BR 800 53
WARNING
Cam gear timing is changed if the crankshaft (11) is
removed from its bearings.
N Remove the engine pan (8) so that the crankshaft
(11) remains in its bearings.
N Pull off oil seals (10 and 12) and replace them.
N Clean sealing faces on engine pan (8) and cylinder
(5).
20.5 Removing Crankshaft with Piston
N Remove the engine pan (8), @ 20.4.
N Pull crankshaft (11) with piston (13) out of the cylinder
(5).
N If running face in cylinder (5) is damaged: Replace
cylinder (5) and piston (13).
N If the ball bearings, connecting rod or gear on
crankshaft are damaged: Replace crankshaft.
N If the running face or crown of piston (13) is damaged:
Replace piston (13), @ 20.6.
N If the piston rings (15 and 16) are damaged: Replace
the piston rings (15 and 16), @ 20.6.
20.6 Removing the Piston
The piston rings (15 and 16) can be removed without
removing the piston (13).
N Remove engine pan (8) and oil seals (10 and 12), @
20.4.
N Remove crankshaft (11) with piston (13), @ 20.5.
N Ease snap ring (18) out of groove at recess (arrow).
N Use the assembly drift 1108 893 4700 to push the
piston pin (17) out of the piston (13).
N If the piston pin (17) is stuck: Hold the piston (13)
steady and tap the end of the drift lightly to drive out
the piston pin (17).
N Lift away the piston (13).
N Remove piston rings (15 and 16).
N If the piston rings (15 and 16) are damaged: Replace
the piston rings (15 and 16).
The snap ring (14) need not be removed.
20.7 Installing the Piston
N Fit the piston rings (15 and 16) so that their gaps
(arrows) are offset 180°.
N Fit piston (13) on the connecting rod so that the arrow
on the piston crown (arrow) points in direction of
exhaust port.
N Push the assembly drift 1108 893 4700 (36) through
the piston (13) and the small end of the connecting
rod.
N Lubricate the piston pin (17) with two-stroke engine
oil.
N Fit the piston pin (17) on the assembly drift 1108 893
4700 (36) and slide it into the piston (13) as far as
stop.
13
17
18
0000-GXX-6691-A0
13
15
16
0000-GXX-6692-A0
17
11
13
36
0000-GXX-6693-A0
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