Filter
Top Products
ENGINE TOP E ND 5-1
5
Engine Top End
Table of Contents
Exploded View........................................................................................................................ 5-3
Exhaust System...................................................................................................................... 5-8
Specifications ......................................................................................................................... 5-11
Special Tools and Sealant ...................................................................................................... 5-12
Clean Air System.................................................................................................................... 5-14
Air Suction Valve Removal................................................................................................ 5-14
Air Suction Valve Installation............................................................................................. 5-14
Air Suction Valve Inspection ............................................................................................. 5-14
Air Switching Valve Removal ............................................................................................ 5-15
Air Switching Valve Installation ......................................................................................... 5-15
Air Switching Valve Operation Test ................................................................................... 5-15
Air Switching Valve Unit Test ............................................................................................ 5-15
Clean Air System Hose Inspection ................................................................................... 5-15
Cylinder Head Cover .............................................................................................................. 5-16
Cylinder Head Cover Removal ......................................................................................... 5-16
Cylinder Head Cover Installation ...................................................................................... 5-16
Camshaft Chain Tensioner ..................................................................................................... 5-18
Camshaft Chain Tensioner Removal ................................................................................ 5-18
Camshaft Chain Tensioner Installation ............................................................................. 5-19
Camshaft, Camshaft Chain .................................................................................................... 5-20
Camshaft Removal ........................................................................................................... 5-20
Camshaft Installation ........................................................................................................ 5-21
Camshaft, Camshaft Cap Wear ........................................................................................ 5-25
Camshaft Runout .............................................................................................................. 5-25
Cam Wear.........................................................................................................................5-26
Camshaft Chain Removal ................................................................................................. 5-26
Cylinder Head......................................................................................................................... 5-27
Cylinder Compression Measurement................................................................................ 5-27
Cylinder Head Removal .................................................................................................... 5-28
Cylinder Head Installation ................................................................................................. 5-29
Cylinder Head Warp.......................................................................................................... 5-30
Valves ..................................................................................................................................... 5-31
Valve Clearance Inspection .............................................................................................. 5-31
Valve Removal .................................................................................................................. 5-31
Valve Installation...............................................................................................................5-31
Valve Guide Removal ....................................................................................................... 5-31
Valve Guide Installation .................................................................................................... 5-32
Valve-to-Guide Clearance Measurement (Wobble Method) ............................................. 5-32
Valve Seat Inspection ....................................................................................................... 5-33
Valve Seat Repair ............................................................................................................. 5-33
Throttle Body Assy Holder...................................................................................................... 5-38
Throttle Body Assy Holder Removal ................................................................................. 5-38
Throttle Body Assy Holder Installation .............................................................................. 5-38
Muffler..................................................................................................................................... 5-39
Muffler Body Removal....................................................................................................... 5-39
Muffler Body Installation.................................................................................................... 5-40
Middle and Rear Exhaust Pipe Removal .......................................................................... 5-41
Middle and Rear Exhaust Pipe Installation ....................................................................... 5-42
Front Exhaust Pipe Removal ............................................................................................ 5-43
Front Exhaust Pipe Installation ......................................................................................... 5-44
www.zxforums.com
www.zxforums.com
www.zxforums.com
www.zxforums.com
www.zxforums.com
www.zxforums.com
www.zxforums.com