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ENGINE TOP END 5-1
5
Engine Top End
Table of Contents
Exploded View................................... 5-2
Specifications .................................... 5-8
Special Tools and Sealant ................. 5-11
Camshaft Chain Tensioner ................ 5-13
Camshaft Chain Tensioner
Removal.................................... 5-13
Camshaft Chain Tensioner
Installation ................................. 5-13
Rocker Case...................................... 5-15
Rocker Case Removal................. 5-15
Rocker Case Installation.............. 5-16
Rocker Arm Removal................... 5-17
Rocker Arm Installation................ 5-18
Rocker Arm Inspection................. 5-18
Rocker Shaft Diameter
Measurement ............................ 5-19
Camshaft ........................................... 5-20
Camshaft Removal ...................... 5-20
Camshaft Installation ................... 5-20
Camshaft Assembly..................... 5-21
Cam Wear.................................... 5-21
Camshaft Bearing Wear ............... 5-22
KACR Inspection.......................... 5-23
KACR Removal............................ 5-23
KACR Installation......................... 5-24
Camshaft Chain Removal............ 5-24
Camshaft Chain Installation......... 5-25
Camshaft Chain Guide Wear....... 5-28
Cylinder Head .................................... 5-29
Cylinder Compression
Measurement ............................ 5-29
Cylinder Head Removal ............... 5-30
Cylinder Head Installation............ 5-30
Cylinder Head Cleaning............... 5-31
Cylinder Head Warp..................... 5-31
Valves ................................................ 5-32
Valve Clearance Inspection ......... 5-32
Valve Clearance Adjustment........ 5-32
Valve Removal ............................. 5-32
Valve Installation .......................... 5-32
Valve Guide Removal .................. 5-32
Valve Guide Installation .. ............. 5-33
Valve-to-Guide Clearance
Measurement ............................ 5-33
Valve Seat Inspection .................. 5-34
Valve Seat Repair (Valve
Lapping) .................................... 5-34
Cylinder and Piston ........................... 5-39
Cylinder Removal......................... 5-39
Piston Removal............................ 5-39
Cylinder, Piston Installation. ......... 5-39
Cylinder Wear .............................. 5-41
Piston Wear ................................. 5-41
Piston/Cylinder Clearance ........... 5-41
Piston Ring, Piston Ring Groove
Wear.......................................... 5-42
Piston Ring Groove Width............ 5-42
Piston Ring Thickness ................ 5-42
Piston Ring End Gap ................... 5-43
Exhaust System................................. 5-44
Spark Arrester Cleaning............... 5-44
Muffler and Exhaust Pipe
Removal .................................... 5-44
Muffler and Exhaust Pipe
Installation ................................. 5-45
Exhaust System Inspection.......... 5-46