Caution!
- The stud bolts should be fitted so that they protrude.
- Distribute Loctite 270 (high-strength) on the thread and screw the stud bolt on the crankcase until they protrude by 137 mm (5.39 in), then make sure the Loctite has set.
Insert a new cylinder base gasket, it should be as thick as the gasket previously removed: 0.40 - 0.50 - 0.60 mm (0.0157 - 0.0197 - 0.0236 in).
The silicone side should be facing the crankcase.
Caution! If the original gasket thickness cannot be checked or should the cylinder be replaced, refer to the "base gasket selection" section.
Before fitting the cylinder, place the chain sliders and the timing chain on the crankshaft; fit the timing chain on the crankshaft from the base side.
Note. Before fitting the cylinder, carefully blow air into the lubrication duct and lubricate the cylinder liner.
Insert the cylinder-head unit on the stud bolts.
Working in a diagonal sequence and in stages, screw the four nuts once the stud bolt threads have been greased.
Screw the screw located outside the cylinder.
Tighten the three screws on the intake and discharge sides.
Screw the two head fixing screws located inside the timing chain compartment.
Check that the intermediate gear pin lubrication holes are clean.
With a hook, hold the timing chain.
Fit the timing chain on the intermediate gear.
Slide in the pin together with a new O-Ring and a washer.
Check that the axial clearance between the pin and the gear is between 0.30 and 0.60 mm (0.0118 - 0.0236 in).
Tighten the intermediate gear pin once Loctite residues are thoroughly removed and a high-strength threadlock is applied on the thread.
Make sure that both timing chain sliders are correctly fitted.
Refit the overhead camshafts following the procedure described in the "Timing" section.
