3-48
ATV2098
1. Install the pistons on the connecting rods making
sure there is a circlip on each side and the open
end of the circlip (A) does not align with the notch
(B) in the piston.
NOTE: The pistons should be installed so the F
is directed toward both front and rear pistons.
ATV2099
NOTE: When installing the circlips in the piston,
compress them only enough to install. Do not over
compress.
2. Install two alignment pins (A) for each cylinder;
then position a new base gasket (B) as shown.
KX360
3. Apply clean engine oil to the piston skirts and
cylinder walls; then install the cylinders and clamp
(A) (rear only) and tighten the cylinder cap screws
(B) to 1.0 kg-m (87 in.-lb). Install the cam chain
guide (C) and the oil pipe (D).
KX361
4. Locate alignment pins (A) as shown; then place a
new head gasket (B) into position and install the
oil pipe (C) and camshaft chain guides (D).
KX362
5. Install the cylinder heads and tighten cap screws
(A) in the sequence illustrated to 2.5 kg-m (18
ft-lb); then in the same sequence, tighten to the
final value of 5.0 kg-m (36 ft-lb). Tighten cap
screw (B) to 1.0 kg-m (87 in.-lb).
ATV2100
6. Using a wrench on the alternator bolt, turn the
crankshaft clockwise to align the “TR” mark (A)
with the notch (B) in the inspection window.
! CAUTION
Incorrect installation of the piston rings will
result in engine damage.
Summary of Contents for 2004 650
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