Remove the 12 cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Secure the upper engine mounts to the frame 2. These oils can adversely affect clutch operation. Valve Stem Outside Diameter intake exhaust 4. Care should be taken to support the connecting Measuring Connecting Rod rod when rotating the crankshaft.
Tighten the Phil- lips-head screws coated with red Loctite 271 securely. Coupling cracked, damaged, or worn. Valve clearance out of adjustment 1. Account for a pin, spring, and O-ring with the chain tensioner bolt. Loosen the cap screw on the end of the ten- 6. Piston Diameter 15 mm 0. Using the red tester lead, contact each end of the 0411-838 fuse holder connector terminals individually.
If any are damaged, replace the complete set. Install reverse idler C ; then install the reverse 17. Primary Drive Clutch Housing 10. Do not allow the calipers to hang from the brake 9. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. Using the red tester lead, probe the commuta- ing.
Install the upper engine mounting brackets to 9. Note the difference inside each bearing ring end for assembling purposes; then remove the bear- ing ring. Measure the main bearing bore diameter A in the crankcase. Piston Ring End Gap - Installed 0. Bend the washer tabs and remove the two cap 7. Carefully examine the element for tears before and after cleaning it.
Inspect the piston for seizure marks or scuffing. Remove the E-clip securing the shift rod to the the differential lock splines and allow engagement. Do not use oils which contain graphite or molybdenum additives. See the following viscosity chart for details. Remove drive gear 2 B. The technician should use discretion and sound judgment. Account for the bearing alignment C-ring on the bearing boss next to the pinion gear.
Tighten the cap screws to specifications. Using an impact driver, loosen but do not remove the two Phillips-head cover screws. With the 50 cm 20 in. Loosen the jam nuts securing adjustment screw 1 forward and adjustment screw 2 rear- ward. Tighten the cap screws to specifications.
While holding the throttle lever in the full-open position, crank the engine over with the electric starter until the gauge shows a peak reading five to 10 compression strokes. Loosen the nut and remove the spring holder; on the pulley compressor base. Reverse Driven Gear Dog 7. Remove the plug cap from the high tension lead; then connect the red tester lead to the high ten- sion lead. Install two engine mounting through-bolts, two bushings, and two washers; then tighten the through-bolt flange nuts to specifications. Valve timing out of adjustment 3.
Install the left footrest; then tighten the 10 mm cap screws to specifications and the 8 mm cap screws to specifications. Maximum runout must not exceed specifica- spring seat. Place the pinion housing in a press and install the input shaft bearing. Loosen the clamp securing the air cleaner to the front boot; then loosen the clamp securing the air cleaner to the rear filter sleeve. Insert an exhaust valve seat pilot shaft into an exhaust valve guide. Remove the battery Table of Contents vent hose; then remove the battery.
If rotating the camshaft is necessary for alignment, do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position. Tighten the cap screws securely. Remove the splined coupler, shifter fork, pin, and spring of the differential lock assembly and set aside. To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. Install the air intake plate. Remove the three Phillips-head screws securing cam plate and guide to the gear shift cam; then the oil pump; then remove the oil pump.