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– Use a clean rag to protect the crankcase opening so as to prevent
foreign matter from accidentally entering. Carefully clean the mating
surface of cylinder with crankcase.
CYLINDER AND PISTON ASSEMBLY
– Fit the roller cage in the con-rod small end after lubricating it with
plenty of fully synthetic mixer oil.
– Fit one of the two gudgeon pin circlips (6) on the piston (2), lubricate
the piston ring grooves and carefully fi t the piston rings (3 upper
and 4 lower). Where present, be careful to fi t the piston rings with
the inscription "TOP" towards the piston crown. Check that the
piston ring enters completely into its seat by pressing slightly with
the fi ngers to confi rm a correct assembly.
– Fit piston (2) ensuring that the arrow at the top points to the cylinder
exhaust port. Fit the lubricated gudgeon pin (5) from the side with
no circlip.
– Fit the second gudgeon pin circlip (6) and make sure that both are
correctly positioned in their seats, without any clearance between
them and their seats.
– Fit the cylinder base gasket (10).
– Lubricate the cylinder barrel (already washed and blown with air).
– Position the piston ring opening at the suitable retainers, push the piston
ring inside the grooves and carefully insert the lubricated cylinder fully
home on the base gasket.
– Manually turn the crankshaft two or three times (holding the cylinder
with your free hand) to ensure engine is correctly assembled).
Check that the piston does not interfere with any part of the engine
crankcase. In case of interference, remove excess material from
the crankcase while protecting the opening from removed material
and refi t piston and cylinder as previously described.

HEAD ASSEMBLY

– Insert the O-Rings (8) and (9) in their seats on head, smearing them
with grease for a better coupling.
– Fit the assembled head (7) on the stud bolts fully home on the
cylinder. Check for the correct position of the O-Rings.
– Tighten the head nuts in a cross pattern and in several steps to a
torque of 12±1 Nm (approx.1.2±0.1 kgm).
– Fit cooling circuit pipes.
– Fit the temperature sensor you had previously removed from scooter
original head.
– Proceed to fi lling the cooling circuit. To avoid any inconveniences,
9

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