Section 03 787 RFI ENGINE
Subsection 03 (TOP END)
F01D8LA
Cylinder Base Gasket
NOTE: The general procedure is to install a new
gasket of the same thickness. However, if you do
not know the gasket thickness that was installed
or if a crank repair has involved replacement of
connecting rods, refer to COMBUSTION CHAM-
BER VOLUME MEASUREMENT in ENGINE MEA-
SUREMENT section to properly determine the re-
quired gasket thickness.
Different thicknesses of cylinder base gaskets are
used for a precise adjustment of the combustion
chamber volume.
To identify gasket thickness, refer to the identifi-
cation holes on the gasket.
F01D67A
1
TYPICAL
1. Identification holes
GASKET THICKNESS
IDENTIFICATION
HOLES
0.3 mm (.012 in) 3
0.4 mm (.016 in)
4
0.5 mm (.020 in) 5
0.6 mm (.024 in) 6
0.8 mm (.031 in) 8
Piston
At assembly, place the pistons no. 3 with the let-
ters ″AUS″ (over an arrow on the piston dome) fac-
ing in direction of the exhaust port.
A01C01A
AUS
1
1. Exhaust side
NOTE: The exhaust ports are located on the same
side as the intake.
Carefully cover crankcase opening as for disas-
sembly.
Piston Pin and Roller Bearing
To install roller bearing no. 4 and piston pin no. 6
use the piston pin puller (P/N 529 035 503) with
the set of sleeves (P/N 529 035 542).
– Replacement bearings are held in place by a lo-
cating sleeve outside and 2 plastic cage halves
inside.
– Push needle bearing together with inner halves
out of the locating sleeve into the connecting
rod bore.
– Replace the inner halves by the appropriate
sleeve tool in the connecting rod bore.
– Insert piston pin into piston until it comes flush
with inward edge of piston hub.
– Warm piston to approximately 50 - 60°C(122-
140°F) and install it over connecting rod.
smr2005-082 81
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