STEP 9: Changing the piston and sleeve assembly
Use a 5/16 inch nut driver to remove the glow plug and
copper gasket.
STEP 10:
Use a 2.5mm allen wrench to remove the four 3x12mm
cap head screws that fasten the cylinder head. Rock
the cylinder head gently from side to side to release it
from the sleeve. Note the thin aluminum head gaskets.
We recommend that you replace these gaskets with
new ones upon reassembly.
STEP 11:
Remove the backplate and the
starter shaft. Replace the backplate
gasket with a new one during
assembly.
STEP 12:
The piston and sleeve are a matched set. When the
piston and sleeve are disassembled, they must be
reassembled in the same orientation. Use a hobby
knife to scratch a mark to indicate the location of the
piston in relation to the pinning of the sleeve.
12
STEP 7:
To separate the engine from the engine mount,
remove the four 3x10mm caphead machine screws.
* Note: You will not need to remove the engine mount
for a basic rebuild of the engine.Do remove the engine
mount if you are exchanging the engine under the
Lifetime Engine Replacement Plan.
REBUILDING THE ENGINE
STEP 1:
Disconnect the red and black wires from the EZ-Start
motor. Remove the EZ-Start gearbox by removing the
three 3x8mm roundhead machine screws.
STEP 8:
Removing the carburetor is not necessary to rebuild
the engine, unless you intend to replace the internal
bearings of the engine. Remove the carburetor by
loosening the 3mm locknut and pulling the carburetor
straight up.
STEP 2:
Unplug the blue wire from the glow plug. Remove the
fuel line from the carburetor inlet and from the exhaust
header pressure fitting.
STEP 3:
Use a 2.5mm hex driver to remove the yellow ground
wire from the engine mount. Move the EZ Start wiring
harness out of the way.
STEP 4:
Use a 2.5mm hex driver to remove the four 3x10mm
caphead machine screws from the engine mount.
STEP 5:
Pull the engine from the chassis.
Remove the exhaust tube from the
header. Turn the engine so that the
throttle linkage to the carburetor will
come out.
STEP 6:
Remove the 3x23mm roundhead machine screws that
fasten the header to the engine. Remove the header
and the old gasket. Replace the header gasket with a
new one during assembly.
