Valve Clearance: Adjustments
VALVE CLEARANCE ADJUSTMENT [L3]1. Remove the plug hole plate.
2. Remove the battery cover.
3. Disconnect the negative battery cable.
4. Disconnect the wiring harness.
5. Disconnect the oil control valve (OCV) connector.
6. Remove the dipstick.
7. Remove the Ignition coils.
8. Remove the spark plugs.
9. Remove the ventilation hose.
10. Remove the cylinder head cover.
11. Remove the front wheel and tire (RH).
12. Remove the engine under cover and splash shield (RH).
13. Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way.
14. Remove the engine front cover lower blind plug.
15. Remove the engine front cover upper blind plug.
16. Remove the cylinder block lower blind plug.
17. Install the SST.
18. Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at TDC of the compression stroke. (Until the counterweight contacts SST and stops.)
19. Release the tension on the timing chain shown in the figure.
(1) Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.
(2) Rotate the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the tension on the timing chain.
(3) Using a suitable bolt (M6 X 1.0 length 25mm-35mm (1.0-1.3 in)) at the engine front cover upper blind plug, secure the tensioner arm at the position where the tension is released.
20. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket installation bolt.
21. Remove the installation bolt and remove the exhaust camshaft sprocket.
22. Remove the OCV.
23. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the camshaft cap.
Note
^ The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.
24. Remove the camshafts.
25. Remove the tappet.
26. Install an appropriate tappet based on the results of the valve clearance inspection.
Selected tappet = Removed tappet thickness +
Measured valve clearance - Standard valve clearance
Valve clearance [Engine cold]
IN: 0.22-0.28 mm (0.009-0.011 in)
EX: 0.27-0.33 mm (0.011-0.012 in)
27. Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST.)
28. Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.
29. Install the camshaft with No.1 cylinder aligned with the TDC position.
30. Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.
31. Temporarily tighten the camshaft cap bolts evenly in 2-3 steps.
32. Tighten the camshaft cap bolts in the order shown in the following two steps.
Tightening procedure
1. 5.0-9.0 N-m (51-91 kgf-cm, 44.3-79.6 in-lbf)
2. 14-17 N-m (1.5-1.7 kgf-m, 10.4-12.5 ft-lbf)
33. Install the OCV.
34. Install a new washer.
Caution
^ Do not tighten the camshaft sprocket installation bolt at this stage. Verify the valve timing before performing the bolt tightening.
35. Install the exhaust camshaft sprocket.
36. Install the SST on the camshaft as shown in the figure.
37. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25 - 35mm (1.0-1.3 in)), and apply tension to the timing chain.
38. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket installation bolt.
Tightening torque
69-75 N-m (7.1-7.6 kgf-m, 50.9-55.3 ft-lbf)
39. Remove the SST from the camshaft.
40. Remove the SST installed in the cylinder block lower blind plug hole.
41. Rotate the crankshaft clockwise two turns and inspect the valve timing.
^ If not aligned, repeat the procedure.
42. Apply the silicone sealant and install the engine front cover upper blind plug.
Tightening torque
8.0-11.5 N-m (81.6-117.2 kgf-cm, 70.9-101.7 in-lbf)
43. Install the cylinder block lower blind plug.
Tightening torque
18-22 N-m (1.9-2.2 kgf-m, 13.3-16.2 ft-lbf)
44. Install a new engine front cover lower blind plug.
Tightening torque
10-14 N-m (102-142 kgf-cm, 88.6-123.9 in-lbf)
45. Connect the drive shaft (RH) to joint shaft.
46. Install the engine under cover and splash shield(RH).
47. Install the front wheel and tire (RH).
48. Install the cylinder head cover.
49. Install the ventilation hose.
50. Install the spark plugs.
51. Install the ignition coils.
52. Install the dipstick.
53. Connect the OCV connector.
54. Connect the wiring harness.
55. Connect the negative battery cable.
56. Install the battery cover.
57. Install the plug hole plate.