

Switch machine off and disconnect negative battery terminal.

Take photo or mark wire locations. Remove all wire, 10mm spanner needed.

Remove these two 10mm nuts

Remove this 8mm bolt.

Remove hose from rocker cover. Hose is just pushed in no tools required.

Remove air box / intake assembly.

Remove these two 10mm nuts.

Remove these two 10mm bolts.

Remove flywheel cover. Then remove ignition switch assembly, x3 10mm bolts.

If you have feeler gauges, Use feeler gauges to measure coil spacing from flywheel. If not grab a piece of paper and fold it until it fits snug between coil and the flywheel and put aside for reassembly. Remove the two 10mm bolts holding on coil.

Remove flywheel nut, 22mm nut. recommend using an impact gun (powertool). If using hand tools you will need to find a way to lock flywheel in place that will not cause damage to any other engine components e.g. engine casings.

Remove these three components keep note of order they come off and orientation.

Use 3 point pulley puller to remove fly wheel. Attach pulley removal tool using x3 (M6x1.25 thread pitch) bolts. Bolts lengths will depend on tool used.

Tighten main bolt of pulley removal tool on the crankshaft pulling the flywheel off. If using a hydraulic removal tool, DO NOT HIT WITH HAMMER as it will brake the tool.
Remove Flywheel.

Keep track of key steel.

Now you can access the two 10mm bolts securing the starter the the engine. Replace faulty starter motor.

Refit key steel.

Refit flywheel.

Refit these three component in the order and orientation they were removed.

Tighten crankshaft nut to 51.5Nm

Refit ignition assembly with three 10mm bolts.

Refit coil using 10mm bolts leave loose. Fit piece of paper that you put aside earlier between the coil and the flywheel. Lightly press on coil applying the light pressure towards the flywheel and tighten 10mm bolts. Remove paper once bolts are tightened.

Refit flywheel cover / pull start assembly making sure these two earth wire are behind the cover. If not, remove cover and put wire on first then refit cover.

Tighten the two 10mm nuts and two 10mm bolts holding cover on. four faster in total holding cover assembly on.

Refit air filter box / intake to engine.

Insert hose back into rocker cover while fitting airbox / intake assembly.

Loosely fit these two 10mm nuts.

Loosely fit this 8mm bolt. Once all three fasteners are on tighten them all.

Before starting engine with starter motor use pull start the turn over the engine a couple of times. You are not trying to start engine in this step you are just checking to make sure there are no rubbing/ scrapping noises.

Refit wire the starter motor using images/ notes you kept while disassembly.

Refit negative battery terminal.

Switch on machine a test new starter motor.