REMOVAL AND INSTALLATION







Removal steps
<<A>>
>>F<<
1.
Balancer shaft RH gear


2.
Thrust spacer


3.
Oil pump assembly


4.
O-ring


5.
O-ring


6.
O-ring


7.
Plug


8.
Relief spring


9.
Steel ball


10.
Oil pump cover


11.
Driven gear assembly


12.
Oil pump body and gear assembly


13.
Woodruff key


14.
Counter balance right shaft

>>E<<
15.
Idler LH gear assembly


16.
Idler A shaft
<<B>>
>>D<<
17.
Balancer shaft LH gear


18.
Thrust spacer


19.
Thrust LH plate assembly


20.
O-ring


21.
Woodruff key


22.
Counter balance left shaft

>>C<<
23.
Idler gear assembly


24.
Idler gear
<<C>>
>>B<<
25.
Idler gear bushing


26.
Idler shaft assembly
<<D>>
>>A<<
27.
Camshaft bolt
<<D>>
>>A<<
28.
Camshaft sprocket (Inlet side)
<<D>>
>>A<<
29.
Camshaft sprocket (Exhaust side)

REMOVAL SERVICE POINTS



PRE-REMOVAL INSPECTION


BACKLASH OF EACH GEAR
Measure backlash between gears, pair by pair, at three or more point. If the reading exceeds the specified standard value, replace defective part.
Standard value:
    Balance shaft gear RH and oil pump gear
    0.040 - 0.192 mm
    Oil pump gear and crankshaft gear
    0.098 - 0.158 mm
    Crankshaft gear and idler gear
    0.082 - 0.142 mm
    Idler gear LH and idler gear
    0.040 - 0.196 mm
    Idler gear LH and balance shaft gear LH
    0.040 - 0.222 mm
    Idler gear and idler B gear
    0.096 - 0.156 mm
AXIAL PLAY
If the reading exceeds the specified standard value, replace defective part.
Standard value:
    Balance shaft LH, RH
    0.09 - 0.24 mm
    Idler gear and sprocket assembly
    0.05 - 0.20 mm
    Idler gear LH assembly
    0.05 - 0.20 mm
Limit:
    Balance shaft LH, RH
    0.3 mm
    Idler gear and sprocket assembly
    0.3 mm
    Idler gear LH assembly
    0.3 mm

<<A>> BALANCER SHAFT RH GEAR REMOVAL


1.Using the bar, hold the balancer shaft drive gear RH.
2.Remove the balancer shaft drive gear RH bolt.

<<B>> BALANCER SHAFT LH GEAR REMOVAL


1.Using the bar, hold the balancer shaft drive gear LH.
2.Remove the balancer shaft drive gear LH bolt.

<<C>> IDLER GEAR BUSHING REMOVAL



Using the special tool Idler sprocket bush puller (MH062462), remove the idler gear bush.

<<D>> CAMSHAFT BOLT / CAMSHAFT SPROCKET REMOVAL



caution
  • When removing the bolt be sure to lock the camshaft by holding the hexagonal part A with a proper wrench. Do not use the timing chain b for the locking.
  • The bolt is inversely threaded. The arrow mark on its head B indicates its turning direction when tightened. To remove, turn the bolt in the reverse direction.
  • The camshaft sprocket a and timing chain b must be meshed in a fixed position. Do not remove the timing chain from the camshaft sprockets unless absolutely necessary.

INSTALLATION SERVICE POINTS



>>A<< CAMSHAFT SPROCKET / CAMSHAFT BOLT INSTALLATION



caution The bolt is inversely threaded. The arrow mark on its head B indicates its tuning direction when tightened.

>>B<< IDLER GEAR BUSHING INSTALLATION



Using the special tool Idler sprocket bush puller (MH062462), press-fit the idler gear bushing into the idler gear from the side showing the match marks "0."

>>C<< IDLER GEAR ASSEMBLY INSTALLATION



Install the idler gear and sprocket assembly onto the idler shaft while aligning the mark "1" with that on the crankshaft gear.

>>D<< BALANCER SHAFT LH GEAR INSTALLATION



1.Assemble the parts shown in the illustration to the balance shaft LH.
Be sure that the washer and thrust spacer face in correct direction as shown. Install the balance shaft LH with the side showing the match mark "0" outward.

2.Insert the completed balance shaft LH assembly into the crankcase assembly and set it in position with the dowel pin on the crankcase assembly.
caution
  • Do not rotate the balance shaft LH assembly during insertion into the crankcase assembly.
    This may cause the O-ring to be slipped out of place.
  • Insert the balance shaft LH assembly using care not to damage the inner surface of the rear bearing in the crankcase.

>>E<< IDLER LH GEAR ASSEMBLY INSTALLATION



Install the idler gear LH assembly onto the idler shaft. At this time, be sure to align the match marks "3" and "0" on the idler gear with the corresponding match marks on the idler gear and sprocket assembly and the balance shaft gear LH.

>>F<< BALANCER SHAFT RH GEAR INSTALLATION



1.Assemble the parts shown in the illustration to the balance shaft RH.
Be sure to install the washer and thrust spacer in the direction shown in the illustration, and install the balance shaft gear RH with its mating mark "0" aligned with the mating mark "6" on the oil pump gear.
2.Insert the completed balance shaft RH assembly into the crankcase assembly while aligning the mating marks "5" on the oil pump gear and the crankshaft gear, and set the shaft assembly in position with the dowel pin on the crankcase assembly.
caution Insert the balance shaft RH assembly using care not to damage the inner surface of the rear bearing in the crankcase.
3.After the timing gear are installed in position, check that all the rotary parts smoothly rotate.