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R
epair
[4] DISASSEMBLY/ ASSEMBLY
[4]-12. Engine block
DISASSEMBLING
(1) It is highly recommended to drain the oil system of Engine block
before starting disassembling because the oil remaining there will
drip out to delay your operation.
(2) From the engine section, remove the following parts:
Cylinder cover, Fuel tank, Blower housing, Muffler cover, Recoil starter
section, Clutch section, Ignition coil, Flywheel section, Insulator section,
Air cleaner assembly, Carburetor, Spark plug, Exhaust muffler
(3) Remove Cylinder. (Fig. 52)
(4) Remove two clips from ends of Piston pin with a pointed tool such as
an awl. (Fig. 53)
Note: • Be careful with Clip because it can pop out unexpectedly
during removal operation.
• Do not reuse removed Clips. Replace them with new ones.
(5) Remove Piston pin with 1R200 or the like. (Fig. 54)
(6) Remove Piston.
Fig. 53
Awl
Clip
ASSEMBLING ENGINE BLOCK
Assemble by reversing the disassembly procedure. Be careful to
the following points.
• "M mark" on Piston has to face Flywheel side. (Fig. 55)
Note: Be sure to apply a little amount of 2-stroke engine oil
to Needle cage 1014 of Crank shaft assembly.
• Insert Piston pin through Piston and Crank shaft, and fix it with
Clips by using an awl (Refer to Fig. 53. Clip has no direction).
• Piston rings have their directions. Their gaps must be put on
the farthest side and one of the gap of Piston ring must be set
by the boss on the groove of Piston ring as drawn in Fig. 56.
Note: Piston rings are easy to break. Do not enlarge them too
much when fixed.
• Apply 2-stroke engine oil to the internal surface of Cylinder
before assembling it to Crankcase assembly. And then,
Assemble Cylinder gasket while aligning its square hole to
that of Cylinder.
• Assemble other parts by reversing the disassembly procedure.
Fig. 54
Clip
Piston pin
Piston
Fig. 52
Cylinder
Crank case
assembly
Crankshaft
assembly
1R200
Fig. 55
Piston
Crank case
assembly
Fig. 56
Boss on groove of Piston
The gap of this piston ring
is at the farthest side from here.
P 14/ 15
"M mark" on Piston
Flywheel
Gap of Piton ring
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