COPY
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Nov./14/ 11
9
．
Cam Sprocket Removal
Notch
Marked “O”
切り欠き
フライホイール
Notch
Flywheel
◇
Rotate the flywheel counterclockwise to align
flywheel’s “T” mark with the cam sprocket’s “O” mark.
◇
Fix the flywheel and remove two cam sprocket’s hex
bolts.
Tools to use:
8 mm socket
14 mm offset box wrench (For flywheel fixing)
◇
Remove the cam sprocket from the camshaft with a
slotted screw driver or the like by prising open the
cam sprocket.
◇
Remove the cam chain from the cam sprocket, and
take the cam sprocket out.
◇
Remove the dowel pin which is stuck in the center of
the camshaft.
10
．
Cylinder Head Side Bolt
Removal.
◇
Remove the cylinder head side bolt(s) which are
used to fix the cylinder head and cylinder.
Tool to use:
10 mm open-end wrench
◇
Loosen the cylinder’s guide roller bolt and the side bolt
between the cylinder and the crankcase.
Tools to use:
10 mm open-end wrench
10 mm offset box wrench
Side bolt
Guide roller bolt
11
．
Cylinder Head Cover Removal.
◇
Remove the four nuts, diagonally across the cover,
which are used to fix the cylinder head cover.
◇
Remove four washers under the nuts.
Tool to use:
10 mm socket
◇
Remove a head cover. (If you cannot dismout the cover
easily, remove the cover by striking it with a plastic
hammer lightly.)
Completely get rid of the gasket
remaining on the cylinder head with a scraper or a cutter.
12
．
Cylinder Head Removal
◇
Pull the cylinder head away from the cylinder to remove
it. (If it is not easy, strike it with a plastic hammer lightly.)
◇
Keep the two dowel pins for reuse.
◇
Remove the cylinder head.
◇
Remove the already-loosened guide roller bolt and the
cylinder side bolt.
13
．
Cylinder Removal
◇
Pull and remove the cylinder. (When it is difficult, with
a plastic hammer, strike a cylinder lightly and remove
it.)
◇
In the process of cylinder removal, a cam chain guide
roller will come out, which do remove.
◇
After the piston has been taken out, remove the cylinder
forward.
14
．
Piston Removal
◇
Stuff a waste cloth into the crankcase’s cylinder hall
and the cam chain not to let any foreign material fall into
it.
◇
Remove one of the two piston circlips.
◇
You can remove it easily by placing the end of a screw
driver at the notch on the piston pin hole and prising the
circlip open.
Tool to use:
A tapered slotted screwdriver
◇
Remove the piston pin, turning it in the direction in
which the piston pin circlip has already been removed.
You can remove it easily by pushing it with a slotted
screwdriver from the side which still has a circlip.
◇
Remove the piston.
15
．
Clearing Mating Surfaces
Cylinder gasket
Rubber packing
◇
If the crankcase center gaskets stick out into the
cylinder base surface and / or cylinder hole, cut them
off.
※
Be careful not to let any foreign material into the
crankcase.
◇
Remove a cylinder gasket and a rubber packing.
◇
When gaskets do not come off completely, wipe them
off with a scraper or a cutter.
◇
If gaskets stick out into the portion pointed by a thumb,
cut them off. (See the picture above.)
Piston circlip
