Service manual

5
ENGINE
ENGINE REMOVAL ........................................................................................5-1
INSTALLING THE ENGINE.......................................................................5-5
INSTALLING THE SHIFT ARM .................................................................5-5
INSTALLING THE EXHAUST ASSEMBLY ...............................................5-5
CYLINDER HEAD............................................................................................5-7
REMOVING THE CYLINDER HEAD.........................................................5-9
CHECKING THE CYLINDER HEAD .........................................................5-9
CHECKING THE CAMSHAFT SPROCKET AND
TIMING CHAIN GUIDE ..........................................................................5-10
CHECKING THE TIMING CHAIN TENSIONER......................................5-10
CHECKING THE DECOMPRESSION SYSTEM.....................................5-11
INSTALLING THE CYLINDER HEAD .....................................................5-11
CAMSHAFT...................................................................................................5-14
CHECKING THE CAMSHAFT.................................................................5-15
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........5-15
INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................5-16
VALVES AND VALVE SPRINGS..................................................................5-17
REMOVING THE VALVES......................................................................5-18
CHECKING THE VALVES AND VALVE GUIDES ..................................5-18
CHECKING THE VALVE SEATS ............................................................5-20
CHECKING THE VALVE SPRINGS........................................................5-21
INSTALLING THE VALVES ....................................................................5-22
CYLINDER AND PISTON..............................................................................5-24
REMOVING THE PISTON ......................................................................5-25
CHECKING THE CYLINDER AND PISTON ...........................................5-25
CHECKING THE PISTON RINGS...........................................................5-26
CHECKING THE PISTON PIN ................................................................5-27
INSTALLING THE PISTON AND CYLINDER .........................................5-27
GENERATOR AND STARTER CLUTCH......................................................5-29
REMOVING THE GENERATOR .............................................................5-31
REMOVING THE STARTER CLUTCH ...................................................5-31
CHECKING THE STARTER CLUTCH ....................................................5-31
INSTALLING THE STARTER CLUTCH ..................................................5-32
INSTALLING THE GENERATOR............................................................5-32
ELECTRIC STARTER ...................................................................................5-34
CHECKING THE STARTER MOTOR .....................................................5-36
ASSEMBLING THE STARTER MOTOR.................................................5-37
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