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2 A . 6
Air-cooled two-stroke engine
8.5 Measure the cylinder bore in the
directions shown
8.6 Cylinders and pistons are size coded
and should always match
8.10 Ring locating pins (arrowed) must be
between the ring ends
illustration).
Calculate any differences
between the
measurements taken to
determine any taper and ovality in the bore.
6 If the bore is tapered, oval, or worn
excessively, or badly scratched, scuffed or
scored, the cylinder and piston will have to be
renewed. Peugeot supply cylinders and
pistons as matching sets. The cylinder and
piston are size coded during manufacture and
it is important that new parts are matched.
The size codes are marked on the top of the
cylinder and the piston (see illustration).
7 If there is any doubt about the serviceability
of the cylinder, consult a Peugeot dealer.
8 Inspect the cylinder head bolt threads in the
crankcase (see Section 14).
Installation
9 Remove any rag from the crankcase
opening. Lay the new base gasket in place on
the crankcase making sure it is the correct
9.3a Remove the circlip
. . .
8.12 Lower the cylinder carefully over the
piston
way round
(see
illustration).
10 Check that the piston rings are correctly
positioned so that the ring locating pins in the
piston grooves are between the ring ends
(see illustration).
11 Lubricate the cylinder bore, piston and
piston rings, and the connecting rod big and
small ends, with the specified type of two-
stroke oil, then locate the cylinder over the top
of the piston (see illustration 8.2).
12 Ensure the piston enters the bore squarely
and does not get cocked sideways. Carefully
compress and feed each ring into the bore as
the cylinder is lowered, taking care that the
ring end gaps remain correctly aligned with
the pins (see illustration). Do not use force if
the cylinder appears to be stuck as the piston
and/or rings will be damaged.
13 When the piston is correctly installed in
the cylinder, check that the base gasket has
not been displaced (see illustration).
9.3b
. .
.
then push out the piston pin
8.9 Ensure the new gasket is positioned
correctly on the crankcase
8.13 Check that the cylinder base gasket
(arrowed) has not been displaced
14 Install the remaining components in the
reverse order of removal.
9 Piston
-
removal, inspection
and installation
Note: This procedure can be cam'ed out with
the engine in the frame.
Removal
1 Remove the cylinder (see Section 8).
2 Before removing the piston from the
connecting rod, stuff a clean rag into the hole
around the rod to prevent the circlips or
anything else from falling into the crankcase.
The piston top should be marked with an
arrow which faces towards the exhaust
(forwards). If this is not visible, mark the piston
accordingly so that it can be installed the
correct way round. Note that the arrow may
not be visible until the carbon deposits have
been scraped off and the piston cleaned.
3 Carefully prise the circlip out from one side
of the piston using needle-nose pliers or a
small flat-bladed screwdriver inserted into the
notch (see illustration). Check for burring
around the circlip groove and remove any with
a very fine file or penknife blade, then push
the piston pin out from the other side and
remove the piston from the connecting rod
(see illustration). Use a socket extension to
push the piston pin out if required. Remove
the other circlip and discard them both as
new ones must be used on reassembly.
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