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CAUTION:
Take caution when handling the crankshaft. It is the main power transfer to the
rest of the engine. If it is out of alignment, it will cause premature failure of your
bearings which can lead to serious damage to the cylinder as well as the rest of
the engine. Do not try to true the crank yourself. Truing the crank should be
done professionally.
CAUTION:
If you split the cases, check the gear tooth faces for chipping & signs of
fatigue.
Check all the bearing for smooth noise free operation.
Engine assembly
CAUTION:
For any seals that are to be installed, apply a light amount of grease to the seals’
ID, assembly lube on all bearings and a small amount of Loctite to the OD.
1. Press the three bearings into the respective holes in each case half.
2. Press in the crank seals such that the concave side faces the crank weights.
3. Press in the counter shaft seal (concave side faces inside of transmission)
4. Press in the water pump assembly
5. Tap both ways axially then verify easy rotation.
6. Inspect the crankshaft for proper true geometry (no more than 0.002 “,
0.05mm, measured at bearing journal area while supported from the ends).
7. Insert the case bolts with the proper lengths at locations shown.
8. Torque to 12Nm (105in-lb). Starting toward the center working outward.
9. Trim away any excess gasket material if necessary.
NOTE: Check engine mount holes for excess material that may cause problems
in engine installation.
10. Install the piston with new wrist pin bearing and, pin and clips.
CAUTION:
Be sure to install the piston such that the arrow on the top piston surface points
to the exhaust (front of bike/engine) and put assembly lube on the connecting rod
bearing.
11. Install the piston rings.
CAUTION:
Ring end gap should be no less than 0.006” (0.016mm) and no more than 0.020”
(0.5mm).
12. Install the base gasket.
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