My nephew seized his 86 TRX250R a few weeks back. I do most of the maintenance on the bike so it's time to do a top end. I've done many top ends on 250R's but this one may be a little different. How do I go about removing the cylinder from the engine when the piston is seized to the cylinder. Any help would be appreciated. Thanks.

Z

Remove the head and gas tank.

Then apply heat to the cylinder and piston.
While doing that, apply force to the cylinder to pull it up.

Good luck.

Wow...that really sucks! I'm no pro but here's what I would do. I would take the head off, remove the bolts from the cylinder and spray some WD-40 in the cylinder to try and get a film of oil between the piston and sleeve. Then using a block of wood, set it on the top of just the piston (try and cover as much of the top of the piston as possible to spread out the force) and "malletize" it some (beat on it) while pulling up on the cylinder. You're obviously not worried about the piston of sleeve, just the rod and crank. Don't beat the piss out of it, but nice placed sharp blows will help break it loose. The heating up idea that Sandpusher stated can be done, but if have never used a torch to break things free, I'd hate to see you warp or damage the cylinder to the point where you couldn't resleeve it. The piston's aluminum and the sleeve is steel. Dissimilar metals don't really fuse, there's just some pieces of piston that have jammed in there I'm sure. Hope this helps and good luck.

Thanks for your input guys. Thecylinder came off fine. Looks like the bottom end grenaded . The crank is stuck and metal is all over the place. Time for a new motor. Thanks again.

Z

damn that sucks

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