Can the top end (cylinder & piston)of a Rev3 be removed with the motor in the frame? If not, what does it take?

Yes, no problem the rad has to be loosened if I remember correctly.

From memory of having one,there isn't enough room to lift the barrell off the piston before it hits the frame.

However you can get round this by undoing the four base nuts and then lifting the piston and barrel together, sliding the piston down slowly until you can see the gudgeon pin, with the conrod as low as possible ie around 6 oclock.

Undo the circlip and push pin out making sure you have stuffed cloth down the crankcase to catch anything that drops!! Remove the whole lump, repalce what you have to and reverse to put it all back.

give it a go!! nothing to lose

From memory of having one,there isn't enough room to lift the barrell off the piston before it hits the frame.

However you can get round this by undoing the four base nuts and then lifting the piston and barrel together, sliding the piston down slowly until you can see the gudgeon pin, with the conrod as low as possible ie around 6 oclock.

Undo the circlip and push pin out making sure you have stuffed cloth down the crankcase to catch anything that drops!! Remove the whole lump, repalce what you have to and reverse to put it all back.

give it a go!! nothing to lose

Don't forget to use a new circlip if you do this. You only need to suffer once the consequences of a circlip coming out not to take the chance a second time!

yes no problem, done loads. take the rad off and i usually remove the frame side rails, its easier to work on. take the head off first, then remove the barrel with the piston at Bottom dead center.

what job are you doing?

yes no problem, done loads. take the rad off and i usually remove the frame side rails, its easier to work on. take the head off first, then remove the barrel with the piston at Bottom dead center.

what job are you doing?

Mine won't clear the frame with piston at BDC, the lug for the top mount catches under the tank. Must be a combination of manufacturing tolerances.

Just done this on an 04 rev 3. like the man says, remove the rad, head and coil. Lift the barrel with the piston off the crankcase bolts. place rag in crankcase apeture (well you never know what will fall in there) got the t-shirt for that one. move the crank so the conrod is at the rear of the engine and tip the barrel forwards, this should give you enough room to slide the barrel off. a little more fiddley to put together. hope this helps.

cheers,

tom,

oh forgot to say when the rings are visable in the lower skirt area i twisted the barrel slightly to miss the top mount. but beware the piston ring locating pins are placed at the rear of the piston, be careful if you have to twist the barrel back, you should not need to but check the ring ends if they are visable.

Tom,