Motor number +066367+ located on the clutch housing

Motor number +066367+ located on the clutch housing

Engine – clutch side – you can see the black oil filler/dipstick (marked MIN-MAX 900ml SAE 40 or 30 oil)

Remove the cylinder head – there isn’t a gasket between it and the cast iron cylinder – I’ll show you why – Ken

Nasty surprise – silicone (never-never). That small groove allows air to exhaust from the engine through a tube and must not be blocked. Fills with carbon, the hole is plugged

More silicone on the cast iron cylinder, must be removed. That upper hole is the crankcase breather

Pull the cylinder and free the piston. You can see the gasket comes with the cylinder (sometimes) and you’ll need a new gasket.

Expose the newly installed piston. This is when you’d usually install a new piston and rings kit.

The cylinder walls have been nicely honed

Breather hole plugged with silicone

Stuffed and taped, ready for media blasting to clean

Stuff cloth in the holes and then tape over with Duct Tape

New gasket – stabilize the piston with something plastic to avoid scratches

Clean off the old gasket residue

A view of the honed cylinder walls

I use a mirror to check ring placement

There’s a small stop peg where the ring ends meet

Compress the rings with your fingers while installing the cylinder, pushing gently.

Cylinder installed, piston at TDC

Now it’s time to clean off the silicone – VERY BAD person who did this (probably didn’t know I’m sure)

Clean out the groove and the breather tube hole

Cylinder head mounted, time to install the new dynastarter

Factory puts tape on the half moon key so it doesn’t get lost

Raised shoulder is on the rear of the pulley

Pulley mounted on the half moon shaft key

24mm socket required

You’ll need to insert a small steel rod to hold the pulley while tightening the nut on the split washer

A new fan belt, original was cracked

Installing the fan belt

Feed the belt onto the pulley from the bottom then turn to the right and it’ll jump over the pulley and into place

You’ll need a pry bar to adjust tension on the belt. There should be no more than a 7mm flex in the belt

Lift the dynastarter gently with the pry bar

13mm wrench to tighten the top bolt first, then tighten the two bottom bolts.