Cylinder

Replacing a cylinder is not that difficult. It is more time consuming than actual physical labor. Removing the engine panels/plastic is a good idea for the extra room to work in. For most air cooled engines it is a matter of removing the exhaust and then the fan cover and air shroud surrounding the cylinder. Pay attention to any hose, cable or electrical routing before removing. I can not stress enough to take notes as you disassemble the components. With the above components removed you will see (4) nuts holding
the cylinder on to the engine block. Take these off paying attention to any washers that might be underneath. Lightly tap the cylinder to loosen the base gasket and slide off the engine. The piston and ring assembly will remain. To remove the piston you will need a small needle nose pliers. Block the engine case with a clean rag so nothing can fall inside the engine. Using the needle nose pliers gently pry the piston clip out of the groove. With it removed push the pin from the other side using a small screwdriver and remove the piston from the rod. Be careful of the wrist pin bearing falling out and getting lost. Make sure the gasket surface is clean for the new assembly. Old gasket material can be removed easily by using a razor blade.

Install the ring /rings on the piston and install one of the piston clips. Confirm that the wristpin bearing is in place. Position the piston [any window/s on the piston skirt should face up. If the top of the piston is marked EX make sure it faces the exhaust port] and slide the wrist pin through. Install the other piston clip. Make sure the open ends of the clips are facing straight up towards the very top of the piston. Visually check to make sure they are seated in the grooves and not bent out of round. If they are, replace them!! They will certainly come out if deformed.

If you have trouble, check the pistons ring position again!!!

Never force the cylinder!!!