Service

Information from the service manual

Cylinder Head and Camshaft Reassembly

Submitted by xjcdadmin on Wed, 06/10/2009 - 17:02

12. Cylinder head and Cam shafts 

a. Install the new cylinder head gasket. Install the dowel pins and "O-rings". Locate the cam chain cavity cylinder seal with the tabs down.

b.   Install the cylinder head onto the cylinder. Pull the cam chain through the cylinder head as it is installed. Tie the cam chain so that it does not fall into the crankcase.

Engine Removal

Submitted by xjcdadmin on Wed, 06/10/2009 - 17:02

ENGINE REMOVAL

NOTE: It is not necessary to remove the engine in order to remove the cylinder head, cylinder, or pistons.

A.   Preparation for Removal

1.    All dirt, mud, dust and foreign material should be thoroughly removed from the exterior of the engine before removal and disassembly. This will help keep harmful foreign material from the engine oil.

Upper Crankcase Reassembly

Submitted by xjcdadmin on Wed, 06/10/2009 - 17:02

ENGINE ASSEMBLY AND ADJUSTMENT

A. Important Information

1.    Gasket and seal

All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces and oil seal lips must be cleaned.

2.    Properly oil all mating engine and transmission parts and bearings during reassembly.

3.    Circlip

Remounting the Engine

Submitted by xjcdadmin on Wed, 06/10/2009 - 17:02

REMOUNTING ENGINE

1. Reverse the applicable removal steps to reinstall.

CAUTION: Always use new bolts in the drive shaft coupling.

2. Install and tighten the engine mounting bolts.

Engine mounting bolt torque:

8 mm bolt: 2.0 m-kg (14.5 ft-lb) 
10 mm bolt: 4.2 m-kg (30.4 ft-lb) 
12 mm bolt: 7.0 m-kg (50.6 ft-lb)

Middle Gear Reassembly

Submitted by xjcdadmin on Wed, 06/10/2009 - 17:02

6. Middle gear (installation only, refer to page 67 for the middle gear adjustment)

a. Install the middle drive gear assembly with the proper size of shim(s) and secure it with the bearing retainers and new "TORX" screws.

Tightening torque: 2.5 m-kg (18 ft-lb)

1. Shims

Lower Crankcase Reassembly

Submitted by xjcdadmin on Thu, 06/04/2009 - 12:15

2. Lower crankcase

a.   Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.

b.   Install the neutral switch.

c. Install the transmission drive axle assembly into the crankcase.