6. Remove bolts connecting power unit and upper casing.
7. Lift the engine and remove the pin.
8. Remove oil strainer and safety valve.
Check the oil strainer for damage and clog. Replace if necessary.
Check the safety valve for damage and crack. Replace if necessary.
9. Remove the woodruff key.
10. Disconnect the engine stop switch wire and ground wire.
11. Remove throttle cable (manual start models) or cable joint (electric start models).
12. Remove charge coil, lighting coil and pulsed coil.
13. Remove high-pressure assembly, CDI unit, ignition coil, oil pressure switch and spark plug.
BELT PULLEY AND TIMING BELT
1. Rotate the flywheel clockwise. Align the mark ‘1’ on the driven belt pulley with the mark “
▼” on the
cylinder cover.
CAUTION:
Please don’t rotate the flywheel counter clockwise. Otherwise, valve system will be damaged.
2. Remove timing belt pulley nut with the special timing belt pulley nut barrel.
NOTE:
Please don’t turn camshaft while unscrewing the timing belt pulley.
3. Remove timing belt from side of driven belt pulley.
CAUTION:
Please don’t rotate the belt pulley before timing belt is fixed. Otherwise, valve system will be
damaged.
4. Remove driven belt pulley bolt, driven belt pulley and woodruff key.
NOTE:
Please remove driven belt pulley bolt with flywheel gripper.
Please don’t rotate camshaft while unscrewing the timing belt pulley.
5. Remove nut, limitative plate, timing belt pulley and woodruff key.
6. Check belt pulley and timing belt for crack, damage and wear. Replace if necessary.
7. Assemble woodruff key and driven belt pulley.
Align the mark “1” on the driven belt pulley with the mark “▼” on the cylinder cover. Tighten the
driven belt pulley bolt temporarily.
CAUTION:
Please don’t rotate the belt pulley before timing belt is fixed. Otherwise, valve system will be
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