COOLING SYSTEM

Remove the fuel tank (page 3-8).

COOLING SYSTEM

Remove the radiator grill (page 7-8).

Check the radiator air passages for clogging or dam­age.

Straighten bent fins, and remove insects, mud or other obstructions with compressed air or low water pressure.

COOLING SYSTEM

RADIATOR HOSES

Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.

Inspect the radiator hoses for cracks or deteriora­tion, and replace them if necessary.

Check the tightness of all water hose clamps (page 1-17).

SECONDARY AIR SUPPLY SYSTEM (’05 and ’06 California type. After ’06)

PAIR CONTROL VALVE

PAIR AIR SUCTION HOSE

* §■

SUPPLY HOSE

A R

COOLING SYSTEM

Remove the right radiator shroud (page 3-4).

Check the air supply and PAIR air suction hoses for damage or loose connector.

Check the vacuum hose between the cylinder head vacuum joint and PAIR control valve for deteriora­tion, damage or loose connection.

Also check that the hose is not kinked or pinched.

VALVE CLEARANCE/DECOMPRESSOR SYSTEM

COOLING SYSTEM

CRANKSHAFT HOLE CAP/O-RING

VALVE CLEARANCE INSPECTION

Inspect and ad/ust the valve clearance while the engine is cold (below 35°С/ 95°Fl

Remove the cylinder head cover (page 9-7). Remove the crankshaft hole cap and O-ring.

PUNCH MARK

INDEX MARK

COOLING SYSTEM

Turn the crankshaft clockwise to align the punch mark with the index mark on the right crankcase cover.

Make sure the piston is at TDC (Top Dead Center) on the compression stroke.

This position can be obtained by confirming that there is slack in the rocker arms. If there is no slack, rotate the crankshaft clockwise one full turn and align the punch mark on the primary drive gear with the index mark on the right crankcase cover again.

Check that the index line on the cam sprocket aligns with the "Д" mark on the camshaft holder.

After ’07:

COOLING SYSTEM

4,_

COOLING SYSTEM

05 — ’07 shown

FEELER GAUGE

Intake side:

Insert a feeler gauge between the valve lifter and cam lobe.

Record the clearance for each valve for reference in shim selection if adjustment is required

Check the valve clearance for the intake valves using a feeler gauge.

VALVE CLEARANCE:

IN: 0.16 ±0.03 mm (0 006-0.001 in)

Exhaust side:

COOLING SYSTEM

FEELER GAUGE

Insert a feeler gauge between the rocker arm and shim.

Record the clearance for each valve for reference in shim selection if adjustment is required.

Check the valve clearance for the exhaust valves using a feeler gauge.

VALVE CLEARANCE.

EX: 0.28 ± 0.03 mm (0.011 ± 0.001 in)

COOLING SYSTEM

COOLING SYSTEM

VALVE CLEARANCE ADJUSTMENT

Remove the camshaft holder assembly.

— ’05 — ’07: (page 9-8)

— After ’07: (page 9-16)

• The shims may stick to the inside of the valve

lifter. Do not allow the shims to fall into the

crankcase.

Remove the shims.

• Mark all valve lifters and shims to ensure correct reassembly in their original locations.

• The shims can be easily removed with tweezers or a magnet.

Clean the valve shim contact area in the valve lifter with compressed air.

VALVE LIFTER

COOLING SYSTEM

COOLING SYSTEMMeasure the shim thickness and record it.

Seventy-three different thickness shims are available from 1.200 mm to 3.000 mm in increments of 0.025 mm.

Calculate the new shim thickness using the equa­tion below.

COOLING SYSTEM

A = (В -C) + D

A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness

• Make sure of the correct shim thickness by mea­suring the shim using a micrometer.

• Reface the intake valve seat if carbon deposits result in a calculated dimension of over 2.450 mm.

COOLING SYSTEM

• Reface the exhaust valve seat if carbon deposits result in a calculated dimension mm.

Install the shims in their original locations.

Install the newly selected shims on the valve spring retainers.

Install the camshaft holder assembly.

— ’05-’07: (page 9-37)

— After ’07: (page 9-39)

Rotate the camshaft by rotating the crankshaft clockwise several times.

Recheck the valve clearance.

SHIMS

COOLING SYSTEM

Check that the O — ring is in good condition, replace it if necessary

Apply oil to the O-ring and install it onto crankshaft hole cap.

Apply grease to the crankshaft hole cap threads. Install and tighten the crankshaft hole cap to the specified torque.

TORQUE: 15 N m (1.5 kgf-m, 11 lbf-ft)

Install the cylinder head cover (page 9-42).

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