3.39
ENGINE
3
Cylinder Installation
NOTE: Clean the gasket surfaces on the crankcase
and cylinder. Remove all traces of old gasket
material and apply a new base gasket
1. Verify the cylinder base dowel pin(s) and a new base
gasket are installed. Position the Piston Support Block (PN
2870390) (A) beneath the piston skirt to support the piston
during cylinder installation.
NOTE: Route cam chain through the cylinder chain
room and secure it, holding it up while rotating the
engine to avoid damage to the chain, drive sprocket
teeth or tensioner blade.
2. Apply clean engine oil liberally to the bore and tapered area
of the cylinder. Place the cylinder on to the studs.
3. Loop the cam chain through the cylinder chain room and
secure with mechanic’s wire. Seat the cylinder fully on the
piston and support block.
4. Push the rings into the cylinder taper using a non-metallic,
blunt-edge tool while pushing the cylinder down. This will
help push the piston past the ring taper into the cylinder.
5. Remove the support block once the piston rings are inside
the cylinder. Seat the cylinder firmly on the base gasket.
6. Install the cam chain guide and dowel pins into the cylinder.
Verify the bottom end of the guide is seated properly in the
crankcase.
Cylinder Head and Camshaft Installation
NOTE: Verify the gasket surfaces on the cylinder
head and cylinder are clean. Remove all traces of old
gasket material.
1. Install the dowel pin(s) and a new cylinder head gasket
over the cylinder studs.
2. Pull the cam chain through the cylinder head chain room
and secure with mechanic’s wire.
3. Place the cylinder head onto the cylinder.
4. Install the two 6 mm base bolts, but do not tighten at this
time.
5. Install the cam according to the “Cam Shaft Timing”
procedure. Verify the cam chain is in place around the
crankshaft gear.
NOTE: Verify camshaft timing is accurate before
installing the rocker and tensioner assemblies.
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