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.
Pistons and Cylinder
a. Install the piston rings onto the pistons. Manufacturer's marks or numbers are located on the top side of the rings.
Install the pistons on the rods. Always use new piston pin clips (1). The arrow on the piston (2) must point to the front of the engine.
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)
b. Install the stator coil assembly onto the crankcase and align the grooves on the stator core with the bolt holes on the crankcase.
6. Middle gear (installation only, refer to _tbd__ for the middle gear adjustment)
a. Install the middle drive gear assembly with the proper size of shim(s) and secure it with the bearing retainers and new "TORX" screws.
Tightening torque: 2.5 m-kg (18 ft-lb)
b. Stake the screw heads to the dents on the bearing retainers with a center punch.
a. Install the thrust plate onto the transmission main axle.
1. Thrust plate
b. Install the oil pump drive sprocket onto the main axle without the spacer collar and place the oil pump drive chain on its sprocket.
1 a. Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.
b. Install the neutral switch. Torque to 2.0 m-kg (14 ft-lb).
c. Install the transmission drive axle assembly into the crankcase.
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.
P. Middle Gear
1. Damper disassembly
Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.
1. Inspect each shift fork for signs of galling on gear contact surfaces. Check for bending. Make sure each fork slides freely on its guide bar.
2. Roll the guide bar across a surface place. If the bar is bent, replace.