7.

CYLINDER HEAD (2-STROKE)/

CYLINDER/PISTON VITALITY 50

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CYLINDER HEAD (2-STROKE)/CYLINDER/PISTON

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SERVICE INFORMATION (2-STROKE).................................... 7- 3

SERVICE INFORMATION (4-STROKE).................................... 7- 4
CYLINDER HEAD (2-STROKE) ............................................... 7- 5
CYLINDER/PISTON (2-STROKE)............................................. 7- 8
CYLINDER/PISTON (4-STROKE) ----------------------------------- 7-13

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7. CYLINDER HEAD (2-STROKE)/
CYLINDER/PISTON VITALITY 50

(2-STROKE)

Torque: 1.1_ 1.7kg-m (cold)

Torque: 1.0_ 1.2kg-m

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7. CYLINDER HEAD (2-STROKE)/
CYLINDER/PISTON VITALITY 50

(4-STROKE)

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7. CYLINDER HEAD (2-STROKE)/
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SERVICE INFORMATION (2-STROKE)

GENERAL INSTRUCTIONS
• The cylinder head, cylinder and piston can be serviced with the engine installed in the frame.
• Before disassembly, clean the engine to prevent dust from entering the engine.
• Remove all gasket material from the mating surfaces.
• Do not use a driver to pry between the cylinder and cylinder head, cylinder and crankcase.
• Do not damage the cylinder inside and the piston surface.
• After disassembly, clean the removed parts before inspection. When assembling, apply the
specified engine oil to movable parts.

SPECIFICATIONS Standard (mm) Service Limit (mm)

Item 2-Stroke
Cylinder head warpage  SF10AF 0.10
Piston O.D.(5mm from bottom of piston 38.970 _ 38.955 38.90
skirt)
Cylinder-to- piston clearance  0.10
Piston pin hole I.D. 12.002 _ 12.008 12.03
Piston pin O.D. 11.994 _ 12.0 11.98
Piston-to-piston pin clearance  0.03
Piston ring end gap (top/second) 0.10 _ 0.25 0.40
Connecting rod small end I.D. 17.005 _ 17.017 17.03
Cylinder bore 39.0 _ 39.025 39.05

TORQUE VALUES
Cylinder head bolt 1.0_ 1.2kg-m
Exhaust muffler joint lock nut 1.0_ 1.4kg-m
Exhaust muffler lock bolt 3.0_ 3.6kg-m
Spark plug 1.1_ 1.7kg-m

TROUBLESHOOTING
Compression too low, hard starting
or poor performance at low speed Abnormal noisy piston
• Leaking cylinder head gasket • Worn cylinder and piston
• Loose spark plug • Worn piston pin or piston pin hole
• Worn, stuck or broken piston and piston rings • Worn connecting rod small end bearing
• Worn or damaged cylinder and piston
Compression too high, overheating
or knocking Abnormal noisy piston rings
• Excessive carbon build-up in cylinder head • Worn, stuck or broken piston rings
or on piston head • Worn or damaged cylinder

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7. CYLINDER HEAD (2-STROKE)/
CYLINDER/PISTON VITALITY 50

SERVICE INFORMATION (4-STROKE)

GENERAL INSTRUCTIONS
• The cylinder and piston can be serviced with the engine installed in the frame.
• Before disassembly, clean the engine to prevent dust from entering the engine.
• Remove all gasket material from the mating surfaces.
• Do not use a driver to pry between the cylinder and cylinder head, cylinder and crankcase.
• Do not damage the cylinder inside and the piston surface.
• After disassembly, clean the removed parts before inspection. When assembling, apply the
specified engine oil to movable parts.

SPECIFICATIONS
Standard (mm) Service Limit (mm)
I.D. 39.00_ 39.01 39.1
Warpage  0.05
Cylinder
Cylindricity  0.05
True roundness  0.05
Ring-to-groove Top 0.015_ 0.055 0.09
clearance Second 0.015_ 0.055 0.09
Top 0.15_ 0.3 0.5
Piston, Ring end gap Second 0.3_ 0.45 0.65
piston ring Oil ring 0.2_ 0.7 0.9
Piston O.D. 38.975_ 38.99 38.9
Piston O.D. measuring position 4.5mm from bottom of 
. Piston-to-cylinder clearance skirt0.040
0.010_ 0.1
Piston pin hole I.D. 13.002_ 13.008 13.04
Piston pin O.D 12.994_ 13.000 12.96
Piston-to-piston pin clearance 0.002_ 0.014 0.02
Connecting rod small end I.D. bore 13.016_ 13.034 13.06

TROUBLESHOOTING
• When hard starting or poor performance at low speed occurs, check the crankcase breather for
white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
Compression too low or uneven
compression Excessive smoke from exhaust muffler
• Worn, stuck or broken piston rings • Worn or damaged piston rings
• Worn or damaged cylinder and piston • Worn or damaged cylinder and piston
Compression too high Abnormal noisy piston
• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings
chamber or on piston head • Worn piston pin hole and piston pin

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7. CYLINDER HEAD (2-STROKE)/
CYLINDER/PISTON VITALITY 50
Spark Plug Cap

CYLINDER HEAD (2-STROKE)

REMOVAL
Remove the rear body cover. (13-6)

Remove the spark plug cap

Fan Cover/Engine Hood

Remove the fan cover. (8-3)

Remove the exhaust muffler. (13-10)

Remove the bolt from the engine hood, then

remove the engine hood.

Bolts

Cylinder Head Cylinder head Bolts

Remove the spark plug.

Remove the cylinder head bolts and the
cylinder head.
°ØLoosen the bolts diagonally in 2 or 3
times.

Remove the cylinder head gasket.

Spark Plug

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CYLINDER/PISTON VITALITY 50
Combustion Chamber
COMBUSTION CHAMBER
DECARBONIZING
Remove the carbon deposits from the
combustion chamber
°Ø
Avoid damaging the combustion
chamber wall and cylinder mating
surface.

Mating Surface

CYLINDER HEAD INSPECTION

Check the cylinder head for warpage with a
straight edge and feeler gauge.
Service Limit: 0.10mm replace if over

Cylinder head Gasket

CYLINDER HEAD INSTALLATION

Install a new cylinder head gasket onto the
cylinder.
Install the cylinder head on the cylinder
properly.
°ØBe careful not to damage the mating
surfaces.

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7. CYLINDER HEAD (2-STROKE)/
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Cylinder head Bolts Spark Plug

Cylinder Head Bolts Installation

Install and tighten the cylinder head bolts
diagonally in 2 or 3 times.
Torque: 1.0_ 1.2kg-m
Install the spark plug.
Torque: 1.1_ 1.7kg-m

Cylinder Head

Spark Plug

Engine Hood Installation

Install the engine hood. (7-5)
Install the spark plug cap. (7-5)
Remove the exhaust muffler. (13-10)

Perform the following inspections after

installation:
• Compression test
• Abnormal engine noise
• Cylinder air leaks
Engine Hood Bolt

Bolts

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CYLINDER/PISTON VITALITY 50
Cylinder

CYLINDER/PISTON
(2-STROKE)
CYLINDER REMOVAL
Remove the cylinder head. (7-5)
Remove the exhaust muffler. (13-10)

Remove the cylinder.

Remove the cylinder gasket.
°ØDo not pry between the cylinder and
crankcase or strike the fins.

Piston Piston Pin

PISTON REMOVAL
Remove the piston pin clip to remove the
piston pin and piston.

°Ø• Do not damage or scratch the piston.

• Do not apply side force to the
connecting rod when removing the
piston pin.
• Place clean shop towels in the
crankcase to keep the piston pin clip
from falling into the crankcase.

Piston Pin Clip

Spread each piston ring and remove by

lifting it up at a point just opposite the gap.
Remove the expander.

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7. CYLINDER HEAD (2-STROKE)/
CYLINDER/PISTON VITALITY 50

CYLINDER/PISTON INSPECTION
Check the cylinder and piston for wear or
damage.
Clean carbon deposits from the exhaust
port area.
°ØBe careful not to damage the cylinder
inside wall.

Measure the cylinder bore at three levels of

A, B and C in both X and Y directions.
Avoid the port area. Take the maximum
figure measured to determine the cylinder
bore.
Service Limit: 39.05mm replace if over

Inspect the top of the cylinder for warpage.

Service Limit: 0.10mm replace if over

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7. CYLINDER HEAD (2-STROKE)/
CYLINDER/PISTON VITALITY 50
A Mark

°ØThe cylinder has a “A” mark or no mark

on it. When replacing the cylinder with a
new one, use a cylinder having the same
mark as the old one.

Measure the piston O.D. at a point 5mm

from the bottom of the piston skirt.
Service Limit: 38.90mm replace if below

Measure the piston-to-cylinder clearance.

Service Limit: 0.10mm replace if over

Measure the piston pin hole I.D.

Service Limit: 12.03mm replace if over

Measure the piston pin O.D.

Service Limit: 11.98mm replace if below

Measure the piston-to-piston pin clearance.

Service Limit: 0.03mm replace if over

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7. CYLINDER HEAD (2-STROKE)/
CYLINDER/PISTON VITALITY 50

PISTON RING INSPECTION

Measure each piston ring end gap.
Service Limits:
Top/Second: 0.40mm replace if over

°ØSet each piston ring squarely into the

cylinder using the piston and measure
the end gap.

CONNECTING ROD SMALL END

INSPECTION
Install the piston pin and bearing in the
connecting rod small end and check for
excessive play.
Measure the connecting road small end I.D.
Service Limit: 17.03mm replace if over

PISTON/CYLINDER INSTALLATION
Piston
First install the expander in the second ring
groove. Top Ring (1st Ring)
Then install the top and second rings in
their respective ring grooves.
The piston rings should be pressed into the
grooves with even force.
After installation, check and make sure that
each ring is flush with the piston at several
points around the ring. Second Ring
A ring that will not compress means that Expander
the ring groove has carbon deposits in it and
should be cleaned.

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7. CYLINDER HEAD (2-STROKE)/
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Cylinder Gasket

Install a new cylinder gasket on the mating

surface between the cylinder and crankcase.

Ring Pins

Make sure that the ring end gaps are aligned

with the piston ring pins in the ring
grooves.

Lubricate the cylinder inside and piston

rings with engine oil and install the piston
into the cylinder while compressing the
piston rings.
°Ø
Be careful not to damage the piston.

Install the cylinder head.

Torque: 1.0_ 1.2kg-m
Install the exhaust muffler and tighten the
exhaust muffler joint lock nuts.
Torque: 1.0_ 1.4kg-m
Tighten the exhaust muffler lock bolts.
Torque: 3.0_ 3.6kg-m
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CYLINDER/PISTON VITALITY 50

Dowel Pin
CYLINDER/PISTON
(4-STROKE)
REMOVAL
Remove the cylinder head. (Refer to the
chapter 6)

Remove the two dowel pins and cylinder

head gasket.

Gasket

Remove cam chain guide and then remove

cylinder.

Cam Chain Guide

Remove the cylinder gasket and dowel pins. Dowel Pins

Clean any gasket material from the cylinder
surface.
°ØBe careful not to drop foreign matters
into the crankcase.

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CYLINDER/PISTON VITALITY 50

Piston Towel
Remove the piston pin clip.
°ØPlace a clean shop towel in the crankcase
to keep the piston pin clip from falling
into the crankcase.

Press the piston pin out of the piston and

remove the piston.

Clip Piston Pin

INSPECTION
Inspect the piston, piston pin and piston
rings.
Remove the piston rings.
°ØTake care not to damage or break the
piston rings during removal.

Clean carbon deposits from the piston ring

grooves.

Inspect the piston wall for

wear/scratches/damage.
If any defects are found, replace the piston
with a new one.

Install the piston rings onto the piston and

measure the piston ring-to-groove clearance.
Service Limits: Top: 0.09mm replace if
over
2nd: 0.09mm replace if
over

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Remove the piston rings and insert each

piston ring into the cylinder bottom.
°ØUse the piston head to push each piston 20mm
ring into the cylinder.

Measure the piston ring end gap.

Service Limit: Top: 0.5mm replace if over
2nd: 0.65mm replace if over
Oil ring: 0.9mm replace if over

Measure the piston pin hole I.D.

Service Limit: 13.04mm replace if over

Measure the piston pin O.D.

Service Limit: 12.96mm replace if below

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7. CYLINDER HEAD (2-STROKE)/
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Measure the piston O.D.
°ØTake measurement at 4.5mm from the
bottom and 90° to the piston pin hole. 4.5mm

Service Limit: 38.9mm replace if below

Measure the piston-to-piston pin clearance.

Service Limit: 0.02mm replace if over

CYLINDER INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D. at three levels of
top, middle and bottom at 90° to the piston
pin (in both X and Y directions).
Cylinder I.D.:
Service Limit: 39.1mm replace if over

Measure the cylinder-to-piston clearance.

Service Limit: 0.1mm repair or replace if
over

The true roundness is the difference

between the values measured in X and Y
directions. The cylindricity (difference
between the values measured at the three
levels) is subject to the maximum value
calculated.
Service Limits:
True Roundness: 0.05mm repair or replace
if over
Cylindricity: 0.05mm repair or replace if
over

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PISTON RING INSTALLATION
Install the piston rings onto the piston.
Apply engine oil to each piston ring.
°Ø• Be careful not to damage or break
the piston and piston rings.
• All rings should be installed with
the markings facing up.
Top
• After installing the rings, they
should rotate freely without sticking. Second
Side Rail
Oil Ring
Side Rail

Measure the connecting rod small end I.D.

Service Limit: 13.06mm replace if over

Measure the connecting rod to piston pin

clearance.
Service Limit: 0.06mm replace if over

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Intake Side Guide
Inspect the exhaust side and intake side
chain guides.
Wear/Damage _ Replace.

Exhaust Side Guide

“IN” Mark
PISTON INSTALLATION
Remove any gasket material from the
crankcase surface.
°ØBe careful not to drop foreign matters
into the crankcase.

Install the piston, piston pin and a new

piston pin clip.
°Ø• Position the piston “IN” mark
on the intake valve side.
• Place a clean shop towel in the
crankcase to keep the piston pin clip
from falling into the crankcase.

CYLINDER INSTALLATION
Install the dowel pins and a new cylinder
gasket on the crankcase.
Coat the cylinder bore, piston and piston
rings with clean engine oil.
Carefully lower the cylinder over the piston
by compressing the piston rings.
°Ø• Apply proper clean engine oil
around cylinder wall.
• Be careful not to damage or break
the piston rings.
• Stagger the ring end gaps at 120°
to the piston pin.

7-18