Split the crankcase (see Crankcase Splitting).
Remove the clutch housing and the primary chain.
Remove the crankshaft with the camshaft chain and pri-
If the crankshaft, bearing inserts or crankcase
halves are replaced with new ones, select the bear-
ing inserts and check clearance with plastigage
before assembling engine to be sure the correct
bearing inserts are installed.
Apply engine oil to the crankshaft bearing inserts.
Install the camshaft and primary chains on the crankshaft.
Align the timing mark on the balancer gear [A] with the tim-
ing mark [B] on the balancer drive gear [C] of the crank-
Assemble the crankcase (see Crankcase Assembly).
Connecting Rod Removal
Remove the crankshaft (see Crankshaft Removal).
Mark and record locations of the connecting rods and
their big end caps so that they can be reassembled in
their original positions.
Remove the connecting rod big end cap nuts, and take off
the rod and cap with the bearing inserts from the crank-
To prevent damage to the crankpin surfaces, do not
allow the big end cap bolts to bump against them.
Connecting Rod Installation
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.
To minimize vibration, the connecting rods should
have the same weight mark. The weight mark is
indicated by a capital letter, and is stamped on the
connecting rod big end. If the connecting rods,
bearing inserts, or crankshaft are replaced with
new ones, select the bearing insert and check
clearance with plastigage before assembling en-
gine to be sure the correct bearing inserts are