Piston Installation
lf the crankshaft is already installed
1. Setthe crankshaftto bottom dead center (BDC) for
each cylinder.
2. Remove the connecting rod caps, then install the
ring compressor, and check that the bearing is
securely in place,
3. Position the arrow {A) facing the cam chain side of
rne engtne.
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer (A).
N4aintain downward force on the ring compressor(B) to prevent the rings from expanding before
entering the cylinder bore.
Stop after the ring compressor pops free, and
check the connecting rod-to-crank journal
alignment before pushing the piston into place.
Check the connecting rod bearing clearance withplastigage (see page 7-8).
lnspect the connecting rod bolts (see page 7 241.
Apply engine oil to the bolt threads, then install the
rod caps with bearings. Torque the bolts to 20 N.m
{2.0 kgf m, 14 lbf ft) + 90'.
6.
7.
2.
1.
lf the crankshaft is not installed
Remove the connecting rod caps. then install the
ring compressor, and check that the bearing is
securely in place.
Position the arrow (A)facing the cam chain side of
Ine engrne.
Position the piston in the cylinder, and tap it in
using the wooden handle of a hammer (A),
Maintain downward force on the ring compressor(B) to prevent the rings from expanding before
entering the cylinder bore.
4. Position all pistons attop dead center.
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7-23
5. Installthe bearing halves in the cylinder block and
conneclrng rods.
6. Apply a coat of engine oilto the main bearings and
rod bearings.
7. Hold the crankshaft so rod journal No.2and rodjournal No. 3 are straight up, and lower the
crankshaft into the block.
8. lnstallthe thrust washers (A) in the No. 4 journal of
the cylinder block.
Apply engine oil to the threads ot the connecting
rod bolts,
Seat the rod journals into connecting rod No. 1 and
connecting rod No. 4. Line up the mark (B) on the
connecting rod and cap, then installthe caps and
bolts finger-tight.
Rotate the crankshaft clockwise, and seat thejournals into connecting rod No.2 and connecting
rod No. 3. Line up the mark on the connecting rod
and cap, then install the caps and bolts finger-tight.
9.
10.
'11 .
\-1
12. Tighten the connecting rod bolts to 20 N.m(2.0 kgf.m, 14 lbf.ft).
13. Tighten the connecting rod bolts an additional 90".
14. Remove old liquid gasket from the lower block
mating surfaces, bolts and bolt holes.
15. Clean and dry the lower block mating surfaces.
16. Apply liquid gasket, P/N 08718-0009, evenly to the
cylinder block mating surface of the lower block
and to the innerthreads ofthe bolt holes.
NOTE: Do not install the parts if 5 minutes or more
have elapsed since applying liquid gasket. Instead,
reapply liquid gasket after removing old residue.
(cont'd)
.\
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Apply liquid gasketalong the broken line.
7-25
