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Do not allow grease to contact the V-belt, primary and secondary pulleys.
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NOTE:
М When installing the belt, screw M6 (more than 45 mm (1.77 in)) bolts 4 to spread apart the secondary sheave and then install the belt. Make sure the belt pullout direction is correct.
М Install the V-belt and secondary sheave assembly onto the primary sheave side.
М Align the a and b during reassembly.
Н Tighten:
secondary sheave nut 1
| T.R. | 90 Nm (9.0 m · kg, 65 ft · lb) |
NOTE:
While holding the secondary sheave with the sheave holder 2, tighten the secondary sheave nut 1.
Sheave holder 90890-01481
О Install:
primary sliding sheave 1
O-rings
spacer
primary sheave nut 2
5 - 68
V-BELT AUTOMATIC TRANSMISSION ENG
Р Tighten:
primary sheave nut 1
| T.R. | 160 Nm (16.0 m · kg, 115 ft · lb) |
CAUTION:
С Before tightening the nut to remount the primary sheave, make sure that the serra-tions of the cam are fitted firmly into the serrations of the crankshaft.
Also, make sure that cam is properly seated.
С Apply grease to the thread and seat of the
Primary sheave nut.
Recommended lubricant
Shell BT grease 3®
NOTE:
While holding the primary sheave with the sheave holder 2, tighten the primary sheave nut 1.
Sheave holder 90890-01481
5 - 69
CRANKCASE AND CRANKSHAFT ENG
CRANKCASE AND CRANKSHAFT
CRANKSHAFT ASSEMBLY
| Order | Job/Part | Q’ty | Remarks |
| Removing the crankshaft assembly | Remove the parts in the order listed. | ||
| Engine | Refer to “ENGINE REMOVAL”. | ||
| Cylinder head | Refer to “CYLINDER HEAD”. | ||
| Cylinder/piston | Refer to “CYLINDER AND PISTON”. | ||
| Starter clutch/A.C. magneto rotor | Refer to “STARTER CLUTCH AND A.C. | ||
| MAGNETO ROTOR”. | |||
| Clutch | Refer to “CLUTCH”. | ||
| Oil pump | Refer to “OIL PUMP”. | ||
| Right crankcase cover | Refer to “V-BELT AUTOMATIC TRANS- | ||
| MISSION”. | |||
| Centerstand assembly | |||
| Timing chain | |||
| Timing chain guide (intake side) | |||
| Left crankcase | Refer to “DISASSEMBLING THE | ||
| CRANKCASE” and “ASSEMBLING THE | |||
| CRANKCASE”. | |||
5 - 70
CRANKCASE AND CRANKSHAFT ENG
| Order | Job/Part | Q’ty | Remarks | ||
| Dowel pin | |||||
| Crankshaft assembly | Refer to “INSTALLING THE CRANK- | ||||
| Balancer cylinder | SHAFT”. | ||||
| Right crankcase | |||||
| Oil strainer | |||||
| Dowel pin | |||||
| Crankshaft main journal bearing | Refer to “REMOVING THE CRANK- | ||||
| SHAFT MAIN JOURNAL BEARINGS” | |||||
| and “INSTALLING THE CRANKSHAFT | |||||
| MAIN JOURNAL BEARINGS” | |||||
| For installation, reverse the removal pro- | |||||
| cedure. | |||||
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5 - 71
CRANKCASE AND CRANKSHAFT ENG
CONNECTING ROD
| Order | Job/Part | Q’ty | Remarks | ||
| Removing the connecting rod | Remove the parts in the order listed. | ||||
| Connecting rod | Refer to “REMOVING THE CONNECT- | ||||
| Connecting rod (balancer) | |||||
| ING RODS” and “INSTALLING THE | |||||
| Connecting rod cap | |||||
| CONNECTING RODS”. | |||||
| Big end bearing | |||||
| Circlip | |||||
| Piston pin | |||||
| Balancer piston | |||||
| Crankshaft | |||||
| For installation, reverse the removal pro- | |||||
| cedure. | |||||
5 - 72
CRANKCASE AND CRANKSHAFT ENG
EAS00385
DISASSEMBLING THE CRANKCASE
Т Remove:
crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
У Remove:
left crankcase
CAUTION:
Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure that the crank-case halves separate evenly.
Ф Remove:
dowel pins
EAS00387
REMOVING THE CRANKSHAFT MAIN
JOURNAL BEARINGS
Х Remove:
crankshaft assembly
crankshaft main journal bearings 1
NOTE:
Remove the main journal bearing by the plane bearing installer 2.
Plane bearing installer 90890-04139
NOTE:
Identify the position of each crankshaft main journal bearing so that it can be reinstalled in its original place.
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5 - 73
CRANKCASE AND CRANKSHAFT ENG
EAS00391
REMOVING THE CONNECTING RODS
The following procedure applies to all of the connecting rods.
Ц Remove:
connecting rod 1
big end bearings
NOTE:
Identify the position of each big end bearing so that it can be reinstalled in its original place.
EAS00399
CHECKING THE CRANKCASE
Ч Thoroughly wash the crankcase halves in a mild solvent.
Ч Thoroughly clean all the gasket surfaces and crankcase mating surfaces.
Ч Check:
crankcase
Cracks/damage → Replace.
oil delivery passages
Obstruction → Blow out with compressed air.
EAS00207
CHECKING THE TIMING CHAIN
Ш Check:
timing chain
Damage/stiffness → Replace the timing chain and camshaft sprockets as a set.
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