Assembly - Husqvarna R135 Workshop Manual

NOTE!
Do not turn the cylinder, as the piston rings can easily be broken.
Tighten the 4 screws diagonally crosswise.
Cylinder and piston

Assembly

Clean the crankcase.
Assemble the piston on the connecting
rod.
NOTE!
Place a rag in the crankcase opening to prevent the circlip from falling into
the crankcase in case it should fl y out. Check that the circlips are correctly
fi tted into the grooves by turning the clips with fl at nosed pliers.
Check that the pulse channel (A) in the
cylinder is open.
Assemble the cylinder with the help of
assembly set 502 50 70-01.
502 50 70-01
Assembly
Clean the crankcase.
Fit the piston on the connecting rod
so that the arrow on the piston points
towards the exhaust port. Lubricate the
gudgeon pin's needle bearing with a few
drops of engine oil.
Direct the arrow on the top of the piston
towards the exhaust port. Press in the
gudgeon pin and fi t the circlips.
Check that the pulse channel (A) in the
cylinder is open.
Place a new cylinder base gasket on
the crankcase. Lubricate the piston and
the big-end bearing with a few drops of
engine oil.
Assemble the cylinder with the help of
the piston ring compressor in the as-
sembly set 502 50 70-01.
Lubricate the seal (A) using silicone
spray or washing-up liquid and press
it into the cylinder connections. Pay
attention to the connection for the pulse
channel.
NOTE!
Do not lubricate the rubber
connection with oil as this can
cause the rubber to swell.
Check that the "distance piece/heat
shield (B) is not cracked or shows signs
of other damage that can cause leakage
from the carburettor connection. Also
check that the impulse channel (D) is
fully open. Lubricate the connections to
the rubber seal using silicone spray or
washing-up liquid and fi t the shield.
Check that the manifold (C) for ad-
ditional air is not cracked or perforated,
which can result in leakage. Fit the
manifold.
NOTE!
Use silicone glue on the
connections for the manifold on
the heat shield.
Assemble the remaining parts in the
reverse order as set out for dismantling.
See respective sections in the manual.
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