3-11
3
KM718A
6. Remove the cam chain guide; then disconnect
the coolant hose and remove the cylinder. Sup-
port the piston with rubber bands or other suit-
able supports. Account for two dowel pins and
the cylinder gasket.
KM450
C. Cylinder
D. Piston
NOTE: Steps 1-6 in the preceding sub-section
must precede this procedure.
7. Using a needle nose pliers, remove one piston
pin circlip. Take care not to drop it into the
crankcase.
KM451
8. Using Piston Pin Puller (p/n 0644-328), remove
the piston pin. Account for the opposite-side cir-
clip. Remove the piston.
NOTE: It is advisable to remove the oppo-
site-side circlip prior to using the puller.
NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install a con-
necting rod holder.
NOTE: If the existing rings will not be replaced
with new rings, note the location of each ring for
proper installation. When replacing with new rings,
replace as a complete set only. If the piston rings
must be removed, remove them in this sequence.
A. Starting with the top ring, slide one end of the
ring out of the ring-groove.
B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
groove.
AT THIS POINT
To service valves and cylinder head, see Servicing
Top-Side Components sub-section.
AT THIS POINT
To inspect cam chain guide, see Servicing Top-Side
Components sub-section.
AT THIS POINT
To service cylinder, see Servicing Top-Side Compo-
nents sub-section.
! CAUTION
When removing the cylinder, be sure to support the
piston to prevent damage to the crankcase and pis-
ton.
! CAUTION
Do not allow the connecting rod to go down inside
the crankcase. If the rod is down inside the crank-
case and the crankshaft is rotated, severe damage
will result.
AT THIS POINT
To service piston, see Servicing Top-Side Compo-
nents sub-section.
AT THIS POINT
To service center crankcase components only, pro-
ceed to Removing Left-Side Components.
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Summary of Contents for DVX 250 2007
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