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kawasaki kfx 50 manualSAFE OPERATION MAINTENANCE AND ADJUSTMENT STORAGE TROUBLESHOOTING GUIDE A Table of Contents is included after the Foreword. Always follow safe operat- NOTICE is used to address practices not re- ing and maintenance practices.That’s why we urge you to read this to cause environmental problems as well as conflicts message before you let any young person ride this with other people. Riding readiness varies widely from one person to another, and while the minimum age recommended for this ATV is 6 years old, there are other factors that you should consider. And remember, it’s the par- essary risks, make bad judgments and don’t obey ent’s responsibility to see that the ATV is properly rules are not ready to ride this ATV.A collision or rollover can occur quickly, even during routine maneu- vers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.Always maintain proper tire pressure as described in this manual.Stopping the Engine.LOCATION OF LABELS.Parking the ATV.LOCATION OF PARTS.ATV in an Emergency.LOADING INFORMATION. SAFE OPERATION. GENERAL INFORMATION.Before Riding.Brake Levers.Read the Owner’s Manual.Front brake. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts. Front wheel 21. Engine cooling-air intake. Right footboard 16. Front brake lever 17. Parking brake 18. Rear brake lever 19.In some cases,. Front brake The front brakes are operated by squeezing the right side brake lever. 1. Rear brake lever 1. Front brake lever. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Always set the parking brake when parking and before starting the engine. To unlock the parking brake, squeeze the front brake lever until the lock pin releases.http://coralie-de-france.com/FCKimages/20201217023438v2hyn.xml
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Avoid filling the tank in the rain or where heavy dust is blowing so that the fuel does not get contaminated. 1. The Antiknock Index is posted on service station pumps in the U.S.A. The WHAT CAN HAPPEN octane rating of a gasoline is a measure of its re- Gasoline is extremely flammable and can be. The fuel tap has three positions.Functions of the respective switch positions are as follows: WHAT CAN HAPPEN Can cause loss of control and result in injury or death. OFF: HOW TO AVOID THE HAZARD All electrical circuits are switched off. If you cannot locate your key number, contact the dealer where you purchased your Kawasaki ATV. It’s possible the dealer may have the number in its records. If the key. To start the engine, be sure to position the engine stop switch at “ ”. When the switch is in the RUN ( ) position, the engine will operate. When the switch is in OFF ) position, the engine will not operate. NOTICE See starting instructions prior to starting en- gine.This allows the supervisor to follow close behind and stop the engine by pulling a tethered cord lead. Practice using it when your youngster first starts riding. Any extensive work requiring additional tools should be performed by your authorized Kawasaki dealer. The tool kit includes the following items: Air pressure gauge. Pushing the lever forward increases decrease maximum engine power for an unskilled engine speed. When released, spring force returns rider. Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN Increases your chances of losing control of WHAT CAN HAPPEN the ATV, which can result in an accident. The throttle cable could be damaged. Be careful not to flood this area when washing your Check local regulations before riding. Check the following items each day before you Failure to properly maintain the ATV. ride. The time required is minimal, and habitual per- formance of these checks will help ensure you a WHAT CAN HAPPEN safe, reliable ride.http://chongros.com/userData/board/korg-m50-service-manual.xml If there is a control or function you do not understand, HOW TO AVOID THE HAZARD ask your Kawasaki dealer. Do not start or run the engine in a closed area such as a garage. HAZARD Exhaust gases are poisonous. WHAT CAN HAPPEN You could be unable to control the ATV, WHAT CAN HAPPEN which could lead to an accident or collision. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation,. Never accelerate hard gine for the first time.Refer to the Climbing Hills section in the SAFE OPERATION chapter for the braking and riding NOTE techniques you must use when climbing hills. Parking the ATV WARNING HAZARD WARNING Parking on a steep incline. HAZARD Operating or parking the vehicle near WHAT CAN HAPPEN flammable materials. May result in the vehicle overturning or rolling down the hill and causing an acci- WHAT CAN HAPPEN dent. Your Kawasaki vehicle has been designed and Parking in a structure without ventilation.However, in order to fully benefit from WHAT CAN HAPPEN Kawasaki’s safety engineering and craftsmanship, it. This is especially ATV and help avert serious injury or death. Be- important for younger riders and beginners. It is an off-road motor the use of off-road vehicles in your riding area. Re- vehicle. spect private property; do not ride there without the The minimum recommended age for this ATV express written permission of the owner. HAZARD Always equip your child with proper protective Failure to follow the age recommendations gear. It is important that your child rides an appro- for this ATV. The terrain should be flat and free of obstacles with a WHAT CAN HAPPEN loose or hard dirt surface, but not a mixture of both. Op- eration on public streets, roads, and highways is not recommended and is not safe. ATV tires are not designed to operate on paved or concrete surfaces. Such surface may seriously affect control of the vehicle. The proper clothing can make riding more comfortable and reduce the chance of injury, If you take a spill.http://superbia.lgbt/flotaganis/1653281655 Long pants will also protect your legs from the hot exhaust system. We want you to enjoy your riding experiences, so WHAT CAN HAPPEN ride carefully and safely. Exercise good judgement. Passengers affect balance and steering and Avoid wheelies and jumps. Check with your doctor. WHAT CAN HAPPEN Increases the chance of an accident, includ- WARNING ing an overturn. Always ride with your feet on the footboards. If your feet touch the ground while you are moving, you WHAT CAN HAPPEN could be injured. If it should roll, it might be damaged or Check the throttle for proper operation. See the Loading Information chapter of this manual for more detailed information. Kawasaki does not recommend that you modify your ATV in any way. Unauthorized modifications may produce dangerous handling conditions or adversely affect vehicle reliability. As noted in Weight Limits your Kawasaki Limited Warranty, costs for repairs. Habitual perfor- mance of these checks will help to insure a safer, WHAT CAN HAPPEN more reliable ride. This vehicle is equipped with low pressure tires. Failure to properly maintain the ATV. Tire inflation and type can affect the vehicle’s han- dling characteristics. Check the tire pressure fre- WHAT CAN HAPPEN quently, using the tire gauge in the tool kit. It is with improper or uneven tire pressure.You should ride only when visibility is good. Keep your speed down until you know the area well. You must know WHAT CAN HAPPEN the land you intend to ride on and be familiar with You can come upon hidden rocks, bumps, or. Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of control or a collision. WHAT CAN HAPPEN Could cause the ATV to overturn. Could cause loss of traction or vehicle con- trol, which could result in an accident, in- HOW TO AVOID THE HAZARD. The screw and locknut in the lower throttle housing can The ATV has a remote engine stop switch.http://leeswoodproducts.com/images/colorado-dmv-driver-s-manual.pdf This be adjusted to limit throttle lever movement. The new rider must learn this turning technique to make turns smoothly and quickly. Slide forward on WHAT CAN HAPPEN the seat, and turn the handlebar in the direction of ATV could go out of control, causing a colli- the turn. Sliding forward on the Removing hands from handlebars or feet seat and shifting body weight onto the outside foot- from footboards during operation. When climbing a hill, HAZARD lean forward to keep the front wheels from lifting. On Operating on excessively steep hills.HAZARD Release the parking brake and ride downhill. Improperly turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. If you can’t Stalling, rolling backwards or improperly dis- see what is on the other side of the crest of a hill, mounting while climbing a hill. Take extra care when approaching blind hill tops and corners. The flagpole bracket is at the rear end. When riding across the side of a hill, keep your body weight toward the top of the hill. Avoid hills with WHAT CAN HAPPEN slippery sides that will cause you to lose traction. Could cause loss of control or cause ATV to Also avoid traversing hillsides covered with rocks or overturn. WARNING HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. You should keep your feet on the footpegs and transfer his weight to the rear of the vehicle, and On slippery or loose surfaces, special care is on the uphill side of the vehicle. These conditions are particularly haz- Skidding or sliding improperly.Re- member that this vehicle is not allowed on public WHAT CAN HAPPEN streets, roads, or highways. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an acci-. To prevent burns, avoid touch- ing the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch WARNING HAZARD Hot exhaust system. To assist you in keeping this record, we have provided space at the end of this manual where an authorized Kawasaki dealer, or someone equally competent, can record the maintenance. You should also retain copies of maintenance work orders, receipts, etc., as verifica-. To ob- tain warranty service, the Kawasaki Limited Emission Control Systems Warranty requires that you return your vehicle to an authorized Kawasaki dealer for remedy under warranty. In order for the engine and transmission to function Operation with insufficient, deteriorated, or properly, maintain the engine oil at the proper level, contaminated engine oil will cause acceler- and change the oil and replace the oil filter in ac- ated engine wear. WHAT CAN HAPPEN Can lock the rear wheels causing an accident and injury. HOW TO AVOID THE HAZARD Check engine oil level before operating vehi- cle, and add oil if it is low. NOTICE 1. Tighten the drain plug to specification. NOTICE Before reinstalling the drain plug, be sure to install the O-ring, compression spring and oil strainer.Place a container under the engine. Remove the oil filler cap and drain plug to drain the oil. NOTICE Be sure no foreign material enters the crankcase. Warm up the engine for several minutes at idle 1. Fill the engine with oil and install the oil filler cap. Warm up the engine for several minutes at idle speed. Check for oil leakage while warming up.WARNING HAZARD Operating this vehicle with insufficient, dete- riorated, or contaminated gear case oil. WHAT CAN HAPPEN Seizure of ring gears in final gear case can lock the rear wheels causing an accident and. Place the machine on a level place. Remove the oil filler bolt and check the level. It Place a container under the engine.If the level Remove the oil filler bolt and drain plug to drain is low, add oil to raise it to the proper level. Instead, take the machine to a Kawasaki dealer. You should periodically re- move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. Wipe off any authorized Kawasaki dealer.A clogged air cleaner restricts the engine’s air in- Element Cleaning take, increasing fuel consumption, reducing engine To clean the air cleaner: power, and causes spark plug fouling. WHAT CAN HAPPEN Can cause the throttle to stick open. This could cause an accident. HOW TO AVOID THE HAZARD Be sure to cover the air cleaner opening to the carburetor after removing the element. WHAT CAN HAPPEN Remove the bolt. Low flash point solvents or gasoline can catch fire or explode. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to 1. Measure the distance the throttle lever moves before the engine begins to pick up speed.Turn the screw in to increase en- Carburetor gine speed, and out to decrease engine speed. Specified idle speed: Carburetor adjustment is done with the idle adjust- 2 000 rpm ing screw. Adjustment WARNING HAZARD Hot engine and exhaust pipe. Accumulation of moisture or sediment in the fuel system will restrict the flow of fuel and cause carbu- WHAT CAN HAPPEN retor malfunction. The system should be checked in Can result in control malfunction and an ac- accordance with the Periodic Maintenance Chart. WHAT CAN HAPPEN Can burn your hands. HOW TO AVOID THE HAZARD Never touch a hot engine or an exhaust pipe during carburetor adjustment.The indicators allow checking the brake pads wear. Have the indicator checked by a Kawasaki dealer Front brake shoe inspection: periodically. If the indicator reaches the wear limit Checking brake shoe wear requires disassembling line, replace the pads. Turn the lower adjusting bolt until specified free play is obtained. These procedures should be performed by Kawasaki dealer. Tighten the upper locknut. Brake fluid inspection: Check if the fluid level is below the lower level mark through the inspection window. Drive chain slack check: Inspect the drive chain while all tires are touching the ground. Check the slack at the position shown in the figure. Use a lubricant for sealed chains to prevent deteri- oration of chain seals. If the chain is especially dirty, clean it using a cleaner for sealed chains following the instructions supplied by the chain cleaner man- ufacturer. Periodic Drive Belt Inspection Requirements Drive belts wear with normal use. Inspection of the. Other tire combinations kg (187 lb).Swelling or When installing the wheel, reverse the removal high spots indicate internal damage, requiring tire procedure. If there is any indi- cation of these troubles, have the joint boot replaced by an authorized Kawasaki dealer. 1. Tie Rods 2. Joint Boots 1. Steering Knuckle. WARNING HAZARD Improper shock absorber adjustment. The battery is located under the seat. Batteries produce hydrogen gas. WARNING WHAT CAN HAPPEN Heed the battery safety label shown here. Sulfuric acid can cause burns. Hydrogen gas can cause an explosion. HOW TO AVOID THE HAZARD Read and understand the battery safety la- bel. For more details, ask your Kawasaki dealer. If you are riding your vehicle infrequently, inspect the battery voltage weekly using a voltmeter. Battery Charging it drops below 12.6 volts, the battery should be. WHAT CAN HAPPEN Could cause health problem. HOW TO AVOID THE HAZARD Wash hands after handling battery. See your authorized Kawasaki dealer for Can create sparks which can cause a fire or repair.The specified fuses are: 7A 1. Fuse holder 2. Clip Slide the old fuse out of the clips and discard it. 1. Fuse holder Lift the seat. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask Kawasaki dealer to replace them. Recommended lubricant: Pressure cable luber or. Recommended lubricant: Frequent, thorough cleaning of your machine will Lithium-soap-based grease not only enhance its appearance but will improve its general performance and extend the useful life of (All-purpose grease) many components. Otherwise, the WHAT CAN HAPPEN repairs may be forgotten by the time you remove the The fuel could explode or ignite. WHAT CAN HAPPEN WHAT CAN HAPPEN The fuel can cause skin irritation.DANGER HAZARD WHAT CAN HAPPEN Running the engine without ventilation. Gases may explode and possibly cause in- jury. WHAT CAN HAPPEN Breathing exhaust gas leads to carbon HOW TO AVOID THE HAZARD monoxide poisoning, asphyxiation,. The warranty does not cover the cost of regularly-scheduled maintenance. The warranty also does not apply to the normal wear of items such as tires, brake pads, transmission drive belts, chains, sprockets, etc. You can go to any Kawasaki dealer for warranty repairs. Your Kawasaki dealer will inspect your vehicle and give you the results of the inspection. The dealer will perform the repairs at no cost to you if it is determined that the problem is covered by the warranty. This owner’s manual should answer most of your questions about your Kawasaki. Your Kawasaki dealer should either be able to answer any other questions you might have immediately or be able to find the answer for you. When using your Kawasaki All Terrain Vehicle (ATV), please follow these Tread Lightly.Date Traveled Distance Maintenance Performed. Special tools, gauges, and testers that are Indicates a procedural step or work to be done.Genuine parts provided as spare parts are listed in the Parts Catalog. Base Manual TROUBLESHOOTING. When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. The meaning of each symbol is included in the table below. Where applicable, comparable Kawasaki products and their part numbers have been included. SYMBOL. Use the Kawasaki Service Manual Supplement along with the KYMCO Base Manual when servicing the Kawasaki KFX50 model. FUEL SYSTEM Read them carefully before starting any ENGINE REMOVAL operation. Use genuine parts and lubricants. When servicing the vehicle, be sure to use special tools for removal and installation. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation. Replace it with a new one according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the coupler, the lock on the coupler shall be released before operation. If the double coupler has a lock, lock it at the Snapping.Before connecting a terminal, check for damaged terminal cover or loose negative terminal. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. Do you understand When a testing device is used, make sure to the instrument? Is. Grease: Transmission Gear Oil (SAE90) Gear Oil: This symbol. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the ATV. Seat Lock Lever Hook SEAT INSTALLATION Tabs To install the seat, insert the hook in the hole and align the tabs on the seat with the grommets on the frame and press the seat down until it locks. Disconnect the front brake stop switch wires. Remove the two screws and speed limiter cover. Front Brake Cables Front Brake Stop Switch Wires Throttle Cable Disconnect the throttle cable. Bolts Remove the four bolts and upper handlebar holders. Adhesive agent: KONISHI Co. Ltd G103 or equivalent rubber adhesive agent Refer to the “BRAKE LEVER FREE PLAY” section in the chapter 3 to adjust brake lever free play. REAR FENDER REMOVAL Starter Relay CDI Unit Remove the front fender. (See page 2-5) Remove the battery. (See page 14-4) Remove the starter relay and CDI unit. Remove the three bolts attaching the rear fender. Nuts Bolts Remove the two bolts attaching the exhaust pipe. Bolt Remove the bolt attaching the exhaust muffler, then remove the exhaust muffler. INSPECTION Exhaust Muffler Inspect the gasket at the front end of the exhaust. Gasket BRAKE LIGHT BULB REMOVAL. Push and turn the bulb clockwise and install it. Projections Lower Lens Notch Install the lower lens as shown. Fit the projection in the notch of the lower lens. Projections. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. Gasoline is extremely flammable and is explosive under some conditions. The working area must be well-ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service ad well as new vehicles that are being prepared for sale. WARNING Gasoline is extremely flammable and can be explosive under certain condition. Do not smoke or allow flames or sparks in your working area. Turn the throttle stop screw to obtain the specified idle speed. Idle Speed: 2000 rpm When the engine misses or run erratic, adjust the Throttle Stop Screw air screw. Special Tool: Pilot screw adjuster: 57001-1665 (Kawasaki) Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Replace the fuel hose if any fraying, leaks, cracks, bulges, or ozonic cracks are noticed. Check that the hoses are securely connected and clamps are installed correctly. When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed. Remove the fuel tap and fuel tank. Replace the fuel hoses with new ones. When installing the fuel hose, avoid sharp bending, kinking, flattening or twisting, and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed. Install a compression gauge and adapter.Replace if necessary. EXHAUST SYSTEM Breather Hose SPARK ARRESTER CLEANING Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. WARNING Always let the exhaust system cool prior to touching exhaust components. If the exhaust gas leaks, retighten the exhaust muffler lock nut or replace the gasket with a new one.Warm up the engine for several minutes and stop it. Place a container under the engine. Reinstall the drain plug and tighten the drain plug to specification. Remove the oil filler bolt and check the oil level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level. Inspect the drive belt for cracks, scaling, chipping or excessive wear. Measure the V-belt width Service limit: 17 mm (0.68 in) Replace the drive belt if out of specification. BRAKES BRAKE SHOES The checking of brake shoes wear will disassemble. FRONT BRAKE LEVER FREE PLAY ADJUSTMENT Loosen the upper lock nut and fully turn in the adjusting bolt. Remove the two screws attaching the brake fluid reservoir cap. Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. Immediately wipe up any brake fluid that spills. Replace the steering column bushings and or bearings if excessive play Tie-rod Ends Check the tie-rod ends. Measure the toe-in. Adjust if out of specification. Toe-in measurement steps: Mark both front tire tread centers. Raise the front end of the machine so that there is no weight on the front tires. Fix the handlebar straight ahead. Tire pressure should be checked when tires are cold.Replace if damage or bends Always balance the wheel when a tire or wheel has been changed or replaced. Never attempt even small repairs to the wheel. Ride conservatively after installing a tire to allow it to seat itself properly on the rim.Retighten the upper and lower axle holding bolts.SUSPENSION LUBRICATION Inject grease into the nipples using a grease gun until slight over flow is observed from the thrust covers. Wipe off the excess grease. JOINT BOOT INSPECTION Rear Swing Arm Nipple TIE-ROD END BOOT INSPECTION. Also, check to see that each cotter pin is in place and in good condition. If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line. Crankcase Cover Bolts OIL PUMP REMOVAL Place a container under the engine. Remove the drain plug to drain the oil. O-rings Dowel Pin DISASSEMBLY Remove the screws and disassemble the oil pump. Bolts Screws Outer Rotor Pump Body INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.25 mm (0.01 in) Service Limit: 0.2 mm (0.008 in) Inner Rotor Measure the rotor end-to-pump body clearance. Service Limit: 0.12 mm (0.0048 in) Dowel Pin ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump body. Inspect the O-rings and replace if damaged. Bolts Install the oil pump and tighten the bolts. Make sure that the pump shaft rotates freely without binding. Oil Pump Oil Pump Gear Install the oil pump gear and tighten the nut. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. Keep sparks and flames away from the work area. Wipe off any spilled gasoline. Remove front fender. (See page 2-5) Screws Switch the fuel tap “OFF”. Disconnect the fuel outlet hose from fuel tap. Install the “ON” fuel hose on the fitting that has screen. “Reserve” Fitting “ON” Fitting Fuel Tap FUEL TAP REMOVAL WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Keep sparks and flames away from the work area. Fuel Tap Body Rubber Gasket INSPECTION Inspect the fuel tap body for dirt and clog. Clean if necessary. Replace the rubber gasket with new ones if they are damaged or deteriorated. Pull out the throttle valve. Throttle Valve Throttle Cable Compress the spring to disconnect the throttle cable by hand. Remove the spring from the throttle valve. Spring. Throttle Valve Check the throttle valve and jet needle for wear or damage. Jet Needle Groove ASSEMBLY Reverse the “DISASSEMBLY” procedures. Install the throttle valve into the carburetor body. Align the groove in the throttle valve with the throttle stop screw on the carburetor body. Remove the bolt at the air cleaner left side. Bolt Breather Hose Screw. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Keep sparks and flames away from the work area. Do not force the screw against its seat to avoid seat damage. Be sure to install the O-ring in the reverse order of removal. Air Screw Throttle Stop Screw Needle Jet. Inspect the float for damage or fuel level inside the float chamber. FUEL RESERVOIR O-RING CHECK O-ring Remove the O-ring. Resistance: 5 (10 minutes minimum after stopping the engine) If the resistance exceeds 5, replace the auto bystarter with a new one. After the engine stops for 30 minutes, connect a hose to the fuel enriching circuit and blow the hose with a blowing tool. Be careful not to damage the machine body, cables and wires during engine removal. Use shop towels to protect the machine body during engine removal. Parts requiring engine removal for servicing: Crankcase Crankshaft. Remove the drive sprocket and washer. ENGINE INSTALLATION Reverse the “REMOVAL” procedures.When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surfaces for initial lubrication. The camshaft is lubricated by engine oil through the cylinder head engine oil passages. Remove the four bolts at the cylinder head cover, then remove the cylinder head cover. Bolts Cylinder Head Cover INSTALLATION Install a new cylinder head cover O-ring and install the cylinder head cover. Remove the lifter tensioner bolts, then remove cam chain tensioner and gasket. Screws Bolts Nuts and Washers Remove the four camshaft holder nuts and washers. Diagonally loosen the cylinder head nuts in 2 or 3 times. Rocker Arm Shafts Camshaft Holder Rocker Arm CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder for wear or damage. Align the cross cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder. Camshaft Bearings CAMSHAFT INSPECTION Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play. Note the following points: 1. Turn the flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase.