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34
CYLINDER/PISTON
Assembly
Oil in
New or cleaned bearings and
piston rings should be oiled in
with 2-stroke oil before assembly.
The arrow pointing
towards the exhaust port
It is important that the arrow is
turned towards the muffler
when assembling the piston on
the connecting rod.
Fit the needle bearing in the
connecting rod. Fit a circlip in
the piston, hold the piston in
position, press in the gudgeon
pin and fit the other circlip.
Cylinder base gasket
Carefully clean off any old
gasket residue from the surfaces
that connect with the gasket.
Fit the gasket on the cylinder.
Assemble the cylinder
Check that the opening on the
piston rings align with the guide
pin.
Press together the piston rings
using the piston ring compres-
sor. Place this a few millimetres
below the top of the piston to
facilitate next phase.
Press down the cylinder over the
piston and let the piston ring
compressor slide over the piston.
Remove the piston ring com-
pressor and the support plate.
Fit the screws on the base of
the cylinder and tighten these
crosswise to a torque of
8–9.5 lbf·ft/11–13 Nm.
Assembly
Oil in
New or cleaned bearings and piston rings
should be oiled in with 2-stroke oil before
assembly to initially ensure satisfactory
lubrication.
The arrow pointing towards the
exhaust port
The piston is not symmetrical. It is
important that the arrow is turned
towards the muffler when assembling the
piston on the connecting rod.
Fit the needle bearing in the con -
necting rod. Fit a circlip in the piston,
hold the piston in position, press in the
gudgeon pin and fit the other circlip.
Check that the circlips are seated correct-
ly in their grooves.
Cylinder base gasket
It is extremely important that the base of
the cylinder seals tight against the crank -
case. Carefully clean off any old gasket
residue from the surfaces that connect
with the gasket.
Fit the gasket on the cylinder.
Assemble the cylinder
Check that the opening on the piston
rings align with the guide pin.
Press together the piston rings using a
suitable piston ring compressor included
in the tool kit 502 50 70-01. Place the
piston ring compressor a few millimetres
below the top of the piston to facilitate
the next phase.
Press down the cylinder over the piston
and let the piston ring compressor slide
over the piston until the cylinder has
past the piston rings.
Remove the piston ring compressor
and the support plate align the cylinder
on the crankcase.
Fit the screws on the base of the
cylinder and tighten these crosswise to a
torque of 8–9.5 lbf·ft/11–13 Nm.
502 53 08-26
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