Connecting Rods, Pistons & Cylinder Sleeves

d)Measure and check the clearance with the piston pin at right angles to the crankshaft axis. (Refer to “Specifications”)

It should require 2 to 6 lbs. pull to move the ribbon gauge.

5.INSTALLATION :

a)Immerse the piston assembly in clean engine oil and fit a ring compressor over the piston.

b)Place the connecting rod in the correct cylinder and push down steadily on the piston until it is completely in the cylinder.

c)Wipe the crankshaft bearing end of the rod to remove and dirt gathered during installation. Wipe the bearing upper half clean then fit it to the connecting rod. Apply oil to the bearing surface and position the connecting rod on the crankshaft with the number to the F.I. Pump side.

d)Wipe the bearing cap and lower half bearing clean then assemble together. Apply oil to the bearing surface and install the cap on the connecting rod with the number to the F.I. Pump side.

e)Tighten the bolts to the specified torque.

f)Proceed as detailed in ops. (a) to (e) for the remaining piston assemblies.

NOTE: When correctly positioned, the connecting rod cap bearing half will stand out 0.7 mm (0.030 in) above the cap surface and will engage inside the connecting rod half bore. Failure to position correctly will result in the bearing halves being out of line when the bearing cap bolts are torqued.

g)Install the oil pump.

h)Install the cylinder head.

6.DISMANTLING :

Using a piston ring expander, remove the piston rings in the following order. First, remove the top compression ring (Fig 11-2); then remove the second compression ring (Fig 12-2) and finally remove the third oil control ring (Fig. 13-2) and the expander. Remove the two circlips (Fig 6-2) and push out the piston pin (Fig 5-2) out of the pin boss. The pin can be pushed out by applying a slight hand pressure. Identify the piston pin and the piston (Fig 4-2) with a paint mark or a tag. Do not interchange pins and pistons while assembling.

The connecting rod can be removed and installed without having to separate the engine from the clutch.