HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic.
Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check
procedures are laid out with the individual steps in sequential order.
9
The manual is divided into chapters and each chapter is divided into sections. The current sec-
tion title is shown at the top of each page
1
.
9
Sub-section titles appear in smaller print than the section title
2
.
9
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section
3
.
9
Numbers are given in the order of the jobs in the exploded diagram. A number indicates a dis-
assembly step
4
.
9
Symbols indicate parts to be lubricated or replaced
5
.
Refer to “ILLUSTRATED SYMBOLS”.
9
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
6
. This step explains removal procedure only. For installation, reverse
the steps.
9
Jobs requiring more information (such as special tools and technical data) are described
sequentially
7
.
3-20
ENG
PISTON, CAMSHAFT, CRANKCASE, AND
CRANKSHAFT
1
2
3
3
4
5
6
7
7
8
9
10
20 Nm (2.0 m á kgf, 14 ft á lbf)
Order
Job/Parts to remove
Q’ty
Remarks
Removing the piston, camshaft and
crankshaft
Remove the parts in the order listed.
Crankcase
Refer to “CRANKCASE” on 3-18.
1
Balancer shaft
1
2
Camshaft
1
3
Valve lifter
2
4
Connecting rod cap
1
5
Crankshaft
1
6
Connecting rod
1
7
Piston pin circlip
2
8
Piston pin
1
9
Piston
1
10
Piston ring set
1
PISTON, CAMSHAFT AND CRANKSHAFT
3-21
ENG
PISTON, CAMSHAFT, CRANKCASE, AND
CRANKSHAFT
REMOVING THE BALANCER SHAFT,
CAMSHAFT, AND VALVE LIFTER
1. Remove:
9
Balancer shaft
1
TIP
Remove the balancer shaft
1
when the bal-
ancer shaft gear mark
a
and the crankshaft
gear mark
b
are aligned.
2. Remove:
9
Camshaft
2
TIP
Remove the camshaft
2
when the camshaft
gear mark
c
and the crankshaft gear mark
d
are aligned.
3. Remove:
9
Intake valve lifter
9
Exhaust valve lifter
CHECKING THE BALANCER SHAFT
1. Check:
9
Balancer gear teeth
9
Balancer shaft
Wear/damage
→
Replace.
2
1
b
a
c
d
1
3
4
5
6
7
2
