Service manual

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To Remove Engine and Support Assembly-Mark IV Only
• Remove the hood and headlight assembly. Refer
to Hood Removal and Installation.
[ C~~TION 1
Always disconnect the sparkplugwires
before working on the engine or drive
elements.
• Remove the console door assembly by turning
the door fastener counterclockwise to release.
• Remove the six screws, washers and locknuts
securing the console tongue assembly to the tool
box and to the
mini-console (see figure 11).
• Remove the drive clutch. Refer to parag~aph
To Remove Drive Clutch.
• Loosen the flexible tube clamps. securing the
muffler exhaust tube to the engine exhaust manifold
and
release the exhaust tubes.
Figure 11
• Disconnect the throttle and choke control cables
and remove the carburetor as described in para-
graph To Remove Carburetor.
• Disconnect the yellow wire lead and the black
wire lead at the engine and the black ground wire
lead at the starter cover. Replace the metric nut
to secure the cover after removing the black wire
lead.
11
SERVICE AND REPAIR
PSld
• Remove the heat shield located between the
engine and the muffler. Remove the attaching hard-
ware at the muffler bracket, heat shield bracket and
at the top near the steering column.
• Remove the locknuts and washers securing the
engine mounting straps to the main frame.
• Lift the engine until the engine mounting straps
clear the studs shown in figure 11. Rotate the
engine counterclockwise and remove the engine
toward the rear and clear of the sled.
• Remove the carriage bolts, washers and locknuts
securing the mounting straps to the engine base.
Remove the mounting straps and bar washers.
NOTE: During reassembly, the mounting straps
and bar washer must be secured to the engine base
before installing the replacement engine.
• Installation procedures are the reverse of
removal.
To Remove Engine and Support Assembly - Mark V Only
• Remove the hood and headlight assembly. Refer
to Hood Removal and Installation.
! CAUTION I
Always disconnect the sparkplugwires
before working on the engine or drive
elements.
• Remove the console door assembly by turning
the door fastener counterclockwise to release.
• Remove the six screws, washers and locknuts
securing the console tongue assembly to the tool
box and
to the mini-console (see figure 11).
• Remove the drive clutch. Refer to paragraph
To Remove Drive Clutch.
• Loosen the flexible tube clamps securing the
muffler exhaust tube to the engine exhaust manifold
and
release the exhaust tubes .
• Disconnect the throttle and choke control cables
and remove the carburetor as described in para-
graph To Remove Carburetor.
• Remove the starting motor assembly. Refer to
paragraph To Remove Starting Mot0r Assembly.