6
35
505 38 17-05
Cylinder and piston
Remove the circlips from the gudgeon pin. Remove the circlips on the gudgeon pin
using a small fl at nosed pliers.
Keep your thumb over the circlip to
prevent it from fl ying out.
Dismantle the piston from the connecting
rod.
Push the gudgeon pin from the piston
using punch 505 38 17-05.
If the pin is too tight, dismantling is
facilitated by carefully heating the piston
using a hot air gun.
Cleaning, inspection
After dismantling, clean the individual components:
1. Scrape carbon deposits from the top of the piston.
2. Scrape carbon deposits from the cylinder’s combustion chamber.
3. Scrape carbon deposits from the cylinder’s exhaust port.
4. Wash all the components.
5. Inspect the different components for damage and wear.
Check the piston and cylinder for seizure damage and wear.
Also see the “Analysis and actions” section.
Check the piston ring for wear and possible breakage.
Also see the “Analysis and actions” section.
Check the gudgeon pin.
– If it has blued, it must be replaced.
– If the piston moves too easily both the piston and the gudgeon pin must be replaced.
Check the needle bearing. If it is discoloured or damaged, it must be replaced.
Check the circlips. If they exhibit cracks or are discoloured (caused by overheating),
they must be replaced.
NOTE!
Scrape carefully with not too sharp a tool so as not to damage the soft
aluminium parts.
NOTE!
Do not lose the two distance rings
that are placed between the piston
and the gudgeon pin bearing.
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