ENGINE
3.36
4. Apply clean engine oil to the piston rings, ring
lands, pistonpin bore,pistonpin, and pistonskirt.
Lubricate the connecting rod (both ends) and
crankshaft main bearing area.
5. Install the piston on the connecting rod with
thepincastingnotchfacing therear ofengine
(starter side). The piston pin should be a
push fit in the piston.
6. Install the other circlip with the gap facing up or
down. (SeeCautionwithStep3above). Pushthe
piston pin inbothdirectionstomakesure theclips
are properly seated in the groove.
7. Placethedowelpinsinthecrankcaseandinstalla
new cylinder base gasket.
8. Lubricate thepiston and ringswithassemblylube
and install a sleeve--type ring compressor on the
piston assembly. Verifythatthering gaps are120
degreesapartfromeachother beforeinstallation.
CYLINDER INSTALLATION
1. Position the Piston Support Block (PN 2870390)
(A) beneath the piston skirt to support the piston
during cylinder installation.
A
2. Applycleanengineoilliberallytothe cylinderbore
and tapered area of the sleeve. Install the
cylinder witha slight rockingmotionuntil therings
are captive in the sleeve.
3. Remove the ring compressor and support block.
4. Push the cylinder downward until fully seated on
the base gasket.
NOTE: If cam chain is installed, hold it up while
rotatingtheenginetoavoiddamagetothe chain,drive
sprocket teeth, or tensioner blade.
5. Install the two 6 mm bolts, but do not tighten.
CYLINDER HEAD
INSTALLA
TION
Clean the gasket surfaces on the cylinder head and
cylinder. Remove all traces of old gasket material.
1. Install the cam chain tensioner guide. Be sure
bottom end of guide is located properly in
crankcase.
2. Installthetwo dowel pinsandanewcylinderhead
gasket.
3. Place the cylinder head on the cylinder. Apply a
film of engine oil to the cylinder head bolt threads
and washers, and hand tighten the bolts.
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