• Valve clearance adjustment must becarriedoutwiththeenginecold.

1. Removethecamcover(seepage3.5).

2. Removea sparkplugfromeachcylindertoreducecompressionresistancewhenturningtheengine.

3. Selectahighgearand,usingtherearwheel,turntheengineoveruntilapairofcamshaftlobesarepositionedpointingdirectlyawayfromthevalves.

4. Usingfeelergauges,measureandrecordtheclearancesforthispairofvalvesonly.

5. Repeattheprocessuntiltheclearancesforallvalveshavebeenchecked.

Ifanyoftherecordedclearancesfalloutsidethespecifiedrange,adjustmentsmustbemade.Ifallmeasuredclearancesarewithintolerance,refitthe camcover(seepage3.6).

ValveClearanceAdjustment

Note:

• Valveclearancecheckingandadjustmentmustbecarriedoutwiththeenginecold.

1. ^{Measureandrecordallvalveclearancesasdescribed}previously.

2. Removethecamshafts(seepage3.9).

3. ^{Removeashimfromoneofthevalveswhoseclearance}requiredadjustment.

4. Measuretheoriginalshim,usingamicrometer.

5. Calculatetheshimthicknessrequiredtogivethecorrectclearance.Clearancetoosmall;fitathinnershim.Clearancetoolarge;fitathickershim.

Note:

• Shimsareavailablerangingfrom2.00mmto3.20mminincrementsof0.025mm.

6. Fittheselected shimtothetappetbucket.

7. Repeattheprocedureuntilallvalvesrequiringadjustmenthavebeencorrectlyset.

B. Refitthecamshafts(seepage3.12).

9. Rotatetheengineseveraltimestofullyseattheshims.

10. Repeattheclearancechecksonallvalves,adjustasnecessary.

11. Refitthecamcover(seepage3.6).

3.14 ServiceManual-RocketIll

CylinderHead

1. Removethefueltank(seepage11.100).

2. Drainthecoolingsystem(seepage12.6).

3. Removetheexhaustheadersystem(seepage

11.134).

4. Removethethrottlebodies(seepage11.122).

5. Removethe oiltank(seepage9.16).

6. Removethecamshafts(seepage3.9).

7. Disconnectthetopandbypasshosesfromthecylinderhead.

9. Removebothenginein-fillpanels.

In-fillpanel

9. Identifythepositionof eachofthetappetbucketsandshimsbeforeremovingthemfromthehead.

10. Removethesoundsuppressionboltfromthecamchainchest.

11. Progressivelyreleasethecylinderheadboltsintheordershownbelow.

1. Tophose

2. Bypasshose

8. Disconnectthecoolanttemperaturesensorandlowoilpressureswitchconnections.

6

ct.qi

4 2 7

Headboltreleasesequence

1.Lowoilpressurewarninglightswitch

13. Removetheheadbolts includingtwosmallerboltssituatedatthefrontoftheengine.

14. Removetheheadfromthecrankcase.Note:

    • Ifnecessary,lightlytaptheheadwithasoft-facedmallettobreakthegasketseal.

15. Removeanddiscardtheheadgasket.

16. Removethecylinderliners(seepage5.18).

Note:

• Cylinderlinersmustberesealediftheheadisremoved.

• ServiceManual·RocketIll

3.15