Engine removal

Engine removal

Watch the walkthrough

Watch on YouTube ↗ · JETSURF Service Tutorials #5. Timestamps in the steps below follow the video's on-screen counter (0:00–2:50).

This is the big teardown — you'll do it for a rebuild, a mount replacement, or major exhaust work. Work in a ventilated area away from any ignition source, and label connectors as you go. Reinstalling the engine and exhaust is covered separately in Service Tutorial #7.

Tools & supplies

• Allen key no. 3
• Allen key no. 4
• Bent-nose pliers (for the exhaust springs)
• 10 mm ratcheting wrench
• Clean rags, nitrile gloves
• Fuel-safe container if you're draining the tank

Removal

1. 0:00 — Disconnect the CPS fitting on the fuel line, then release the fuel pump connector on the left side of the tank (relative to the direction of travel). See Fuel tank removal & installation for detail.
2. 0:32 — Loosen the Velcro strap securing the tank and carefully lift the tank out.
3. 0:43 — Disconnect the vent line connector by pressing the locking tab toward the tank.
4. 0:52 — Using Allen key no. 3, remove the bolts from the freewheel cover.
5. 0:58 — Using Allen key no. 4, remove the throttle cable and detach it.
6. 1:29 — Using Allen key no. 3, remove the ground wire at the starter and disconnect the connectors.
7. 2:04 — Disconnect the hoses and remove the spark plug.
8. 2:23 — Using bent-nose pliers, remove the two exhaust springs.
9. 2:37 — Using a 10 mm ratcheting wrench, loosen the four nuts on the engine mounting rails.
10. 2:50 — Lift the engine out.