Installation
Rocker Arm Assembly Removal and Installation
Installation
1. Rocker Arm Assembly
1. If the rocker arm assembly is disassembled, reassemble the rocker arm assembly.
2. Install the oil control orifice (A) with a new O-ring (B).
3. Install the rocker arm assembly (C).
4. Install the lost motion assembles (D) and the lost motion holder (E).
NOTE: Apply new engine oil to the lost motion assembly.
5. Tighten each bolts two turns at a time in sequence.
2. Valve Clearance Adjustment
1. Set the No. 1 piston at top dead center (TDC). The "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.
2. Select the correct feeler gauge for the valve clearance you are going to check.
3. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No. 1 cylinder, and slide it back and forth; you should feel a slight amount of drag.
4. If you feel too much or too little drag, loosen the locknut, and turn the adjusting screw (A) until the drag on the feeler gauge is correct.
5. Tighten the locknut to the specified torque, and recheck the clearance. Repeat the adjustment if necessary.
6. Rotate the crankshaft clockwise. Align the No. 3 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.
7. Check and, if necessary, adjust the valve clearance on the No. 3 cylinder.
8. Rotate the crankshaft clockwise. Align the No. 4 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.
9. Check and, if necessary, adjust the valve clearance on the No. 4 cylinder.
10. Rotate the crankshaft clockwise. Align the No. 2 piston TDC groove (A) on the camshaft sprocket with the top edge of the head.
11. Check and, if necessary, adjust the valve clearance on the No. 2 cylinder.
3. Cylinder Head Cover and/or Packing
1. Thoroughly clean the head cover gasket and the groove.
NOTE: Check and, if necessary, replace the head cover gasket.
2. Install the head cover gasket (A) in the groove of the cylinder head cover (B).
3. Make sure the head cover gasket is seated securely.
4. Clean the head cover contacting surfaces with a shop towel.
5. Remove the old liquid gasket from the top edge matting surfaces of the oil pump (A) and cylinder head (B).
6. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the chain case contact areas. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
* Apply a 5 mm (0.20 in) diameter bead of liquid gasket to the mating surfaces (C).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
7. Install the cylinder head cover.
8. Tighten the bolts in two steps. In the final step, torque all bolts in sequence to 10 Nm (1.0 kgfm, 7 lbfft).
NOTE:
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine for at least 3 hours after installing the head cover.
9. Connect the breather hose (A).
10. Install the dipstick (B).
4. Alternator Cable - Move
1. Install the harness clamp (A).
5. Cylinder Head Cover Peripheral Assembly
1. Install the harness holders (A).
2. Connect the connecters (B).
6. Engine Cover
1. Install the engine cover.