3.74
CRANKCASE ASSEMBLY
1. Prepare upper and lower crankcase and install all
components as described previously.
2. Inspect crankshaft seals to be sure they are aligned
flush with ends of crankcase.
3. Be sure balance shaft end plugs are installed with
retaining flange fitted in the grooves of crankcase.
4. Be sure oil passage tube is installed with new O-
rings..
5. Clean crankcase mating surfaces to remove all oil
and grease.
6. Apply a thin, continuous film of crankcase sealant
PN 2871557 to upper and lower crankcase mating
surfaces as shown on Crankcase Sealant and
Torque values, page 3.73. Do not allow sealant to dry
before assembly.
7. Apply engine oil to crankshaft main bearings in the
lower crankcase half.
8. Carefully place lower crankcase on upper case,
making sure the oil supply tube and oil pump drive
gear are aligned.
9. Tap with a rubber hammer to seat cases together.
10. Apply a light film of engine oil o flange and threads of
M9 crankcase bolts.
11. Install all crankcase bolts and tighten all lightly by
hand.
12. Inspect mating surfaces to be sure they are joined
properly. Investigate the cause of any gaps.
13. Torque all crankcase in sequence shown on
Crankcase Sealant and Torque Values, page 3.73 to
final torque value, then repeat the sequence to verify
final torque.
TORQUE
M6 Bolts:
7 ft-lb (10 Nm)
M8 Bolts:
14ft-lb (17 Nm)
14. Install cylinder head (Cylinder Head Installation,
page 3.75).
CYLINDER HEAD ASSEMBLY
NOTE
Assemble valves one at a time to maintain proper order.
1. Apply engine oil to valve guides and seats.
2. Coat valve stem with Premium Starter Grease
(2871460).
3. Install valve in guide.
4. Valve seals should be installed after the valves are in
the head to avoid valve seal damage. Install NEW
valve seals on valve guides carefully with a rotating
motion.
5. Dip valve spring and retainer in clean engine oil.
6. Install spring with tight wind facing DOWN (toward
head).
NOTE
Install valve spring with the orange coil marking towards
the top.
7. Place top retainer on spring.
8. Compress spring.
9. Install split keepers with gap even on both sides.
NOTE
To prevent damage to the valve seals, do not compress
the valve spring more than necessary to install the
keepers. A small magnet can be used to aid installation.
10. Repeat procedure for remaining valves. When all
valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the split
keepers.
WARNING
Do not tap on the top retainer or split keepers could
dislodge, causing serious injury. Tap only on the end of
the valve stem.
ENGINE / COOLING SYSTEM
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