14
STEP
15:
Remove the connecting rod and piston through the
top of the crankcase.
STEP
16:
To remove the connecting rod from the piston, use
a sharp-pointed tool to remove the small metal
G-clip
in
the
side
of the
piston.
Do
not
re-use
the
old G-clip. When installing a new connecting
rod,
use the supplied new G-clip.
STEP
21:
Remove the crankshaft by pulling it straight out of
the crankcase.
STEP
22:
The bearings are press-fit into the crankcase. To
remove them, the crankcase must be heated with
a heat gun or torch. The crankcase will expand
with heat and release the bearings. To avoid
the possibility of burns
or other damage, do not
attempt
to remove the
bearings.
Clean
the
bearings
by flushing them with denatured alcohol and then
place one or two drops of after-run oil on the races.
STEP
23:
Before
installing
a
new
connecting
rod,
you
can
increase connecting rod life by polishing the
crankshaft journal. Use 1200 grit sandpaper to
remove the surface scratches followed by liquid
metal polish to buff the crankshaft journal to a bright,
sm
oo
th
sh
ine
.
R
in
se
th
o
ro
ug
hl
y
wi
th
d
en
at
ur
ed
alcohol. Lube with after-run oil.
STEP
24:
Use the 1200 grit sandpaper and the liquid metal
polish on the wrist pin also. Rinse thoroughly with
denatured alcohol and lube with after-run oil.
STEP
13:
Pull the sleeve straight up and out of the crankcase.
If
the
sleeve
will
not
move,
rotate
the
crankshaft
until
the sleeve pushes up.
STEP
14:
Rotate the crankshaft to bottom dead center. Lightly
grab the connecting rod with a pair of needlenose
pliers and gently pull it off of the crankshaft journal.
Removing the clutch and
flywheel
STEP
17:
It is not necessary to remove the clutch assembly
unless
you
are
servicing
the
clutch,
crankshaft,
or
engine bearings. Use the tip of a small screwdriver
to remove the E-clip that holds the clutch bell gear.
STEP
18:
Remove the clutch bell gear and the clutch shoes.
Note
that
there are
two
5x8mm PTFE
washers, one
on each side of the clutch
bell gear. Check the clutch
shoes for
excessive wear
or
cracking
around
the
pin
holes. If the clutch shoes
are worn to
the point
that
the clutch spring contacts
the clutch bell, then the
shoes must be replaced.
STEP
19:
Grip the flywheel with a
pair of pliers (locking pliers
work best). Remove the
clutch adapter nut with a
10mm deep socket. Hold
the engine just above
your workbench and tap
the flywheel from behind
with a non-marring hammer (plastic or wood).
Several easy blows may be necessary to release the
flywheel and split beveled cone.
STEP
20:
The flywheel and the split-beveled
cone should pull
smoothly
off of the crankshaft.