E-TON ATV3U 150, Service Manual

Page: 10 / 225

ENGINE
..........................................................................................................4-1
EXHAUST PIPE/MUFFLER, CABLES AND LEADS................................ 4-1
ENGINE MOUNTING BOLTS ................................................................. 4-2
REMOVING THE ENGINE ...................................................................... 4-3
INSTALLING THE ENGINE..................................................................... 4-3
CYLINDER HEAD
.......................................................................................... 4-4
REMOVING THE CYLINDER HEAD.......................................................4-6
CHECKING THE CAMSHAFT SPROCKET ............................................4-7
CHECKING THE CYL. HEAD COVER ASSY..........................................4-7
CHECKING THE TIMING CHAIN GUIDES............................................. 4-7
CHECKING THE TIMING CHAIN TENSIONER ASSEMBLY ................. 4-7
CHECKING THE CYLINDER HEAD ....................................................... 4-8
INSTALLING THE CYLINDER HEAD .....................................................4-8
CAMSHAFT, ROCKER ARMS AND VALVES .............................................. 4-11
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 4-12
REMOVING THE VALVES AND VALVE SPRINGS ...............................4-12
CHECKING THE CAMSHAFT.................................................................4-13
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 4-13
CHECKING THE VALVES AND VALVE SPRINGS ................................ 4-15
INSTALLING THE VALVES AND VALVE SPRINGS .............................. 4-18
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 4-19
CYLINDER AND PISTON
.............................................................................. 4-20
REMOVING THE PISTON ....................................................................... 4-21
CHECKING THE CYLINDER AND PISTON ...........................................4-21
CHECKING THE PISTON RINGS............................................................ 4-23
CHECKING THE PISTON PIN ................................................................ 4-24
INSTALLING THE PISTON ..................................................................... 4-24
INSTALLING THE CYLINDER ................................................................ 4-25
C.D.I. MAGNETO
............................................................................................ 4-26
REMOVING THE C.D.I. MAGNETO ROTOR ......................................... 4-27
CHECKING THE PICKUP COIL/STATOR ASSEMBLY.......................... 4-27
INSTALLING THE C.D.I. MAGNETO ROTOR ........................................ 4-27
CHAPTER 4
ENGINE
BELT DRIVE ................................................................................................... 4-28
CRANKCASE COVER.............................................................................. 4-28
KICKSTARTER........................................................................................ 4-29
INSTALLING THE KICKSTARTER.......................................................... 4-30
V-BELT, CLUTCH, DRIVE AND DRIVEN PULLEY................................. 4-31