Service Manual

ENGINE TOP END 5-19
Cylinder, Piston
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 molybdenum disulfide oil solution oil to the inner
surface [A] of the connecting rod big end [B] and caps
[C].
○
The molybdenum disulfide oil solution is a mixture of en-
gine oil and molybdenum disulfide grease with a weight
ratio (10:1).
•
Install the connecting rod big end caps on their original
position on each connecting rod big ends.
•
Apply a thin layer of engine oil to the thread [D] and seat-
ing surface [E] of the cap bolts.
•
Tighten:
Torque - Connecting Rod Big End Cap Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
•
Install the removed parts (see appropriate chapters).
Piston/Cylinder Seizure
•
In case of seizure, remove the pistons (see Piston Re-
moval).
•
Visually inspect the cylinder and pistons for damage.
If there is only light damage, repair the damaged piston
surface with #400 emery cloth. Remove the small alu-
minum deposits from the cylinder with #400 emery cloth
or light honing.
If the damage is severe, replace the crankcase and pis-
tons.
Piston Cleaning
•
Remove the piston and piston rings (see Piston Re-
moval).
CAUTION
Never clean the piston head with the engine assem-
bled. Carbon particles will fall between the piston
and cylinder, and damage the crankshaft bearings.
•
Scrape the carbon off the piston head.
•
Use the scraping tools [A] carefully. Do not gouge the pis-
ton head. To avoid gouging, use scrapers that are made
of a material that will not cause damage.