Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder heads and Valve mechanisms - Disassemble and Inspect .................. 5-3
1.1 Valve clearance - Inspect ......................................................................................................... 5-4
1.2 Rocker shaft assembly - Remove............................................................................................. 5-4
1.3 Cylinder head bolt - Remove .................................................................................................... 5-4
1.4 Cylinder head assembly - Remove........................................................................................... 5-5
1.5 Valve sinkage - Measure .......................................................................................................... 5-5
1.6 Valve and Valve spring - Remove ............................................................................................ 5-5
2. Rear equipment - Disassemble and Inspect ......................................................... 5-6
2.1 Flywheel face and radial runouts - Measure............................................................................. 5-7
2.2 Flywheel - Remove ................................................................................................................... 5-7
2.3 Rear plate - Remove................................................................................................................. 5-7
3. Front equipment - Disassemble and Inspect ........................................................ 5-8
3.1 Damper face and radial runouts - Measure .............................................................................. 5-9
3.2 Damper and Crankshaft pulley - Remove................................................................................. 5-9
3.3 Timing gear case - Remove...................................................................................................... 5-9
3.4 Timing gear backlash - Measure .............................................................................................. 5-9
3.5 Idler gear and camshaft end play - Measure .......................................................................... 5-10
3.6 Fuel injection pump - Remove ................................................................................................ 5-10
3.7 Oil pan - Remove.................................................................................................................... 5-10
3.8 Oil strainer - Remove.............................................................................................................. 5-10
3.9 Oil pump gear - Remove......................................................................................................... 5-11
3.10 Idler gear - Remove ................................................................................................................ 5-11
3.11 Camshaft - Remove................................................................................................................ 5-11
3.12 Camshaft gear - Replace........................................................................................................ 5-12
3.13 Front plate - Remove .............................................................................................................. 5-12
3.14 Oil pump - Remove................................................................................................................. 5-12
4. Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect 5-
13
4.1 Piston protrusion - Measure.................................................................................................... 5-14
4.2 Carbon deposits from the upper part of cylinder - Remove .................................................... 5-14
4.3 End play of connecting rod big end - Measure ....................................................................... 5-14
4.4 Connecting rod cap - Remove ................................................................................................ 5-14
4.5 Piston - Remove ..................................................................................................................... 5-15
4.6 Piston ring - Remove .............................................................................................................. 5-15
4.7 Piston pin and Piston - Remove ............................................................................................. 5-15
4.8 Crankshaft end play - Measure............................................................................................... 5-16
4.9 Main bearing cap - Remove.................................................................................................... 5-16
4.10 Crankshaft - Remove.............................................................................................................. 5-16
4.11 Tappet - Remove .................................................................................................................... 5-16

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

1. Cylinder heads and Valve mechanisms - Disassemble and Inspect

Chapter 5 DISASSEMBLY OF BASIC ENGINE

Understanding the current condition of the engine before disassembling is very important in order to investigate the faulty part
of the engine and to maintain the engine efficiently.
Depending on the maintenance purpose, inspect the following items before disassembling the engine.
Valve clearance - Inspect
Valve sinkage - Measure

1
Replace

10
9
4 8

3 Wear

Damaged threads, 5
wear on rod contact surface Wear on contact surface with
2 valve cap, clogged oil holes
7
Wear, clogged oil holes 12

6 11 Wear at both ends,

deflection
15
16
Crack, damage, carbon deposits,
Fatigue, damage 17 water scale adhesion
Replace 20
14
Wear 21
Replace
13

Uneven wear

Uneven wear on stems and faces,

damage, fatigue
19
18

Cylinder heads and Valve mechanisms - Disassemble and Inspect

Disassembling sequence
1 Rocker cover 8 Rocker arm 15 Valve cotter
2 Adjusting screw 9 Rocker shaft spring 16 Valve retainer
3 Rocker shaft bracket bolt (short) 10 Rocker shaft 17 Valve spring
4 Rocker shaft bracket bolt (long) 11 Valve cap 18 Inlet valve
5 Rocker shaft bracket 12 Push rod 19 Exhaust valve
6 Snap ring 13 Cylinder head bolt 20 Valve stem seal
7 Rocker arm 14 Cylinder head 21 Cylinder head gasket

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

1.1 Valve clearance - Inspect

Inspect the valve clearance, and recognize the current condi-
tion. 20 ± 2 N·m
For the inspection procedure, refer to “Valve clearance - Adjusting screw {2.0 ± 0.2 kgf·m}

[0.0098 in.]
[15 ± 1.4 lbf·ft]

0.25 mm
Lock nut
Inspect and Adjust” of “ASSEMBLY OF BASIC
ENGINE”.

Valve clearance - Inspect

1.2 Rocker shaft assembly - Remove

Adjusting screw
Always loosen shorter bolts first. Failing to do so
Rocker bracket bolt
may cause the damage to the rocker shaft bracket.
(1) Loosen the adjusting screw on each rocker arm.
(2) Remove the rocker shaft bracket bolt (short).
Rocker arm
(3) Remove the rocker shaft bracket bolt (long).
(4) Remove the rocker shaft assembly from the cylinder
head.
Note: Keep the removed rocker shaft assembly together with
the bolts. Rocker shaft assembly - Remove
(5) Remove push rods.
(6) Disassemble the rocker shaft assembly.
Rocker shaft spring
Note: Do not remove the rocker bushing unless it is defective
or its inside diameter exceeds the limit.

Rocker shaft
Rocker arm

Bracket

Snap ring
Rocker shaft assembly - Disassemble
1.3 Cylinder head bolt - Remove
Loosen cylinder head bolts in the numerical order as shown
in the illustration.

6 14 22 21 13 5
2 10 18 25 17 9 1
Front 4
3 7 11 15 19 23 24 20 16 12 8
Number of bolts: 25

Cylinder head bolt - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

1.4 Cylinder head assembly - Remove

Cylinder head
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase sur-
face with the screwdriver or other tool.
(1) Lift up the cylinder head assembly, and remove the cyl-
inder head assembly from the crankcase.
Note: If the cylinder head assembly cannot be removed due
to crimping of the cylinder head gasket, tap the thick
area on the side of the cylinder head using a plastic
hammer to give a shock. Cylinder head assembly - Remove
Do not lift up the cylinder head by yourself. Use a
crane or lift it up with two persons.
(2) Remove the cylinder head gasket.
Note: If there is a cylinder head problem, check the bolts for
tightness with a torque wrench before removing the
cylinder head bolts.

1.5 Valve sinkage - Measure

Measure the valve sinkage, and recognize the current condi-
tion.
Seat width
For the measurement procedure, refer to “Valve sinkage -
Measure” of “ASSEMBLY OF BASIC ENGINE”.

Valve seat
Valve margin
angle
Valve sinkage

Valve sinkage - Measure

1.6 Valve and Valve spring - Remove

Using a valve spring pusher, compress the valve spring
Valve spring pusher
evenly and remove the valve cotters. P/N:30691-04500
Note: If valves are reusable, mark each valve seat and the
mating valve guide for identifying their original posi-
tions. Do not mix valve seats with other valves.

Valve and Valve spring - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

2. Rear equipment - Disassemble and Inspect

Understanding the current condition of the engine before disassembling is very important in order to investigate the faulty part
of the engine and to maintain the engine efficiently.
Depending on the maintenance purpose, inspect the following item before disassembling the engine.
Flywheel face and radial runouts - Measure

4
2

1
3 Damaged threads
Replace

Crack, knock hole defect

Lip wear, damage, aging

Crack, knock hole defect,

gear damage

Rotational state

Rear equipment - Disassemble and Inspect

Disassembling sequence
1 Flywheel 2 Rear plate 3 Rear oil seal 4 Rear packing

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

2.1 Flywheel face and radial runouts - Measure

Measure the face and radial runouts of the flywheel, and
recognize the current condition.
For the measurement procedure, refer to “Flywheel face and
radial runouts - Measure” of “ASSEMBLY OF BASIC Face runout
ENGINE”. measuring point

Radial runout
measuring point

Flywheel face and radial runouts - Measure

2.2 Flywheel - Remove

(Front) (Rear)
(a) Be careful not to cut yourself with the ring gear
when pulling out the flywheel.
(b) Be careful not to drop or hit the flywheel. This
may not only cause damage to the flywheel but
also personal injury.
(c) The personnel who holds the pulley must pay Guide
due attention to safety. Also, personnel must Prevent flywheel from
bolt
stay in close contact with each other during rotating using wrench
work. Flywheel - Remove
(1) One personnel must firmly hold the pulley with a
wrench to prevent the flywheel from rotating.
(2) Remove one bolt from the flywheel.
(3) Screw a guide bolt into the threaded hole of the bolt that
has been removed.
(4) Remove remaining bolts from the flywheel.
(5) Hold the flywheel firmly with both hands, and by mov-
ing it back and forth, pull it out straight.
Note: The ring gear is shrink fitted to the flywheel. Do not re-
move the ring gear unless it is defective.

2.3 Rear plate - Remove

Oil seal
Be careful not to damage the oil seal.
Using a guide bolt, remove the rear plate from the crank-
case.

Rear plate - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

3. Front equipment - Disassemble and Inspect

Understanding the current condition of the engine before disassembling is very important in order to investigate the faulty part
of the engine and to maintain the engine efficiently.
Depending on the maintenance purpose, inspect the following items before disassembling the engine.
Damper face and radial runouts - Measure
Timing gear backlash - Measure
Idler gear and camshaft end play - Measure

Wear, damage
Flaking,
uneven contact, Replace 11
damage, Clogged of oil
key groove hole, wear
defect, 5
abnormal wear Wear, damage
13
bushings
12
Clogged
10 oil hole
Replace
Replace 7
Wear 15

9 14
Replace
4

Flaking, 8
uneven contact,
damage, Replace 6
key groove defect,
abnormal wear Lip wear, Replace
bushings damage, aging

Wear on belt groove

Crack, knock hole

defect
Damaged threads
1 3
Crack, knock hole
2
defect

Front equipment - Disassemble and Inspect

Disassembling sequence
1 Damper 6 Oil pan 11 Camshaft
2 Crankshaft pulley 7 Oil strainer 12 Camshaft gear
3 Cover 8 Oil pump gear 13 Thrust plate
4 Timing gear case 9 Thrust plate 14 Front plate
5 Fuel injection pump 10 Idler gear 15 Oil pump

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.1 Damper face and radial runouts - Measure

Measure the face and radial runouts of the damper, and rec-
ognize the current condition.
For the measurement procedure, refer to “Damper face and
radial runouts - Measure” of “ASSEMBLY OF BASIC
ENGINE”.

Face
runout

Radial
runout

Damper face and radial runouts - Measure

3.2 Damper and Crankshaft pulley - Remove

(Front) (Rear)
Prevent crankshaft
The bar that stops the crankshaft from rotating may from rotating
come off. Pay due attention to safety.
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Stick a bar across the guide bolts
to prevent the crankshaft from rotating.
(2) Remove the crankshaft pulley and the damper.
Guide bolt
(M12 × 1.25 mm)
Damper and Crankshaft pulley - Remove
3.3 Timing gear case - Remove

Cover
The front plate is bolted to the crankcase from inside
the gear case. Do not attempt to remove the front
plate together with the gear case by tapping.
(1) Remove the cover from the timing gear case.
(2) Remove the timing gear case from the front plate.
Note: Bolts have different lengths. Pay attention to the posi-
tions of bolts to ensure correct assembling. Packing
Timing gear case

Timing gear case - Remove

3.4 Timing gear backlash - Measure
Measure the timing gear backlash, and recognize the current
Dial gauge
condition.
For the measurement procedure, refer to “Timing gear back-
lash - Measure” of “ASSEMBLY OF BASIC ENGINE”.

Timing gear backlash - Measure

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.5 Idler gear and camshaft end play - Measure

Measure the idler gear and camshaft end play, and recognize
the current condition.
For the measurement procedure, refer to “Idler gear and
camshaft end play - Measure” of “ASSEMBLY OF BASIC
ENGINE”.

Idler gear and camshaft end play - Measure

3.6 Fuel injection pump - Remove
Remove the fuel injection pump from the front plate.
Fuel Injection pump

O-ring

Fuel injection pump - Remove

3.7 Oil pan - Remove

Oil pan
Do not insert a chisel or screwdriver between the oil
pan and crankcase to remove the oil pan, as it could
deform the oil pan flange.
(1) Invert the engine.
(2) To remove oil pan from the crankcase, tap bottom cor-
ners of the oil pan with a plastic hammer.

Bolt
Oil pan - Remove

3.8 Oil strainer - Remove

Remove the oil strainer from the crankcase.
Oil strainer

Oil strainer - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.9 Oil pump gear - Remove

Remove the oil pump gear from the oil pump.

Oil pump gear

Oil pump gear - Remove

3.10 Idler gear - Remove
Remove the idler gear from the crankcase.

Idler gear

Idler gear - Remove

3.11 Camshaft - Remove

Be careful not to damage the cams of camshaft and

the bushings.
(1) Remove the thrust plate bolt. Camshaft gear
(2) Remove the camshaft from the crankcase.

Camshaft - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

3.12 Camshaft gear - Replace

3.12.1 Camshaft gear - Remove
Remove with press

Do not remove the camshaft gear from the camshaft

unless the camshaft gear or the thrust plate is defec- Camshaft gear
tive.

Using a press, remove the camshaft gear and thrust plate

Camshaft Thrust plate
from the camshaft.

Camshaft gear - Remove

3.12.2 Camshaft gear and Thrust plate - Install
Press fit with press
(1) Install the woodruff key and the thrust plate on the cam-
shaft.
Note: Be sure to install the thrust plate before installing the
camshaft gear. Camshaft gear
(2) Heat the camshaft gear with a gear heater to a tempera- Thrust plate
ture of about 150°C [302°F].
(3) Press fit the camshaft gear with press. Camshaft

Camshaft gear and Thrust plate - Install

3.13 Front plate - Remove

Remove the front plate from the crankcase.
Packing
Note: If it is difficult to remove the front plate, lightly tap it
with a plastic hammer.
Front plate

Front plate - Remove

3.14 Oil pump - Remove
Remove the oil pump from the crankcase.

Oil pump

O-ring

Oil pump - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

4. Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect

Understanding current condition of the engine before disassembling is very important to investigate the faulty part of engine
and to maintain the engine efficiently.
Depending on the maintenance purpose, inspect the following item before disassembling the engine.
Piston protrusion - Measure
End play of connecting rod big end - Measure
Cylinder inside diameter - Measure

Wear, damage
4
5
6 Scratches on outside surface, cracks,
Fatigue damage, wear, carbon deposits

Wear 19
9
7 8
Cracks,
Wear, clogged Wear
clogged oil holes oil holes

10
Damaged threads 14
3
Serration for cracks, wear

Scratches on inside and 2

outside surfaces, adhesion, 18
17
flaking, wear 1
16
Adhesion of water scale, corrosion, flaking
15
Scratches, cracks, dent, 14
clogged oil holes, wear
Flaking, uneven contact

14
12
13
Scratches on inside
Note: When replacing the crankcase, and outside surfaces,
remove the parts installed in adhesion, flaking 11
the crankcase (relief valve,etc.)
carefully for reuse. Cracks Damaged threads

Piston, Connecting rod, Crankshaft and Crankcase - Disassemble and Inspect

Disassembling sequence
1 Nut 8 Piston pin 15 Lower main bearing
2 Connecting rod cap 9 Piston 16 Crankshaft
3 Connecting rod bearing 10 Connecting rod 17 Upper main bearing
4 No. 1 compression ring 11 Main bearing cap bolt 18 Tappet
5 No. 2 compression ring 12 Main bearing cap 19 Crankcase
6 Oil ring 13 Side seal
7 Snap ring 14 Thrust plate

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

4.1 Piston protrusion - Measure

Measure the piston protrusion, and recognize the current
condition.
For the measurement procedure, refer to “Piston protrusion
- Measure” of “ASSEMBLY OF BASIC ENGINE”.

Piston protrusion - Measure

4.2 Carbon deposits from the upper part of cylinder - Remove

Be sure to remove hard carbon deposits from the

upper part of the cylinder before removing the piston.
They could cause damage to the piston and piston
ring.
(1) Lay the engine on its side.
(2) Remove hard carbon deposits from the upper part of
cylinder using a carbon remover.
Hard carbon
Note: Be careful not to damage the inner surface of the cyl-
inder. Carbon deposits from the upper part of cylinder -
Remove

4.3 End play of connecting rod big end - Measure

Measure the end play of connecting rod big end, and recog-
nize the current condition.
For the measurement procedure, refer to “End play of con-
necting rod big end - Measure” of “ASSEMBLY OF BASIC
ENGINE”.

Thickness gauge

End play of connecting rod big end - Measure

4.4 Connecting rod cap - Remove
(1) Mark the cylinder number on the connecting rod and
connecting rod cap so that their combination is not
changed when assembling.
(2) Remove the connecting rod caps.
Note: Mark the cylinder No. and upper/lower on connecting
rod bearings to ensure correct assembling.

Connecting rod cap - Remove

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 Chapter 5 DISASSEMBLY OF BASIC ENGINE

4.5 Piston - Remove

(1) Rotate the crankshaft to bring the piston to top dead
center.
(2) Using a piece of wood such a hammer handle, push the
mating surface of the connecting rod cap, and pull the
piston and connecting rod upward from the cylinder.

Piston - Remove
4.6 Piston ring - Remove
Remove the piston rings using piston ring pliers.
Piston ring pliers
P/N:31391-12900

Piston ring - Remove

4.7 Piston pin and Piston - Remove
(1) Remove the snap ring with snap ring pliers.
(2) Using a wooden block and mallet, remove the piston
pin, and separate the piston from the connecting rod.
Snap ring pliers
Note:(a) Do not tap the piston pin directly with a mallet.
(b) If the piston is stubborn, heat the piston with a heat-
er or in hot water.

Piston pin and Piston - Remove

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Chapter 5 DISASSEMBLY OF BASIC ENGINE

4.8 Crankshaft end play - Measure

Measure the crankshaft end play, and recognize the current
condition.
For the measurement procedure, refer to “Crankshaft end
play - Measure” of “ASSEMBLY OF BASIC ENGINE”.

Crankshaft end play - Measure

4.9 Main bearing cap - Remove

When removing the main bearing cap from the crank-

case, be careful not to damage the lower main bear-
ing or the lower thrust plate that are attached to the
cap. Also be careful not to drop those parts, which
may damage the crankshaft.
(1) Remove the main bearing cap bolt.
(2) Remove the main bearing cap.
(3) Remove the lower thrust plate from the rearmost main
bearing cap. Main bearing cap - Remove

4.10 Crankshaft - Remove

When placing the crankshaft onto a pallet or other

stands, be careful not to damage the crankshaft.
Once placed on a pallet, the crankshaft should be
locked in place to prevent it from rotating.
(1) Keeping the crankshaft in a horizontal position, slowly
raise the crankshaft.
Note: Do not attach a metal chain or other hoisting devices
directly onto the crankshaft, as they could damage the
crankshaft. Place cloth belts or pads in position where Crankshaft - Remove
a chain or other hoists are hooked before raising crank-
shaft.
(2) Remove the upper main bearing from the crankcase,
paying attention to the lug position, and remove the
upper thrust plate on the rear side.

4.11 Tappet - Remove

Remove the tappets using a magnet.
Note: Be sure to arrange the removed tappets for assembling
to the same tappet hole.

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