6-17
75º
Setting cylinder front to TDC
– Loosen the crankshaft locking bolt and turn the engine
counterclockwise 1 rotation and then 75° towards the front cylinder's
TDC position, keeping the timing chain on the cylinder rear slightly
tensioned and holding the conrod in the center of the opening in the
case.
!
CAUTION
!
– T
HE
CRANKSHAFT
MUST
BE
TURNED
1
ROTATION
AND
75°
IN
A
COUNTERCLOCKWISE DIRECTION
,
OTHERWISE THE IGNITION INTERVAL WILL NOT
BE CORRECT AND THE MOTOR WILL NOT RUN
.
– I
F YOU DO NOT HOLD THE CHAIN
,
IT MAY GET JAMMED BETWEEN THE TIMING
CHAIN ON THE CRANKSHAFT AND THE TENSIONING RAIL
.
– I
F THE CONROD IS NOT POSITIONED IN THE CENTER OF THE OPENING IN THE
CASE
,
THE CONROD BOTTOM WILL BLOCK ON THE BALANCER SHAFT AND
PREVENT THE CRANKSHAFT FROM TURNING
.
– Screw the crankshaft locking bolt back in.
Cylinder head front with cylinder and timing chain
– Mount a new base gasket.
NOTE: make sure the crankshaft is blocked in the cylinder front TDC
position.
– Fit the timing chain and chain tensioning rail in the cylinder. Tilt the
chain tensioning rail
1
towards the chain to allow it to engage in the
chain tunnel of the engine case.
NOTE:
– The chain guide is mounted on the intake side of cylinder front .
– The timing chain should be drawn up and held in the chain tunnel
with a thin welding wire or a rubber band.
– Push the cylinder head and cylinder over the stud bolts until the
piston pin can be pressed into the piston by hand from the output
end. Insert a new piston pin retainer with a screwdriver into the
piston groove.
!
CAUTION
!
– D
O NOT PULL THE PISTON OUT OF THE CYLINDER UP TO THE OIL SCRAPER RING
SINCE THE PISTON RING WILL BE DAMAGED BY THE LOWER EDGE OF THE
CYLINDER
.
– T
HE OPENING TOWARDS THE CRANKSHAFT SHOULD BE COVERED WITH A CLOTH
TO PREVENT THE PISTON PIN RETAINER FROM FALLING OUT OF THE ENGINE CASE
.
– T
HE PISTON PIN RETAINER
2
MUST BE IN THE POSITION SHOWN IN THE
ILLUSTRATION
.
1
2
