ENGINE DISASSEMBLY
  1. Raise the cylinder slowly from the cylinder base gasket to prevent breaking the gasket.
  2. Stuff a clean rag into the crankcase opening under the cylinder to prevent any debris from falling in.
  3. Remove the cylinder from the cylinder studs.  Be sure to support the piston so it can't fall against the crankcase or cylinder studs when the cylinder clears it.

    4.  

     

    NOTE: If the engine has been run under dirty or wet conditions and you do not intend to disassemble the crankcases, turn the engine upside down before removing the cylinder. Mud and rust can accumulate in the holes for the cylinder studs and fall into the crankcase and mainbearing oil passages.

  1. Be sure the clean rag is wrapped all around the connecting rod before removing the wrist pin circlips, so they can't fall into the crankcase.
  2. Remove the wrist pin circlips with a needle nosed pliers and throw them away.  Don't use them again when reassembling the engine.
  3. Use tool number 999-202, a wrist pin drift, to remove the wrist pin.
  4. Hold the piston with one hand.  Push the wrist pin drift against the end of the wrist pin (see Figure 3) and push it out of the piston.
  5. If the wrist pin is too tight to be pushed out by hand, do not hit the drift with a mallet, not even a gentle tap. You can easily bend the con­necting rod or damage the rod bearing.
  6. In such a case, remove the wrist pin with a pushing tool (see Figure 4).
  7. Remove the piston and needle bearing from the connecting rod.
  8. Remove the cylinder base gasket and throw it away.

MAGNETO SIDE COMPONENTS

Removal
  1. Remove the four screws holding the magneto side cover.
  2. The side cover is located by two guide pins which may hold it to the engine case after the screws are removed.
  3. Push the clutch actuating arm inward to force the magneto side cover outward off the guide pins.
  4. Remove the side cover.  Be sure you don't lose the clutch actuating plunger, the small round piece that fits into the clutch actuating mechanism on the inside of the case.
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