new pulsar 125 Workshop-manual : Page 72

          7. CYLINDER/PISTON                                                         Pulsar   CK    125

                                                                           Shop Towel
 Remove any gasket material from the
 crankcase surface.
 Place a shop towel in the crankcase to
    prevent foreign matters from falling into
    the crankcase.




                                                                                        Gasket
                                                                  Piston
 Install the piston, piston pin and a new piston
 pin clip.
 · Position the piston top "IN" mark on
     the intake valve side.
   · Place a clean shop towel in the
     crankcase to prevent the piston pin clip
     from falling into the crankcase.



                                                          Wave Washer        Cam Follower Shaft
 CYLINDER INSTALLATION
 Install the 12mm washer (wave washer) into
 the groove.
 Install the cam follower and cam follower
 shaft.
 Apply engine oil to the cam follower shaft
 O-ring and install it with even force.
 Install the cam follower shaft with the
    slot on the shaft in vertical position.
 Install the dowel pins and a new cylinder
 gasket on the crankcase.                          Cylinder                Cam Follower    O-ring

 Carefully lower the cylinder over the piston
 by compressing the piston rings.                  Cylinder
 · When installing the cylinder, be careful
      that the ring end gap should not be 90°
      to the piston pin.
    · The ring end gaps should align with the
      four cylinder head lock nuts.
 Stagger the ring end gaps as shown. (Refer
 to 7-6.)
 Install the cylinder head gasket, dowel pins
 and O-ring.
                                                               Piston

7-7