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Fit the cap and shell onto the

Corresponding rod, aligning the markings

(arrowed)

lubricate the crankpin with a 50/50 mixture of molybdenum disulphide grease and clean engine oil. Fit the connecting rod onto the crankpin.

27 Fit the bearing cap with its shell onto the connecting rod (see illustration).Make sure the cap is fitted the correct way round so the connecting rod and bearing cap markings are aligned.

28 Lubricate the threads and seats of the cap nuts with clean engine oil (see illustration).Fit the nuts to the connecting rod bolts and tighten them evenly, in two or three stages, to the specified torque setting.

29 Check that the crankshaft is free to rotate easily. Check to make sure that all components have been returned to their original locations using the marks made on disassembly.

30 Check that the rods rotate smoothly on the crankpin. If there are any signs of roughness or tightness, remove the rods and re-check the bearing clearance. Sometimes tapping the bottom of the connecting rod cap will relieve tightness, but if in doubt, recheck the clearances.

31Reassemble the crankcase halves (see Section 20).

23 Pistons- removal, inspection §^

and installation jjt

Note:To remove the pistons the engine must be removed from the frame.


Lubricate the cap nuts before fitting

Removal

1Remove the engine from the frame (see Section 5). Remove the cylinder head (see Section 10), and separate the crankcase halves (see Section 20). Note:Once the cylinder head has been removed, rest the engine upside-down on a block of wood to avoid damaging the camchain and camchain guides, and to provide sufficient clearance for the pistons and connecting rods to be withdrawn from the cylinders.

2 Remove the piston/connecting rod assemblies (see Section 22).

3 Before removing the piston from the connecting rod, use a sharp scriber or felt marker pen to write the cylinder identity on the piston crown, or on the inside of the skirt if the piston is dirty and going to be cleaned. Each piston should also have an 'IN' mark on its crown with corresponding large valve cutaways which should face the inlet side of the engine (see illustration).If the 'IN' mark is not visible, mark the piston accordingly so that it can be installed the correct way round.

4 Carefully prise out the circlip on one side of the piston using needle-nose pliers or a small flat-bladed screwdriver inserted into the notch (see illustration).Push the piston pin out from the other side to free the piston from the connecting rod (see illustration).Remove the other circlip and discard them as new ones must be used. When the piston has been removed, install its pin back into its bore so that related parts do not get mixed up.


 





Date: 2016-01-14; view: 563


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Bearing shell selection | Note the IN mark which faces the inlet side of the cylinder
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