Specifications

Engine Removal
To service the bottom end/transmission, the engine must be removed from the
frame.
Tools required
10, 11, 13, 22 mm wrench
8, 10, 14, 17 & 19 mm sockets
3, 4 & 5 mm Allen wrench
7 mm nut driver, flat or Phillip, screwdriver for hose clamps
Spring remover
Flywheel / clutch puller (#MCMUTL68)
Clutch nut removal tool (#ECMU0078)
CFD gear stop (#EAMU0004)
Procedure
1. Remove the seat.
2. Turn of the fuel at the petcock and disconnect the fuel line.
3. Remove the tank (8 mm socket).
4. Remove the carburetor from the inlet (flat head or Phillips head
screwdriver, 7 mm nut driver).
5. Remove the silencer & pipe (spring remover, 8mm socket).
6. Locate a suitable container for the engine coolant and disconnect the
coolant lines connected to the engine (8 mm socket).
NOTE: If the coolant looks to be free of contaminates it may be reused.
7. Remove the master link from the chain.
8. Remove front engine mount bolt (13 mm socket, 6 mm hex key).
9. Remove the swingarm bolt (19mm socket).
NOTE: Only drive the swingarm bolt far enough to clear the engine, leave it
holding the one side of the swingarm to the frame
10. Remove the engine from the right side of the frame.
Complete Engine Disassembly Procedure
1. Remove the ignition cover (4mm Allen)
2. Remove the bolt from the water pump shaft (4mm Allen) and slide off the
belt cover and the water pump belt
3. Using a flywheel holding tool and 14mm socket remove the nut that
secures the flywheel.
4. Using the Cobra flywheel / clutch puller (#MCMUTL68), remove the
flywheel from the crankshaft.
5. Remove the stator (4mm Allen).