Product Dissection Plan for Group 26

Product Dissection Plan

The following is a step-by-step procedure on how to disassemble the product. All of the procedures and tools necessary are listed in the table, accompanied by images of the said step where needed.

The difficulty of each step is labeled using a scale of 1 to 5. A task that is given a difficulty level of 1 is one that is easy and/or simple to perform, such as using a socket wrench to remove a bolt from the outside of of the engine. Conversely, a step that is given a 5 is the most difficult to perform, generally being more complex procedures with more limited amounts of space to perform them in. This product is intended to be taken apart easily for someone who is familiar with tools and engines. Each step is relatively easy; the only difficult part consists of knowing what tool to use and when you need to use it. For example, removing the flywheel is a little tricky when you first attempt to disassemble the product. Once the flywheel is hit a few times with a rubber mallet however, it loosens up and easily comes apart.

Product Dissection

Step #	Process	Tools Necessary	Difficulty	Image
1	Disconnect two bolts on the gas tank.	10 mm socket wrench	1
2	Remove the remaining bolt connecting the gas tank.	8mm socket wrench	1
3	Remove the hose by squeezing the pressure clamp.	None (pliers are optional)	2
4	Disconnect the electrical wiring that is connected to the spark plug, sensor in the engine, and the power switch.	None	1
5	Remove the fly wheel shield by disconnecting the four bolts holding it onto the engine.	8mm socket wrench	1
6	Disconnect the springs that are attached to the carburetor.	None	1
7	Remove the two nuts holding the exhaust to the engine.	13mm socket wrench	1
8	Slide the exhaust and the gasket off the studded bolts.	None	1
9	Remove the two screws holding the air cleaner, the carburetor, and the gaskets to the intake manifold.	10mm socket wrench	1
10	Slide the air cleaner, the carburetor, and the gaskets off of the studded bolts.	None	1
11	Remove the two bolts holding the heat shield to the side of the engine.	8mm socket wrench	1
12	Remove the four bolts holding the valve cover to the top of the engine.	8mm socket wrench	1
13	Take off the valve cover and the gasket.	None	1
14	Remove the four bolts holding the head to the engine (There are two bolts located inside the head and two bolts located outside of the head).	12mm socket wrench	1
15	Remove the head from the engine.	None	1
16	Remove the rocker arm.	10mm socket wrench	1
17	One end of the rocker arm is connected to the rod and the other end is resting on the valve spring.	None	1
18	Remove the valve springs by pushing down on them and turning them to detach them from the valve.	None	2
19	Remove the valves and the rods from the head.	None	3
20	Remove the six bolts holding the engine cover in place.	10mm socket wrench	2
21	Take off the engine cover and its gasket.	None	1
22	If oil is located inside of the engine, drain it out into a pan and dispose of it properly.	Oil Dispenser and Funnel	1
23	Remove the cam shaft. It should easily slide out of the engine.	None	1
24	Directly above the camshaft are two lifters that the rods were connected to. Remove those lifters from the engine.	None	2
25	Attached to the crankshaft is the piston. There are two bolts holding the piston to the crank. Remove these bolts and slide the piston out of the top of the engine.	10mm socket wrench	2
26	Remove the nut holding the flywheel to the crankshaft. This nut is on the outside of the engine.	22mm socket wrench	1
27	Remove the plastic cover and the metal guard from the flywheel.	None	1
28	If necessary, after the nut, plastic cover, and the guard are removed, take a rubber mallet and hit the fly wheel to loosen it up.	Rubber mallet	2
29	Once it is loose, remove the flywheel and then crank shaft.	None	1
30	Engine is now disassembled	N/A	N/A

Downloadable PDF version of this chart

Tools Required

The tools necessary are a basic metric socket set (only the 8mm, 10mm, 12mm, 13mm, and 22mm sockets are needed), a rubber mallet, and open-end wrenches. A pair of pliers and a funnel are optional tools.

Types of Fasteners Used

The fasteners that are used in this product are bolts, nuts, wing nuts, cotter pins, and clamps. Each fastener has a different purpose and function. Bolts and nuts are used to keep things together extremely tightly. Cotter pins are used to keep something from falling out but still able to freely rotate. Clamps are used for hoses to keep them from leaking and coming apart.