Removal
Note: The connecting rods and cap are etch-marked on one side to identify their correct orientation. However, the cylinder from which they are individually removed should also be identified, using a laundry marker or similar.
1. Remove the engine from the frame (see section 10.2).
2. Separate the lower and upper crankcases (see page 5.5).
3. Remove the cylinder head (see page 3.5).
4. Remove the connecting rod bolts. Discard the bolts.
1. Connecting rod bolts; 2. Connecting rod cap
5. Collect the big end caps.
6. Push the connecting rod up through the liner and collect the piston and connecting rod from the liner top.
7. Label the assembly to identify the cylinder from which it was removed.
8. Mark the position of each liner in the crankcase to ensure it is reassembled in its original position.
9. Remove the cylinder liners using tool T3880061, (see page 5.18).
Installation
Note: Connecting rod bolts and nuts are treated with an anti-rust solution, which must not be removed.
1. Clean the connecting rod with high flash-point solvent.
2. Select new big end bearings (see page 5.12).
3. Fit the selected big end shells to the connecting rods and big end caps.
4. Fit the piston and connecting rod assemblies into the liners as described on page 5.17.
5. Thoroughly clean the liner removing all traces of old silicone sealer.
6. Remove all traces of sealer from the crankcase bores.
7. Apply a thin bead of silicone sealer to the liner to crankcase mating face.
1. Liner; 2. Sealer area
8. Fit the liner into the crankcase ensuring that the arrow on the piston faces to the right hand side of the engine/bike (the same side as the exhaust headers).
1. Piston; 2. Arrow
Right hand (exhaust) side
Note: Ensure that the piston/liner/connecting rod assemblies align correctly with the crankpins during assembly into the crankcase.
1. Crankpin; 2. Big end
Warning! Always renew the big end bolts. The bolts are torqued near to their yield point when first installed and are severely weakened if reused. Re-using the original bolts may cause bolt breakage resulting in engine damage, loss of motorcycle control and an accident.
9. Align the connecting rod to the crankshaft and fit the big end cap. Tighten the NEW cap bolts as follows:
Warning! The torque characteristics of the connecting rod bolts are sensitive to the rate at which they are tightened. If all the torque is applied in one action, the bolts will be stretched beyond their yield point. This may cause bolt breakage resulting in engine damage, loss of motorcycle control and an accident.
Lubricate the under-head and thread areas of the bolts with undiluted molybdenum disulphide grease. Tighten the bolts, in two stages as follows;-
- a) Tighten to 14 Nm.
- b) Tighten through 120° of bolt rotation as measured using the Triumph torque turn gauge 3880105-T0301.
Service Tool 3880105-T0301