Timing Belt

REMOVAL AND INSTALLATION

Removal Service Points
[A] Timing Belt Removal





1. Mark the belt running direction for reference in reinstallation.
2. Loosen the tensioner mounting bolt.
3. Insert a cross-tip screwdriver into the hole of the tensioner arm as shown illustration.
4. Move the screwdriver all the way in the direction of the arrow, and tighten the tensioner mounting bolt to hold this position.
5. Remove the timing belt.

NOTE:
1. Water oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent.
2. If there is oil or water on any part, check the front case oil seal, camshaft oil seal and water pump for leaks.





[B] Camshaft Sprocket Bolt Loosening

Installation Service Points





]A[ Camshaft Sprocket Bolt Tightening

]B[ Timing Belt Tensioner Installation





1. Install the timing belt tensioner in the illustrated position, and then tighten the tensioner mounting bolt.

]C[ Tensioner Spring Installation





1. Install the tensioner spring onto the boss of the front case, and then hook the spring end "A", (shorter one) to the front case rib.
2. Grip the spring end "B" (longer one), and then hook it onto the tensioner arm.

]D[ Timing Belt Installation





1. Align the crankshaft sprocket timing mark with the timing mark on the front case, and then rotate the crankshaft sprocket three teeth counterclockwise.

CAUTION: Aligning the timing marks positions the piston to the top dead center. Then, if the camshaft turns, the valves might interfere and damage the pistons.





2. Align the camshaft sprocket timing mark with the timing mark on the cylinder head.





3. Rotate the crankshaft sprocket three teeth counterclockwise, and align the crankshaft sprocket timing mark with the timing mark on the front case.
4. Keeping the tension side of the timing belt tight, fit the timing belt onto the crankshaft sprocket, water pump sprocket, camshaft sprocket and tensioner puller in that order.





5. Slightly loosen the timing belt tensioner bolt to tension the belt by a force of the tensioner spring.





6. Turn the crankshaft twice in the clockwise direction.

CAUTION: This procedure utilizes the camshaft's driving torque to apply tension evenly to the timing belt. Be sure to turn the crankshaft as described above. Do not turn the crankshaft counterclockwise.

7. Check that the timing marks are correctly aligned.
8. Tighten the timing belt tensioner locking bolt to the specified torque.

INSPECTION
Timing Belt
Check the timing belt closely. Replace the belt with a new one if any of the following defects are evident:





1. Hardened backing rubber (the backing rubber is glossy, non-elastic, and so hard that scratching with fingernails leaves no mark.)





2. Surface cracks on the backing rubber.
3. Cracks or peeling of the canvas.
4. Cracks on the tooth bottom.
5. Cracks on the belt sides.





6. Abnormal wear on the belt sides.

NOTE: The sides of the belt are normal if they are sharp as if cut by a knife.





7. Abnormal wear on teeth.
Initial stage: Canvas worn (fluffy canvas fibers, rubbery texture gone, white discoloration, canvas texture indistinct)
Final stage: Canvas worn, exposing rubber (tooth width reduced)
8. Missing teeth.

Tensioner Puller





1. Check the pulley for smooth rotation, without play and are not noisy.