Cylinder Removal

Benelli T50 engine Breakdown
PART 3

In the third part of the tutorial, you will learn how to remove the cylinder, piston, and casing bolts from the T50 engine to prepare for splitting the engine casing. Parts such as the piston head, piston rings and cylinder can become worn or damaged and may need replacing. I can recommend tomosmopedparts.nl and benelliparts.de for replacement parts.

01

Exhaust
Manifold

Remove two 26 mm socket cap Allen Key bolts and their 12mm diameter washers. Revealing two paper gaskets on either side of a plastic spacer (only one is shown in image). 

Exhaust Manifold attached to cylinder
Exhaust Manifold Gasket
Exhaust Manifold Spacer
Exhaust Manifold Parts

02

Cylinder Head

Unbolt four 10mm nuts to remove the cylinder head along with a 13 mm diameter washer for each nut.

Cylinder Head
Cylinder Head Nuts and Washers

03

Cylinder
Removal

The aluminium cylinder can now be carefully slid up the 4 stud bolts.

Engine Cylinder
Engine Cylinder Removal

04

Casing
bolts

The remaining socket cap casing bolts can now be removed; two from the underside and one from the back of the engine casing.

Underside Casing Bolts
Rear Side Casing Bolts

05

Spillway &
other bolts

Unscrew the spillway bolt from the top of the casing and the two bolts from the underside. These include the tensioning bolt for the kickstart spring and the bolt that secures the selected gear.

Other Engine Bolts
Underside engine bolt
Spillway
Engine bolts other

06

Piston Head

Apply a small screw driver into the slot in the side of the piston head to dislodge the retaining pin. A plastic pen is ideal for pushing out the piston pin. Lastly remove the cage bearing.

Piston head
Piston pin

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