klm4755
(Minor Revisions and PDF conversion by RickMJr)
Tank bracket (special washer and locating damper) 8) To view the crankshaft location remove this plug
removed also.
Gas tank brackets and associated parts are shown 9) To remove the valve cover you’ll need a 5mm allen
below. socket and a 5mm allen key. There are five 5mm allen
head bolts, all of same size (diameter and grip length),
so don’t worry about mixing them up.
9a) Start the exhaust side (front cover). There are 9d) Photo of the exhaust cover off
three allen head bolts to remove. The allen bolts
closest to you can be removed with the socket. The
others require the allen key.
9b) Next remove the two bolts on the intake side (rear
cover). Again the closest bolt can be removed using
the allen socket. The other bolt requires the allen key.
10) Attach 17mm socket to this crankshaft bolt, use These are the 3 radial groves on the flywheel, the one
small 4" extension in the middle is top dead center (TDC), however a four
stroke engine may read bottom dead center ( I’m not
that sure about this statement). However, it is not
important. What is important is to check the exhaust
gap while you have the center groove visible. If you can
get a .003" feeler gage in the gap your at TDC. If not
rotate the flywheel another 360 degrees counter-
clockwise and check the gap. This time it will be there.
So, you have a 50/50 chance of getting it right the first
time. By the way don’t use the ratchet function on your
tool. Once you see the flywheel notches, just spin your
tool one full revolution to see notches
again!
14) Repeat the same procedure for the intake valve but
use feeler gauges between .002-.004 inches.
Tighting the intake 17) Inspect intake valve cover too. Clean and inspect
the rubber seal.
20) Clean and inspect the crankcase plugs. Verify that 22) Replace the gas tank bracket and damper. Install
the O-rings are OK. Screw the plugs back on. the gas tank with the rounded groove rails first (the
front of the tank) and then bolt it down.
21) Torque the two allen head cover bolts that are
accessible by the torque wrench (one intake and one 23) Torque the gas tank bolt to 5 ft*lbs.
exhaust) to 7.2 ft*lbs. Other three allen head bolts will
need to be attached by allen key, no room for torque
wrench. Just remember that 7.2 ft*lbs is just barley
tighter than snug. Here’s the intake side.
24) Reattach fuel line.