Chapter 8 – Cylinder and Piston
Service Manual AJP PR3/PR4 8 - 4
CYLINDER
AND
PISTON
REMOVAL
The following procedures must be performed
with cold engine.
Note:
It is necessary to remove the engine
out of the frame to remove the cylinder and
piston, particularly in the case of 240cm
3
engine.
Cylinder removal
Remove the engine (see Chapter 6);
Remove the cylinder head (see Chapter 7);
Remove the cylinder head gasket with the two
(or three in the case of some engines) guide
bushings of the cylinder head and the timing
chain guide.
Remove the timing chain guide.
Remove the cylinder;
Note:
In some engines 200 and 240, it may
be necessary to repeatedly move the cylinder
up and down to remove of the cylinder if the
left front stud hole is very soiling. If you need
to hit the cylinder to detach it of the crankcase
use a rubber or plastic hammer with careful
not to break the fins.
Remove the bottom cylinder gasket. If it is
glued, can be removed with a chisel but very
gently, to avoid scratch the contact surface.
Remove the two cylinder guide bushings on
the base of the crankcases and the seal
gasket.
Piston removal
Note:
A plastic / protection should be placed
beneath the piston to prevent the piston pin
circlip from fall inside engine crankcases
during removal and installation.
Using a pointy tips pliers remove the circlip
from the piston pin;
