Rear cylinder head
1. Install:
- dowel pins
- gasket
Note: The "5EL" mark on the gasket must face up side of the cylinder.
2. Install:
- nuts (cylinder head) (M12: 1-4) 50 Nm (5.0 m·kg)
- cap nut (cylinder head) (M10: 5) 35 Nm (3.5 m·kg)
- bolts (cylinder head) (M8: 6-7) 20 Nm (2.0 m·kg)
Note:
- Tighten the bolts and nuts in the proper sequence.
- Follow the numerical order shown in the illustration. Tighten the bolts and nuts in two stages.
3. Install: camshaft sprocket
a. Temporarily install the rotor nut and left crankcase cover without the pickup coil and stator coil.
b. Turn the crankshaft clockwise.
c. Align the "T" mark (a) with the stationary pointer (b) on the crankcase cover (left).
d. Install the camshaft sprocket with the timing mark (c) facing out.
e. Turn the camshaft just enough to remove any slack from the intake side of the timing chain.
f. Insert your finger into the hole and timing chain tensioner hole and push the timing chain guide inward.
g. While pushing the timing chain guide, be sure that the timing mark (c) and the stationary pointer (d) are properly aligned at TDC.
4. Install: timing chain tensioner
a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
b. While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver (1) until it stops.
c. With the screwdriver still inserted into the timing chain tensioner, install the timing chain tensioner (2), and gasket.
Then, tighten the timing chain tensioner bolts (3) to the specified torque.
Warning! Always use a new gasket.
Note: The "UP" mark on the timing chain tensioner should face up.
Timing chain tensioner bolt: 10 Nm (1.0 m·kg)
d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tighten the cap bolt to the specified torque.
- Cap bolt: 8 Nm (0.8 m·kg)
5. Install: bolt (camshaft sprocket) (1) 55 Nm (5.5 m·kg)
Note:
- Be sure the projection on the camshaft sprocket plate is aligned with the hole in the sprocket.
- Use the sheave holder (2) to hold the rotor.
- Sheave holder: 90890-01701
6. Check: alignment marks
If the marks do not align → Adjust.
7. Measure: valve clearance
Out of specification → Adjust. Refer to "Adjusting the valve clearance".
Front cylinder head
Note: When installing the front cylinder head, repeat the rear cylinder head installation procedure. However, note the following points.
1. Install: camshaft sprocket
a. Turn the crankshaft clockwise 290°.
b. Align the "I" mark (a) with the stationary pointer (b) on the crankcase cover (left).
c. Install the camshaft sprocket with the timing mark (c) facing out.
d. Turn the camshaft just enough to remove any slack from the intake side of the timing chain.
e. Insert your finger into the hole and timing chain tensioner hole and push the timing chain guide inward.
f. While pushing the timing chain guide, be sure that the timing mark (c) and the stationary pointer (d) are properly aligned at TDC.
