Service manual

ENGINE
PISTON IDENTIFICATION
The piston have an identification mark for piston
placement.
Note the directional and identification marks when
viewing the pistons from the top. The letters “IN” must
always be toward the intake side of the engine.
The other numbers are used for identification as to
diameter, length and design. Four stroke engine rings are
rectangular profile. The numbers or letters on all rings
(except oil control rings) must be positioned upward. See
text for oil control ring upper rail installation. Use the
information below to identify pistons and rings.
The following components require engine removal
for service:
1. Cam Chain and Sprockets
2. Cylinder Head
3. Cylinder
4. Piston/RIngs
5. Camshaft
6. Crankshaft
7. Crankshaft Main Bearings
8. Crankcase
9. Transmission
10. Valves
NOTE: Cam chain service requires crankshaft
removal, as the chain is located on the pto side of the
engine.
NOTE: Crankshaft components are not serviceable.
Replace crankshaft as an assembly.
ACCESSIBLE COMPONENTS
The following components can be serviced or
removed with the engine installed in the frame:
1. Flywheel
2. Alternator/Stator
3. Starter Motor/Starter Drive
4. Oil pump
5. Rocker Arms
6. Carburetor
7. Transmission
ENGINE REMOVAL
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables.
4. Drain engine oil.
5. Drain radiator water.
6. Disconnect spark plug high tension lead.
7. Disconnect all electrical wires from the engine.
8. Disconnect radiator tubes.
9. Remove the following parts as required.
◎ Seat
◎ Left and Right Side Covers
◎ Fuel Tank Cover / Front Cab
◎ Fuel Tank
10. Remove exhaust pipe.
11. Remove airbox.
12. Remove carburetor. Insert a clean shop towel into the
carburetor flange to prevent dirt from entering the intake
port.
13. Starter motor. Note ground cable location. Mark
positive (+) cable mounting angle and remove cable.
14. Remove transmission link rod(s) from gear selector
and secure out of the way.
15. Remove engine to chassis ground cable.
16. Refer to Chapter 5 to remove the swing arm and drive
shaft assemblies.
17. Remove all engine mount nuts and / or engine mount
plates.
18. Remove engine through left side of frame.
_ 4.6