Motorcycle Piston Kit Installation Instructions

Compatibility:

This piston kit is suitable for 50cc, 70cc, and 90cc 2T engines.

Tools Required:

Before you begin the installation, make sure you have the following tools on hand:

1. Socket Set (with various sizes)
2. Wrench Set
3. Screwdrivers (flathead and Phillips)
4. Piston Ring Tool (optional but recommended)
5. Torque Wrench
6. Clean Cloths (for cleaning surfaces)
7. Engine Oil (for lubrication)
8. Safety Goggles (to protect your eyes)
9. Gloves (to protect your hands)

Installation Steps:

1. Preparation:

   • Ensure the engine is cool and disconnected from the power source.
   • Gather all tools and materials needed for installation.

2. Removing the Old Piston:

   • Begin by removing any components obstructing access to the cylinder. This may include the exhaust pipe, air filter, and carburetor.
   • Carefully detach the cylinder head using appropriate socket and wrench sizes.
   • Once the cylinder head is off, remove the cylinder to access the old piston.
   • Detach the old piston from the connecting rod by removing the circlips with a screwdriver or piston ring tool.

3. Installing the New Piston:

   • Before installation, compare the new piston size (40.3mm, 47mm, or 49mm) to ensure proper fit.
   • Lubricate the piston rings and piston with engine oil for smooth operation.
   • Insert the new piston into the cylinder, making sure the piston rings are properly aligned and seated.
   • Reattach the circlips to secure the piston to the connecting rod.

4. Reassembling the Engine:

   • Carefully place the cylinder back onto the crankcase.
   • Secure the cylinder in place by tightening the cylinder head bolts to the recommended torque.
   • Reattach any additional components that were removed earlier, such as the exhaust pipe and carburetor.

5. Final Checks:

   • Ensure all bolts and screws are tightened properly.
   • Check the oil levels in the engine.
   • Make sure there are no tools left in the engine compartment.

6. Testing:

   • Start the engine and let it idle for a few minutes to ensure proper operation.
   • Observe for any unusual noise or issues.

Safety Tips:

• Always wear safety goggles and gloves during installation.
• Work in a well-ventilated area to avoid inhaling fumes.

By following these installation instructions, you can easily replace the piston kit in your motorcycle, enhancing its performance and responsiveness.