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dropped to 90% of its original value the engine will be down on power and would
benefit from a rebuild. When it's dropped to 80% it really needs rebuilt! Using the
table below will help you determine monitor the condition of your top end.
Engine is Fresh
Measured Value
Example
110 psi
Your Values
Procedure for Compression Testing
1. Shut off the fuel petcock.
2. Install the compression gauge into the spark plug hole.
3. Hold the throttle to wide open, and kick repeatedly (approximately 20 times)
or until the gauge reading does not increase in value with each kick.
Engine Removal
To service the bottom end and transmission, the engine must be removed from
the frame.
Tools required
•
10, 11, 13, 22 mm wrench
•
8, 10, 14, 17 & 19 mm sockets
•
3, 4 & 5 mm hex key (Allen wrench)
•
7 mm nut driver, flat or Phillip, screwdriver for hose clamps
•
Spring remover
•
Flywheel / clutch puller (#MCMUTL68)
•
Clutch nut removal tool (Call local dealer for details).
Procedure
1. Remove the seat.
2. Turn of the fuel at the petcock and disconnect the fuel line.
3. Remove the tank (8 mm socket).
4. Remove the carburetor from the inlet (flat head or Phillips head screwdriver, 7
mm nut driver).
5. Remove the silencer & pipe (spring remover, 8mm socket).
6. Disconnect the ground wire from the cylinder head (11 mm wrench).
7. Leaving the coolant lines connected to the engine, remove the radiator from
the frame (8 mm socket).
8. Remove the master link from the chain.
9. Remove front engine mount bolt (13 mm socket, 6 mm hex key).
10. Remove the swingarm bolt (22mm socket).
NOTE:
Engine Down on Power
Measured Value * 0.9
110 psi * 0.9 = 99 psi
41
Engine NEEDS Rebuilt
Measured Value * 0.8
110 psi * 0.8 = 88 psi
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