CYLINDER HEAD/VALVES 23. Nem (2.3 kgm, 17 feb 10.Nem (1.0 kgm, 10 Nem (1.0 kgm 7 felb) a 7 feb) e 12. Nem (1.2 kgm, 9 felbb 3 Nem (2.3 kgm, 17 fib 28 Nem (2.8 kg-m, ‘ 20 fen) —_ 28 Nem (2.8 kgm 20 Feb) if iy . —_, “se, 36 Nem 3.8 kgm, 26 felt6. CYLINDER HEAD/VALVES SERVICE INFORMATION TROUBLESHOOTING CYLINDER HEAD COVER DISASSEMBLY CAMSHAFT REMOVAL CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY CYLINDER HEADCOVERREMOVAL = 6-3. CAM CHAIN TENSIONER REMOVAL —6-9. 61 VALVE SEAT INSPECTION AND 62 REFACING 6-12 CYLINDER HEAD ASSEMBLY 6-15 CYLINDER HEAD INSTALLATION 6-16 64 CAMSHAFT INSTALLATION 6-17 65 CYLINDERHEAD COVERASSEMBLY 6-18 6-9 CYLINDER HEAD COVER INSTALLATION 6-10 6-19 SERVICE INFORMATION GENERAL dures can be pertormed with the engine in # Coat the camsheft bearings with clean eng # Pour clean engine cil into the oil pockets in the frame. ine oll to provide inital lubrication. the cylinder head to lubricate the cam. This section covers maintenance of the cylinder heed, values, camshaft, rocker arms and sub-rocker arms. These proce: ® Boiors aszambly, apply molybdenum disulfide grease to camshaft journals to provide initial lubrication, Trew STANDARD SERVICE LMT Cyne compression : 105-125 yen’ 149.117.7550 | Coreraht | 88: WN 31. 155—31.316 mm (1.2266—1.2329 int 31.05 mm(.222m)_| Cam tobe height EX__| __31,091—31.251 mm (1.2241 1.2304 in|__| 31.00 mm (1.220 in) AFTER ‘88: _ IN 31.101 31.341 mm (1.2244 —1,2339 in| 30.48 mm {1.200 in) eX | 81.072=31.312 mm t1-2288—1.2828 in) | 90.86 min (1.199 ind fun out — : 0.04 mm (0,002 in) [Rocker arm 1 7 500711518 rm (0.4028= 0.4595 11.38 ew (0.455 Bub roker om 1D IN| €000-8.015 mm (0.9150-0.3166 in) | 8.05 mm (0.317 in) eX 7.007.018 mm {0.2756—0.2762 In) | 7.08 mm (0.278 1) The om shah OD 11.46611.48% mm (0.48140.4521 in) | 11.41 mm (0.449 in) Subrocker arm shaft 0.0. [Nl 7.969-7.972 mm 10.3137-0.8198n | 7.92. (0.312 9 _| x $060 6.072 mm (0.2744—0.2748 ie) 6.92 mm 0.772 il Rocker am sheftto-arm clearance (0,016 —0.052 mm (0.9005—0.0020 in) (0.14 mm (0.006 in} Sub-rocker aim shaft-to-aim clearence, 0.013 0,043 mm {0.0005 0.0017 in) (0.10 mmm (0.004 ini Vale spring, Free length inner 36.1: mm (1.38 in) 34.1 mm (7.34 in) [Preeidirat re [8.14204 8 mm 13.888 = 088 / Valve Stem 0.0. iN 6.575— 6.590 mm (0.2589 0.2594 in) 6.56 mm (0.258 in} guide [in tan 01S 0.259600 2606 ni | 668 mm 0.261) Somtoqude [in| bano=sad 0.00080 00788) | E680 mm 0.0028 a) Clearance Ex 0.030—0.055 mm |0.0012—0.0022 in) 0.080 mr {0.0031 in) ~0.9-1.7 mm (0.04—0.67 in) Cylinder | Warpage (0.10 mm 0.004 in)_| head Valve seat width |IN/EX | _ 1.2—1.4 mm (0.05—0.06 ini 2.9 mn (0.08 ind) a 6-1CYLINDER HEAD/VALVES TORQUE VALUES Cylinder head bolt Cam sprocket bolt Racker arm shaft Sub-tocker arm sheft (INP (Ex! Cylinder head cover boit (8 mm} (6mm) (Emm si Spark plug Engine hanger plate nut (8 mm) (10 mm) Gil pipe bolt TOOLS Speci ‘Cam chain tensioner holder Valve guice reamer ‘Common Valve spring compressor Valve guide remover, 6.6 mm TROUBLESHOOTING Engine top-end problems 2 usually performance. 30.Nem (3,6 ka-m, 22 ft4b| Apply oll to the threads 20 Nor (2.0 kgm, 14 Ft) 28N-m (2.8 kgm, 20 ft1bi Apply e locking agent to the threads: 28 Nem (2.8 kgvan, 20 feb) 23 Nem (2.3 kgm, 17 feb) 23 Nem (2.3 kam, 17 feb) 12Nem (1.2 kg-m, 9 Ftlb} 1ONem (1.0 kgm, 7 fib} 18.Nen (1.8 kg-mn, 13 feb) 34 Nem (3.4 kg'm, 25 feb) 60 Nem (6.0 kam, 43 fb) SO Nem (1.0 kg-m, 7 F-lb) 07973— 07984 07767 077421 620002 or 07973. MG30003 5510000 or 07984—6570106 (U.S.A. only) 0010000 0010200 or 07984—6570100 lated and can usually be diagnosed by a compression test. Engine noises can usually be sraced to the top-end with @ sounding rod or stethoscope. Low Compression + Valve Incorrect valve adjustment — Burned or bent valves Incorrect valve timing —Broken valve spring + Cylinder head Leaking or damaged head gasket — Warped or erecked cylinder head + Cylinder end piston (Refer co Section 7) + Faulty decompressor cam High compression + Exessive carbon build-up on piston head or combustion chamber + Decompressor does not operate cr is damaged Excessive Noise Incorrect valve adjustment Sticking valve or broken valve spring Damaged or woin rocker arm o- camshatt Worn or damaced cam chain tensioner Worn cam sprocket teeth Faulty cam chain tensioner + Loose or worn cam chain Poor idling + Compression too low + Faulty decomprestor cam 6-2 eeCYLINDER HEAD/VALVES INDER HEAD COVER REMOVAL ove the folowing components: uel tank (page 4-3) {Cabure:or and carburetor insularot (page 4-7 end 8} Ol pipe buts, sealing washers and ot pipe “Cylinder head cover breather tube Spark phia cap “Clutch cable clamp Engine hanger plates Stapet hole caps Remove the crankshaft hole cep and timing hole cap. Tum the crankshaft end align the “7” mark on the flywheel with the index notch on the lett crankease cover when on the compression stroke (page 3-6). Remove the cvlinder head cover bolts. NOTE © Loosen the bolts indicated by the arrows. Remove the: bolts after removing the cylinder head cover Sldo the cylinder head cover to th Femove the belts from the cylinder head cov intake side and romove it.CYLINDER HEAD/VALVES Hemove the dowel pins and head cover gasket iy Dowel Fins CYLINDER HEAD COVER DISASSEMBLY Flomove the tapet hole cops from the eylinder head cover. (CAPS: Fomove the cub-rockor arm chafte, sealing washers, wave washers and sub-rocker erms from the cylinder head cover. v %2 (3) SUB-ROCKER ARMS 1) SHAFTS. AND WAVE WASHERS Remove the racker arm shafts, copper washers and rocker {1} COPPER WASHERS |. (2) ROCKER ARMS arms from the cylinder head cover. 6-4CYLINDER HEAD/VALVES DIL PIPE INSPECTION (1) OlL PPE BOLTS ‘heck the ol pipe and cil pie bolts for bands or clogging Check te condition of the sesling washers, | me oe (2) SEALING: : 43) O1L PIPE WASHER ROCKER ARM INSPECTION or dam- Inspect the rocker arme and eub-rocker arms for we: gt NOTE Tf any rocker arms require servicing or replacarment, inspect the cam lobes for scoring, chipping or fiat spots. Measura the I.D. of the rocker arms and sub-rocker arms. SERVICE LIMITS: Rocker arm: 11.55 mm (0.455 in) Sub-rocker atm: IN: 8.05 mm (0.317 ind EX: 7.05 mm {0.277 in} ROCKER ARM SHAFT INSPECTION Inspect the racker arm and sub-rocker arm shafts for wear oF damage. ‘Measure each shaft 0.D. SERVICE LIMTS: Rocker arm shaft: 11.41 mm (0.449 in} Sub-rocker arm eheft: IN: 7-92 mm (0.312 in} EX: 6.92 mm (0.272 in} Calculate the rocker arm-to-shaft clearance. SERVICE LIMIT: 0.14 mm (0.006 in) Calculate the sub-rocker erm-to-shatt clearance, SERVICE LIMIT: 0.08 mm (0.003 in} CAMSHAFT REMOVAL Remove the com chain tonsioner shaft bolt.CYLINDER HEAD/VALVES Push down the tensioner lever using a ecrevicriver and insert the pin of the tensioner holder into the hole of the tensioner 10, hold the tensioner. Slowly retosco tho tensionor until the tool rate againat the eyl- Inder head casting, TOOL: Cam chain tensioner holder «7873 M@30002 or 07973-63003 ‘Turn the crankshaft and remove the cam sorocket bolts, CAUTION + Be careful not drop the bolts into the erankeave Separate the cam sprocket from the cam sprocket holder and !1! TENSIONER Fomove the cam chain from the spracket. HOLDER Suspend the cam chain with @ plece of wire to prevent it fram falling Into the crankcase, Remove the camshaft, cam sprocket and tensioner holder. Remove the camehatt bearing oot pine, reverse decompressor ‘cam stopper and spring,_— BEARING INSPECTION tho outer race of each beating with your finger. The beer- Ings should turn srroothly and quietly. Also check that the hating innr race fie tightly on the camehart. Ifthe outer races do not tun smoathly end quietly or innar feces fit locsely on the camshaft, replace the bearings. Remove the bearings from the camshaft. CAMSHAFT INSPECTION Chock aach cam lobo ‘er woar or damage, Moesure each cam lobe height. SERVICE LIMITS: Intake: 31.05 mm (1.222 in) Eshaust: 31.00 mm (1-220 in} Support both ends of the camshaft with blocks. Measure the camshaft runout with a dial indicator ‘Actual runout is 1/2 of the totel indieater reading. SERVICE LIMIT: 0.04 mm (0,002 in} DECOMPRESSOR SYSTEM DISASSEMBLY Press the cam sprocket holder aff the camshaft, Remove the thrust washer, one way clutch, reverse decom bressor cam end decompressor cam with sina, Note © De not confuse the cam spring with the clutch pring, CYLINDER HEAD/VALVES 1) BEARINGS Pe (SPRING (7) CAMSHAFT. (6) THRUST WASHER (5) CAM SPROCKET HOLDER (2) DECOMPRESSOA CAM (3) REVERSE DECOMPRESSOR CAM (a) ONE WAY CLUTCHCYLINDER HEAD/VALVES INSPECTION (7) OUTER Check the one way clutch outer, rollers and springs for weer or damage Check both decempressor cams for wear or damage, replace it necessary. Inspect the cams’ sliding surface on the camshait for scoring (3) ROLLERS (2) SPRINGS DECOMPRESSOR SYSTEM ASSEMBLY (1) REVERSE DECOMPRESSOR CAM] | {_ @yone way cuter Lubricate both decompressor cams, one way clutch and the Siro wastorwthothanfretat fcommpense-cantty | Lp Ls its spring, onto the camshatt, Install the reverse decompressor cam and the on2 way clutch ‘with a pin —_— Inezall the the thrust washer. —_ q | 15 DECoMPRESSOR CAM Te) PIN Press the cem sprocket holder onto the camshaft after aligning (2) LUG the lug en the camshaft with the indentation on the cam > sprocket helder. [1 INDENTATION Be sure that the one way clutch outer rotates in one direction only.CYLINDER HEAD/VALVES LINDER HEAD REMOVAL 11) gours the following components: Exhaus: pipes (page 15-7) ‘yjinder haod cover (page 6-3) Camsheft (page 0-9) = Gyfinder head nts = Gyinder head boits tor © Loosen the bolts in a crisscross pattern in two or more Ps. Remove the cylinder hoad, ‘CAUTION (2) GASKET Be careful not 0 damage the evlinder ead mating surfaces Remove the dowel pins, cylinder head gasket anc cam chain ulte. Inspect the cam chain guide for wear or damage. (1) CAM CHAIN GUIDE Replace the guide with a now one, if noceseary. CAM CHAIN TENSIONER REMOVAL Remove the tensioner shatt, Remove the cam chain tensioner and soring.CYLINDER HEAD/VALVES CAM CHAIN TENSIONER INSPECTION Insert the tensioner sheft into the tensioner and inspect the tensioner by turning the shaft The tensioner snatt turns clockwise freely and should not turn counterclockwise, Check the tonsionor lifter and toneioner ahatt for excessive or abnormal wear or damage. CYLINDER HEAD DISASSEMBLY Using a valve spring compressor, remove the valve spring cotters, retainers, sprigs, spring sezts and valves from the cy! inder heed. TooL: Velve spring compressor 07757—0010000 CAUTION + To prevent toss of tension, do not compress ihe valve springs ‘more ihen necessary to remove the colters. NOTE + Mark all parts to ensure that they are ‘eassembled in thelr ‘original positions. Remove the valve stem seals and discard them. NOTE + Whenover the stem seals are removed, replace them with nowieny CYLINDER HEAD INSPECTION Check the spark plug hole and valve areas for ctacks. Check tha eyiinder head fer warpage with a straight edge and 2 foclar gauge, SERVICE LIMIT: 0.10 mm (0.004 in} 6-10CYLINDER HEAD/VALVES VE SPRING INSPECTION 19 te frae length of the inner and outer valve springs. umtrs: INNER: 34.1 mm (1.34 in} “OUTER: 35.0 mm (1.38 in} pect each valve for bending, buing, scratches or oimal stem wear. ‘Check valve movement in tho guide, and measure end record gach valve stem 0.0. ‘SERVICE LIMITS: IN: 6.56 mm (0.268 in} EX: 6.55 mm (0.258 in} Fear the velve quides to remove any carbon deposits before checking clearances. NoTe + ita importent that the reamer ie alwaye rotated in the seme diection when it ' inserted! or removed. Tool: Vave guide rear (07984—5510000 or 07984—657010C (S.A. only) ‘ Meacuto and record each valve guide ID. SERVICE LIMITS: IN: 6.63 mm (0.261 in} EX: 6.63 mm {0.261 in} Caulate the valve stom-to-guide clearance. SERVICE LIMITS: IN: 0.085 mm (0.0026 in} EX: 0.080 mm (0.0031 in) If te stem-to-quide clearance exceeds the service limit, deter- mine ifa new guide with standard dimansions weuld bring the tlearance within tolerance. IF eo, replace guides ae ne and rearn to fit If stom-to-quide clearances still exceeds the service limit when new guides are installed, replace tha vaives. Nore + Reface valve seats wherever new valve guices are in- stalled.CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement guides in the freezer for about an hour, Heat the cvlinder head to about 130— 140°C (275~290°F] with a hot plate or a oven. Do not heat the cylinder heed beyond 300°F (50°F), Use Temperature indicator sticks, avelleble from welding supply stores, to be sure the cylinder head is heated to the proper temperature. + To avoid burns, wear heavy gloves when handling the heated cylinder head. CAUTION + Da not use a torch to heat the cylinder, it may cause werping. Nore + To Gear the valve guides, set the cylinder head on proper blocks. Support the evlinder head and drive our the old guides from the combustion chamber side of the cylinder head, CAUTION + Be careful not to damage the eplinder head TooL: Valve guide remover, 6.6 mm 077420010200 or 07942—6570100 Place anew O-ring on the new valve guide Drive in the valve from the rackor arm side. Inspect the velve guides for damage. Too: Valve guide remover, 6.6 mm 077420010200 ot 07984—6570100 Roam the new valve guides after installation. NOTE + Use cutting oil on the reainer during this operation ‘lean the evinder need Hhroygly to vernove any ral pon cee Tele the valve soet (pogo 0:13) TooL: Valve guide reamer, 6.6mm _ 07984—6570000 or 07384—657010C (U.S.A. only) VALVE SEAT INSPECTION AND REFACING Clean all intaxe and exhaust valves thoroughly 10 remove caroan deposits Apaly « light coating of Prussian Blue to each valve face.Lap ach valve and cest using # rubber hose or other hand leppina ‘0h Remove end inspect each valve CAUTION + Watves cannot be ground. If the valve face & burned or badly worn or if it contacts the seat unevenly, replace the valve. 6-12tthe wlath of each valve seat NCE LIMITS: 2.6 mm (0.10 in} ithe seat is too wide, too nerravr or has low spots, the seat st be ground. JALVE SEAT CUTTERS nda Volvo Seat Curtere, grinder or equivalent valve facing equipment ere recommended to correct a worn valve ‘Follow the refacer manufacturer's operating instructons. VALVE SEAT REFACING Ure 2 45 degree cutter to remove any roughness or iregulari- tles itor the seat NOTE + Refece the seat with 45 degree cutter when a valve guide is reolaced C Uso 2 32 degree cutter to remove the top 1/4 of the oxieting vaive seat material 45° (1) SEAT CUTTER (2) FLAT CUTTER 43) INTERIOR CUTTER (1) ROUGHNESS/IRREGULARITIES 45° (2) VALVE SEAT CYLINDER HEAD/VALVES (1) VALVE SEAT WIDTH 50° (1) QLD SEAT WIDTHCYLINDER HEAD/VALVES Use = 60 degree cutter to remove the bottom 1/4 of the old seat. Remove the cutter and inspect the area you have rofaced, (1) OLD SEAT WIDTH | SS Insta 2.45 degree finish cutter and cut the saat to the proper ‘width. Make sure that all pitting and irregularities are removed. Fofinsh if nacessary. 09-11 mm (0,035 —0.083 in) Apply a thin coating of Prussian Blue to the valve seat. Press the value through the valve quica and onto the seat to make a ck (1) CONTACTY TOO HIGH loar pattorn. NOTE — —___ (2) OLo Sear WIDTH | +The location of the valve seat in relation to the velva face 16 | very important for good sealing 32 It the contact arga Is too high on the valve, the eat must be lowered using a 32 degree flat cutter. If the contact ares ie too low on the vaive, the raiged using @ 60 degree inner custer. (1) CONTACT TOO Low (2) OLD SEAT WIDTH 6-14irish the seat to specifications, using a 45 dagree finish te. 4 cutting the seat, apply lapping compound to the valve and lap the valve using ight pressure. J lapping, wash all residual compound off the cylinder and valve. Do rot allow lapping compound to enter the guides. CYLINDER HEAD ASSEMBLY Inctall the valve spring seats and new stem seals. Lubiioste cach valve stem with MoS2 paste arease (page 2:14) and insert the valve into the valve guide. Install the valve springs and retainers. NOTE T nstall the valve springs with their narrower pitches facing to the cylinder head. + Reploce the stem seals with new ones whenever they sre removed. + install the valves inte the valve guides, turning ther sjowly s0 you de not damage the stam seals. , Compress the value springs using the valve spring compres- for, then install the valve cotters. CAUTION [To prevent loos of tension, do not compress the valve springs more than necessary 10 install the vaive corters. TooL: Valve spring compressor 07787—0010000 “Gy stem o SEAL (6) OUTER SPRING CYLINDER HEAD/VALVES ae jsrcorters = CYLINDER. HEADCYLINDER HEAD/VALVES ‘Tap the valve stems gently with @ plastic hammer to firmly seat the cotters. CAUTION + Suppor the evlinder head above the work bench surface to pre- vent possible valve demage. CYLINDER HEAD INSTALLATION (SPRING ‘the spring on the cam chain tensiener aligning, the holo in the tensioner with the spring end. (2) HOLE AND. SPRING END Install the cam chain tensioner into the cyliner head, Apply angino oil to 0 now O-ring ond inetall it in the groove of ‘the cam chain tensiener shan. Insert the tensioner shatt through the tensioner and into the cylinder head. Install the cam chain guide, dowel pins anda new head gasket. 6-16CYLINDER HEAD/VALVES fall he following parts: (Gylindar head Camshaft beering set pins ‘Spring and reverse decompresso: cam stopper oilto the evlinder head balts and washers. the cylinder hoad bolts in a crisscrosspattemn in two or ‘steps. {QUE: 36N-m {3.6 kg-m, 26 ft-lb) ten the cylindor head nuts. il the exhaust pipes {page 15-7) ISHAFT INSTALLATION ply oll to the camshaft bearings and inetall them onto the shat encs wth thelr sealed ends facing out. ly MoS2 paste (page 2-14) to the cam jobe surfaces and yshaft journal le pushing down the tensioner's lever, sot the cam chain ioner hoder onto the tensioner, aligning the pin of the folder with the hole in the tensioner. Slowly release the tansioner lever until the holder rests against the oyinder head casting. Mos2 TOOL: Cam chain tensioner holder —-(07973—MG30002 or 07973—-MG30003 fi1) TENSIONER HOLDER Jaca the carn sorocket 10 the camshott over the aight oar fl theft bearing with the “OUT” mark facing the outside Intl the camshaft through the cam chain Aamove the crankshaft hola cap anc tinina hole cap, Tunthe trankshate countorclockwiso and align the T"” mark tn tho ywheal withthe index notch on the let erankease sover : Ral te cam chain over the cam sprocket chain so shat the fining morks on the sprocket alin with the unper surface of the oylindr head Instal the cam sprocket onto the sprackat holder of the cam- ii 9H shaft. (5) CAM SPROCKET NOTE + Do rot turn the sprocket when installing it onte the sprock et holder. ‘Apply locking agent to the threads of the cam sprocket bolts ard seraw one bolt in Ioosely, then screw the other bolt in etter ‘turning the crankshaft. Tighien Ure sprocket belts to the epecified torque TORQUE: 20 Nem (2.0 kg-m, 14 tt-b) Remove the tansioner holier.CYLINDER HEAD/VALVES ‘Turn tho erenkshett counterciockwiee 360° end align the “T"" (2) TIMING MARKS mark on the flywheel with the index notch en eft crankcase | (TF INGEX NOTCH cover again Make sure that the timing marks on the cam sprocket elion With the upper surface of the cylinder haad Align the holes in the cylincer head and tensioner shatt by turning the tensioner sheft clockwise. Install and tighten the bolt. CYLINDER HEAD COVER ASSEMBLY NOTE + Each rocker arm is stamped with its letter code in the loca- tion as shown. Install properly. (2) TAB 6-18CYLINDER HEAD/VALVES: leech rocker arm in the correct positon, referring to the (1) ROCKER sion on page 6-18. ARMS. cil to the rocker atm shat sliding surface. iy a lacking agent 10 the threads of the rocker arm shatts, the copper washers. insert the rocker arm shafts through jeyinder head cover and rocker arms, and tighton thom to specified torque. UE: 28 Nom (2.8 kg-m, 20 ft-lb) Apply MoS2 paste (page 2-14) to the rocker arm slippor eur- ces. (3) ROCKER ARM SHAFTS (2) SUB-ROCKER ARM SHAFTS ee E Hi Scop ie ‘petal tho cub-rocker arme and wave washers in the comrost postions, referring to the ilustiation on page 0-18. Apply oil to the sub-rocker atm shaft sliding surfaces. Apply a locking agent to the threads of the sub-tocker arm ‘shaft, thon inoar: tham through tho eyiindor head cover and Sibrocker arm with copper washers. Tighten the sub-rocker arm shaft. ‘TORQUE: INTAKE: 28 Nem (2.8 kg-m, 20 ft-lb) EXHAUST: 23 Nem (2.3 kgem, 17 ft-lb) (4) SUB ROCKER ARMS 12) SUB-ROCKER ARM SHAFTS Aoply MoSz paste (nage 2-14} to the sub-rocker arm slipper surfaces. CYLINDER HEAD COVER INSTALLATION Pour clan engine cil into the oil pockets in the cylinder head se ‘at the cain lobes are submerged. Install the dowel pins end @ new gasket.CYLINDER HEAD/VALVES Tay HEAD COVER] ‘Set the 8 mm bolt and 6 mm SH bolt on the head caver, then Slide the cylinder heed cover over the cylinder hoad. ‘Tighten the cylinder head cover bolts. {0} @ mm SH BOLT, TORQUE: mm bolt: 23 Nem (2.3 kg-m, 17 fd) Gm bolt: 12 Nem (1.2kgem, 9 feb) 6 mm SH Bott: 10 Nem (1.0 kg-m, 7 fel NOTE Tighten the cylinder head cover bolts n'a crisscross pattern in two or more steps. Install and tighten the spark plus. TORQUE: 18 Nem (1.8 kgm, 13 feb) Ingtall the engine hanger plates, bolts and nuts, ‘Tighten the nuts to the specified torque ‘TORQUE: 8 mm bolts: 34. Nem (3.4 kg-m, 25 ft} 410 mm bolt: 60 Nem (6.0 ko-m, 43 ft) Install the clutch cable clamp end tighten the bolt. 10 Nem 11.0 kgem, 7 ft-b) Connect the cylinder head cover breather tube, and secure it ‘with the clip. Install the spark plug cap. Adjust velve clearance (page 2-6). Install the ol pipe with four sealing washers, and tighten the oil pipe bolts, TORQUE: 10 Nem (1.0 kg-m, 7 ft1b) Install the following components: — Carburetor {page 4-15) — Fuol tank (page 4-3) — Seat and side covers (page 16-2) a 6-20 ——_—_—_—_——— j fae |