Repair 7

Turn off the bike if it is not already turned off. If you just turned it off, wait 2 hours before disassembling it.

Read over the troubleshooting section of the manual and check out which parts may have problems. Also, look over the assembly diagram to familiarize yourself with the machine.

Unscrew the screws on the case with a screwdriver from the toolkit. Lift away the case and lay it on the ground. Pull the wire away from the spark plug. Locate the motor towards the front end of the bike. Unbolt the bolts on the motor and caully lift the motor towards the front of the bike and then away from the bike. Set it gently on the floor or a worktable.

Remove the spark plug by unscrewing and then pulling it away. Remove the bolts holding the carburetor in place. Lift the carburetor away from the rest of the motor. Remove the cylinders, pistons, and bearings by pulling them away from the motor.

Check all the parts for consistency with the manual. Check for broken, rusted, or irregularly shaped parts. Also, check for missing parts. Order any parts that need replacement.

Install the bearings, pistons, and cylinder by pushing them back into place. Match the holes on the carburetor with the poles on the motor and gently lay the carburetor down on the motor. Bolt the carburetor in place with a socket wrench from the toolkit. Install the spark plug by screwing it back into its socket with your hand.

Pick the motor up and match it with the poles sticking out from the frame around 2 feet behind the wheel. Stick the motor in and bolt it in place. Stick the wire socket back on to the spark plug by pushing it firmly. Screw the case back on the bike.

Start the bike, and allow it to idle for a few minutes until the engine is up to temperature. Do not lean the bike on its side stand, as this will cause the oil to collect in one side of the crank case. Use the center stand, or sit on the bike if it does not have one. Turn off the bike. An important characteristic of the running-in process is gradually increasing the periods of time for which the bike is running. Once it has cooled enough to touch, start it again.

Ride the machine for a short 5- to 10-minute run, keeping the throttle below 50 percent, and ensuring that all other components; brakes, shifting, steering, etc.; are all functioning OK. Return home, and allow the bike to cool down completely again. This will generally take at least 30 minutes, but the longer the better. You should be able to touch the pipes and radiator without feeling any residual heat.

Start the bike again, and head out for another ride. This time, the throttle can be pushed to 60 percent. After 10 to 15 minutes, return home again, and allow the bike to cool once more. Repeat this process another four times, increasing your throttle limit by 10 percent on each run, every time allowing the bike to cool down completely every time.

Ensure all fasteners are still fully tightened. Your two-stroke engine should now be ticking over smoothly. Allowing the engine to properly cool after each run helps small quantities of oil to act as a seal at the points where different components meet, reducing the possibility of damaging the pistons.