2. Remove thermostat cover and gasket.
3. Remove exhaust outer cover, gasket and pin.
Clean the anode surface and check the anode. Replace if the corrosion of anode is abnormal.
Check the exhaust outer cover for crack, distortion or corrosion. Replace if necessary.
4. Remove breather.
Check the breather body for crack, distortion or corrosion. Replace if necessary.
5. Remove the crankcase bolts according to below drawing, and remove the crankcase.
TORQUE
M8 3.0KGM
22 FTLB
M6 1.2KGM
9FTLB
1
56
78
43
9
2
10
6. Remove the connecting rod bolts and connecting rod cover, remove the crank, and remove
connecting rod and piston assy.
7. Remove piston pin circlip with pliers, and remove piston pin and piston.
8. Remove oil seal, pin and main bearing.
Piston
Measure piston outside diameter at the specified measuring point.
If out of specification, replace.
Piston diameter: 58.950~58.965mm
Measuring point○
a
: 5mm
Cylinder bore
1. Measure cylinder bore separately at measuring point ○1, ○2, ○3.
At each point, measure the cylinder bore at places D1, D3, D5
parallel to the crankshaft and at places D2, D4, D6 vertical to
a
D
②
③
①
D1&D2
D3&D4
D5&D6
the crankshaft.
Measuring point height: ○
1
10mm;
○
2
40mm;
○
3
70mm
Cylinder bore: 59.00~59.02mm
Limit size: 59.10mm
2. Calculate taper limit and round limit. If out of specification, replace crankcase.
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