COPY
‑ 6 ‑
Nov./14/ 11
Cautions to observe when
installing an aluminum cylinder
Due to the misalignment of the R and
L crankcases and for other reasons,
there may be interferance in sleeve
hole of the crankcase’s mating sur-
face, “O” mark, shaded areas of the
cylinder sleeve, and inside the case
when installing the cylinder. Since
interferance will lead to sleeve de-
formation and engine troubles, do not
fail to check and rectify the interfer-
ence.
Modification Procedures
1
．
Stuff up cloth inside the
crankcase not to let any shaving
fall into it.
2
．
Rasp the convex surface on the
mating surfaces of the crankcase
till the surface becomes level.
3
．
Then, remove the waste cloth
with care not to let swarf go
inside the case.
4
．
Then stuff up the case hole with
a clean cloth.
5
．
Right after running the engine idle
for several minutes after the kit
assembly is over, exchange the
engine oil for new one. Then, all
set.
S - Stage Kit
Installation
1
．
Piston Installation
◇
Fit a piston pin circlip, attached to the left side of the
piston, in the circlip groove firmly.
◇
At this point, fix the circlip so the circlip’s end gap does
not meet with the notch on the pin hole.
Exhaust mark
Left
side
Tool to use:
A tapered slotted screwdriver
◇
It is relatively easy to install the circlip if you push it with
a driver. But be careful not to damage the piston itself.
◇
Apply engine oil to the ring grooves and install the
piston rings in the following order: oil ring expander,
lower oil ring side rail, upper oil ring side rail, second
ring, and top ring.
◇
Arrange the piston rings so the ring-end gaps are
to be in the correct positions as shown in the figure
below.
“R” is engraved on the top ring
upper surface, and “RN” on the
second ring counterpart.
エキスパンダー
60°
サイドレール
120°
120°
トップリング
セカンドリング
60°
120°
Top ring
Second ring
Expander
Side rails
ピストン
エキスパンダー
Second ring
Side rails
Top ring
Expander
Piston
Take note of cross section
◇
Attach the oil ring expander.
◇
Attach the lower oil ring side rail.
◇
Attach the upper oil ring side rail.
◇
Attach the second ring (black) with the engraved side
up.
◇
Attach the top ring (brown) with the engraved side up.
◇
Apply engine oil to the piston pin and con’rod, and
install the piston pin.
Exhaust mark
◇
Fit the kit’s piston pin circlip to the groove precisely.
◇
It is also an easy way to install it by inserting 1 / 3 of
the piston pin into the piston.
◇
Install the piston so the arrow on the piston head
points downward (exhaust side).
◇
Remove the cloth.
◇
It is relatively easy to install the circlip, if you push it
with a driver. But be careful not to damage the piston
itself.
※
Push it with care because there may be a case where
the circlip is sent flying while you are pushing it.
2
．
Cylinder Installation
◇
Degrease the cylinder and the crankcase sides of
the cylinder base gasket surface with thinner or
something else.
Cylinder gasket
Dowel pin
Rubber packing (black)
◇
Apply engine oil to the inside of kit’s cylinder, and
then spread the oil evenly with fingers.
◇
Install the cylinder.
◇
Make sure that two dowel pins B (12mm) are
attached, and install a cylinder gasket and a rubber
packing (black).
