Piston cylinder Replacement ON MOTOR DERBI EURO 3

1) Disassemble the saddle and the front fairings.

2) Disconnect the fuel tank hose.

3) Remove the fuel tank.

4) Drain the coolant by unplugging the coolant hose.

5) Once the hose is removed, simply open the expansion tank cap so that the liquid is empty.

6) Remove the muffler.

7) Use a wrench to remove it.

8) Remove the temperature sensor from the cylinder head.

9) Also remove the spark plug from the cylinder head.

11) Loosen the 5 screws from the cylinder head cover.

11) Remove the cylinder head cover.

11) Loosen the 4 nuts from the cylinder block.

11) Remove the breech block.

11) Remove the cylinder head gasket.

11) Remove the cylinder. If it is a little stuck to the joint, you can tap it with a mallet.

11) Remove the piston clips and the piston.

11) To prevent the clips from falling into the lower engine, insert a clean cloth. Push the piston pin with a screwdriver.

11) It is advisable to change the needle cage when replacing the piston cylinder. For the assembly of the segments you can help yourself from one set of shim to mount the bottom segment.

11) The black segment (sealing segment) is at the bottom and the gray segment (fire segment) is at the top. Watch out for the centering pin.

11) Fit the needle cage with a little oil.

11) Fit the piston and shaft with oil as well. Pay attention to the mounting direction of the piston (arrow to the exhaust).

11) Put on the clips and remove the cloth to install the base gasket.

11) Install the new cylinder. For a good assembly, it is advisable to put some oil in the cylinder. Attention, it is necessary that the segments are well placed on the piston (in front of the pins of centering) so that the cylinder can return.

11) To put the cylinder, simply press the segments. The cylinder will slide on it.

11) With the help of kick, check that the piston goes up and down correctly in the cylinder. Then wipe off the excess oil.

11) Install the cylinder head gasket, then the cylinder block.

11) Tighten the bolt stud to the torque (18Nm), then fit the bolt cover.

11) Information: To tighten the cylinder head, always make it crosswise, in the following order: 1,2,3,4.

11) Reassemble the temperature sensor, spark plug and all coolant hoses.

11) Then reassemble the muffler.

11) Fill the tank with coolant.

11) Reassemble the fuel tank and the fairings. Start the motorcycle, check that there is no coolant leakage. Let your vehicle run and fill up the coolant level.