R-71
CHAPTER 4
ENGINE OVERHAUL
ENGINE REMOVAL
SIDE COVERS, SEAT AND FUEL TANK REMOVAL ................ 4-1
ENGINE OIL DRAIN ................................................................... 4-1
BATTERY .................................................................................... 4-1
CARBURETOR ........................................................................... 4-1
CLUTCH CABLE ........................................................................ 4-1
DRIVE CHAIN ............................................................................. 4-2
EXHAUST MUFFLER ................................................................. 4-2
FOOTREST ASSEMBLY ............................................................ 4-2
SHIFT PEDAL ............................................................................. 4-3
BATTERY BOX REMOVAL ........................................................ 4-3
LEADS ........................................................................................ 4-3
ENGINE REMOVAL .................................................................... 4-3
MOUNTING ON ENGINE STAND .............................................. 4-3
ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND PISTON ........................... 4-4
CLUTCH ..................................................................................... 4-7
OIL PUMP ................................................................................... 4-8
KICK STARTER .......................................................................... 4-9
SHIFT SHAFT ............................................................................. 4-9
C.D.I. MAGNETO ....................................................................... 4-10
GUIDE STOPPER AND TIMIMG CHAIN ................................... 4-10
CRANKCASE ............................................................................. 4-11
TRANSMISSION AND SHIFTER ............................................... 4-12
CRANKSHAFT ........................................................................... 4-12
CYLINDER HEAD ROCKER ARMS, CAMSHAFT & VALVES .. 4-13
INSPECTION AND REPAIRS
CYLINDER HEAD ....................................................................... 4-15
VALVE SEATS ............................................................................ 4-16
VALVE SPRINGS AND VALVES ................................................ 4-18
CAMSHAFT ................................................................................ 4-19
ROCKER ARMS AND ROCKER ARM SHAFTS ....................... 4-20
TIMING CHAIN, SPROCKETS AND CHAIN GUIDES ............... 4-21
TIMING CHAIN TENSIONER ..................................................... 4-21
CYLINDER AND PISTONS ........................................................ 4-22
PISTON RINGS .......................................................................... 4-23
PISTON PIN ................................................................................ 4-24
CRANKSHAFT ........................................................................... 4-25
PRIMARY DRIVE GEAR ............................................................ 4-26
CLUTCH ..................................................................................... 4-26
PUSH ROD ................................................................................. 4-27
SHIFT FORK SHIFT CAM .......................................................... 4-28
KICK STARTER .......................................................................... 4-29
OIL PUMP ................................................................................... 4-30
OIL DELIVERY PASSAGE(CC COVER RH) ............................. 4-31
CRANKCASE ............................................................................. 4-31
