Make sure that the groove on the shaft is pointing toward the center of the screw [D].
If the shaft position is incorrect, refer to the following NOTE and procedures to electrically adjust the shaft position.
Torque - Exhaust Butterfly Valve Actuator Pulley Bolt: 4.9 N·m (0.50 kgf·m, 43 in·lb)
NOTICE
If the pulley bolt is tightened without holding, the actuator damage will occur.
41.7° ±7° [B]
This position is original position of the pulley.
NOTE
Correct the position electrically after confirming the use is discontinued and there is no damage when differing from the angle of shown in the figure.
NOTICE
Do not correct the pulley position with the tool, forcibly. The actuator damage will occur.
If the pulley angle is wrong, adjust the angle as follows.
Connect: 2 pins Connector 3 pins Connector
Turn the ignition switch to ON.
Confirm the pulley turns clockwise or counterclockwise then it stops at the original position.
If the pulley position has not been returned to the original position, electrically adjust the shaft position as follows.
Remove: 2 pins Connector 3 pins Connector
Turn the pulley to the original position by turning it clockwise or counterclockwise by connecting the battery to the 2 pin connector terminals. To turn the pulley gradually, intermittently connect the battery positive (+) terminal to the 2 pin connector terminal while connecting the battery negative (–) terminal to the connector.
Pink (–) lead terminal [A] Gray (+) lead terminal [B]
Clockwise: Pink (–) lead terminal to battery (–) terminal Gray (+) lead terminal to battery (+) terminal
Counterclockwise: Pink (–) lead terminal to battery (+) terminal Gray (+) lead terminal to battery (–) terminal
Reconnect the 2 pins connector and 3 pins connector, and turn the ignition switch ON.
Make sure that the pulley turns clockwise and then counterclockwise.
The pulley should returns to the original position.
Turn the ignition switch OFF.
If the pulley does not return to the original position, check the exhaust butterfly valve actuator resistance (see Exhaust Butterfly Valve Actuator Resistance Inspection).
Clutch Installation
Apply engine oil to the needle bearing [A] and the sleeve
[B].
Install:
Needle Bearing
Sleeve
Install the clutch housing [A].
Fit the holes [B] and projections [C].
Engage the clutch housing gear and the crankshaft primary
gear.
Install the spacer [A] and the clutch ...
Inner Tube Inspection
Visually inspect the inner tube [A].
If there is any damage, replace the inner tube. Since
damage to the inner tube damages the oil seal, replace
the oil seal whenever the inner tube is replaced.
NOTICE
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by ...
Valve Installation
NOTICE
Do not lap the valve to the valve seat, using the
grinding compound. It will come off oxide film
treated surface of the valve.
Replace the oil seal with a new one.
Apply a thin coat of molybdenum disulfide grease to the
valve stem before valve installation.
Install the springs so ...