DK00026.fm
REPAIR MANUAL
BRP-Powertrain
Effectivity: 125 MAX/125 Junior MAX/125 Mini
MAX/125 Micro MAX
Edition 2 / Rev. 0
Chapter 4
Page 27
December 01/2010
4.2) Installation of piston
General See Figure 19.
4.2.1) Installation of piston pin
Special tools The following special tools and equipment are required:
Instructions See Figure 19.
Proceed as follows to install the piston pin:
In order to protect the piston pin circlip from uninten-
tional loss in the crankcase, a suitable clean cloth
should be used to cover the open cylinder bore.
Part number Description Use
Part no. 676035 Installation tool Piston
n.e. Engine oil Piston pin
Mount the piston with the locking pin of the piston ring
facing the intake port.
The piston pin is fixed in the piston with two circlips
(groove at bottom).
Step Procedure
1 Always use new circlips. Used or previously installed cir-
clips have too little tangential tension, and they may twist
and work their way out of the groove in the piston.
For easier installation we recommend installing one circlip
before installing the piston.
2 Coat the piston pin retainer with engine oil.
3 Insert the piston pin retainer into the upper connecting rod eye.
4 Mount the piston and piston pin on the con rod.
5 Place the new circlip (1) flat on a level surface.
6 Push the mounting sleeve (2) with the circlip over it.
7 Push the circlip deeper into the mounting sleeve with the tapered side of the
installation tool (3).
8 Rotate the installation tool and continue to push the mounting sleeve until the
circlip locks into the mounting sleeve groove.
9 Place the installation tool with the cutout of the circlip down on the piston (4).
10 Protect the piston with your hand and press into the piston with the hook ring.
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