- 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 of the valve inspection hole and also to bring the cams to the position as shown.
Note: At the above condition, the No. 1 (Front) cylinder is at TDC of compression stroke and also the engraved lines (А) on the camshafts are parallel with the mating surface of the cylinder head cover.
Front cylinder camshaft
- Remove the camshaft journal holders.
Caution: Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally.
Front cam chain tension adjuster
- After loosing the spring holder bolt (1), remove the cam chain tension adjuster.
Front cylinder head
- Remove the cam drive idle gear/sprocket (1) by removing its shaft with the copper washer and the thrust washer (2).
Note: Do not the drop the thrust washer (2) into the crankcase.
- Remove the cylinder head bolts and cam chain tensioner mounting bolt.
- Remove the cam chain tensioner.
Starter motor
- Remove the starter motor.
- Remove the cylinder head nut.
- Loosen the cylinder nuts.
- Remove the oil cooler mounting bracket (1).
- Remove the cylinder head bolts.
- Remove the cylinder head.
Note:
- When loosening the cylinder head bolts, loosen each bolt little by little diagonally.
- To identify each cylinder head, mark the cylinder as the front and rear, cylinder head uses the same part.
Front cylinder
- Remove the cylinder.
Note: Firmly grip the cylinder at both ends, and lift it straight up. If the cylinder does not come off, lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose.
- Remove the cylinder base gasket and dowel pins.
Front piston
- Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase.
- Remove the piston pin circlip.
- Remove the piston by driving out the piston pin.
Note: Scribe the cylinder number on the head of the piston.
Rear cylinder head cover
- Remove the rear cylinder head cover (1).
- Turn the crankshaft to bring the "F | T" line mark on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown.
Note: At the above condition, the rear cylinder is at ATDC 90° on expansion stroke and also the engraved lines (А) on the camshafts are parallel with the mating surface of the cylinder head cover.
Caution: Pull the front cam chain upward, or the chain will be caught between the crankcase and cam drive idle gear/sprocket when turning the crankshaft.
Rear cylinder camshaft
- Remove the two camshaft journal holders.
Caution: Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally.
- Remove the camshafts.
Note: Do not drop the dowel pins into the crankcase.
Rear cam chain tension adjuster
- After loosing the spring holder bolt (1), remove the cam chain tension adjuster.
Rear cylinder head
- Remove the cam drive idle gear/sprocket (1) by removing its shaft, the copper washer and the thrust washer (2).
Note: Do not drop the thrust washer (2) into the crankcase.
- Remove the cylinder head bolts and cam chain tensioner mounting bolt.
- Remove the cam chain tensioner.
- Remove the cylinder head nuts (1).
- Remove the cylinder head nut (2).
- Loosen the cylinder nuts (3).
- Remove the cylinder head bolts.
- Remove the cylinder head.
Note:
- When loosening the cylinder head bolts, loosen each bolt little by little diagonally.
- To identify each cylinder head, mark the cylinder as the Front and Fear.
Rear cylinder
- Remove the rear cylinder.
Note: Firmly grip the cylinder at both ends, and lift it straight up. If the cylinder does not come off, lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose.
- Remove the cylinder base gasket and dowel pins.
Rear piston
- Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase.
- Remove the piston pin circlip.
- Remove the piston by driving out the piston pin.
Note: Scribe the cylinder number on the head of the piston.