10.2
Section 10
Reassembly
Figure 10-2. Installing Oil Seal in Crankcase.
Install Crankshaft
1. Lubricate the cranksha journals and connecting
rod bearing surfaces with engine oil.
2. Carefully slide the fl ywheel end of the cranksha
through the main bearing in the crankcase. See
Figure 10-3.
Figure 10-3. Installing Crankshaft.
Install Connecting Rods with Pistons and
Rings
NOTE: The cylinders are numbered on the crankcase.
Make sure to install the piston, connecting
rod, and end cap into its appropriate cylinder
bore as previously marked at disassembly.
Do not mix the end caps and connecting
rods.
NOTE: Proper orientation of the piston/connecting
rod assemblies inside the engine is extremely
important. Improper orientation can cause
extensive wear or damage. Be certain the
pistons and connecting rods are assembled
exactly as shown in Figure 10-4.
Figure 10-5. Installing Piston Assembly Using Ring
Compressor Tool.
4. Install the inner rod cap to the connecting rod
using the two hex fl ange screws. Torque in
increments to 11.6 N·m (103 in. lb.). Illustrated
instructions are provided in the service rod
package. See Figure 10-6.
Figure 10-4. Proper Piston Connecting Rod
Orientation.
1. Stagger the piston rings in the grooves until the
end gaps are 120° apart. The oil ring rails should
also be staggered.
2. Lubricate the cylinder bore, piston, and piston
rings with engine oil. Compress the rings using a
piston ring compressor.
3. Make sure the Fly stamping on the piston is
facing towards the fl ywheel side of the engine.
Use a hammer with a rubber grip and gently tap
the piston into the cylinder as shown in Figure
10-5. Be careful that the oil ring rails do not
spring free between the bo om of the ring
compressor and the top of the cylinder.
Cylinder #1
Cylinder #2
4.5 mm
(.177 in.)
Oil Seal
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