Cylinder Head/Valve

9. Cylinder Head/Valve

Services information 9-1 Valve guide replacement 9-7

Troubleshooting 9-2 Valve seat Inspection/Adjustment 9-8
Camshaft Removal 9-3 Cylinder head Assembly 9-11
Cylinder Head Removal 9-5 Cylinder Head Installation 9-12
Cylinder Head Disassembly 9-5 Camshaft Assembly 9-13

Service Information
General Safety
ƃ The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must
be removed from the frame to maintain the cylinder head.
ƃ The oil of camshaft oil is supplied through the cylinder head oil hole. Clean the oil hole prior to
assembling the cylinder head.

Specifications Unit: mm(in)

Item Standard value Service limit !
Rocker arm inner diameter 12.016-12.034(0.4731-04738) 12.060(0.4748)
Rocker arm
Rocker arm shaft outer diameter 11.982-12.000(0.4717-0.4724) 11.950(0.4705)
IN 33.835-33.995(1.321-1.3384) 33.625(1.3234)
Cam height
Camshaft EX 33.984-34.144(1.380-1.3443) 33.765(1.3293)
Camshaft inner diameter 15.005-15.018(0.5907-0.5913) 15.040(0.5921)
Cylinder head warpage - -
Valve spring free length IN, EX 37.21(1.465) 36.90(1.4528)
IN 4.972-4.984(0.1957-0.1962) 4.920(0.1937)
Valve stem
EX 4.952-4.964(0.1950-0.1954) 4.900(0.1929)
Valve
Valve guide IN, EX 5.000-5.012(0.1969-0.1973) 5.030(0.1980)
Valve guide
Clearance between IN 0.016-0.040(0.0006-0.0016) 0.090(0.0035)
stem and guide EX 0.036-0.060(0.0014-0.0024) 0.120(0.0047)
Valve seat width 0.8~1.0(0.031~0.039) 1.4(0.055)

Torque values
ƃ Cam chain tensioner pivot bolt 1.0kg-m(10N.m, 7ft-lb)
ƃ Spark plug 1.2kg-m(12N.m, 8ft-lb)
ƃ Camshaft holder 8mm nut 2.0kg-m(20N.m, 14ft-lb) - Apply engine oil
ƃ Cam chain tensioner mounting bolt 1.2kg-m(12N.m, 9ft-lb) - Apply engine oil
ƃ Cam chain tensioner sealing screw 0.4kg-m(4N.m, 2.9ft-lb)
ƃ Cylinder head cover bolt 0.9kg-m(9N.m, 6.5ft-lb)

9-1
Cylinder Head/Valve

Tools
Valve guide reamer
Valve guide driver
Valve spring compressor
Valve seat cutter
Seat Cutter IN 37Ƃ(21.5mm)
EX 37Ƃ(18.5mm)
IN 45Ƃ(22mm)
EX 45Ƃ(22mm)
IN 55Ƃ(20mm)
EX 55Ƃ(20mm)

Troubleshooting
ƃ Cylinder head operation problem can be diagnosed,
in general, by a compression test, or by checking
noises on the top of the engine.

Low compression or uneven compression Compression too high

ƃ Valves - Excessive carbon build-up on piston head or
- Faulty hydraulic tappet combustion chamber
- Burned or bent valves Excessive noise
- Incorrect valve timing ƃFaulty hydraulic valve tappet system
- Broken valve spring - Low engine oil level
ƃ Cylinder head - Contaminated oil
- Leaking or damaged head gasket - Low oil pressure
- Warped or cracked cylinder head - Damaged hydraulic tappet
ƃ Cylinder and piston (Refer to Section 10) ƃ Sticking valve or broken valve spring
ƃ Damaged or worn camshaft
ƃ Loose or worn cam chain
ƃ Worn or damaged cam chain tensioner
ƃ Worn cam sprocket teeth

9-2
 Cylinder Head/Valve

Camshaft Removal
Cylinder head cover
ƃ Remove the luggage box. (ਨ 4-5)
ƃ Remove the center cover. (ਨ 4-4)
ƃ Remove the shroud R/L.(ਨ 8-2)
ƃ Remove the cylinder head cover bolt and cover.

ƃ Remove the fan cover from the R shroud. Turn

the crankshaft to the left, and align the “T” mark
of the flywheel with the index mark of the R crank
case cover.
ƃ Verify that the piston is located at the top dead
center. (Make all camshaft lobes face downward.)
ƃ If all camshaft lobes face upward, rotate the
crankshaft to the left for 1 turn (360Ƃ), and align th
“T” mark with the index mark once again.
“T” mark

ƃ Loosen the four 8mm nuts of the camshaft holder.

Sealing screw
ƃ Remove the camshaft holder from the cylinder
head.

Cam chain
tensioner

ƃ Loosen the four 8mm nuts of the camshaft holder.

ƃ Remove the camshaft holder from the cylinder
head.

Nut

9-3
Cylinder Head/Valve

ƃ Remove the cam chain from the camshaft.

Camshaft
NOTE
ҮTake precautions not to allow the cam chain to
drop into the crank case.

ƃ Remove the camshaft.

Cam
chain

ƃ Insert the 6mm bolt into the rocker arm shaft, and
pulling bolts to remove the rocker arm shaft.
ƃ Remove the rocker arm.
ƃ Remove the other side rocker arm shaft and
rocker arm in the same sequence.

Rocker
arm

Inspection
ƃ Check the rocker arm and rocker arm shaft for Rocker
wear or damage. arm
ƃ Measure the inner diameter of the rocker arm.
Service limit: 12.060mm (0.4748in)
ƃ Measure the outer diameter of the rocker arm
shaft. Contact
Service limit: 11.950mm (0.4705in) part

Rocker arm
shaft

ƃ Check the cam lobes of the camshaft for wear or

damage.
ƃ Measure the height of the cam lobe.
Service limit: IN: 33.615mm (1.3234 in)
EX: 33.765mm (1.3293 in)

9-4
 Cylinder Head/Valve

ƃ Manually turn the camshaft bearing outer race,

and check if it turns smoothly. Bearing

ƃ Check the bearing for wear or damage.

Cylinder Head Removal

ƃ Remove the engine from the frame.(ਨ section 5)
Cylinder head
ƃ Remove the camshaft.
ƃ Remove the cylinder head from the cylinder.

ƃ Remove the gasket, dowel pin and cam chain

Cam chain guide
guide from the cylinder.

Cylinder Head Disassembly

ƃ Remove the carburetor insulator. Carburetor
ƃ Remove the spark plug from the cylinder head. insulator

9-5
Cylinder Head/Valve

ƃ Remove the valve spring, valve cotter, retainer,

spring and valve.
Tool: Valve spring compressor
NOTE
ҮTo prevent the loss of tension, do not compress
the valve spring more than necessary.

NOTE Valve spring compressor

ҮMark the disassembled parts so that they can be

reassembled into the original position later.
ƃ Remove the valve spring seat and valve stem
seal. Remove carbon deposits from the inside of
the combustion chamber.

Cylinder Head
ƃ Remove gasket marks from the cylinder head
gasket.

NOTE
ҮTake precautions not to damage the cylinder
head gasket attachment.
ƃ Check the spark plug assembling hole and the
valve seat for cracks.
ƃ Using a square and a feeler gauge, check the
cylinder head distortion.
Service limit: 0.1mm(0.004in)

Valve Spring
ƃ Measure the free length of the valve spring.
Service limit: 36.90mm(1.4528in)

NOTE
ҮReplace the valve spring with new one if the
length of any one is less than the service limit.

Clearance Between Valve Steam and Guide

ƃ Check the valve for bend, seizure, or damage, and
check the stem for abnormal wear.
ƃ Insert the valve into the valve guide, and check
the operation.
ƃ Measure, and record, the outer diameter of the
valve stem.
Service limit: I N: 4.920mm(0.1937in)
EX: 4.900mm(0.1929in)

9-6
 Cylinder Head/Valve

ƃ Insert the valve guide reamer into the combustion

chamber, and remove the carbon deposits.

NOTE Valve guide

reamer
Ү Always insert the reamer while turning it right.
If it is inserted without turning, or while turning
left, interior part of guide will be damaged.

Tool: Valve guide reamer

ƃ Measure, and record, the inner diameter of the

valve guide.
Service limit: 5.030mm(0.1980in)
ƃ Check the clearance between the valve stem and
guide.
Service limit: I N: 0.090mm(0.0035in)
EX: 0.120mm(0.0047in)
ƃ Measure the inner diameter of the new valve
guide. If the clearance is not within the service
limit, replace the valve.

Valve Guide Replacement

NOTE
ҮAfter changing the valve guide, make sure to Valve
guide
adjust the valve seat. driver
Valve
guide
ƃ Heat all cylinder heads uniformly to approximate
levels of 130~140Ű
NOTE
ҮDo not allow the temperature to exceed 150Ű

NOTE

ҮTake particular precautions as poor handling

may lead to serious burns.
ҮDo not locally heat the cylinder head with a gas
burner as it may cause cylinder head distortion.

9-7
Cylinder Head/Valve

ƃ Support the cylinder head, and strike and remove

the valve guide from the combustion chamber by Valve guide driver
using a valve guide driver.
Tool: Valve guide driver

NOTE
ҮTake precautions not to damage the cylinder head.

ƃ Install new O-ring and new valve guide.

ƃ Insert the valve guide from the top of the cylinder

head.
Tool: Valve guide driver
ƃ After inserting the valve guide, insert the valve
guide reamer through the cylinder head
combustion chamber side to trim the valve guide.

CAUTION

ҮMake sure the reamer is not tilted when trimming

the valve guide. If the reamer is tilted when
cutting, the valve hole will also be tilted, causing
the stem seal to leak, or the valve seat border will be
expanded excessively to an uncorrectable extent.
Valve guide reamer
ҮInsert the reamer while turning it clockwise. If the
reamer is inserted while turning it counterclock-
wise, or without turning, the guide interior part will
be damaged.

Tool: Valve guide reamer

ƃ Clean the cylinder head to remove foreign
matters.
ƃ Check the valve seat border, and adjust properly.

Valve Seat
Inspection/Adjustment
ƃ Remove carbon deposits from the valve.
ƃ Apply a light coating of prussian blue to the
cylinder head valve seat.
ƃ Gently strike the valve with the valve guide
reamer, without turning the valve, to accurately
set the fit position.

9-8
 Cylinder Head/Valve

ƃ Remove the valve, and check the status of the seat

contact, with a light coating of prussian blue applied
to the valve face.
ƃ If the valve seat is damage, make necessary repair.
If the valve is tilted, check the clearance between
the valve guide and stem. Replace the valve guide
if the clearance is abnormal.
NOTE
ҮValve cannot be corrected. If the valve face is
seized, excessively worn, and if the contact is
poor, change the valve. Valve seat

ƃ Measure the valve seat width.

Standard value: 0.8-1.0mm(0.031-0.039in)
Service limit: 1.4mm(0.055in)
45Ƃ

Valve Seat Cutter

ƃ Repair the damaged valve seat by using valve
seat cutters and grinders. 55Ƃ
37Ƃ
NOTE
ҮFollow the seat cutter user’s manual.

Valve Seat Repair

ƃ If the seat surface is rough or otherwise damaged,
Roughness
use a 45ŭcutter to grind the surface.

NOTE
ҮGrind the seat surface after the valve guide is
replaced.

ƃ Correct the plane slightly using a 37֦ cutter.

37Ƃ

9-9
Cylinder Head/Valve

ƃ Use a 55֦ cutter to make minor repairs on the

inside.

55Ƃ

ƃ Use a 45֦ cutter to make adjustment within the

level of prescribed width.

Seat width

45Ƃ

ƃ Apply a light coating of prussian blue to the

valve seat. Gently strike the valve with a valve
guide reamer to check the status of contact, Too high
without turning the valve.
ƃ If the contact surface is too high, grind the
surface with a 37 ֦ cutter, and finish to the
prescribed width with a 45֦ cutter.
37Ƃ

ƃ If the contact surface is too low, grind the surface

with a 55֦ cutter, and finish to the prescribed
width with a 45֦ cutter. Too low

55Ƃ

9-10
 Cylinder Head/Valve

ƃ After adjustment, apply compound evenly to the

valve seat and set the valve with a valve guide
reamer.
NOTE
ҮDo not excessively press and turn the valve to set it as
it may cause damage. Gently strike and set the valve.
ҮThe seat surface may become worn on one side if the
valve is set in the same position. Turn the valve
slightly when setting it.
ҮTake precautions not to allow compound to get into
the clearance between the stem and guide while the
valve is being set.

Cylinder Head Assembly

ƃ Assemble the valve spring seat and new stem seal. Stem seal Valve
ƃ Apply molybdenum grease to the valve stem. Spring
Retainer
Turn valve slowly and insert it into the guide,
Cotter
taking precautions not to damage the stem seal.
ƃ Verify that valve is moving up and down
smoothly.

ƃ Assemble the spring with its narrow side pitch

facing the cylinder head.

Narrow side

ƃ Assemble the spring retainer.

ƃ Compress the valve spring and install the valve
cotter.

NOTE
ҮDo not compress the valve spring more than
necessary.
Tool: Valve spring compressor
Valve spring compressor

9-11
Cylinder Head/Valve

ƃ Lightly strike the valve stem end for about 2-3

times to ensure better installation of the valve
and cotter.

NOTE
ҮTake necessary precautions not to damage valve.

ƃ Apply engine oil to the new O-ring, and

assemble it to the carburetor insulator groove. Carburetor
ƃ Tighten the carburetor insulator with mounting insulator
bolts.
ƃ Install the cam chain tensioner, and assemble
pivot bolts.
Torque valve: 1.0kg-m (10N.m, 7ft-lb)
ƃ Assemble spark plugs.
Torque valve: 1.1kg-m (11N.m, 8ft-lb)

Cylinder Head Installation Cam chain

ƃ Clean the gasket marks from the cylinder head guide
gasket.
ƃ Assemble the cam chain guide to the cylinder.
ƃ Assemble the dowel pins and new gaskets.

ƃ Assemble the cylinder head.

ƃ Install the camshaft.
ƃ Install the engine to the frame. (ਨ section 5) Cylinder head

9-12
 Cylinder Head/Valve

Cam Shaft Assembly Shaft

Rocker Rocker
arm arm Shaft
ƃ Apply engine oil to the rocker arm shaft, and
assemble the rocker arm to the camshaft holder.

ƃ Tighten the rocker arm shaft with 6mm bolts, and

align the bolt hole of the camshaft holder with
the fitting side of the rocker arm shaft.

ƃ check the camshaft assembly for abnormal

condition, and place it on the cylinder head. Camshaft
ƃ Put the cam chain on the cam sprocket.

Cam
chain

ƃ Slowly turn the crankshaft to the left, and align

the “T” mark of the flywheel with the index mark
of the R. crank case cover.

NOTE
ҮTake precautions not to allow the cam chain to
come off the camshaft timing gear while turning
the camshaft

“T” mark

9-13
Cylinder Head/Valve

ƃ Apply engine oil to the camshaft, and install it on

the cylinder head with the cam thread facing
downward.
ƃ Assemble the cam chain and cam sprocket after
Dowel pin
matching the cam sprocket timing mark in
parallel with the top of the cylinder head.

ƃ Install the dowel pins on the cylinder head.

ƃ Install the camshaft holder.

NOTE

ҮThe hole of the camshaft holder and the fitting

section of the rocker arm shaft fit section must be
in alignment.
ҮOf IN and EX, the shorter rocker arm should be
installed on the IN side.

ƃ Apply engine oil to the threaded part; install the

camshaft holder nut and bolts, and tighten them
driving with 2 or 3 times.
Torque values: 8mm nut 2.9kg-m(29N.m, 21ft-lb)

Nut

ƃ Remove the sealing screws and washers from the

cam chain tensioner lifter.
ƃ Turn the tensioner shaft to the right with a small
driver, and insert the shaft into the body
Tensioner lifter
completely.

NOTE
ҮIf the cam chain tensioner lifer is dropped, the
shaft will advance by the spring force.

9-14
 Cylinder Head/Valve

ƃ Fix the tensioner shaft with a hard clip.

ƃ assemble a new gasket to the tensioner lifter, and
install the tensioner lifter on the cylinder.
ƃ Tighten the tensioner mounting bolts.
Torque values: 1.2kg-m (12N.m, 9ft-lb)

ƃ Remove the tensioner shaft clip from the

Sealing screw
tensioner lifter. Assemble sealing washers and
screws to the tensioner lifter.
Torque values: 0.4kg-m(4N.m, 3ft-lb)

Cam chain
tensioner

ƃ Fill clean engine oil into the operating parts of the

cylinder head. Gasket
ƃ Adjust the valve clearance. (ਨ 3-5)

ƃ Remove oil from the cylinder head cover

grooves, and accurately assemble the gasket to
the cover.
ƃ Assemble the cylinder head cover.
ƃ Tighten the cylinder head cover bolt.
Torque values: 1.3kg-m (13N.m, 9ft-lb)
- Install the R/L shroud. (ਨ 8-2)
- Install the luggage box. (ਨ 4-5)
- Install the center cover. (ਨ 4-4)
Cylinder head cover

9-15
Cylinder/Piston

Piston top ring

Piston 2ND ring
Piston Oil ring

Piston pin clip

Piston pin clip

OIL
OIL

10-0
 Cylinder/Piston

10. Cylinder/Piston

Services information 10-1 Piston 10-3

Troubleshooting 10-1 Piston/Cylinder assembly 10-5
Cylinder 10-2

Service Information
General Safety
ƃ Take precautions not to damage the joint part with a driver when removing the cylinder, or not to damage
the cooling pin by striking the cylinder too hard.
ƃ Take precautions not to damage the inside of the cylinder or the exterior part of the piston.
ƃ Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.
Specifications Unit: mm(in)
Item Standard value Service limit
Inner diameter 56.000-56.010(2.2047-2.2051) 56.100(2.2087)
Cylindricality ӹӹӹ 0.050(0.002)
Cylinder
Out of roundness ӹӹӹ 0.005(0.0002)
Head contact warpage ӹӹӹ 0.020(0.0008)
Piston skirt outer diameter 55.925-55.945(2.2018-2.2026) 54.832(2.1587) 
Piston pin hole inner diameter 15.002-15.008(0.5906-0.5909) 15.038(0.5920)
Piston pin outer diameter 14.994-15.000(0.5903-0.5906) 14.960(0.5890)
Piston,
Piston-to-piston pin clearance 0.002-0.140(0.0001-0.0006) 0.020(0.0008)
Piston pin,
Piston ring-to groove Top 0.040-0.057(0.0016-0.0026) 0.110(0.0043)
Piston ring
clearance Second 0.025-0.052(0.0010-0.020) 0.080(0.0031)
Piston ring Top/second 0.10-0.25(0.004-0.010) 0.50(0.020)
joint gap Oil(side rail) 0.20-0.70(0.008-0.028) 1.10(0.040)
Cylinder-to piston clearance 0.055-0.085(0.0022-0.0033) 0.340(0.0134)
Connecting rod small end inner diameter 15.010-15.028(0.5909-0.5917) 15.060(0.5930)
Gap between connecting rod small end and piston pin 0.010-0.034(0.004-0.0013) 0.040(0.0020)

Troubleshooting
Compression low Overheating
ƃ Worn cylinder or piston rings ƃ Excessive carbon build-up on the piston
ƃ Leaking valve seats combustion
ƃ Incorrect spark plug
Excessive smoke
ƃ Worn cylinder or piston Knocking or abnormal noise
ƃ Improper installation of piston rings ƃ Worn piston and cylinder
ƃ Scored or scratched piston or cylinder wall ƃ Excessive carbon build-up
ƃ Low octane fuel

10-1
Cylinder/Piston

Cylinder Cam chain guide

Removal
ƃ Remove the cylinder head. (ਨ 9-5)
ƃ Remove the cam chain guide from the cylinder.
ƃ Remove the cylinder.

ƃ Remove the gasket and dowel pin. Remove the

gasket residues attached to the cylinder.

NOTE Gasket

ҮTake precautions not to damage the gasket.

Inspection Cylinder gauge

ƃ Measure, and record, the cylinder inner diameter
from the 6 top, middle and bottom places in the
piston direction and the perpendicular axial
(X and Y direction) direction.
ƃ The maximum value shall be the cylinder inner
diameter.
Service limit: 56.100mm(2.2087in)
ƃ Measure the piston outer diameter.
ƃ Subtract the piston outer diameter value from the
cylinder inner diameter value, and measure the
clearance between the cylinder and piston.
Service limit: 0.340mm(0.0134in)
ƃ Based on each measured value, calculate the out
of roundness (difference between X direction and
Top
Y direction) and cylindericality (Difference of top,
middle and bottem inner diameter in the
Middle
direction of X or Y).
Service limit: Out of roundness 0.005mm(0.0002in)
Cylindricality 0.05mm(0.002in) Bottom

10-2
 Cylinder/Piston

ƃ Check the cylinder distortion.

Service limit: 0.02mm (0.0008in)

Piston Piston pin

Disassembly
ƃ Remove the piston pin clip

NOTE
Piston
ҮTake precautions not to drop the piston pin clip
into the crank case.

ƃ Remove the piston pin, and separate piston.

ƃ Check the piston ring.

ƃ Remove the piston ring.

NOTE

ҮBe careful not to damage the piston with the

piston ring while removing the ring.

ƃ Check the clearance between the piston ring and

groove. Piston ring
Service limit: Top 0.110mm(0.0043in)
Second 0.080mm (0.003in)
Oil 0.280mm(0.0110in)
ƃ Check the piston for wear or damage.

10-3
Cylinder/Piston

ƃ Insert the piston ring into the inside of the

cylinder, and check the piston ring clearance.
Feeler gauge
NOTE
ҮUse the piston head to insert the piston ring so
that the piston can be level.

Service limit: Top/second 0.50mm (0.020in)

Oil (side rail) 1.10mm (0.040in)

ƃ Measure the piston outer diameter at a point

10mm from the piston bottom in the direction of
90Ŋto the piston pin
Service limit: 55.82mm (2.198in)

ƃ Measure the inner diameter of the piston pin hole.

Service limit: 15.038mm (0.5920in)

ƃ Measure the outer diameter of the piston pin.

Service limit: 14.960mm (0.5890in)

ƃ Check the clearance between the piston and piston pin.

Service limit: 0.020mm (0.00008in)

ƃ Measure the inner diameter of the connecting rod

small end.
Service limit: 15.060mm (0.5930in)

ƃ Check the clearance between inner diameter of

the connecting rod small end and the piston pin.
Service limit: 0.040mm (0.0020in)

10-4
 Cylinder/Piston

Piston/Cylinder Assembly
Piston Ring Assembly
ƃ Clean the piston ring groove with oil, and Mark
assemble the piston ring.

NOTE
R
ҮThe ring is easily broken. Take necessary
precautions not to break it, and not to damage
the piston during assembly.
ҮAssemble the ring with the marked side facing
upward. Top ring
ҮDo not confuse the top ring and the second ring.
Second ring
ƃ Stagger the ring end gaps 120Ŋapart.
ƃ Do not match the oil ring side rail ends with each
other.
Side rail

Oil
Spacer
ring

20mm(3/4in)
Side rail

ƃ After assembling, verify the ring is rotating

smoothly.

Top ring

Second
ring

Piston/Cylinder Assembly
ƃ Remove the gasket from the crank case.

NOTE
Ү Be careful not to damage the gasket surface.
Ү Place a piece of cloth over the crank case to
prevent the gasket from falling into the crank
case.

10-5
Cylinder/Piston

ƃ Assemble the piston, and piston pin to the

Piston pin
connecting rod.
ƃ Assemble new piston pin clips.

NOTE
ҮLet the “IN” mark face towards the intake valve
Piston
side.
ҮPlace a piece of cloth over the crank case to
prevent the piston pin clips from falling into the
crank case.
ҮMake sure the piston pin clip joint is not aligned
with the piston groove.

ƃ Assemble new gaskets and dowel pins.

Gasket Dowel pin

ƃ Apply engine oil to the cylinder inside and the

Cylinder
piston ring, and assemble the piston ring.

NOTE
ҮBe careful not to damage the piston ring.
ҮTake precautions to prevent the cam chain from
falling into the crank case.
Cam chain

ƃ Assemble the lower part of the cam chain guide to Cam chain guide
the crank case lost, and install the cam chain guide
by aligning the tangs with the cylinder slots.
ƃ Assemble the cylinder head. (ड 9)

10-6
MEMO