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TROUBLESHOOTING & REPAIR
F-61 F-61
RANGER 8
ENGINE/ROTOR REMOVAL
AND REPLACEMENT (continued)
ENGINE AND ROTOR
REMOVAL PROCEDURE
1. Refer to Figure F.14 for component loca-
tions.
2. Remove the engine spark plug wires.
3. With the 5/16” nut driver, remove the 6
sheet metal screws from the case top.
4. Remove the rubber gasket (cover seal)
from the lift bail.
5. Remove the fuel cap. The rubber gasket
for the fill tube will come off with the case
top.
6. Remove the case top, the reinstall the fuel
cap.
7. WIth the 5/16” nut driver, remove the 5
screws holding the right case side and the
5 screws holding the left case side.
8. Remove the case sides by lifting up and
out.
9. WIth the 3/8” wrench, remove the battery
cover.
10. Disconnect the negative battery cable,
then the positive battery cable. BE SURE
TO DISCONNECT THE NEGATIVE BAT-
TERY CABLE FIRST. Remove the battery
and set it aside.
11. With the diagonal cutters, cut the cable
ties around the leads from the starter sole-
noid and disconnect the leads. Remove
lead 209A from the harness bundle.
12. Disconnect the large black plug in front of
the fuel tank spout.
13. With the 3/8” wrench, remove the cowling
covers at the rear on the stator, both sides
of the machine.
14. WIth the 3/8” wrench, remove the two
screws that hold the vertical fan baffle in
place. Slide the baffle forward toward the
rectifier bridge heat sink assembly.
15. Hold the rotor shaft with locking pliers and
unscrew the blower fan. Turn the fan
counterclockwise. You do not need to
remove the fan from the machine, but be
sure it is completely unscrewed from the
rotor shaft.
15. With the 1/4” nut driver, disconnect the
engine choke cable from the engine. Mark
the location of the retainer for reassembly.
The other end can remain connected.
16. Disconnect the idle linkage by unsnapping
the plastic clip at the engine end of the
idler rod. Snap the clip back onto the rod
to avoid losing it; remove the rod for
reassembly.
17. Disconnect the fuel line from the fuel tank.
Plug the hose and also plug the connec-
tion at the fuel tank to prevent the escape
of gasoline fumes.
18. Cut the cable ties and remove leads 224C
and 210 from the oil pressure switch.
19. With the 9/16” wrenches, remove the
ground lead from the right engine foot
mounting bolt.
20. With the 7/16” wrench, remove the brush
holder bracket and leads #219 & 200A
from the stator frame.
20A. (For Onan Engine only) with a 1/2”
wrench remove the muffler support bolt.
21. Support the engine with a chain hoist. Lift
bails are provided on the top of the engine
for this purpose.
22. With the 9/16” wrench, remove the right
and left engine foot mounting bolts.
23. With the 9/16” wrench, remove the four
bolts that hold the stator to the engine.
There is one lock washer per bolt.
24. With the chain hoist, unweight the engine
gently. Use a pry bar to carefully pry
between the engine and the stator frame in
order to unseat the bearing on the end of
the rotor shaft. Separate the engine and
rotor from the stator frame, supporting the
rotor by hand to prevent damage to the
rotor core.
25. Move the engine and rotor assembly to a
bench. The engine is off balance with the
rotor still attached; therefore, support the
end of the rotor with a wooden two-by-
four before unhooking the chain hoist.