Suzuki AX100 Cylinder Removal

Here are the tools you need. The socket is 12mm. The dual wrench came with the Suzuki and is 10mm/12mm. Missing from this shot is a 17mm wrench for the exhaust pipe. The needle nosed pliars are for removal of the piston pin circlip if removal of the piston is necessary.

First take off the spark plug.

Take off the exhaust pipe. The stock pipe is held onto the swingarm axle with a 17mm nut.

Remove the cylinder head nuts.

Loosen the front carburetor clamp.

Remove the left side cover.

Loosen the rear carburetor clamp.

Remove the air box bolts and remove the box.

Pull the carburetor back to the rear.

Remove the 10mm nuts holding down the rear of the cylinder.

Pull the head up and then off to the side.

Put your finger on the piston top and move the kickstart till the piston is at the bottom.

Pull the cylinder up a bit and then look all around to see which surface the base gasket is sticking to, the cylinder, the cases, or a little of both. If both then use a knife to position it totally towards the cylinder or to the cases.

Pull off the oil injector line. The first time it will need to be pryed off. Afterwards it can be pulled off just by pulling on it.

If the base gasket is mostly sticking to the cylinder then put your fingers under it all around the cylinder and lift the cylinder up. That is to keep it from catching on the cylinder studs and tearing. Then move the cylinder forward till it straddles the front two studs. Then you can move it sideways and out.

Assembly is just the reverse.