the cylinder head nuts (5/16”).
2. Remove the outer cylinder head.
3. Remove the inner cylinder head.
