Kymco XCITING 500 - Service Manual > Cylinder/piston installation

Cylinder/Piston / Cylinder/piston installation

PISTON RING INSTALLATION

Carefully install the piston rings into the piston ring grooves with the markings facing up.

Be careful not to damage the piston and rings.

Stagger the piston ring end gaps 120ยบ degrees apart from each other.

Stagger the side rail end gaps as shown.

Cylinder/Piston

Cylinder/piston installation

Clean any gasket material from the cylinder mating surfaces of the crankcase and oil passage.

Apply engine oil to the piston pin.

Apply engine oil to the connecting rod small end and piston pin hole.

Install the piston with the "IN" mark face intake side and piston pin.

Cylinder/Piston

Place a clean shop towel over the crankcase prevent the clip from falling into the crankcase.

Install the new pin clip.

Cylinder/Piston

Install the dowel pins.

Cylinder/Piston

Install the gasket.

Apply engine oil to the cylinder wall, piston and piston ring outer surfaces.

Pass the cam chain through the cylinder and install the cylinder over the piston.

Be careful not to damage the piston rings and cylinder walls.

Install and tighten the two cylinder bolts to specified torque.

Torque: 10 N*m (1 kgf*m, 7 lbf*ft)

Install the block pin.

Connect the water hose.

Cylinder/Piston

See also:

 Kymco XCITING 500 - Service Manual > Service information

SCHEMATIC DRAWING SERVICE INFORMATION

 Kymco XCITING 500 - Service Manual > Drive and Driven Pulley