57
18. Rotate the crankshaft until the second cap screw
securing the sprocket to the camshaft can be
installed; then install the cap screw (threads coated
with red Loctite #271). Tighten to 11 ft-lb; then bend
the tab to secure the cap screw.
19. Rotate the crankshaft until the first cap screw (from
step 17) securing the sprocket to the camshaft 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 down-
wards.
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 mat-
ing surface of the valve cover; then place the valve
cover into position. Note that the two alignment 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.
FI719
26. In a crisscross pattern starting from the center and
working outward, tighten the cap screws (from step
25) to 8 ft-lb.
27. Adjust valve/tappet clearance (see Periodic Mainte-
28. Place the two tappet covers with O-rings into posi-
tion; then install and tighten the cap screws to 9 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 need 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 dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
Summary of Contents for HDX 500 2017
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