13
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
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,
smooth
shine.
Rinse
thoroughly
with
denatured
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.
STEP
17:
Removing
the
clutch
and
flywheel
It
is
not
necessary
to
remove
the
clutch
assembly
unless
you
are
se
rvicing
th
e
clutch,
crankshaf
t,
or
engine
bearings.
Use
the
tip
of
a
small
screwdriver
to
remove
the
E-clip
which
holds
the
clutch
bell
gear.
STEP
18:
Remove
the
clutch
bell
gear
and
the
clutch
shoes.
Note
that
there
are
two
5x8mm
Teflon
®
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.
