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Note

• Variable valve timing actuator can not be disassembled because it is a precision unit.

• Intake camshaft sprocket is integrated with the variable valve timing actuator and cannot be disassembled.

1.Disconnect the negative battery cable.

2.Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [L5].)

3.Disconnect the wiring harness.

4.Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [L5].)

5.Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [L5].)

6.Disconnect the ventilation hose from the cylinder head cover.

7.Remove the dipstick.

8.Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [L5].)

9.Remove the front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION).)

10.Remove the under cover.

11.Set the front mudguard (RH) out of the way.

12.Remove the splash shield (RH).

13.Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [L5].)

14.Remove the engine front cover lower blind plug.

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15.Remove the engine front cover upper blind plug.

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16.Remove the cylinder block lower blind plug, and install the SST.

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17.Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at top dead center (TDC) of the compression stroke. (Until the counterweight contacts SST and stops.)

18.Loosen the timing chain using the following procedure.

(1)Insert a suitable bolt (M6 X 1.0, length 25—35 mm {1.0—1.3 in}) into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)

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(2)Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.

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(3)Using a Hex bit socket (2.5 mm {0.098 in}) or T15 Torx bit socket, unlock the chain tensioner ratchet so that it can be lifted up.

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(4)Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.

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Note

• The chain tensioner rack is compressed using the chain tension generated by applying force to the exhaust camshaft in the direction of the engine rotation.

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(5)Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.

Note

• The racket has not been unlocked if the bolt cannot be pressed in approx. 5 mm {0.2 in}.

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• If the tensioner arm cannot be secured, return the bolt to its original position and repeat the procedure from Step 3.

19.Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket bolt.

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20.Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.

Caution

• Perform the work carefully so that the washer does not drop out.

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21.Remove the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [L5].)

22.Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the camshaft cap.

Note

• The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.

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23.Remove the variable valve timing actuator and the camshaft on the intake air side as a single unit.

24.Remove the variable valve timing actuator.

(1)Mark the camshaft and variable valve timing actuator as shown in the figure to make sure they are installed in their original position.

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(2)Secure the camshaft in a vise.

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(3)Loosen the variable valve timing actuator tightening bolt.

25.Install the variable valve timing actuator.

Note

• When the variable valve timing actuator is replaced with a new one, mark it in the same location as the old one.

(1)Secure the camshaft in a vise.

(2)Install a new washer.

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(3)Align the marks of the camshaft and variable valve timing actuator.

(4)Tighten variable valve timing actuator tightening bolt.

Tightening torque

69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}

Note

• When the variable valve timing actuator is replaced with a new one, mark it in the same location as the old one.

26.Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST.)

27.Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.

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28.With No.1 cylinder cam aligned at TDC of the compression stroke, install the variable valve timing actuator and the camshaft on the intake air side as a single unit.

29.Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.

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30.Temporarily tighten the camshaft cap bolts evenly in 2—3 steps.

31.Tighten the camshaft cap bolts in the order shown in the following two steps.

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32.Install the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [L5].)

33.Install the timing chain, exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.

Caution

• Install a washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt being careful not to drop the washer.

• Do not tighten the camshaft sprocket bolt at this stage. Verify the valve timing before performing the bolt tightening.

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34.Install the SST on the camshaft as shown in the figure.

Europe

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Except Europe

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35.Remove the bolt (M6 X 1.0 length 25—35mm {1.0—1.3 in}) from the engine front cover upper blind plug hole, and apply tension to the timing chain.

36.Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket bolt.

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37.Remove the SST from the camshaft.

38.Remove the SST installed in the cylinder block lower blind plug hole.

39.Rotate the crankshaft clockwise two turns and inspect the valve timing.

• If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 34.

40.Install the cylinder block lower blind plug.

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41.Apply the silicone sealant and install the engine front cover upper blind plug.

Caution

• Install the engine front cover upper blind plug before the applied silicone sealant starts to harden.

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42.Install a new engine front cover lower blind plug.

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43.Install the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [L5].)

44.Install the splash shield (RH).

45.Install the front mudguard (RH).

46.Install the under cover.

47.Install the front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION).)

48.Install the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [L5].)

49.Install the dipstick.

50.Connect the ventilation hose.

51.Install the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [L5].)

52.Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [L5].)

53.Connect the wiring harness.

54.Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [L5].)

55.Connect the negative battery cable.