7. CYLINDER/PISTON Pulsar CK 125 SERVICE INFORMATION.......................7-1 CAM FOLLOWER REMOVAL ............... 7-2 TROUBLESHOOTING..............................7-1 PISTON REMOVAL/INSTALLATION... 7-2 CYLINDER REMOVAL ...........................7-2 CYLINDER INSTALLATION ................. 7-7 SERVICE INFORMATION GENERAL INSTRUCTIONS · The cylinder and piston can be serviced with the engine installed in the frame. · After disassembly, clean the removed parts and dry them with compressed air before inspection. Item Standard (mm) I.D. 56.556.6 Warpage Cylinder Cylindricity 0.01 True roundness 0.01 Ring-to-groove Top 0.50.75 clearance Second 0.50.75 Top 0.150.35 Piston/ Ring end gap Second 0.150.35 piston Oil side rail 0.20.5 ring Piston O.D. 56.4556.48 Piston O.D. measuring position 10mm from bottom of skirt Piston-to-cylinder clearance 0.010.075 Piston pin hole I.D. 15.00215.008 Piston pin O.D 14.915 Piston-to-piston pin clearance 0.0010.007 Connecting rod small end I.D. 15.0115.028 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 Excessive smoke from exhaust muffler · Worn, stuck or broken piston rings · Worn or damaged piston rings · Worn or damaged cylinder or piston · Worn or damaged cylinder or piston Compression too high Abnormal noisy piston · Excessive carbon build-up in combustion · Worn cylinder, piston or piston rings chamber or on piston head · Worn piston pin hole or piston pin 7-1