ENGINE REMOVAL
ENGINE REMOVAL
MUFFLER AND EXHAUST PIPE
Removing the muffler and exhaust pipe. Remove the parts in the order listed. Seat/fuel tank cover/side covers (left and right)Fuel tank and right foot protector/engine skid plate.
THE EXHAUST PIPE AND MUFFLER”.
2 Muffler
3 Muffler protector
4 Gasket
5 Exhaust pipe
6 Exhaust pipe protector
7 Gasket
INSTALLING THE EXHAUST PIPE AND MUFFLER
1. Install:
• gasket 1 (to muffler)
NOTE: Install the gasket with the chamfer a, located on an inner rim of the gasket, and the chamfer located on an outer rim of the gasket, as shown. Installed depth of gasket c 1 ~ 1.5 mm (0.04 ~ 0.06 in).
2. Install:
• exhaust pipe protector
• exhaust pipe protector screws
NOTE: Tighten the screws to the specified torque in the proper tightening sequence as shown.
3. Install:
• exhaust pipe 1
• nut (exhaust pipe) 2
• bolt (exhaust pipe) 3
NOTE: First, temporarily tighten the nut (exhaust pipe), then tighten the bolt (exhaust pipe) 20 Nm (2.0 m · kg, 14 ft · lb). After that, retighten the nut (exhaust pipe) 13 Nm (1.3 m · kg, 9.4 ft · lb) and then the bolt (exhaust pipe) 24 Nm (2.4 m · kg, 17 ft · lb).
4. Install:
• clamp
NOTE: Slide the clamp onto the end of the muffler and insert the projection a of the clamp into a slot b in the muffler. Tighten the clamp after installing the muffler.
LEADS, CABLES AND HOSES
Removing the leads, cables and hoses. Start by emoving the parts in the order listed. Engine oil drain, coolant drain and radiator outlet hose/water pump inlet pipe
1 Ignition coil
2 Cylinder head breather hose
3 Oil tank breather hose
4 Radiator inlet hose
5 Crankcase breather hose
6 Starter motor lead
7 Battery negative lead
8 Clutch cable
9 Parking brake cable
10 Oil pipe
11 A.C. magneto coupler
12 Plastic band
13 Oil pipe
14 Neutral switch lead
For installation, reverse the removal procedure.
ENGINE MOUNTING BOLTS
Removing the engine mounting bolts. Remove the parts in the order listed.
1 Engine lower bracket bolt 4
2 Engine mounting bolt (middle)/nut
3 Engine lower bracket (right)
4 Engine lower bracket (left)
5 Engine mounting bolt (lower)/nut
6 Engine upper bracket bolt
7 Engine stay bolt/washer
8 Engine stay
9 Engine mounting bolt (upper)/washer
10 Engine upper bracket (right)
11 Engine upper bracket (left)
12 Pivot shaft/nut/washer
13 Engine assembly
NOTE: Remove the engine assembly from the right side of the machine.
INSTALLING THE ENGINE
1. Install:
• pivot shaft/nut/washer
• engine upper bracket (left)
• engine upper bracket (right)
• engine mounting bolt (upper)
• engine stay
• engine stay bolts/washers
• engine upper bracket bolts
• engine mounting bolt (lower)/nut
• engine lower bracket (left)
• engine lower bracket (right)
• engine mounting bolt (middle)/nut
• engine lower bracket bolts
• pivot shaft/nut
• engine mounting bolt (upper)
• engine stay bolts
• engine upper bracket bolts
• engine mounting bolt (lower)/nut
• engine mounting bolt (middle)/nut
• engine lower bracket bolts
CAMSHAFTS - CYLINDER HEAD COVER
Removing the cylinder head cover Remove the parts in the order listed.
1 Spark plug
2 Engine upper bracket (right)
3 Engine upper bracket (left)
4 Engine stay
5 Cylinder head breather hose
6 Oil tank breather hose
7 Cylinder head cover
8 Cylinder head cover gasket
9 Timing chain guide (top side)
Refer to “REMOVING THE CAMSHAFTS” and “INSTALLING THE CAMSHAFTS”.
Removing the camshafts Remove the parts in the order listed.
1 Tensioner cap bolt
2 Timing chain tensioner
3 Gasket
4 Exhaust camshaft cap
5 Clip
6 Exhaust camshaft
7 Intake camshaft cap
8 Clip
9 Intake camshaft
REMOVING THE CAMSHAFTS
1. Remove:
• timing mark accessing screw
• crankshaft end accessing screw
2. Align:
• “I” mark on the A.C. magneto rotor (with stationary pointer on the A.C. magneto cover)
a. Turn the crankshaft counterclockwise.
b. When the piston is at the Top Dead Center (TDC) on the compression stroke, align the “I” mark a on the A.C. magneto rotor with the stationary pointer b on the A.C. magneto cover.
• In order to be sure that the piston is at the Top Dead Center (TDC), the punch mark c on the exhaust camshaft sprocket and the punch mark d on the intake camshaft sprocket must align with the cylinder head mating surface, as shown in the illustration.
• The Top Dead Center (TDC) on the compression stroke can be found when the camshaft lobes are turned away from each other.
3. Loosen:
• tensioner cap bolt
4. Remove:
• timing chain tensioner
5. Remove:
• camshaft cap bolts
• camshaft caps
NOTE: Remove the camshaft cap bolts in a crisscross pattern, working from the outside in.
CAUTION:To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the outside in.
6. Remove:
• exhaust camshaft 1
• intake camshaft 2
• clips
NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3.
CHECKING THE CAMSHAFTS
1. Check:
• camshaft lobes. Pitting/scratches/blue discoloration → Replace the camshaft.
2. Measure:
• camshaft lobe dimensions. Out of specification → Replace the camshaft.
4. Measure:
• camshaft-journal-to-camshaft-cap clearance. Out of specification → Measure the camshaft journal diameter.
a. Install the camshaft into the cylinder head (without the camshaft caps).
b. Position a strip of Plastigauge® 1 onto the camshaft journal as shown.
c. Install the circlip and camshaft caps.
• Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
• Do not turn the camshaft when measuring the camshaft-journal-to-camshaft-cap clearance with the Plastigauge.
d. Remove the camshaft caps and then measure the width of the Plastigauge® 1.
5. Measure:
• camshaft journal diameter. Out of specification → Replace the camshaft.
Within specification → Replace the cylinder head and camshaft caps as a set.
CHECKING THE CAMSHAFT SPROCKETS
1. Check:
• camshaft sprockets. Wear/damage → Replace the camshaft sprockets and timing chain as a set.
CHECKING THE DECOMPRESSION SYSTEM
1. Check:
• decompression system
a. Check that the decompressor lever pin projects from the camshaft.
b. Check that the decompressor cam moves smoothly.
CHECKING THE TIMING CHAIN GUIDE
1. Check:
• timing chain guide (top side) Wear/damage → Replace.
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
• chain tensioner rod Damage/wear → Replace.
2. Check:
• timing chain tensioner play
a. While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise.
b. When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly.
c. If not, replace the tensioner assembly.
INSTALLING THE CAMSHAFTS
1. Install:
• exhaust camshaft 1
• intake camshaft 2
a. Turn the crankshaft counterclockwise until the “I” mark a on the rotor is aligned with the stationary pointer b on the A.C. magneto cover.
b. Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head.
The camshafts should be installed onto the Cylinder head so that the exhaust camshaft sprocket punch mark c and the intake camshaft sprocket punch mark d align with the mating surface of the cylinder head. Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result.
2. Install:
• clips
• intake camshaft cap 1
• exhaust camshaft cap 2
• camshaft cap bolts
Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result.
3. Install:
• timing chain tensioner
a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1.
b. With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the gasket and the timing chain tensioner 2 onto the cylinder block.
The “UP” mark a on the timing chain tensioner should face UP.
c. Tighten the timing chain tensioner bolts 3 to the specified torque.
d. Remove the screwdriver, mark sure that the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque.
4. Turn:
• crankshaft (counterclockwise several turns)
5. Check:
• A.C. magneto rotor “I” mark Align with the A.C. magneto cover stationary pointer.
• camshaft sprocket punch marks Align with the cylinder head mating surface.
Out of alignment → Adjust.
Refer to “INSTALLING THE CAMSHAFTS”.
6. Measure:
• valve clearance. Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE”
.
Tensioner cap bolt 7 Nm (0.7 m · kg, 5.1 ft · lb)
7. Install:
• timing chain guide (top side)
• cylinder head cover gasket
• cylinder head cover
• Apply Sealant (Quick Gasket®) or bond No. 1215 1 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket.
• Apply Sealant (Quick Gasket®) or bond No. 1215 2 onto the mating surfaces of the cylinder head cover gasket and cylinder head.
