Inspection

•Inspecteachbearingofupperandlowercrankcasesforanydamage.

SELECTION

•Placetheplastigaugeaxiallyalongthecrankshaftjournal,avoid•

ingtheoilhole,asshown.

SJ09900-22301:Plastigauge

Iacautioni

Neverrotatethecrankshaftwhenapieceofplastigaugeisinstalled.

^_,

•Matethelowercrankcasewiththeuppercrankcase,andtightenthecrankcasebolts(M9)withthespecifiedtorquevalueintheindicatedorder.

(!JCrankcasebolt(9mm)

Initial:18n·m(1.8kgf·m,13.0lb-ft)Final:32n·m(3.2kgf·m,23.0lb-ft)

•Removethelowercrankcaseandmeasurethewidthofthecompressedplastigaugeusingtheenvelopescale.Thismea•surementshouldbetakenatthewidestpartofthecompressedplastigauge.

^{mCrankshaftjournaloilclearance:}

Standard:0.016-0.040mm(0.0006-0.0016in)ServiceLimit:0.080mm(0.031in)

•Iftheoilclearanceexceedstheservicelimit,selectthespeci•

fiedbearingsfromthebearingselectiontable.

•Checkthecorrespondingcrankcasejournall.D.codenumber

®·"A"or"B"whicharestampedontherearofuppercrank•

case.

•CheckthecorrespondingcrankshaftjournalO.D.codenumber

®·"A","B"or"C"whicharestampedonthecrankshaft.

_{RBearingselectiontable}

Crankshaftjournal0.0.@

^CodeABc

_Crankcase^AGreenBlackBrown

^l.D.®_{BBlackBrownYellow}

•Crankcase1.0.specification

Code^{1.0.specification}

A

35.000-35.008mm

(1.3780-1.3783in)

B

35.008-35.016mm

(1.3783-1.3786in)

~Crankshaftjournal0.0.specification

Code^{0.0.specification}

A

31.992-32.000mm

(1.2595-1.2598in)

B

31.984-31.992mm

(1.2592-1.2595in)

c

31.976-31.984mm

(1.2589-1.2592in)

1r1i8L109900-20202:Micrometer(25-50mm)

-Bearingthicknessspecification

Color(PartNo.)^Thickness

Green1.488-1.492mm

(12229-35FOO-OAO)(0.0586-0.0587in)

Black1.492-1.496mm

(12229-35FOO-OBO){0.0587-0.0589in)

Brown1.496-1.500mm

(12229-35FOO-OCO)(0.0589-0.0591in)

Yellow1.500-1.504mm

(12229-35FOO-OOO)(0.0591-0.0592in)

NOTE:

Upperandmiddlecrankshaftjournalbearingsarethesame.

INSTALLATION

•Whenfittingthecrankshaftjournalbearingstotheupperandlowercrankcases,besuretofixthestopperpart~firstandpresstheotherend.

IACAUTIONI

Donottouchthebearingsurfaceswithyourhands.Graspbytheedgeofthebearingshell.

CRANKSHAFTTHRUSTBEARING

•Withthecrankshaftright-sidethrustbearingandleft-sidethrustbearinginsertedintheuppercrankcase,measurethethrustclearanceontheleftsidebyusingthethicknessgauge.

^{®:Right-sidethrustbearing}

CD:Left-sidethrustbearing

NOTE:

Pullthecrankshafttotheleft-side,sothatthereisnoclearanceontheright-sidethrustbearing.

1root109900-20803:Thicknessgauge

EThrustclearance:

Standard:0.055-0.110mm(0.0022-0.0043in)

•Ifthethrustclearanceexceedsthestandardrange,adjustthethrustclearancebythefollowingprocedures.

CRANKSHAFTTHRUSTCLEARANCEADJUSTMENT

•Removetheright-sidethrustbearingandmeasureitsthick•

nesswithamicrometer.

•Ifthethicknessoftheright-sidethrustbearingisbelowstan•dard,replaceitwithanewoneandonceagainperformthethrustclearancemeasurementlistedabove,checkingtomakesureitiswithinstandard.

1Riiit109900-20205:Micrometer

~Right-sidethrustbearingthickness:

Standard:2.425-2.450mm(0.0955-0.0965in)

•Iftheright-sidethrustbearingiswithinthestandardrange,re•inserttheright-sidethrustbearingandremovetheleft-sidethrustbearing.

•Asshownintheillustration,measuretheclearancebyusingathicknessgaugebeforeinsertingoftheleft-sidethrustbearing.

•Selectaleft-sidethrustbearingfromtheselectiontable.(c:::r

3-65)

~Thrustbearingselectiontable

_{Clearancebefore}

insertingleft-sidethrustbearing	Color (PartNo.)	Thrustbearing thickness	Thrustclearance
2.560-2.585mm	White	2.475-2.500mm	0.060-0.11Omm
(0.1008-0.1018in)	(12228-17EOO-OFO)	(0.0974-0.0984in)	(0.0024-0.0043in)
2.535-2.560mm	Yellow	2.450-2.475mm	0.060-0.110mm
(0.0998-0.1008in)	(12228-1?EOO-OEO)	(0.0965-0.0974in)	(0.0024-0.0043in)
2.510-2.535mm (0.0988-0.0998in)	Green (12228-1?EOO-OOO)	2.425-2.450mm (0.0955-0.0965in)	0.060-0.110mm (0.0024-0.0043in)
2.485-2.510mm (0.0978-0.0988in)	Blue (12228-17EOO-OCO)	2.400-2.425mm (0.0945-0.0955in)	0.060-0.110mm (0.0024-0.0043in}
2.460-2.485mm (0.0969-0.0978in)	Black (12228-1?EOO-OBO)	2.375-2.400mm (0.0935-0.0945in)	0.060-0.110mm (0.0024-0.0043in)
2.430-2.460mm (0.0957-0.0969in)	Red (12228-1?EOO-OAO)	2.350-2.375mm (0.0925-0.0935in)	0.055-0.11Omm (0.0022-0.0043in)

•Afterselectingaleft-sidethrustbearing,insertitandagainperformthethrustclearancemeasurementtomakesureitfallswithinthestandardrange.

NOTE:

Right-sidethrustbearinghasthesamespecificationasthe

GREEN(12228-17EOO-ODO)ofleft-sidethrustbearing.

ENGINEREASSEMBLY

•Reassembletheengineinthereverseorderofdisassembly.

•Thefollowingstepsrequirespecialattentionorprecautionarymeasuresshouldbetaken.

NOTE:

Applyengineoiltoeachrunningandslidingpartbeforereas•

sembling.

•Besuretoinstallthefollowingitemstothecrankcase.

•Crankshaftjournalbearing(L7'3-62)

*Gearshiftfork(L7'3-56)

*Gearshiftforkshaft(L7'3-56)

•Gearshiftshaftbearing(L7'3-55)

*Gearshiftcambearing(L7'3-55)

*Gearshiftforkbearing(L7'3-55)

•Gearshiftcam(L7'3-55)

*Bearingretainer(L7'3-56)

_{*Oiljets(c::::::t3-58)}

PISTONANDCONROD

•Positionthegapsofthethreeringsasshown.Beforeinsertingeachpistonintothecylinder,checkthatthegapsaresolo•

_cated.

EX

•2ndring

•Lowersiderail

•Uppersiderail

•Rubasmallquantityofmolybdenumoilsolutionontoeachpis•

tonpin.

[l1MOLYBDENUMOIL

•Assemblethepistonandconrod.

NOTE:

"Wheninstallingthepistons,theindent®onthepistonheadmustbefacedtoanothersideofIDcode@onconrodface.

•Installthepistons.

NOTE:

Besuretoinstallthepistonsinthecylindersfromwhichtheywereremovedindisassembly,refertothecylindernumbers,"1"through"4",scribedonthepiston.

•Installthepistonpincirclips<1).

ACAUTION¹

Usenewpistonpincirclipstopreventcirclipfailurewhich

willoccurwithabendone.

NOTE:

Endgapofthecirclipshouldnotbealignedwiththecutawayinthepistonpinbore.

•Topring

IN•Spacer

•Applyengineoiltotheslidingsurfaceofthepistonsandcylin•

derwalls.

•Installthepistonsandconrodsintothecylindersfromupside.

NOTE:

Wheninstallingthepistons,theindent@ofthepistonheadmustbefacedtoeachexhaustside.

ACAUTIONI