Section 03 ENGINE
Sub-Section 04 (CDI SYSTEM)
03-04-2
NOTE:
The following procedures can be done
without removing the engine from chassis. To fa-
cilitate magneto removal, hold drive pulley with
tool (P/N 529 0276 00).
CDI means Capacitor Discharge System.
CLEANING
Clean all metal components in a non-ferrous met-
al cleaner.
DISASSEMBLY
2,5, Magneto and Magneto Flywheel Nut
To gain access to magneto assembly, remove the
following parts as needed on different engines:
– tuned pipes and muffler
– rewind starter
– starting pulley
– flywheel no. 4 on 699 engine (mark position be-
fore removal)
To remove magneto flywheel retaining nut:
Use magneto puller ring (P/N 420 8760 80) modi-
fied 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 fasten-
er it is first necessary to tap on the fastener to
break threadlocker bond. This will eliminate the
possibility of thread breakage.
To remove magneto flywheel, install the puller (P/N
529 0225 00).
– Tighten puller bolt and at the same time, tap on
bolt head using a hammer to release magneto
flywheel from its taper.
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.
-
CAUTION
Clean stator and magneto using only a clean
cloth.
A06E23A
1
A06E22A
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