Removing
1. Remove the ground wire from the battery. Remove the head cover.
2. Set the piston of the first cylinder to top dead center on the compression stroke and fix the crankshaft.
3. To improve access to the fuel pump sprocket cover, do the following:
- remove the air filter cover and front exhaust pipe;
- remove the auxiliary drive belt;
- unscrew the nut securing the power unit support on the right side of the engine, raise the engine as far as possible so as not to deform the hoses and tubes.
4. Remove the upper and lower chain tensioners.
5. Unscrew the idler pulley auxiliary post, base plate bottom bolt and pivot bolt, and remove the idler from the engine.
6. Unscrew bolts and remove a cover of an asterisk of the fuel pump.
7. Install the locking pins in the fuel pump and camshaft sprockets.
8. Remove the bolts and remove the upper chain guide from the top of the cylinder head.
Warning! Before unscrewing the upper chain guide bolts, they must be heated to soften the composition that prevents the bolts from loosening.
9. Heat the upper chain guide bolts to make them easier to unscrew.
10. Remove the upper chain guide bolts.
11. Remove the top chain guide.
12. Using a wrench, secure the camshaft from turning and loosen the camshaft sprocket mounting bolt.
13. Check that the chain is correctly installed on the camshaft sprocket and, using soft wire, tie the chain to the sprocket. If lockout pins are used, remove them before loosening the sprocket mounting bolts and reinstall after loosening the bolt.
14. Remove the fuel pump lockout pins and loosen the bolts securing the fuel pump sprockets to the pump lug. Unscrew bolts and remove an asterisk of the fuel pump.
15. Remove the chain from the fuel pump sprocket, then remove the sprocket from the camshaft and remove it with the chain from the top of the cylinder head.
Lower chain and sprockets
16. Remove the top chain and sprockets.
17. Remove the chain cover.
18. Put alignment marks on the chain and sprockets.
19. Remove the fuel pump sprocket along with the chain.
20. Remove the sprocket from the crankshaft.
21.. Remove the segment key from the crankshaft.
Examination
1. Check the condition of the sprocket teeth for wear and damage. If the sprockets are defective, the sprockets and chain must be replaced.
2. Check the condition of the chain guides and tensioner blades for wear and damage.
Installation Warning! When installing the camshaft sprocket and new chain guide, new bolts must be used.
Upper chain and sprockets
1. If new parts are installed, transfer the alignment marks to them from the previously standing parts. Check that the crankshaft is fixed at the top dead center position of the piston of the first cylinder. Install the fuel pump sprocket with chain through the top of the cylinder head.
2. Install the fuel pump sprocket and put the chain on it.
3. Check that the previously made marks are aligned and install the fuel pump and camshaft sprocket. Remove the wire tying the chain to the camshaft sprocket.
4. Align the fuel pump sprocket alignment mark with the hole in the pump lug and finger-tighten the mounting bolts.
5. Install a new camshaft sprocket bolt and hand tighten.
6. Install the lower chain tensioner.
7. Install the upper chain guide and secure with bolts, tightening them to the required torque.
8. Install the pump, camshaft and crankshaft blocking pins. Adjust the timing gear if necessary
9. Install the upper chain tensioner.
10. Check that the mating surfaces of the fuel pump sprocket cover and chain cover are clean and dry. Install the cover using a thin gasket or a thin layer of sealant. Tighten the cover bolts to the required torque.
11. Install the drive belt tensioner.
12. Convert right power unit support to cylinder head.
13. Install the cylinder head cover.
14. Install the front exhaust pipe, air cleaner housing and crankshaft sensor.
Lower chain and sprockets
15. When installing new parts, transfer the alignment marks from previously removed parts to them.
16. Install the keyway into the crankshaft keyway and install the crankshaft sprocket, aligning the keyway on the sprocket with the keyway.
17. Check that the fuel pump sprocket is correctly aligned and that the engine crankshaft is locked at top dead center on the #1 piston.
18. Check the alignment of the marks, install the chain on the fuel pump sprocket and install the sprocket in place. Check that all marks made before removal are correctly aligned.
19. Install the chain cover and install the upper timing chain.
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