Section 03 ENGINE
Sub-Section 04 (LEAK TEST AND ENGINE DIMENSION MEASUREMENT)
03-04-10
Install 2 short pieces (13 mm (1/2 in) long) of sol-
der directly on rotary valve, one above and one be-
low rotary valve gear. Apply grease to hold solder
in position.
Reinstall cover in place WITHOUT its O-ring and
torque screws to 20 N•m (15 lbf•ft).
Remove cover then clean and measure com-
pressed solder thickness, it must be within the
specified tolerance.
TYPICAL
1. Solder
CHECKING SURFACE FLATNESS
Intake manifold, intake manifold cover, rotary
valve cover can be checked for perfectly mating
surfaces.
Lay part on a surface plate (marble, mirror or thick
glass plate).
Holding down one end of part, try pushing down
the other end.
If any play is felt, part must be rectified.
RECTIFYING SURFACES
Stick a fine sand paper sheet on the surface plate
then lightly oil the sand paper.
Rub manifold mating surface on sand paper using
8-figure movements.
Sand until mating surface is perfectly straight.
CHECKING CRANKSHAFT
ALIGNMENT
Install a degree wheel (P/N 414 3529 00) on crank-
shaft end.
Remove both spark plugs.
Install a TDC gauge (P/N 414 1047 00) in spark
plug hole on MAG side.
Bring MAG piston at top dead center.
Rotate degree wheel (not crankshaft) so that 360°
mark aligns with center of crankcase. Scribe a
mark on crankcase.
Remove TDC gauge and install it on PTO side.
Bring PTO piston to top dead center.
Interval between cylinders must be exactly 180°.
Any other reading indicates a misaligned (twisted)
crankshaft.
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