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
removed with the engine installed in the frame:
1. Flywheel
2. Alternator/Stator
3. Starter Motor/Starter Drive
4. Oil pump
5. Rocker Arms
6. Carburetor
7. Transmission
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 side of the
engine.
NOTE: Crankshaft components are not serviceable.
Replace crankshaft as an assembly.
ENGINE REMOVAL
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables.
4. Drain engine oil.
5. Drain radiator water.
6. Disconnect spark plug high-tension lead.
7. Disconnect all electrical wires from the engine.
8. Disconnect radiator tubes.
9. Remove the following parts as required.
◎ Seat
◎ Left and Right Side Covers
◎ Fuel Tank Cover / Front Cab
◎ Fuel Tank
10. Remove exhaust pipe.
11. Remove air box.
12. Remove carburetor. Insert a clean shop towel into the
carburetor flange to prevent dirt from entering the intake port.
13. Starter motor. Note ground cable location. Mark positive
(+) cable mounting angle and remove cable.
14. Remove transmission link rod(s) from gear selector and
secure out of the way.
15. Remove engine to chassis ground cable.
16. Refer to Chapter 5 to remove the swing arm and
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