650G (Euro)

11. Pistons and Cylinder a. Install the pistons on the rods. The arrow on the piston must point to the front of the engine.

NOTE:--------------------------------------------------------

Before installing the piston pin clips, cover

the crankcase with a clean rag so you will

not accidentally drop the circlip into the

crankcase.

INSPECTION AND REPAIR

A.   Cylinder Head Cover

Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:

Place #400 or #600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.

B.   Cylinder Head

H. Oil Pump Removal and Disassembly

1. Remove the strainer cover. Note the wire harness clip position.

2. Remove the oil pump securing bolts and remove the sprocket cover and oil pump assembly.

—CAUTION:-------------------------------------------

8. A.C. Generator

a. Install the rotor onto the shaft and

tighten the bolt using the rotor holding

tool (special tool) as shown.

1. Rotor holding tool

Tightening torque: 5.5 m-kg (39.8 ft-lb)

C. Piston

1.   Mark each piston to aid in reassembly.

2.   Place a clean towel or rag into the crank-case to keep circlips and material from falling into the engine.

3.    Remove piston pin clips, piston pins, and pistons.

D. Pick-up Coil Assembly

12. Cylinder head and Cam shafts 

a. Install the new cylinder head gasket. Install the dowel pins and "O-rings". Locate the cam chain cavity cylinder seal with the tabs down.

b.   Install the cylinder head onto the cylinder. Pull the cam chain through the cylinder head as it is installed. Tie the cam chain so that it does not fall into the crankcase.

P. Middle Gear

1. Damper disassembly

NOTE:-------------------------------------------------------

Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.

a. Place the middle drive shaft in a press with the damper compressor (special tool) in place as shown.

ENGINE ASSEMBLY AND ADJUSTMENT

A. Important Information

1.    Gasket and seal

All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces and oil seal lips must be cleaned.

2.    Properly oil all mating engine and transmission parts and bearings during reassembly.

3.    Circlip

D. Valve Spring and Lifters

1. Checking the valve springs

a. 
 This engine uses two springs of different sizes to prevent valve float
or surging. The valve spring specifications show the basic value
characteristics.