Refitting the cylinder/piston assembly
If new units are used, it is necessary to couple the cylinders and pistons of the same selection (see chapter "Overhauling the cylinder/piston components").
Note
If the pistons have been separated from their cylinders, before reassembling these components, position the piston ring gaps at 120° from one another (the markings must always face the piston crown).
Use a universal tool to carefully insert the piston into the cylinder (first lubricate the inside of the cylinder with engine oil). Position the cylinder with the smallest valve recess is on the side of the exhaust.
Remove any deposits and degrease the contact surfaces of the crankcase half and the cylinders.
Check that the cylinder centring dowels (B) are fitted on the crankcase.
Apply sealant to the gasket (11) then locate the gasket on the crankcase.
Using cap no. 88713.1920, fit the O-rings (A) on each thru bolt and guide them into their seats in the crankcase.
Bring the connecting rod small end close to TDC and slide the cylinder-piston assembly (12) and (4) onto the crankcase thru bolts.
Push the connecting rod small end into the piston close to the gudgeon pin (9) hole. Lubricate and insert the gudgeon pin.
The gudgeon pin (9) must slide smoothly in the connecting rod small end bush and in the piston (12).
Close the crankcase opening with a cloth to prevent foreign objects from falling inside and then fit the snap ring (10).
Important
Always fit new circlips upon reassembly.
Push the cylinder (8) down until it seats against the crankcase.
Refit the bushes (7).
Fit the cylinder head gasket (6) over the thru bolts. The side marked with the part number must be facing the cylinder head.
Note
The shape of the gasket prevents incorrect fitting, provided that the fluid flow holes are aligned with those on the cylinder.
Repeat the procedure for the other cylinder and refit the cylinder heads (Refitting the cylinder head assemblies).
In case they have been removed, apply prescribed threadlocker to unions (5) and tighten them to a torque of 25 Nm (Min. 23 Nm - Max. 27 Nm) (Engine tightening torque values).
Fit hoses (2) and (3), and tighten the clamps (1) to a torque of 2.5 Nm (Min. 2 Nm - Max. 3 Nm) (Engine tightening torque values).
Refit the heads on the engine block (Refitting the cylinder head assemblies).
Refit the intake manifolds (Refitting the intake manifold and water union).
Refit the timing belts (Refitting the timing belts) and the timing belt external covers (Refitting timing belt external covers).
Refit the exhaust system.
Refit the water radiator on the engine (Refitting the water radiator).
Refit the cooling system hoses and unions on the engine block (Refitting the cooling system hoses and unions).
Refill the cooling system (Changing the coolant).
Refit the injectors on the intake manifolds and the supply system.
Refit the blow-by and the oil breather pipe, the throttle body (Refitting the throttle body) and the airbox (Refitting the airbox).
Refit the air filter (Refitting the air filters).
Refit the fuel tank (Refitting the fuel tank).
Refit the side fairings (Refitting the fairings).
Refit the seat (Refitting the seat).