Connecting Rods - Installation

note
Connecting rod bolts are treated with an anti-rust solution which must not be removed.Clean the connecting rod with high flashpoint solvent.Remove all bearings and inspect for damage, wear and any signs of deterioration and replace as necessary.
warning
Connecting rod bolts MUST only be used once. If the bolts are removed or undone for any reason, new bolts MUST always be used.Reusing bolts can cause connecting rods and their caps to detach from the crankshaft causing severe engine damage, loss of motorcycle control and an accident.
note
Ensure the piston is fitted correctly to the connecting rod.If a previously run engine is being rebuilt, always ensure that the piston and connecting rod are assembled in the same orientation, and to the same cylinder, as prior to disassembly.
  1. Fit the piston onto the connecting rod (see Pistons - Assembly Piston Assembly).
  2. Apply silicone sealer to the liner-to-crankcase mating face (at the factory, ThreeBond 1216E is used).
    3. Liner (cbef_1_1)

    1. Liner

    2. Sealer area

  3. Fit the piston and connecting rod assembly into the liner from the bottom.
    4. Cylinder Liners Installation (ccvl)

    Arrowed: Liner-Piston Fitment

  4. Fit the liner into the crankcase ensuring that the arrow on the piston faces forward.
  5. The liners must be positioned such that they do not touch each other - it must be possible to pass a 0.1 mm feeler gauge between the centre liner and its adjacent liner on either side. If the liners touch at any point, rotate the liners until there is a minimum 0.1 mm clearance.
    6. Connecting Rods - Bore Clearance

    1. Liners

    note
    Ensure that the piston/liner/connecting rod assembly aligns correctly with the crankshaft journal during assembly into the crankcase.
  6. Select the big end bearing shells (see Connecting Rod Big End Journal Checking, Measuring and Bearing Selection).
  7. Fit the bearing shells to the connecting rod and big end cap and lubricate with a 50/50 solution of engine oil and molybdenum disulphide grease.
  8. Align the connecting rod to the crankshaft and fit the big end cap.
    9. Graphic from Installation (cdur.svg)

    1. Big end cap

    2. Connecting rod bolt

    caution
    The torque characteristics of the connecting rod bolts are sensitive to the correct lubrication being applied. If the threads and under-head areas are not lubricated with molybdenum disulphide grease, the bolts may be stretched and may become loose when in service resulting in an expensive engine failure.
  9. Lubricate the threads and under-head area of the new bolts with molybdenum disulphide grease. Tighten the bolts evenly and progressively in two stages as follows:
    10. caution
    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 bolt may be stretched and may become loose when in service resulting in an expensive engine failure.

  • Tighten to 14 Nm.

  • Tighten through 210° of bolt rotation as measured using service tool T3880105.

T3880105

T3880105 - Torque Angle Gauge