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Table of Contents
1. INFORMATION
...................................................................................................................................... 3
1.1 Safety .................................................................................................................................................3
1.2 Notes ..................................................................................................................................................3
1.3 Specifications .....................................................................................................................................4
1.4 VIN & Engine Number ......................................................................................................................6
1.5 Standard Torque Values .....................................................................................................................7
2. MAINTENANCE
..................................................................................................................................... 8
2.1 Maintenance Schedule .......................................................................................................................8
2.2 Maintenance Record ..........................................................................................................................8
2.3 Fuel Lines & Filter .............................................................................................................................9
2.4 Throttle Operation ..............................................................................................................................9
2.5 Throttle Cable Adjustment .................................................................................................................9
2.6 Air Cleaner .......................................................................................................................................10
2.7 Spark Plug ........................................................................................................................................10
2.8 Idle Speed.........................................................................................................................................11
2.9 Drive Chain ......................................................................................................................................11
2.10 Braking Systems ............................................................................................................................12
2.11 Wheels & Tires ..............................................................................................................................13
2.12 Steering System .............................................................................................................................13
2.13 Toe-In .............................................................................................................................................13
2.14 Gear Oil ..........................................................................................................................................14
3. ENGINE REMOVAL AND INSTALLATION
........................................................................................ 15
3.1 Service Information .........................................................................................................................15
3.2 Engine Removal ...............................................................................................................................15
3.3 Engine Installation ...........................................................................................................................15
4. FUEL AND LUBRICATION SYSTEMS
................................................................................................ 17
4.1 Trouble Shooting .............................................................................................................................17
4.2 Fuel Tank .........................................................................................................................................18
4.3 Carburetor ........................................................................................................................................18
4.4 Engine Oil Level & Changing .........................................................................................................20
4.5 Oil Pump removal / Installation .......................................................................................................22
5. ENGINE COMBUSTION SYSTEM
...................................................................................................... 26
5.1 Service & General Information ........................................................................................................26
5.2 Trouble Shooting .............................................................................................................................26
5.2 Trouble Shooting .............................................................................................................................27
5.3 Top End Removal ............................................................................................................................28
5.4 Cylinder Head Removal ...................................................................................................................30
5.5 Cylinder Head Assembly .................................................................................................................33
6. CYLINDER & PISTON
......................................................................................................................... 36
6.1 Service Information .........................................................................................................................36
6.2 Trouble Shooting .............................................................................................................................36
6.3 Cylinder & Piston Removal .............................................................................................................37
6.4 Piston Installation.............................................................................................................................41
7. TRANSMISSION SYSTEM
.................................................................................................................. 44
7.1 Service Information .........................................................................................................................44
7.2 Shift Mechanism C.D.I. ....................................................................................................................45
7.3 Automatic Variable Speed Transmission (C.V.T.) ..........................................................................45
7.4 C.V.T. Belt .......................................................................................................................................46
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