Crankshaft and Pistons Removal

Crankshaft and Pistons Removal

1.	Remove the cam chain.

2.	Remove the cylinder head.

3.	Remove the oil screen (A), then remove the oil pump (B).   AB

4.	Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time: repeat the sequence until all bolts are loosened.   (1)(7)(9)(5)(3)(4)(6)(10)(8)(2)

5.	Remove the bearing cap bridge.

6.	Remove the rod caps/bearings. Keep all caps/bearings in order.

7.	Lift crankshaft out of the cylinder block, bearing careful not to damage the journals.

8.	Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.

9.	If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.   A

10.	Use the wooden handle of a hammer (A) to drive out the pistons (B).   AB

11.	Reinstall the bearing cap bridge and bearings on the cylinder block.

12.	Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.

13.	To avoid mixup on reassembly, mark each piston/connecting rod assembly with its cylinder number. NOTE: The existing number on the connecting rod does not indicate its position in the block, it indicates the rod bore size.