Removal and Installation

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

Removal
1. Remove engine, refer to Engine Assembly Replacement. [1][2]Procedures
2. Remove timing case cover, refer to Lower Cover. Service and Repair
3. Remove end cover
4. Remove pistons. Service and Repair
5. Unbolt crankshaft bearing caps (2, 2a)

NOTE:
^ The crankshaft bearing caps (2, 2a) are consecutively numbered, beginning with the first crankshaft bearing cap.
^ Pay attention to the interference fit of front crankshaft bearing cap

6. Remove crankshaft (20) from crankcase


Installation
Install in the reverse order, noting the following:
- Oil bearing shells before inserting the crankshaft
- The oil grooves in the thrust washers (22) and (23) must face toward the thrust collars of the crankshaft.
- The thrust washers (22) in the bearing cap each have two locating lugs as an anti-twist lock





- Refer to the bearing diagram of crankshaft during bearing installation





- Install the bearing caps as follows:
a. The crankshaft bearing caps are machined together with the crankcase and must not be inter changed.
b. The crankshaft bearing caps are interference fitted in the side of the crankcase.
c. The fit is off centered 0.5 mm with the. result that it is only possible to install the bearing caps in one position.
d. If the bearing caps are correctly installed, the lug (arrow) on the crankshaft bearing cap is facing toward the left (intake side), when viewed in the direction of travel.





e. The crankshaft bearing caps (2, 2a) are consecutively numbered, beginning with the first crankshaft bearing cap at the front.





- Examine bolts of crankshaft bearing caps as follows:
Measure the length (L), if the length (L) is greater than specifications, replace the bolts.
Bolt Specifications:
Thread Diameter: 11 mm
Length when new: 62.8 mm
Maximum Length: 63.8 mm

- Tighten main bearing bolts as follows:
Oil thread and bolt head contact surface of bolts of crankshaft bearing caps
Tighten from the inside to the outside, beginning at the center.
Tighten as follows:
1st step, tighten to: 55 Nm
2nd step, Turn: an additional 90 to 100°
- Rotate crankshaft; check that it rotates freely