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The update process may take approximately two hours and will be performed free of charge through November 1, The mid rocker arm should move independently of the primary rocker arm B and secondary rocker arm C. If the mid rocker arm moves freely, go to step 6.
If the intake mid rocker arm does not move, remove the mid, primary, and secondary intake rocker arms as an assembly, then check that the pistons in the mid and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the mid, primary, and secondary rocker arms as an assembly, and retest.
Repeat step 5 on the remaining intake mid rocker arms with each piston at TDC. When all the mid rocker arms pass the test, go to step 7. Check that the air pressure on the shop air compressor gauge indicates over kPa 7. Remove the No. Loosen the valve on the regulator, and apply the specified air pressure. Specified Air Pressure: kPa 4. Make sure that the intake primary rocker arm A and intake secondary rocker arm B are mechanically connected by the piston and that the mid rocker arm C does not move when pushed manually.
If any intake mid rocker arm moves independently of the primary and secondary rocker arms, replace the rocker arms as a set. NOTE: If the synchronizing pistons do not move after applying air pressure, move the primary or secondary rocker arm up and down manually.
Remove the special tools. Tighten the rocker shaft bolts to 24 N. Align the pointer A on the front upper cover with the No. Select the correct thickness feeler gauge for the valves you're going to check.
Valve Clearance Intake: 0. Exhaust: 0. Insert the feeler gauge A between the adjusting screw and the end of the valve stem on No. If you feel too much or too little drag, loosen the locknut A , and turn the adjusting screw B until the drag on the feeler gauge is correct. Tighten the locknut and recheck the clearance. Repeat the adjustment, if necessary. Rotate the crankshaft clockwise.
Check and, if necessary, adjust the valve clearance on No. Remove the right front wheel. Remove the splash shield. Hold the pulley with the holder handle A and holder attachment B. Remove the bolt with a heavy duty 19 mm socket C and breaker bar, then remove the crankshaft pulley.
Remove any oil or clean the pulleys A , crankshaft B , bolt C , and washer D. Lubricate new engine oil as shown in Fig. Install the crankshaft pulley, and tighten the bolt. Do not use an impact wrench. Install the splash shield. Install the right front wheel.
Remove the front upper cover. Inspect the timing belt for cracks and oil or coolant contamination. Replace the belt if it is cracked, or is contaminated with oil or coolant. Wipe off any oil or solvent that gets on the belt. Turn the crankshaft so its white mark A lines up with the pointer B.
Check that the No. Support the engine with a jack and wood block under the oil pan. Remove the upper half of the side engine mount bracket. Remove the front upper cover A and rear upper cover B. Remove the lower cover. Remove one of the battery clamp bolts from the battery tray, and grind the end of it as shown in Fig. Screw the battery clamp bolt in as shown in Fig. Tighten it by hand; do not use a wrench. Remove the timing belt guide plate A.
Remove the lower side engine mount bracket. Remove the idler pulley bolt A and idler pulley B , then remove the timing belt. Discard the idler pulley bolt. Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers. Set the timing belt drive pulley to top dead center TDC by aligning the TDC mark A on the tooth of the timing belt drive pulley with the pointer B on the oil pump. Loosely install the idler pulley with a new idler pulley bolt so the pulley can move but does not come off.
Install the timing belt in a counterclockwise sequence starting with the drive pulley. Take care not to damage the timing belt when installing it. Tighten the idler pulley bolt.
Remove the battery clamp bolt from the back cover. Install the lower half of the side engine mount bracket. Install the timing belt guide plate as shown in Fig. Install the lower cover. Install the front upper cover A and rear upper cover B. Rotate the crankshaft pulley about five or six turns clockwise so the timing belt positions itself on the pulleys. Turn the crankshaft pulley so its white mark A lines up with the pointer B. Check the camshaft pulley marks. Unlimited access to personal support reps who are always available to assist you.
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