Scotty's Dirt Bike Spares

Remove seat, tank/shrouds, expansion chamber and chamber mount springs.

Drain coolant from the 4mm allen head bolt on waterpump cover with radiator cap removed.

 Disconnect the radiator hoses from the water pump, return and both from the top of the cylinder head.

Remove both radiator louvers.

Remove lower radiator mounts bolts from the bottom of thr radiator and loosen the top mount.

Push Radiators forward and remove cylinder head stay bolt.

Loosen top stay bolt enough so they swing out of the way.

Careful hanging brackets don’t scratch your front guard.

Release power valve drain tube on R/H side.

Release power valve drain tube on L/H side.

Remove power valve cover plates from both sides of the cylinder.

Remove 8mm nut from power valve actuating lever spigot. Don’t over tighten this during assembly. The lever should move freely, held back only by the power valve governor spring.  

Pull actuating arm from spigot.

Lossen and remove all 4 cylinder nuts evenly. You might have to modifier some 13mm ring spanners so they have clearance on the front cylinder nuts. (leave cylinder head on)

Carefully remove cylinder.

Remove base gasket with scraper or blade. Take care not to damage case surfaces or drop bits of gasket into crankcases.

Uses a non Harding case sealant under the base gasket were the cases join. Make sure studs are tight.

Reverse for assembly. Torque cylinder base nuts to 25 Nm (20ftp) in diagonal pairs. The cylinder head nuts also tighten to 25Nm in diagonal pairs, if removed.