user manual

ENGINE TOP END 5-29
Cylinder, Pistons
Cylinder Removal
•
Remove:
Cylinder Head (see Cylinder Head Removal)
Water Hose [A]
•
Remove the cylinder [B].
Cylinder Installation
NOTE
○
If a new cylinder is used, use new piston ring.
•
Install the pins [A] and new cylinder gasket [B].
•
Apply engine oil t o the cylinder bore.
•
The piston ring openings must be positioned as shown in
the figure. The openings of the oil ring steel rails must be
about 30 – 40° of angle from the opening of the top ring.
[A] Top Ring
[B] Second Ring
[C] Oil Ring Steel Rails
[D] Oil Ring Expander
[E] Hollow
•
Position the crankshaft at #2, #3 piston TDC.
•
Prepare t wo auxiliary head bolts with their head cut.
○
Install the two cylinder head bolts [A] diagonally in the
crankcase.
•
Install the cylinder block [B].
Pistons [C]
○
First insert the #2, #3 pistons, and then rotate the crank-
shaft at 90° angle.
○
Insert the piston rings with your thumbs or the thin ( –)
screwdriver.
Piston Removal
•
Remove the cylinder (see Cylinder Removal).
•
Place a clean cloth under the pistons and remove the pis-
ton pin snap ring [A] from the outside of each piston.