41145-ZV5-020 Honda GEAR, FR. BEVEL (Honda Code 8757189).

Setting Valve Clearance
Important:Adjust clearance with engine cold.1. Remove rocker chamber cover(s).2. Turn crankshaft until valves of respective cylinder overlap (Fig. 2-1). Turn farther through 360°.
2-1 Note for Refitment:The exhaust valve is left-hand as viewed from the exhaust side.Fig. 2-2
2-23. Release locknut of adjusting screw and adjust rocker arm/valve stem clearance. Retighten locknut.Fig. 2-34. Recheck clearance and readjust if necessary.
2-35. Apply sealing compound to new gaskets for rocker chamber cover(s) and fit cover(s).Fig. 2-4
2-4Checking The Compression Pressure
The specified pressure applies to min. 150/min starting speed of engine and 20° C reference temperature. Prior to checking, run up engine briefly to medium speed, so the combustion chamber will be sufficiently sealed by an oil film. Perform check at zero delivery of injection pump.1. Disconnect injection and back-leakage piping, and remove injector(s).2. Replace injector by connector No. 100020/100050 and clamp down.Fig. 2-5
2-5 ImportantFL 511 W : Remove heater plug(s) and fit connector No. 100010.Fig. 2-6
2-63. Connect compressiometer and determine pressure.Fig. 2-7
2-7 Important:Check that pressures are within the range specified and are equal on the two-cylinder models.Fig. 2-8
2-8Determining TDC
This job is required where no marks are available following removal of flywheel and / or V-belt pulley or existing marks are not accessible.1. Remove rocker chamber cover(s).2. Turn crankshaft until valves overlap, then give crankshaft another half turn.3. Mount setting device. Using pressure screw of device, press down one rocker arm through 5 - 6 mm.Fig. 2-9
2-94. Fit dial gauge with preload.Fig. 2-10
2-105. Turn crankshaft carefully in nominal direction until piston pushes up the valve. Slowly turn farther until gauge pointer changes the direction. Set gauge at "0".6. Turn back crankshaft through about one revolution of gauge pointer, then again in original direction up to 0.1 mm (10 graduations) from 0-position.7. Provide marking on V-belt pulley opposite the marking on the front wheel cover (or an indicator provided before).8. Turn crankshaft in running direction beyond "0" through about one revolution of the gauge and turn back up to 0.1 mm (10 graduations) before "0".9. Provide second mark as under 7. Determine mid-position between both marks by steel rule and mark.Fig. 2-11
2-11 Note for Refitment:The mid-position mark is the TDC, i. e. as this mark agrees with the mark on the spur gear cover, the piston is in TDC position.Fig. 2-12
2-12Setting The Injection Timing (by H. P. pump)
In the absence of an FB-mark (for commencement of injection) on the V-belt pulley, provide this mark according to the Specification Data through arc measure to be calculated, considering the pulley's diameter and starting from the TDC previously determined. Running direction of V-belt : CCL1. Disconnect fuel feed and injection piping from injection pump.2. Connect overflow pipe to delivery valve holder in place of injection line.Fig. 2-13
2-133. Connect delivery pipe of H. P. pump to injection pump in place of fuel feed line.Fig. 2-14
2-144. Run suction pipe of H. P. pump into a vessel filled with fuel or, if possible, connect to fuel tank. Important:Be sure both vessel and fuel are perfectly clean.5. Turn crankshaft in counter-running direction up to about 45° before TDC mark.6. Do not press starting fuel allowance button.7. Operate H.P. pump until fuel comes out at the overflow pipe connected to the injection pump.Fig. 2-158. Turn crankshaft slowly in running direction, while continuously operating H.P. pump, until fuel flow is dribbling. Once the interval between droplets is 5 - 8 seconds, the injection timing is correct.
2-159. At the same time, the marks must agree.Fig. 2-16
2-1610. Provided the injection pump has the clearance specified (Fig. 2-17), adjust injection timing by moving pump sideways.Fig. 2-18Displacement toward "a" = early injectionDisplacement toward "b" = late injection
2-17
2-18 Note for Refitment:The pump's clearance is varied by shims under the pump.Fig. 2-19
2-1911. Connect fuel and injection piping.Fig. 2-20
2-20Testing The Injection Nozzle (by testing outfit)
1. Connect injector to outfit.Fig. 2-21
2-212. With pressure gauge cut in, press outfit pump lever several times. Read opening pressure (Fig. 2-22) and inspect spray pattern. Compare readings with Specification Data.
2-22 Important:At 25 - 30 bar below specified opening pressure, check that no fuel will dribble from nozzle.3. On FL 511 adjust nozzle opening pressure by shims below the spring (adding shims increases pressure and vice versa).Fig. 2-23
2-23On FL 511 W adjust pressure by screw (turning inside increases pressure and vice versa).Fig. 2-24
2-244. Repeat test and recheck spray pattern. The jet(s) should be solid without surrounding mist. Fig. 2-25
2-25FL 511: several jets of equal thicknessFL 511 W: one jet onlyFig. 2-26
2-265. Check that there is no after-dribble.6. If nozzle works unsatisfactorily, replace.Testing The Injection Pump (by testing outfit)
To be tested is the tightness of the delivery valve and the pump elements. The test requires the fuel feed pump to work properly.1. Disconnect injection line(s) and attach outfit to the delivery valve holder concerned.Fig. 2-27
2-272. Turn crankshaft until outfit is bled. Tighten bleed plug.Fig. 2-28
2-283. Turn crankshaft slowly and pressurize valve with 150 bars. Check that pressure will not fall off through more than 10 bar within one minute.4. For testing the element, apply 300 bar pressure.Fig. 2-29
2-295. Be sure to overhaul or replace defective pumps.6. Detach testing outift. Reconnect injection line(s), Fig. 2-30, and bleed system.
2-307. Fit air cowl