Engine components removable with engine in place* The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions. Engine left side PARTS REMOVAL INSTALLATION Generator rotor 3-31...
Engine removal* Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. Drain engine oil. (2-13) Drain engine...
Engine installation* Remount the engine in the reverse order of engine removal. Pay attention to the following points: Note: The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Be sure to use new nuts, and then tighten...
Engine top side Remove the thermostat. Remove the valve timing inspection plug (1) and generator cover plug (2). Front cylinder head cover Remove the front cylinder head cover (1). Turn the crankshaft to bring the "F | T" line on generator rotor to the index mark...
Engine bottom side* Oil filter Remove the oil filter with the special tool. 09915-40610: Oil filter wrench Remove the generator cover. Remove the starter torque limiter (1) and starter idle gear (2). Remove the bushings (1) from the crankcase and generator cover....
Cylinder head cover Disassembly Caution: Be sure to identify each removed part as to its location, and lay the parts out in groups designated as "No.1", "No.2" "Exhaust", "Intake", so that each will be restored to the original location during assembly. Remove the...
Camshaft — wear and runout Caution: Be sure to identify each removed part as to its location, and lay the parts out in groups designated as "No.1", "No.2", "Exhaust", "Intake", so that each will be restored to the original location during assembly. Camshaft All camshafts...
Cam chain tension adjuster The cam chain tension adjusters are maintained at the proper cam chain tension automatically. Unlock the ratchet (A), and move the push rod (B) in place to see if it slides smoothly. If any stickiness is noted or ratchet mechanism is faulty, replace...
Cam chain guide and cam chain tensioner Check the cam chain guide and tensioner for wear and damage. If they are found to be damaged, replace them with the new ones. 1. Front cam chain tensioner; 2. Rear cam chain tensioner; 3. Front and Rear cam chain guide
Cylinder head Remove the tappets and shims (1) by fingers or magnetic hand. Using special tools, compress the valve spring and remove the two cotter halves (2) from the valve stem. 09916-14510: Valve lifter 09916-14910: Valve lifter attachment 09916-84511:...
Valve seat servicing* The valve seats for both intake and exhaust valves are machined to four different angles. (The seat contact surface is cut 45°.) INTAKE EXHAUST 45° N-615 or N-626 N-615 or N-626 60° N-211 N-211 15° N-615 30° N-626 Note: The valve seat contact area...
Valve spring The force of the coil spring keeps the valve seat tight. Weakened spring results in reduced engine power output, and often account for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measuring...
Cam drive idle gear/sprocket thrust clearance Install the cam drive idle gear/sprocket (1), its shaft (2), copper washer (3) and thrust washer (4) to each cylinder head. Tighten the shaft (2) to the specified torque. Use a thickness gauge to measure the thrust clearance between the cylinder...
Cylinder head reassembly Install the valve spring seats. Oil each oil seal, and press-fit them into position with the valve guide installer. 09916-44910: Valve guide remover/installer Caution: Do not reuse the removed oil seals. Insert the valves, with their stems coated...