35
l
Put timing chain through tunnel on cylinder head and
hold on holder camshaft on cam shaft.
l
Fix cylinder head with the help of special copper
plated washers and dome cap nut. Apply torque of
2.0 to 2.2 Kg.m. to dome cap nuts.
l
Assemble two flanged bolts on cylinder head joining
cylinder head and cylinder block with crankcase.
l
Assemble chain on timing sprocket and fix it with the
help of two bolts.
Keep piston at TDC position with the help of rotor and
marking provided on crankcase magneto side. Check
that the marking on timing chain sprocket matches
with marking provided on cylinder head.
Assembly of cylinder head
l
Position chain tensioner assembly into the bore
provided on cylinder block and fix it with the help of
2 flanged bolts.
l
Release the tensioner bolt by 1 thread and tighten it
again.
l
Align rotor marking with crankcase marking. Check
that marking on timing chain sprocket matches with
marking on cylinder head. Also check that both the
valves are in closed position by checking freeness of
tappets.
Set tappet clearance on intake valve with the help of
feeler gauge and tappet tightening tool. Lock the
tappet locking nut after setting tappet clearance to
0.8 to 1.2 mm.
Repeat the same procedure for exhaust valve keeping
tappet clearance 0.8 to 1.2 mm.
l
Rotate rotor anticlockwise 3-4 times and check again
the tappet clearance by feeler gauge after aligning
markings as stated above.
l
Fix 'O' ring on manifold and assemble it on crankcase
alongwith insulator. Fix 3 flanged bolts.
l
Assemble 'O' ring on camshaft cover and fix it on
cylinder head. Align the holes of cover with cylinder
head and fix two flanged bolts.
l
Assemble 'O' ring on cap for intake and exhaust
valves. Fix the caps on respective position on
cylinder head and tighten it to the torque of 0.5 to 0.9
kg.m.
l
Prefix spark plug by hand and tighten it to the torque
2.5 to 3 kg.m.
l
Assemble fan cover and cowling into the slots of
each other. Fix the fan cover and cowling screws.
l
Assemble H.T. Coil alongwith its bracket on crankcase
magneto side with the help of two screws.
Summary of Contents for Legend 00300728
Page 1: ...Service Station Manual Service Station Manual USA MODEL NO 00300728...
Page 26: ...22...
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