Part 3

Engine

Disassembly (Steps 61-92)





61. Remove the 15 bolts and the 2 nuts. Remove the cylinder block cradle.





62. Remove the 2 bolts, the oil pump pickup tube and the oil pump intermediate shaft.





63. Remove the oil filter adapter.





64. Remove the rear jackshaft plug.





65. Using the special tool, hold the crankshaft.





66. Remove the rear jackshaft sprocket-retaining bolt and the spacer.





67. Remove the RH cassette bolt.





68. Remove the RH cassette.





69. Remove the oil pump bolt and retainer and then remove the oil pump drive.





70. Using the special tool, loosen the front sprocket retaining bolt.





71. Remove the bolts and the chain tensioner.





72. Remove the chain guide.





73. Remove the bolt.





74. Remove the jackshaft sprocket and chain.





75. Remove the LH cassette bolt.





76. Remove the LH cassette.





77. Remove the jackshaft thrust plate.





78. Remove the jackshaft.





79. If equipped, remove the balance shaft tensioner.
1 Install a pin in the balance shaft tensioner.
2 Remove the 2 bolts.
3 Remove the balance shaft tensioner.
80. If equipped, remove the 2 bolts and the balance shaft chain guide.

81. NOTE: DO NOT remove the balance shaft sprocket bolt.





If equipped, remove the balance shaft chain and crankshaft sprocket.





82. If equipped, remove the balance shaft.
1 Remove the 2 bolts.
2 Remove the balance shaft.
83. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's instructions.

84. NOTE: Clearly mark the connecting rods and rod caps in numerical order for correct reassembly.





Remove the connecting rod caps.
1 Remove the connecting rod nuts.
2 Remove the connecting rod caps.





85. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.





86. Remove the connecting rod bearings.





87. Remove the piston rings.
88. Clean and inspect the pistons.

89. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.

NOTE: Number (or mark) the crankshaft bearing caps before removing them.





Remove the bolts and the crankshaft main bearing caps.





90. Remove the crankshaft rear oil seal from the crankshaft.





91. Remove the crankshaft.





92. Remove the crankshaft main bearings and the thrust bearing.