Service Manual

5-12 ENGINE TOP END
Cylinder, Piston
Piston Removal
•
Split the crankcase (see Camshaft/Crankshaft chapter).
•
Remove the camshaft (see Camshaft/Crankshaft chapter).
•
Turn the crankshaft to expose the connecting rod cap bolts [A].
•
Remove the bolts and take off the connecting rod caps [B].
NOTE

Note the position of the connecting rod caps for reinstalling the
caps.
•
Push the connecting rod end into the cylinder, and pull the piston and
connecting rod out of the cylinder.
CAUTION
Note the location of the arrow match mark [A] on the piston
head in relation to K Mark [B] on the connecting rod.
No.1 cyl. K Mark on the connecting rod is face to face with
No.2 cyl. K Mark on the connecting rod.
Keep parts together as a set.
•
Remove one of the piston pin snap rings [A] with needle nose pliers
[B].
•
Remove the piston by pushing the piston pin [A] out the side from
which the snap ring was removed.
•
Remove the top and second rings with piston ring pliers.
Special Tool - Piston Ring Pliers: 57001–115
•
If the special tool is not available, carefully spread the ring opening
with your thumbs and then push up on the opposite side of the ring
[A] to remove it.
•
Remove the 3-piece oil ring with your thumbs in the same manner.