7.9.3
Crankshaft
Always check and, if necessary,
repair the fuel system, carburetor,
air filter and ignition system before
looking for faults on the engine. See
also "Troubleshooting", b 4.
– Remove the lower half of the
crankcase, b 7.9.2
3
: Lift the crankshaft (1) and pull the
piston out of the cylinder at the
same time.
: Pull off the oil seals (2 and 3).
– Inspect cylinder running face for
signs of damage and serious
scores. Install new cylinder with
piston if necessary, b 7.9.7
40
3
1
: Examine ball bearings (1),
connecting rod (2) and gear (3).
– If one of these parts is damaged,
install a new crankshaft
assembly.
Install in the reverse sequence.
2
1
– Coat piston and piston rings with
oil.
– Fit piston rings so that their gaps
are offset 120 degrees.
– Use new oil seals.
– Lubricate sealing lips of oil seals
with grease, b 13.
– Apply thin coating of sealant to
outer diameter of oil seals, b 13.
– Carefully fit piston in the cylinder.
– Install the crankshaft with new oil
seals in the cylinder.
– Fit lower half of crankcase,
b 7.9.2
– Align the flywheel and fit the cam
gear, b 7.5
Install all other parts in the reverse
sequence.
7.9.4
Piston
2
1
– Remove the crankshaft, b 7.9
Always wear safety glasses when
working with spring washers and
snap rings.
: Use a suitable tool to ease the
hookless snap ring out of the
groove.
1
: Use the assembly drift (2)
1110 893 4700 to push the piston
pin (1) out of the piston.
BR 500, BR 550, BR 600
2