cam chain tensioner hole and tension the chain. The
timing mark on the cam sprocket (B,
Figure 14
)
should align with the pointer on the cylinder head
(C) as noted during removal.
19. If the timing marks do not align, remove the
sprocket. Use a screwdriver to walk the cam chain
one way or the other and reinstall the cam sprocket.
Repeat this as necessary until the timing mark on
the cam sprocket aligns with the pointer on the cyl-
inder head while you press the rear chain guide
inward.
NOTE
A cam sprocket plate is not used on
the rear cylinder.
20. When working on the front cylinder, install the
cam sprocket plate onto the camshaft. Make sure
the dimple (A,
Figure 24
) on the sprocket plate en-
gages the timing mark (B) on the camshaft.
21. Install the cam sprocket bolt and washer (rear
cylinder: C,
Figure 10
; front cylinder: C,
Figure
12
). Finger-tighten the bolt at this time.
22. Install the cam chain tensioner and new gasket
as follows:
a. Apply a medium-grade threadlocking com-
pound to the chain tensioner mounting bolts.
b. Insert a screwdriver into the tensioner body.
c. Turn the screwdriver clockwise until the
plunger fully retracts into the chain tensioner
body. Do not remove the screwdriver at this
time. See
Figure 25
.
d. Slide a new gasket onto the tensioner body.
e. Insert the tensioner into the cylinder while
holding the screwdriver. Make sure the UP
mark on the tensioner faces up. Do not release
the screwdriver until the tensioner is seated in
the cylinder.
f. Press the tensioner against the cylinder. Re-
lease the plunger by turning the screwdriver
slightly counterclockwise, and remove the
screwdriver. See
Figure 26
.
g. When installing the chain tensioner into the
front cylinder, slip the air filter bracket (C,
Figure 13
) over the tensioner.
h. Install the mounting bolts (A,
Figure 13
).
Evenly finger-tighten the bolts to hold the
tensioner in place.
i. Torque the cam chain tensioner mounting
bolts to 10 N•m (89 in.-lb.).
j. Install the cap bolt (D,
Figure 13
) onto the
cam chain tensioner. Torque the cap bolt to 8
N•m (71 in.-lb.).
23. Hold the flywheel with a sheave holder, and
tighten the cam sprocket bolts (rear cylinder: C,
Figure 10
; front cylinder: C,
Figure 12
). Torque the
cam sprocket bolts to 55 N•m (41 ft.-lb.).
NOTE
A breather plate is not used in the rear
cylinder head.
23. When working on the front cylinder, install a
new O-ring onto the breather plate (A,
Figure 7
)
and set the breather plate in place in the cam
sprocket cover (B).
24. Lubricate a new O-ring with lithium soap
grease, and install it into the cam sprocket cover
(
Figure 27
). Set the cam sprocket cover onto the
cylinder head. Install the two cover bolts (A,
Figure
6
), and torque the cam sprocket cover bolts to 10
N•m (89 in.-lb.).
NOTE
The exhaust valve cover on the front
cylinder is chrome plated.
96
CHAPTER FOUR
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