12
STEP 7:
Remove the 3x23mm cap-head machine
screws that fasten the header to the
engine. Carefully remove the header to
avoid damaging the gasket.
To separate the engine from the engine
mount, remove the four 3x8mm cap-head
machine screws.
Rebuilding the Engine
STEP 1:
Remove the 4mm locknut from the front
pipe hanger. Pull the pipe from the rear
exhaust header.
STEP 2:
Unplug
the blue wire
from the
glow plug. Remove
the
fuel line from the carburetor inlet and from the exhaust
header pressure fitting. Disconnect the red and black
wires from the EZ-Start
®
motor.
STEP 3:
Remove the EZ-Start gearbox by removing the three
3x8mm round-head machine screws.
STEP 4:
Use a 2.5mm hex driver to remove the yellow ground
wire from the engine mount. Move the EZ-Start
wiring
harness out of the way.
STEP 5:
Use a 2.5mm hex driver to remove the three
remaining 3x10mm cap-head machine screws from
the engine mount.
STEP 6:
Pull the engine from the chassis. Turn the engine
so that the throttle linkage to the carburetor will
come out.
STEP 9: Changing the piston and sleeve assembly
Use a 5/16 inch nut driver to remove the glow plug and
copper gasket.
STEP 10:
Use a 2.5mm allen wrench to remove the four 3x12mm
cap-head screws that fasten the cylinder head. Rock
the cylinder head gently from side
to side
to release
it
from the sleeve. Note the thin aluminum head gaskets.
We recommend that you replace these gaskets with
new ones upon reassembly.
STEP 11:
Remove the backplate and the
starter shaft. Replace the backplate
gasket with a new one during
assembly.
STEP 12:
The piston and sleeve are a matched set. When the
piston and sleeve are disassembled, they must be
reassembled in the same orientation. Use a hobby
knife to scratch a mark to indicate the location of the
piston in relation to the pinning of the sleeve.
STEP 8:
Removing the carburetor is not necessary to rebuild
the engine, unless you intend to replace the internal
bearings
of
the
engine.
Remove
the
carburetor
by
loosening the 3mm locknut and pulling the carburetor
straight up.
