ENGINE TOP END 4-1

Table of Contents

Exploded View , , 4-2 Valve

Valve
Valve
Valve
Measure Clearance
Removal
Guide
Installation
Seat
Seat Valve-to-Guide Width
Outside
Repair Removal
Installation Adjustment Inspection
(Valve Diameter Lapping)
Clearance
..4-15
Specifications 4-4 ..4-16
Special Tools 4-6 ..4-16
Sealant , 4- 7 ..4-16
Cylinder Head Cover 4-8 ..4-16
Removal 4-8 ..4-17
Installation 4-8 ..4-17
Camshaft Chain Tensioner 4-9 ..4-17
Removal 4-9
Installation 4-9 Cylinder, Cylinder
Cylinder
Piston
Cylinder
Piston (Wobble Pistons
Wear
Removal
Installation
Ring, Wear
Removal
Installation Method) Piston Ring ,
Groove , Wear
.4-19
Camshaft 4-10 .4-20
Camshaft Removal 4-10 .4-20
Camshaft Installation 4-11 .4-20
Camshaft, Camshaft Cap Wear 4-12 ..4-21
Camshaft Chain Wear 4-12 ..4-21
Rocker Arm, Rocker Shaft 4-13 ..4-21
Rocker Arm and Rocker Shaft Removal 4-13 ..4-22
Rocker Arm and Rocker Shaft ..4-22
Installation Notes 4-13 Carburetor
Muffler Piston
Installation
Removal
Removal
Installation Ring Holders End , Gap
..4-22
Rocker Arm and Rocker Shaft Inspection Note 4-13 ..4-23
Cylinder Head 4-14 ..4-23
Cylinder Compression Measurement 4-14 ..4-23
Removal 4-14 ..4-23
Installation 4-14 ..4-23
Valves 4-15 ..4-23
 ENGINE TOP END 4-3

r c .~
~-
"
~
:"
~c:::c
~ ""'
.,

~"
~"

~
~

~ ,~
~
~
~
,
~
~
~
B
e >@
@ 0 ~
0
\\
~ \
~\
~
~
I ~
@
~-~ "'~
\ e P"
--, p. ~
, ~
I ~ ! ,~

~ @ e J@ mil'
~oq;;::::: ) ~ t
~

1 A ~

/
~

/
~

'@
/\
CD

T1: 8.8 N-m (0.9 kg-m. 78 in-Ib)

T2: 9.8 N-m (1.0 kg-m. 7.0 ft-Ib)
T3: 12 N-m (1.2 kg-m. 8.5 ft-Ib)
T4: 25 N-m (2.5 kg-m. 18.0 ft-Ib)
L: Apply a non-permanent locking agent to the
threads.
M: Apply molybdenum disulfide grease.

, 88: Apply silicone sealant to the threads.

 4-4 ENGINE TOP END

Specifications

Item Standard Service Limit

Camshaft:

Cam height

Inlet 31 .778 -31 .918 mm 31 .68 mm

Exhaust 31.469 -31.609 mm 31 .37 mm
Camshaft, camshaft cap clearance
A 0.028 -0.071 mm 0.16 mm
B 0.078- 0.121 mm 0.21 mm
Camshaft journal diameter: A 23.950 -23.972 mm 23.92 mm
B 23.900 -23.922 mm 23.87 mm
Camshaft bearing inside diameter 24.000 -24.021 mm 24.08 mm
Camshaft runout 0.1 mm TIR
Camshaft chain 20-link length 127.0- 127.4 mm 1 28.9 mm

Cylinder Head:
Cylinder compression (Usable range) 1 686 -1 079 kPa
(7.0 -11.0 kg/cm2, 99 -156 psi)
@330 r/min (rpm)
Cylinder head warp 0.05 mm

Valves:

Valve clearance Inlet 0.12- 0.17 mm

Exhaust 0.16- 0.21 mm
Valve spring free length 38.2 mm 36.4 mm
Valve head thickness: Inlet 0.5mm 0.25 mm
Exhaust 0.7 mm 0.35 mm
Valve stem bend 0.02 TIR or under 0.05 mm TIR
Valve seat cutting angle 45°, 32°, 60°
Valve seat surface:
Width: Inlet 0.5 -1 .0 mm ---
Exhaust 0.5 -1 .0 mm --
Outside diameter: Inlet 21 .5 -21 .7 mm
Exhaust 18.5- 18.7 mm

Camshaft Journal Diameter

~
 ENGINE TOP END 4-5

Item Standard Service Limit

Valve/valve guide clearance

(wobble method):
Inlet 0.031 -0.140 mm 0.34 mm

Exhaust 0.085- 0.180 mm 0.41 mm

Valve stem diameter

Inlet 3.975 -3.990 mm 3.96 mm

Exhaust 3.955 -3.970 mm 3.94 mm

Valve guide inside diameter 4.000 -4.012 mm 4.08 mm

Cylinder. Piston:
Cylinder inside diameter ~ 57.000 -57.01 2 mm 57.10 mm

Piston diameter 56.942 -56.957 mm 56.79 mm

Piston/cylinder clearance 0.043 -0.070 mm

Oversize piston and rings + 0.5 mm
Piston ring/groove clearance 0.030 -0.070 mm 0.17 mm

Piston ring end gap:

Top 0.20 -0.40 mm 0.70 mm

Second 0.35 -0.50 mm 0.80 mm

Valve Head Valve Stem Bend

4-6 ENGINE TOP END

Special Tools

Compression Gauge: 57001 -221

Compression Gauge Adapter, M10 X 1.0: 57001-1317

Rocker Arm Holder: 57001 -1270 Valve Guide Reamer, <!>4: 57001-1274

Valve Spring Compressor Assembly: 57001-241 Valve Seat Cutter Holder, <!>4: 57001-1275

Valve Spring Compressor Adapter, <1>21: 57001-1272 Valve Seat Cutter, 45° -4>24.5: 57001 -1113
 ENGINE TOP END 4-7

Valve Seat Cutter, 3L -<t>25: 57001-1118

Valve Seat Cutter, 60. -<f>30: 57001-1123

Sealant

Valve Seat Cutter, 32.- <!>22: 57001 -1206

4-8 ENGINE TOP END

Cylinder Head Cover

Removal
.Remove the following.
Fuel Tank (see Fuel System chapter)
Air Cleaner Housing (see Fuel System chapter)
Ignition Coils
Throttle Cable
Choke Cable
Baffle Plate

1. Silicone Sealant Applied Areas

A. Baffle Plate Bolt

.Remove the cylinder head cover bolts and take off the
cover.

A. Bolts B. Cylinder Head Cover

I nsta!lation
.Replace the head cover gasket with new one if it is
damaged.
.Apply silicone sealant to the cylinder head as shown.
.Tighten the cover bolts to the specified torque (see
Exploded View).
 ENGINE TOP END 4-9

Camshaft Chain Tensioner

Removal
.Remove the pickup coil cover.
.Remove the mounting bolts and take off the camshaft
chain tensioner.

A. Taper Part (Stopper) B. Push Rod

.Compressing the spring against the push rod head,

insert a thin wire through the hole in the push rod to
keep the spring in place.

A. Camshaft Chain Tensioner c. Lock Bolt

B. Mounting Bolts

.Pull out the rod from the cam chain guide (rear side)

A. Wire B. O-ring

.Apply grease to the O-ring.

.Install the top end of a extension rod into a hole of the
chain guide.

! nsta!!ation
.Compressing the push rod. into the tensioner body and
lock it.
O Remove the lock bolt on the side of the tensioner body.
OWhile pushing the taper part of the stopper, push the
rod.

A. Extension Rod B. Chain Guide

.Install the tensioner body on the engine.

.Apply a non-permanent locking agent to the mounting
bolts and tighten them to the specified torque (see
Exploded View).
.Pull the wire out and tighten the lock bolt.
.Install the pickup coil cover.
4-10 ENGINE TOP END
OApply silicone sealant to the crankcase parting line and
grommet (see 4-12). Camshaft
OApplya non-permanent locking agent to only one bolt
(see 4-12).
Camshaft Removal
.Remove the following.
Lower Fairings (see Frame chapter)
Pickup Coil Cover
Damper Rubber (from Rear Cam Chain Guide)
.Remove the following.
Carburetor (see Fuel System chapter)
Cylinder Head Cover (this chapter)
Spark Plug Retainer
Camshaft Chain Tensioner (this chapter)

NOTE

OBefore removing the chain tensioner, position the

crankshaft at # 1, 4 piston TDC.

1. TDC Mark 3. Front

2. Timing Mark (Crankcase Parting Line)

.Remove the camshaft cap bolts and take off the

camshaft caps, camshafts and upper chain guide.

A. Camshaft Caps C. Upper Chain Guide

B. Camshafts

.Stuff a clean cloth into the chain tunnel to keep any

parts from falling into the crankcase.
 ENGINE TOP END 4-11
.Pull the tension side (exhaust side) of the chain taut to
install the chain.
OThe timing marks must be aligned with the cylinder
head upper surface and positioned respectively as
shown, after the camshaft chain slack is taken up by the
tensioner.

Camshaft Installation
.Installation is the reverse of removal. Note the follow-
ing.
.Apply engine oil to all cam parts. If the camshaft(s)
and/or cylinder head are replaced with new ones, apply
a thin coat of molybdenum disulfide grease to the new
cam part surfaces.

NOTE
0 The exhaust camshaft has an EX mark and the inlet
camshaft has an IN mark. Be careful not to mix up these
shafts.

.The camshaft cap locations are numbered. Install the

caps in the positions as shown.

CD
Itr=

1. EX Mark 2. IN Mark

.Position the crankshaft at TDC for the #1 and #4

pistons, engage the cam chain with the camshaft
sprockets as shown.

1 .Camshaft Cap 3. Location Number

2. Upper Chain Guide

.Tighten the camshaft cap bolts to the specified torque

(see Exploded View).
.Install the camshaft chain tensioner.
.Install the pickup coil cover, noting the following.
OApply silicone sealant to the following.
Crankcase Parting Line
Grommet
 4-12 ENGINE TOP END

NOTE
0 Do not turn the camshaft when the plastigage is
between the journal and camshaft cap.

*If any clearance exceeds the service limit, measure the

diameter of each camshaft journal with a micrometer.

Camshaft. Camshaft Cap Clearance

#1. #4 Journals
Standard: 0.028 -0.071 mm
Service limit: 0.16 mm
#2. #3 Journals
Standard: 0.078- 0.121 mm
A. Apply silicone sealant. Service limit: 0.21 mm

.Apply a non-permanent locking agent to the following *If the camshaft journal diameter is less than the service
bolt only. limit (see Specifications), replace the camshaft with a
new one and measure the clearance again.
* If the clearance still remains out of the limit, replace the
cylinder head unit.

Camshaft Chain Wear

.Hold the chain taut with a force of about 5 kg in some
manner, and measure a 20-link length. Since the chain
may wear unevenly, take measurement at several places.
* If any measurement exceeds the service limit, replace the
chain.

Camshaft Chain 20-Link length

A. Apply a non-permanent locking agent. Standard: 127.0 -127.4 mm

Service Limit: 128.9 mm

Chain length Measurement

Camshaft, Camshaft Cap Wear

.Measure each clearance between the camshaft and the
camshaft cap using plastigage (press gauge).

NOTE
0 Tighten the camshaft cap bolts to the specified torque
(see Exploded View).

A. Plastigage Width
 ENGINE TOP END 4-13

Rocker Arm, Rocker Shaft I ~ I

Rocker Arm and Rocker Shaft Removal -L&- <D~.;~

.Remove the camshafts(this chapter).

NOTE
0 Mark the rocker arms so they may be put back in the
same position.

.Remove the rocker shaft plug and rocker shaft. and take
-
off the rocker arms.

1. Springs (conical)
2. Springs

.Tighten the following to the specified torque (see

Exploded View).
Upper Chain Guide Bolts
Camshaft Cap Bolts
Rocker Shaft Plug

Rocker Arm and Rocker Shaft Inspection Note

.1 nspect the rocker arms and rocker shafts.
*If they are badly worn, replace them.
A. Plug c. Rocker Shaft

B. Rocker Arms

Rocker Arm and Rocker Shaft

Installation Notes
.Blow the rocker arm oil passage clean with compressed
air and apply oil to the rocker arm bore before installa-
tion.

1. Rocker Arm 2. Oil Pressure

.Apply engine oil to the rocker shaft, and insert the shaft
running it through the cylinder head, the rocker arms
and springs.
.Install the retainer spring on each rocker arm as shown.
4-14 ENGINE TOP END

Removal
Cylinder Head .Drain coolant (see Cooling System chapter)
.Remove the following.
Radiator (see Cooling System chapter)
Cylinder CompressionMeasurement Muffler
Camshafts (see this chapter)
NOTE Oil Hose (Cylinder Head)
0 Use the battery which is fully charged. Engine Mounting Bracket Bolts, Nuts (Cylinder Head)
.Remove the cylinder head bolts and take off the cylinder
.Warm up the engine thoroughly. head.
.Remove the following.
Fuel Tank (see Fuel System chapter)
Surge Tank (see Fuel System chapter)
Spark Plugs I nstal/ation
.Attach the compression gauge and adapter (special .Installation is the reverse of removal. Note the follow-
tools) firmly into the spark plug hole. ing.
.Install the new cylinder head gasket with a new one.
.When the engine is mounted on the frame, install the
chain guide (rear side) into the cylinder head, and
tighten the mounting bolt to the specified torque (see
Exploded View) .
.Beforehand install the chain guide into the cylinder
head.
.Tighten the following bolts to the specified torque (see
Exploded View).
Camshaft Chain Guide Bolt (rear side)
Cylinder Head Bolts
Camshaft Cap Bolts
Upper Chain Guide Bolts
Oil Hose Mounting Bolts
Engine Mounting Bolts
A. Compression Gauge: 57001-221 .Tighten the cylinder head bolts following the tightening
B. Adapter: 57001 -1317 sequence.

.Hold the throttle wide open and crank the engine with
the starter.
.When the gauge stops rising, stop cranking and read the
gauge.

Cylinder Compression
Usable Range:
686 -1 079 kPa @330 r/min (rpm)
(7.0 -11.0 kg/cm2. 99 -156 psi)

*If cylinder compression is higher than the specified

range, check the following.
O Carbon build-up on the cylinder head combustion
chamber
OCarbon build-up on the piston head
.Install the chain guide (front side)
* If cylinder compression is lower than the specified
range, check the following.
O Valve not seating properly
O Piston/cylinder clearance excessive
O Gas leakage around the cylinder head gasket
O Valve clearance too small
O Piston ring/piston ring groove clearance
 ENGINE TOP END 4-15

Valves

Valve Clearance Adjustment

NOTE
0 Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).

.Remove the following.

Cylinder Head Cover
Spark Plug Retainer
.Using a thickness gauge, measure the valve clearance
between the rocker arm and the cam.
OWhen positioning #4 piston TDC at the end of
the compression stroke:
inlet valve clearance of #2 and #4 cylinders
exhaust valve clearance of #3 and #4 cylinders (see
Camshaft Removal)

Measuring Valves ;f!;Jnmyi;

1. Exhaust Valves 3. Cylinder Numbers

2. Inlet Valves

0 When positioning #1 piston TDC at the end of

the compression stroke:
inlet valve clearance of #1 and #3 cylinders
exhaust valve clearanceof #1 and #2 cylinders

Measuring Valves ttl~f

1. Exhaust Valves 3. Cylinder Numbers

2. Inlet Valves

Valve Clearance (between Cam and Rocker Arm)

Standard: Inlet: 0.12 -0.17 mm

Exhaust: 0.16 -0.21 mm
4-16 ENGINE TOP END
.Apply engine oil to the O-ring, install the spark plug
retainer.
*If the valve clearance is not within the specified range,
first record the clearance, and then adjust it.
.To change the valve clearance, replace the shim with
one of a different thickness.

NOTE
0 Mark and record shim locations so they can be
reinstalled in their original positions.

.To select a new shim which brings the valve clearance

within the specified range.
0 Remeasure any valve clearance that was adjusted.
Readjust if necessary.
1 .Split Keeper 5. Spring Seat
2. Retainer 6. Oil Seal
3. Valve Spring 7. Valve Stem
4. Closed Coil End
Valve Removal
.Perform the following.
O Using the valve spring compressor assembly (special
tool), remove the valve.
Valve Guide Removal
.Using the valve guide arbor (special tool), tap out the
valve guide.

"'--'

(D;
" ~
0

A. Valve Spring Compressor Assembly: 57001-241

B. Adapter: 57001 -1272
C. Valve Spring Compressor Joint: 57001 -1271
1. Valve Guide Arbor: 57001-1273

NOTE
Valve Installation CHeat the area around the valve guide to 120- 150 oC
.Replace the oil seal with a new one.
(248 -302°F).
.Applya thin coat of molybdenum disulfid~ grease to the
valve stem before valve installation.
.Install the springs so that the closed coil end faces
downwards.
Valve Guide Installation
.Using the valve guide arbor (special tool), drive the
valve guide until its flange touches the cylinder head.

NOTE
OHeat the area around the valve guide hole to 120 -
1500C (248 -302°F).
OApply oil to the valve guide outer surface before valve
guide installation.

.Using the valve guide reamer (special tool), ream the

valve guide.
 ENGINE TOP END 4-17

1 .Good 2. Too wide

1. Valve Guide Reamer: 57001-1274

Valve Seat Outside Diameter

.If the outside diameter of the seating pattern on the
valve seat is too large or too small, repair the valve seat.

Valve Seat Outside Diameter

3. Too narrow 4. Uneven
Standard: Inlet : 21.5 ~ 21.7 mm
Exhaust : 18.5 ~ 18.7 mm

Valve Seat Repair {Valve Lapping)

.Using the valve seat cutters (special tools), repair the
Valve Seat Width Inspection valve seat.
.Check the valve seat width.
O Measure the seat width of the portion where there is no Valve Seat Cutters
build-up carbon (white portion) of the valve seat with
Inlet Valves: 45° -Q>24.5 57001-1113
a vernier caliper.
32° -Q>25 57001-1118
60° -Q>30 57001-1123
Exhaust Valves: 45° -Q>22 57001-1205
32° -Q>22 57001-1206
60° -Q>30 57001-1123

Holder and Bar

Holder: 57001-1275
Bar: 57001-1128

*If the manufacture's instructions are not available, use

the following procedure.

Seat Cutter Operating Care:

1.Valve 1 .This valve seat cutter is developed to grind the valve for
2. Valve Seat repair. Therefore the cutter must not be used for other
3. Seating Surface Outside Diameter purposes than seat repair.
4. Valve Seat Width 2. Do not drop or shock the valve seat cutter, or the
diamond particles may falloff.
Valve Seat Width (IN and EX) 3. Do not fail to apply engine oil to the valve seat cutter
Standard: 0.5 --1.0 mm before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.

* If the valve seat width is not within the specified range,

repair the valve seat.
4-18 ENGINE TOP END

NOTE
ODo not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operate

the cutter in one hand. Do not apply too much force
to the diamond portion.

NOTE
0 Prior to grinding, apply engine oil to the cutter and
during the operation, wash off any ground particles
sticking to the cutter with washing oil.

5. After use, wash it with washing oil and apply thin layer
of engine oil before storing. 1. Outer Diameter of Cutter
2. Angle of Cutter
3. Cutter

Operating Procedures:
.Clean the seat area carefully.
.Coat the seat with machinist's dye.
.Fit a 45° cutter into the holder and slide it into the valve
guide.
.Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.

1. Cutter 3. Bar
2. Cutter Holder
.Measure the outside diameter of the seating surface
with a vernier caliper.
*If the outside diameter of the seating surface is too
small, repeat the 45° grind until the diameter is within
Marks Stamped on the Cutter:
the specified range.
The marks stamped on the back of the cutter represent
*If the outside diameter of the seating surface is too large,
the following.
make the 32° grind described below.
45° Cutter angle
24.5<1> Outer diameter of cutter
*If the outside diameter of the seating surface is within
the specified range, measure the seat width as described
below.
.Grind the seat at a 32° angle until the seat O.D. is within
the specified range.
OTo make the 32° grind, fit a 32° cutter into the holder,
and slide it into the valve guide.
OTurn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
 ENGINE TOP END 4-19

Valve Lapping

::70
l'"-'

-r-~
-""~ccccc..iccc.-c ~~
@

@,

OAfter making the 32° grind, return to the seat O.D. 1 .Lapper 3. Valve
measurement step above. 2. Valve Seat
.To measure the seat width, use a vernier caliper to
measure the width of the 45° angle portion of the seat
at several places around the seat.
*If the seat width is too narrow, repeat the 45° grind until Measure Valve-to-Guide Clearance
the seat O.D. measurement step above.
(Wobble Method)
* If the seat width is too wide, make the 60° grind If a small bore gauge is not available, inspect the valve
described below. guide wear by measuring the valve to valve guide
.Grind the seat at a 60° angle until the seat width is clearance with the wobble method as indicated below.
within the specified range. .Insert a new valve into the guide and set a dial gauge
OTo make the 60° grind, fit 60° cutter into the holder, and against the stem perpendicular to it as close as possible
slide it into the valve guide. to the cylinder head mating surface-
OTurn the holder, while pressing down lightly. .Move the stem back and forth to measure valve/valve
O After making the 60° grind, return to the seat width
guide clearance.
measurement step above. .Repeat the measurement in a direction at a right angle
.Lap the valve to the seat, once the seat width and O.D.
to the first.
are within the ranges specified above. *If the reading exceeds the service limit, replace the
O Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head. guide.
O Spin the valve against the seat until the grinding
NOTE
compound produces a smooth, matched surface on
both the seat and the valve. 0 The reading is not actual valve/valve guide clearance
0 Repeat the process with a fine grinding compound. because the measuring point is above the guide.
.The seating area should be marked about in the middle
of the valve face. Valve/Valve Guide Clearance (Wobble Method)
*If the seat area is not in the right place on the valve, Standard Service Limit
check to be sure the valve is the correct part. If it is, it Inlet 0.031 -0.140 mm 0.34 mm
may have been refaced too much; replace it.
Exhaust 0.085 -0.180 mm 0.41 mm
.Be sure to remove all grinding compound before
assembly.
.When the engine is assembled, be sure to adjust the
valve clearance (see Valve Clearance Adjustment).
4-20 ENGINE TOP END

Cylinder, Pistons

Cylinder Removal
.Remove the following.
Cylinder Head (see Cylinder Head Removal)
Camshaft Chain Guide (exhaust side)
Water Pipe
.Remove the cylinder.

Cylinder Installation
.Install the new cylinder gasket.
.Apply engine oil to the cylinder bore.
.Using the piston base (special tools), install the cylinder
block.

1. New Valve 3. Move the Valve.

2. Valve Guide

A. Piston Base: 57001 -147

.Install the cylinder and the chain guide (exhaust side)

as shown.

1. Chain Guide
 ENGINE TOP END 4-21

Piston Removal
.Remove the cylinder (see this chapter).
.Place a clean cloth under the pistons and remove the
piston pin snap rings from the outside of each piston.
.Using the piston pin puller assembly (special tool),
remove the piston pins.

@--

t}

@@
1.TopRing 4. Oil Ring Expander

2. Second Ring 5. Arrow

3. Oil Ring Steel Rails

Piston Installation
.The top and second rings must be installed with the R
marks on the rings facing up.

Cylinder Wear
.Measure the cylinder inside diameter taking a
side-to-side and a front-to back measurement at each
of the two positions (total of four measurements)
shown below.

1. Top Ring 2. Second Ring

.The arrow on the piston head must point toward the

front of the engine. Cylinder Inside Diameter:
.The piston ring openings must be positioned as shown
below. The openings of the oil ring steel rails must be Standard: 57.000 -57.012 mm
Service limit: 57.10 mm
about 30 -40° of angle from the opening of the top
rinc.
 4-22 ENGINE TOP END

Piston Wear Piston Ring End Gap

.Measure the piston outside diameter 5 mm up from the .Place the piston ring inside the cylinder, using the
bottom of the piston at a right angle to the direction of piston to locate the ring squarely in place. Set it close
the piston pin. to the bottom of the cylinder, where cylinder wear is
low.
Piston Outside Diameter .Measure the gap between the ends of the ring with a
Standard: 56.942 -56.957 mm thickness gauge.
Service Limit: 56.79 mm
Piston Ring End Gap
Piston Diameter Measurement Standard Service limit
Top 0.20 -0.40 mm O.7mm
Second 0.35 -0.50 mm O.8mm

I
YJ I

(LCD .,i

I.

1. Piston Outside Diameter

2. 5mm up from bottom
--@

Piston Ring, Piston Ring Groove Wear

.Check for uneven groove wear by inspecting the ring
seats.
*The rings should fit perfectly parallel to the groove
surfaces. If not, the piston must be replaced.
.With the piston rings in their grooves, make several
measurements with a thickness gauge to determine 1. Gap 2. Piston Ring

piston ring/groove clearance.

Piston Ring/Groove Clearance

Standard: 0.03 -0.07 mm
Service Limit: 0.17 mm

1. Thickness Gauge
 ENGINE TOP END 4-23

Carburetor Holders M uffler

Removal Removal
.Remove the following. .Remove the following.
Clamps Lower Fairing
Allen Bolts Radiator {Do not remove the hoses and not drain
.Remove the inlet pipes. coolant.)
.Remove the nuts and take off the exhaust pipe holders.

A. Carburetor Holders B. Inlet Pipes

A. Nuts B. Holder
.Take off the holders from the inlet pipes.
.Remove the muffler mounting bolt and nut (rear step
bracket).
.Remove the muffler.
I nstal/ation
.Install the carburetor holder so that the pipe is upward.
.Install the holder clamps as shown being careful of the
screw position and the screw head direction. I nstal!ation
.Installation is the reverse of removal.
.Replace the exhaust gaskets.

1 .Holder Clamp 3. Screw Head

2. Screw 4. Stopper