Instructions / Assembly

4.ENGINE REASSEMBLY
Engine reassembly procedure
1.Notice
・ Clean parts completely specifically the PISTON, CYLINDER, CRANKCASE, CRANKSHAFT
and BEARINGS.
・
Remove completely all the carbon deposit from the COMBUSTION CHAMBER and the PISTON top.
・
Test the lip of the OIL SEALS for damage. Replace damaged OIL SEALS with new ones.
Apply oil over the lip before reassembly.
・ Replace all GASKETS with new
ones.
・ Replace PINS and SCREWS with new ones if necessary.
・
Tighten up the tightening torque specified parts according to the specified tightening torque.
・ Apply 4-stroke engine oil over the rotating portions and sliding surfaces.
・ Check and adjust the clearances.
・ After reassembling each of the rotatable main parts, rotate by hand to test it for
2.Tightening torque
No. Tightening part
Tightening torque
(kg･cm)
Screw PCS
1
CRANKCASE
～RETAINER PLATE
30
+10
0
M4×10 SW SOCKET １
2
CYLINDER BLOCK
～CRANKCASE
55
±10
M5×14 SOCKET ８
3
CRANKCASE
～CASE,OIL
45
+10
-5
M5×18 W,SW SCREW ４
4 COVER,CAMGEAR 45
+10
-5
M5×14 W,SW SCREW ３
5 IGNITION COIL 20
+20
0
M4×20 W,SW SCREW ２
6 FLYWHEEL 105
±15
M6×16 W,SW BOLT １
7
R O C K E R A R M A D J U S T
SCREW～NUT
50
+15
0
M5 NUT ２
8 ROCKER COVER 45
+10
-5
M5×16 W,SW SCREW ３
9 MUFFLER EXHAUST 75
+15
-5
M5×40 W SOCKET ２
10 PLUG,SPARK 110
±20
M10×P1.0 １
11 INSULATOR 45
+10
-5
M5×18 W,SW SCREW
M5×14 W,SW SCREW
２
１
12
PLATE,AIR CLEANER
～CARBURETOR
～INSULATOR
20
+20
0
M5×68 SUS SCREW ２
13 PIPE,OIL 45
+10
-5
M5×12 W,SW SCREW １
14 RECOIL STARTER 15
+10
-5
M4×16 W,SW SCREW ２
13
bad movements and abnormal noises.