Crankshaft and Piston Removal
Removal1. Remove the engine assembly.
2. Remove the transmission:
^ Manual transmission (M/T)
^ Continuously variable transmission (CVT)
3. Remove the cylinder head.
4. Remove the cam chain.
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 main bearing cap. Keep all bearings in order.
7. Remove the rod caps/bearings. Keep all caps/ bearings in order.
8. Lift the crankshaft out of the engine, being careful not to damage the journals.
9. If you can feel a ridge of metal or hard carbon around the top of each 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.
10. Use the wooden handle of a hammer (A) to drive out the piston (B).
11. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
12. To avoid mix-up on reassembly, mark each piston/ 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.