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Published byBo Rayment Modified over 10 years ago
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Motor number +066367+ located on the clutch housing
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Engine – clutch side – you can see the black oil filler/dipstick (marked MIN-MAX 900ml SAE 40 or 30 oil)
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Remove the cylinder head – there isn’t a gasket between it and the cast iron cylinder – I’ll show you why – Ken
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Nasty surprise – silicone (never-never). That small groove allows air to exhaust from the engine through a tube and must not be blocked. Fills with carbon, the hole is plugged
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More silicone on the cast iron cylinder, must be removed. That upper hole is the crankcase breather
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Pull the cylinder and free the piston. You can see the gasket comes with the cylinder (sometimes) and you’ll need a new gasket.
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Expose the newly installed piston. This is when you’d usually install a new piston and rings kit.
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The cylinder walls have been nicely honed
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Breather hole plugged with silicone
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Stuffed and taped, ready for media blasting to clean
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Stuff cloth in the holes and then tape over with Duct Tape
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New gasket – stabilize the piston with something plastic to avoid scratches
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Clean off the old gasket residue
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A view of the honed cylinder walls
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I use a mirror to check ring placement
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There’s a small stop peg where the ring ends meet
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Compress the rings with your fingers while installing the cylinder, pushing gently.
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Cylinder installed, piston at TDC
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Now it’s time to clean off the silicone – VERY BAD person who did this (probably didn’t know I’m sure)
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Clean out the groove and the breather tube hole
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Cylinder head mounted, time to install the new dynastarter
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Factory puts tape on the half moon key so it doesn’t get lost
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Raised shoulder is on the rear of the pulley
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Pulley mounted on the half moon shaft key
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24mm socket required
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You’ll need to insert a small steel rod to hold the pulley while tightening the nut on the split washer
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A new fan belt, original was cracked
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Installing the fan belt
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Feed the belt onto the pulley from the bottom then turn to the right and it’ll jump over the pulley and into place
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You’ll need a pry bar to adjust tension on the belt. There should be no more than a 7mm flex in the belt
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Lift the dynastarter gently with the pry bar
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13mm wrench to tighten the top bolt first, then tighten the two bottom bolts.
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