English – 45
Repair instructions
7.22 Piston and cylinder – removal
1
The fuel tank does not need to be removed when
removing the cylinder.
Remove:
• cylinder cover
• carburettor (see “Carburettor – removal”)
• silencer
• spark plug
2
Undo the four cylinder bolts from the underside and
lift the cylinder off carefully. (see fi gure 51)
3
Cover the opening in the crankcase. (see fi gure 53)
4
Remove the circlips from the ends of the gudgeon
pin and press it out. Then lift off the piston. (see
fi gure 52 and 53)
5
Remove the bearing from the little end of the con-
necting rod. (see fi gure 53)
If replacing the cylinder:
Remove the intake manifold, see “Air intake sys-
tem – removal”.
Cleaning and inspection
Clean all the components, scraping off all traces of
old gasket and carbon from the following places:
• Piston crown
• Top of the cylinder bore
• Cylinder exhaust port
• Decompression valve channel
• Cylinder base and/or crankcase
(see fi gure 54)
Fig 52
Fig 51
Fig 54
Fig 53
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