1
3
5
7
8
9–11 Nm
CRANKCASE
2
4
6
9
10
Crankshaft
Tools
The tool kit 544 10 36-02 is used to press
in the crankshaft in the bearings.
Threaded fittings are available for the
clutch and flywheel, M12V and M10x1.
Assembly
Picture 1.
Attach the crankcase half in a vice with
soft jaws.
Picture 2.
Push the crankshaft in all the way by
hand. Use the support plate to hold the
connecting rod in an upright position.
Picture 3.
Insert the tool kit sleeve on the crankcase
half. Screw the threaded fitting M12V on
the crankshaft by hand until it reaches
the bottom. Note that the crankshaft has
a left handed thread on the clutch side.
Picture 4.
Lock the threaded mandrel's movement
and press in the crankshaft by turning
the nut until the bearing reaches the stop
in the crankcase half. Make sure that the
connecting rod is not held against the
crankcase half.
Picture 5.
Fit the guides.
Picture 6.
Fit the new crankcase gasket.
Picture 7.
Fit the second crankcase half using the
same method as the first. Use the fitting,
M10x1.
Support the crankcase half in position
with a long screw at the rear attachment
point. Fit the crankcase bolts as soon as
possible to ensure that the gasket is pro-
perly fitted and that the crankcase halves
meet in the correct position.
Picture 8.
Fit the screws and tighten these crosswise
to a torque of 6.5–8.0 lbf·ft/9–11 Nm.
Check that the crankshaft runs free
after assembly. Knock the ends of the
shaft using a small plastic hammer
usually releases any tension.
Picture 9.
Cut the gasket on the cylinder plane and
the carburettor seating.
Picture 10.
Fit new stuffing boxes (page 37).
Once the cylinder has been assembled
the crankcase should be leakage tested.
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