CYLINDER HEAD INSTALLATION

Install the dowel pins and a new gasket.

Install the cylinder head onto the cylinder.

Apply oil to the cylinder head nut threads and seat­ing surface.

Be careful nol to let the nuts and washers fall into the left crankcase.

Install the washers and cylinder head nuts.

Tighten the nuts to the specified torque in a criss­cross pattern in two or three steps.

TORQUE: 66 Nm (6.7 kgf m, 49 Ibf ft)

CYL NDER HEAD MOUNTING BOLTS

Install the cylinder head mounting bolts.

Tighten the cylinder mounting bolt and cylinder head mounting bolts securely.

CYLINDER MOUNTING BOLT £

CYLINDER HEAD INSTALLATION

RADIATOR HOSE

BAND SCREW

Connect the radiator hose to the water hose joint. Tighten the hose band screw securely.

HANGER PLATES BOLTS

HANGER PLATES.

CLAMP

Install the upper engine hanger plates, bolts, fuel hose clamp, clutch cable guide and nut.

Tighten the engine hanger plate bolts to the speci­fied torque.

TORQUE: 26 N m (2.7 kgf m, 19 Ibf-ft)

Tighten the upper engine mounting nut to the spec­ified torque.

TORQUE: 54 N m (5.5 kgf m, 40 Ibf ft)

CYLINDER HEAD INSTALLATION

CABLE GUIDE

UPPER MOUNTING BOLT/NUT

CYLINDER HEAD INSTALLATION

SHIMS

CAMSHAFT INSTALLATION (’05 — ’07)

Apply molybdenum oil solution to the outer surface of each valve lifter.

Install the valve Install the valve lifters into the camshaft holder.

lifters m their (yig^g sure the dowel pins are installed into the cam-

onginal location. shaft holder_

Install the shims.

Install the following:

— Spark plug (page 4-13)

— Camshaft holder assembly (’05 — ’07: page 9-8, After ’07: page 9-16)

— Carburetor (page 6-24)

— Exhaust pipe (page 3-14)

— Ignition coil (page 18-8)

Install the PAIR control valve (page 6-30).

Fill the cooling system with recommended coolant mixture (page 7-7).

Apply molybdenum oil solution to the cam lobes and camshaft bearings.

Install the camshaft holder assembly with the intake cam lobes facing up.

Apply oil to the camshaft holder mounting bolt threads.

Install the camshaft holder mounting bolts.

Tighten the bolts in a crisscross pattern in two or three steps to the specified torque.

TORQUE: 14 N m (1.4 kgf-m, 10 Ibf-ft)

Be careful not to let the shims fall into the left crankcase. Install the shims in their original location.

‘05 and ‘06 California type, After ’06:

VALVE LIFTERS

CYLINDER HEAD INSTALLATION

і

DOWEL PINS

CYLINDER HEAD INSTALLATION

BOLTS

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

Be careful not to tarn the cam chain against the crankcase.

CYLINDER HEAD INSTALLATION

Install the cam chain onto the cam sprocket.

Install the cam sprocket while aligning the index line on the cam sprocket with the "Д" mark on the cam holder.

Clean and apply locking agent to the cam sprocket bolt threads.

Align the cam sprocket bolt holes with the cam sprocket and camshaft.

Temporarily install the one cam sprocket bolt.

Turn the crankshaft clockwise 360° and insert the special tool into the sprocket over the gasket sur­face.

TOOL:

Cam sprocket holder 07AMB-MEBA100 (U. S.A. only)

Tighten the other sprocket bolt to the specified torque.

TORQUE: 20 N m (2.0 kgf m, 15 Ibf ft)

Remove the special tool, turn the crankshaft clock­wise one turn and reinsert the special tool into the sprocket

Tighten the another cam sprocket bolt to the speci­fied torque.

TORQUE: 20 N m (2.0 kgf m, 15 lbf-ft)

Remove the stopper tool from the cam chain tensioner lifter.

CYLINDER HEAD INSTALLATION

Install the bolt with a new sealing washer.

If decompressor cam assembly was disassembled, xye

tighten it to the specified torque while holding the crankshaft.

TORQUE: 24 Nm (2.4 kgf-m, 18 lbf-ft)

Tighten the cam chain tensioner lifter bolt securely.

Check the O-ring is in good condition, replace it if necessary.

Apply oil to the O-ring.

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