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ENGINE TOP END 5-1
5
Engine Top End
Table of Contents
Exploded View................................... 5-2
Exhaust System Identification ........... 5-6
Specifications .................................... 5-8
Special Tools and Sealants ............... 5-10
Clean Air System............................... 5-13
Air Suction Valve Removal........... 5-13
Air Suction Valve Installation........ 5-14
Air Suction Valve Inspection ........ 5-15
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.................................. 5-16
Cylinder Head Cover ......................... 5-17
Cylinder Head Cover Removal .... 5-17
Cylinder Head Cover Installation . 5-17
Camshaft Chain Tensioner ................ 5-19
Camshaft Chain Tensioner
Removal .................................... 5-19
Camshaft Chain Tensioner
Installation ................................. 5-19
Camshaft, Camshaft Chain ............... 5-20
Camshaft Removal ...................... 5-20
Camshaft Installation ................... 5-21
Camshaft, Camshaft Cap Wear
Inspection.................................. 5-24
Camshaft Runout Inspection........ 5-24
Cam Wear Inspection .................. 5-25
Camshaft Chain Removal ............ 5-25
Cylinder Head.................................... 5-26
Cylinder Compression
Measurement ............................ 5-26
Cylinder Head Removal ............... 5-27
Cylinder Head Installation ............ 5-28
Cylinder Head Warp Inspection ... 5-29
Valves ................................................ 5-30
Valve Clearance Inspection ......... 5-30
Valve Clearance Adjustment........ 5-30
Valve Removal ............................. 5-30
Valve Installation .......................... 5-30
Valve Guide Removal .................. 5-30
Valve Guide Installation ............... 5-31
Valve-to-Guide Clearance
Measurement (Wobble
Method) ..................................... 5-32
Valve Seat Inspection .................. 5-32
Valve Seat Repair ........................ 5-33
Cylinder, Pistons................................ 5-38
Cylinder Removal......................... 5-38
Cylinder Installation...................... 5-38
Piston Removal............................ 5-39
Piston Installation......................... 5-40
Cylinder Wear Inspection............. 5-41
Piston Wear Inspection ................ 5-41
Piston Ring, Piston Ring Groove
Wear Inspection ........................ 5-41
Piston Ring Groove Width
Inspection.................................. 5-41
Piston Ring Thickness Inspection 5-42
Piston Ring End Gap Inspection .. 5-42
Throttle Body Assy Holder................. 5-43
Throttle Body Assy Holder
Removal .................................... 5-43
Throttle Body Assy Holder
Installation................................. 5-43
Muffler................................................ 5-44
Muffler Body Removal.................. 5-44
Muffler Body Installation............... 5-46
Exhaust Pipe Removal................. 5-49
Exhaust Pipe Installation.............. 5-49
Exhaust Butterfly Valve Cable
Removal .................................... 5-49
Exhaust Butterfly Valve Cable
Installation................................. 5-51
Exhaust Butterfly Valve Actuator
Removal .................................... 5-52
Exhaust Butterfly Valve Actuator
Installation................................. 5-53
Exhaust Butterfly Valve Actuator
Adjustment ................................ 5-54
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