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Discussion Starter · #3 ·
Auto part Suspension part Suspension Engine Automotive tire

Begin by removing the 17mm oil drain plug.

next remove the header pipe. the bolts are 12mm on the head and where the muffler attaches in the rear under the shock. The stock pipe will also have a bolt under the right foot rest that will need to be removed.

Auto part Wheel Tire Automotive wheel system Rim
 

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Discussion Starter · #5 ·
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Remove the seat to gain access to the screws for the right side body panel. Removing this will make the job much easier.

Remove the round side cover with the allen nut, underneath you will find a 10mm bolt. Auto part Vehicle Wheel Car Automotive design

In the front remove the phillips head screw and there is a plastic body clip. Push in the center and it will come out.
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Hidden under the muffler is also a body clip. Automotive exterior Tire Automotive design Auto part Material property
 

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Discussion Starter · #7 ·
Auto part Automotive exterior Bumper When removing the panel make sure to slide it up first. There is a plastic hook and if not removed like this the hook will snap off.

The hook goes through this slot in the air filter housing. Auto part Engine Automotive engine part Differential Exhaust system
 

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Discussion Starter · #10 · (Edited)
Auto part Engine Fuel line Automotive engine part Carburetor
remove the plastic cover to gain better access to the three throttle body bolts. Use a 10mm ratcheting wrench to remove the three bolts.
Next loosen the clamp and move the throttle body out of the way. Set the brown spacer aside.
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Remove the connectors for the injector and throttle position sensor. Auto part Engine Fuel line Automotive engine part Vehicle
note: if you have an MSX 125 you will also have an idle air control valve.

It is not necessary to remove the fuel line unless you want it off and out of the way, but it is easy to do. If you do remove it push in on the white clip and slide in the clip in toward the line. This will allow you to slide it off and remove the fuel line. Auto part Engine Automotive engine part Fuel line Carburetor
 

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Discussion Starter · #13 ·
Next remove the cam gear cover, the crankshaft plug and the timing mark cover. The large one requires a 10mm allen wrench and the smaller is a 6mm.

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Discussion Starter · #14 ·
Hold the crank shaft bolt with a 17mm socket and remove the cam bolt wit a 12mm socket. Auto part Vehicle Engine Tire Automotive wheel system

Remove the cam chain idler pulley retainer bolt. Finger Auto part Hand Bicycle part Wheel

back out the cam chain tensioner bolt (14mm) on the bottom of the engine. there will now be enough slack in the chain to remove the cam sprocket. Auto part Tire Exhaust system Fuel line Automotive exhaust
 

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Discussion Starter · #16 ·
Auto part Engine Motor vehicle Vehicle Automotive tire remove the four head bolts with a 12mm socket.
Note: one of the bolts has a copper washer. It must go back in the same place.

Remove the two bolts next to the cam cover (8mm).

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Discussion Starter · #17 ·
Now simply slide the head off along with the head gasket. Auto part Engine Vehicle Disc brake Wheel

Slide the cylinder off carefully in the same way. Auto part Engine Automotive engine part Carburetor Vehicle

Set the cam chain idler off to the side. Auto part Metal

Using a precision flat head screwdriver remove one of the circlips on the wrist pin, slide it out and remove the piston. Auto part Auto part Fishing reel Disc brake Vehicle brake Rim
 

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Great Job Snake. Thank you.
 

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Discussion Starter · #20 · (Edited)
Important! Lube the cylinder bore and new piston with oil.

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Install the oil ring first (3parts)

Carefully stretch and install the rings from the top.
Note: rings are made of hard metal, but are brittle and will snap so put one end in a grove and work them around into the gap.

After the oil ring is assembled in its grove install the Ring marked "RN", followed by the "R" ring in the top groove. Make sure the markings are facing up, they should look like this when complete. Auto part Wheel

Make sure he gap in the rings are not lined up or there will be blowby.
 
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