Hi:

I am planning on doing a top end rebuild on my 88 Trail Boss 2x4.

(Summary of why: lost power recently out riding, difficult to restart and only idles when I do. Pulled the carb to check it, and looking into the intake port to the cylinder, looks like the piston skirt is broken.)

The head came off easy, but I am unable to get the cylinder off the crankcase. All 4 nuts to the crankcase are off, plus the 2 holding the cylinder to the bracket fastening it to the frame, and the exhaust is off. Piston is cycled down to its lowest point.

Any ideas how to break the seal ? I don't have a rubber mallet, so I have used a regular hammer hitting a piece of 2x4 wood up against the cylinder vanes.

There is not much to hit against, and I am concerned that I am bending the vanes on the cylinder.

This is an old quad I got for free, and I enjoy doing projects like this, so I am pretty open to ideas that don't cost much.

 

Have the piston at bottom of cylinder and invest in deadblow/rubber mallet! Take your time,sometimes old cylinders are hard to get off. OPT