Valve Clearance: Adjustments

VALVE CLEARANCE ADJUSTMENT [LF, L3]

1. Remove the plug hole plate. Service and Repair

2. Remove the battery cover. Removal and Replacement

3. Disconnect the negative battery cable.

4. Disconnect the wiring harness.

5. Disconnect the OCV connector.

6. Remove the front wheel and tire (RH). Service and Repair

7. Remove the engine under cover and splash shield (RH).

8. Remove the ignition coils. Service and Repair

9. Remove the ventilation hose.

10. Remove the cylinder head cover.

11. Remove the engine front cover lower blind plug.






12. Remove the engine front cover blind plug.






13. Remove the cylinder block lower blind plug, and install the SST.






14. 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.)

15. Loosen the timing chain using the following procedure.
a. Insert a suitable bolt (M6 X 1.0, length 25-35 mm {0.99-1.3 in}) into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)






b. Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.






c. Using a Hex bit socket (2.5 mm {0.098 in}) or T15 Torx bit socket, unlock the chain tensioner ratchet so that it can be lifted up.






d. Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.






NOTE:
- The chain tensioner rack is compressed using the chain tension generated by applying force to the exhaust camshaft in the direction of the engine rotation.






NOTE:
- The ratchet has not been unlocked if the bolt cannot be pressed in approx. 5 mm {0.2 in}.

e. Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.






- If the tensioner arm cannot be secured, return the bolt to its original position and repeat the procedure from Step 3.

16. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket bolt.






CAUTION:
- Perform the work carefully so that the washer does not drop out.

17. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.






18. Remove the oil control valve (OCV). Service and Repair

NOTE:
- The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.

19. Loosen the camshaft cap bolts in two or three passes in the order shown in the figure and remove the camshaft cap.






20. Remove the camshafts for the intake and exhaust sides.

21. Remove the tappet.

22. Install an appropriate tappet based on the results of the valve clearance inspection.

- Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance

Standard [Engine cold]
- IN: 0.22-0.28 mm {0.0087-0.0110 in}
- EX: 0.27-0.33 mm {0.0107-0.0129 in}

23. Verify that the No.1 cylinder is at TDC of the compression stroke. (The position counter weight contacts the SST.)

24. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in the figure.






25. Install the camshaft with No.1 cylinder aligned with the TDC position.

26. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure.






27. Tighten the camshaft cap bolts in the order shown with the following two steps.






Tightening torque
- 1st step: 5.0-8.0 Nm {51.0-81.5 kgf-cm, 44.3-70.8 in-lbf}
- 2nd step: 14-17 Nm {1.43-1.73 kgf-m, 10.4-12.5 ft-lbf}

28. Install the OCV. Service and Repair

CAUTION:
- Install a washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt being careful not to drop the washer.
- Do not tighten the camshaft sprocket bolt at this stage. Verify the valve timing before performing the bolt tightening.

29. Install the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.






30. Install the SST to the camshaft as shown in the figure.






31. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25-35mm {0.99-1.3 in}), and apply tension to the timing chain.

32. Rotate the crankshaft clockwise and verify that the No.1 cylinder is at TDC of the compression stroke. (The position counter weight contacts the SST.)

33. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket bolt.






Tightening torque
- 69-75 Nm {7.1-7.6 kgf-m, 50.9-55.3 ft-lbf}

34. Remove the SST from the camshaft.

35. Remove the SST from the block lower blind plug.

36. Rotate the crankshaft clockwise two turns until the TDC position.

- If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 30.

37. Apply the silicone sealant and install the engine front cover upper blind plug.






Tightening torque
- 8.0-11.5 Nm {82-117 kgf-cm, 71-101 in-lbf}

38. Install the cylinder block lower blind plug.






Tightening torque
- 18-22 Nm {1.9-2.2 kgf-m, 13.3-16.2 ft-lbf}

39. Install a new engine front cover lower blind plug.






Tightening torque
- 10-14 Nm {102-142 kgf-m, 89-123 in-lbf}

40. Install the cylinder head cover. Service and Repair

41. Install the ventilation hose.

42. Install the ignition coils. Service and Repair

43. Install the engine under cover and splash shield (RH).

44. Install the front wheel and tire (RH). Service and Repair

45. Connect the OCV connector.

46. Connect the wiring harness.

47. Connect the negative battery cable.

48. Install the battery cover. Removal and Replacement

49. Install the plug hole plate. Service and Repair