Connecting Rods - Removal

Connecting rods may be removed from the engine after first removing it from the frame. The cylinder head must be removed and the crankcase halves separated.

  1. Mark each big end cap and connecting rod to identify both items as a matched pair and to identify the correct orientation of the bearing cap to the connecting rod.
  2. Release the connecting rod bolts and remove the big end cap. Ensure that the bearing shell remains in place in the cap.
    3. Graphic from Installation (cdur.svg)

    1. Big end cap

    2. Connecting rod bolt

    note
    It may be necessary to gently tap the big end cap with a rubber mallet to release the cap.
  3. Push the connecting rod up through the crankcase and collect the piston and connecting rod from the top.
  4. Label the assembly to identify the cylinder from which it was removed.
    5. caution
    Never reuse connecting rod bolts. If the connecting rod cap is disturbed, always renew the bolts. Using the original bolts may lead to severe engine damage.
  5. Remove the liner using service tool T3880101 (see Cylinder Liner - Removal).
  6. Detach the piston from the connecting rod (see Pistons - Disassembly).