Repair Instructions
The cylinder and the piston are two of the components exposed to most strain in the engine. They must
withstand, for example, high speeds, large temperature swings and high pressure. Moreover, they must
be resistant to wear. Despite these tough working conditions, major piston and cylinder failure is relatively
uncommon. The reasons for this include new coatings in the cylinder bore, new types of oil and grease
and refined manufacturing techniques.
When servicing these components, cleanliness is of the utmost importance. It is therefore recommended
that the cylinder and the area around it be thoroughly cleaned before being dismantled from the
crankcase.
7.18 Dismantling the cylinder and piston
Dismantle the following components to make the
cylinder accessible:
•
The starter and air filter.
•
The muffler with heat guard plate.
•
The spark plug.
•
The carburettor.
•
The clutch cover and shaft.
1
Remove the four screws holding the cylinder. See
figure 60.
2
Carefully remove the cylinder straight up by rocking
it backwards. Make sure that no dirt enters the
crankcase.
Use a rag to cover the crankcase opening under
the piston.
3
Using long-nose pliers remove the gudgeon pin
circlips. See figure 61.
Keep your thumb over the circlip to prevent it from
flying out.
44
- English
Cylinder and piston
Fig 60
Fig 61