If a circlip is dropped into the crankcase, it must be recovered before the crankshaft is
rotated. Failure to do so will result in serious engine damage.
1. Remove and discard the gudgeon pin circlip from one side of the piston.
Removing the Gudgeon Pin Circlip
Never force the gudgeon pin through the piston. This may cause damage to the piston
which may also damage the cylinder barrel when assembled.
If the gudgeon pin is found to be tight in the piston, check the piston for a witness
mark caused by the circlip. Carefully remove the mark to allow the pin to be removed.
2. Remove the gudgeon pin by pushing the pin through the piston and connecting rod
toward the side from which the circlip was removed.
3. Remove the remaining circlip from the piston and discard it.
The rings may be removed using a proprietary piston ring expander tool or, if a tool is
not available, carefully spread the ring opening using thumb pressure then push up on
the opposite side of the ring to remove it from the piston.
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