COPY
‑ 5 ‑
Jun./13/ 11
１０．
Cylinder Head Cover Removal
◇
Turn counterclockwise diagonally four nuts, which
are holding the cylinder head cover, to detach the
nuts.
◇
Detach four washers below the nuts.
◇
Detach the head cover.(If it is hard to take it out,
strike it lightly with a plastic hammer.) In case
gaskets remain on the cylinder head, wipe them out
completely with a scraper or a cutter.
１１．
Cylinder Head Removal
Tool: 10mm box wrench
◇
Demount the cylinder head by pulling it away from
the cylinder. (If it is hard to take it out, strike the
cylinder head lightly with a plastic hammer.)
◇
Detach and keep two dowel pins for reuse.
◇
Remove the cylinder head.
１２．
Cylinder Removal
◇
Turn the already-loosened guide roller bolt and the
cylinder side bolt counterclockwise to remove them.
◇
While pulling out the cylinder, the cam chain guide
roller will come out, which please detach.
◇
Detach the cylinder by pulling it out. (In case it’s hard
to pull it out, strike the cylinder lightly with a plastic
hammer.)
◇
After the piston has come out, pull out the cylinder
away from the crankcase.
１３．
Piston Removal
◇
Plug the cylinder hole in the crankcase and cover the
cam chain, with a waste cloth not to allow any dust or
part to get into them.
◇
Detach one of the piston circlips. It can be rather easily
separated if you prise it with the screwdriver tip on the
notch of the piston pin hole.
◇
Pull out the piston pin to the side where the piston
circlip is not fixed. The push with a flat tip screwdriver
from the side where a piston circlip is fixed will easily
push out the piston pin.
◇
Detach the piston.
◇
If you cannot wipe out the gasketes completely, cut
them thoroughly with a scraper or a cutter, being
careful not to scratch the crank case. At this stage, cut
the crankcase gaskets, if any, sticking out on the
cylinder base or onto the cylinder hole.
Never get the dust or part into the crankcase.
１４．
Removal of Cylinder Base
Gasket and O-Ring Dowel Pin
Tool: Flat tip screwdriver with a fine tip
◇
Cut the gasket, if any, sticking out in the location pointed
with a finger in the picture above.
Cautions for installing an
aluminum cylinder
In some cases, due to right-side and
left-side crank cases being out of
alignment and for other reasons, in
installing the cyliner, the sleeve hole in
the mating surface of the crank case,
the circle-marked portion, the shaded
portion of the cylinder sleeve, and the
inside of the case may interfere with
one another. Since such interference
will lead to sleeve deformation and
engine troubles, do not fail to check
for interference, and make
modifications, if there is any
interference.
The difficulty level of the work is quite
high. So, you may feel like being
almost a professional if you have
successfully completed the job.
Modification Procedures
１．
Plug the crank case securely
with a waste cloth not to get
the chips in the crankcase.
２．
Rasp the convex portions on
the mating surfaces of the
crankcase till the concave and
convex surfaces become level.
３．
When you are through with the
rasping, take off the waste cloth
with great care not to let the
chips into the crankcase.
４．
After taking off the waste cloth,
plug the crankcase with a clean
waste cloth.
５．
After the assembly of the kit,
run the engine idle for a few
minutes. And then without loss
of time, change the engine oil
with the new one. Now,
everything is set.
Installation of S-Stage
Kit
１．
Install the piston.
◇
Attach the piston pin circlip of the kit to one of the
pin holes, fitting the circlip right into the grooves
on the pin hole.
Set the circlip so the end gap is not on the notch.
Piston circlip
Cylinder Base Gasket
O-ring
Interferring portion
Sleeve
Cylinder
Left-side crank case
Right-side crank case
gasket
After
modification
