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MAINTENANCE AND REPAIR INSTRUCTIONS
17
4. Disconnect the spark plug wire.
5. Clean dirt from around the spark plug. Remove the
spark plug from the cylinder head by turning a 5/8 in.
socket counterclockwise.
6. Remove the engine cover.
NOTE: Pull the starter rope out a little, to give some
slack, to ease the removal of the engine cover.
7. Clean dirt from around the rocker arm cover.
Remove the screw holding the rocker arm cover with
a large flat blade screwdriver or Torx T25 bit
(Fig. 30). Remove the rocker arm cover and gasket.
Rocker Arm Cover
Screw
Fig. 29
Fig. 30
Spark Plug Hole
8. Pull the starter rope slowly to bring the piston to the
top of its travel, (known as top dead center). Check
that:
• The piston is at the top of its travel while looking in
the spark plug hole (Fig. 30).
• Both rocker arms move freely, and both valves are
closed.
If not, repeat this step.
9. Slide the feeler gauge between the rocker arm and
the valve return spring. Measure the clearance
between the valve stem and rocker arm (Fig 31).
Do both intake and exhaust valves.
The recommended clearance for both intake and
exhaust is .003 – .006 in. (.076 – 0.152 mm). Use a
standard automotive .005 in. (0.127 mm) feeler gauge.
The feeler gauge should slide between the rocker arm
and valve stem with a slight amount of resistance,
without binding (Fig. 32).
Adjusting Nuts
Feeler Gauge
Rocker Arms
Gasket
Fig. 31
Fig. 32
Feeler Gauge
Adjusting Nut
Rocker Arm
.003–.006 in.
(.076–0.152 mm)
Valve Stem
10. If the clearance is not within specification:
a. Turn the adjusting nut using a 5/16 inch (8 mm)
wrench or nut driver (Fig. 32).
• To increase clearance, turn the adjusting nut
counterclockwise.
• To decrease clearance, turn the adjusting nut
clockwise.
b. Recheck both clearances, and adjust as necessary.
11. Reinstall the rocker arm cover using a new gasket.
Torque the screw to 20–30 in•lb (2.2–3.4 N•m).
NOTE: A rocker arm cover gasket, Part # 182099 can be
purchased from your local authorized dealer.
12. Reinstall the engine cover. Check alignment of the
cover before tightening the screws. Tighten screws.
13. Replace the muffler cover. Slip the long tabs on the
muffler cover into the engine cover. Slide the
notches on the side of the muffler cover over the
tabs on the engine cover and snap into place
(Fig. 27).
14. Check the spark plug and reinstall. See
Replacing
the Spark Plug.
15. Replace the spark plug wire.