COPY
‑ 8 ‑
Nov./14/ 11
◇
Install the head side bolt. Fully tighten the guide roller
bolt and cylinder side bolt which were temporarily
tightened.
Tools to use:
10 mm open -end wrench
10 mm offset box wrench
5
．
Cam Sprocket Installation
Notch
◇
Align “T” mark on the fly wheel with the notch on the
crankcase.
※
If you install the optional cam, follow the instruction
manual for the cam.
◇
Set the camshaft so that cam’s top faces the piston
side when you turn the cam sprocket bolt hole to the
cylinder head’s notch. The cam shaft is right at the
top dead center on the compression stroke.
◇
Remove the hex bolt next to the change pedal’s shaft.
Thus, the cam chain’s tensioner, which is pulling at the
cam chain, gets loosened; then you can easily install
the sprocket.
Wipe off after tightening,
since a little oil comes out.
※
This is a difficult work, so do your best here!
◇
Fit the cam chain so the “O” mark on the cam sprocket
and the notch on the cylinder head meet each other, and
then install it on the cam shaft.
◇
After fitting the cam sprocket, install and tighten bolts.
◇
Fix the flywheel and tighten the two cam sprocket bolts.
Tools to use:
8 mm socket
14 mm offset wrench
◇
Reinstall the hex bolt next to the change pedal shaft.
Tool to use:
10 mm offset box wrench
6
．
Tappet Clearance Adjustment
Very difficult work. Do your best!
Flywheel side
Notch
Cylinder head side
Notch
Engraved “O” mark
◇
Align the “O” mark on the camshaft and “T” mark on the
flywheel with each notch. Though the flywheel cannot
stop at the precise position due to magnetic repulsion,
it will be all set if “T” and “O” marks meet together after
installation of cam sprocket.
Valve clearance
(Intake side)
Valve clearance
(Exhaust side)
Adjustment screw
Thickness gauge
Valve stem
◇
Tighten a rocker arm’s tappet screw , and put in a 0.05
mm thickness gauge in between the tappet screw and
the valve stem end. And tighten a tappet nut securely to
the extent that you can pull out the 0.05 mm thickness
gauge only with a little resistence. (If you have no idea
about the right resistance in pulling out the gauge,
prepare a 0.07 mm and a 0.03 mm gauge. If the 0.07 mm
thickness gauge does not fit in between the tappet screw
and the valve stem end, and, at the same time, if you can
put in the 0.03 mm gauge with almost no resistance,
this means that the clearance is about 0.05 mm. Adjust
the clearance at 0.05mm both at EX and IN sides.
Tools to use:
Needle nose plier
9 mm offset box wrench
Thickness gauge
◇
Check for the alteration to the tappet clearance.
If altered, adjust again. If there is no change, it’s all
right.
◇
After tappet adjustment, turn the flywheel
counterclockwise two times by hand, and then align
the “T” and “O” mark with each other.
◇
Install two tappet caps.
Tool to use:
17 mm offset box wrench
7
．
Cylinder Head Left Cover
Installation
◇
Install the cylinder head L cover gasket and the L
cover. (Set the protrusion at the stopper so left-side
cover does not move right as the bolt is screwed.)
See the picture below.
(Set the protrusion at the whirl-stop.)
Caution: Apply the specified torque.
For guide roller bolt 10 N
・
m(1.0 kgf
・
m)
For upper and lower side bolts
10 N
・
m(1.0 kgf
・
m)
Caution: Apply the specified torque.
Torque: 10 N
・
m (1.0 kgf
・
m)
Caution: Apply the specified torque.
Torque: 9 N
・
m (0.9 kgf
・
m)
Caution: Apply the specified torque.
Torque: 12 N
・
m (1.2 kgf
・
m)
