MAINTENANCE
DISASSEMBLY
Fig. 31
Spark arrester
Exhaust muffler
[4] DISASSEMBLY/ASSEMBLY
[4]-13. Spark arrester
(1) Remove Cylinder cover.
(2) Remove Exhaust Muffler.
(3) Remove Spark arrester from Exhaust muffler and
sweep it if dirt or soot is on Spark arrester. (
Fig. 31
)
Replace it with a new one if spark arrester has a breakage or fray.
(4) Assemble Spark arrester to Exhaust muffler.
(5) Fix Exhaust muffler in place.
Note
: • Do not forget to put Muffler gasket.
• Two M5x40 Hex socket head bolts for fixing Exhaust muffler are
threadlocker type. Apply ThreeBond 1342 / Loctite 242 to
the threads of Bolts once removed for repair.
(6) Set Cylinder cover in place.
Fig. 32
[4]-14. Engine block
Cylinder block
1R171
Clip
Piston pin
Awl
1. Remove the following parts from Engine:
•
Cylinder cover,
•
Tank guard,
• Fuel tank, • Clutch case,
• Recoil starter assembly, • Clutch, • Ignition coil, • Flywheel,
• Rocker cover inner, • Rocker cover gasket, • Rod 2.5,
• Rocker arm assembly, • Cam lifter, • Cam gear, • Insulator,
•Air cleaner, • Carburetor, Muffler, • Spark plug
2. Open Cylinder block by removing
M5x16 Hex socket head bolts (6pcs).
(1) Drain the oil from Engine as much as possible to minimize oil spill out of Cylinder block when opened.
(2) Disassemble Engine and open Cylinder block. (
Fig. 32
)
(3) Disassemble Piston. (
Fig. 32
)
R
epair
P 1
2
/ 1
4
3. Remove Clip from Piston with an awl.
Note:
•
Be careful if the clip pops out.
• Replace the used clip to the new one
once it is removed.
4. Push Piston pin out with 1R171 and
remove Piston.
