ENGINE TUNE-UP ENGINE OIL COOLING SYSTEM: DRIVE. BEL Tevsiessssseeees eteesetesseresssseessaneessnness AIR CLEANER ‘irttitriisseeeeeeeeteeneeeeee ee eeeeeeeneeeee BATTERY -cocccccecccc cee ccc eee ee eee centers cee tet e eee reer SPARK PLUG --------- HIGH TENSION CORD - DISTRIBUTOR ‘eetisstteisessessesseesseeessneeee WAL VE TIMING s:000scsisccsosrsstssaresencasieseovaivassens CHAIN TENSIONER * 00 00ers cre eseess tees eeeseeeees VALVE CLEARANCE -2-10 CARBURETOR “2-14 INITIAL IDLE SPEED (W/Al SYSTEM) -------- 2-12 INITIAL IDLE SPEED (W/O Al SYSTEM) ~~" 2-15 BEAST MDD Beietisenecsas veges ynasecn savy czspaoevesevssibcevesney 2-16 THROTTLE POSITIONER - -2-16 DASH POT COMPRESSION PRESSURE “2-17 -2-1T72-2 Fig. 22 Fig. 2-3 ENGINE TUNE-UP — Engine Oil, Cooling System ENGINE OIL LEVEL CHECK AND REPLENISH- MENT Oil level should be up to the F line on the level gauge. If low, add oil up to the F line, Use AAPI service SE classification engine oil. QUALITY CHECK Pull out the oil level gauge and examine the oil adhering on the graduated part. The oil should not be discolored or thin OIL FILTER REPLACEMENT [+>] 1, Remove the oil filter by using SST (00228.44010] 2. For installation, tighten firmly the oil filter by hand, Add engine oil. After starting the engine, check for oil leak and recheck the oil level 3. 4. COOLING SYSTEM COOLANT LEVEL CHECK AND REPLENISHMENT If coolant is tow, fill, resorvoir tank up to “Full” line,ENGINE TUNE-UP - Co ve Belt 2-3 Syster Fig. 25 Fig. 2-8 COOLANT QUALITY CHECK There should not be any excessive deposit of rust or scales around the radiator cap or radiator filler hole, and the coolant should also be free from oil, Replace the coolant if excessively dirty. INSPECTION OF COOLING SYSTEM PARTS There should be no defects such as listed below: 1, Damage, deterioration, or loose clamps in radiator hoses, water hoses. 2. Leakage due to corrosion or damage in radiator core. 3, Leakage due to loose water drain cock, 4. Leakage from water pump. 5. Faulty operation of radiator cap. Inspect the radiator cap pressure regulating and vacuum valves for spring tension and seating condition. If the valve opens at a pressure level below the specified value or is otherwise detective, replace'the radiator cap, Valve opening pressure limit 0.6 kg/cm? ( 8.5 psi) Standard 0.75 — 1.05 kg/em? (10.7 = 14.9 psi) DRIVE BELT VISUAL CHECK There should be no defects such as listed below: 1. Cracked, deteriorated, stretched, or worn belt. 2, Adherence of oil or grease,24 ENGINE TUNE-UP — Drive Belt, Air Cleaner 3, Improper contacting of belt agi pulley. TENSION CHECK AND ADJUSTMENT When the belt is pressed down with 10 kg (22 Ib) force, the belt should deflect the specified ‘Adjust Nut amount. A:18-21.5mm (0.71 -0.85in.) B: 8-12 mm (031-047 in) Fig. 2-11 AIR CLEANER ELEMENT CLEANING 1. In removing the air cleaner or element, and after removal, use care not to drop dirt and dust down into the carburetor, 2. In cleaning the element, blow air from the inner side, 3. In case the element is torn or excessively dirty, replace with new element. Fig. 2-12 INSPECTION OF HOT AIR INTAKE Check air control valve operation with engine idling Valve should close cold air intake when cold, hot air intake when warm,ENGINE TUNE-UP - Bat Spark Plug 2-5 Fig. 2-13: BATTERY VISUAL CHECK Hf very dirty, remove and clean before checking There should be no defects such as listed below. 1, Rusted battery mounting hardware. 2. Damage or leakage in battery, 3. Loose connection, rusting, deterioration, or corrosion of battery terminals, SPECIFIC GRAVITY MEASUREMENT Hold the hydrometer so that the float will not contact against the cylinder wall and read the graduation, Specific gravity 1.25 101.27 ELECTROLYTE LEVEL CHECK AND REPLENISHMENT The electrolyte level should be up to the upper level. If low, add distilled water (or purified water), Lower Level SPARK PLUG VISUAL CHECK Condition is good if none of the following defects are present 1, Cracks or damages in the threads or insulator. 2. Wear in the electrodes, 3. Damaged or deteriorated gaskets. 4, Burnt condition of electrode and undesirable carbon deposit.2-6 ENGINE TUNE-UP — Spark Plug, High Tension Cord Fig. 2-17 CLEANING pe 1. Do not use spark plug cleaner longer than necessary. 2. Blow off cleaning compound and carbon on the threads thoroughly with air. 3. Clean off the dirt from the outer surface of insulator and threads, Fig. 2-18 GAP ADJUSTMENT Check the plug gap with plug gap gauge. If not to specified value, adjust by bending the ground Standard Gap (outer) electrode, s Plug gap 0.7 — 0.8 mm (0.028 — 0.031 in.) Recommended spark plug Exc, ECE For ECE NO wigeP W20EPR NGK BPSES-L BPRGES Fig. 2-19 HIGH TENSION CORD = A ons When pulling out the spark plug cord form the A plug, always grip the end of plug cord. Good Fig 2-20 Check the resistance of resistivity cord, Resistance Less than 25 k® per cord.ENGINE TUNE-UP Fig. 2-21 Wear Burning Fig. 2.24 DISTRIBUTOR CAP INSPECTION Clean the distributor cap and inspect the cap and rotor for: 1, Cracks, damage, dirty cord hole, corrosion, burning, 2. Center piece spring action, 3. Burnt electrode terminal, POINT GAP ADJUSTMENT 1, If the points are excessively burnt or pitted, replace the breaker points. 2. Adjust point gap and dwell angle should be whthin 38° to 44° (41°) Point gap 0.4 t0 0.5 mm (0.016 to 0.020 in.) DWELL ANGLE MEASUREMENT Check if dwell angle is within the specified value when the engine is running at’ low and high speed, Dwell angle 38° to 44° = Caution = Do not connect dwell, tacho tester lead to distributor terminal, but to ignition coil terminal to prevent misfire. IGNITION TIMING INSPECTION Set the engine revolution at idle speed. The octane selector must -be set at standard position, Ignition 8° BTDC (Exe. ECE) 12° BTDG (For ECE)2-8 TUNE-UP — Distributor Fig. 2:25. Fig. 2-26, ADJUSTMENT Set the engine revolution at idle speed, and inspect the ignition timing using a timing light. Adjust by turing the distributor housing or octane selecter to either side Ignition timing 8° BTDC (Exe. ECE) 12° BTDC (For ECE) GOVERNOR OPERATIONAL INS- PECTION 1. Rotor should return quickly when turned clockwise by hand and released 2. Rotor should not be excessively loose. 3, Start the engine and disconnect the vacuum hose from the distributor. The timing mark should vary in accordance with the opening and closing of throttle valve, VACUUM ADVANCE OPERATIONAL INSPECTION Connect the distributor vacuum hose. ‘The octane selector should vary in accordance with the opening and closing of throttle valve:ENGINE TUNE-UP alve Timing, Chain Tensioner 29 Fig. 2-29 VALVE TIMING INSPECTION 1, Turn the crankshaft in normal direction until the No.1 piston is set at TOC/compression. 2. Check to see that the flange timing pin in camshaft is within the embossed mark on valve rocker support No.1 Fig. 2-30 ADJUSTMENT Adjust the valve timing in the following sequence 1, Turn the crankshaft in normal direction until the flange timing pin in camshaft is aligned with the embossed mark on valve rocker support No.1, 2. At this position, read the timing chain cover graduation, 3. Remove the chain tensioner. 4, Loosen the camshaft timing gear set bolt 1 Retarded 30 9 Degrees (LH threads) and remove the camshaft timing gear. 5. After resetting the position of straight pin ‘Second Straight Pin Hole hole as instructed below, install the camshaft timing gear. a. If retarded 3 to 9 degrees Align the camshaft timing gear to the second straight pin hole, fing, has the No.1 piston set at TDC/eompression. 6. Install the chain tensioner, Recheck the valve timing, ‘CHAIN TENSIONER ADJUSTMENT Adjustment method with engine stopped. 1, Turn the crankshaft in normal direction until the chain slack side is at the most slacked condition, 2. Loosen the locknut, and turn the screw clockwise until resistance is felt. Screw In Until Resistance Is Felt