Removal & Installation

1. With cylinder heads removed, mark pistons and cylinder sleeves with matching numbers. Note cylinder sleeve position for installation reference. Place piston at TDC.
2. Pull out sleeve until piston pin snap ring is visible through hole in cylinder housing. Remove piston pin circlip.
3. Remove piston pin. Remove piston and cylinder sleeve.
4. Remove piston and sleeve at pulley end of crankshaft before removing piston and sleeve at flywheel end. Remove rubber sealing rings from cylinder sleeve. Clean all scale deposits and sealing compound from cylinder head and cylinder housing surfaces.
5. Install new sealing rings on sleeve. Thick Black ring is inner ring and thin Green ring is outer ring. Piston and sleeve assemblies at flywheel end of crankshaft must be installed first. Align all marks made and noted at removal.
6. Install piston in cylinder sleeve so piston pin can be installed. Install piston pin snap ring on flywheel side of piston. Place installing piston cylinder on TDC.
7. Align connecting rod and piston. Install piston pin through access hole in cylinder housing. Install piston pin snap ring. Ensure piston and rod move freely on pin. Push cylinder sleeve in until it seats in cylinder housing. To complete installation, reverse removal procedure.

Fitting Pistons

1. Measure piston diameter at bottom of skirt, about 5/8" (15.0 mm) from edge and at 90 degrees to pin bore. Measure inside diameter of cylinder sleeve near top of sleeve. See PISTON, PINS & RINGS TABLE under ENGINE SPECIFICATIONS at end of article.
2. Replace piston and/or cylinder sleeve as necessary. Arrow on piston top faces flywheel end. Size, weight and installation direction are marked on crown of piston. Weight group is indicated by "+" or "-" mark. Pistons marked "-" weigh 16.12-16.37 oz. (457-464 g). Pistons marked "+" weigh 15.80-16.08 oz. (448-456 g).

Fitting Rings

1. Insert piston ring squarely into cylinder sleeve near bottom end. Using a feeler gauge, measure end clearance. See PISTON, PINS & RINGS TABLE under ENGINE SPECIFICATIONS at end of article. If not within specification, replace as necessary.
2. Install rings on piston with TOP mark up. See Fig. 8. Using feeler gauge, measure piston ring side clearance. If clearance is not within specification, replace rings and/or pistons. See PISTON, PINS & RINGS TABLE under ENGINE SPECIFICATIONS at end of article.

ENGINE SPECIFICATIONS