ENGINE 82

WATER PUMP

• Install the water pump.

NOTE:

• Apply grease to the O-ring.

• Set the water pump driven shaft end ○A to the water pump

drive shaft ○B .

OIL FILTER

• Apply engine oil lightly to the O-ring.

• Install the oil filter turning it by hand until feeling that the filter

gasket contacts the mounting surface. Then tighten it 2 turns

using the oil filter wrench.

TOOL: Oil filter wrench

ENGINE TOP SIDE

PISTON

• Install the piston rings in the order of oil ring, 2nd ring and

1st ring.

• The first member to go into the oil ring groove is a spacer

1 .After placing the spacer, fit the two side rails ○2 .

NOTE:

Side designations, top and bottom, are not applied to the spacer

and side rails: Those can be positioned each either way.

CAUTION

When Installing the spacer, be careful not to allow

Its two ends to overlap in the groove.

○

• Install the 2nd ring ○A and 1st ring ○B .

NOTE:

1st ring and 2nd ring differ in shape.

ENGINE 83

• 1st ring and 2nd ring have letter "R" marked on the side. Be

sure to bring the marked side to the top when fitting them to

the piston.

• Position the gaps of the three rings as shown. Before

inserting

the piston into the cylinder, check that the gaps are so

located.

• Apply a light coat of molybdenium oil solution to the piston

pin.

MOLYBDENUM OIL

• Install the piston and piston pin.

NOTE:

When installing the piston, the punched mark ○A on the piston

head is located to the exhaust side.

A

○

• Place a cloth beneath the piston, install the circlip ○1 .

CAUTION

When turning the crankshaft, pull the cam chain upward,

or the chain will be caught between the crankcase and

the cam drive sprocket.

• Fit the dowel pins and the new gasket.

CAUTION

Use a new gasket to prevent gas leakage.

• Coat BO ND " 1 2 0 7 B " lightly to the mating sur-

faces among the crankcase mating surfaces.

BOND "1207B" (USA)

○

1

ENGINE 84

CYLINDER

• Hold each piston ring with properly position, insert the piston

into the cylinder.

• Tighten the cylinder base nuts temporarily.

CAUTION

When installing the cylinder and cylinder head, pull

the cam chain upward, or the chain will be caught

between the crankcase and cam drive sprocket.

• Install the cam chain guide ○1 .

• Fit the dowel pins and new cylinder head gasket.

CAUTION

Use a new gasket to prevent gas leakage.

CYLINDER HEAD

• Install the cylinder head and tighten the cylinder head bolts

diagonally to the specified torque.

Cylinder head bolt

Initial: 25 Nm (2.5 kgf-m, 18.0 Ib-ft)

Final: 38 N m (3.8 kgf-m, 27.5 Ib-ft)

○

1

• Tighten the cylinder head bolts to the specified torque.

Cylinder head nut

6 mm: 10 N m (1.0 kgf-m, 7.0 Ib-ft

8 Mm: Internal 10 n m (1.0 kgf-m, 7.0 Ib-ft)

Final 25 N m (2.5 kgf-m, 18.0 Ib-ft)

• Tighten the cylinder base nuts and cylinder head nuts to the

specified torque.

Cylinder base nut: 10 N m (1.0 kgf-m, 7.0 Ib-ft)

ENGINE 85

• Install the cam chain tensioner.

CAMSHAFT

• Align the line ○A on the generator rotor with the index mark

○

B on the crankcase.

○

A

B

○

CAUTION

Pull the cam chain upward, or the chain will be

caught between crankcase and cam drive sprocket.

• Align the marks ○A on the camshaft so that they are

parallel with the surface of the cylinder head.

NOTE:

Do not rotate the generator while doing this. When the sprocket is

not positioned correctly, turn the sprocket.

• Engage the chain on the cam sprocket with the locating pin

hole ○B as shown.

○

B

○

A

ENGINE 86

○

C

• Recheck the position of the line ○C and the marks ○A .

• Install the C-ring ○1 .

○

A

○

1

• Install the lock washer so that it is covering the locating pin.

• Apply THREAD LOCK SUPER "1303" to the bolts and

tighten them to the specified torque.

Cam chain sprocket bolt: 15 N m (1.5 kgf-m, 11.0 Ib-ft)

THREAD LOCK SUPER "1303"

• Bend up the washer tongue positively to lock the bolts.

ENGINE 87

CYLINDER HEAD COVER

• Clean the mating surfaces of the cylinder head and head

cover before matching.

• Install the dowel pins to the cylinder head.

• Apply BOND "1216B" to the mating surface of the cylinder

head cover.

• Fit the camshaft end cap ○1 .

BOND "1216B"

○

1

• Lightly tighten the cylinder head cover bolts diagonally, and

then if everything is satisfactory, tighten securely with a

torque wrench to the specified torque.

Cylinder head cover bolt: 10 N m (1.0 kgf-m, 7.0 Ib-ft)

NOTE:

When tightening the cylinder head cover bolts, the piston must

be at top dead center on the compression stroke.

ENGINE 88

LIQUID GASKET APPLYING PLACE

LOCATION OF CYLINDER HEAD COVER BOLT

ENGINE 89

CAM CHAIN TENSION ADJUSTER

• Insert the ○

-

screwdriver into the slotted end of the cam

chain tension adjuster, then turn it clockwise to lock the

spring tension.

○

1

• Install the new gasket ○1 and cam chain tension adjuster.

• Install the new gaskets ○2 and tighten the bolts to the

specified torque.

Cam chain tension adjuster mounting bolt:

10 N m (1.0 kgf-m, 7.0 Ib-ft)

○

2

• After installing the cam chain tension adjuster, turn a ○

screwdriver counterclockwise.

NOTE:

As the slotted end turns, the tension rod is advanced under

spring force and pushes the cam chain tension adjuster against

the cam chain.

-

• Install the new gasket ○3 and tighten the spring holder

bolt to the specified torque.

Spring holder bolt: 8 N m (0.8 kgf-m, 5.7 Ib-ft)

• Apply grease to the new O-rings and install the valve

inspection caps.

ENGINE 90

STARTER MOTOR

• Install the starter motor.

NOTE:

Apply grease to the new O-ring.

• Install the new O-ring to the water pipe.

CAUTION

Use a new O-ring to prevent engine coolant leakage.

NOTE:

Apply engine coolant to the O-ring.

• Install the water hose/pipe.