How to: Remove Oil Injection - Off-Road Forums & Discussion Groups
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post #1 of (permalink) Old 02-26-2003, 07:57 AM
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How to: Remove Oil Injection

After removing the oil injection:

Premix 32:1 or 36:1
Oil - Cold Climates: Belray H1R synthetic two stroke oil
Oil - Warm Climates: Maxima 927 synthetic two stroke oil

Here's the procedure to remove the oil injection courtesy of Raptor720 .....

1. Turn your gas off (non Kasea models only)
2. Stand the quad up on it's tail.
3. Remove any floor boards or plastic in your way (some non Kasea models).
4. Remove the fan cover.
5. Remove the flywheel using a standard puller (Honda XL650)
6. Remove the two screws holding the stator in place (you don't need to un-plug it just pull the rubber gromet toward the stator to give more room.
7. Remove the gasket that was behind the stator.
8. Remove the clip that holds the white plastic gear in place and also remove the gear drive pin.
9. Reassemble in reverse order.
10. Replace the throttle cable with a single cable (if you desire).
11. Plug the oil inlet by soldering up the hole in the carb or with a vacuum plug.
12. Mix Maxima 927 at 32:1 (note, because you are now mixing oil in the gas, you may need to jet up to prevent a lean burn condition)
13. Have fun

I used the BelRay H1R oil because it is cold here in NJ. The Maxima 927 oil will seperate if it is cold.

Tony P.
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post #2 of (permalink) Old 02-26-2003, 01:43 PM
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Re: How to: Remove Oil Injection

Remember to be careful with the stator it is easy to damage.

There is also one other way of removing the oil injection if you do not want to buy a puller.

1. turn gas off
2. stand quad on tail
3. remove fan and cylinder cover
4. Remave spark plug
5. Remave cylinder head
6. Remove cylinder (it may be nessary to remove one or more studs to get the cylinder out)
7. remove oil injection pump
8. remove drive gear from oil injection pump
9. remove cable and replace with single throttle cable
10. replace oil injection pump minus drive gear
11. inspect cylinder and piston for wear
12. reinstall cylinder, head, and covers in reverse order
13. solder up the injection inlet on carb. Do not use vacuum caps as they might fall off an cause a lean condition damaging the engine
14. Fill tank with your favorite premix at 32:1
15. check plug to make shure jetting is correct
16. have fun
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