Cylinder

DISASSEMBLING CYLINDER AND PISTON (Fig. 8C-1)

Strip motorcycle as described in "Stripping Motorcycle for Engine Repair," Section 3A, steps 1 through 10.

Remove cylinder head as described in "Disassembling Cylinder Head," Section 3B.

Figure 3C-1. Cylinder - Exploded View

Remove all cylinder base stud nuts and washers (1) except one on rear cylinder using Cylinder Base Nut Wrench, Part No. 94585-30. Raise front cylinder and piston enough to permit placing a cloth over crank-case opening. This will prevent dirt or pieces of broken ring from falling into crankcase. With piston at bottom of stroke, remove cylinder (2). Remove remaining stud nut from rear cylinder. Remove rear cylinder in same manner. Discard cylinder to crankcase gasket (3).

Spring piston rings (4) outward until they clear ring grooves in piston and lift off. Use a commercial ring expander if necessary. Pry right piston pin lock ring (5) off piston pin using the Piston Lock Ring Tool, Part No. 96780-32A and screwdriver as shown in Fig. 3C-2. Right end of piston pin has slots for this purpose. Tap out piston pin (6) and lift off piston (7).

Remove piston pin bushing (8), if necessary (see "Cleaning and Inspection"), using Piston Pin Bushing Tool, Part No. 95970-32A. Do not drive bushing out with a drift pin unless rod is disconnected and well supported around piston pin hole.

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