Piston Kit Installation Instructions for 125cc Engines

Introduction:
This Piston Kit is designed for 125cc four-stroke engines, available in multiple piston diameters (52.4mm, 57.4mm, 58.5mm, 61mm, and 63mm) to meet various model requirements. Follow the instructions below for a successful installation.

Tools Required:

1. Socket wrench set
2. Torque wrench
3. Screwdriver set (flat and Phillips)
4. Piston ring compressor
5. Engine oil (for lubrication)
6. Clean rags
7. Safety gloves
8. Safety goggles
9. Gasket scraper (if necessary)
10. Replacement gaskets (if required)

Installation Steps:

1. Preparation:

   • Ensure the engine is cool to avoid burns.
   • Disconnect the battery for safety.
   • Remove any necessary bodywork to access the engine.
   • Drain the oil if required.

2. Remove the Cylinder Head:

   • Use the socket wrench to remove the bolts securing the cylinder head.
   • Carefully lift the cylinder head off the cylinder.

3. Remove the Old Piston:

   • Take note of the orientation of the old piston and connecting rod.
   • Remove the piston pin clips using a screwdriver and remove the piston pin.
   • Carefully slide the old piston out of the cylinder.

4. Install the New Piston:

   • Apply a light coat of engine oil to the new piston and rings for proper lubrication.
   • Using the piston ring compressor, compress the piston rings and insert the new piston into the cylinder with the correct orientation.
   • Align the piston pin with the connecting rod and insert it, secure it with the piston pin clips.

5. Reassemble the Cylinder Head:

   • Place a new gasket (if required) on the cylinder.
   • Carefully position the cylinder head back into place and secure it with bolts.
   • Use a torque wrench to tighten the bolts to the manufacturer’s specifications.

6. Final Checks:

   • Reinstall any components removed during disassembly.
   • Reconnect the battery.
   • Fill the engine with fresh oil if it was drained.
   • Check for any potential leaks.

7. Test Start:

   • Start the engine and allow it to idle.
   • Listen for any unusual noises and ensure optimal performance.

Conclusion:
Your Piston Kit installation is now complete. Enjoy enhanced performance and a smoother riding experience with your 125cc engine. Always consult your motorcycle’s owner manual for specific details pertaining to your model.

Safety Note:
Always wear safety goggles and gloves during installation to protect yourself from debris and sharp edges. If you are uncertain about any step, consult a professional mechanic.