jasonp
Well-Known Member
The biggest thing here guys is take your time, and do it right. If you don't have the right tool for the job go get it. It will make your life much easier. Keep everything clean! You don't have to pry or use excessive force on any of this stuff... if you are then you will break something.
Good luck! Have fun and I hope this helps some of you guys that are a little worried about taking your fourwheeler appart. It's really simple just use your head and take your time. I also hope this saves you guys some money.
There are actually a couple of things that you can apply this to if you have to pull the flywheel or cover so I will go there. I have to pull the stator appart anyway because my source coil is bad so I decided it was a good time to get adjustable cam sproket and new cam chain as I got new valve high tension valve springs.
I only have a couple hours on the bike so I want to keep this oil in it for now. So I propped it up using two 5 gallon pales.
Remove the engine cam cover making note of the o-ring on the cover. Remove the engine crankshaft bolt cover (6mm allen wrench). Loosen up the cam bolt (17mm I believe) before taking the crankshaft bolt out.
Make sure and have your 8mm socket ready!
Remove the flywheel bolt and seal/bearing/flywheel stay.
Remove the cam tensioner... nut first then spring. Then you can remove the body of the tensioner, 8mm bolts. This is where you can tell how worn the chain is by looking at how far the adjuster is out. Mine was a little more then half way so not to bad but I thought it would be a good idea anyway.
Find the other end of the stator electral plugs and unplug them.
Remove the bolts, 8mm that hold the stator engine cover to the engine making note which bolts go where and how long they are.
Use both hands to wiggle the cover off slowly. Sometimes the gasket will hold it on and they have have to take a rubber hammer to it break it loose.
Here you'll see how just to replace the stator. Pretty simple. You may have to use a impact drive to get thoughs bolts out as there locked in there pretty good.
Next we move on to the flywheel. Put the crankshaft bolt back in the crank and then put the puller on. It takes quite of bit of force to break it loose and if the bolt is not in there it will mushroom out the crankshaft and could damage it.
Next pull the one way cluch off. (by hand) Now you'll see the cam chain.
Here you can see the flywheel key if you where to be replacing it with an advance key. I like to use just a little dab of loc tite so when pressing the flywheel on the shaft the key will not move. It's hard to get out this way but we don't need to, to replace the chain.
Pull the cam gear off and don't be affraid and let the cam chain fall. You'll use a piece of wire to bring the other chain back up.
Next let the cam chain fall to the crankshaft. And just work it out with your hands.
.......... More to come when I get the parts......
Good luck! Have fun and I hope this helps some of you guys that are a little worried about taking your fourwheeler appart. It's really simple just use your head and take your time. I also hope this saves you guys some money.
There are actually a couple of things that you can apply this to if you have to pull the flywheel or cover so I will go there. I have to pull the stator appart anyway because my source coil is bad so I decided it was a good time to get adjustable cam sproket and new cam chain as I got new valve high tension valve springs.
I only have a couple hours on the bike so I want to keep this oil in it for now. So I propped it up using two 5 gallon pales.
Remove the engine cam cover making note of the o-ring on the cover. Remove the engine crankshaft bolt cover (6mm allen wrench). Loosen up the cam bolt (17mm I believe) before taking the crankshaft bolt out.
Make sure and have your 8mm socket ready!
Remove the flywheel bolt and seal/bearing/flywheel stay.
Remove the cam tensioner... nut first then spring. Then you can remove the body of the tensioner, 8mm bolts. This is where you can tell how worn the chain is by looking at how far the adjuster is out. Mine was a little more then half way so not to bad but I thought it would be a good idea anyway.
Find the other end of the stator electral plugs and unplug them.
Remove the bolts, 8mm that hold the stator engine cover to the engine making note which bolts go where and how long they are.
Use both hands to wiggle the cover off slowly. Sometimes the gasket will hold it on and they have have to take a rubber hammer to it break it loose.
Here you'll see how just to replace the stator. Pretty simple. You may have to use a impact drive to get thoughs bolts out as there locked in there pretty good.
Next we move on to the flywheel. Put the crankshaft bolt back in the crank and then put the puller on. It takes quite of bit of force to break it loose and if the bolt is not in there it will mushroom out the crankshaft and could damage it.
Next pull the one way cluch off. (by hand) Now you'll see the cam chain.
Here you can see the flywheel key if you where to be replacing it with an advance key. I like to use just a little dab of loc tite so when pressing the flywheel on the shaft the key will not move. It's hard to get out this way but we don't need to, to replace the chain.
Pull the cam gear off and don't be affraid and let the cam chain fall. You'll use a piece of wire to bring the other chain back up.
Next let the cam chain fall to the crankshaft. And just work it out with your hands.
.......... More to come when I get the parts......
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