Service manual

ENGINE
3. The connecting rod utilizes a roller bearing. Clearance
is minimal and cannot be measured. Visually inspect
bearing journal for scoring, damage or excessive wear.
Replace crankshaft if it fails visual inspection.
4. Inspect the clearance of connecting rod big end and flywheel
by feeling gauge. If clearance is excessive replace the
crankshaft assembly.
Connecting rod clearance limit:
0.5 mm
5. Inspect chain for worn or missing rollers or damage.
Replace if worn excessively or as part of any crankshaft
repair.
CRANKCASE / BEARING INSPECTION
NOTE: Removal and installation of new seals is
recommended anytime the crankcase is disassembled.
1. Inspect the bearings in the crankcase.
NOTE: Due to extremely close tolerances and minimal
side wear, the bearing must be inspected visually and by
feel. Look for signs of discoloration, scoring or galling.
Turn the inner race of bearing. The bearing should turn
smoothly and quietly. The outer race should fit tightly in
the crankcase. The inner race should be firm with minimal
side to side movement and no detectable up and down
movement.
2. To remove crankcase bearings, use a blind hole
bearing puller.
NOTE: Bearings are stressed during the removal
procedure and should not be re-used.
3. Remove all traces of gasket sealer from the crankcase
mating surfaces. Inspect the surfaces closely for nicks,
burrs or damage.
CRANKCASE OIL STRAINER INSPECTION
1. Remove drain plug.
2. Remove oil strainer and visually inspect for any rips,
tears or obstructions in screen.
3. Replace oil strainer if it fails visual inspection.
BEARING /SEAL INSTALLATION
NOTE: To ease crankcase bearing installation, warm the
crankcase until hot to the touch. Placing the bearing in a
freezer prior to installation will assist the assembly
process.
1. Install the bearing so the numbers are visible.
2. Drive or press the new bearing into the crankcase,
using the proper driver.
CAUTION
Press only on outer race of bearing to prevent bearing
damage.
3. Install new seals with the lip facing in.
CAUTION
Press only on outer diameter to prevent damage.
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