Repair Procedure: Procedure

A.
■ Key Information

Do the following before starting your work.

Remove:
- Right Front Wheel
■ Sub-Procedure

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• Installation
- Make sure the direction of the sensor connector (a) as shown.
B.
■ Sub-Procedure

• Installation

NOTE: Install new coolant separator A/B in the engine block whenever the engine block is replaced.
C.
■ Key Information

Do the following before starting your work.

Remove:
- Right/Left Engine Undercover Lid
- Exhaust Pipe A
■ After Installation
- CKP Pattern Clear/Learn
D.
■ Key Information

Do the following before starting your work.

Remove:
- Drive Plate

■ Key Information

Do the following before starting your work.

Remove:

Drive Plate

■ Sub-Procedure

• Removal

NOTE: Be careful not to damage the crankshaft and the engine block.

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• Installation

Clean and dry the oil seal housing.

Lubricant Specifications

Application Position	Type
Lip of the oil seal	Engine Oil

Installation Depth

Specifications
a: 0.2-1.2 mm (0.008-0.047 in)

Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.

■ Key Information

Do the following before starting your work.

Remove:

■ Sub-Procedure

Figure 1

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• Removal

1. Remove the bolts in the sequence shown. (Figure 1)

Figure 2

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2. Remove the bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. (Figure 2)

Figure 3

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3. Using a flat blade screwdriver, separate the lower block from the engine block in the places shown. (Figure 3)4. Remove the lower block and the bearings.

NOTE: Keep all the bearings in order.

Figure 4

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• Installation

1. Remove all of the old gasket from the mating surfaces of each part and clean it.

Liquid Gasket Specifications (Figure 4)

Application Position	Type	Diameter
a	Liquid Gasket (P/N 08718-0003, 08718-0004, or 08718- 0009)	b: 3.5 mm (0.138 in)

NOTE:

Install the component within 5 minutes of applying the liquid gasket.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the parts.

Figure 5

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Figure 6

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2. Tighten the bolts, in sequence. (Figure 5)

Lubricant Specifications

Application Position	Type
Threads Washer	Engine Oil

Tightening Procedure (Figure 6)

Step	Specifications
1	35 N.m (26 lbf.ft)

Step	Specifications
2	c: 41°

Figure 7

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3. Tighten the bolts, in sequence, to the specified torque. (Figure 7)

■ After Installation

CKP Pattern Clear/Learn

NOTE: Keep all removed parts in order, and install them of the original position when installing.

■ Key Information

Do the following before starting your work.

Remove:

Crankshaft

■ Sub-Procedure

Figure 1

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Figure 2

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• Removal

NOTE:

If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (a). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the piston as it is pushed out. (Figure 1)
Take care not to damage the cylinder with the connecting rod. (Figure 2)
Mark each piston/connecting rod assembly with its cylinder number to make sure they are reinstalled in the original order.
The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.
Keep all connecting rod bearings in order.

Figure 3

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• Installation

1. Check the connecting rod bearing is securely in place.

Lubricant Specifications

Application Position	Type
Piston Inside of Ring Compressor Cylinder Bore	Engine Oil

2. Position the piston/rod assembly with the arrow (b) facing the cam chain side of the engine block. (Figure 3)

Figure 4

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3. Push down on the ring compressor (c) to prevent the rings from expanding before entering the cylinder bore. (Figure 4)4. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.

■ Key Information

Do the following before starting your work.

Remove:

Engine Assembly
Lower Block

■ Sub-Procedure

NOTE:

Keep all removed parts in order, and install them of the original position when installing.
Be careful not to damage the journals and the CKP pulse plate.
Be sure to install the lower block when removing/installing the connecting rod cap.

• Removal

Remove the connecting rod cap and bearing half.

Figure 1

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• Installation

1. Adjust the main bearing . (if necessary)

2. Install the crankshaft.

Lubricant Specifications

Application Position	Type
Main Bearings Connecting Rod Bearings	Engine Oil

3. Install the washer (a) as shown. (Figure 1)

Lubricant Specifications

Application Position	Type
Washer Surfaces	Engine Oil

Figure 2

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Figure 3

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4. Adjust the connecting rod bearing . (if necessary)

5. Install the connecting rod cap. Line up the mark (b) on the connecting rod and the connecting rod cap. (Figure 2)

Lubricant Specifications

Application Position	Type
Threads Flange	Engine Oil

Tightening Procedure (Figure 3)

Step	Specifications
1	5.0 N.m (3.7 lbf.ft)
2	39 N.m (29 lbf.ft)
3	c: 120°

NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 1 of the tightening procedure. Do not loosen it back to the specified angle.

6. Inspect the connecting rod and crankshaft end play - Refer to: Connecting Rod and Crankshaft End Play Inspection or Piston, Ring, Pin, and Connecting Rod Inspection

(if necessary)

■ After Installation

CKP Pattern Clear/Learn

■ Sub-Procedure

NOTE: Be careful not to damage the CKP pulse plate.

• Installation

Lubricant Specifications

Application Position	Type
Bolt Threads Bolt Flange	Engine Oil

■ After Installation

CKP Pattern Clear/Learn

■ Sub-Procedure

NOTE: Keep all removed parts in order, and install them of the original position when installing.

Figure 1

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• Removal

Using a ring expander. (Figure 1)

Figure 2

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• Installation

Clean all ring grooves thoroughly with a squared-off broken ring or a ring groove cleaner with a blade to fit the piston grooves. File down a blade if necessary. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tools.
If necessary, inspect the piston ring end gap - Refer to: Piston, Ring, Pin, and Connecting Rod Inspection or Block and Piston Inspection .

NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.

Ring Groove Specifications (Figure 2)

Position	Specifications
a	1.5 mm (0.059 in)
b	1.0 mm (0.039 in)
c	2.0 mm (0.079 in)

Figure 3

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Figure 4

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Figure 5

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The manufacturing marks (d)/(e) must be facing upward. (Figure 3)

Marking Details (Figure 3)

Marking Position	Mark
d	1RF
e	2RF

Piston Ring Specifications (Figure 4)

Position		Specifications
Top Ring	f	2.7 mm (0.106 in)
Top Ring	g	1.5 mm (0.059 in)
Second Ring	f	2.7 mm (0.106 in)
Second Ring	g	1.0 mm (0.039 in)

Lubricant Specifications

Application Position	Type
Piston Rings	Engine Oil

Rotate the rings in their grooves to make sure they do not bind.
Position the ring end gaps as shown. (Figure 5)

■ After Installation

If necessary, inspect the ring-to-groove clearance - Refer to: Piston, Ring, Pin, and Connecting Rod Inspection or Block and Piston Inspection .

■ Sub-Procedure

NOTE: Keep all removed parts in order, and install them of the original position when installing.

Figure 1

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Figure 2

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• Removal

1. Remove the snap rings.

Lubricant Specifications (Figure 1)

Application Position	Type
a	Engine Oil

-1. Turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (b). (Figure 1)

NOTE: Take care not to damage the ring grooves.

-2. Remove the snap rings from both sides of each piston. Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear goggles or safety glasses to prevent eye injury. (Figure 2)

Figure 3

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2. Remove the piston pin. (Figure 3)

Heat the piston/rod assembly to about 158 °F (70 °C).

3. If necessary, do the following inspection.

Piston Pin - Refer to: Piston, Ring, Pin, and Connecting Rod Inspection or Block and Piston Inspection
Piston Pin-to-Piston Clearance - Refer to: Piston, Ring, Pin, and Connecting Rod Inspection or Block and Piston Inspection
Piston Pin-to-Connecting Rod Clearance - Refer to: Piston, Ring, Pin, and Connecting Rod Inspection or Block and Piston Inspection
Piston Skirt Diameter - Refer to: Block and Piston Inspection or Cylinder Bore Honing
Piston-to-Cylinder Bore Clearance - Refer to: Block and Piston Inspection or Cylinder Bore Honing

Figure 4

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Figure 5

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• Installation

1. Install the snap ring. (only on one side)

2. Install the piston pin.

Lubricant Specifications

Application Position	Type
Piston Pin Bore (Piston/Connecting Rod) Piston Pin	Engine Oil

Heat the piston to about 158 °F (70 °C). (Figure 4)
Align the arrow (c) with the groove (d) direction on the connecting rod as shown. (Figure 5)

3. Install the remaining snap ring.

Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston.