Removal
1. Assemble the frame from tool T3880315 to tool T3880101 as shown below.
1. Frame from tool T388031S; 2. Tool T3880101
1. Paint mark
2. Mark each liner to identify correct orientation and the cylinder number from which it has been removed.
3. Turn the crankshaft until the piston in the liner to be removed is at the bottom of its stroke.
1. Tool T388031S and T3880101; 2. Extraction nut; 3. Locking nut
4. Check that the locking nut on tool T3880101 is loose, then fully unscrew the extraction nut.
5. Carefully fit the tool fully into the cylinder bore, positioning the tool legs on the crarkcase. Turn the locking nut clockwise until the rubber sleeve on the tool tightly grips the bore of the liner.
6. Check that the tool legs are positioned to allow withdrawal of the liner, then turn the extraction nut clockwise to extract the liner. Take care to ensure that the piston/connecting rod is not allowed to fall against the inside of the crankcase.
7. Turn the locking nut counter-clockwise to release the liner.
Note:
- The tool must be used to release the seal between the liner and the crankcase.
- lt is not intended that the tool is used to fully extract the liner. Once the seal is released, the tool must be removed and the liner extracted by hand.
Installation
1. Thoroughly clean the liner removing all traces of old silicone sealer.
2. Remove all traces of sealer from the crankcase bores.
3. Apply silicone sealer to the liner to crankcase mating face (at the factory, ThreeBond 1215 is used).
4. Fit each liner over the piston using a gentle rocking motion to allow compression of the piston rings.
1. Liner; 2. Sealer area; 3. Chamfer
Note: The liners have a large chamfer at the bottom of the bore enabling fitting of the piston without need for a piston ring compressor.
Caution: Fit each liner over whichever piston is at TDC. When turning the engine, do not allow the pistons to contact the inside of the crankcase and also do not allow fitted liners to lift off the crankcase base.
5. Continue fitting each liner in turn until all are fitted and sealed.
Note: When the liners have been fitted, they should not be disturbed. If it is necessary to remove the liner after fitting, the sealer must be re-applied.
Crankcase Breather
The upper crankcase is fitted with a labyrinth type breather system, which requires no maintenance. During engine disassembly and overhaul, check the oil drain tube for blockage and contamination.