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Removing
the cylinder head:
With
the coolant completely drained and the exhaust removed you
are now ready to proceed.
This
is really the easy part. Using a set of pliers, remove
the OEM hose clamps that go to the large and small hoses
attached to the cylinder head (see
picture 1). Now, just twist and pull on the hoses
until they come off. Some water will drain at this
point, which is fine. Next using a proper 13/16” spark
plug socket remove the stock spark plug (circled green in picture
1). Now using a deep-well socket, remove the water
spigot, which is where the small coolant hose attached to
(see picture 2). If
you are using a Top Performance big-bore kit, you will reuse
this part, so set it aside. If you are using any other
big-bore kit, this will be a leftover part.
Next,
using the proper size deep-well socket remove the temperature
sending unit from the stock head (circled red in picture
1). The temperature sending unit is the only part
of the head that has an electrical wire running to it. Now
that the head is bare, you now need to remove the four nuts
that hold down the head and cylinder to the crankcase. Note,
sometimes the entire stud comes out instead of the nut alone…this
is not a big deal, you just have to locate a stud installer
tool or use a pair of M7 nuts to re-install the cylinder
stud. With the nuts removed you simply pull up on
the head and it will come off. Make sure to collect
all of the four small and two large o-rings (see
picture 3).
Removing
the cylinder:
Try
to soak up any remaining coolant in the water jacket of the
cylinder. You really do not want a ton of water going
into the crankcase. Next, pull up on the cylinder itself,
it should slide off with some very light effort. Try to
pull it up as even and square as possible (see
picture 4). The friction you feel is the piston rings pressing
on the bore, which is completely normal. Also, keep a
hand underneath to catch the connecting rod, so it does not
bang against the crankcase when the cylinder comes off. After
the cylinder is off, place a few clean rags into opening in
the crankcase. You DO NOT want anything falling into the
crankcase.
Removing
the piston and wristpin:
The
piston in held onto the connecting rod by the wristpin and two
small circlips (highlighted in picture
5). The circlips fit into small grooves in the piston,
and keep the wristpin from falling out. Using a pair of
needle nose pliers grab the tab on the circlip that retains
the wristpin and gently pull on it (see
picture 5). It helps to give the pliers a twisting
motion too, as if you are tightening the circlip onto itself. Make
sure you have clean rags stuffed in the crankcase, just in case,
you drop the circlip. You DO NOT want it to fall into
the motor.
With
just one circlip removed, you can then use a properly sized
socket and extension to push the wristpin out from the other
side (see picture 6). There
is a special tool for this, but the wristpins on the RS50
come out very easy. Hold the piton very firmly with
one hand while removing the wristpin. You do not want to
put any lateral strain on the connecting rod and big-end
bearing. The piston will now come off of the connecting
rod. You will also notice at this point, the small-end
bearing (see picture 7). You
can either replace it at this time or simply re-use it. Finally,
make sure to remove all traces of base gasket from the top
of the crankcase.
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