Section04ENGINE
Subsection 03 (MAGNETO SYSTEM)
GENERAL
NOTE: The following procedures can be done
without removing the engine. To facilitate mag-
neto removal, hold drive pulley with tool (P/N 529
027 600).
During assembly/installation, use the torque val-
ues and service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, etc.) must
be installed or replaced with new ones where
specified. If the efficiency of a locking device
is impaired, it must be renewed.
CLEANING
Clean all metal components in a non-ferrous metal
cleaner.
CAUTION: Clean stator and magneto flywheel
using only a clean cloth.
DISASSEMBLY
Magneto Flywheel
To gain access to magneto flywheel no. 3 assem-
bly, remove the following parts as needed on dif-
ferent engines:
– tuned pipe and muffler
– rewind starter
– starting pulley no. 2.
To remove magneto flywheel nut no. 1:
– Use magneto puller ring (P/N 420 876 080). For-
mer puller must be modified as shown.
A06E23A
1
1. Cutby25mm(1in)
– Install puller ring with its tab in magneto housing
opening.
CAUTION: UseonlyM8x20mmscrewstobolt
puller to magneto flywheel. When a counter-
weight no. 7 is installed on magneto flywheel
use M8 x 30 mm screws.
A06E22B
1
2
TYPICAL
1. Tab in magneto housing opening
2. M8 screws
– 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 fas-
tener, first tap on the fastener to break thread-
locker bond. This will avoid thread breakage.
mmr2004-Rev 123
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