- Re fit studs (if removed)
- Double Nut top of stud and tighten from top nut repeat for all 4 studs
Fit piston
- Lubricate well with 2 stroke oil
- Small end bearing
- Big end bearing
- Place blue roll around bottom of con rod to stop anything dropped from going into crank case
- Fit piston over con rod with arrow to front (exhaust) and boost port to rear (inlet). Hold the top end bearing in place and push through gudgeon pin.
- Fit circlips either side of gudgeon pin in piston
Fit barrel
- Lubricate well the barrel with 2 stroke oil
- Base Gasket governs the squish
- Squish Ideal 0.9mm (Between 0.85mm -1mm)
- Measure old Base Gasket Replace like with like
- Check squish after barrel fitted and torqued down and adjust as needed
- Fit Barrel Pinch piston ring in so barrel will slip past the piston, make sure the barrel its properly on the base gasket
- Put head on
- Tighten down M10 Head nuts in an X pattern 1st to 9 ftlbs then to 18 ftlbs
- Check squish
- Use 1.5mm solder Bent in 90 deg curve so the bent section can reach the outside of the barrel
- Put down the spark plug hole to Left and right of piston above the gudgeon pin line, NOT front and rear.
- Both sides measure with vernier or micrometer
- Check timing with a dial gauge
- If adjusted check clearance between rotor and stator with feeler gauge 0.008”
- Check clutch action
