Disassembly

DISASSEMBLY





1. PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT
1) Remove service hole cover and service hole plugs using hexagon wrench (14 mm).





2) Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders.





3) Draw out piston pin from #1 and #2 pistons by using ST. ST 499097500 PISTON PIN REMOVER

CAUTION: Be careful not to confuse original combination of piston, piston pin and cylinder.

4) Similarly remove piston pins from #3 and #4 pistons by using ST.
5) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders.
6) Back off bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.





2. CYLINDER BLOCK
1) Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts.
2) Separate left-hand and right-hand cylinder blocks.

CAUTION: When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.

3) Remove rear oil seal.
4) Remove crankshaft together with connecting rod.
5) Remove crankshaft bearings from cylinder block using hammer handle.

CAUTION: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.

6) Draw out each piston from cylinder block using wooden bar or hammer handle.

CAUTION: Do not confuse combination of piston and cylinder.





3. CRANKSHAFT AND PISTON
1) Remove connecting rod cap.
2) Remove connecting rod bearing.

CAUTION: Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confusion.

3) Remove piston rings using the piston ring expander.
4) Remove the oil ring by hand.

CAUTION: Arrange the removed piston rings in good order to prevent confusion.

5) Remove circlip.