11/11/2017 Engine Disassembly - Large Frame

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nowthatyouhavedrainedtheoilandremovedthemotorfromthe
Go scooteritstimetotearitdown.
Aenginestandandbenchvicewillmakeyoulifealoteasier
Iwillspinitaroundtoshowyouhowcoolthisenginestandisand
howmuchaccessitgivesyou
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Letsbegin
Startbyremovingtheforkedsparkplugclip

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unclipthehightensioncoilwire

removethebottomscrewfromtheflywheelcoverandcylinder
shroud

removetheboltfromthecylindershroud

removeit

pullthesparkplugandthrowitaway

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removethespacernut

removethe4nutsthatholdtheheadinplace

youshouldhavea
nut
flatwasher
lockwasher

nowyoucanremovethehead

nextthecylinder

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checkthepistonforscoring,cracks,etc..

removethecirclipsthatholdthewristpininplace

theymaylooklikethisoryoumayneedspecialcirclippliersto
removethem

usethespecialwristpinpunch

topushthewristpinout

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removethesmallneedlebearing

removethebasegasket(replaceit)

removetherestofthescrewsthatholdtheflywheelcoveron

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removetheflywheelcover

removetherubberplug
youcanpryitoutwithascrewdriver

thisisanaccessholegotpointsadjustment

useaflywheelholdertobeabletoloosentheflywheelnut

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thismethodworksifyoudonothaveanimpact
striketheendoftheratchetwithahammeritworksquitewell

behindthenutthereisastarwasher

usetheflywheelpuller
someVespascootershaveacirclipthatactsasthepuller
backtheboltallthewayout

insertthepullerandtightenitalltheway

holdthepullerandtightenthebolt

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theflywheelwillcomerightoff

inspectthewoodruffkeyfordamage
alsobecarefulitdoesn'tfallout(itsprettysmall)

iftheflywheelwasevertooloosethiswillbedamagedandwillneed
tobereplaced

disconnectthecoilwire

removethejunctionbox
itcanbepriedupwithascrewdriver

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itisagoodideatomarkthepositionofthestatorbeforeyouremove
it.
3screwsholditinplaceremoveallofthem

youshouldhaveaflatandwavywasher

pullthestatoroff

feedthewiresdownthroughthecase
inspectthemforbrittlewiresorifthecopperisgreenreplacethem

wearegettingthere

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removethecarbboxtopscrews

thereare2ofthem

Thisiswhattheylooklike

removethecarbboxtop

removetherubbergasketfromthetopofthebox

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unscrewtheairfilterscrews

theyaredifferent
S14743thisisthebackone
S14436thisisthefrontone

removetheaircleaner

removethecarbbolts
11mmsocket

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thereare2ofthemandtheyhaveaflatwasherandlockwasher

see

removethecarburetor
Iusuallyleavetheboltsandwashersinthecarbbodyitslessstuff
tolose

removethegasketwithapicktoolorjustripitbecauseyouwill
replaceit

removethescrewthatisunderthegasket
thisholdsthecarbboxon

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thecarbboxwillnowliftoff

removethegasketundertheboxandreplaceit

spinthemotortogetaccesstotherearwheel

removethecap
youcanpryitoffwithascrewdriver

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pullthecotterpinoutwithpliers
bendtheearsstraight

pullitout

usea22mmsockettoremovethecastlenut

thereisawasherbehindthenut

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nowyoucanremovethehunitshouldjustsliderightoff

removetheclipsonthebrakeshoepost
apairofneedlenosepliersworkwell

afteryouremovebothoftheclips
pushthebrakeleverasifyouweresteppingonthepedal

thiswillallowyoutostickapryparorscrewdriverunderthebrake
shoebetweenthepinandtheshoe

nowgetanotherprybarandplylikeso
thebrakeshoewillcomerightoff

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thisiswhatyoushouldhave

removethe3screwsthatholdthebackplate

Removethebackplate

Thereare4rubberORingsbehindit
Removethemwithasmallpicktool

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Thisiswhatyoushouldhave

NextpryouttheRearHubSeal

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Removethe3screwsthatholdtheClutchCovertheyare6mmand
youusea10mmsocket

Youshouldhave16mmLockand16mmFlatwasher

Removethecover

removeandreplacetheOringoffthecover

withasmallpicktoolremovethepressureplate
pulldownontheretainingclip

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thenpulloutlikethis

Youwillnoticethetabwasherhasoneofthetabsbentintothe
castlenutbenditoutsoyoucanremovethenut.

replaceoneoftheclutchcoverbolts

inserttheclutchholdingtool(likesoyouwilldoitoppositetoinstall
thenut)

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Usetheclutchnutremovaltooltoremovethenut

ittakesa17mmsocketorwrench

afteryouremovethenutuse2prybarsor2largescrewdriversto
helpprytheclutchoff
itshouldnottaketoomuchforce(don'tdamagethecase)

youcanremoveittherestofthewaybyhand

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pulloutthewasherandreplaceit

removethespacerfrombehindtheclutch
andremovethewoodruffkey

thisiswhatyoushouldhave

spinthemotoraroundtothefrontside
removethecoilbracketusingaphilipssrewdriverandan8mm
wrench
thereare2ofthem

removethecoil

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youshouldn'treplaceitifitisworkingbutitsnotabadideatocarry
anextraone(generallytheyworkortheydon't)

nowmoveontotheselectorbox
removethe27mmnutswitha11mmsocket

youshouldhave2nuts,2flatwashers,and2splitwashers

onceyouhavethenutsremovedputascrewdriverinthepinchbolt
area
spinitdownasifyouwerechanginggears

itwillcomeofflikeso
youcanpullitofftherestofthewaybyhand

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removeandreplacethegasket(itcomesinyourgasketset)

nowyoucanbeginremovingthecasebolts
thereare8boltsoneofthemislongerthantheothers(itstheone
thatthecableholderisattachedto)
youwillprobablynotbeabletogetthelongeroneout.youcanjust
removethenutandwashersandleaveitinthecasehalf
behindwherethestatorwasthereare4studstheyouwillhaveto
removethenutsfromaswell

thebottomboltisbackwardsandthenutisontheotherside

afteryouremoveall12nutsandwashersyoucansplitthecase
halfs

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thistabcanbeusedtoforcethemapartifyoudonthavetheCase
SeperatorTool

useapunchandtapthebottomapart(gently)

onceitseperatedalittleusetherubbermalletandtapthetop
repeattheprocedureonthebottomthentop,workingthehalfs
apartalittleatatime.
thekickstartgearandspringwillprobablefallout,justmakesure
youfindthem.

ifyouhavetheCaseSeperatorToolitwillbeALOTeasierandthere
islesschanceyouwillscrewupthecase

startbybackingoutthelargeboltonthepulleralltheway

usingthethumbscrewsprovidedthreadthemintotheholesthat
holdtehflywheelcoverinplace

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thereare3ofthem
thighenallofthemastightasyoucangetthembyhand

nowslowlytightenthebolt

thecasewillbegintoseperate
afterafewmoreturnsyouwillbeabletoseperateitbyhand

ifthekickstartgearspringdidn'tfalloutremoveit

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removethecasegasketanddon'teventhinkofreusingit

agoodwaytoremovetherearaxleistothreadthecastlenuton
backwards

tapitwithahammer

onceyouknockitfreeyoucanremoveitbyhand

spinthemotorandbendtheTabWashersoyoucantakethenutoff

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removethenut

youcnabuyaKittoreplaceeverything(sinceyouarebendingthe
tabwasheritsagoodideatoreplaceit)

toremovetheCushDrivejustpushtheendyoujusttookthenutoff.
withyourotherhandholdaragtocatchtheNeedleBearings

dontlosetheseguys

simplypulltheshaftout

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andpulltheCushDriveout
HEREaresomeinstructionsonhowtoRebuildit

Iusallydon'tremovetheOilSlingunlessImgonnasandblastthe
casebutifyoudoDON'TFORGETTOPUTITBACKIT.
Whenyouhavetomotorputbacktogetherandyouseeitinyou
partsbowlorwhateveryouusetostoreyourpartsyouwillbe
pissed

toremovethecrankyoucandothesamemethodasremovingthe
rearaxlebyputtingtheclutchnutonbackwards

anotherwayistouseapointedpuch

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setitintotherecessinthecrankandtapatapatapa

youcanfinishitoffwiththerubbermallet

poptheClutchSideSealoutwithascrewdriverandREPLACEIT

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removethelargeCirClipthatholdstheMainBearing

toremovethebeaingyouwillneedtheBearingTool

inserttheshaftintothecanteroftheBearingfromtheClutchside

insertthepinintoothersideofthetool

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putthecuppieceonandthredthenuton

justmakeitsnug

inserttheboltintheshafttotightenitonthebearing

nowtightenthelargenutwhileholdingtheshatfromturning

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thebearingwillcomerightout
Youcanalsotapitoutwithalargesocket(butbecareful)

nowremovetheRearHubBearing
startbyremovingthecirclip

fromtheinsidepunchitoutyoucanusealongsocketextensionor
alongpunch

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itwillcomerightout

nextremovetheBrakeArmandCam
theonlyreasontoremovethisistoreplacethe2rubberoringson
theCam

letthetensionoffthearmbyremovingthespringfromit

pulloutthecotterpin

SlideouttheCam

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herearetheORings(theyareintheGasketSet)

nowremovetheKickStartQuadrent

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justtapitwiththerubbermallet
catchthemontheotherside

theQuadrentandSpringwillcomeoutatthesametime
thereisanOringinsidethecaseyoushouldreplace(itcanbea
causeofanoilleak)

removeandthrowawaytheKickStartBuffers

samegoesfortheFlyWheelSideSeal

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usetheBearingExtractortoremovetheFlyWheelSideBearing

usethesameprocedureasabove

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removetheOutputShaftBearing

thebestwayIcameupwithwastotapitoutwithasmallaluminum
punch
youwillhavetoreplaceififyoudoitthisway

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ifyouarereusingtheCrankshaftyouwillhavetoremovethehalfof
theFlySideBearingthatstayontheCrank

youcancutitoff(notreccomended)
orusethisPuller

thislipgoesundertheBearing

likeso

inserttheCrankWedge(orawoodenwedge)

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insertthepullerwiththecollarallthewayup

gentlytapitdownuntilitbottomsout

holdthetoolwithawrenchandtwistclockwisebyhand

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