3-22
CYLINDER AND PISTON
REMOVAL/DISASSEMBLY
1. Strip motorcycle as described under DISASSEMBLING
ENGINE FOR CYLINDER HEAD REPAIR on page 3-8.
2. Remove cylinder head as described under CYLINDER
HEAD, REMOVAL on page 3-11.
3. Clean crankcase around base of cylinder to prevent dirt and
debris from entering crankcase while removing cylinder.
4. See Figure 3-27. Turn engine over until one piston (3) is
at bottom of its stroke.
5. Carefully raise cylinder just enough to permit placing
clean towel under piston to prevent any foreign matter
from falling into crankcase.
NOTE
If cylinder does not come loose, tap lightly with plastic ham-
mer. Never try to pry cylinder up.
6. Carefully lift cylinder over piston and studs. Do not allow
piston to fall against cylinder studs. Discard cylinder base
gasket (5).
1
CAUTION
With cylinder removed, be careful not to bend the studs.
The slightest bend could cause a stress riser and lead to
stud failure.
7. Install a 6 in. (150 mm) length of 1/2 in. (12.7 mm) ID
plastic or rubber hose over each stud. This will protect
the studs and the pistons.
1
WARNING
The next step covers removing the piston pin retaining
rings. These rings are highly compressed in the ring
groove and may “fly out” with considerable force when
pried out of the groove. Safety glasses or goggles must
be worn while removing or installing retaining rings or
personal injury may occur.
1
CAUTION
The piston pin retaining rings must not be reused.
Removal may weaken retaining rings and they may break
or dislodge. Either occurrence may damage engine.
8. Insert an awl in the recessed area below the piston pin
bore, and pry out the piston pin retaining rings. To pre-
vent the ring from flying out, place your thumb over the
retaining ring.
Figure 3-27. Cylinder and Piston
1. Cylinder
2. Dowel (2)
and O-ring (2)
3. Piston
4. Stud (4)
5. Gasket
6. Ring set
7. Retaining ring (2)
8. Piston pin
9. Piston pin bushing
10. Connecting rod
7
10
9
3
7
2
4
1
6
8
5
b0056x3x
3
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