3.18
ENGINE
ENGINE DISASSEMBLY
Engine Removal
Refer to page 3.7 - 3.10 for Engine Removal / Installation
Notes
Cam Chain Tensioner / Rocker Arm /
Camshaft Removal
1. Remove ignition timing inspection plug from recoil
housing.
To position crankshaft at Top Dead Center (TDC) on
compression stroke:
2. Rotate engine slowly in the direction of rotation watching
intake valves open and start to close.
3. Continue to rotate engine slowly, watching camshaft
sprocket marks and the mark in the timing inspection hole.
4. Align single (TDC) mark on flywheel with projection in
inspection hole, and the cam sprocket pin (facing upward)
aligned with the camshaft to crankshaft center line.
NOTE: The cam lobe should be pointing down and
valves should have clearance at this point.
5. Remove cam chain tensioner plug, sealing washer, and
spring. CAUTION: The plug is under spring tension.
Maintain inward pressure while removing.
6. Remove the two 6x25 mm cam chain tensioner flange bolts.
7. Tap lightly on tensioner body with a soft face hammer and
remove tensioner.
Cam Chain Tensioner Inspection
1. Pull cam chain tensioner plunger outward to the end of its
travel. Inspect teeth on ratchet pawl (A) and plunger teeth
(B) for wear or damage.
2. Push ratchet pawl and hold it. The plunger should move
smoothly in and out of the tensioner body.
3. Release ratchet pawl and push inward on plunger. It should
remain locked in position and not move inward.
TDC “T” Mark
Rotation
Advance Marks
B
A
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