ENGINE REASSEMBLY 62


Top End Installation

1. Trim away any part of the center gasket that protrudes from the cases at the cylinder mounting bosses.

2. Squirt a small amount of oil into the two main bearing oil holes drilled in the transfer port cutouts.

3. Turn the crankshaft until the connecting rod is at top dead center.  Wrap a clean rag around the rod to cover the crankcase opening.

4. The piston, wrist pin, wrist pin bearing, and connecting rod are coded to allow perfect fit on assembly.

5. The rod will have a dab of green, yellow, or red paint below the wrist pin boss.

6. The piston has a dab of black or white paint on the wrist pin boss underneath.

7. The wrist pin has a dab of black or white paint inside the hole on one end.
8. The wrist pin bearings have no identifying marks.  They all have the same number, with a different suffix for the four different sizes.

9. The color code on the piston and wrist pin must be the same.

10. Check the color code on the rod and use Figure 35 to determine the correct bearing to use with this assembly.

11. If you're in doubt about which bearing you have, install it in the rod and install the wrist pin.  The pin should slide easily into it, but the bearing should allow no up and down movement inside the rod end.

12. Select the proper top end components and then install a new cylinder base gasket.  Be sure none of the gasket protrudes into the transfer port cutouts.  Trim with a knife if necessary.

13. Squirt some oil on the wrist pin bearing and install in the rod end.


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