06323-ZW5-U13 Honda PANEL KIT, CONTROL (A)

M 01.10 Removing and installing balancing weights - 2L/3L
Preparatory work:
- Remove the crankshaft, see M 02.00.Dismantling:
- Unscrew and remove machine screws (1/1) at driver (1/2). On the 3 L, also unscrew and remove the machine screws at the divided driver.- Unscrew and remove the machine screws (2/1) at the plate (2/2) and take off the plate. (On more recent version: secured with stud bolts and nuts)- Unscrew the plug from the thrust bushing at the timing end of the engine and drive the shaft out towards the flywheel end; see Fig. 3.- Drive out the thrust bushing (timing end).- Take the balancing weights and driver out of the lower part of the crankcase.Checking / repairs:
- Check the shaft at its bearing points for score-marks and correct dimensions; for values, see Section 4.- Check the needle roller bearings of the balancing weights for score-marks.- Check the gearwheel with balancing weight and the crankshaft-end gearwheel for the balancing weights for signs of damage.- Renew the O-ring seals at the thrust bushings.
1 (L3/106)
2 (L3/107)
3 (L3/108)Assembling:
- Insert the thrust bushing (timing end) until flush with the housing.- Place the gearwheel with balancing weight (flywheel end) and the balancing weight (timing end) in the lower part of the crankcase, insert the driver and screw hand-tight to the balancing weights. Insert the shaft with thrust bushing (4/1) from the flywheel end, see Fig. 4, and drive it fully into the timing-end thrust bushing.- Tighten the machine screws for the driver and use a depth gauge to measure end-play at the balancing weights; see Fig. 5. The timing-end thrust bushing (5/1) forms part of the sealing face at the timing case cover, and must therefore be flush with the endface of the crankcase after driving in the shaft. Endplay can be adjusted by moving the flywheel-end thrust bushing axially until the value stated in Section 4 is obtained.- Apply sealant D to the machine screws (6/1) and attach the plate; also coat the screw plug for the timing-end thrust bushing with sealant D and screw it in. Turn the balancing weights to ensure free rotation. When installing the oil sump and the crankcase cover, apply sealant D to two M8 hex bolts in each case at the timing and flywheel ends, where a through-hole has been drilled.
4 (L3/109)
5 (L3/110)
6 (L3/111)M 01.20 Removing and installing balancing weights - 4 L
Preparatory work:
- Remove the crankshaft; see M 02.00.- Take off the oil sump.Dismantling:
- Unscrew the machine screws (7/1) at the bearing journals (7/2) and pull them out. Using two machine screws, loosen the bearing journals and pull them out. Mark the installed positions of the bearing journals.- Invert the lower part of the crankcase. The joint line is a sealing face, and must not be damaged. Place the crankcase on a wooden grid or frame; see Fig. 8.- Unscrew splash plate (9/1) and take out balancing weights (9/2), then remove splash plate (9/3).
7 (L3/110)
8 L3/113)
9 (L3/114)- Check dimensions of bearing bushings (10/1) and, if necessary, drive them out with a suitable drift. First drive the end caps out of the crankcase bores (10/2).Checking/repairs:
- Check the bearing journals and bushings for score-marks and incorrect dimensions; for values, see Section 4.- Check the balancing weight gearwheels and the crankshaft-end gearwheel for the balancing weights for damage.Assembling:
- Blow through the oilways thoroughly with compressed air. Before installing the bearing bushings, make sure that the oil hole is in the correct position; see Fig. 11.- Coat the bearing bushings (12/1) with sealant D and drive them into the housing until flush, using a suitable drift; see Fig. 12.- Coat the sealing faces of the end caps (10/2) with sealant C and insert them again.- Renew the end caps.
10 (L3/115)
11 (L3/116)
12 (L3/117)- Insert spacing rollers for the M8 screws in the correct positions as shown in Fig. 13. Insert the longer spacing rollers (13/1) at the oil filter flange side.- Insert splash plate as shown in Fig. 14, insert the lower machine screws (14/1) and tighten them. Screw the upper machine screws (14/2) in only hand-tight.- Insert the balancing weight with circle and line markings as shown in Fig. 15, and push in the bearing journal. This balancing weight is driven directly from the crankshaft.
13 (L3/118)
14 (L3/118)
15 (L3/120)- Insert the balancing weight with circle mark (16/1) and push in the bearing journal. When installing this balancing weight (16/1), make sure that the circle mark on it is between the two line marks on balance weight (16/2). In this position, the circle mark on balancing weight (16/2) must face the crankshaft.- Take out the two machine screws at holes (17/1) again. Place spacing rollers (17/2) on the splash plate.Insert splash plate (17/3) and screw in hex bolts (17/4) hand-tight.- Insert machine screws (17/1) and tighten.; also tighten hex bolts (17/4).- Turn the lower part of the crankcase back upright again (joint line at the top).- Insert the machine screws at the bearing journals and tighten them to the specified torque with a torque wrench; Fig. 18.- Rotate the balancing weights and check for free movement. When attaching the oil sump, apply sealant D to two M8 hex bolts in each case at the timing and flywheel ends, since these are inserted in through-holes. Engines with an oil sump attached must not have a Ø 40 mm end cap installed in the lower part of the crankcase.
16 (L3/121)
17 (L3/122)
18 (L3/123)M 01.30. Cleaning the crankcase, installing the oil spray jets
- 41 -Cleaning the crankcase
- Remove all screw plugs from the oilways and, after cleaning the crankcase by immersion in a cleaning bath or with high-pressure cleaning equipment, blow it dry with compressed air; flush out all oilways particularly thoroughly and blow through them, so that no particles of dirt or swarf remain.- After this, insert all screw plugs again and check that the aluminium or sheet-metal plugs for the oilways are firmly seated. In case of doubt, renew them; apply sealant E to all plugs before inserting. To