8
2. Replace any drain that is cracked or shows any signs
of hardening or deterioration.
3. Wipe any accumulation of oil or gas from the filter
housing and drains.
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the fol-
lowing procedure.
1. Remove the timing inspection plug; then remove the
tappet covers and spark plug(s) (for more detailed
information, see Engine/Transmission - Servicing
Top-Side Components).
NOTE: On the 1000 models, remove the crankshaft
end cap and install the special cap screw (left-hand
threads) to rotate the engine.
2. Rotate the crankshaft to the TDC position on the
compression stroke (front cylinder on the 1000 mod-
els).
GZ063
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
Feeler Gauge Procedure
A. Using a feeler gauge, check each valve/tappet
clearance. If clearance is not within specifica-
tions, loosen the jam nut and rotate the tappet
adjuster screw until the clearance is within speci-
fications. Tighten each jam nut securely after
completing the adjustment.
CC007DC
B. On the 1000 models, rotate the engine 270° to the
TDC position of the rear cylinder; then repeat step
A.
GZ059
Valve Adjuster Procedure
NOTE: The seat, storage compartment cover
assembly, compartment box, air filter/filter housing,
and left-side/right-side splash panels must be
removed for this procedure.
A. Place Valve Clearance Adjuster onto the jam nut
securing the tappet adjuster screw; then rotate the
valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
B. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
C. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
D. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the proper
valve/tappet clearance.
CAUTION
The drain to the right is the clean air section of the filter
housing. Any leak of this drain will allow dirt into the
engine intake causing severe engine damage.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measure-
ment of clearance. Failure to measure the valve clear-
ance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
500
0.08-0.12 mm (0.003-0.005 in.) - Intake
0.15-0.20 mm (0.006-0.008 in.) - Exhaust
550/700/1000
0.08-0.12 mm (0.003-0.005 in.) - Intake
0.13-0.17 mm (0.005-0.007 in.) - Exhaust