P 16/ 18
Repair
[4] DISASSEMBLY/ASSEMBLY
[4]-14. Spark arrester (Only for some countries, i.e., having dry atmospheres at high temperature)
(1) Remove Cylinder cover.
(2) Remove Exhaust Muffler.
(3) Remove Spark arrester from Exhaust muffler. (Fig. 68)
Sweep it off if dirt or soot is on Spark arrester.
Replace it with a new one if spark arrester has a breakage or fray.
(4) Assemble Spark arrester to Exhaust muffler.
(5) Set Exhaust muffler in place.
Note: • Refer to Parts breakdown, and do not forget muffler gasket.
• Two M5x40 Hex socket head bolts on Exhaust muffler are
threadlocker type. Once removing them for repair, apply
ThreeBond 1342 / Loctite 242 to the threads to screw them.
(6) Set Cylinder cover in place.
(1) Drain the oil from Engine as much as possible so that the remaining oil is not spilled out when disassembling.
(2) Remove the following parts from Engine.
• Cylinder cover • Tank guard • Fuel tank • Clutch case
• Recoil starter assembly • Clutch • Ignition coil • Flywheel
• Rocker cover inner • Rocker cover gasket • Rocker arm assembly
• Rod 2.5 • Cam lifter • Cam gear • Insulator • Air cleaner • Carburetor
• Spark plug • Muffler
(3) Open Cylinder block by removing six M5x16 Hex socket head
bolts. (Fig. 69)
(4) Remove Clip from Piston with needle. (Fig. 70)
Note: • Be careful as the clip pops out.
• Use the new clip. Do not use the used clip.
(5) Push out Piston pin with 1R171. (Fig. 71)
(6) Remove Piston.
Fig. 68
Fig. 69
Fig. 70 Fig. 71
MAINTENANCE
DISASSEMBLING
[4]-15. Engine block
Spark arrester
Exhaust muffler
Cylinder block
1R171
Clip
Piston pin
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