Guide: Installing cylinder, piston and adjust squish Big bore cylinderkit (part 5)

You need to be extra careful when you install a "Hyperkit"


First - Wash all parts with gasoline and clean with compressed air!


Picture 01
The piston ring must be measured and adjusted if necessary


Picture 02
Push the pistonring about 5mm into the cylinder


Picture 03
Push the piston up from the bottom so that the pistonring aligns


Picture 04
Now are the pistonring in the correct position to be measured


Picture 05
Measure with a feeler gauge opening on the piston ring
The gap should be 0.15 mm


Picture 06
How it should look like according to Malossis drawings


Picture 07
If you need to adjust the gap, you should file a with a diamond whetstone "outside to inside"
This is to maintain the coating on the pistonring


Picture 08
You must also grind off the corners so it will be 45 degree angles


Picture 09
Fit a circlips
NOTE
Make sure it ends up properly in the groove
The end of circlips must be vertically
Put a rag in the engineblock, If you drop anything


Picture 10
Put oil on the crankshaft bearing


Picture 11
Push a piece of the piston pin into the piston
NOTE
You should not install the piston ring yet


Picture 12
Push the piston pin so it touches the circlips you mounted
And mount circlips the same way as on the other side
NOTE
The arrow on the piston must point down
(towards the exhaust port)

Inserting the cylinder and aligne the piston


Picture 13
I install new studs with threadlock on


Picture 14
Insert the cylinder base gasket and push the piston in the cylinder without piston ring


Picture 15
Put washers on the cylinder and tighten the nuts on the studs


Picture 16
Crank the handle gently by spinning the variator
Check if the piston hitting anything in the engineblock


Picture 17
Check with a feelergauge if the piston is aligned in the block
NOTE
If the crankhalfes are processed wrong or if the crankshaft is bent you have a problem...
But everything was perfect in my case with a new crank and all.


Adjust squish

First fit the medium size cylindergasket
Do not apply the piston ring yet


Picture 18
Cut two pieces of solder that are approximately 1 mm shorter than the width of the piston


Picture 19
Tape them on the piston


Picture 20
Fit the head, tighten it to the correct torque (1.2 Kgm)


Picture 21
Crank the piston about 5 laps


Picture 22
Measure the flattened solder.
How to measure:
- Measure the smallest place
- Calculate the average of the two value
Check the table (Table 2) included with the kit which value you must have
You may experiment with the cylindergaskets to get the desired measurement


Table 2
In my case:
- The gap on the pistonrings should be 0.15 mm
- "Squish" measurement should be 0.8 mm
- And I need a sparkplug W34ES-ZU


Picture 23
Do not forget to install the pistonring


Picture 24
Lubricate the cylinder and mount it


Picture 25
Attach the head and all O-rings
NOTE
- Clean the head carefully first
- Do not forget the O-rings and make sure they are all in


Picture 26
More O-rings ..


Picture 27
And this one..

Links to Malossis assembly instructions


Done!
Soon it's time for the carburetor, etc.