Tuesday 1 May 2012

Cagiva Mito 125 Top End Removal ( Cylinder barrel - Piston )

Removing the top end and replacement it very easy to do and anyone with basic tools can do this is a day or 2 after you have done it a few times (which you will if you keep you mito for long in one afternoon)

remove the five bolts holding down the head

piston to the BDC , then undo the four bolts situated on each corner .

Now the cylinder itself is ready to be removed ,try to avoid small parts falling into the crank case if you do engine removal and swilling out with old diesel will be required
 , lift the cylinder off the crank case making sure its going up straight and not at an angle, lift it about 25mm and stuff a rag into the crank case tightly t avoid any debree falling into the crank case.

9. Once the cylinder is out of the way you can begin to remove the C clips which are are at the side of the piston (set in about 5mm) once these are gone remove the  piston pin / gudgeon pin this can be tight so be carful when tapping and removing it brace piston if tapping is required once pin is  removed, the piston will come off the con rod and you can remove the little end bearing.

Put a new little end bearing in the conrod (oil it before hand with 2 stroke oil, also oil the top of the con rod, now oil the new wrist/gudgeon/piston pin and place that inside the bearing. Next put the piston rings onto the piston, Every piston ring will have a stamp mark near the ring gap, This MUST be installed facing upwards. Also, locate the "locating pin" in the piston groove. The ring gap will go here, do this for both piston rings.

Now your piston is ready to go on the conrod, there will be an arrow on top of the piston, this faces the exhaust port (forwards facing on most bikes), place the piston over the con rod end and get the piston "holes" inline with the wrist pic which is already installed, once you have it inline place the C clips inside the "holes" so it locks the piston to the conrod and wrist pin, once there in fully make sure the gaps in the clips are not near the little groove or indentation in the wrist pin/piston holes else they may fall out.

Oil the piston with 2 stroke oil, especially around the rings. Now get your new cylinder or reconditioned one and lube the bore with 2 stroke. Now that your cylinder is ready place your base gasket onto the crank case cover (i would you the medium thickness one but this can be altered for squish readings when more advanced ) get your cylinder ready , hold the piston rings tight so they compress and slide the cylinder onto the piston, very slowly at first it will be difficult, once you get the rings into the bore it will slide straight on , once its on just work your way from step 6 to 1 in reverse order.

see very very easy

Cagiva Mito 125 engine cylinder barrel removal

This is the coolant drain for Cagiva Mito 125 engine

let the coolant all drain out 

Cagiva Mito 125 engine cylinder barrel removal

Cagiva Mito 125 engine cylinder barrel removal

start undoing all of the hoses and remove them 

Cagiva Mito 125 engine cylinder barrel removal

Cagiva Mito 125 engine cylinder barrel removal

Now remove the CTS power valve unit 

Cagiva Mito 125 engine cylinder barrel removal

The head will come of really easy just remove all bolts 

Cagiva Mito 125 engine cylinder barrel removal

Cagiva Mito 125 engine cylinder barrel removal

Cagiva Mito 125 engine cylinder barrel removal

its easy to remove the piston just undo the 2 circlips holding it
in place and slide gudgeon pin free

Cagiva Mito 125 engine cylinder barrel removal

Nice new Cagiva Mito top end with flare piston ready for fitting 

cagiva barrel , cylinder head
cagiva mito engine rebuild
Cagiva mito engine 

Checking Squish Clearance Video 


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