1968 DATSUN 510 service

II

CHAPTER
SIX

ENGINE

Cylmder
block

Crankshaft

PistOns
and

connectmg
rods

Cyhnder
head

Camshaft

Valve
mechamsm

Camshaft
dnve

Mamfolds

011

pump

Fuel

pump
Carburetor

Emission
control
devIces

Engme
removal

Engme
dISassembly

Pistons
and

connectmg
rods

Cyhnder
head

Engme
mspectIon
and

replllr

Engme
reassembly

Service
data
and

speCifications

CHAPTER
SEVEN

FUEL
SYSTEM

Air
cleaner

Fuel
strlllner

Fuel

pump
Carburetor

Fuel
tank

1
CHAPTER

EIGHT

COOLING

SYSTEM

DescnptIon

Water

pump

Fan
clutch
Thermostat

Radiator

CHAPTER
NINE

ENGINE

ELECTRICAL
SYSTEM

Starter

Overrunmng
clutch

assembly

ChargIng
ClrcUlt

Alternator

Alternator

output

Voltage
regulator
DIstrIbutor

Condenser

Igrntlon
cod

SpeCifications

Spark
plugs

CHAPTER

TEN

EMISSION

CONTROL

SYSTEM

Exhaust
emiSSIOn

control

Crankcase

emission
control

Air

mJectlon
system
Engme
modifications

Evaporative
emiSSion
control

Exhaust

system

CHAPTER
ELEVEN

CLUTCH

TRANSMISSION
AND
DRIVESHAFT

Clutch

TransmissIon

Master

cyhnder
TransmissIon
data
and

speCIfications

Operating
cyhnder
Dnveshaft

Withdrawal
lever

adjustment
Dnveshaft
data
and

speCIfications

Clutch

system

bleedmg
Automatic
transmIssIon
checks

Clutch
data

and

speCIfications
31

62

84

91

114

127

CHAPTER

TWELVE

DIFFERENTIAL
REAR
AXLE
AND
REAR
SUSPENSION
149

DIfferentIal

Rear
axle
and

suspension

Codspnng

Shock
absorber

Rear

suspensIOn
arm

Rear
axle

shaft
Wheel

beanngs

Seals

Rear

spnng

Axle
case

SpecificatIons

CHAPTER
THIRTEEN

FRONT

AXLE
FRONT
SUSPENSION
AND
STEERING
168

Wheel
hub
and

bearmg

StabilIzer

TenSion
rod

Spnng
and
strut

assembly

Transverse
lInk

Lower
ball

Jomt
Front

suspension
adjustment

Wheel

alignment

Posture

adJustment

Steenng
system

SpeCificatIons

CHAPTER
FOURTEEN

BRAKES
187

Brake

pedal

Master

cylInder

Front
diSC
brakes

Rear
brakes

Front
drum
brakes
Wheel

cylInders

Brake

system
bleedIng

Handbrake

Service
data
and

speCificatIons

CHAPTER
FIFTEEN

BODY
ELECTRICAL
SYSTEM

Wmng

SWitches
and
fuses

Instrument

meters
and

panels

Heater
205

Wmdshleld

wipers

Wmdslueld
washers

Headlamps

WIrIng
diagrams

CHAPTER

SIXTEEN

BODY

223

Front

body
trIm

Bumpers

Hood
lock
control

Doors
Door
locks
and

regulators

Trunk
lId
and

rear

bumper

Seats

Tad

gate

INDEX

235

I

CHAPTER
ONE

GENERAL
INFORMATION

This
manual

provides
maintenance
informa

tIon
on
the
Datsun
510
Series
and
521
Series
of

vehlcles
The
510
Series
includes
the
two
door

sedan
four
door
sedan
and
station

wagon
The

521
Senes
IS
the

pIck

up
truck

Coverage
is
from

1968

through
1972
models

All
models
use
the
L16

engme
a
96
horse

power
four

cylmder
overhead
camshaft

design

The
510
has
a

fully
synchronized
four

speed

manual
or
three

speed
automatic
transmisSIon

The
521
has
a
four

speed
manual
transmission

only
In
1972

horsepower
ratIng
was

lowered

to
92

horsepower
due
to

changes
m
emission

control
device

requirements
Figure
1
is

an
over

all
view
of
the
four
door
sedan

Figure
2
shows

the

station

wagon
and

Figure
3
illustrates
the

pick
up
truck

Over
the

years
the
510
and
521
series
have

remained

essentIally
the
same
with
the

excep

tion
of

changes
to
the

emISsion
control

systems

and
overall

body
stylmg
In
this
manual

every

effort
has
been
made
to

pinpoint
significant
c
if

ferences
between
model

years

The
use
of

SpecIal
tools
and
test

equipment

has
been
avoided
wherever

possible
When

necessary
special
tools
and
test

equipment
are

illustrated
either
in
actual
use
or
alone
A
well

equipped
mecharuc

may
find
he
can

substitute
similar
tools
or
make
his

own
to
fulfill
a
e

Ii

ment

Recommendations
are

occasionally
made
to

refer
servIce
or
mamtenance
to
a
Datsun
dealer

or
a

SpecIaliSt
in
a

specIfied
field
In
these
cases

work
WIll

probably
be
done
more

qUlckly
and

economIcally
than
if
the
mecharuc

performs

them
himself

MODEL
IDENTIFICATION

Body
Number
Plate

The

body
number
IS

stamped
on
the
fire
wall

in
the

engine
compartment
The
numbers

give

the
chasSIS
model
and
serial
number

Model
Identification
Plate

The
model
Identification

plate
Figure
4
is

mounted
WIthin
the

engine

compartment
TIns

plate
gIves
engine
number
and
veh1cle

number

Engine
Identification

The

engine
identrlicatlon

marking
is

stamped

on
the

right
hand
SIde
of
the

cylinder
block

just

below
the
third
and
fourth

sp8l
k

plugs

Model
Identification
Numbel
ll

The

following
numbers
have
been

assigned
to

the
510
and
52
I
Series

vehicles

oj

4

CHAPTER
ONE

chassIs

number
Write
the
numbers
down
and

carry
them
ill

your
wallet

Service
Hints

Throughout
thIs

manual
keep
two
conven

bons

ill
mmd
Front
refers
to
the
front
of
the

vehicle
The
left
and

nght
sides
of
the

ve

hicle
refer
to
a

person
sittIng
ill
the

car

facing

forward
For

example
the

steenng
wheelIS

on

the
left
hand
Side
All
dimensIOns
and

capacities

are
expressed

ill
units
fanuhar

to
a
Umted

States

mechaniC
such
as
illches
and

pounds
Metric

measurements

are
also

given
Metnc

tools
are

reqUITed
to
work

on
the
Datsun
CD

DATSUN

IENGINE
CAPACITY

IMAX
HP
RPM

IWHEELBASE

IENGINE
NUMBER

FAR
NO

NlSSAN

MOTOR

co
LTD

YOKOHAMA
JAPAN
TYPEI
510

1595
cc

961P
6600

rpm

mm

L

1
00988

P61
l
O
1
l
M

Table
1
MAIN
SPECIFICATIONS

AND
DIMENSIONS

r
ITEM
Sedan

Wagon
Plm

up

EnglDe
Type
L16

L16
L16

Valve

Arrangement
Overhead

Cam
Overhead
Cam
Overhead
Cam

Bore
3
26n
ID
83mm

3
2677
ID
83mm
3
2677
ID
83mm

Stroke
2902
ID

73
7mm
2
902
ID

73
7mm
2
902
In

73
7mm

Displacement
97
3
cu
ID

l595cc
97
3
cu
In

l595cc
97
3
cu
ID
1595cc

CompressIOn
Ratio
851

851
851

MaXimum
SAE

Hompower
96

@
5

600

rpm
96

@
5
600

rpm
96

@
5
600

rpm

MaXimum
SAE

Torque
998ft
Ib
138

kg
m
998ft
Ib
138

kg
m

9911
ft
Ib
138

kg
m

Fuel
Octane
85

85
85

Lengtb
1622
ID

4
12Omm
163
2
ID
4
I45mm
168
9
ID
4
290mm

Width

61
4
ID

l
560mm
61
4
ID
1
560mm
62
8
In

Cl
595mm

Height
55
lID
1
400mm
565
ID

Cl
435mm
60
8
ID

Cl
545mm

Wheelbase

95
3
ID

2
42Omm

95
3
ID

2
420mm
99
6
In

2
530mm

Room

Space

Inner

Length
63
3
In
1
61Omm
673
ID

1
710mm
72
8
ID

1
850mm

Inner
Width

499
ID
1
27Omm

507
ID

1
29Omm
563
In

1
430mm

Inner

Height
44
4
In
1
130mm

44
61D
1
135mm
15
7
ID

399mm

Tread

Front

50
4
ID

28Omm
502
In
1
275mm
492
In
1
250mm

Rear
504
In

1
280mm
496
In

Cl
260mm
499
ID
1
267mm

Road

Clearance
741n

l88mm
64
ID
l63mm
787
ID
200mm

Weight

4

Speed
2
0611b
935

kg
2
138
Ib

970

kg
2
127
Ib
965

kg

Automatic

2
114Ib
959

kg
2
182
Ib
990

kg

Minimum

Turning
RadiUS
157ft
48m

157ft
48m
171
ft
52m

Seating

Capaaty
5

5
2

Battery

Volt

12

12
12

Capacity
400rSOAH

400r50AH
40
or
60
AH

Connection

Negative
ground
Negative
ground
Negative
ground

Fuel

Tank

Capaaty
11

9

gal
45
liter
11
9

gal
45
liter
108

gal

41J
r

011

Pan

Capacity
42

qts
40

liter
4
2

qb
40
liter

1
06

gal
40
Iller

011
Filter

Capaaty
74

ql
07
liter
74

ql
0
7
liter
1
48

Pint
0
7
liter

Transmission

Capaaty
1
8

ql
1
7
liter

18

ql
1
7
Iller
2
11

qt
20
Iller

Dlflerenbal

Capaaty
85

ql
80
liter
11

ql
1
0
liter
87

ql
0
83
lIter

Coolant

Capaaty
7
2

ql
6
8
liter
7
2

ql
6
8
lIter
7
2

qt
6
8
Iller

Clutch

Type

Dry
Single
diSC

Dry
slDgle
diSC

Dry
slDgle
diSC

Draphragm
spnng
Diaphragm

spnng
Diaphragm

spnng
l

16

CHAPTER

TIlREE

sary
Also
check
all

parts
for

mlSaltgnment
and

uneven
wear

TRANSMISSION

1

Difficult
to
mesh

gears

Make
certam
the

clutch

pressure
plate
and
re

lease

beanng
are
m

good
condItion
The
trouble

can
be

caused

by
worn

gears
shaft
and
or
bear

mgs
DISassemble
and

repaIr
as

requIred
Also

can
be
caused

by
msufficlent

operatmg
stroke

due

to
worn
or
loose

sltdmg
parts
or
a
defective

synchronIZer
DIsassemble

carefully

InSpect
and

replace
as

requIred

2
Gears

slip
out

of
mesh

Generally
thIS
trouble
occurs
when

the
mterlock

plunger
check
ball
and

or

spnng
IS
weakened

or
worn
The
trouble
can

also
be
caused

by
worn

fork
rod
ball

groove

damaged

bearings
or
dam

aged

gears
DIsassemble

carefully
mspect
and

replace
as

required

3
NOIse

If
nOISes
are
heard

wIth
the

engme
idlmg
and
the

clutch

disengaged
the
nOIse
IS

probably

conung

from
the

transmISSIOn
Several
Items

can
cause

nOISes

either

smgly
or
m
combmatIon

Check
the

qualIty
and

quantity
of
lubrIcant

in
the
trans

mISSIon

Replace
or

replenISh
as

necessary
Worn

bearIngs
wIll

usually
produce
a

lugh
humming
at

hIgh
speed
and

a

cycltc
knockIng
sound
at
low

speed
Worn

or

damaged
splInes
and

bushmgs

will
also
cause

nOIse

BRAKES

1
Brake

pedal

goes
to

floor

There

are
numerous
causes
for
thIS

includIng

excessIvely
worn

Itnmgs
aIr
in
the

hydraultc

sys

tem

leaky
brake
lmes

leaky
wheel

cylmders
or

leaky
or
worn

master

cylmder
Check
for
leaks

and
thIn
brake

linmgs
Bleed
and

adjust
the

brakes
If

thIS
doesn
t
cure
the
trouble

rebwld

wheel

cylmders
a
nd
or
master

cylmder

2

Spongy

pedal

Normally
caused

by
aIr
m
the

system
blee
d
and

adjust
the
brakes

3

Brakes

pull

Check

brake

adjustment
Also
check
for
contam
inated

brake

Itmngs
from
leaks

leaky
wheel

cyltnders
loose

caltpers
frozen

or
seIZed

pIstons

and
restrIcted
brake
lmes

or
hoses
In
addItion

check
front
end

alignment
and

suspensIOn
dam

age
such
as
broken
front

or
rear

sprmgs
shocks

etc
Check
condItIon

of
tIres

4
Brakes

squeal
or
chatter

Check
brake

lmmg
thickness

and
brake
drum

roundness
Ensure

that
the
shoes
have
cham

ferred
ends

and
are
not
loose

Inspect
the
condI

tion
of

the
rotors
on
the
front
wheel
dISC

brakes

to
make

certain

they
are
not
scored

or

damaged

Clean

away
all
dIrt
on
shoes

pads
rotors

or

drums

5

Draggmg
brakes

Check

brake

adjustment
includmg
handbrake

Check
for
broken
or

weak
shoe
return

springs

swollen
rubber

parts
due
to

unproper
brake
flUId

or
other
contammatIon

Clean
or

replace
de

fectIve

parts

6
Hard

pedal

Check
brake

linmgs
for

contammation
Also

check
for

restrIcted
brake
lines

and
hoses

7

High
speed
fade

Check

for
dIstorted
or
out
of
round
drums

and

contamInated
brake

lmmgs
Make

certam
the

recommended
brake
flUId
IS

used
Dram
entIre

system
and
refill
If
In
doubt

8

Pulsatmg
pedal

Check
for
dIStorted
or
out
of
round
drums

or

rotors
Check
for

excessIVe
brake

dISC
run
out

STEERING
AND

SUSPENSION

NOTE
Unusual

steermg
pullmg
or

wandermg
IS

usually
caused

by
bent

or
otherwise

mIsaligned

suspenszon

parts
Because

of
the

speCialized
equIp

ment

reqUired
to
evaluate
and

correct

these

faults
It
IS
recommended

t
tat

servIce
to

the

steermg
and

suspension

system
be

referred
to

your
Datsun

dealer

oca

quallfied
specrallst
m

thiS

field

1
VibratIOn

felt
m

steermg
wheel

VIbratIon
can
be
caused

by
several

thmgs
includ

ing
lll1proper
aIr

pressure
m
tIres

uneven
wear

TROUBLESHOOTING
17

of
tIre
loose
wheels

unproper
adjustment
or

wear
of
front
wheel

bearIngs
faulty
wheel

align

ment
or
wear
of
transverse
lInk
and
tension
rod

bushings
Inspect
all

parts
carefully
for
wear
or

damage

Replace
or

replUI
parts
as

required

2
Shock

transmltled

through
steering
wheel

This
is

usually
most
noticeable
when

traveling

over
bad
roads
at

relatively
high
speeds
Causes

Include

damage
to
the
idler
ann
insuffiCient

tIghtening
of

steenng
gear
box
wear
of
the
steer

Ing
linkage
and
wear
of
the

suspension
ball

joint

Inspect
all

parts
for
wear
or

damage
Refer
to

Chapter
ThIrteen
for
service
or

repair
you
can

perform
and
for

procedures
which
should
be

referred
to

your
deal
r

3

Shlmmymg

This
is

usually
most
noticeable
when
a

specIfic

speed
IS
attained
and
will

normally
repeat
at
that

speed
Causes
are

generally
unbalanced
wheels

unproper
adjustment
of

steenng
gear
insuffi

cient
backlash
malfunction
of
the
shock
ab

sorbers
or
loose
bolts
for
the
strut

mountIng

Reparr
or

replace
defective

parts
as

required

Refer
to

Chapter
Thirteen

4

Wandermg
of
car
m
one
dlrectlOnl

This

problem
can
be
caused

by
improper
air

pressure
loose
wheel

nuts
difference
in
tire
tread

wear
from
left

to

right
side
Incorrect

adjustment

of
wheel

bearings
defectIve
wheel

beanngs

collapsing
or

twistIng
of
front

spnng
or
Incorrect

wheel

alignment
Also

binding
of
the
brake

shoes
worn

bushings
in
the
transverse
link
or
the

tension
rod
and
deformation
of
s

enng

lInkage

and

suspension
link
can
cause
wander

Carefully

iuspect
all

parts
for
looseness
and
wear
and
re

place
or

repaIr
as

required
In
some
c
ases
a
de

fective
rear

suspension
may
also
cause
the

vehicle
to
wander

5

InstabIlity

Instability
can

be
caused

by
unproper
tIre

pres

sures
worn

bushings
in
the
transverse
link
and

tension
rod
mcorrect
wheel

alignment
worn

steenng
linkage
Incorrect

adjustment
of
steer

ing
gear
and
unbalanced
wheels

Inspect
all

parts
carefully
for
wear
and

damage
Adjust

repair
or

replace
as

required
6

Heavy
feelmg
m

steering

This
can
be
caused

by
improper
tIre

pressures

insuffiCient
or
contamInated
lubncant
in

gear

box

damage
or
insuffiCient

grease
In

suspeuslon

ball

Joint
damaged
or

badly
adjusted
wheel

bearIngs
worn
or

damaged
steermg
gear
dam

age
of

upper
strut

bearing
and
mterference
of

steenng
column
With
turn

signal
SWitch

Inspect

all

parts
carefully
for
wear
and

damage
Adjust

repair
or

replace
as

required

7
ExceSSIve

play
m

steermg
wheel

This
is

usually
caused

by
Incorrect

adjustment
of

the

steenng
gear
worn

bushings
in
the

steering

linkage
or
Idler
arm
mcorrect

adjustment
of
the

front
wheel

bearings
worn

bushIngs
in
the
trans

verse
lInk
and
tension
rod

Carefully
inspect
all

parts
for
wear
or

damage
Adjust
repair
or
re

place
as

reqUIred

TIRE
WEAR
ANALYSIS

Abnormal
tIre
wear
should

always
be
ana

lyzed
to
deternune
the

cause
The
most
common

are
Incorrect
tIre

pressure
improper
dnving

overloading
and

Incorrect
wheel

ahgDment

Figures
2A

through
2F

identify
wear

patterns

and
mdicate

likely
causes

Of

I

1

l

D

1

Undennflatlon
Worn
more
on
Sides
than
In

center

ENGINE
AND
IGNITION
TUNE
UP
21

many
types
of
test

eqUipment
and

may
be
used

as
a

gUide
If
the
manufacturer

s

mstructioQs
are

not
aVailable
Connections
shown
in

Figure
1

are
as
follows

1
Voltmeter

a
PosItive
lead
to
resistor
side
of
COli

b

Negative
1
ead
to

ground

2

Tlmmg
Light

a
PosItive
lead
to

posItive
battery
termmal

b

Tngger
lead
to
number
1

spark
plug

c

Negative
lead
to

ground

3
Tachometer

a
PosItive

lead
to
dlstnbutor
Side
of
coil

b

Negative
lead
to

ground

4
Dwell
Meter

a

PosItive
lead
to
dlstnbutor
Side
of
COlI

b

Negative
lead
to

ground

BAlTERY
INSPECTION
AND
SERVICE

1
Check
the
level
of
the

electrolyte
m

battery

cells
If

necessary
replemsh
with
distilled
water

Do
not
overfill

2

Measure
the

speCific
gravity
of
the

battery

electrolyte
Refer
to
the

followmg
table
2
Use
the

proper
size
socket
and
wrench
to

remove

spark
plugs
from
the

cyhnder
head

Make
certam
that
the

gaskets
are
removed
from

the

spark
plug
holes

3

Wipe
off
the
msulator
With
a
clean

rag
to

remove

grease
and
dirt

4

Carefully

mspect
the
msulator
and

body
of

each

plug
for

signs
of

cracks
or

chips

Replace

If

faulty

5

Inspect
spark
plug
threads
and
electrodes
for

damage
or
excessive
wear

Replace
as

requrred

Figure
2
shows
the

cond1t
J
on
of

normal
and
de

fectIVe

spark
plugs
along
with

an

explanation

of
the

causes
of

the
abnormal
conditions

6
If
the

spark
plugs
are
still
serviceable
clean

them

thoroughly
With
a

stiff
brush
or

preferably

With
a
sand

blasting
type
of
cleaner

7
File
the

center
electrode

so
that

It
has

a
fiat

surface

8
File
the
surfaces
of
the
outer
electrode

so
that

all
surfaces

are
fiat
and
smooth

9

Usmg
a
feeler

gauge
adjust
clearance
be

tween
the
electrodes
to
0
031
to
0
035
m
0
8

to
0
9mm
as
shown
m

Figure
3

Full

Charge
Value

CD
68

degrees
F

PermiSSIble
Value
20

degrees
C
3

Frigid
chmates

Tropical
chmates

Other
climates
Over
1
22

Over
118

Over
1
20
128

123

126

3
Clean

top
of

battery
and
termmals
With
a

solutIOn
of

bakmg
soda
and
water
Rmse
off
and

dry
thoroughly
Top
of

battery
must
be
clean
to

prevent
current

leakage
between
termmal
and

from

pOSitive
termmal
to
hold
down

clamp
Pro

longed
accumulatIOn
of
aCid
and
dirt
on

top
of

battery
may
cause

blIstenng
of
the
matenal
cov

enng
on
the
connector

straps
and
detenoration

of
the

straps
themselves

4

Tighten
the
cable

connectors
to
the
termmal

securely

5
Coat
the
termmals

lIghtly
With

petrolatum
to

protect
them
from
corrosion

SPARK
PLUGS
INSPECTION

AND
SERVICE

1
Remove

spark
plug
WIres
Mark
them
to
fi

sure
correct

replacement
J

J

I

I

j

j

10
Remstall

spark
plugs
Make
certam
to
use

a
new

gasket
for
each

plug
Use
a

torque
wrench

to

tighten
spark
plugs
from
11
0
to
150
ft
lb

1
5
to
2
0

kg
m

11
Remstall
WIres

DISTRIBUTOR
INSPECTION

AND
SERVICE

Dependmg
on
the
model

year
velucles
have

a

smgle
pomt
or
a
dual

pomt
dlstnbutor

system

ENGINE
AND
IGNITION
TUNE
UP
4

25

block
the
throttle
and
choke
m
the
WIde

open

position

3
Remove
all
four

spark
plugs

4

Sequentially
press
a

compressIOn
test

gauge

mto
each
of
the

spark
plug
holes
and
crank
the

engme
for
at
least
four
strokes
Record
the
com

pressIOn
readmg
for
each

cylmder
Standard

compressIOn
readmg
IS
171
Ibs
m
12
0

kg
cm
Mmlmum

acceptable
readmg
IS
159

lbs
m
2

11
5

kg
cm

5
No

readmg
should
be
less
than
80
of
the

highest
cylmder
reading
ExceSSive

vanatiC
ns

between

cylmders
accompanied
by
low

speed

mlssmg
of
the

cyhnder
or

cylmders
that
read

low

usually
mdlcates

a
valve
not

properly
seat

mg
or
a
broken

piston
ring

Low

pressures
even

though
uniform

may

mdicate

worn

nngs
ThIS

IS

especlall
true
1f
ex

cessive
011

cQIlsumptlon
has
been
noticed
If
one

or
more

cylmders
read
low

or
uneven

inject

about
a

tablespoon
of

engine
ail

on

top
of
the

piston
of

that

cylinder
and
crank
the

engine

several
tlmes

noting
the

compressIOn
reading

If

compressIOn
has
nsen
the

piston

nngs
or

cylmders
are
worn
and
should

befserviced
If

compressIOn
has
not

unproved
after

addmg
oil

the
valves
are

Stlcking
or
are
not

seating

prop

erly

If
two

adjacent
cylmders
have
low

compres

sion
and

mjectmg
01

9es
not
increas
the
read

mg
the
head

gasket
between
the

cylmders
IS

probably
leaking

VALVE
CLEARANCE
ADJUSTMENT

Valve

adjustment
should
be
done
in
two

steps
first
With
the

engme
cold
and
then
at

operatmg
temperature
Refer
to

Figure
6

and

proceed
as
follows

1
Remove

arr
liter

2
Remove
rocker

arm
cover
Take

care
not
to

damage
the

gasket

3
Remove
the

spark
plugs
and

rotate
the
en

gine
unt1l
number
1

cylinder
IS
at

top
dead
center

o
l
the

compressIOn
stroke
This
can
be
de

tepnmed
w
hen
the

top
dead
center
mark
on

the
crankshaft

pulley
is

m

alignment
With
the

statIOnary

pomter
and
both
valves
for

number

1

cylmder
are
closed

I
4

Counting
from
the
front
of
the

engme
ad

Just
valves
1
2
3

and
5
as
follows
Loosen
the

pivot
lockmg
nut
and
turn
the

pivot
screw
unt1l

clearance
between
the

pivot
screw
and
the
rock

er
ann
IS
0
0079

m
0
200mm
for
the
mtake

valves
and

0
0098
in
0
25mm
for
the

exhaust

valves
Check

clearances
With

a
feeler

gauge
as

shawn
When
correct

tlghten
the

pivot
locking

nut

l

1

5
Rotate
the
crankshaft
unt1l
the
number
4

pISton
IS
at

top
dead

center
an
the

compressIOn

stroke
This

IS
one

complete
revolution
of
the

crankshaft

Agam
the
0

degree
mark
should

align
With
the

pomter
and
both

valves
on
num

ber
4

cylinder
should
be
closed

6

Adjust
valves
4
6
7
and
8

as
above

i

I

7

Replace
spark
plugs
Ignition
WIres

r
ick
r

1

arm
cover

gasket
and
air
filter

8
Start

engine
and

run
it
unt1l

operating
tem

perature
IS
reached

9
Remove
rocker

ann
cover
and

repeava
iius

ment
Clearances
should
be

0
0098

m
0

25fumj

for
the

mtake
valves
and
00Il8
m
0
30mi

for
the
exhaust
valves
Check
clearances
before

loosening
the

pivot
lockmg
nuts
as

they

may

already
be

properly
set
If

not

adjust
as
re

quir
l

ADDmONAL

CHECKS

l

Qunng
tune

ups
check
the

followmg
Ite

far

SignS
of
defects

or
excessive
wear
I

i

1

Inspect
the
carburetor
for

buildup
of

foreign

matenal

Pay
Special
attention
to
the

throat
and

linkages
Clean
or
overhaul
as

required
Det8
1ls

for
carburetor
mamtenance
are

given
in

Chapter

seven