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center. Next, loosen the two Step Bolts [120]<120> and then remove the Clutch Set [123]<123>. To
remove the Starter Pulley Ass'y [67]<66>, lock the Crank Shaft Ass'y [60]<59> and lightly strike the
Starter Pulley Ass'y [67]<66> with a plastic hammer to turn it counterclockwise.
NOTE: Use a clean wire rope to lock the crank shaft. Also be careful not to leave cut pieces of
wire rope inside the Cylinder Set PN [19]<19>.
(10) Removing the magneto rotor comp.
Loosen the Hex. Nut M8 [125]<125>. Make the upper face of the Hex. Nut M8 [125]<125> level with
the threaded end face of the Crank Shaft Ass'y [60]<59>, and then lightly hit the end face of the
Crank Shaft Ass'y [60]<59> while holding the Magneto Rotor Comp. [136]<136> by hand to remove
it.
Hex. Nut M8 [125]<125>
(11) Removing the cylinder set
Loosen the four Hex. Hole Bolts 5 x 20S [11]<11> and then slowly pull out the Cylinder Set PN
[19]<19>.
(12) Removing the piston set and piston ring
Remove the two Cir Clips [57]<56> by using long-nose pliers, lightly strike the Piston Pin [58]<57> to
remove it, and then remove the Piston Set PN [55]<54>. Remove the Piston Ring [56]<55> while
expanding the closed gap of the ring. Because the Piston Ring [56]<55> is a cast-iron part, do not
forcibly expand it. Doing so may break the ring.
(13) Removing the crank case ass'y (starter side and driving side)
Loosen the four Hex. Hole Bolts 5 x 20S [11]<11>, remove the Crank Case Ass'y [61]<60> by using a
wooden hammer to lightly strike the Crank Shaft Ass'y [60]<59>, and then remove the Crank Shaft
Ass'y [60]<59>.
2. Reassembling the engine
(1) Removing carbon
Before reassembling the engine, remove carbon from the head of the Piston Set PN [55]<54>, the
exhaust port of the Cylinder Set PN [19]<19>, and inside the combustion chamber. If the Piston Ring
[56]<55> fitted in the ring groove of the Piston Set PN [55]<54> cannot be moved smoothly, carefully
wipe off carbon from the ring groove and side surface of the Piston Ring [56]<55>. During cleaning, be
careful not to damage the surfaces of the Cylinder Set PN [19]<19> and the Piston Set PN [55]<54>.
Also remove carbon from the intake and exhaust ports of the Muffler (B) [8] or Muffler <8>.
(2) Cleaning the parts
Be sure to thoroughly clean the Crank Shaft Ass'y [60]<59>, Piston Set PN [55]<54>, and Cylinder Set
PN [19]<19> with gasoline.
While holding the Magneto Rotor Comp.
[136]<136> by hand, use a hammer to
Hammer
strike the end face of the crank shaft.
Be careful not to deform the screw thread.
Crank Shaft Ass'y [60]<59>
Magneto Rotor Comp. [136]<136>
-12-
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