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10. Disassembly and reassembly of the cylinder and scavenging cover
[Tools required]
Ɣ Hex. bar wrenches (4 mm and 5 mm)
Ɣ Phillips screwdriver
Ɣ Socket wrenches (13 mm and 19 mm)
(1) Disassembly
Ɣ Use a 19-mm socket wrench to remove Spark Plug BPM-7A/BPMR7A [46].
Ɣ Use a 5-mm hex. bar wrench to remove the four Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37]. Then
remove the Cylinder [73].
Ɣ Use a Phillips screwdriver to remove the eight Seal Lock Screws M4 x 10 [16]. Then remove
Scavenging Cover (A) [74] and Scavenging Cover (B) [17].
CAUTION: The threads of the Seal Lock Screws M4 x 10 [16] may be easily broken. Therefore,
do not tighten the screws too much.
Ɣ Use a 13-mm socket wrench to remove the Decomp. [45].
(2) Reassembly
Reassembly can be conducted by reversing the disassembly procedure. However, special attention
should be given to the following items.
Ɣ Do not reuse the Cylinder Packing (C51) [75], Cover Packing [18], and Intake Packing (C51) [47].
Ɣ Do not reuse the Seal Lock Screws M4 x 10 [16], Seal Lock Hex. Socket Hd. Bolts M6 x 20 [37], and
Hex. Socket Hd. Bolts M5 x 12 (Precote) [38].
Ɣ Before mounting the Cylinder [73], degrease the screw holes of the Engine Case (A) Ass’y [87] and
Engine Case (B) Ass’y [80].
Ɣ Before mounting Scavenging Cover (A) [74] and Scavenging Cover (B) [17], degrease the screw holes
of the Cylinder [73].
Ɣ Before mounting the Intake (CS51) [48], degrease the screw holes of the Cylinder [73].
Ɣ Reassemble the packings by ensuring the proper alignment of the holes.
Ɣ Pay attention to the directional property of the Cylinder Packing (C51) [75]. (At reassembly, match it
with the shape of the vent port.)
Ɣ Pay attention to the directional property of the Cover Packing (C51) [18]. (Assemble so that the lower
part of the Cover Packing (C51) [18] protrudes between Scavenging Cover (A)
[74] and Scavenging
Cover (B) [17].)
Ɣ When removing the Cylinder [73], remove all carbon deposits on the exhaust port and combustion
chamber by being careful not to scratch the cylindrical surface, and then carefully clean these parts by
using gasoline.
Ɣ Prevent the entry of foreign matter through the respective ports of the Cylinder [73] at reassembly.
Ɣ Before mounting the Cylinder [73], lightly apply 2-cycle oil to the cylindrical surface of the Cylinder [73]
and the periphery of the Piston (44) (M) [77].
Ɣ Fit the lip portion of the Intake (CS51) [48] into the groove of the Carburetor Insulator (C51) [50] when
mounting the Intake (CS51) [48] to the Carburetor Insulator (C51) [50].
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