Crankshaft and Piston Removal

Crankshaft and Piston Removal
1. Remove the cam chain.
2. Remove the oil pump.





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





4. Remove the 8 mm bolts securing the lower block.





5. 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.





6. Remove the lower block and bearings. Keep all bearings in order.
7. Remove the rod caps and bearings. Keep all caps and bearings in order.





8. Lift the crankshaft out of the engine, being careful not to damage the journals.





9. Use the wooden handle of a hammer (A) to drive out the pistons (B).
10. Reinstall the connecting rod bearings and caps after removing each piston and connecting rod assembly.
11. To avoid mix-up on reassembly, mark each piston and connecting rod assembly with its cylinder number.

NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.