2T-G ENGINE TUNE-UP Page 2T-G ENGINE TUNE-UP ITEM. COOLING SYSTEM DRIVE BELT... AIR CLEANER BATTERY... SPARK PLUG... HIGH TENSION CORD DISTRIBUTOR . ENGINE OIL. DWELL ANGLE... IGNITION TIMING . NO.2 CHAIN TENSIONER... + 3-10 3-10 VALVE TIMING.......... 3-10 VALVE CLEARANCE .... 3-14 IGNITION TIMING ........ 8-21 DISTRIBUTOR .... 8-21 CARBURETOR... 8-22 COMPRESSION PRESSURE .......-::++.c00.-:s1- 8-2927-G ENGINE TUNE-UP — 71.6 Engine Tuneup Item vem ‘REMARK 1 COOLING sysTEN Coolant lve eck Ful ine vat cece coolant capacity (w/ester) | 87s 82USat 7.7 Imp. at 2) onIVE BELT ‘Tension Fan — Alternator New | 6-Bmm —@2-03in, us a= 12mm 03-051, AIC Compresior— Crankshaft | 11— 14mm — O4—Oin. AIR CLEANER Elomant cleaning 4) BATTERY Specie weaity 1251.27 20° (68°F) Eloctolyt evel 5) SPARK PLUG Visual eek Cleaning Pug 929 07 08mm 0028-0031 in. 6| HIGH TENSION CORD Resistance ‘Less than 25 ker cord 7) pisTmBuTOR Distributor cep Rubbing block asp 04=08mm C018 —0.020in, ‘Damping spring gap 04-04mm 0004-0016 in. 8) ENGINE OL it teat ehece Ful tine it replenishment PI eviews SE lasitication it capoity Dry refit —wlOitfiter | 45th 48 US et 40 Imp. at Drain & refit W/O ter | 3.8 liters 4.0 USet 33 Imp. at ‘wlo OW fiter | 22Khter 34 US qt 28 Imp.at Cualiy check Olt Fito replacement sssT(0s228-44010) 9] oweLLancLe ot Variation within 3° fain to 2,000 cpt [eoto conITioNI 10] IGMITION TimiNe 12° BTOC (Referee) 11] NO2CHAINTENSIONER Bockstroke 05—1.0mmat3—5 kg 002 ~0.08 in. 86 —11.01 v2) vatve Tins seTlovzsa.z701012T-G ENGINE TUNE-UP — 71-6 Engine Tuneup ten tate speed “Manifold vacuum {at ale speed) Front and eer diference (0a t 2000 rom) ate mixture sdjusting (60 Concentration (tlle speed) 119] compression PRessunE stD mie Ditforenes between each cylinder em REMARK ha | VALVECLEARANCE iw 0.282 0.05 mm (0.011 0.02 in) x 0.38 0.05 mm (0.013 0.002.) ‘WARM UP ENGINE [HoT conoITion 14 | IGMITION TIMING at Engine stop 12° BTDCI000 rom 18 | bistAIEUTOR Governor sdvaneee ‘Veewum advancer 16) CARBURETOR Flot evel 8110924027010} or [os280-270201 20-21mm 073-083 in. 17 | ACCELERATION PUMP Fue discharsing tne 11= 1.7 econ Fel injection dtcetion State wire 50° (at rotary dis) ‘Throttle valve fll open 18 IDLE SPEED IOLE MIXTURE ADJUSTMENT ssT[0s240-270101 oF {09240-27020} 1,000 + 60 rpm More than 385 mmM 15.2in.Ha) Below 10 mrtg (04 in Ma Serew out 1-1/2 turn 19-18% 116 kglom? 165 51 10.0 ksfom? — 142 Less than 1.0 eafem? (14 psd3427-6 ENGINE Fig. 341 TUNE-UP. System COOLING SYSTEM COOLANT LEVEL CHECK & REPLENISHMENT IF coolant is tow, fil reservoir tank up t0 Full lina COOLANT QUALITY CHECK ‘hare should not be any excesivedopost of rust or ecles round tha radiator cao or raatr filer hale, and the coolant should i be free fram cil, Repiae the coolant i excesivay ety INSPECTION OF COOLING SYSTEM PARTS There shuld be n9 defects such a ted below 1. Damape, deterioration, or loose clamps in 2. Leskage du to corrosion or damage in 3, Laakage due to Loose wate dein cock, 44, Caskage from water pumo, Faulty oparstion of radiate cop Inapost te raiator cap preure rotating fand vacuum salves for spring tension an blow the specified value ois ‘terse defective, replace the radiotor «ap ‘lve opaning ras: STD 09 kafem? (128 ps) Limit 06 gfe? (95 pat21-G ENGINE TUNE-UP-orive Bett, Air Coane 3-5. Fig. 25 DRIVE BELT | fj] visuat check Thats should be ap delete sucha ietd blo | 1. Cracked, deoriocated, stretched, oF worn bet, 2, Adherence of oil or areas, 3. Improsior contacting of belt agsinst the ty fa.97 TENSION CHECK & ADJUSTMENT ‘on tet preset dum with 1 ha (22 . 9 1) ere, th ba al dts the sped Ls ero . ry Drive belt tensior ‘sk carionar cw A New te rao (04 -0.6i0) Fig. 38 7 AIR CLEANER [ig] cement ceanine 1 In emotng the ai lata or slmnt, anc after removal, use care not co drop dit and fhust dow into the carburetor 2. In cleaning she slam, low ar from the insr sid, 3, In cio the elemant if tn or excessively sire replace with naw ane38. 27-6 ENGINE TUNE-UP~ ds Spark Pig Fig. 29 Fig, 840 ie Fig, 211 Fig. 212 BATTERY VISUAL CHECK very dirty, renew and chen before checking, ‘Thre soul be no defct sch a ted below 1. Rote battery mounting horcere, 2, Damage ar nakege in bay 3. Loose eonnection, rusting, deterioration or corresion of battery termina SPECIFIC GRAVITY MEASUREMENT Hold she hycrometer so thatthe Sloat ysl not contact agaiest the cylinder wall and read the advation Speciic avity: 1.28 — 1.27 at 20°C (es"F) ELECTROLYTE LEVEL CHECK & REPLENISHMENT “The electrolyte lev should be up 10 the upper leva, If low, 244 distilled water for purified wate. SPARK PLUG VISUAL CHECK Condition is good H none of the flowing Aolets ae preset: 1 Cracks ce damages in te threads or insu lacor 2. Wear on the electodes, 3. Damaged or dotrioratadgsrkos 4 Burnt condition of electrode and unde sirable carbon deposit,27-G ENGINE TUNE-UI Fig. 3.13 A Fig. 216 park Pua. Hi Tension Coré CLEANING 1. Do not use spark plug daar longer than sceey Blow oll cleaning compound an carbon ‘on the threads thorough wit i (Coon aff diet trom the outer surfoce of Inguletor and teed, 2 8 GAP ADJUSTMENT ‘hecho plug gop with pla gop ane. not to sacifiod value, adjust by bending the ground (outer ateovode Plug gap: 0.7 — 028 rum (0.028 —0.031 in. HIGH TENSION CORD = Nowe — ‘Wihen pulling out the spark plug cord trom the ‘plug, slays grip the end of plug cord. Check a eitencs of vexeiy oe, Resistance: Let than 25 KO per cord3:8 27-6 ENGINE TUNE-UP-Distibutor, Engine Oi Fig. 347 iy, Carrovion,Buring Fig. 3.19 DISTRIBUTOR CAP INSPECTION (lean the dstroutar cap and nspoct theca ant ratr for 1. Cracks, damage, dirty cod hole, corrosion, bring 2, Canter pece sping action 3, Burnt electode terminal POINT GAP ADJUSTMENT 1 he pois are excesivly burnt or pited, replace te bree points 2. ‘Adjust rubbing block gap and damping soving, Rubbing block sap: 04 — 05 mn (0.016 -0.0201m) ‘Damping soring or: 01 = 04 me (0.008 —0.018in) GOVERNOR OPERATIONAL INSPECTION 1. ator should turn quickly when turned Clockwise by and and ees 2. Rotor should not be excessively loom. ENGINE OIL, LEVEL CHECK & REPLENISHMENT Oil level should be up ta he F tne on the level (up flow, a oil up tothe Fine Use API sevice SE clsiiation erieFig. 3.28 27-G ENGINE TUNE-UI iy Ez nei, Dwell Ange 9-9 QUALITY CHECK aahering on the gecinted part. Toe oil should ‘ot be discolored o thi OIL FILTER REPLACEMENT 1. Rema the ol fier by using ssr[oa2244010] by hanes Alter starting the engine, check for ci ek DWELL ANGLE (chock if cet anal is witin the sect value Dull ange: 52° Veration! Within 3° {at iting to 2,000 cpm3410 __27-G ENGINE TUNE-UP-~ lgntion Timing, No.2 Chain Tensions, Valve Timing Fig. 325, (COLD CONDITION) =] IGNITION TIMING INSPECTION Set the gine revalution at lle spond, the {anion timing 12° BTDC (Reference) ctor must be stot standard position Fig, 326 NO.2 CHAIN TENSIONER Pree “JR cneex tHe eack sraoke ADJUSTMENT 7 the folowing pre plunge with 3 — 5 ka (8.9 — he plunge. ‘adjust out V3 — VALVE TIMING INSPECTION the Nact evinder to TOCKe i this pation, the tig ait oth27-G_ ENGINE TUNE-UP- valve Timing aun 3, Chock the postions of camshaft No.1 and No.2 with SST ssT[os24827010) [08am 4 Valve timing ermisble ear: (on the camshaft outer tang): 2 Camstatt rotation angle £05 mm Camsratt Mange outer per (o.02in) mec. Fig. 331 ADJUSTMENT [\. + Fee: onde Tticomesson ZX. % co ncamon mount3. Rotate the washar unt the pin sd is completly exposed, 4. Pullout the pin = Wote— ‘This wil be avin i tho comshott fe cumed slighty forward to provide sone psy. 5, When wave tiring is advanca 11 Align with the pin hole ia covate ockwise lection, (2) Tuen the cat so that the otis aligned with the oaust guage and Irsart te Bo, 8. When valu timing i oor, (1) Align the in hole in tho clockwise tlcestion, (2) Turn the cameatt so that the ait aligned with the sajvst-snuge and inset ae pin27-6 ENGINE TU Support the pin withthe waner end tempo: racly tighten the casa mounting bot Fetate tho cranishat inthe dockaise dao: tion url Net oylinder is at TOCHeom- reson, Fechock ho No.1 camshaft abe timing ‘The canst snd SST protrusion should Vio up. ssT10s24827010] Recheck the No.2 camshalt valve timieg ‘he camsnaft ait and SST protrusion souls ssT [09249-27010]17, Hold the combat with a wrench and tighten the camsah mourn VALVE CLEARANCE 4, AN seen 1. Sat the No.1 evindee to TOC/comorasion, 3 In this position, the timing check asin the camchatt ange are facingupwacd 2. Mescure and! Keap a rotor of the clearances ‘of ony the valas indicated by arrows inthe Figure indicated by arrays in the igure} ‘Vals clearance: IW 0.29 0,05 mm (0.011 0002in.) EX. 0:34.05 mm (0.013 0002n) A 3. Tun the crankshaft 360” forward ta Nad cylinder TOC/eompresson,2T-G ENGINE TUNE-UP-vaiveClenrance 3-18 4 1 check the remaining valve cranes ofthe reoining valves (indicated by arrows inthe figure. ADJUSTMENT Aust the clearance of any vave not within specification Remove the No: chain tnscne. Pace aligning marks between No.2 chain and teers and betwen the respective oars andl in Noles for corrctreesetly Femove parts as felove. (1) No.2 chain damper (2) Comsat timing gar3.16 __27-G ENGINE TUNE-UP- vaive Crarance 13) Camhatt Wo.1 voxirgeae. 14) Graduailylocsan No.2 to No.5 bearing cap usin 2 t0 3 ans (8) Comshat, Femovs wave liter when valve earance nol win specified val, Kap the valves and sejustig aad in ard, ig. 382 7, Selet 8 now pa that wall he thesoectiog ‘ae elorance a follows (1) Mossue the pad that wm off with &2T-G ENGINE TUNE-UP—vaveClesence 3-17 (2) Calculate thickness of new pad so valve elerance come within epecitiod val, Ta Tks of pe Usd ALL Vale elarance massured Invoke side New pad thine ST +A 029m) (ort in chase sie ‘Mow pad thicenase =T#1A 024 mm) (0013 i) (3 Selecta pad with a thickness a cose te pombe to the vake ealevlated, ads are avilable in 41 sia, in ieree ‘mente of 0.05 rom (0,002 tn), Home 1,00 mm (0.099 in.) to 3.00 mm (osn8ing, AX & rst shcarstt (1) Rotate the crankshaft sbout 90° the ravarse direction, = Caution — ‘Lower plston to provent interferes of piston thea and valve.Poston sit of carats upward as st in the figure Inet the Wo.2 to MoS camsnatt ‘bering caps. Face te arto mark tow font Gradally tighten tearing eap nuts io 3104 stam, “Then tighon No.) arin ao, “Tightaning torque: 1.2=1.8 kom (13 fe Aechock inate se vale larance, 11) Eshavet side vate lifter No.2 and Nod should praude the samo AAporox. 1.6 mm (0.06: Measure inake side valve clorance, 1 outside the spaced! vale, choose snather pa, ‘Valve earns IW 0292005 mm (0.0112 0.002 in EX 0240.05mm (0.132 0.002 in)27-@ ENGINE TUNE-UP-vaive lssranee Fig. 360 11. check exhaust side value cranes. (1) Intake sie waive liter No and No.4 should prowrude the same amour Approx. 1.6m (0.06 in) (2) Meoeur exhoutt id vv elarancs, IW utide the specie’ value, choose nothor pa ‘Valve elarancs IN 0.29008 mm {0.011 0,002 in) X 0:34 005mm (0.013 0.002 in.) 12, Insta tha No.2 esa aed carat ous, 1} Postion the No.7 and No.2 camshaft slit vertically upward wth SST ssricazas-270101 (2) Set the Not cylinder to TOCKcom- Fig. 3.63 (8) Align the chain and gee with mrting rade betove css (4) Align the canshate and gna pin hole {0 postion belors dsasenbly and insort pin, (51 Hold the pin withthe washer3-20___27-G_ENGINE TUNE-UP~ vate Clsrance Fig. 3.64 (6) Turn the crankantt slighty in armsal leezton, unt thae i 9a sacks the pins, gears, and earchats, and then tighten the bolts tospecitid torques “Tghtoning trque: 70-80 kom (6157 fet) 17) ane the No chin tensioner stroke: 05 — 1.0mm (0.02 ~0.04in.) 3-5k5 (65 ~ 11.016) 13, Recheck valve timing, 1) Rotate the crankattt ta turnsin the normal diction until No cylinder is TDCieampresion (2) Rachack value timing with SS. sT(924827010)27-G ENGINE TUNE-UP- Ignition Timing, Ditibutor 3-21 (HOT CONDITION) IGNITION TIMING INSPECTION Align te ting marks by turning the cstibutor boa, Tanition timing: 12" BTDC/1,000 rpm DISTRIBUTOR GOVERNOR ADVANCER OPERATION Start the engine ond lgconneet thevacuurn hose from the distributor. The timing marke shoulé vary in ascorance with the engine wm VACUUM ADVANCE OPERATION ‘ie unoing the engine at aout 1,800 rm fsconnact and conest the ocana selector hae and insure that te timing mars owes,$.22___27-6 ENGINE TUNE-UP — cumucetor CARBURETOR CARBURETOR ADJUSTMENT PROCEDURES, ‘Check the following tens beforehand ‘Ale Cleaner Spark Pi High Tension Cord Iopiion Ting Value Ting 1 Valve Clearance —[ crack and aast] — ‘Check are aust sarier ‘al njction direction. | r Hrecosry ie Fig. 371 FLOAT LEVEL x INSPECTION Start the engine and idle ‘About 1,000 rem assembled for : By] 2 aes SST i eae tm when thes jet holder wae reroved, $8T100240-27010} or 109240:27020] 4, Check the gaalne level iede the saoge see if iin the iit Fost level: 20 ~ 21 mm (0.79-083in)27-G ENGINE TUNE-UP —Cerburetor 3-29 ig, 2.78 ADJUSTMENT 1. Adjust by turning the Hoot level adlusting (One tue Flot lve change to 1.8 mm 1007 im) 2, Rochock the flat oval CCondlion waar she fuel pure is operating and applying fos presse Float evel: 20~ 21 mn (073-0383 in} ACCELERATION PUMP INSPECTION 1. Remove the cxbarstor 2. Chuck the fl in the oat chamber. Fig. 2.76 3. Check the fo! aecharaing time Discharging time: 1.1 ~1,7 weeondFig. 37 27-6 ENGINE TUNE-UP — cabun ce Tp] & et tatnndecon AL ‘al STARTER WIRE Insure that dhe carburetor die ae in he fll pen position when tha ster Knob is pulled completely out and fly eeees action when ‘returns IDLE SPEED & IDLE MIXTURE ADJUSTMENT INSPECTION 1, The saluting ead mesuring conditions should bo a Flows 0 2 a w 6 8) ” ‘Arcane installa ‘Nowra! operating coolant tomporature All acasoras aici off All vacuum ines connected Transmission in renge lgnician ding set Zora setting of CO moter warmed up [Mount the tachometer an the dust vacuum uae 0 the weuum take af eonnaction on ‘the No. ae Nodt imake manifolds.21-G ENGINE TUNE-UP — carburetor 3-25 Fig. 380 3. Cheek the ile soned and the ference wnat ore oecof 22] FF=HH]|[B]] * ce tone me narmentt cen ano tale sped 1,000 60 rpm ‘ano. vacuums Manifold vacau: om rs {atte speat) ‘More than 226 mma Tease J (152 in.H9) eae ee oi oT Front and rar vacuum stference VACUUM ae {ie t9 2.000 rpm) 2 |e rhs Below 10 mt (0. into) ADJUSTMENT 1. The adjusting andl messuring conditions shouldbe as Follows: (1) Air cleaner install (2) Normal operating coolant perature (G)_Allacossionea smichedott (2) Ailvacuum tines connected (6) Transmision in range (6) Ignition timing set (} Zero setting of CO meter warmed up Fig. 381 Mount the tachometer and the dul wecwun sugo to the vaewurn take affconaection on the No. and No. nrake moral, 3, Disconnect the connecting ox atthe bay,Loosen the rear idle som lusting screw Lani itis ra ram the lever Set to 1,809 ep by turing the Front ile speed austing sre, Engine spoed: 1,800 pm Check the engine speed aftr raising the naine spd Set to front and rear vacuum diference 10 atin 10 an (0. in.) By turning the synchronizing screw. ‘ron and ver vacuum difference: Below 10 mmty (04 int (Check the vacuum fren after rising the engine pees Loosen the trot lale seed adjusting sew and lower the engine sod to 850 ~ 1050, om Engine speed: 1,000 2 50 rpm Chock tho engine spead afr rising the engin seed.27-6 ENGINE TUNE-UP — Ceruretor Fig. 387 Sigtlyseow inthe rear ale peed acusting, ‘ert and ass tha engin sad then adit the engine pee 0.980 ~ 1080 rpm Engine speed: 1,000 "50 rpm Check the engine speed after raising the eine peed, Fendt front and rear vacuum eiference. rant and rear vcuum efferones: ‘Below 10 mmHg (0.4 ino Aalst the il iar asin sre with Sst. ST (00243-00010) ee 09288-00020) Screw out all of the idle mixture acting sere 1-1/2 tut fram fully coed postion. = Note Serew in goatly until Fully elosd, aking care not to damage the earburatr idle port ofthe serew ‘taped point. 11, Set to the maximum vacuum reading by {uring each ile mist ating ere ~ caution — Repant the adjustment 2 oF 3 ties to obtain maximum vacuum set tale spe: 4,000 rom Manifold vacuum: More than 386 men (15.2 intta) 12, Reads the following 2 or time 11) allo speed adusting screw lee speed: 1,000 80 rom 2 9 serav dle to. 2000, Front and rea vacuum “ference: Below 10 mmHp @ ton 10 mn 52inHa)3:28 __27-G ENGINE TUNE-UP ~ corburoor Fig. 291 Fig. 292 Fig. 99 1. Measure the CO concentration M1) Before measring, mace the gine at shout 2,000 rpm for 30 ~ 60 seco Aust the CO concentration (2) Measure te CO concentration asin (3) IF suit high, ile mixture edhuting = Note — Do not slow rem to be below dle speed, 18, Check som at aac evinge when if sites. Decrease in cpm approximately 70 ~90 ep All four eylindets should) show same decrease t with tha idle mixture adjusting27-G ENGINE TUNE-UP. 9 burtor, Compression Presure 16, Connect tha connactng ro. 17, Check to sea thatthe engine rewens to Tele spore) wien both sodomy and. slowly ‘ecelerated, Opening toute valve srokualy. should cause the anglne to speed u> enocthly In ‘elation to amount of te vale coin, COMPRESSION PRESSURE | 1, Warm up the engine. 2. amovoall srk plans. 3, Disconnect the high tension cod tom Iontion cc to eutt tho secandary circu 4, Insert a competion gouge into the spar ‘nthe throttle ale fully. and measure ‘We compression presure while ranking the engine with starter motor. {Compression presiure (t 200 rol: ‘STD. 11.8kg/om* (165 pi) Limit 10.0 afer? (142 pad Difference betweon sacheviner: ‘Less than 1.0 kaa (14 piMEMO