User Guide

Chapter 2 Part A Engine, clutch and transmission (XV535 models)
2A-17
8.47a install the engine mounting bracket on the right side of the
rear cylinder head ...
8.47b ... install the cylinder head cover bracket next and thread
two of the short nuts onto the studs on top of the
cover bracket...
8.47c ... On the left side of the engine, install the engine
mounting bracket (A) and two thin washers (B), then install two
short nuts ...
8.50 Fit the cam sprocket into the chain so its dowel hole will
align with the camshaft dowel
44 Install the O-ring on the large dowel and install the two smaller
dowels, then install the new head gasket on top of the cylinder (see
illustrations). Never reuse the old head gasket and don't use any type
oil gasket sealant.
45 Install the cam chain damper on the exhaust side (if removed)
with its UP mark up (see illustration).
46 Position the cylinder head on the studs and guide the cam chain
damper through the slot in the cylinder head (see illustration). Be sure
8.47d ... the installed brackets should look like this
the upper end of the cam chain damper fits into the. notch in the
bottom of the cylinder head (see illustration).
47 Install the cylinder head bolts and nuts together with the engine
mounting brackets and cylinder head cover bracket (see illustrations).
Four of the shorter nuts go on the rear cylinder head; the longer nuts
and the remaining four short nuts go on the front cylinder head.
Tighten the bolts and nuts evenly in several stages, in a criss-cross
pattern, to the torque listed in this Chapter's Specifications.
48 Make sure the camshaft locating dowel is aligned with the mark
on the cylinder head (see illustration 8.13).
49 If you're working on the rear cylinder head, make sure the line on
the timing rotor with a T mark next to it aligns with the notch in the
timing window (see illustration 8.6a). If it's necessary to turn the
crankshaft, hold the timing chain up while you're turning so it doesn't
fall off the crankshaft sprocket and become jammed.
50 Engage the camshaft sprocket with the timing chain so its dowel
hole aligns with the dowel (see illustration). Slip the sprocket onto the
camshaft over the dowel.
51 Install the oil baffle plate with its concave side out, away from the
sprocket (see illustration 8.11).
52 Turn the cam sprocket clockwise far enough to remove all slack in
the cam chain, but no farther. Insert a finger in the tensioner hole and
push against the chain damper. Make sure the timing marks on the
cam sprocket and crankshaft are aligned correctly (see illustrations
8:6a and 8.6b).
53 With the marks correctly aligned, tighten the cam sprocket bolt to
the torque listed in this Chapter's Specifications.
54 Install the cam chain tensioner (see Section 7).