Information from the service manual
INSPECTION AND REPAIR
A. Cylinder Head Cover
Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:
Place #400 or #600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.
H. Oil Pump Removal and Disassembly
1. Remove the strainer cover. Note the wire harness clip position.
2. Remove the oil pump securing bolts and remove the sprocket cover and oil pump assembly.
CAUTION:
8. A.C. Generator
a. Install the rotor onto the shaft and tighten the bolt using the rotor holding tool (special tool) as shown.
1. Rotor holding tool
Tightening torque: 5.5 m-kg (39.8 ft-lb)
b. Install the stator coil assembly onto the crankcase and align the grooves on the stator core with the bolt holes on the crankcase.
C. Piston
1. Mark each piston to aid in reassembly.
2. Place a clean towel or rag into the crank-case to keep circlips and material from falling into the engine.
3. Remove piston pin clips, piston pins, and pistons.
D. Pick-up Coil Assembly
12. Cylinder head and Cam shafts
a. Install the new cylinder head gasket. Install the dowel pins and "O-rings". Locate the cam chain cavity cylinder seal with the tabs down.
b. Install the cylinder head onto the cylinder. Pull the cam chain through the cylinder head as it is installed. Tie the cam chain so that it does not fall into the crankcase.
P. Middle Gear
1. Damper disassembly
NOTE:
Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.
a. Place the middle drive shaft in a press with the damper compressor (special tool) in place as shown.
1. Damper compressor
ENGINE REMOVAL
NOTE:
It is not necessary to remove the engine in order to remove the cylinder head, cylinder, or pistons.
A . Preparation for Removal
1 All dirt, mud, dust and foreign material should be thoroughly removed from the exterior of the engine before removal and disassembly. This will help prevent any harmful foreign material from getting into the engine oil.
ENGINE ASSEMBLY AND ADJUSTMENT
A. Important Information
1. Gasket and seal
All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces and oil seal lips must be cleaned.
2. Properly oil all mating engine and transmission parts and bearings during reassembly.
3. Circlip
D. Valve Spring and Lifters
1. Checking the valve springs
a. This engine uses two springs of different sizes to prevent valve float or surging. The valve spring specifications show the basic value characteristics.
D. Remounting Engine
Refer to page 30 for engine removal. Reverse the applicable removal steps.
CAUTION:
Always use new bolts in the drive shaft coupling.
2. Install and tighten the engine mounting bolts.
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Engine mounting bolt torque: |