650G (Euro)

Pistons and Cylinder Reassembly

Submitted by xjcdadmin on Thu, 06/04/2009 - 12:15

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.

Cylinder Head and Valves -- Inspection & Repair

Submitted by xjcdadmin on Thu, 06/04/2009 - 12:15

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

Cylinder Head and Camshaft Reassembly

Submitted by xjcdadmin on Thu, 06/04/2009 - 12:15

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.

Engine Removal

Submitted by xjcdadmin on Thu, 06/04/2009 - 12:15

ENGINE REMOVAL

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

It is not necessary to remove the engine in order to remove the cylinder head, cylinder, or pistons.

A . Preparation for Removal 

Upper Crankcase Reassembly

Submitted by xjcdadmin on Thu, 06/04/2009 - 12:15

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