xv Starting Systems . . . . . . . . . . . . . . . . 433 Kick-Starting Systems . . . . . . . . . . . . . .433 Electric Starting Systems. . . . . . . . . . . .435 Side Stand Switch Operation. . . . . . . . .435 Starting System Operation . . . . . . . . . .436 Chapter 20 Engine Disassembly. . . . 441 Preparing for Engine Removal . . . 441 Clean the Vehicle . . . . . . . . . . . . . . . . .442 Is Engine Removal Necessary? . . . . . . .442 Read the Service Manual . . . . . . . . . . .443 Drain Fluids . . . . . . . . . . . . . . . . . . . . 443 Disconnect Electrical System . . . . 443 Disconnect Control Cables. . . . . . . 445 Fuel System Disassembly . . . . . . . . 445 Carburetor Removal . . . . . . . . . . . . . . .445 Fuel Injection System Disassembly . . . .446 Disconnect Final Drive . . . . . . . . . . 446 Exhaust System Removal . . . . . . . . 446 Engine Removal . . . . . . . . . . . . . . . . 446 Follow Safety Rules. . . . . . . . . . . . . . . .447 Engine Stand . . . . . . . . . . . . . . . . . . . .447 Engine Removal Summary . . . . . . 447 Engine Parts Organization . . . . . . 447 Storage Containers. . . . . . . . . . . . . . . .448 Tags and Markings . . . . . . . . . . . . . . . .448 Engine Fasteners . . . . . . . . . . . . . . . . .448 Mating Parts. . . . . . . . . . . . . . . . . . . . .448 Shims and Thrust Washers . . . . . . . . . .449 Dividing the Engine . . . . . . . . . . . . . 449 Engine Top and Bottom Ends. . . . . . . . .449 Engine Left and Right Sides. . . . . . . . . .449 Transmission . . . . . . . . . . . . . . . . . . . .450 Holders and Pullers . . . . . . . . . . . . . 450 Engine Holders . . . . . . . . . . . . . . . . . . .450 Pullers . . . . . . . . . . . . . . . . . . . . . . . . .451 Using Heat to Aid Disassembly . . . 452 Heat Use Warnings . . . . . . . . . . . . . . . .452 Sequence of Disassembly . . . . . . . . 452 Typical Engine Disassembly Problems. . . . . . . . . 453 Cylinder Head and Cylinder Block Removal Problems . . . . . . . . . . . . . .453 Wrist Pin Removal Problems . . . . . . . . .453 Cylinder Head Disassembly Problems . . . . . . . . . . . . . . . . . . . . .453 Primary Drive Disassembly Problems . . . . . . . . . . . . . . . . . . . . .453 Flywheel Removal Problems . . . . . . . . .453 Crankcase Separation Problems . . . . . .453 Chapter 21 Two-Stroke Engine Overhaul. . . . . . . 457 Top End Service. . . . . . . . . . . . . . . . . 457 Cylinder and Piston Inspection . . 458 Cylinder Problems . . . . . . . . . . . . . . . .458 Piston Damage. . . . . . . . . . . . . . . . . . .458 Piston and Cylinder Measurement. . . . .459 Engine Decarbonizing . . . . . . . . . . 462 Parts Reconditioning and Replacement. . . . . . . . . . . . . . . . . . 462 Cylinder Boring and Honing. . . . . . . . . .463 Engine Lower End Service . . . . . . . 464 Measuring Rod Big End Bearing Clearance. . . . . . . . . . . . . . . . . . . . .464 Connecting Rod Side Play. . . . . . . . . . .465 Main Bearings . . . . . . . . . . . . . . . . . . .465 Crankshaft Wheel and Axle Condition. . .466 Crankshaft Reconditioning . . . . . . . . . .466