Fig. 2-80
Fig. 2-82
AN020
AN024
NOTE: To ensure the cleanliness of the flywheel magnets, place the flywheel (with the magnets facing upward) on a clean bench.
6. Remove the four nuts and lock washers securing the exhaust manifold; then remove the manifold and account for the two exhaust gaskets.
4. Scribe a line on the stator plate and magneto case to aid in assembly; then remove the two Allen-head cap screws, lock washers, and washers securing the stator plate. Remove the stator plate from the engine.
7. Remove the three cap screws securing the thermostat cap; then remove the cap, gasket, and thermostat. NOTE: The thermostat is of the lock-open type. If the thermostat is ever allowed to fully open, it will remain open and replacement will be necessary.
Fig. 2-81
8. Remove the four cap screws securing the thermostat manifold to the cylinder heads. Remove the manifold and discard the gaskets. 9. Remove the spark plugs. 10. Remove the six cap screws and O-rings securing each head; then separate from the cylinder. Account for two large O-rings beneath each head.
AN022
NOTE: The stator plate screws had Loctite applied to the threads during assembly. Using an impact driver, apply a sharp blow to the head of each screw to break the Loctite loose before removal.
11. Remove the oil-injection hose from each cylinder and the crankcase nozzle. Fig. 2-83
5. On the 440 cc, remove the cap screws and washers securing the CDI unit and the external coil; then remove from the engine.
AN032
12. Remove the eight nuts, lock washers, and washers securing the cylinders to the crankcase; then using a rubber hammer, gently tap the cylinders and remove from the crankcase by lifting them straight up off their studs. Account for two gaskets.
2-20