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9. Trim away any excess gasket material
if necessary.
NOTE:
Check engine mount holes for excess material that may cause problems
in engine installation.
10. Install the piston with new wrist pin bearing and, pin and clips.
CAUTION:
Be sure to install the piston such that the arrow on the top piston surface points
to the exhaust (front of bike/engine) and put assembly lube on the connecting rod
bearing.
11. Install the piston rings.
CAUTION:
Ring end gap should be no less than 0.006” (0.016mm) and no more than 0.020”
(0.5mm)
12. Install the base gasket.
CAUTION:
See base gasket selection at the beginning of service section.
13. Install the cylinder being sure that the piston rings are properly
aligned with the indexing pins.
CAUTION:
Never force the cylinder. If resistance is felt, determine the
problem and solve it. Once installed, slightly rotate the cylinder
back and forth insuring that the rings are properly seated.
14. Install cylinder head insert.
NOTE:
A light application of silicone grease can help hold the
O-rings into position during assembly.
15. Install O-RINGs as shown in figure 33.
16. Install the cylinder head.
17. Install the washers (with flat side down) and nuts. Torque to
123 in-lb (14 Nm)
Figure 33
18. Install reed and intake manifold with new gasket. Torque to 55 in-lb. (6.2Nm).
CAUTION:
The intake manifold bolts will require being checked and torque values reset after
a few heat cycles.
19. Leak check the engine at 20 psi to ensure proper seal.
20. Install stator reinstalling the grommet and wires.
21. Install the rotor per
Rotor Installation
section, under the
S3: