Disassembly and  Assembly Section

i02754798

Installation Procedure

Engine Support  (Front) -

Remove and Install

Table 21

Required Tools

Tool

Part Number

Part Description

Qty

Guide  Stud

(M12 by 100mm)

A

-

2

Removal Procedure

Table 20

1.  Ensure that the front of the engine is supported.

Required Tools

Tool

Part Number

Part Description

Qty

Guide  Stud

(M12 by 100mm)

A

-

2

Start By:

a.  Remove the vibration damper and the crankshaft

pulley. Refer to Disassembly  and Assembly,

“Vibration Damper and Pulley -  Remove and

Install”.

1.  Support the front of the engine.

g01380895

Illustration 91

2.  Install Tooling (A) to positions (X) on the cylinder

block.

3.  Install a suitable  lifting device to  engine

support (2). The weight of engine support (2) is

approximately 25 kg (55 lb).

4.  Use the lifting device to align engine support (2)

with Tooling (A). Install the engine support to the

cylinder block.

5.  Install bolts (1) finger tight. Remove Tooling (A)

and install the remaining bolts. Tighten bolts to a

torque of 100 N·m (74 lb ft).

g01380895

Illustration 90

2.  Attach a suitable  lifting device to engine

support (2). The weight of the engine support is

approximately 25 kg (55 lb).

End By:

a.  Install the vibration damper and the crankshaft

pulley. Refer to Disassembly  and Assembly,

“Vibration Damper and Pulley  - Remove and

Install”.

3.  Remove bolts (1) from positions (X) and install

Tooling (A) to positions (X). Remove the remaining

bolts (1).

4.  Use the lifting device to remove engine support

(2) from the cylinder block.

5.  Remove Tooling (A).

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KENR6906

41

Disassembly and  Assembly Section

i02754801

5.  Remove the remaining bolts (1). Use the lifting

device in order to remove flywheel (2).

Flywheel - Remove

Removal Procedure

Table 22

Required Tools

Part

Tool

Number

Part Description

Qty

Guide  Stud

M16 by 120mm

A

-

2

Start By:

g01389418

Illustration 93

Typical example

a.  Remove the electric starting motor. Refer  to

Disassembly and Assembly, “Electric Starting

Motor - Remove and Install”.

6.  Inspect flywheel (2) and ring gear (3) for wear or

damage. Replace any components that are worn

or damaged.

NOTICE

Keep all parts clean from contaminants.

7.  To remove the ring gear, follow Steps 7.a and 7.b.

a.  Place flywheel (2) on a suitable support.

Contaminants may cause  rapid wear and  shortened

component life.

Note: Identify the orientation of the teeth on the ring

gear.

b. Use a hammer and a punch in order to remove

ring gear (3) from flywheel (2).

i02754802

Flywheel - Install

Installation Procedure

Table 23

Required Tools

Tool

Part Number

Part Description

Qty

Guide  Stud

M16 by 120mm

A

-

2

g01383279

POWERPART

Threadlock and Nutlock

Illustration 92

B

21820117

1

Typical example

1.  Attach a suitable lifting device to flywheel (2).

Support the weight of the flywheel. The weight of

the flywheel is approximately 50 kg (110 lb).

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

2.  Use a suitable tool to lock flywheel (2). Loosen

bolts (1).

3.  Remove two bolts (1) from positions (X).

4.  Install Tooling (A) to positions (X).

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42

KENR6906

Disassembly and  Assembly Section

g01389418

Illustration 94

Always  wear  protective  gloves  when  handling

parts that have been heated.

g01389447

Illustration 95

1.  If the ring gear was removed, follow Steps 1.a

through 1.c in order to install a new ring gear to

the flywheel.

Typical example

3.  Install Tooling (A) to  positions (X) on  the

crankshaft.

a.  Identify the orientation of the teeth on new ring

gear (3).

4.  Install a suitable lifting device to flywheel (2). The

weight of the flywheel is  approximately 50 kg

(110 lb).

Note: The chamfered side of the ring gear teeth must

face toward the starting motor when the flywheel is

installed. This will ensure the correct engagement of

the starting motor.

5.  Use the lifting device in order to position flywheel

(2) onto Tooling (A). Ensure that Marks (Y) on the

flywheel and on the crankshaft are aligned.

b. Heat ring  gear (3) in an oven to a maximum

temperature of 316  °C (600 °F) prior  to

installation.

6.  Apply Tooling (B) to the threads of bolts (1).

7.  Install bolts (1). Remove Tooling  (A). Install

remaining bolts (1).

Note: Do not use a torch to heat the ring gear.

8.  Use a suitable tool to prevent the flywheel from

rotating. Tighten bolts (1) to a torque of 300 N·m

(221 lb ft).

c.  Ensure that the orientation of ring gear (3) is

correct and quickly install the ring gear onto

flywheel (2).

9.  Remove the lifting device from flywheel (2).

2.  Inspect the crankshaft rear seal for leaks. If there

are any oil leaks, replace the crankshaft rear seal.

Refer to Disassembly and Assembly, “Crankshaft

Rear Seal - Remove”.

10. Check the runout of the  flywheel. Refer to

Systems Operations, Testing and  Adjusting,

“Flywheel - Inspect”.

End By:

a.  Install the electric starting  motor. Refer to

Disassembly and Assembly, “Electric Starting

Motor - Remove and Install”.

This document has been printed from SPI². Not for Resale

KENR6906

43

Disassembly and  Assembly Section

i02754803

i02754805

Crankshaft Rear Seal - Remove

Crankshaft Rear Seal - Install

Removal Procedure

Installation Procedure

Start By:

Table 24

Required Tools

Part

a.  Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.

Tool

Number

Part Description

Qty

POWERPART

Threadlock and Nutlock

NOTICE

Keep all parts clean from contaminants.

A

21820117

1

Contaminants may cause  rapid wear and  shortened

component life.

NOTICE

Keep all parts clean from contaminants.

1.  Ensure that the crankshaft flange and the housing

for the crankshaft rear seal is clean, dry and free

from damage. It is possible to reclaim a crankshaft

flange that has a worn seal surface, or a damaged

seal surface by installing a wear sleeve. Refer to

Disassembly and Assembly, “Crankshaft Wear

Sleeve (Rear) - Remove and  Install” for more

information.

g01389635

Illustration 96

1.  Remove bolts (1) and (3).

2.  Remove crankshaft rear seal (2).

3.  Remove the O-ring seal from crankshaft rear seal

(2).

g01389636

Illustration 97

This document has been printed from SPI². Not for Resale

44

KENR6906

Disassembly and  Assembly Section

i02807660

Crankshaft Wear Sleeve (Rear)

- Remove and Install

Removal Procedure

Start By:

a.  Remove the crankshaft rear  seal. Refer to

Disassembly and Assembly, “Crankshaft Rear

Seal - Remove”.

g01395750

Illustration 98

Tightening sequence for the crankshaft rear seal

NOTICE

Keep all parts clean from contaminants.

2.  Install a new O-ring seal to crankshaft rear seal

(2). A new crankshaft rear seal is supplied with a

plastic sleeve. Ensure that the plastic sleeve is

squarely installed within the crankshaft rear seal.

Contaminants may cause  rapid wear and  shortened

component life.

Note: Wear sleeves are used to reclaim worn seal

surfaces or damaged seal surfaces. Wear sleeves

are not original equipment.

Note: The plastic sleeve  is included in order to

protect the lip of the seal as the seal is pushed over

the crankshaft flange.

1.  Use a sharp tool to score a deep line across the

crankshaft wear sleeve.

Note: Do not lubricate the crankshaft rear seal or

the crankshaft flange. The crankshaft rear seal

must be installed dry.

Note: Take care to avoid damaging the crankshaft.

3.  Align the plastic sleeve with the crankshaft flange.

Ensure that the plastic sleeve is engaged onto the

crankshaft flange. Push new crankshaft rear seal

(2) squarely onto the crankshaft flange.

2.  Insert a thin blade between the crankshaft wear

sleeve and the crankshaft below the scored line.

The crankshaft wear sleeve will separate along

the line.

During this process, the plastic  sleeve will be

forced out of the crankshaft rear seal. Discard the

plastic sleeve.

3.  Remove the crankshaft wear sleeve from the

crankshaft.

Installation Procedure

4.  Apply Tooling (A) to the threads of bolts (3). Install

bolts (1) and (3). Tighten the bolts to a torque of

12 N·m (105 lb in) in the numerical sequence that

is shown in Illustration 98.

Table 25

Required Tools

Tool

Part Number

21820518

CVT0017

-

Part Description

Qty

1

End By:

POWERPART

Liquid Gasket

A

a.  Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Install”.

Installer

1

B

Bolt

(M16 by 30 mm)

3

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

This document has been printed from SPI². Not for Resale

KENR6906

45

Disassembly and  Assembly Section

Note: Wear sleeves are used to reclaim worn seal

surfaces or damaged seal surfaces. Wear sleeves

are not original equipment.

Start By:

a.  Remove the electric starting motor. Refer  to

Disassembly and Assembly, “Electric Starting

Motor - Remove and Install”.

1.  Ensure that the crankshaft is thoroughly clean and

dry. Remove any areas of raised damage.

b. Remove the flywheel. Refer  to Disassembly and

2.  Apply a small continuous bead of Tooling (A) to the

inner surface of the crankshaft wear sleeve. Apply

the bead of Tooling (A) 5.00 mm (0.2 inch) from

the chamfered end of the crankshaft wear sleeve.

Assembly, “Flywheel - Remove”.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

g01401603

Illustration 99

Sectional view of  the crankshaft, the wear sleeve  and the

installation tool

1.  Support the rear of the engine.

3.  Align crankshaft wear sleeve (1) with crankshaft

(2). Install Tooling (B) to crankshaft (2). Evenly

tighten the bolts of Tooling (B) in order to install

the crankshaft wear sleeve.

4.  Remove Tooling (B).

End By:

a.  Install a new crankshaft rear  seal. Refer to

Disassembly and Assembly, “Crankshaft Rear

Seal - Install”.

i02754806

Flywheel Housing - Remove

and Install

g01383281

Illustration 100

Removal Procedure

2.  Attach a suitable lifting  device to flywheel

housing (2). The weight of the flywheel housing is

approximately 25 kg (55 lb).

Table 26

Required Tools

Tool

Part Number

Part Description

Qty

3.  Remove bolts (1) from positions (X). Install Tooling

(A) to positions (X).

Guide  Stud

(M14 by 100mm)

A

-

2

4.  Remove the remaining bolts (1). Use the lifting

device to remove flywheel housing (2) from the

cylinder block.

This document has been printed from SPI². Not for Resale

46

KENR6906

Disassembly and  Assembly Section

Note: It is not necessary to remove the dowels in the

cylinder block that locate the flywheel housing.

g01389649

Illustration 101

5.  Remove O-ring seal (3) from housing (4).

Installation Procedure

g01383281

Illustration 103

Table 27

3.  Apply Tooling (B) to the rear face of the cylinder

block.

Required Tools

Part

Note: The flywheel housing must be installed within

ten minutes of applying Tooling (B).

Tool

Part Description

Qty

Number

Guide  Stud

(M14 by 100mm)

A

B

-

2

1

4.  Install Tooling (A) to positions (X) in the cylinder

block.

CH10879

Sealant

5.  Attach a suitable lifting  device to flywheel

housing (2). The weight of the flywheel housing is

approximately 25 kg (55 lb).

1.  Ensure that the mating surfaces of the flywheel

housing and the cylinder block are clean and free

from damage.

6.  Use the lifting device to align flywheel housing (2)

with Tooling (A).

7.  Install flywheel housing (2) to the cylinder block.

8.  Install bolts (1). Remove Tooling (A). Install the

remaining bolts. Tighten the bolts to a torque of

160 N·m (118 lb ft).

End By:

a.  Install the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Install”.

b. Install  the electric starting motor.  Refer to

Disassembly and Assembly, “Electric Starting

Motor - Remove and Install”.

g01389649

Illustration 102

2.  Install a new O-ring seal (3) to housing (4).

This document has been printed from SPI². Not for Resale