Carefully lower the lower crankcase half onto the upper crankcase half

some grease to the inside of the new seal on installation (see illustration).

14Generously lubricate the crankshaft and transmission shafts, particularly around the bearings, with clean engine oil, then use a rag soaked in high flash-point solvent to wipe over the mating surfaces of both crankcase halves to remove all traces of oil.

15 If removed, install thethree locating dowels and the two oil nozzles in the upper crankcase half (see illustration 20.10).The oil nozzles must be fitted with the wider aperture facing out, ie towards the crankcase lower half.

16 Apply a small amount of suitable sealant to the outer mating surface of the lower crankcase half (see illustration).

Caution: Do not apply an excessive amount of sealant as it will ooze out when the case halves are assembled and may obstruct oil passages. Do not apply the sealant on or too close to any of the bearing inserts orsurfaces.

17Check again that all components are in
position, particularly that the bearing shells
are still correctly located in the lower
crankcase half and that the camchain guides
are correctly located in the upper crankcase
half. Carefully install the lower crankcase half
down onto the upper crankcase half, making
sure each gear selector fork locates correctly
in the groove in its pinion, that the guide pins
on the forks locate correctly in the grooves in

the selector drum and that the crankcase dowels all locate correctly into the lower crankcase half (see illustration).

18Check that the lower crankcase half iscorrectly seated. Note:The crankcase halves should fit together without being forced. If the casings are not correctly seated, remove the lower crankcase half and investigate the problem. Do not attempt to pull them together using the crankcase bolts as the casing will crack and be ruined.

19Clean the threads of the twelve 8 mm lower crankcase (crankshaft and balancer shaft journals) bolts. Apply clean engine oil to the threads and seating surfaces of the bolts and install them with new washers in their original locations (see illustration).Secure all bolts finger-tight at first, then tighten them evenly and a little at a time in a criss-cross pattern, starting from the centre and working outwards, to the torque setting specified at the beginning of this Chapter.

20Clean the threads of the eight 6 mm lower crankcase bolts and insert them in their original locations. Secure all bolts finger-tight at first, then tighten them evenly a little at a time in a criss-cross pattern to the torque setting specified at the beginning of this Chapter (see illustration).

21Turn the engine over. Ensure the camchain is secured to prevent it dropping into the crankcase. Clean the threads of the single 10 mm upper crankcase bolt and insert

it into the rear left-hand corner of the crankcase. Tighten the bolt to the specified torque (see illustration).

22Clean the threads of the two 8 mm upper crankcase bolts and insert them in their original locations with new sealing washers. Secure the bolts finger-tight at first, then tighten them evenly a little at a time to the torque setting specified at the beginning of this Chapter (see illustration).

23Clean the threads of the five 6 mm upper crankcase bolts and insert them in their original locations. Fit new sealing washers where the bolt locations are identified by a triangle cast into the crankcase. Secure the bolts finger-tight atfirst, thentighten them evenly a little at a time in a criss­cross pattern to the torque setting specified at

Date: 2016-01-14; view: 586