Part 3
Engine
Disassembly (Steps 69-104)
69. Remove the bolt and the oil pump screen cover and tube.
70. NOTE: Note the location of the 2 silver-colored bolts with the washer seals. These bolts must be installed in the same position from which they were removed with new washer seals.
Remove the cylinder block cradle inner bolts. Remove and discard the 2 washer seals.
71. Remove the cylinder block cradle Torx(R) bolts.
72. Remove the 15 bolts and the 2 nuts. Remove the cylinder block cradle.
73. Remove the oil pump pickup tube, the oil pump and the oil pump intermediate shaft.
74. Remove the oil filter adapter.
75. Inspect and install new O-ring seals, if necessary.
76. Remove the jackshaft rear plug.
77. Using the special tool, hold the crankshaft.
78. Remove the jackshaft sprocket rear bolt.
79. Remove the RH cassette bolt.
80. Remove the RH cassette.
81. Remove the oil pump bolt and retainer and then remove the oil pump drive.
82. Using the special tool to hold the crankshaft, loosen the front sprocket retaining bolt.
83. Remove the bolts and the chain tensioner.
84. Remove the chain guide.
85. Remove the bolt.
86. Remove the jackshaft and crankshaft sprockets and the chain.
^ Remove the crankshaft key.
87. Remove the bolt and the front cassette.
88. Remove the jackshaft thrust plate.
89. Remove the jackshaft.
90. Remove the balance shaft tensioner.
1 Install a pin in the balance shaft tensioner.
2 Remove the bolts.
3 Remove the balance shaft tensioner.
91. Remove the 2 bolts and the balance shaft chain guide.
92. NOTE: DO NOT remove the balance shaft sprocket bolt.
Remove the balance shaft chain and crankshaft sprocket.
93. Remove the balance shaft.
1 Remove the bolts.
2 Remove the balance shaft.
94. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's instructions.
95. NOTE: Clearly mark the connecting rods and rod caps in numerical order for correct reassembly.
Remove the connecting rod caps.
1 Remove the connecting rod cap.
2 Remove the connecting rod nuts.
96. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.
97. Remove the connecting rod bearings.
98. Remove the piston rings.
99. Clean and inspect the pistons.
100. CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
Remove the bolts.
101. NOTE: Number (or mark) the crankshaft bearing caps before removing them.
Remove the crankshaft main bearing caps.
102. Remove the crankshaft rear oil seal from the crankshaft.
103. Remove the crankshaft.
104. Remove the crankshaft main bearings and the thrust bearing.
