Section 04 ENGINE
Sub-Section 05 (CDI SYSTEM)
04-05-3
NOTE : The following procedures can be
done without removing the engine from
chassis. To facilitate magneto removal, hold drive
pulley with tool (P / N 529 0276 00).
CLEANING
Clean all metal components in a non-ferrous met-
al cleaner.
CAUTION : Clean stator and magneto us-
ing only a clean cloth.
DISASSEMBLY
2,5, Magneto and Magneto Flywheel Nut
To gain access to magneto assembly, remove the
following parts as needed on different engines :
– muffler
– rewind starter
– starting pulley
To remove magneto flywheel retaining nut :
Use magneto puller ring (P / N 420 8760 80) mod-
ified as shown.
1. Cut by 25 mm (1 in)
Install puller with its tab in magneto housing open-
ing.
TYPICAL
1. Tab in magneto housing opening
– Remove magneto flywheel nut, using a 30 mm
socket machined to 40 mm (1.580 in) outside
diameter by 16 mm (5/8 in) long.
NOTE : To correctly remove a threadlocked
fastener it is first necessary to tap on the fas-
tener to break threadlocker bond. This will elimi-
nate the possibility of thread breakage.
To remove magneto flywheel, install the suitable
puller as shown.
– Tighten puller bolt and at the same time, tap on
bolt head using a hammer to release magneto
flywheel from its taper.
4, Hydro Damper Ass’y
Check for oil leaks and for noisy ring inside. Re-
placed it in both cases.
6,7, Trigger Coil and Screw
Magneto and stator plate must be removed be-
fore trigger coil removal.
To replace trigger coil :
– Disconnect trigger coil connector housing.
– Remove grommet from crankcase where trig-
ger coil wire exits magneto housing.
– Remove retaining screws.
– Remove trigger coil and carefully pull wires.
– Thread magneto harness through crankcase
hole before trigger coil harness.
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