3.13
ENGINE
3
TOP-END DISASSEMBLY
Engine Removal/Installation
Refer to page 3.12 for engine removal / installation notes.
Finding Top Dead Center (TDC)
1. Remove the cooling shroud.
2. Remove the inspection cap from the stator housing.
3. Remove the valve cover and emissions pipe assembly.
To position the crankshaft at Top Dead Center (TDC) on the
compression stroke:
4. Rotate the engine slowly in the direction of rotation while
watching the intake valve open and start to close.
5. Continue to rotate slowly while watching the camshaft
sprocket marks and timing mark in the inspection hole.
6. The engine is at Top Dead Center when the single (TDC)
mark on flywheel is visible within the inspection hole and
the cam sprocket hole is facing upward. NOTE: The
sprocket marks should align with the gasket surface, the
cam lobes must be pointed downward and the rockers
must have valve clearance at this point.
Cam Chain Tensioner Inspection
1. Remove the two cam chain tensioner flange bolts. NOTE:
The plunger is under spring tension. Maintain inward
pressure on the tensioner body while removing.
2. Allow the cam chain tensioner plunger to extend outward
to the end of its travel. Inspect tensioner and plunger (A)
for wear or damage.
3. Using a small flat blade screwdriver, turn the tensioner
clockwise to retract the plunger. The plunger should move
smoothly in and out of the tensioner body.
4. Tap lightly on tensioner body with a soft face hammer to
loosen and remove tensioner if required.
5. Replace tensioner assembly if any part is worn or damaged.
Single TDC Mark Aligned
TDC Mark
Rotation
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