3-22
19. Rotate the crankshaft until the first cap screw
(from step 17) securing the sprocket to the cam-
shaft can be addressed; then tighten to 11 ft-lb.
Bend the tab to secure the cap screw.
20. Install the cylinder head plug with the cupped end
facing the camshaft and the opening directed
downwards.
21. Place the cam chain tensioner assembly and gasket
into the cylinder. Tighten to 10 ft-lb.
22. Using a flat-blade screwdriver, turn the tensioner
screw counterclockwise to apply tension to the
cam chain; then install the cap screw plug and
washer and tighten securely.
FI608
23. Loosen the adjuster screw jam nuts; then loosen
the adjuster screws on the rocker arms in the valve
cover.
24. Apply a thin coat of Three Bond Sealant to the
mating surface of the valve cover; then place the
valve cover into position. Note that the two align-
ment pins are properly positioned.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
25. Install the four top-side cap screws with rubber
washers; then install the remaining cap screws.
Tighten only until snug.
MD1261
26. In a crisscross pattern starting from the center and
working outward, tighten the cap screws (from
step 27) to 8 ft-lb.
27. Adjust valve/tappet clearance (see Section 2).
28. Place the two tappet covers with O-rings into posi-
tion; then install and tighten the cap screws to 8
ft-lb.
FI602
29. Install the spark plug and tighten securely; then
install the timing inspection plug.
Left-Side Components
NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.
NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.
Removing Left-Side
Components
A. Water Pump
B. Speed Sensor
C. Magneto Cover/
Stator Assembly
1. Remove the coolant hose connecting the water
pump to the cylinder; then remove the water pump
cover.
AT THIS POINT
To service any one specific component, only limited
disassembly of components may be necessary. Note
the AT THIS POINT information in each sub-section.
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