B.
ASSEMBLY
AND
REPAIR
INSTRUCTIONS
FOR ENGINE
1.
Removal from Frame
1.1
Remove the tank
1.2
Remove the exhaust
1.3
Remove the carburetor
1.4
Remove the cylinder
head and top engine
brace
1.5
Remove the ignition
wire
1.6
Remove the 10 mm x 1 engine mount
bolts
front and rear
1.7
Disconnect
the chain
1.8
Loosen the 8 mm bolt on bottom
of engine
1.9
Remove the clutch
cable
1.10 Remove the engine
22. Piston Disassembly
2.
Disassembly of Engine
We suggest using the original
MAl CO engine stand.
2.1
Drain gear oil - one (SW 17mm) drain plug
on lower left side.
2.2
Remove the cylinder
by loosening the four
8 mm nuts (SW 13mm) at the base of the
cyl inder. The paper base gasket is removed
taking care not to tear it. Make sure no dirt
enters the crank case.
2.3
Remove the piston -
the circlips
on both
sides of the piston are removed with
needle
nose pliers. An aluminium
pin is used to re-
move the piston
pin by tapping the pin
lightly.
Use caution
not to apply any pres-
sure to the side of the connecting
rod.
2.4
Lay engine on primary
case side and remove
timing
cover.
2.5
Remove stator by loosening and removing
23. Pulling
Ignition
Magnet
3 - 6 mm screws. Push rubber plug out with
screw driver.
2.6
Remove the 8 mm hex bolt from the center
of the rotor
magnet and remove the nut
which keeps the magnet in position
on the
crank shaft. A pin, available through
your
dealer 60 mm long, is inserted in the middle
of the magnet and the 8 mm bolt is re-inser-
ted and tightened
while crank shaft is held
stationary
by a wooden
fork arou nd the
connecting
rod after piston pin is re-inserted,
widging
against the wooden
fork.
The bolt
is tightened
until
the magnet pops off.
2.7
The engine is turned
around with
the prima-
ry case facing up. The kickstarter
lever is
removed and the 7 case screws. The cover
can then be lifted
off.
2.8
Disassembly
of the clutch
is done with
the
help of a two-prong
puller.
By compressing
the clutch
on the clutch
push pin with
the
puller, the two keeper rings are removed
24. Clutch
Disassembly
