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1. Special Tools .................................... 5-2
2. Parts Layout .................................... 5-3
Engine ................................................ 5-3
Magneto ............................................. 5-4
Cylinder & Oil Pan ................................. 5-6
Cylinder Head & Valve & Camshaft ............ 5-10
Piston & Crankshaft .............................. 5-12
Recoil Starter ....................................... 5-13
Top Cowl ............................................. 5-14
3. Inspection Items .............................. 5-15
1) Inspection of Compression Pressure ...... 5-15
2) Inspection of Valve Clearance ............... 5-16
3) Removing Power Unit ........................ 5-18
4) Removal and Disassembly of
Crank Case Head .............................. 5-19
5) Inspection of Crank Case Head ............ 5-20
6) Assembly of Crank Case Head ............ 5-20
7) Installation of Crank Case Head ............ 5-21
8) Disassembly of Power Unit .................. 5-21
9) Removal of Rocker Arm ..................... 5-24
10) Removing Cylinder Head ..................... 5-25
11) Inspection of Rocker Arm and Pivot ...... 5-25
12) Inspection of Push Rod Plate ............... 5-26
13) Inspection of Push Rod ..................... 5-26
14) Disassembly and Inspection of
Oil Pump .......................................... 5-26
15) Disassembly of Cylinder and Oil Pan ...... 5-28
16) Disassembly and Inspection of
Breather Chamber .............................. 5-30
17) Inspection of Lifter .............................. 5-30
5
Power Unit
18) Inspection of Camshaft ........................ 5-31
19) Inspection of Piston Outer Diameter ...... 5-32
20) Inspection of Cylinder Inner Diameter ...... 5-32
21) Inspection of Piston Clearance ............ 5-32
22) Inspection of Piston Ring
Side Clearance ................................. 5-33
23) Inspection of Piston Rings .................. 5-33
24) Inspection of Piston Pin ..................... 5-34
25) nspection Connecting Rod Small End
Inner Diameter ................................. 5-34
26) Inspection of Connecting Rod Big End
Inner Diameter ................................. 5-34
27) Inspection of Connecting Rod Big End
Side Clearance ................................. 5-35
28) Inspection of Crankshaft ..................... 5-35
29) Disassembly and Inspection of Oil Pan ... 5-36
30) Removal of Valves and Springs ............ 5-37
31) Inspection of Valve Springs .................. 5-37
32) Inspection of Valve ........................... 5-38
33) Inspection of Valve Guide .................. 5-38
34) Inspection of Valve Seat ..................... 39
35) Correction of Valve Seat ..................... 5-40
36) Installation of Valves ........................... 5-43
37) Installation of Piston and
Connecting Rod ................................. 5-44
38) Assembly of Cylinder Oil Pan ............... 5-45
39) Installation of Cylinder Head ............... 5-47
40) Installing Flywheel .............................. 5-49
41) Installation of Power Unit ..................... 5-52
5
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