Warning!
- Make sure the motorcycle is stabilised and adequately supported.
- A correctly supported motorcycle will help prevent it from falling.
- An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Perform the following operations:
Note: It will be necessary to remove the connecting rods from the crankshaft when refitting the barrel.
1. Remove and discard the gudgeon pin circlip from one side of the piston.
Caution! If a circlip is dropped into the crankcase, it must be recovered before the crankshaft is rotated. Failure to do so will result in serious engine damage.
Removing the gudgeon pin circlip
2. Remove the gudgeon pin by pushing the pin through the piston and connecting rod toward the side from which the circlip was removed.
Caution! Never force the gudgeon pin through the piston. This may cause damage to the piston which may also damage the cylinder barrel when assembled.
Note: If the gudgeon pin is found to be tight in the piston, check the piston for a witness mark caused by the circlip. Carefully remove the mark to allow the pin to be removed.
3. Remove the remaining circlip from the piston and discard it.
Note: The rings may be removed using a proprietary piston ring expander tool or, if a tool is not available, carefully spread the ring opening using thumb pressure then push up on the opposite side of the ring to remove it from the piston.
4. Remove the piston rings.
Note: If the piston rings are to be reused, note the orientation of the oil control rings prior to removal.