Service manual

ENGINE
TENSIONER BLADE INSTALLATION
1. Install the tensioner blade and tighten the mounting
bolt to specified torque.
Tensioner Blade Mounting Bolt Torque:
10 Nm (7.4 ft. lbs.)
3. Install the cam chain guide and dowel pins into the
cylinder. Verify the bottom end is seated properly in the
crankcase.
4. Pull the cam chain through the cylinder chain room
and secure with mechanic’s wire.
5. Position crankshaft at Top Dead Center (TDC) on
compression stroke.
CYLINDER INSTALLATION
NOTE: Clean the gasket surfaces on the crankcase
and cylinder. Remove all traces of old gasket material
and apply a new base gasket
1. Install the dowel pin(s). Install an new base gasket
onto the mating surface and install the piston into
cylinder.
NOTE: Route cam chain through the cylinder chain
room and secure it, holding it up while rotating the
engine to avoid damage to the chain, drive sprocket
teeth or tensioner blade.
2. Apply clean engine oil liberally to the bore and
tapered area of the cylinder. Place the cylinder on to the
studs.
CYLINDER HEAD AND CAMSHAFT
INSTALLATION
NOTE: Clean the gasket surfaces on the cylinder head
and cylinder. Remove all traces of old gasket material.
1. Install the dowel pin(s) and a new cylinder head
gasket.
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