36
Disassembling Engine
1. With the engine secured to a suitable engine stand,
drain oil, and remove oil filter, water pump, and hose
(see Fuel/Lubrication/Cooling section and see Starter
Motor sub-section in Electrical System section).
NOTE: Gear from water pump can be accessed
when upper oil pan is disassembled.
2. Remove the spark plug with a spark plug removal
tool. Then remove three bolts holding cylinder head
cover. Discard O-ring.
LYC001
3. Remove the cylinder head cover. Account for the
gasket. Remove fitting (A) if needed by removing
circlip. Account for O-ring. Oil cap (B) and valve
cover gasket (C) may also be removed.
LYC002
4. Rotate crankshaft in the direction of engine opera-
tion to the top dead center (TDC) position. Verify
TDC by removing the inspection cap from mag-
neto cover. Align magneto rotor so timing mark is
centered in inspection hole.
NOTE: If there is reason to suspect the engine is not
at TDC, perform a secondary check of TDC through
the spark plug hole.
NOTE: Remove magneto cover to determine the
cause of a misaligned timing mark.
LYC034
5. Position cam lobes facing away from each other
when slots are in line.
NOTE: A 6mm Allen wrench or bar placed between
both camshaft slots will ensure slots are in line.
LYC035
6. Remove chain tensioner and account for seal.
LYC036
7. Remove seven screws holding the cam bridge to cyl-
inder head using a crisscross sequence and remove
cam bridge (A). Account for O-ring. Chain guard
does not have to be removed from cam bridge unless
replacing either part.
CAUTION
Failure to perform timing steps could result in piston
damage.
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