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TROUBLESHOOTING & REPAIR
ENGINE/ROTOR REMOVAL
AND REPLACEMENT (continued)
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ENGINE AND ROTOR REMOVAL PROCEDURE
1.Refer to Figure F.14 for component loca- tions.
2.Remove the engine spark plug wires.
3.With the 5/16” nut driver, remove the 6 sheet metal screws from the case top.
4.Remove the rubber gasket (cover seal) from the lift bail.
5.Remove the fuel cap. The rubber gasket for the fill tube will come off with the case top.
6.Remove the case top, the reinstall the fuel cap.
7.WIth the 5/16” nut driver, remove the 5 screws holding the right case side and the 5 screws holding the left case side.
8.Remove the case sides by lifting up and out.
9.WIth the 3/8” wrench, remove the battery cover.
10.Disconnect the negative battery cable, then the positive battery cable. BE SURE TO DISCONNECT THE NEGATIVE BAT- TERY CABLE FIRST. Remove the battery and set it aside.
11.With the diagonal cutters, cut the cable ties around the leads from the starter sole- noid and disconnect the leads. Remove lead 209A from the harness bundle.
12.Disconnect the large black plug in front of the fuel tank spout.
13.With the 3/8” wrench, remove the cowling covers at the rear on the stator, both sides of the machine.
14.WIth the 3/8” wrench, remove the two screws that hold the vertical fan baffle in place. Slide the baffle forward toward the rectifier bridge heat sink assembly.
15.Hold the rotor shaft with locking pliers and unscrew the blower fan. Turn the fan counterclockwise. You do not need to remove the fan from the machine, but be sure it is completely unscrewed from the rotor shaft.
15.With the 1/4” nut driver, disconnect the engine choke cable from the engine. Mark the location of the retainer for reassembly. The other end can remain connected.
16.Disconnect the idle linkage by unsnapping the plastic clip at the engine end of the idler rod. Snap the clip back onto the rod to avoid losing it; remove the rod for reassembly.
17.Disconnect the fuel line from the fuel tank. Plug the hose and also plug the connec- tion at the fuel tank to prevent the escape of gasoline fumes.
18.Cut the cable ties and remove leads 224C and 210 from the oil pressure switch.
19.With the 9/16” wrenches, remove the ground lead from the right engine foot mounting bolt.
20.With the 7/16” wrench, remove the brush holder bracket and leads #219 & 200A from the stator frame.
20A. (For Onan Engine only) with a 1/2” wrench remove the muffler support bolt.
21.Support the engine with a chain hoist. Lift bails are provided on the top of the engine for this purpose.
22.With the 9/16” wrench, remove the right and left engine foot mounting bolts.
23.With the 9/16” wrench, remove the four bolts that hold the stator to the engine. There is one lock washer per bolt.
24.With the chain hoist, unweight the engine gently. Use a pry bar to carefully pry between the engine and the stator frame in order to unseat the bearing on the end of the rotor shaft. Separate the engine and rotor from the stator frame, supporting the rotor by hand to prevent damage to the rotor core.
25.Move the engine and rotor assembly to a bench. The engine is off balance with the rotor still attached; therefore, support the end of the rotor with a wooden