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2 A . 4
Air-cooled two-stroke engine
5.14 Remove the bolts securing the rear shock (A) and the
7.2a The engine cowling is secured by a bolt on the cooling fan
frame (B) to the engine unit
cowling..
.
caliper, then temporarily refit the rear wheel
(see Chapter 8). Unclip the brake hose from
the underside of the drive belt casing (see
illustration 5.12)
.
14 Check that all wiring, cables and hoses are
clear of the engine/transmission unit. With the
aid of an assistant, support the weight of the
machine on the rear grab handle. Remove the
bolt securing the rear shock absorber to the
transmission casing, then remove the front
engine mounting bolt and lift the frame away
from the engine/transmission unit (see
illustration).
15 If required, remove the stand (see Chap-
ter 6) and the rear wheel (see Chapter 8)
.
Installation
16 Installation is the reverse of removal,
noting the following points:
Make sure no wires, cables or hoses
become trapped between the engine and the
frame when installing the engine.
Tighten the engine mounting bolts to the
torque settings specified at the beginning of
this Chapter.
Make sure all wires, cables and hoses are
correctly routed and connected, and secured
by any clips or ties.
Bleed the oil pump (see Section 13) and
check the adjustment of the oil pump cable
where fitted (see Chapter 1).
Check the operation of the rear brake
before riding the machine (see Chapter 8).
6 Disassembly and
reassembly
-
general infonnatior
I
Disassembly
1 Before disassembling the engine, the
external surfaces of the unit should be
thoroughly cleaned and degreased. This will
prevent contamination of the engine intemals,
and will also make working a lot easier and
cleaner. A high flash-point solvent, such as
paraffin can be used, or better still, a
proprietary engine degreaser such as Gunk.
Use an old paintbrush to work the solvent into
the various recesses of the engine casings.
Take care to exclude solvent or water from the
electrical components and inlet and exhaust
ports.
A
Warning:
The use o f petrol
(gasoline) as a cleaning agent
should be avolded because of the
risk of fire.
2 When clean and dry, arrange the unit on the
workbench, leaving suitable clear area for
working.
Gather a selection of small
containers and plastic bags so that parts can
be grouped together in an easily identifiable
manner. Some paper and a pen should be on
hand to permit notes to be made and labels
attached where necessary. A supply of clean
rag is also required.
3 Before commencing work, read through the
appropriate section so that some idea of the
necessary procedure can be gained. When
removing components it should be noted that
great force is seldom required, unless
specified. In many cases, a component's
reluctance to be removed is indicative of an
incorrect approach or removal method
-
if in
any doubt, re-check with the text.
4 When disassembling the engine, keep
'mated' parts that have been in contact with
each other during engine operation together.
These 'mated' parts must be reused or
renewed as an assembly.
5 Complete engine disassembly should be
done in the following general order with
reference to the appropriate Sections. Refer
to Chapter 2C for details of transmission
components disassembly.
Remove the cooling fan (see Section 11)
Remove the alternator (see Chapter 9 )
Remove the variator (see Chapter 2C)
Remove the cylinder head (see Section 7 )
Remove the cylinder (see Section 8)
Remove the piston (see Section 9)
Remove the oil pump (see Section 13)
Remove the reed valve (see Chapter 4)
Remove the starter motor (see Chapter 9)
Separate the crankcase halves (see
Section 14)
Reassembly
6 Reassembly is accomplished by reversing
the general disassembly sequence.
i "
+
"'
..
--
-.w
*-.
sg
7 Cylinder head
-
removal, inspecti
and installation
Note: This procedure can be camed out with
the engine in the frame. If the engine has been
removed, ignore the steps that do not apply.
Caution: The engine must be completely
cool before beginning this procedure or the
cylinder head may become warped.
Removal
1 Remove the body panels as necessary
according to model (see Chapter 7).
2 Pull the spark plug cap off the spark plug,
then remove the bolts securing the engine
cowling and remove the cowling, noting how
it fits (see illustrations).
3 Remove the spark plug, then unscrew the
7.2b
. . .
a bolt on the left-hand side front
of the cowling
. . .
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