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Old 09-26-2015 | 10:25 PM
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blis
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Joined: May 2008
Posts: 3,478
From: Brisbane
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  1. Remove the clutch and leave the flywheel on (You'll need it to remove the liner)
  2. Remove Air cleaner, wash in soapy water and leave to dry
  3. Remove the pullstart if applicable
  4. Clean the engine - including head bolts
  5. WARM UP THE ENGINE with a hair drier so it's hot to touch, not scolding.
  6. Loosen the glow plug
  7. Check the carby is tight, if you want to service the carby, remove it and be mindful of o-rings
  8. Remove the back plate
  9. Remove the head, if separate head, try to turn the flywheel to pop the button.
  10. If you have to pry, pry equally, opposing each one forming a star and use a plastic blade!
  11. Grab a cable tie small enough to fit through exhaust port. Position the head of the cable tie in the cylinder so a small portion of the cable tie is lined up with teh liner and the rest with the piston.
  12. Turn the flywheel, if the liner is free, then it should lift as the piston gently pushes upward. NOTE: I said gently, if the liner is stuck, this isnt going to work.
  13. If the liner is stuck, then I'd add more heat and try again, if that fails, then I take piston up to TDC and pry the liner upwards with a plastic screwdriver of types using the crank for leverage... If that fails, you may have to put the engine block in the over (minus carby) and hope 120c-150c helps
  14. Once you have the liner out, remove the piston by using thumb and index finger at TDC.
  15. Remove the flywheel, if you dont have a puller, put an old clutch screw back into the crank as far as you can go and give the screw a tap with a rigid metal object and it should pop the flywheel collet
  16. Slide out the crank shaft, checking bearings along the way.
  17. Clean but don't remove anything, don't touch the edges
  18. Flush your bearings with brake cleaner and two drops of oil
  19. Clean the oxides off the crank and clean out rings and ports.
  20. If removing G clips from piston, do it in a large clear plastic bag. (And you'll still lose them)
  21. Carby's usually only need a rubber boot clean and make sure you have a good seal when you rebuild it.
  22. Careful of head shims, they bend and warp easily.
  23. Hand lube it all and put it back the way you found it.
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