
ENGINE
4-39
PISTON INSTALLATION
CAUTION: Do not re-use circlips. Circlips become
deformed during the removal process. Do not
compress the new clip more than necessary to
prevent loss of radial tension. Severe engine damage
may result if circlips are re-used or deformed during
installation.
1. Install a new circlip on one side of the piston with the end
gap facing up or down.
2. Apply clean engine oil to the piston rings, ring lands, piston
pin bore, piston pin, and piston skirt.
Lubricate the connecting rod (both ends) and crankshaft main
bearing area.
3. IMPORTANT-- Install the piston on the connecting
rod with the ’IN” casting mark facing the intake side
of engine. The piston pin should be a push fit into the
piston.
4. Install the other circlip with the gap facing up or down. (See
Caution with Step 3 above). Push the piston pin in both
directions to make sure the clips are properly seated in the
groove.
5. Place the dowel pins in the crankcase and install a new
cylinder base gasket.
6. Lubricate the piston and rings with assembly lube and install
a ring compressor on the piston assembly. Verify that the ring
gaps are 120
°
apart from each other before installation.
7. Push the rings into the taper using a metallic, blunt-edge tool
while holding the cylinder down.
This will help push the piston past the ring taper into the
cylinder.
CYLINDER INSTALLATION
NOTE: Clean the gasket surfaces on the crankcase
and cylinder. Remove all traces of old gasket material
and apply a new base gasket.
1. Install the dowel pin(s). Install a new base gasket onto the
mating surface and install the piston into cylinder.
NOTE: Route cam chain through the cylinder chain
room and secure it, holding it up while rotating the
engine to avoid damage to the chain, drive sprocket
teeth or tensioner blade.
2. Apply clean engine oil liberally to the bore and tapered area
of the cylinder. Place the cylinder on to the studs.
Summary of Contents for AT56-69E
Page 35: ...MAINTENANCE 2 25 ...
Page 45: ...CVT SYSTEM 3 4 CVT EXPLODED VIEW ...
Page 56: ...ENGINE 4 3 ENGINE ILLUSTRATION ENGINE EXPLODED VIEW ...
Page 57: ...ENGINE 4 4 ...
Page 58: ...ENGINE 4 5 COOLING SYSTEM EXPLODED VIEW ...
Page 59: ...ENGINE 4 6 OIL FLOW DIAGRAM ...
Page 125: ...FUEL AND CARBURETOR 6 15 FUEL TANK SYSTEM ...
Page 135: ...BODY SUSPENSION STEERING 7 6 SUSPENSION ...
Page 142: ...BODY SUSPENSION STEERING 7 13 STEERING ...
Page 151: ...BRAKES 8 6 FRONT BRAKE EXPLODED VIEW MASTER CYLINDER ...
Page 196: ...ELECTRICAL 9 31 WIRE DIAGRAM ...