Removing the cylinder/piston assembly
Note
The figures show an engine block removed from the frame.
To work with the engine block installed in the frame it is necessary to remove the components indicated below.
Remove the seat (Removing the seat).
Remove the side fairings (Removing the fairings).
Remove the fuel tank (Removing the fuel tank).
Remove the airbox (Removing the airbox), the throttle body (Removing the throttle body), the blow-by and the oil breather pipe.
Remove the supply system and the injectors from the intake manifolds.
Drain the coolant (Changing the coolant).
Remove the cooling system hoses and unions from the engine block (Removing cooling system hoses and unions).
Remove the exhaust system (Removing the exhaust system).
Remove the timing belt external covers (Removing the timing belt covers) and the timing belts (Removing the mobile tensioner/timing belt).
Remove the intake manifolds (Removing the intake manifold and water union).
Remove the heads from the engine block (Removing the engine heads).
Loosen the clamps (1) and remove the hoses (2) and (3) from the cylinders (4) and from the generator cover.
If damaged, unscrew the unions (5).
Remove the cylinder head gasket (6) from the piston-cylinder assy.
Remove the bushes (7).
Use tool (B) no. 88765.1657 to bring the piston of the horizontal cylinder near the TDC.
Carefully lift the cylinder (8) off the crankcase, keeping it vertical. If necessary, rock the cylinder slightly using both hands or tap its base gently with a rubber mallet.
Continue to lift the cylinder until you can access the gudgeon pin (9).
Since insertion of piston in the cylinder is a difficult operation to perform at the time of reassembly, remove the piston together with the barrel as described below.
Stuff the crankcase opening with a rag or soft paper to prevent foreign material from falling inside.
Remove the snap ring (10) from the gudgeon pin (9) on the clutch side.
Working from the opposite side, drive out the gudgeon pin sufficiently to release the connecting rod.
Lift the cylinder-piston assembly clear of the crankcase thru bolts.
If work is to be carried out on the piston, carefully withdraw it from the cylinder.
Remove from the cylinder head thru bolts the four O-rings (A) located on the crankcase between the cylinder and the gasket (11).
To remove the vertical cylinder-piston assembly, bring the vertical piston to TDC and proceed as for removal of the horizontal cylinder.
Important
Mark the pistons to show from which cylinder they were removed:
V= Vertical - O= Horizontal.