Sikk 27cc cylinder to the Zenoah 231/260 Bottom end

1. install the Sikk 27cc piston using the new wrist pin bearing, retainers and wrist pin clips on the Zenoah rod. A trick here is to chuck up the old zenoah wrist pin in a hand drill and hold it against a bench grinder wheel making one end a concave surface with sharp edges, this will be used to help install those pesky wrist pin clips. Slide open side of clip with gap towards the top and when the clip is ½ way into the groove, then use the old wrist pin tool you made set on the clip and press into place. Double check the clip is completely in the groove and the gap is at the top.

2. use the old Zenoah base gasket to determine the amount the Sikk cylinder bolt holes must be oblong. This picture shows the case material that should be removed to match the transfers. The flat side of the gasket must be trimmed about 1/8" (3.2mm) so it will have clearance for the coil mount housing. You might also want to assemble this part inside a large clear ziplock bag just in case the clip jumps and takes flight.

3. Fitting Cylinder to base... Use a rat tail file on the cylinder bolt holes and go slow, a chamfer must be made in the area of the skirt on the case for proper clearance . A tip here is to use a permanent marker on the cylinder skirt and if any is scraped off during trial assembly. you will need to make some clearance, keep checking the fit and when the cylinder will bolt down with no interference you are there when trial fitting the cylinder to the case you don't need the ring in the piston 

4. Line ring end gap with ring locating pin. Place one side in ring land and slide finger over top of piston ring. It will slide right in.

5. Make dead sure positive that the small circle on the piston top faces the EXHAUST PORT

6. Cut original ignition mount stub off and grind a notch in the fin to clear the Zenoahs coil mount

7. The completed Sikk/Zenoah conversion

Instructions by Larry Broman