Table of contents
1. General precaution and safety information for engine reconstruction ...................................... 31
2. Special tools ............................................................................................................................ 31
3. Preparation .............................................................................................................................. 32
4. Removal of components .......................................................................................................... 33
4.1) REMOVAL OF COOLANT HOSES, RADIATOR, RADIATOR BRACKET .......................... 33
4.1.1) Dismantle coolant hoses ............................................................................................. 33
4.1.2) Radiator ...................................................................................................................... 34
4.1.3) Radiator bracket .......................................................................................................... 35
4.2) REMOVAL OF CARBURETOR, CARBURETOR FLANGE AND REED VALVE ASSY. ..... 36
4.2.1) Dismantle carburetor ................................................................................................... 36
4.2.2) Carburetor flange ........................................................................................................ 37
4.2.3) Reed valve assy. ......................................................................................................... 39
4.3) REMOVAL OF IGNITION SYSTEM ................................................................................... 40
4.3.1) Dismantle ignition coil ................................................................................................. 40
4.3.2) Spark plug ................................................................................................................... 41
4.4) REMOVAL OF CYLINDER COMPONENTS ...................................................................... 42
4.4.1) Dismantle cylinder head cover .................................................................................... 42
4.4.2) Combustion chamber insert ........................................................................................ 42
4.4.3) Cylinder ....................................................................................................................... 43
4.4.4) Piston, piston pin ......................................................................................................... 45
5. Installation of components ....................................................................................................... 47
5.1) INSTALLATION OF CYLINDER COMPONENTS .............................................................. 47
5.1.1) Installation of piston, piston pin ................................................................................... 47
5.1.2) Cylinder ....................................................................................................................... 49
5.1.3) Combustion chamber insert ........................................................................................ 50
5.1.4) Cylinder head cover .................................................................................................... 51
5.1.5) Inspection and adjustment of “squish gap” .................................................................. 52
5.2) INSTALLATION OF THE IGNITION SYSTEM ................................................................... 52
5.2.1) Spark plug ................................................................................................................... 52
5.2.2) Ignition coil .................................................................................................................. 52
5.3) INSTALLATION AND CONNECTION OF THE CARBURETOR ........................................ 53
5.3.1) Reed valve assy. ......................................................................................................... 53
5.3.2) Carburetor flange ........................................................................................................ 53
5.3.3) Carburetor ................................................................................................................... 54
5.3.4) Fuel lines .................................................................................................................... 54
5.4) INSTALLATION AND CONNECTION OF THE RADIATOR ............................................... 55
Seite/page 4/59
Ausgabe/Edition 09/2014
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