DISASSEMBLY -- ENGINE REMOVED
mark, indicated by a capital letter, is stamped on the
connecting rod big end.
A. Weight Mark (Alphabet)
3. The connecting rod big end cap is machined with
the connecting rod as a set, so it must be replaced
together with the connecting rod as a
If a new crankshaft and/or connecting rod is
select the proper bearing insert in accordance with
the combination table (Table F4) for the connect-
ing rod and the crankshaft marks (Figs. F55 and
If the crankshaft is not replaced, first measure
the diameter of connecting rod journal of the crank-
Then mark its flywheel with the diameter (Pg.
and select the proper bearing insert in accord-
ance with Table F4.
The connecting rods are not symmertrical. Install
them in the direction shown in the figure.
Connecting Rod Installation
(Viewed from left side)
6. Check to see that the big end bearing inserts are in
Apply a molybdenum disulfide engine assembly
grease to the big end bolt threads and seating sur-
face of the bolt and the nut. Finger-tighten the nuts
first, then finger-tighten the bolts.
the nuts and bolts in the same sequence to 3.5 kg-m
(25 ft-Ibs) of
eRemove the pistons (Pg. 77)
eRemove the engine (Pg. 96)
eSplit the crankcase
eRemove the transmission (Pg. 101).
eRemove the secondary shaft, camshaft chain, timing
chain, and secondary chain (Pg. 108).
eRemove the cran kshaft together with the connecting
rods, primary chain, alternator rotor, and cran kshaft
eRemove the timing chain guide (Pg. 110).
eRemove the oil pressure switch (Pg. 89).
eRemove the external shift mechanism (Pg. 83).
eRemove the shift drum positioning pin
eRemove the shift drum and forks
The upper and lower crankcase halves are machined
at the factory as an
and must be replaced
together as a set.
2. When the crankcase halves are replaced, install the
original shims, check the clearance between the needle
thrust bearing and the crankcase and the bevel gear
backlash and tooth contact pattern. Adjust them if
115 and Pg. 112).
Backlash and Tooth Contact of Bevel Gears
Improper backlash and/or tooth contact of bevel
gears lead to noise and damage of
When replacing anyone of the following parts which
influence the backlash and tooth contact of bevel gears,
make sure to check and adjust them
First, adjust the
and then get the correct tooth contact
pattern by replacing shims.
Parts which change the backlash and tooth contact
Output Shaft Bevel GeareD
Driven Shaft Bevel Gear
Driven Shaft Ball Bearing
Output Shaft Ball BearingCD