CHAPTER ONE

ENGINE DISASSEMBLY 


Refer to Figures 1A and IB (pages 6-9) for 1 exploded views of the engine.
 

CYLINDER AND PISTON REMOVAL

  1. 1. Clean the outside of the engine carefully.
  2. 2. Remove the drain plug from the crankcase and drain the transmission oil.
  3. 3. Tilt the engine from side to side and from front to back to allow the oil to flow around obstacles inside the transmission to the drain hole.
  4. 4. Check the drain plug and gasket for wear or damage.  Replace if necessary.
  5. 5. Install the drain plug and gasket and tighten the plug.
  6. 6. Remove the spark plug from the cylinder head.
  7. 7. Use a 12mm socket wrench to loosen the four cylinder head nuts 1/4 turn each in the sequence shown in the illustration (see Figure 2).  The first nut to be loosened is at the left front side of the cylinder head.  The second nut is at the right rear side, and so forth.  Be sure you only loosen each nut 1/4 turn.
  8. Repeat the same sequence, loosening each nut another 1/4 turn.  Repeat this procedure until all nuts are completely loose.  Be sure to follow this procedure carefully, or you may warp the cylinder head.
  9. 9. Remove the cylinder head nuts and washers.
  10. 10. Remove the cylinder head from the cylinder.

  11. 11. The aluminum cylinder head gasket will usually stick to the cylinder head upon removal.  Remove it with your fingers.  Don't damage the cylinder head mating face.


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