*
- Engines may be properly assembled with gaskets thicker than 0.8mm (0.032”)
although a slightly different measuring technique will be required that uses base
gasket of known thickness at the starting point.
Upon completion, your final assembly squish clearance should agree with the
chart below
Figure 22
Engine Removal
To service the bottom end and transmission, the engine must be removed from
the frame.
Tools required
•
10, 11, 13, 22 mm wrench
•
8, 10, 14, 17 & 19 mm sockets
•
3, 4 & 5 mm hex key (Allen wrench)
•
7 mm nut driver, flat or Phillip, screwdriver for hose clamps
•
Spring remover
•
Flywheel / clutch puller (#MCMUTL68)
•
Clutch nut removal tool (Call local dealer for details).
Procedure
1. Remove the seat.
2. Turn of the fuel at the petcock and disconnect the fuel line.
3. Remove the tank (8 mm socket).
4. Remove the carburetor from the inlet (flat head or Phillips head screwdriver, 7
mm nut driver).
5. Remove the silencer & pipe (spring remover, 8mm socket).
6. Locate a suitable container for the engine coolant and disconnect the coolant
lines connected to the engine (8 mm socket).
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