Assembly - Triumph Thunderbird Service Manual

Assembly
1. Use high flash-point solvent to clean the crankcase
mating faces. Wipe the surfaces clean with a lint-free
cloth.
2. If removed, install the camshaft drive chain and idler
gear to the crankcase. Lock the idler gear in position
using service tool T3880039 and pre-load the
backlash gear using service tool T3880041 (see
page
3-13>.
3. Position the transmission shafts and the selector
drum in the neutral position.
4. Ensure that the three locating dowels are in position
in the upper crankcase.
1. Upper crankcase
2. Dowels
5. Apply a thin bead of silicone sealant to the lower
crankcase mating faces (at the factory,
ThreeBond 1215J is used).
6. If removed, insert the two piston cooling jets into the
main bearing housings in the upper crankcase.
3~
I
~1~
~
1 . Main bearing housing
2. Oil gallery
3. Piston cooling jet
Ensure the two piston cooling jets are installed. If the
piston cooling jets are omitted, oil pressure will be
reduced. Running the engine with low oil pressure will
cause severe engine damage.
Z
Install and lubricate the crankshaft main bearing
shells with clean engine oil (see bearing selection on
page 5-13 before proceeding).
8. Install the crankshaft ensuring the crankshaft to idler
gear timing is correct (see page 5-9).
9. Fit the big end caps and tighten them (see page 5-10
for the tightening sequence and torque).
10. Install and lubricate the balancer shafts ensuring they
are timed to the crankshaft correctly (see page 6-4).
11. Lubricate the crankshaft journals with clean engine
oil.
12. Position the lower crankcase to the upper. An
assistant may be required to support the crankcase
during alignment.
13. Fit the screws into the lower crankcase and hand
tighten them.
14. Tighten the crankcase screws as follows:
Note:
cfvm
Sealer Areas
•
The crankcase screws are tightened in stages.
Do not use excessive amounts of sealer. The extra sealer
may become dislodged and could block the oil passages
in the crankcases, causing severe engine damage.
Failure to follow the correct screw tightening sequence
may result in permanent crankcase damage.
5.6
SelVice Manual - Thunderbird