4.10 ServiceManual-RocketIll

7. Refittheclutchpullrod.

8. Refittheclutchpressureplatetogetherwiththespringsandbolts.Tightentheboltsto10Nm.

Note:

• Thepullrodshouldbefreetomoveinandoutandalsoitshouldbefreetoturn.

Fittheclutchcoverasdescribedonpage4.7.

ServiceManual-RocketIll

4.11

Thispageintentionallyleftblank

12. ServiceManual-RocketIll

5Crankshaft

TableofContents

ExplodedView-Crankshaft,ConnectingRodandPiston 5-2

ExplodedView-CrankcaseFixings. 5-3

ExplodedView-CrankcaseandLiners 5-4

Crankcases. 5-5

Removal 5-5

Disassembly 5-5

Assembly 5-7

Crankshaft. 5-9

Removal 5-9

Installation 5-9

ConnectingRods 5-10

Removal 5-10

Installation 5-10

Righthand(exhaust)side. 5-11

ConnectingRodBigEnd BearingSelection/CrankpinWearCheck 5-12

ConnectingRodBearingSelection. 5-13

CrankshaftMainBearing/JournalWear 5-13

CheckingcrankshaftclearanceusingPlastigage 5-13

CrankshaftEndFloat 5-14

Pistons 5-15

Disassembly 5-1.5

PistonWearCheck 5-15

PistonRings/RingGrooves. 5-16

PistonRingGap 5-16

PistonAssembly 5-16

Cylinder Wear 5-18

CylinderLiners 5-18

Removal 5-18

Installation 5-19

• ServiceManual- RocketIll ^5.1

2. ServiceManual-RocketIll

i!>

^c:: :::>

^c:: :>

ExplodedView-CrankcaseFixings

ALLFIXINGS-SEETEXT

• ServiceManual-RocketIll ^5.3

ExplodedView-CrankcaseandLiners

cx:gj

5.4 ServiceManual-RocketIll

45Nm

Crankcases

Note:

• Thecrankcasehalvesmaybeseparatedwiththecylinderheadfitted.

Removal

1. Removetheenginefromtheframe(seepage

10.2).

2. Removetheclutch(seepage4.7).

3. Removethestartermotor(seepage18.18).

4. Removethealternator(seepage18.15).

5. Removetheoilpumpdriveandpressureoilpump(seepage9.11).

6. Removethetorsionaldampershaft(seepage

8.11).

7. Removethesump(seepage9.9).

8. Removethecamchain(seepage3.6).

Disassembly

1. Removetheoilpipesfromthe lowercrankcase.

1. Oiipipes

2. Removethenon-returnvalvefrom the scavengeoilpump,bygentlypullingitoutwardsfromitslocation.

1.Non-returnvalve

3. Inthesequenceshownbelow,releasetheboltssecuringthemainbearingladdertothecrankcases.

6 51 9

2

Mainbearingladderboltreleasesequence

• ServiceManual-RocketIll

5.5

3. Collectthebolts,thendetachtheladderandbaffleplatefromthecrankcasenotingthepositionofbothlocationdowels,whichshouldberemovedforsafe-keeping.

1.Dowels

5. Startingfrombolt11,releasethelowercrankcaseboltsinthesequenceshowninthediagrambelow.Removeanddiscardthebolts.

Cl "

14

Lk.-1!<--";I 32

-.....<l-1--13

30

"

"

16

35

15 11

LowerCrankcaseBoltReleaseSequence

5. Frominsidetherearofthecrankcases,collectthebearingcapsecuringtheoutputshafttothelowercrankcase.

1. Outputshaftbearingcap

Note:

• Alwayscheckthatallboltshavebeenreleasedbeforeattemptingtoseparatethecases.Boltsarefittedindiscreetlocationssuchasunderthepressureoilpumpandinsidehollowbosses.

7.Separatethelowerandupper crankcasesnotingthepositionofthethreelocationdowels,whichshouldberemovedforsafe-keeping.

1.Dowellocations

8.Atthispoint,thebalancershaftmayberemoved.Todetach thecrankshaft,thebigendcapsmustalsoberemoved(seepage5.10).