5.6 ServiceManual-RocketIll

Assembly

1. Usehighflash-pointsolventtocleanthecrankcasematingfaces.Wipethesurfacescleanwithalint-freecloth.

2. Ensurethatthethreelocatingdowelsareinpositionintheuppercrankcase.

1.Dowels

3. Applyathinbeadofsiliconesealanttothelowercrankcasematingfaces(atthefactory,ThreeBond12078isused).

Sealerareas

Donotuseexcessiveamountsofsealer. Theextrasealermaybecomedislodgedandcouldblocktheoilpassagesinthecrankcases,causingsevereenginedamage.

4. Installandlubricatethecrankshaftmainbearingshellswithcleanengineoil(seebearingselectiononpage5.13beforeproceeding).

5. Installthecrankshafttotheuppercrankcase.

Installingthecrankshaft

6. Installandlubricatethebalancerensuringitis'timed'tothecrankshaftcorrectly(seepage7.4).

7. Lubricatethecrankshaftjournalswithcleanengineoil.

8. Positionthelowercrankcasetotheupper.Anassistantmayberequiredtosupportthecrankcaseduringalignment.

9. Fitthescrewsintothelowercrankcaseandhandtightenthem.

1O.Positionthemainbearingladderandbaffletothecrankcase(bafflelugsfacingintotheengine).

""'

1. Mainbearingladder

2. Baffle

3. Bafflelugs

11. Tightenthecrankcasescrewsasfollows:

Note:

• Thecrankcasescrewsaretightenedinstages.

ServiceManual-RocketIll

5.7

Stage1-allscrews

Inthecorrectsequence,tightenallcrankcasefixingsto10Nm.

Crankcasefixingtighteningsequence,allfixingsStage2

Inthecorrectsequence,tighten fixings1through8to

40Nm.

Crankcase bolttighteningsequence,fixings1-8

Stage3

Inthecorrectsequence,tightenfixings9through35to28Nm.

Crankcasefixingtighteningsequence,fixings9-35

5.8 ServiceManual-RocketIll

Crankshaft

Removal

1. Removetheenginefromtheframe(seepage

10.2).

2. Separatetheloweranduppercrankcases(seepage5.5).

3. Liftthebalanceroutoftheuppercrankcase.

Installation

Alwayscheckthemainbearingjournalclearance(seepage5.13),beforefinalassemblyofthecrankshaft.Failuretocorrectlyselectcrankshaftbearingswillresultinsevereenginedamage.

1. Selectandfitnewmainandbigendbearingshellsusing theselectionprocessesdetailedonpages5.12and5.13.

2. Lubricateallbearingswithengineoil.

3. Ensurethatthecrankshaftisclean,andthattheoil wayswithinthecrankshaftare cleanandfreefromblockagesanddebris.

4. Installthe crankshaftensuringthatthecrankpinsalignwiththecorrespondingbigends.

"'"

Removingthebalancer

4. Removetheconnectingrodbigendcaps(seepage5.10).Discardtheboltsafterremoval.

5. Liftthecrankshaftfromtheuppercrankcase.Supporttheconnectingrodsduringcrankshaftremovaltopreventdamagetotherods,linersanduppercrankcase.

Removingthecrankshaft