Installingthecrankshaft

5. Aligntheconnecting rodbig ends tothecrankpins.

6. Fitthebigendcapsandtightenthem(seepage

5.10forthetighteningsequenceandtorque).

5. Installthebalancer(seepage7.4).

6. Assemblethecrankcases(seepage5.7).

• ServiceManual-RocketIll

5.9

ConnectingRods

RemovalNote:

• Theconnectingrodsandcapareetch­markedononesidetoidentifytheircorrectorientation.However,thecylinderfromwhichtheyareindividuallyremovedshouldalsobeidentified,usingalaundrymarkerorsimilar.

1. Removetheenginefromtheframe(seesection

10.2).

2. Separatetheloweranduppercrankcases(seepage5.5).

3. Removethecylinderhead(seepage3.5).

4. Removetheconnectingrodbolts.Discardthebolts.

1. Connectingrodbolts

2. Connectingrodcap

5. Collectthebigendcaps.

6. Pushtheconnectingrodupthroughthelinerandcollectthepistonandconnectingrodfromthelinertop.

7. Labeltheassemblytoidentifythecylinderfromwhichitwasremoved.

8. Markthepositionofeachlinerinthecrankcasetoensureitisreassembledinitsoriginalposition.

9. RemovethecylinderlinersusingtoolT3880061,(seepage5.18).

InstallationNote:

• Connectingrodboltsandnutsaretreatedwithananti-rustsolution,whichmustnotberemoved.

1. Cleantheconnectingrodwithhighflash-pointsolvent.

2. Selectnewbigendbearings(seepage5.12).

3. Fittheselectedbigendshellstotheconnectingrodsandbigendcaps.

4. Fitthepistonandconnectingrodassembliesintothelinersasdescribedonpage5.17.

5. Thoroughlycleanthelinerremovingalltracesofoldsiliconesealer.

6. Removealltracesofsealerfromthecrankcasebores.

7. Applyathinbeadofsiliconesealertothelinertocrankcasematingface.

cbyc

1. Liner

2. SealerArea

5.10 ServiceManual-RocketIll

8.Fit thelinerintothecrankcaseensuringthatthearrow onthepistonfacestotherighthandside oftheengine/bike(thesamesideastheexhaustheaders).

1.Piston

2. Arrow

Righthand(exhaust)side

Note:

• Ensurethatthepiston/liner/connectingrod

9.Aligntheconnectingrodtothecrankshaftandfitthebigendcap.TightentheNEWcapboltsasfollows:

Lubricatetheunder-headandthreadareasof theboltswithundilutedmolybdenumdisulphidegrease.Tightenthebolts,intwostagesasfollows;-

1. Tightento14Nm.

2. Tightenthrough120°ofboltrotationasmeasuredusingtheTriumphtorqueturn gauge3880105-T0301.

assemblies	align	correctly	with	the
crankpins	during	assembly	into	the
crankcase.

1.Crankpin

2.BigEnd

"'"

ServiceTool3880105-T0301

ServiceManual-RocketIll

5.11

ConnectingRodBigEndBearingSelection/CrankpinWearCheck

1. Measurethebearingandcrankpinclearanceasfollows.

Note:

• Thecrankpinclearancesaremeasuredusing'Plastigage'(Triumphpartnumber3880150·T0301).Donotturntheconnectingrodandcrankshaftduringtheclearancemeasurementasthiswilldamagethe'Plastigage'.

2.Removethebigendcapfromthejournaltobechecked.

3. Wipetheexposed areas ofthecrankpin,andthebearingfaceinsidethecap.

4. Applyathinsmear ofgreasetothejournalandasmallquantityofsiliconereleaseagenttothebearing.

5. TrimalengthofthePlastigagetofitacrossthejournal.FitthestriptothejournalusingthegreasetoholdthePlastigage inplace.

6. Lubricatethe threadsoftheboltandunder-headareawithundilutedmolybdenum disulphidegrease.Refitthebearingandcapandtightenthebigendboltsas describedearlier.

7. Releasetheboltsandremovethecapbeingmeasured.UsingthegaugeprovidedwiththePlastigagekit,measurethewidthofthecompressedPlastigage.

CheckingtheMeasuredClearance

Note:

• Crankpindiameter
  Standard	40.946-40.960mm
  Servicelimit	40.922mm

  Ifthemeasuredclearanceexceedstheservicelimit,measurethecrankpindiameter.

Note: