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Connecting Rod – Installation
Connecting rod bolts MUST only be used once. If the bolts are removed or undone for
any reason, new bolts MUST always be used. Reusing bolts can cause connecting rods
and their caps to detach from the crankshaft causing severe engine damage, loss of
motorcycle control and an accident.
Make sure the three piston cooling jets are installed and are protected by service tool
T3880504. If the piston cooling jets are omitted or get damaged, oil pressure will be
reduced. Running the engine with low oil pressure will cause severe engine damage.
Always check the bearing journal clearance (see Connecting Rod Big End Journal
Checking, Measuring and Bearing Selection and Crankshaft Main Bearing/Journal
Checking, Measuring and Bearing Selection), before final assembly of the
crankshaft. Failure to correctly select bearing journal shells will result in severe engine
damage.
Perform the following operations:
• Check that the three oil spray jets are fitted and service tool T3880504 is also fitted.
• Check, measure and, if necessary, select new connecting rod big end bearing shells
(see Connecting Rod Big End Journal Checking, Measuring and Bearing
Selection)
• Check, measure and, if necessary, select new crankshaft main bearing shells (see
Crankshaft Main Bearing/Journal Checking, Measuring and Bearing Selection)
1. Fit the three piston and connecting rod assemblies into the barrel from the bottom
as noted for removal. Make sure that the piston alignment mark on the piston faces
the same direction as noted for removal.
2. Fit the barrels to the crankcase (see Barrels - Installation).
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