Repair
[4]DISASSEMBLY/ASSEMBLY
MAINTENANCE
(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.
P 12/ 14
Fig. 31
Exhaust muffler | Spark arrester |
[4]-14. Engine block
DISASSEMBLY
(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)
Fig. 32
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).
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.
Awl
Clip
Cylinder block
Piston pin
1R171
