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502 50 18-01
A
Cylinder and piston
The cylinder and the piston are two of the compo-
nents exposed to most strain in the engine. They must
withstand, for example, high speeds, large tempera-
ture swings and high pressure. Moreover, they must
be resistant to wear. Despite these tough working
conditions, major piston and cylinder failure is rela-
tively uncommon. The reasons for this include new
coatings in the cylinder bore, new types of oil and
grease and refined manufacturing techniques.
When servicing these components, cleanliness is of
the utmost importance. It is therefore recommended
that the cylinder and the area around it be thoroughly
cleaned before being dismantled from the crankcase.
Remove the circlips from the gudgeon
pin.
Using long-nose pliers remove the
gudgeon pin circlips.
Keep your thumb over the circlip to
prevent it from flying out.
Dismantling
Dismantle the following components to make the cylinder accessible:
Starter, cylinder cover, muffler guard, muffler and spark plug.
NOTE!
The throttle need not be removed to dismantle the cylinder and piston.
Loosen the clamp (A) and unscrew the bolt a good distance (to facilitate the coming
assembly) so that the clamp can be turned around the inlet manifold without
affecting the cylinder.
Then loosen the 4 bolts holding the cylinder.
Carefully lift out the cylinder by twisting is backwards and forwards until it loosens
from the inlet manifold. Make sure that no dirt enters the crankcase.
Use a rag to cover the crankcase opening under the piston.