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Photo 8 of 59 Finish removing the cylinder jug and set aside. Don't be of concern if the gasket tears up at this time. When putting back together we w

Photo 8 of 59 Finish removing the cylinder jug and set aside. Don't be of concern if the gasket tears up at this time. When putting back together we w

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58 Split case

58 Split case

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Photo 5 of 59 Remove these two 6mm bolts. These are 2 of 8 that hold the case together.

Photo 5 of 59 Remove these two 6mm bolts. These are 2 of 8 that hold the case together.

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Photo 1 of 59 Remove engine from bicycle and place on an uncluttered, clean work area. Easier to keep track of both parts and tools.

Photo 1 of 59 Remove engine from bicycle and place on an uncluttered, clean work area. Easier to keep track of both parts and tools.

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54 Remove clutch drive gear nut

54 Remove clutch drive gear nut

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Photo 7 of 59 Here you can see the set (2) rings on the piston.

Photo 7 of 59 Here you can see the set (2) rings on the piston.

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09 Pin keeper

09 Pin keeper

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Photo 6 of 59 After the head is removed pull cylinder jug up to expose the piston.

Photo 6 of 59 After the head is removed pull cylinder jug up to expose the piston.

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56 Pry up gear

56 Pry up gear

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26 Removing drive gear

26 Removing drive gear

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Photo 3 of 59 Remove the (4) cylinder/head nuts, washers, and lock washers. If not already done, I'd replace the OEM studs and acorn (not to be

Photo 3 of 59 Remove the (4) cylinder/head nuts, washers, and lock washers. If not already done, I'd replace the OEM studs and acorn (not to be

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10 Remove wirst pin keeper

10 Remove wirst pin keeper

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Photo 2 of 59 If you haven't already done so, remove the spark plug. You will notice that the pictures are posted in the wrong sequence as the engine

Photo 2 of 59 If you haven't already done so, remove the spark plug. You will notice that the pictures are posted in the wrong sequence as the engine

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28 Drive gear puller

28 Drive gear puller

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43 Notice washer and spring

43 Notice washer and spring

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Photo 4 of 59 Remove head and check for a true flat surface. I mill the head as little as possible (couple of thousands) with 200-320 grit DA self sti

Photo 4 of 59 Remove head and check for a true flat surface. I mill the head as little as possible (couple of thousands) with 200-320 grit DA self sti

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20 Remove coil cover

20 Remove coil cover

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23 Coil removed Remove magnet key

23 Coil removed Remove magnet key

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57 Remove 3 case screws 6,7 and 8 of 8

57 Remove 3 case screws 6,7 and 8 of 8

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14 Remove piston

14 Remove piston

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25 Removing drive gear

25 Removing drive gear

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11 Side with keeper

11 Side with keeper

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18 Clutch pin and ball

18 Clutch pin and ball

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46 Use supplied plug wrench or 19mm socket

46 Use supplied plug wrench or 19mm socket

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