My $120 ebay piston, rings and cylinder replacement kit is supposed to be here tomorrow. I was looking for instruction in the manual I just bought, but it shows that they completely remove the engine first. I was hoping that it would be a quick and easy fix as I was led to believe. I have never worked on a 2 stroke before.

• Do most people do remove the engine or do they just take off the head where the engine sits?
• Are there any step by step guides or videos that you know of for this?
• What has been your experience relating to this?
• Any tips, pointers, etc?

 

I'm new to these bikes as well, but it seems to me it could be done w/o engine removal. I would sure try! I youtubed a couple of vids yesterday that talked about 45 minute complete top end rebuilds, however, they were on other types of bikes. I already have ideas brewing to hop mine up a bit--after I get it running good, but I sure don't want to have to R&R the motor to do it!

Let's see what the great ones have to say!

 

The motor stays in.
Remove the pipe, motor cover (plastic), and the CDI/coil.
Remove the 4 head nuts and take the head off.
The cylinder will pull up and off.
Clean the old gasket off the motor.
Install rings on piston (T is up) and install piston on the rod. ARROW toward exhaust..
Lubricate the cylinder and piston.
Align the ring ends with the pins in the ring groove and slide the cylinder on. You'll need to squeeze the rings in.
No top or bottom to the head gasket. It goes either way.
100 inch pounds on the head nuts.

 

Thanks LT80! About how long would you estimate this taking for someone that is used to working on other types of engines?

 

A hour or so.

 

Is there anything special I need to do to break it in?

 

Do a cpl hot and colds. Then a few minutes of putting around.
Long sustained full throttles are the enemy for a tank of gas or 2.
Not much of a break in required for cast pistons.

 

Got it running!! it goes like a champ now! Thanks!!