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Cylinder Overhaul of a 1975 Yamaha

DT125B Motorcycle
Disassembly, machining, and replacement of the cylinder unit

Table of Contents
Introduction

Tools List

Background

Section 1: Preparations

Section 2: Opening the Cylinder

Section 3: Removing the Cylinder

Section 4: Replacing the Piston

Section 5: Reassembling the Cylinder

Section 6: Closing the Cylinder

Section 7: Preparing Motor for Regular Use

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Appendix A: Motor Layout

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Appendix B: Piston Schematic & Labeled Parts

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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.

Recommended Tools List

Philips Screwdriver (#2)


Flathead Screwdriver (1/4)
Needlenose Pliers
Razor Blade
Socket Wrench
17 mm Hex Socket
13 mm Hex Socket
12 mm Hex Socket
Shop Rags
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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.

C. Remove exhaust by unscrewing bolts


indicated below

A. Turn off the gas by turning the petcock


and disconnect the tank from the
carburetor. Remove the gas tank from
the motorcycle frame in order to reduce
the risk of gas spillage.

D. Loosen the clamps on both ends of the


carburetor and remove the bolts connecting to the cylinder.

B. Take off spark plug cap.

E. Remove the carburetor from the air box


and intake.

Section 2: Opening the Cylinder


A. Loosen and remove cylinder casing
bolts as indicated below. Note that
there are 2 bolts which mirror those
indicated that cannot be seen in the
image below.

Tip: When removing bolts it is a good idea


to bag and label them

B. Remove the head and head gasket from


the cylinder in order to open the
casing.

Section 3: Removing the Cylinder


A. Bring piston down to its lowest point
with the kick starter.

C. Remove the intake and reed valves from


the cylinder.

These valves can be pulled directly out of the


unit with a pair of needle-nose pliers.
This is how the piston looks at its lowest
point. Rotate the unit with the kick starter
until the cylinder stops moving downward.
If necessary, rotate the unit through an
entire cycle to get a feel for where the
bottom position is. This makes the cylinder
easier to remove.

B. Remove the cylinder from its casing.

Note: Following this section, you should take


the cylinder to a motorcycle shop to get it
bored. It is easier and cheaper to get the
existing cylinder bored than to get a brand
new cylinder. In addition, you will need to
purchase a new, larger piston to fit the new
cylinder.

This whole unit should lift off


assuming all other components so far have been fully
removed.
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Section 4: Replacing the Piston


A. Apply brake or carburetor cleaner to the F. Remove old base gasket.
bored cylinder and wipe clean.
G. Make sure all gasket surfaces are clean
B. Stuff rag around rod in motor
and smooth for new gaskets.
Tip: This is to prevent debris from dropping
into the bottom end of the motor.
C. Remove circlips (below left) on either
side of the old piston and push out the
wrist pin (below right) from the piston
joint.

H. Put on new base gasket.


I. Put a new wrist pin bearing in the rod as
indicated in the below diagram (No. 5
below).
J. Put a circlip into one side of piston as
indicated (No. 4 below).
K. Place the piston (No. 2 below), with the
arrow on top of the piston facing
towards the exhaust port of the cylinder,
on top of the rod and push the wrist pin
through the piston and wrist pin bearing
until it hits previously inserted circlip.

D. Remove piston

L. Install 2nd circlip on the opposite site of


the wrist pin (No. 4 below).

Example of a piston being removed

E. Remove wrist pin bearing from rod.


M. Install new rings on the piston (No. 1
above) making sure the rings are lined
up with location pins that are in the
grooves of the piston.
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Section 5: Reassembling the Cylinder


A. Remove the rag from the bottom end of
the motor.
B. Coat the inside of the cylinder with 2stroke oil.

E. Make sure the piston moves up and


down the cylinder smoothly by carefully holding the cylinder and pushing the
kick starter down.

Tip: This is to lubricate and prevent metal


on metal friction.
C. Raise the piston to the top of the stroke
with the kick starter, as seen below.

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.

Section 6: Closing the Cylinder


E. Replace the exhaust.

A gasket set for the motorcycle

A. Install the new head gasket.

An example of a cylinder intake without reeds, this is


where to you place the gasket. Note: This is where the
carburetor connects to the cylinder.

F. Replace the carburetor.


G. Replace the fuel tank on the bike frame.
H. Reattach the fuel line back to the
carburetor.
I. Replace the spark plug cap on the top of
the spark plug.
Head gasket (not shown) goes on top of the
cylinder. Example of the top of a cylinder
shown above

B. Install the head of the cylinder casing.


C. Install the four bolts into the head of the
cylinder casing and tighten the bolts.
D. Install the reads and intake with new
gaskets.
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Section 7: Preparing Motor for Regular Use

A. Start the motor and allow it to idle for


approximately 10 minutes.
B. Shut off the motor and allow it to fully
cool.
C. Repeat steps A-B three times.
D. Ride the bike at 1/2 throttle for 15
minutes.
E. Shut off the bike and allow it to fully cool.
F. Repeat steps D-E three times.

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Appendix A:
Motor Layout

Left Side View (When sitting on the motorcycle)

Right Side View (When sitting on the motorcycle)

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1.

Petcock: Can be used to cut off gas flow to carburetor

2.

Spark plug Cap: Connects to spark plug, which is screwed into the cylinder head

3.

Cylinder Head: Connected to the top of the cylinder

4.

Carburetor: Connected to cylinder, lets in gas from gas tank

5.

Cylinder: Where the piston is housed and where combustion takes place

6.

Exhaust: Where the exhaust pipe is connected to the cylinder

7.

Exhaust Pipe: Carries exhaust out of the cylinder

8.

Kickstarter: Used to start the motorcycle

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Appendix B:
Piston Schematic & Labeled Parts

1.

Piston Rings

2.

Piston Head

3.

Wrist Pin (Piston Pin)

4.

Circlips

5.

Wrist Pin Bearing (Cylindrical Bearing)

5
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