ENGINE
4-54
PISTON IDENTIFICATION
The piston has an
identification mark for piston placement.
Note the directional and identification marks when
pistons from the top. The letters “IN” must always be toward
the intake side of the engine.
The other numbers are used for identification as to diameter,
length and design. Four stroke engine rings are rectangular
profile. The numbers or letters on all rings (except oil control
rings) must be positioned upward. See text for oil control ring
upper rail installation. Use the information below to identify
pistons and rings.
ACCESSIBLE COMPONENTS
The following components can be serviced or
the engine installed in the frame:
1. Flywheel
2. Alternator/Stator
3. Starter Motor/Starter Drive
4. Oil pump
5. Rocker Arms
6. Throttle Body
7. Injector and all EFI system
8. Transmission
9. Valve gap adjustment
The following components require engine removal for
service:
1. Cam Chain and Sprockets
2. Cylinder Head
3. Cylinder
4. Piston/Rings
5. Camshaft
6. Crankshaft
7. Crankshaft Main Bearings
8. Crankcase
9. Transmission
10. Valves
NOTE: Cam chain service requires crankshaft
removal, as the chain is located on the pto side of
engine.
NOTE: Crankshaft components are not serviceable.
Replace crankshaft as an assembly.
ENGINE REMOVAL
IMPORTANT: Some engine repair procedures can be
performed without removing the scooter engine
assembly from the vehicle.
Always wear safety glasses and proper shop
clothing when performing the procedures in
this manual. Failing to do so may lead to
possible injury or death.
1. Clean work area.
2. Thoroughly clean the scooter engine and chassis.
3. Disconnect battery cables.
4. Drain engine oil.
5. Drain radiator water.
6. Open the seat then remove the luggage box.
7. Remove all chassis protect shield, both bottom cover, both
foot well and both side cover.
8. Disconnect spark plug high-tension lead.
9. Disconnect all electric and EFI wires from the engine.
10. Disconnect radiator tubes.
11. Lift middle of body frame by jack.
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General