Piston Assembly - Ezgo 1600xd Repair Manual

6.3.4 PISTON ASSEMBLY

1. Remove the piston rings (1) using a removal tool.
2. Take out the piston pin springs (2) using pliers and
remove the piston pin (3).
3. Remove the connecting rod (4) and bushing.
4. Install in the reverse order of removal.
5. After heating the piston to approx. 80~100°C, lubri-
cate and assemble it with the connecting rod.
REMARK
• Piston ring removal tool
6. Install the top ring with its manufacturer mark (Y) to
the top of the piston.
3
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ENGINE - DISASSEMBLY, SERVICE AND ASSEMBLY
S76W2O7A
UUVW2F8A
S76W2O8A
7. The cutout of expander (A) of the oil ring should
face the opposite side of the oil ring end gap (B),
and the end gaps of the second ring and oil ring
should be 120° away from the top ring end gap.
When doing so, place the top ring end gap on the
opposite side of the combustion chamber.
Oil groove
(Undercut)
8. Assemble the second ring(1) undercut to be facing
down.
S76W2O9A
T46W2C5B
SUUV-W00 Apr. 2011