954 11 Crankcase Piston Cylinder

8/14/2019 954 11 Crankcase Piston Cylinder

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SERVICE INFORMATION 11-1 PISTON/CONNECTING ROD 11-4TROUBLESHOOTING 11-2 CRANKCASE COMBINATION 11-12

CRANKCASE SEPARATION 11-3

SERVICE INFORMATIONGENERAL

NOTICE 1The main journal 9-mm bolts t ightening method uses the Plastic Region Tightening Method (page 11-12).Always use a new main journal 9-mm bolts (page 11-12).

The main journal 9-mm bolts is pre-coated wi th an oil additive for axial tension stability. Donot remove the oil additive

Be sure to fol low the t ightening procedure on page 11-12 for crankcase bol t tightening .

This section covers crankcase separation for service o f the crankshaft an d pistons.

The following parts must be removed before separating the crankcase.

from the new 9-mm bolt surfaces.

- Alternator/flywheel (Section 10)- Clutch/gearshift linkage (Section 9)- Cylinder head (Section 8)

- Engine (Section 7)- Oil pu mp (Section 4)

Mark and store the disassemble parts to ensure that they are installed in their original locations.

Mark and store the bearing inserts to be sure of their correct locations for reassembly. If the inserts are improperlyinstalled, they wi ll block the oil hole, causing insufficient l ubricati on and eventual engine seizure.

The connecting rod bearing inserts are select fit and are identified by colo r codes. Select replacement bearings fro m thecode tables. After installing new bearings, recheck the m wit h plastigauge to verify clearance. Apply mol ybde num disul-fide oil to the crank pin dur ing assembly.

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CRANKCASE/PISTON/CY LINDERCRANKCASE SEPARATI8N

Refer to Service Info rmat ion (page 11-1)for removal of

necessary parts before separating the crankcase.

Remove the mainshaft bearing set plate bolts andplate.

Remove the upper crankcase 8 mm bo l t skea l ingwashers and 6 m m bol t.

Remove the lo wer crankcase 6 mm bolts (ten), 8 mmbolts (seven) and 10 mm bolt.Loosen the ten l ower crankcase 9 mm bolts in a criss-

cross pattern in tw o to three steps, then remove thebolts.

Separate the lower crankcase from the upper

crankcase.

10 mm B

6 mm BOLTS\

I8 mm BOLTSRemove the sw inga rm pivot collars, dowel pins andoil orifices. COLLARS

\\OIL ORIFICES

DOWE

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NDER

ROD BEARING CAP

",, p u , . ' ISTON/CONNECTING ROD REMOVAL/n g removalso I NOTICE 1they canbereplacedin t h e r

Do not interchange the bearing inserts. They must beinstalled in their origina l locations or the correct bear-

ing oil clearance may not be obtained, resulting inengine damage.

Donot damagethe piston ringsduring removal.

Remove the nuts and connecting rod bearing cap.

Remove the pistonkonnecting rod assembly from thetop of the cylinder.

PISTON REMOVAL

Remove the piston pin clip with pliers.

Press the piston pin out of the piston and remove thepiston from the connecting rod.

PISTON DISASSERemove the piston rings.


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Push the rings

into the cylinder

with the topof

the piston tobesure they are

squarely in thecyiin o'er

PlSTON INSPECTlONTemporarily install the piston rings to their proper

position with the mark facing up.

Measure the pis ton ring-to-ring groove clearance withthe rings pushed into the grooves.

SERVICE LIMITS:

Top: 0.08 mm (0.003 in)

Second: 0.06 mm (0.002 in)

Inspect the p iston for wear or damage.

Insert the piston ring squarely into the bottom of the

cylinder and measure the ring end gap.

SERVICE LIMITS:Top: 0.5 mm (0.02 in)Second: 0.7 mm (0.03 in)

Oil (side rail): 0.9 mm (0.04 in)

Measure the diameter of the piston at 4 m m (0.2 in )from the bottom and 90 degrees to the piston pinhole.

SERVICE LIMIT: 74.895 mm (2.949 in)


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Measure the piston pi n bore.


Measure the O.D. of the piston pin.


Calculate the piston-to -piston pin clearance.

STANDARD: 0.002 - 0.014 mm (0.0001- 0.0006 in)

CYLINDER INSPECTION

Inspect the to p of the cylinder for warpage.SERVICE LIMIT: 0.05 mm (0.002 in)

Inspect the cylinder bore for wear or damage.Measure the cylinder I.D. i n X and Y axis at three lev -els.

Take the max imu m reading to determine the cylinder

wear.


Calculate the piston-to-cylinder clearance.

Take a ma ximu m reading to determine the clearance.

Refer to page 11-5 for measurement of the piston O.D.

STANDARD: 0.020 - 0.055 mm (0.0008 - 0.0022 in)

* .. .: . .

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CRANKCASE/PISTON/CYLINDERCalculate the taper and out -of -round at three levels in

the X and Y axes, Take the ma xi mum reading todetermine them.

SERVICE LIMITS:Taper: 0.10 rnm (0.004 in)

Out-of-round: 0.10 rnm (0.004 in)

The cylinder mu st be rebored and an oversize pistonfitted if the service l imi ts are exceeded.

The piston to cylinder clearance for the oversize pis-

to n must be: 0.015 - 0.050 mm (0.0006 - 0.0020 in).

CONNECTING ROD INSPECTION

Measure the connecting ro d small end I.D.SERVICE LIMIT: 17.04 rnrn (0.671 in)

Temporarily install the connecting rod to the crank -

shaft.

Install the bearing inserts and bearing cap, and tight-

en the nuts.Measure the connecting rod side clearance.

SERVICE LIMIT: 0.30 mrn (0.012 in)

CRANKPIN BEARING INSPECTIONWipe all oil fro m the bearing inserts and crankpins.Put a piece of plastigauge on each crankpin.

Do not put the plastigauge over the oil hole in thecrankpin.Do not rotate the crankshaft durin g inspection.

' P L ~ T I G A U G E


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CRANKCAS E/PISTON/CY LlNDERInstall th e bearing caps and connecting rods on a cor-rect crankpins, and tighten the cap nuts to the speci -

fied torque.

TORQUE: 35 N*m (3.6 gfom, 26 b f e )

Remove the connecting rod caps and measure the

compressed plastigauge on each crankpin.

SERVICE LIMIT:0.062mm (0.0024in)

If the connecti ng rod bearing clearance is b eyond tol -

erance, selects replacement bearing.

CRANKPIN BEARING SELECTIONRecord the connecting ro d I.D. code numbe r ( 1 , 2 or 3)or measure the I.D. with the bearing cap installedwit hou t bearing inserts.

etters (A,5

orC)on the crankweight arethe

c o d e s f o r t h e If yo u are reusing the crankshaft, measu re thecrankp in O D sstartingfrom th e

/ef t

If you are replacing the crankshaft, record the corre-sponding crankpin O.D.code letter (A, B or C ) .

crankpin O.D. with the micrometer.

CONNECTING ROD I.D. CODE


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CRANKCASE/PISTON/CYLINDER

CONNECTING ROD I.D. CODE1 2 3

39.000 - 39.006 39.006 - 39.012 39.012 - 39.018

(1.5354- 1.5357) (1.5357- 1.5359) (1.5359 - 1.5361)~35.997 - 36.003 E D C

A (1.4172- 1.4174) (Yellow) (Green) (Brown)CRANK PIN 35.991 - 35.997 D C B

O.D. CORD (1.4170- 1.4172) (Green) (Brown) (Black)

35.985 - 35.991 C B A(1.4167- 1.4170) (Bro wn) (Black) (Blue)

~~~~

Align the bearingfabs wi th the

groove inthe con-

necting rod andbearing cap

Cross-reference the c rankp in and rod codes t o deter-min e the replacement bearing color.

BEARING THICKNESS:

A (Blue): Thick

B (Black):

C [Brown):

D (Green)

E (Yellow) Thin

IDENTIFICATION COLOR

1

Install the bearing inserts into the connecting ro d and

bearing cap.

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KCASE lPISTO N/C Y LINDERPISTON ASSEMBLY

Clean the piston ring grooves thoroughly and install

the piston rings.

Apply oil to the piston rings.

Avoid piston and piston r ing damage during instal-

Install the piston rings wit h the marking (R: top ring,

Do not switch the top and second rings; the top ring

lation.

RN: second ring) facing up.

is narrower than the second ring in width.

Space the piston rin g end gaps 120 degrees apart.

Do not align the gaps in the oil rings (side rails).

After installation, the rings should rotate freely in the

ring grooves.

PISTON INSTALLATION

Assemble the piston and connecting rod with the

journal bearing tab facing to the piston intake side( " 0 "mark).

SECOND RING TOP RING

/ i--f-." \ \/SPACE- SIDE RAILS

Apply molybdenum disulfide oil to the piston pin

outer surface.

Install the piston pin, and secure it using a new pistonDono ta i i gn thep ~ s t o npin d i p s pin clips.

gap with thepistoncu t-out


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CRANKCASE/PISTON/CYLlNDERApply oil to the cylinder sleeves and piston rings.

lnstaii thed assembly wi t h compressor tool.

Install the piston/connecting rod assembly into thecylinder using a commercially available piston ring

th e p is ton "O" When reusing the connecting rods, they must befacing to theIntake side. installed in their original locations.

While installing the piston, being careful not to

damage the top surface of the cylinder, especiallyaround the cylinder bore.

Be careful not to damage the cylinder sleeve andcrankpin with the connecting rod bol t threads.

Make sure the

sits f iush withthe top surface of

the cylinder

Use the handle of a plastic hammer to tap the pistonring compressor into the cylinder.

IPISTON RING COMPRESSOR

Apply molybdenum disulfide oil to the crankpin bear-ing surfaces.

Install the bearing cap.

Insure that the marks on the caps are aligned wi th themarks on the connecting rods.

Apply oil tothe connecting rod nut threads and seat-

ing surfaces.

Install the connecting rod bearing cap nuts and tigh t-en the nuts gradually and alternately, then tightenthem to the specified torque.

TORQUE: 35 N*m (3.6kgf*m, 26 Ibf.ft)

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LINDERCRANKCASE COMBINATlO N

Apply a light, but thorough coating of liquid sealantto

the crankcase mat ing surface except to the main bear-ing journal bolt (lo wer crankcase bolt, 9 mm) area andthe o il passage area as shown .

Install the three do wel pins.

Install oil orifices aligning their cut-outgroove i n the upper crankcase.

Install the swi ngarm pivot collars.

Tighten the main journal 9 mm bolts

with

using

the

thePlastic Region tightening Method described below.Do not reuse the mai n journal 9 m m bolts, because

the correct axial tension will not be obtained.

The main journal 9 mm bolt is pre-coated with an

oil additive for axial tension stability. Do no tremove the oil additive from the new 9 m m bolt sur-face.

Install the lower crankcase onto the upper crankcase.

PLASTIC REGION TIGHTENING METHOD:

Install the new m ain journal 9 mm bolts.Loosely install all the l ower crankcase bolts.Make sure the uppe r and low er crankcase are seated

securely.Make sure the swingarm pivot collar flanges are seat-ed in the crankcase securely.

Tighten the main journal 9 m m bolts as follow:

Tighten the 9 m m bolts i n numerical order in the illus-tration to the following torque.

TORQUE: 10 N*m (1.0 kgf.m, 7 Ibf.ft)Retighten the 9 mm bolts in the same order above tothe following torque..

TORQUE: 20 N*m (2.0 kgf*m, 14 Ibfa)

COLLARS \\ OIL ORIFICES

DOWEL

Further tighten the 9 m m bolts 150 degrees.

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CRANKCASE/PISTON/CY LlNDERTighten the 6 mm bolts securely.

Tighten the 10 mm bolt, and then 8 mm bolts to thespecified torque.

TORQUE:10 mm bolt: 39 N*m (4.0 kgfim, 29 Ibf*)25 N*m (2.5 kgf*m, 18 Ibf.ft)8 mm bolt:

The sealing wash-er locations are

indicatedon the

crankcaseusing the "A "

Instal l the upper crankcase 8 mm bolts, sealing wash-ers and 6 mm bolt.

Tighten the 8 mm bolts t o the specified torque.

TORQUE: 25 N*m (2.5 kgf*m, 18 Ib fWTighten the 6 mm bol ts securely.

6 mm BOLTS

\

/8 mm BOLTS

\10mm BOLTS

a!@6 mm BOLTS/ %& SEALING WASHERS

6 mm BOLTII8 mm BOLTS/ SEALING WASHERS

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Apply a locking agent to the mainshaft bearing set

plate bolt threads.

Install the mainshaft bearing set plate with its "OUT-SIDE'' mark facing out.

Tighten the m ountin g bolts to the specified torque.

TORQUE: 12 Nom (1.2kgforn, 9 bfrft)Install the removed parts in the reverse order of

removal.

954 11 Crankcase Piston Cylinder

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