Yamaha YZF-R125 Service Manual: Installing the piston and cylinder

Yamaha YZF-R125 Service Manual / Engine / Cylinder and piston / Installing the piston and cylinder

1. Install:

  • Top ring "1"
  • 2nd ring "2"
  • Oil ring expander "3"
  • Lower oil ring rail "4"
  • Upper oil ring rail "5"

NOTE:

Be sure to install the piston rings so that the manufacturer marks or numbers face up.

Installing the piston and cylinder


2. Install:

  • Piston "1"
  • Piston pin "2"
  • Piston pin clips "3"

NOTE:

  • Apply engine oil to the piston pin.
  • Make sure the arrow mark "a" on the piston points towards the exhaust side of the cylinder.
  • Before installing the piston pin clips, cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase.

Installing the piston and cylinder


3. Lubricate:

  • Piston
  • Piston rings
  • Cylinder (with the recommended lubricant)

4. Offset:

  • Piston ring end gaps

a. Top ring

b. Upper oil ring rail

c. Oil ring expander

d. Lower oil ring rail

e. 2nd ring

f. 20 mm (0.79 in)

A. Intake side

5. Install:

  • Dowel pins
  • Cylinder head gasket

  • Cylinder "1"

NOTE:

  • While compressing the piston rings with one hand, install the cylinder with the other hand.
  • Pass the timing chain and timing chain guide (intake side) through the timing chain cavity.

Installing the piston and cylinder


    Checking the piston pin
    1. Check: Piston pin Blue discoloration/grooves  Replace the piston pin and then check the lubrication system. 2. Measure: Piston pin outside diameter "a" Out of specification ...

    Generator and starter clutch
    ...

    Other materials:

    Installing the thermostat
    1. Install: Thermostat NOTE: Install the thermostat with its breather hole "a" facing up. 2. Install: Copper washer Coolant temperature sensor CAUTION:Use extreme care when handling the coolant temperature sensor. Replace any part that was dropped or subjected to ...

    Setting the normal mode
    NOTE: The engine speed, coolant temperature, and fault code, if detected, can be displayed on the LCD of the FI diagnostic tool when the tool is connected to the vehicle and is set to the normal mode. 1. Set the main switch to "OFF" and the engine stop switch to "". 2. Disconnect the self- ...

    Removing the rear brake caliper
    NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: Union bolt "1" Copper washers "2" Brake hose "3" NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. ...

    2019 Copyright www.yam-r125.net |