PART A: ENGINE

Chapter 1: Disassembly of the Engine	Page
Section 1: Removing the Cylinder and Piston	1
Section 2: Removing the Magneto Side Components	3
Section 3: Removing the Primary Drive Components	4
Section 4: Parting the Engine Cases	8
Section 5: Removing the Gearbox Components	10
Section 6: Removing the Crankshaft and Bearings	11
Chapter 2: Repairing the Engine Components
Section 1: Repairing the Crankshaft Assembly	13
Section 2: How the Transmission Works -
(A) Terminology - Locating and Identifying the Components	15
(B) Power Transmission Through the Gears	21
Section 3: Checking the Gearbox Components for Wear	27
Section 4: Shimming and Gear Engagement	36
Section 5: Repairing the Cylinder and Piston	48
Section 6: Piston Sizing Information	53
Section 7: Installing a New Cylinder Liner	54

Chapter 3: Reassembly of the Engine
Section 1: Installation of New Bearings and Bushings	56
Section 2: Alignment of the Crankshaft	59
Section 3: Reassembling the Engine Cases	64
Section 4: Installing the Primary Side Components	66
Section 5: Installing the Top End Components	76
Section 6: Installing the Magneto Side Components and Timingthe Magneto	81

 

PART B: CARBURETION

Chapter 1: Operation	Page
Section 1: Metering Systems	87
Double Needle Carburetors
Section 2: 0 to 1/8 Throttle: The Pilot Metering System	89
Section 3: 1/8 to 1/4 Throttle: Slide Cutaway and Mid-Range Needle	91
Section 4: 1/4 to 1/2 Throttle: Slide and Mid-Range MeteringSystem "	93
Section 5: 1/2 to 3/4 Throttle: Slide Cutaway and High SpeedNeedle	97
Section 6: 3/4 to Full Throttle: Slide and High Speed Main Jet	99
Section 7: The Float Metering Device	100
Single Needle Carburetors
Section 8: 0 to 1/8 Throttle: The Pilot Metering System	103
Section 9: 1/8 to 1/4 Throttle: Slide Cutaway and Needle Jet	105
Section 10: 1/4 to 3/4 Throttle: Slide Needle Position and BoosterSystem	107
Section 11: 3/4 to Full Throttle: Slide and Main Jet	109
Section 12: The Float Metering Device	109