5-14 ENGINE TOP END

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below:

When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in "Camshaft Chain Tensioner Installation."

Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves.

•Remove:

Fuel Tank (see Fuel System (DFI) chapter)

Cap Bolt [A]

Washer [B]

Spring [C]

• Rod [D]

Remove the mounting bolts [E] and take off the camshaft chain tensioner.

Camshaft• Chain Tensioner Installation

Release the stopper [A] and push the push rod [B] into

•the tensioner body [C].

Install the tensioner body so that the stopper faces upward.

•Tighten the tensioner mounting bolts [A].

Torque - Camshaft Chain Tensioner Mounting Bolts: 11

• N·m (1.1 kgf·m, 95 in·lb)

•Install the rod, spring and washer. Tighten the cap bolt [B].

Torque - Camshaft Chain Tensioner Cap Bolt: 28 N·m (2.9

• kgf·m, 21 ft·lb)

Turn the crankshaft 2 turns clockwise to allow the tensioner to expand and recheck the camshaft chain timing.

ENGINE TOP END 5-15

Camshaft, Camshaft Chain

Camshaft• Removal

Remove:

Cylinder Head Cover (see Cylinder Head Cover Removal)

• Pickup Coil Cover

Position the crankshaft at #1, 4 piston TDC.

TDC mark [A] for #1, 4 Pistons

Timing Mark (crankcase halves mating surface) [B]

•Remove:Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Removal)

Camshaft Cap Bolts [A]

Chain Guide

Camshaft Caps [B]

• Camshafts [C]

Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase.

CAUTION

The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket.

Camshaft• Installation

Be sure to install the following parts.

Plug Hole Gaskets [A]

Dowel Pins [B]

•Apply engine oil to all cam parts and journals.

•If a new camshaft is to be used, apply a thin coat of molybdenum disulfide grease to the cam surfaces.

NOTE

○The exhaust camshaft has a 1182 EX mark [A] and the inlet camshaft has a 1182 IN mark [B]. Be careful not to mix up these shafts.