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DT125B Motorcycle
Disassembly, machining, and replacement of the cylinder unit
Table of Contents
Introduction
Tools List
Background
Section 1: Preparations
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Introduction:
Many problems with motorbike engines can be explained by a need to replace the piston
head and seals, and possibly re-boring the cylinder. Quite often, the user notices a lack of
power. The bike might not even start. Symptoms like these can be indicative of several
different problems. Problems with the fuel, ignition, or air intake systems could be to
blame. However, certain signs can point to the problem being within the cylinder itself.
For example, if the kick-starter moves more freely than it should, it could indicate
pressure loss in the engine. On bikes not equipped with a kick-starter, diagnosis might
require a more iterative system of checks. Is the fuel system working? Is the spark plug
working? Is the air intake plugged? If the problem cannot be found anywhere else, it may
be time to open the cylinder and inspect the piston seals. If the seals appear damaged, the
walls of the cylinder marred, or the piston itself deformed, an overhaul is required.
Please Note:
This document is dedicated to the process of disassembling and overhauling the cylinder
itself, and is not intended to be a diagnosis guide. Please refer to other guides, such as the
owners manual, or to professionals for diagnosis of the problem.
Background:
This section describes the physical processes and conditions that would require a cylinder overhaul.
This page can be skipped in the interest of time.
All motorcycle and ATV engines run on cylinders. Combustion occurs in the cylinder, which
converts thermal energy to mechanical energy. This mechanical energy is then transferred
through the gears to the wheels, moving the unit. The piston, within the cylinder, moves up and
down to convert the pressure to translational motion. The carburetor, attached to the cylinder,
forces fuel into the cylinder. A spark plug ignites the fuel. The exhaust system removes
combustion products from the engine. These components work together cyclically to power the
bike.
Figure 1: The basic two-stroke engine cycle. From left to right: (1), fuel and air are compressed into
the top end of the cylinder. At the same time, air and fuel (from the carburetor) are drawn into the
bottom of the cylinder.(2), the spark plug ignites the mixture. The rapid increase in temperature and
pressure forces the piston down. (3), as the piston nears the bottom of its stroke, the gases are
allowed to escape via the exhaust system. (4), new air and fuel are forced into the cylinder.
In older motors the gap between the cylinder walls and piston head can grow. This growth is
often caused by the piston seal wearing away, and can also be caused by deformation of the
cylinder head. As the gap between the cylinder walls and the piston head grows, more pressure
is lost from the engine. Pressure loss results in power loss, translating to decreased
performance. In severe cases, the engine may not even start.
When this gap becomes too large, the piston seals must be replaced. In severe cases, the cylinder
must be re-bored, meaning the walls of the cylinder must be machined to restore the surface
finish of the cylinder walls. Re-boring the cylinder requires that material be removed, resulting
in a slightly larger cylinder diameter, thus creating the need for a larger piston head.
Note: With proper maintenance of the engine, the pistons should not become deformed and the
cylinders not need to be re-bored. Abuse or neglect of the engine can result in the need for more
drastic repairs.
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Section 1: Preparations
Warning: If this first step is
not completed, gas may leak
from the tank and cause a
safety hazard.
D. Remove piston
Piston Down
Piston Up
Warning: Be careful not to pinch your fingers during the next step.
D. Carefully lower the cylinder over the
piston while compressing the rings with
your fingers until the cylinder slides
down easily.
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Appendix A:
Motor Layout
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1.
2.
Spark plug Cap: Connects to spark plug, which is screwed into the cylinder head
3.
4.
5.
Cylinder: Where the piston is housed and where combustion takes place
6.
7.
8.
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Appendix B:
Piston Schematic & Labeled Parts
1.
Piston Rings
2.
Piston Head
3.
4.
Circlips
5.
5
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