Iacautioni

IReplacethegasketswithnewones.

(!)23N·m

(2.3~lb-ft)

•Installandadjustthefollowingitems.

•Engineoil(o=2-13)

*Enginecoolant(o=2-19)

*Throttlecableplay(o=2-16)

*Clutch(o=2-17)

*Idlingadjustment(o=2-15)

*Throttlevalvesynchronization(o=4-73)

*Drivechainslack(c::::::r2-20)

*Wiringharness,cablesandhoses.(o=8-14-22)

_ENGINE3·15

ENGINEDISASSEMBLY

ACAUTIONI

Identifythepositionofeachremovedpart.Organizethepartsintheirrespectivegroups(e.g.,intake,exhaust)sothattheycanbereinstalledintheiroriginalpositions.

•Removethesparkplugs.(CT2·5)

STARTERMOTOR

•Removethestartermotor.

PAIRVALVE

•RemovethePAIRvalveG).

CYLINDERHEADCOVER

•Removethecylinderheadcoveranditsgaskets.

•Removethedowelpinsand0-rings.

CAMSHAFTS

•RemovethevalvetiminginspectioncapG).

•Turnthecrankshafttobringtheline®onthestarterclutchtotheindexmark@ofthevalvetiminginspectionholeandalsotobringthecamstothepositionasshown.

•Removethecamchaintensionadjustercapbolt<D.oilhoseunionbolt(?)andoilhose.

_{•Removethespring,ballandcamchaintensionadjuster.}

•RemovethecamchainguideCZ>.

•Removetheintakecamshaftjournalholder@.

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•Removetheexhaustcamshaftjournalholder@.

ACAUTIONI

Besuretoloosenthecamshaftjournalholderboltsevenlybyshiftingthewrenchdiagonally.

•RemovetheintakecamshaftG).

•Removetheexhaustcamshaft(%).

CYLINDERHEAD

•RemovethewaterhoseG).

•Removethethermostatcover(%)andthermostat.THERMOSTATINSPECTION:c::::::rs-10

•Removetheenginecoolanttemp.gaugeQ).

ENGINECOOLANTTEMP.GAUGEINSPECTION:c::::::rs-8

•Removethecylinderheadsidebolt@anditsgasket.

IACAUTIONI

Whenremovingthecylinderheadsidebolt,pullthecamchainupward,orthechainwillbecaughtbetweenthecylinderheadandthesidebolt.

•Removethecylinderheadbolts(M6)@.

•Removethecylinderheadboltsandwashers.

NOTE:

Whenlooseningthecylinderheadbolts,looseneachboltlittlebylittlediagonally.

•Removethecylinderhead.

J..,.~c

_Jc.-...

CLUTCH

_{•Removetheclutchcover.}

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•Holdtheclutchhousingwiththespecialtool.

ACAUTIONI

Becarefulnottodamagetheclutchhousingorclutchplates.

ir1idu09920-53740:Clutchsleevehubholder

•Removetheclutchsprings.

NOTE:

Loosentheclutchspringsetboltslittlebylittleanddiagonally.

•Removethepressureplate,clutchplates,springwasherandwasher.

•RemovetheclutchpushpieceG),thebearing·"?_)andthethrustwasher\t.

•Removetheclutchpushrod@).

NOTE:

Ifitisdifficulttopulloutthepushrod@,useamagnetichandorawire.

•Unlocktheclutchsleevehubnut.

•Holdtheclutchsleevehubwiththespecialtool.

1Qit109920~53740:Clutchsleevehubholder

•Removetheclutchsleevehubnut.

•RemovethewavewasherG)washer(2),clutchsleevehub@

andwasher.

•Removetheprimarydrivengearassembly@.

NOTE:

Ifitisdifficulttoremovetheprimarydrivengear,rotatethecrank•

shaft.

•Removethespacer@andbearing'ID.

•Removethethrustwasher(/).

OILPUMP

•RemovethecirclipG).

•Removetheoilpumpdrivengear(?).

NOTE:

DonotdropthecirclipG),thepin®andthewasher®intothe

crankcase.

•Removethepin®andthewasher®·

•Removetheoilpump@.

GEARSHIFTSYSTEM

•WiththecirclipG)removed,removethegearshiftshaftassern•

bly(?).

•Removethegearshiftcamplatebolt®andgearshiftcamplate

@.

•Removethegearshiftcamstopper@.

STARTERIDLEGEAR

•Removethestarteridlegearcover.

•RemovetheshaftG),wavewasher~washerQ)starteridlegearNo.I@.bearing@andwasher@.

•Removethestarterclutchcover.

•Removethewavewasher'D.thestarteridlegearNo.2'6)anditsshaft®·

STARTERCLUTCH

•Holdthestarterclutchwiththespecialtool.

ITMI09920-34830:Starterclutchholder

•Removethestarterclutchboltandwasher.

•Removethestarterclutchassembly.

CAMCHAIN,CAMCHAINTENSIONER,CAMCHAINGUIDE

•RemovethecamchaintensionerG)andcamchainguide~-

•Removethecamchain@andcamchaindrivesprocket@.

CKPSENSOR

CKPSENSORINSPECTION:c::::77-24

•RemovetheCKPsensor.

GENERATORCOVER

•Removethegeneratorcover.

GENERATORROTOR

•Holdthegeneratorrotorwiththespecialtool.

!Mi09930-44520:Rotorholder

•Removethegeneratorrotorbolt.

•Installasuitablebolt®totheleftendofcrankshaft.SUITABLEBOLT®[M12,length:28-38mm]

•Removethegeneratorrotorwiththespecialtool.

_{1r'Ciot109930-34980:Rotorremover}

_28-38mm

WATERPUMP

•RemovethewaterhoseCD.(Z)andinletcover~.

•Removethewaterpump@.

WATERPUMPSERVICING:c::::?S-11

GEARPOSITIONSWITCH

•Removethegearpositionswitch.

_{•Removetheswitchcontactsandsprings.}

BREATHERCOVER

•Removethebreathercover.

-

^•_,.•......,

····-~·:

OILFILTER

•Removetheoilfilterwiththespecialtool.(c:::::;r2-14)

!Ml09915~40610:Oilfilterwrench

OILCOOLER

•Removetheoilcooler.

OILPAN

•RemovethecowlingbracketsG).

•Removetheoilpan.

OILPRESSUREREGULATOR

•RemovetheoilpressureregulatorG).

OILPRESSURESWITCH

•Removetheoilpressureswitch~-

OILSTRAINER

•Removetheoilstrainer®and0-ring.

LOWERCRANKCASE

•Removethelowercrankcasebolts(6mm).

•Removethelowercrankcasebolts(8mm).

•Removethelowercrankcaseassembly.

TRANSMISSION

•Removethetransmissionand0-rings.

MIDDLECRANKCASE

•Removethecrankcasebolts(6mm).

NOTE:

Loosenthecrankcaseboltsdiagonallyandthesmallersizesfirst.

•Removethecrankcasebolts(8mm).

CRANKSHAFT

•Removethe0-ringG).

•Loosenthebearingcapboltsbyusing1Omm,12pointsocketwrench,andtapthebearingcapboltlightlywithplasticham•mertoremovethebearingcap.

•Removethecrankshaftandthrustwashers(2).

PISTONANDCONROD

•Pushtheconrodtoupwardandremovethepistonandconrodfromtheuppercrankcase.

ACAUTIONI

Becarefulnottodamagethecylinderwallbytheconrod.

•Removethepistonpincirclip.

•Separatethepistonandconrodbydrivingoutthepistonpin.

NOTE:

Scribethecylindernumberontheheadofthepiston.

ENGINECOMPONENTSINSPECTIONANDSERVICE

IACAUTIONI

Identifythepositionofeachremovedpart.Organizethepartsintheirrespectivegroups(i.e.,intake,exhaust,No.1orNo.2)sothattheycanbeinstalledintheiroriginallocations.

PAIRVALVE

PAIRREEDVALVE

•RemovethePAIRvalvecover.

•Inspectthereedvalveforthecarbondeposit.

•Ifthecarbondepositisfoundinthereedvalve.replacethe

PAIRcontrolvalvewithanewone.

-

_-

^{PAIRCONTROLVALVE}

•InspectthatairflowsthroughthePAIRcontrolvalveairinletporttotheairoutletports.

•Ifairdoesnotflowout,replacethePAIRvalvewithanewone.

•Connectthevacuumpumpgaugetothevacuumportofthecontrolvalveasshowninthephotograph.

•Applynegativepressureofthespecificationslowlytothecon·

trolvalveandinspecttheairflow.

•Ifairdoesnotflowout,thecontrolvalveisinnormalcondition.

•Ifthecontrolvalvedoesnotfunctionwithinthespecification,replacethecontrolvalvewithanewone.

~Negativepressurerange:Morethan66.6kPa

(491mmHg)

~09917-47010:Vacuumpumpgauge

IACAUTIONI

Useahandoperatedvacuumpumptopreventthecon•

trolvalvedamage.

CYLINDERHEADCOVER

CAMPOSITIONSENSOR

•InstalltheoilsealG)andcampositionsensorczi.

NOTE:

Wheninstalling,cleanthecampositionsensor'sface.

(!)Campositionsensorbolt:8N·m(0.8kgf·m,5.8lb-ft)

CAMSHAFT

CAMSHAFTIDENTIFICATION

Theexhaustcamshaftcanbedistinguishedfromthatoftheintakebytheembossedletters"EX"(forexhaust)asagainstletters"IN"(forintake).

CAMWEAR

•Checkthecamshaftforwearordamage.

•Measurethecamheight<Blwithamicrometer.

!Mi09900-20202:Micrometer(25-50mm)

~Camheight(8):

ServiceLimit:(IN.):36.28mm(1.428in)(EX.):34.98mm(1.417in)

CAMSHAFTJOURNALWEAR

•Determinewhetherornoteachjournalisworndowntothelimitbymeasuringtheoilclearancewiththecamshaftinstalledinplace.

•Usetheplastigaugetoreadtheclearanceatthewidestpor•

tion,whichisspecifiedasfollows:

BCamshaftjournaloilclearance:

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ServiceLimit:(IN&EX):0.150mm(0.0059in)

irTuh09900-22301:Plastigauge