Service Manual

5-14 ENGINE TOP END
Cylinder, Piston
•
Apply engine oil to the piston skirt and the cylinder bore.
Using the piston ring compressor grip [A] and the belt [B], lightly tap
the top of the piston with a plastic mallet [C] to insert the piston and
connecting rod into the cylinder.
Special Tools - Piston Ring Compressor Grip: 57001–1095
Piston Ring Compressor Belt: 57001–1096
•
Insert the piston and connecting rod so that the arrow mark [A] on
the top of the piston is facing the flywheel side [B].
CAUTION
The connecting rod and the connecting rod big end cap are
machined at the factory in the assembled state, so they must
be replaced together as a set.
•
Apply engine oil to the inner surface [A] of the connecting rod big end
[B] and caps [C].
•
Install the connecting rod big end caps in their original position on
each connecting rod big ends.
•
Apply a small amount of engine oil to the thread [D] and seating
surface [E] of the cap bolts.
•
Tighten the cap bolts.
Torque - Connecting Rod Big End Cap Bolts: 5.9 N
1 m (0.60 kgf 1 m, 52
in
1 lb)
•
Install:
Camshaft (see Camshaft/Crankshaft chapter)
Crankcase Cover (see Camshaft/Crankshaft chapter)
Piston/Cylinder Seizure
•
In case of seizure, remove the piston.
•
Visually inspect the cylinder and piston damage.
If there is only light damage, smooth the position with #400 emery
cloth. Remove the small aluminum deposits from the cylinder with
#400 emery cloth or light honing.
If the damage is severe, both cylinders must be bored oversize and
oversized pistons installed.