Service Manual

ENGINE TOP END 5-1
5
Engine Top End
TABLE OF CONTENTS
Exploded Vi ew........................................................................................................................... 5- 2
Specifications ............................................................................................................................ 5- 4
Special Tools ............................................................................................................................. 5- 5
Cylinder Head.................... ............ ........... ............ ............ ......................... ................................ 5- 6
Compression Measurement................................................................................................. 5- 6
Cylinder Head Assembly Removal ...................................................................................... 5- 7
Cylinder Head Assembly Installation ................................................................................... 5- 7
Push Rod Removal .............................................................................................................. 5- 8
Push Rod Installation ........................................................................................................... 5-8
Push Rod Inspection............................................................................................................ 5- 8
Valve Mechanism Removal/Installation ............................................................................... 5- 9
Cleaning and Inspection ...................................................................................................... 5- 9
Rocker Arm Inspection......................................................................................................... 5-10
Valves ........................................................................................................................................ 5-11
Valve Clearance Inspection ................................................................................................. 5-11
Valve Clearance Adjustment................................................................................................ 5-11
Valve Seat Inspection .......................................................................................................... 5-11
Valve S eat Repair ................................................................................................................ 5-11
Valve Head Thickness ......................................................................................................... 5-11
Valve Stem Runout .............................................................................................................. 5-11
Valve Stem Diameter ........................................................................................................... 5-11
Valve Guide Inside Diameter ............................................................................................... 5-12
Valve Spring Inspection ....................................................................................................... 5-12
Automatic Compression Release (ACR) Device Inspection ................................................ 5-12
Cylinder, Piston......................................... ................................................................................. 5-13
Piston Removal.................................................................................................................... 5-13
Piston Installation................................................................................................................. 5-14
Piston Cleaning.................................................................................................................... 5-16
Piston Ring and Ring Groove Wear..................................................................................... 5-17
Piston Ring End Gap ........................................................................................................... 5-17
Piston Pin, Piston Pin Hole, and Connecting Rod Wear...................................................... 5-18
Piston Diameter ................................................................................................................... 5-18
Cylinder Inside Diameter...................................................................................................... 5-19
Muffler ....................................................................................................................................... 5-20
Muffler Removal................................................................................................................... 5-20
Muffler Installation................................................................................................................ 5-20
Inspection............................................................................................................................. 5-20