250-500cc Cylinder removal procedure

[rockdancer]

I was thinking about changing my base gasket and just wondering if a procedure for disassembly of the cylinder has been covered anywhere ?

I have done it many times on a 125 but am wondering if you need to remove power valve assembly to remove the cylinder . Rather not pull that part apart if I don't have to .

I always seem to coolant everywhere - wondering what the best method of draining coolant is

If anyone has a procedure they'd like to share - or fill in my rough one below


Remove
-seat
- tank
- pipe
- drain coolant
- remove radiator hoses
- remove power valve cover & linkage
- remove carb
- remove head bracket and head bolts
- remove cylinder ( give it a gentle tap with a rubber mallet if required)
- remove reed cage ( if required or to check reeds)
- place rag around base of conrod
- remove piston if required
( edited )
cheers
Ashley

 

[Claybilly17]

The Power Valve does not have to be removed to remove the cylinder just the linkage that goes into the side cover. Here is a short time lapse of me tearing down my engine. I took the power valve out because is was going to clean it. And sorry for not included actually taking the cylinder off I thought my battery was charged but it ended up dying on me, but it got everything before taking the cylinder off.

View: https://www.youtube.com/watch?v=ceffcIf7po8

 

[rockdancer]

Ok thanks - remove linkage connection ofcourse

 

[ohmygewd]

Ash...l tend to take the radiator cap off and then drain via the water hose, l get very little spillage.
Also, now l like to zip bags for all the bolts and brackets instead of just dumping then in the magnetic tray.
Rest of the procedure is pretty spot on except missing removing the carb off...l tend to pull the cylinder with the reed assembly intact then disassemble when the whole cylinder is off.

 

[rockdancer]

Oh yes that's different - the reeds are connected to cylinder ( not on 125 )
Water hose ? Which one ?
Can you pull cylinder off with engine in bike ?

 

[shawbagga]

Oh yes that's different - the reeds are connected to cylinder ( not on 125 )
Water hose ? Which one ?
Can you pull cylinder off with engine in bike ?

Yep cylinder off in frame jus hold ya tongue right nah pretty easy really. Y not jus drain coolant thru drain bolt on WP cover? Are u reusing coolant? Unless u using exy stuff jus drain it on back lawn(water it in with hose!) n chuck fresh stuff in

 

[ohmygewd]

Sorry which bike are we talking about here...WR250 or WR300?

Water hose that's a typo (my bad) meant the water pump house or like Shawry said the drain bolt but ya gunna take the pipe off anyway so l always drop the coolant from there into a bucket.

 

[ohmygewd]

My procedure for both the 250 or 360 and probably applies to 300.
PS. Excuse my order as l'm finding l'm becoming more padantic.

Stick a few coldies in the fridge

1. Place bike on a stand or crate..sidestand is a prick of a position.
2. Remove tank
3. Remove Expansion chamber
4. Remove pipe and that side plate.
5. Take radiator cap off.
6. Stick a bucket under and undo water pump hose that leads to cylinder.
7. Loosen front and rear carby boot clamp.
8. Take off subframe bolts maybe disconnect rear light loom and lift the subframe enough to pull the rear carb boot off (don't forget the clamp that will hit the floor)
9. Take the carb throttle cap off and then pull the carb out, placing the slide/throttle cable over the top frame.
10. If you have an air compressor, blow the whole motor down and the top frame just to make sure no crud drops in.
11. Take the plug off, put the plug lead over the tank mounting rubber.
12. Take the radiator hoses off the head and place over the top frame in a criss cross.
13. Pull the clutch side PV cover off and then disconnect the PV plastic arm ball joint thingy thing or disconnect that mechanism from the PV arm leading from the case.
14. Undo the head bolts and take the head off.
15. Place the head o-rings in a ziplck bag.
16. Take the cylinder nuts off and then give the cylinder a few taps with a rubber or plastic dead blow and up she comes.
17. Place some rags under the conrod.
18. Cover the whole piston/crankcase with a towel or rag (extra insurance).

Finally, crack open a coldie and possibly light up a dart and your done

You don't have to take the subframe bolts off but l find lifting the subframe to disconnect and reconnect the carb so much easier.

 

[shawbagga]

Pffft that's all arse about OMG, crack a stubby first n then again after steps 5, 9, 14 & sevèral at the end.

Then wake up the next day n question yaself on whether u remembered to install the little end bearing or put the piston in backwards.

Seriously though gotta have a few whilst ya doin it! No ciggies tho ya filthy rotten smoker