Here I have already taken all the topside stuff off; dog house oil cooler,
fan shroud, alternator, fuel pump,oil filler, dipstick, and distributer. Taking all this
off makes it easier to drop the engine out of the bottom because you won't have to raise
the rear end up as high. Don't forget to drain the oil.
After I removed the engine from the transaxle the engine dropped right out.
After I dropped the engine out it was time to tear the engine apart. First, I took off the heater
boxes, then came the fly wheel. The flywheel nut is 36mm and torqued down to 300 ftlbs. so when
using an impact wrench it will take a few minutes of impacting for it to finally come loose. After
that it was time to put it on the enginestand. Once on the enginestand everything comes right off;
heads, cylinders, pushrods and tubes, and the oil pump. The next thing was to split the case. After
you loosen all the nuts from the studs take a hammer and tap around the perimeter of the case and slowly
the case will split. Once it is split the crank, cam and distributor gear come right out.
Once you remove everything from the case clean the case as well as you can. Once you are done take the
case to get inspected to be sure you can reuse it. I took mine to Donsco and the machinist, Ken, checked it out.
Unfortunately, I couldn't reuse my case. It had four cracks, three in the cylinders and one where the oil cooler
attaches to the case. My case went to the graveyard. Ken hooked me up with another case that had already been
bored for 94mm pistons, align bored, and tapped for full flow for $250. As of May 9, 2001 I am waiting for my
heads, counterweighted crank, Engle 120 cam, and Kennedy clutch kit to come in from Kymco Motorsports.