7
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 (for more detailed
information, see Engine/Transmission - Servicing
Top-Side Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
GZ063
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
CHECKING
Using a feeler gauge, check each valve/tappet clearance.
If clearance is not within specifications, loosen the jam
nut and rotate the tappet adjuster screw until the clear-
ance is within specifications. Tighten each jam nut
securely after completing the adjustment.
CC007DC
ADJUSTING
NOTE: The seat, storage compartment cover assem-
bly, 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
CHECKING for the proper valve/tappet clearance.
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by 0.05
mm (0.002 in.) per mark.
E. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
3. Install the spark plug and timing inspection plug.
4. Place the tappet covers into position making sure the
proper cap screws are with the proper cover. Tighten
the cap screws securely.
Testing Engine
Compression
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.
3. Remove the spark plug; then attach the high tension
lead to the plug and ground the plug on the cylinder
head well away from the spark plug hole.
4. Attach the Compression Tester Kit.
NOTE: The engine should be warm (operating tem-
perature) and the battery fully charged for an accu-
rate compression test. Throttle must be in the
wide-open throttle (WOT) position. In the event the
engine cannot be run, cold values are included.
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
0.08-0.12 mm (0.003-0.005 in.) - Intake
0.13-0.17 mm (0.005-0.007 in.) - Exhaust
! WARNING
Always wear safety glasses when using compressed
air.
Summary of Contents for 2016 Alterra 500
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