dummytext

9. LUBRICATION SYSTEM

S.R DO
.L.
RS A
TO RIZ
MO TO
BA AU
LUBRICATION SYSTEM DIAGRAM ············9-2 OIL STRAINER/
PRESSURE RELIEF VALVE ························ 9-6
SERVICE INFORMATION ·····························9-3

DO O
OIL PUMP ····················································· 9-8 9

OR N
TROUBLESHOOTING···································9-4
OIL COOLER ·············································· 9-12

- C SO
OIL PRESSURE INSPECTION ·····················9-5

.L. U
.R O
S S ÓN
OR CI
OT IBU
AM R
OB IST
RD D
CO SU
21 O
-20 BID
-01 HI
07 O
PR

9-1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
LUBRICATION SYSTEM

S.R DO
OIL COOLER

.L.
RS A
TO RIZ
CAMSHAFT

MO TO
OIL FILTER CARTRIDGE

BA AU
PISTON

DO O
OR N
- C SO
.L. U
.R O CRANKSHAFT

PRESSURE
RELIEF VALVE
S S ÓN
OR CI
OT IBU
AM R

MAINSHAFT
OB IST
RD D
CO SU
21 O

COUNTERSHAFT
-20 BID

PRESSURE
RELIEF VALVE
-01 HI

OIL PUMP
07 O
PR

OIL STRAINER

9-2
 LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL

S.R DO
.L.
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as

RS A
possible after handling used oil.

TO RIZ
• This section covers service of the oil pump and oil cooler.
• The oil pump can be serviced with the engine installed in the frame.
• The service procedures in this section must be performed with the engine oil drained.

MO TO
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
• The oil pump has twin pump rotors; feed and cooler. The feed pump rotors draw oil from the oil cooler and crankcase and
delivers it under pressure to the bearing and other important parts of the engine. The cooler pump rotors draw oil from the

BA AU
crankcase and sends it to the oil cooler.
• After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct.
• The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

DO O
• For EOP switch inspection (page 20-14).

OR N
SPECIFICATIONS

- C SO
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Engine oil After draining 3.0 liter (3.2 US qt, 2.6 Imp qt) –

.L. U
capacity After draining/filter change 3.2 liter (3.4 US qt, 2.8 Imp qt) –
After disassembly 3.8 liter (4.0 US qt, 3.3 Imp qt) –
.R O
Recommended engine oil Honda "4-stroke motorcycle oil" or an
equivalent
API service classification: SG or higher
S S ÓN

(except oils labeled as energy conserving –

on the circular API service label)
JASO T 903 standard: MA
OR CI

Viscosity: SAE 10W-30

Oil pressure at oil pressure switch 490 kPa (5.0 kgf/cm2, 71 psi) at
–
6,000 min-1 (rpm)/(80°C/176°F)
OT IBU

Oil pump Feed pump Tip clearance 0.15 (0.006) 0.20 (0.008)
rotor Body
0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
clearance
AM R

Side
0.02 – 0.09 (0.001 – 0.004) 0.10 (0.004)
clearance
OB IST

Cooler pump Tip clearance 0.15 (0.006) 0.20 (0.008)

Body
0.15 – 0.22 (0.006 – 0.009) 0.35 (0.014)
clearance
RD D

Side
0.020 – 0.075 (0.0008 – 0.0295) 0.10 (0.004)
clearance
CO SU

TORQUE VALUE
21 O

THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
-20 BID

Oil pump assembly bolt 1 6 12 (1.2, 9) CT bolt

-01 HI
07 O
PR

9-3
LUBRICATION SYSTEM
TROUBLESHOOTING
Oil level too low, high oil consumption
• Oil consumption

S.R DO
• External oil leaks
• Worn piston rings

.L.
• Improperly installed piston rings
• Worn cylinders

RS A
• Worn valve stem seals
• Worn valve guide

TO RIZ
• Worn or damage oil pump
Low oil pressure
• Oil pressure relief valve stuck open

MO TO
• Oil level low
• Clogged oil strainer
• Faulty oil pump

BA AU
• Internal oil leaks
• Incorrect oil being used
No oil pressure
• Oil level too low

DO O
• Oil pressure relief valve stuck open

OR N
• Broken oil pump drive chain
• Broken oil pump drive or driven sprocket
• Damaged oil pump

- C SO
• Internal oil leaks
High oil pressure
• Oil pressure relief valve stuck closed

.L. U
• Clogged oil filter, gallery or metering orifice
• Incorrect oil being used
.R O
Oil contamination
• Oil or filter not changed often enough
S S ÓN

• Worn piston rings

• Improperly installed piston rings
• Worn cylinder
• Worn valve stem seals
OR CI

• Worn valve guide

• Blown cylinder head gasket
OT IBU

Oil emulsification
• Blown cylinder head gasket
• Leaky coolant passage
AM R

• Entry of water
OB IST
RD D
CO SU
21 O
-20 BID
-01 HI
07 O
PR

9-4
 LUBRICATION SYSTEM
OIL PRESSURE INSPECTION
• If the oil pressure indicator light remains on a few
[2]

S.R DO
seconds, check the indicator system before
checking the oil pressure.

.L.
• The exhaust system becomes very hot and remains
hot for some time after the engine is run. Wear

RS A
insulated gloves or wait until the exhaust system

TO RIZ
have cooled before handing.
If the engine is cold, the pressure reading will be
abnormally high.

MO TO
Warm up the engine to normal operating temperature
before starting this test.
Stop the engine.

BA AU
Remove the oil filter cartridge [1] using the special tool. [1]

TOOL:
[2] Oil filter wrench 07HAA-PJ70101

DO O
Install the gauge joint attachment to the engine block,

OR N
[1] [2]
then tighten the nut.

- C SO
TOOL:
[1] Gauge joint attachment 070MJ-0010101
Install the oil filter cartridge [2] (page 3-13).

.L. U
Install the oil pressure gauge attachment and oil
pressure gauge to the gauge joint attachment.
.R O
TOOLS:
[3] Oil pressure gauge set 07506-3000001 or
S S ÓN

equivalent
commercially
available [3] [4]
OR CI

[4] Oil pressure gauge 07406-0030000 or

attachment equivalent
OT IBU

commercially
available
Inspect the oil level and add the recommended engine
oil if necessary (page 3-12).
AM R

Start the engine and check the oil pressure at 6,000

OB IST

min-1 (rpm) and 80°C (176°F).

OIL PRESSURE:
490 kPa (5.0 kgf/cm2, 71 psi) at 6,000 min-1 (rpm)
RD D

(80°C/176°F)
CO SU

Stop the engine and remove the special tools.

Install the oil filter cartridge (page 3-13).
21 O
-20 BID
-01 HI
07 O
PR

9-5
LUBRICATION SYSTEM
OIL STRAINER/PRESSURE RELIEF
VALVE
REMOVAL

S.R DO
Drain the engine oil (page 3-12).

.L.
[2] [1]
Remove the oil cooler pipe joints from the oil pan (page
9-12).

RS A
Remove the exhaust pipe (page 2-15).

TO RIZ
Remove the oil pan flange bolts [1] and oil pan [2].

MO TO
BA AU
DO O
Remove the dowel pins [1] and O-rings [2].

OR N
- C SO
.L. U
.R O
S S ÓN

[1]/[2]
OR CI

Remove the pressure relief valve [1] and O-ring [2].

[1] [2]
OT IBU
AM R
OB IST
RD D
CO SU

Remove the oil strainer [1] and packing [2].

[1]
Clean the oil strainer screen.
21 O
-20 BID
-01 HI
07 O
PR

[2]

9-6
 LUBRICATION SYSTEM
INSPECTION
Check the operation of the pressure relief valve by
[3]
pushing on the piston [1].
Disassemble the relief valve by removing the snap ring

S.R DO
[2].

.L.
Inspect the piston for wear, sticking or damage.
Inspect the spring [3] for weakness or damage.

RS A
Assemble the relief valve in the reverse order of

TO RIZ
disassembly.

• Install the snap ring with the chamfered edges facing

MO TO
the thrust load side.
• Make sure the snap ring is seated in the groove.
[1] [2]

BA AU
INSTALLATION
Apply engine oil to a new packing [1] and install it onto
[1]
the oil strainer [2].

DO O
Install the oil strainer to the oil pump while aligning its

OR N
grooves with the boss on the oil pump body.

- C SO
.L. U
.R O
Align [2]
S S ÓN

Apply engine oil to a new O-ring [1] and install it onto

[2]
the pressure relief valve [2].
OR CI

Install the pressure relief valve into the crankcase.

OT IBU
AM R
OB IST
RD D

[1]

Install the dowel pins [1].

CO SU

Apply engine oil to new O-rings [2] and install them to

the dowel pins.
21 O
-20 BID
-01 HI
07 O

[1]/[2]
PR

9-7
LUBRICATION SYSTEM
Clean the oil pan mating surface thoroughly.
Apply liquid sealant (Three Bond 1207B or an
equivalent) to the mating surface.

S.R DO
.L.
RS A
TO RIZ
MO TO
Carefully install the oil pan [1] onto the lower crankcase.

BA AU
[1] [2]
Install the oil pan flange bolts [2].
Tighten the all bolts in a crisscross pattern in 2 – 3
steps.

DO O
Install the exhaust pipe (page 2-15).
Install the oil cooler pipe joints to the oil pan (page 9-

OR N
13).
Fill the recommended engine oil and check for oil leaks

- C SO
(page 3-12).

.L. U
.R O
OIL PUMP
S S ÓN

REMOVAL
Remove the clutch (page 11-12).
[1] [2]
Remove the oil pan and oil strainer (page 9-6).
OR CI

Remove the flange bolts [1] and oil pump assembly [2].
OT IBU
AM R
OB IST
RD D
CO SU

Remove the dowel pins [1].

[1]
21 O
-20 BID
-01 HI
07 O
PR

9-8
 LUBRICATION SYSTEM
DISASSEMBLY
Straighten and remove the cotter pin [1].
[2]/[3]/[4]
Remove the spring seat [2], spring [3] and pressure
relief valve [4].

S.R DO
Check the pressure relief valve for wear or damage.

.L.
RS A
TO RIZ
MO TO
[1]

BA AU
Remove the oil pump assembly bolts [1] and oil pump
[2]
body [2].

DO O
OR N
- C SO
.L. U
.R O
[1]
S S ÓN

Remove the dowel pins [1], cooler pump outer rotor [2]
[4] [3] [2]
and inner rotor [3] from the oil pump cover [4].
Remove the drive pin [5].
OR CI
OT IBU
AM R
OB IST

[1] [5]
RD D

Remove the oil pump spacer [1] and dowel pins [2].
CO SU
21 O
-20 BID
-01 HI
07 O

[1] [2]
PR

9-9
LUBRICATION SYSTEM
Remove the oil pump shaft [1], thrust washer [2], drive
[4] [5] [2]
pin [3], feed pump outer rotor [4] and inner rotor [5] from
the oil pump body [6].

S.R DO
.L.
RS A
TO RIZ
MO TO
[1] [3] [6]

INSPECTION

BA AU
• Measure at several points and use the largest
reading to compare the service limit.

DO O
• If any portion of the oil pump is worn beyond the
specified service limits, replace the oil pump and oil

OR N
pump cover as an assembly.
Temporarily assemble the inner rotor, outer rotor, drive

- C SO
pin and oil pump shaft into the oil pump body (feed
pump) or oil pump cover (cooler pump).
TIP CLEARANCE

.L. U
Measure the rotor tip clearance for the feed and cooler
pumps.
.R O
SERVICE LIMITS:
S S ÓN

Feed pump: 0.20 mm (0.008 in)

Cooler pump: 0.20 mm (0.008 in)
OR CI
OT IBU
AM R
OB IST

BODY CLEARANCE
Measure the pump body clearance for the feed and
cooler pumps.
RD D

SERVICE LIMITS:
Feed pump: 0.35 mm (0.014 in)
CO SU

Cooler pump: 0.35 mm (0.014 in)

21 O
-20 BID
-01 HI
07 O
PR

9-10
 LUBRICATION SYSTEM
SIDE CLEARANCE
Measure the side clearance for the feed and cooler
pump using a straight edge and feeler gauge.

S.R DO
SERVICE LIMITS:
Feed pump: 0.10 mm (0.004 in)

.L.
Cooler pump: 0.10 mm (0.004 in)

RS A
TO RIZ
MO TO
BA AU
ASSEMBLY
Dip all parts in engine oil.

DO O
Assemble the oil pump in the reverse order of
disassembly.

OR N
- C SO
OIL PUMP BODY

.L. U DOWEL PIN

.R O
DRIVE PIN
SPACER
S S ÓN

COOLER PUMP INNER ROTOR

OR CI

12 N·m (1.2 kgf·m, 9 lbf·ft) COOLER PUMP OUTER ROTOR

OT IBU

OIL PUMP COVER

THRUST WASHER
AM R

FEED PUMP OUTER ROTOR

OB IST

FEED PUMP INNER ROTOR

DOWEL PIN
RD D

OIL PUMP SHAFT

CO SU

DRIVE PIN

PRESSURE
RELIEF VALVE
COTTER PIN SPRING
21 O

SPRING SEAT
-20 BID
-01 HI
07 O
PR

9-11
LUBRICATION SYSTEM
Hold the spring seat [1] and install a new cotter pin [2].
[1]
Bend the cotter pin securely as indicated in the
illustration.

S.R DO
.L.
RS A
TO RIZ
MO TO
[2]

INSTALLATION

BA AU
Check the following point and install the oil pump in the
reverse order of the removal.

DO O
Install the oil pump [1] into the crankcase while aligning
[3]
the pump shaft lug [2] with the water pump shaft groove

OR N
[3].

- C SO
Install the oil strainer and oil pan (page 9-7).
Install the clutch (page 11-17).
Fill the recommended engine oil and check for oil leaks

.L. U
(page 3-12).
Inspect the oil pressure (page 9-5).
.R O
S S ÓN

[2] [1]
OR CI

OIL COOLER
OT IBU

REMOVAL
Drain the engine oil (page 3-12).
[3] [2]
Remove the right and left front side cowls (page 2-6).
Remove the right and left under cowls (page 2-10).
AM R

Remove the oil cooler pipe joint bolts [1].

OB IST

[4] [4]
Remove the oil cooler mounting bolts [2], oil cooler [3]
and O-rings [4].
RD D
CO SU
21 O

[1]
-20 BID
-01 HI
07 O
PR

9-12
 LUBRICATION SYSTEM
Remove the right and left oil cooler pipe bolts [1],
[4] [3] [4]
harness clamp stay [2] oil cooler pipes [3] and O-rings
[4].

S.R DO
.L.
RS A
[2]

TO RIZ
MO TO
[1]

Remove the right and left oil cooler pipes [1] from the

BA AU
stays [2].

INSPECTION

DO O
Check the oil cooler air passage for clogging or

OR N
damage.
Straighten bent fins with a small, flat blade screwdriver [1]

- C SO
and remove insects, mud or other obstructions with
compressed air.
Check for any oil leakage from the oil cooler and pipes.

.L. U [1] [2]

.R O
INSTALLATION
S S ÓN

Install the oil cooler in the reverse order of removal.

Fill the recommended engine oil (page 3-12).
OR CI
OT IBU
AM R
OB IST

OIL COOLER O-RING

RD D
CO SU
21 O
-20 BID

O-RING
O-RING
-01 HI
07 O

O-RING
LEFT OIL COOLER PIPE
PR

RIGHT OIL COOLER PIPE

9-13
 PR
07 O
-01 HI
-20 BID
21 O
CO SU
RD D
OB IST
AM R
OT IBU
MEMO

OR CI
S S ÓN
.R O
.L. U
- C SO
OR N
DO O
BA AU
MO TO
TO RIZ
RS A
S.R DO
.L.
dummytext

10. CYLINDER HEAD/VALVES

S.R DO
.L.
RS A
TO RIZ
MO TO
BA AU
COMPONENT LOCATION ··························10-2 CYLINDER HEAD COVER ························· 10-6

SERVICE INFORMATION ···························10-3 CAMSHAFT··············································· 10-11

DO O
OR N
TROUBLESHOOTING·································10-5 CYLINDER HEAD ····································· 10-22
10

- C SO
CYLINDER COMPRESSION TEST·············10-6 CAM CHAIN TENSIONER LIFTER··········· 10-38

.L. U
.R O
S S ÓN
OR CI
OT IBU
AM R
OB IST
RD D
CO SU
21 O
-20 BID
-01 HI
07 O
PR

10-1
CYLINDER HEAD/VALVES
COMPONENT LOCATION
CYLINDER HEAD/VALVES

S.R DO
.L.
RS A
TO RIZ
44 N·m (4.5 kgf·m, 32 lbf·ft)

MO TO
BA AU
DO O
OR N
- C SO
26 N·m (2.7 kgf·m, 19 lbf·ft)

.L. U
.R O
S S ÓN
OR CI
OT IBU
AM R

12 N·m (1.2 kgf·m, 9 lbf·ft)

OB IST
RD D

12 N·m (1.2 kgf·m, 9 lbf·ft)

CO SU
21 O
-20 BID

10 N·m (1.0 kgf·m, 7 lbf·ft)

-01 HI
07 O
PR

12 N·m (1.2 kgf·m, 9 lbf·ft)

10-2
 CYLINDER HEAD/VALVES
SERVICE INFORMATION
GENERAL
• This section covers service of the cylinder head, valves and camshaft.

S.R DO
• The camshaft, front and rear cylinder head can be serviced with the engine installed in the frame.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.

.L.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.

RS A
• Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder
head.

TO RIZ
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.

SPECIFICATIONS

MO TO
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT

BA AU
Cylinder compression 1,265 kPa (12.9 kgf/cm2, 183 psi) at 300
–
min-1(rpm)
Valve Normal side IN 0.20 ± 0.03 (0.008 ± 0.001) –
clearance EX 0.35 ± 0.03 (0.013 ± 0.001) –

DO O
VTEC side IN 0.20 ± 0.08 (0.008 ± 0.003) –
EX 0.35 ± 0.08 (0.013 ± 0.003) –

OR N
Camshaft Cam lobe height IN 36.36 – 36.44 (1.431 – 1.435) 36.33 (1.430)
EX 36.21 – 36.29 (1.426 – 1.429) 36.18 (1.424)

- C SO
Runout – 0.05 (0.002)
Oil clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Valve lifter Valve lifter O.D. 25.978 – 25.993 (1.0228 – 1.0233) 25.97 (1.022)

.L. U
Valve lifter bore I.D. 26.010 – 26.026 (1.024 – 1.0246) 26.04 (1.025)
Valve, Valve stem O.D. IN 4.475 – 4.490 (0.1762 – 0.1768) 4.465 (0.1758)
.R O
valve guide EX 4.465 – 4.480 (0.1758 – 0.1764) 4.455 (0.1754)
Valve guide I.D. IN/EX 4.500 – 4.512 (0.1772 – 0.1776) 4.540 (0.1787)
S S ÓN

Stem-to-guide IN 0.010 – 0.037 (0.0004 – 0.0015) 0.075 (0.0030)

clearance EX 0.020 – 0.047 (0.0008 – 0.0019) 0.085 (0.0033)
Valve guide Normal side 12.15 – 12.50 (0.478 – 0.492) –
projection above
OR CI

VTEC side 19.65 – 20.00 (0.774 – 0.787) –

cylinder head
Valve seat width IN/EX 0.90 – 1.10 (0.035 – 0.043) 1.5 (0.06)
OT IBU

Valve spring Spring A outer 42.3 (1.67) 41.5 (1.63)

free length Spring B outer 54.3 (2.14) 53.2 (2.09)
Spring A inner 39.8 (1.57) 39.0 (1.54)
AM R

Spring B inner 39.1 (1.54) 38.3 (1.51)

Cylinder head warpage – 0.10 (0.004)
OB IST
RD D
CO SU
21 O
-20 BID
-01 HI
07 O
PR

10-3
CYLINDER HEAD/VALVES
TORQUE VALUES
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)

S.R DO
Cylinder head special bolt/washer 12 9 44 (4.5, 32) Apply engine oil to the
threads and flange surface.

.L.
Cylinder head orifice bolt 4 6 8 (0.8, 5.9)
Camshaft holder A/B flange bolt 24 6 12 (1.2, 9) Apply engine oil to the

RS A
threads and flange surface.

TO RIZ
Cylinder head cover bolt 8 6 10 (1.0, 7)
Breather plate flange bolt 4 6 12 (1.2, 9) Apply a locking agent to the
threads.
Coating width: 6.5 ± 1.0 mm

MO TO
(0.26 ± 0.04 in) from tip
CT bolt
PAIR check valve cover bolt 4 6 12 (1.2, 9) CT bolt

BA AU
Cam sprocket bolt 8 7 20 (2.0, 15) UBS
Apply a locking agent to the
threads.
Coating width: 6.5 ± 1.0 mm

DO O
(0.26 ± 0.04 in) from tip
Cam chain tensioner flange bolt 2 8 26 (2.7, 19) Apply a locking agent to the

OR N
threads.
Coating width: 6.5 ± 1.0 mm

- C SO
(0.26 ± 0.04 in) from tip
Cam chain guide flange bolt 2 6 12 (1.2, 9) Apply a locking agent to the
threads.

.L. U
Coating width: 6.5 ± 1.0 mm
(0.26 ± 0.04 in) from tip
Insulator band screw (cylinder head side) 4 – – See page 10-30
.R O
ECT sensor 1 12 23 (2.3, 17)
S S ÓN
OR CI
OT IBU
AM R
OB IST
RD D
CO SU
21 O
-20 BID
-01 HI
07 O
PR

10-4
 CYLINDER HEAD/VALVES
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by
tracing engine noises to the top-end with a sounding rod or stethoscope.

S.R DO
• If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for
a seized piston ring (page 13-12).

.L.
Compression too low, hard starting or poor performance at low speed

RS A
• Valves:
– Incorrect valve adjustment

TO RIZ
– Burned or bent valve
– Incorrect valve timing
– Broken valve spring
– Uneven valve seating

MO TO
• Cylinder head:
– Leaking or damaged head gasket
– Warped or cracked cylinder head

BA AU
• Worn cylinder, piston or piston rings (page 13-12)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston crown or on combustion chamber

DO O
Excessive smoke
• Cylinder head:

OR N
– Worn valve stem or valve guide
– Damaged stem seal

- C SO
• Worn cylinder, piston or piston rings (page 13-12)
Excessive noise
• Cylinder head:

.L. U
– Incorrect valve adjustment
– Sticking valve or broken valve spring
– Damaged or worn camshaft
.R O
– Loose or worn cam chain
– Worn or damaged cam chain
S S ÓN

– Worn or damaged cam chain tensioner

– Worn cam sprocket teeth
• Worn cylinder, piston or piston rings (page 13-12)
OR CI

Rough idle
• Low cylinder compression
OT IBU
AM R
OB IST
RD D
CO SU
21 O
-20 BID
-01 HI
07 O
PR

10-5
CYLINDER HEAD/VALVES
CYLINDER COMPRESSION TEST
Warm up the engine to normal operating temperature.
[1]
Stop the engine and remove the all spark plugs (page

S.R DO
3-6).
Disconnect the fuel pump 3P (Black) connector (page

.L.
7-4).

RS A
Install the compression gauge [1] into the spark plug
hole.

TO RIZ
TOOL:
Compression gauge 07RMJ-MY50100 or
attachment equivalent

MO TO
commercially
available
Open the throttle all the way and crank the engine with

BA AU
the starter motor until the gauge reading stops rising.
To avoid The maximum reading is usually reached within 4 – 7
discharging the seconds.

DO O
battery, do not
operate the starter
Compression pressure:

OR N
motor for more than 1,265 kPa (12.9 kgf/cm2, 183 psi) at 300 min-1 (rpm)
seven seconds. Low compression can be caused by:

- C SO
– Blown cylinder head gasket
– Improper valve adjustment
– Valve leakage

.L. U
– Worn piston ring or cylinder
High compression can be caused by:
.R O
– Carbon deposits in combustion chamber or on
piston head
S S ÓN

CYLINDER HEAD COVER

OR CI

REMOVAL
OT IBU

Front: Remove the oil cooler (page 9-12).

FRONT: [1] [2]
Disconnect the PAIR air hose [1] from the PAIR check
valve cover [2].
AM R

Disconnect the direct ignition coil 3P (Black) connectors

OB IST

[3].
Remove the bolts [4], clamp [5] and direct ignition coils
[6] from the spark plug. [5] [3]
RD D
CO SU

[4] [6] [3] [6]

21 O

Rear: Remove the air cleaner housing (page 7-12).

REAR: [1] [2]
-20 BID

Disconnect the crankcase breather hose [1] from the

cylinder head cover [2].
[6]
Disconnect the PAIR air hose [3] from the PAIR check
valve cover [4]. [7]
-01 HI

Disconnect the direct ignition coil 3P (Black) connectors

07 O

[5]. [7] [5]

Remove the bolts [6] and direct ignition coils [7] from
PR

the spark plug.

[5]

[4] [3]

10-6
 CYLINDER HEAD/VALVES
Remove the bolts [1], mounting rubbers [2] and cylinder
[3] [1]/[2]
head cover [3].

S.R DO
.L.
RS A
TO RIZ
MO TO
[1]/[2]

Remove the air joint collars [1] and O-rings [2].

BA AU
[2]

DO O
OR N
- C SO
.L. U [1]
.R O
Remove the cylinder head cover packings [1].
S S ÓN
OR CI
OT IBU
AM R
OB IST

[1]

DISASSEMBLY
RD D

Remove the bolts [1], breather plate [2] and gasket [3]
[1]
from the cylinder head cover.
CO SU
21 O
-20 BID
-01 HI
07 O

[2]/[3]
PR

10-7
CYLINDER HEAD/VALVES
Remove the bolts [1] and PAIR check valve cover [2].
[2]

S.R DO
.L.
RS A
TO RIZ
MO TO
[1]

Remove the PAIR check valves [1].

BA AU
[1]
Check the PAIR check valve for wear or damage,
replace them if necessary.

DO O
OR N
- C SO
.L. U
.R O
ASSEMBLY
S S ÓN

Install a new gasket [1] and breather plate [2] to the

[2]
cylinder head cover.
OR CI
OT IBU
AM R
OB IST

[1]
RD D

Apply locking agent to the breather plate flange bolt [1]

threads (page 1-11).
CO SU

Tighten the bolts to the specified torque.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
21 O
-20 BID
-01 HI
07 O

[1]
PR

10-8
 CYLINDER HEAD/VALVES
Install the PAIR check valves [1] onto the cylinder head
[1]
cover.

S.R DO
.L.
RS A
TO RIZ
MO TO
Install the PAIR check valve cover [1] and tighten the

BA AU
[1]
bolts [2] to the specified torque.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

DO O
OR N
- C SO
.L. U [2]
.R O
INSTALLATION
S S ÓN

Install the cylinder head cover packings [1] into the

groove of the cylinder head cover.
OR CI
OT IBU
AM R
OB IST

[1]
RD D

Apply sealant (Three Bond 5211C or equivalent) to the

cylinder head semi-circular cut-outs as shown.
CO SU
21 O
-20 BID
-01 HI
07 O
PR

10-9
CYLINDER HEAD/VALVES
Install the air joint collars [1] and new O-rings [2].
[2]

S.R DO
.L.
RS A
TO RIZ
MO TO
[1]

Install the cylinder head cover [1] onto the cylinder

BA AU
[5] [2]/[4]
head.
Install the mounting rubbers [2] with their "UP" mark [3]
facing up.

DO O
Tighten the " " Install and tighten the cylinder head cover bolts [4] to
marked [5] side the specified torque.

OR N
bolts first.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

- C SO
.L. U [1] [2]/[4]
.R O
[2]
S S ÓN
OR CI
OT IBU
AM R
OB IST

[3]

Rear: Install the bolts [1] and direct ignition coils [2] to the
REAR: [6] [7]
RD D

spark plug.
Connect the direct ignition coil 3P (Black) connectors
CO SU

[3]. [1]
Connect the PAIR air hose [4] to the PAIR check valve [2]
cover [5].
21 O

Connect the crankcase breather hose [6] to the cylinder [2] [3]
head cover [7].
-20 BID

Install the air cleaner housing (page 7-12).

[3]
-01 HI

[5] [4]
07 O
PR

10-10
 CYLINDER HEAD/VALVES
Front: Install the direct ignition coils [1], clamp [2] and bolts [3]
FRONT: [5] [6]
to the spark plug.
Connect the direct ignition coil 3P (Black) connectors
[4].

S.R DO
Connect the PAIR air hose [5] to the PAIR check valve

.L.
cover [6].
Install the oil cooler (page 9-12). [2] [4]

RS A
TO RIZ
MO TO
[3] [1] [4] [1]

CAMSHAFT

BA AU
REMOVAL
Front: Remove the front cylinder head cover (page 10-6).
FRONT: [3]

DO O
Remove the timing hole cap and O-ring (page 5-7).

OR N
Turn the crankshaft clockwise, align the "4T" mark [1] [2]
on the CKP sensor rotor with the index mark [2] on the

- C SO
right crankcase cover.
Make sure that the index lines [3] on the front cam
sprocket are facing outward and that the No.4 piston is

.L. U
at TDC (Top Dead Center) on the compression stroke.
.R O
S S ÓN

[1]
Rear: Remove the rear cylinder head cover (page 10-6).
REAR:
OR CI

Remove the timing hole cap and O-ring (page 5-7).

[3]
Turn the crankshaft clockwise, align the "3T" mark [1]
OT IBU

on the CKP sensor rotor with the index mark [2] on the [2]
right crankcase cover.
Make sure that the index lines [3] on the rear cam
AM R

sprocket are facing outward and that the No.3 piston is

at TDC (Top Dead Center) on the compression stroke.
OB IST
RD D

[1]
CO SU

Remove the cam chain tensioner sealing bolt and

sealing washer.
Turn the cam chain tensioner lifter shaft fully in
(clockwise) and secure it using the tensioner stopper [1]
21 O

to prevent damaging the cam chain.

-20 BID

TOOL:
Tensioner stopper 070MG-0010100
-01 HI
07 O
PR

[1]

10-11
CYLINDER HEAD/VALVES
Remove the bolts [1] and cam chain guide B [2].
FRONT: [2]
Loosen the cam sprocket bolts [3] at this moment as
[4]
follows:

S.R DO
• It is not necessary to remove the cam sprocket [4]

.L.
from the camshaft except when replacing the
camshaft and/or cam sprocket.

RS A
• Be careful not to drop the cam sprocket bolts into the

TO RIZ
crankcase.
[3]
Loosen the cam sprocket bolts, turn the crankshaft
clockwise one full turn (360°) and, loosen the other cam
sprocket bolts.

MO TO
Turn the crankshaft clockwise one full turn (360°), [4] [1]
loosen the other cam sprocket bolts.

BA AU
REAR: [4] [5]
Front: Remove the cam sprocket bolts, turn the crankshaft
clockwise one full turn (360°) and remove the other cam [2]
sprocket bolt and cam sprockets from the camshafts.

DO O
Rear: Remove the cam sprocket bolts, turn the crankshaft
clockwise one full turn (360°) and remove the other cam

OR N
sprocket bolt, CMP sensor rotor [5] and cam sprockets
from the camshafts.

- C SO
Suspend the cam chain with a piece of wire to prevent
the cam chain from falling into the crankcase.

.L. U
[3]
[1]
.R O
Suspend the cam Remove the camshaft holder B flange bolts [1]
FRONT SIDE Shown: [2] [3] [3]/[4]
chain with a piece gradually in several steps and remove the camshaft
S S ÓN

of wire to prevent holder B [2]. [1]

the chain from
Remove the camshaft holder A flange bolts [3], sealing
falling into the
washers [4] and camshaft holder A [5].
OR CI

crankcase. [1]
OT IBU

From outside to inside, loosen the bolts in a crisscross

pattern in several steps or the camshaft holder might
break.
AM R

Do not forcibly remove the dowel pins from the

camshaft holder.
OB IST

[2] [3] [5]

Remove the joint collars [1] and O-rings [2] from the
FRONT SIDE Shown: [1]
cylinder head.
RD D

Remove the camshafts [3].

CO SU
21 O

[3]
-20 BID
-01 HI

[2]
07 O
PR

10-12
 CYLINDER HEAD/VALVES
Remove the valve lifters [1] and shims [2] from the
FRONT SIDE Shown: [3] [1]
normal valve lifter bore [3].

• Be careful not to damage the valve lifter bore.

S.R DO
• Shim may stick to the inside of the valve lifter. Do
not allow the shims to fall.

.L.
• Mark all valve lifters and shims to ensure correct

RS A
reassembly in their original locations.
• The valve lifter can be easily removed with a valve

TO RIZ
lapping tool or magnet.
• The shims can be easily removed with a tweezers or
magnet.

MO TO
[3] [2]

Remove the valve lifters [1], slide pin holders [2] and

BA AU
FRONT SIDE Shown: [4] [1]
outer valve springs [3] from the VTEC valve lifter bore
[4].

DO O
• Be careful not to damage the valve lifter bore.
• Mark all valve lifters to ensure correct reassembly in

OR N
their original locations.
• The valve lifter can be easily removed with a valve

- C SO
lapping tool or magnet.

.L. U [4] [2]/[3]

.R O
INSPECTION
S S ÓN

CAMSHAFT HOLDER
Inspect the bearing surface [1] of the camshaft holder
for scoring, scratches, evidence of insufficient
OR CI

lubrication.
Inspect the oil orifices of the holders for clogging.
OT IBU
AM R
OB IST
RD D

[1]

CAMSHAFT RUNOUT
CO SU

Support both ends of the camshaft journals with V-

blocks and check the camshaft runout with a dial
gauge.
21 O

SERVICE LIMIT: 0.05 mm (0.002 in) MEASURING POINT

-20 BID
-01 HI
07 O
PR

10-13
CYLINDER HEAD/VALVES
CAM LOBE HEIGHT
Using a micrometer, measure each cam lobe height.

SERVICE LIMIT:

S.R DO
IN: 36.33 mm (1.430 in)
EX: 36.18 mm (1.424 in)

.L.
RS A
TO RIZ
MO TO
BA AU
CAMSHAFT OIL CLEARANCE
Wipe any oil from the journals of the camshaft, cylinder
head and camshaft holders.

DO O
Lay a strip of plastigauge [1] lengthwise on top of each
camshaft journal.

OR N
Install the camshaft holder A and B (page 10-15).

- C SO
.L. U
.R O
[1]
S S ÓN

Do not rotate the Apply engine oil to the threads and flange surfaces of
[1]
camshaft when the camshaft holder A/B flange bolts.
OR CI

using plastigauge.
Tighten the camshaft holder A flange bolts [1] in a
crisscross pattern in two or more steps until the holder
OT IBU

rests lightly on the cylinder head surface.

Tighten the Tighten the camshaft holder B flange bolts [2] gradually
camshaft holder in two or more steps.
bolts, starting with
AM R

Tighten the camshaft holder A flange bolts to the

the bolts at the
specified torque, then the camshaft holder B flange
OB IST

dowel pins, in two or

bolts.
more steps.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) [2]
RD D

Remove the camshaft holders and measure the width

CO SU

of each plastigauge.
The widest thickness determines the oil clearance.
SERVICE LIMIT: 0.10 mm (0.004 in)
21 O

When the service limits are exceeded, replace the

-20 BID

camshaft and recheck the oil clearance.

Replace the cylinder head and camshaft holders as a
set if the clearance still exceeds the service limit.
-01 HI
07 O
PR

10-14
 CYLINDER HEAD/VALVES
INSTALLATION
Install the VTEC side outer valve springs into the VTEC
valve lifter bore with the tightly wound coils facing the
combustion chamber.

S.R DO
.L.
RS A
TO RIZ
MO TO
COMBUSTION CHAMBER SIDE

BA AU
Apply molybdenum oil solution to the valve lifter [1]
FRONT SIDE Shown: [3]
outer sliding surface (page 1-17).
Install the slide pin holders [2] and valve lifters into the [1]

DO O
VTEC valve lifter bore [3].

OR N
- C SO
.L. U
.R O
[3] [2]
S S ÓN

Apply molybdenum oil solution to the valve lifter [1]

FRONT SIDE Shown: [3] [1]
outer sliding surface (page 1-17).
Install the shims [2] and valve lifters into the normal
OR CI

valve lifter bore [3].

OT IBU
AM R
OB IST

[3] [2]
RD D
CO SU
21 O
-20 BID
-01 HI
07 O
PR

10-15
CYLINDER HEAD/VALVES
– If the camshaft holder replacement is required,
replace the holder and cylinder head as an
assembly.
– Follow this procedure from beginning to end, even if
you are only servicing one cylinder head camshafts.

S.R DO
– Check the camshaft marks so that you install each

.L.
camshaft in its correct location.
– The identification mark [1] on the camshaft have the

RS A
following meanings. [1]
– FR: Front cylinder camshaft

TO RIZ
– RR: Rear cylinder camshaft
– IN: Intake camshaft
– EX: Exhaust camshaft

MO TO
– Apply molybdenum oil solution to the cam lobes,
journals and thrust surface (page 1-17).
If the cam sprockets and/or CMP sensor rotor are

BA AU
removed, install the cam sprockets and/or CMP sensor
rotor onto the camshafts.
Clean and apply locking agent to the cam sprocket bolt
threads (page 1-11).

DO O
Temporarily install the cam sprockets and bolts.

OR N
– Check the camshaft holder A [1] marks as noted
[3]
during removal, so that you install each camshaft

- C SO
holder in its correct location.
– The identification mark [2] on the camshaft holder B
[3] have the following meaning:
– FI: Front cylinder intake camshaft

.L. U
– FE: Front cylinder exhaust camshaft
– RI: Rear cylinder intake camshaft
.R O
– RE: Rear cylinder exhaust camshaft
S S ÓN
OR CI

[2] [3] [1]

WHEN BOTH THE FRONT AND REAR CAMSHAFTS

OT IBU

WERE REMOVED:
Turn the crankshaft clockwise and align the "3T" mark
[2]
[1] on the CKP sensor rotor with the index mark [2] on
the right crankcase cover.
AM R

Make sure that the No.3 piston is at TDC (Top Dead

OB IST

Center) on the compression stroke.

RD D
CO SU
21 O

[1]
-20 BID
-01 HI
07 O
PR

10-16
 CYLINDER HEAD/VALVES
Apply molybdenum oil solution to the camshaft journals.
[1]
Install the rear cylinder intake [1] and exhaust [2]
camshafts with the index lines [3] ("RI", "RE" marks) on
the cam sprocket facing outward.

S.R DO
.L.
RS A
TO RIZ
[3]

MO TO
[2]
Always replace the Install the joint collars [1] and new O-rings [2] onto the
[1]

BA AU
O-rings with new rear cylinder head.
ones.

DO O
OR N
- C SO
.L. U [2]
.R O
Install the camshaft holder A [1] to the rear cylinder
[2] [3]
head with the "IN" mark [2] facing to the intake side.
S S ÓN

Install the camshaft Install the "I" marked camshaft holder B [3] onto the
holder B with their intake camshaft and the "E" marked camshaft holder B
bosses facing the [4] onto the exhaust camshaft.
OR CI

holder A.
OT IBU
AM R
OB IST

[1] [4]

Apply engine oil to the threads and flange surfaces of

[2] [3]
RD D

the camshaft holder A/B flange bolts.

Install new sealing washers [1] and camshaft holder A
CO SU

flange bolts [2].

Tighten the camshaft holder A flange bolts in a
crisscross pattern in two or more steps until the holder
rests lightly on the cylinder head surface.
21 O

Tighten the Tighten the camshaft holder B flange bolts [3] gradually
in two or more steps.
-20 BID

camshaft holder
bolts, starting with
the bolts at the
dowel pins, in two or
-01 HI

more steps.
[1]/[2] [2]
07 O
PR

10-17
CYLINDER HEAD/VALVES
Tighten the Tighten the camshaft holder A flange bolts [1] to the
[1] [2]
camshaft holder specified torque, then the camshaft holder B flange
bolts in a crisscross bolts [2].
pattern in 2 or 3
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

S.R DO
steps.

.L.
RS A
TO RIZ
MO TO
Turn the crankshaft clockwise 1-1/4 turn (450°) and

BA AU
[2]
align the "4T" mark [1] on the CKP sensor rotor with the
index mark [2] on the right crankcase cover.
Make sure that the No.4 piston is at TDC (Top Dead
Center) on the compression stroke.

DO O
OR N
- C SO
.L. U [1]
.R O
Apply molybdenum oil solution to the camshaft journals
(page 1-17).
S S ÓN

Make sure that the Install the front cylinder intake and exhaust camshafts
index lines on the with the index lines [1] ("FI", "FE" marks) on the cam
cam sprockets are sprocket facing outward.
OR CI

facing outward and

are flush with the
OT IBU

cylinder head.

[1]
AM R
OB IST

With the No.4 piston is at TDC, make sure that the rear
RD D

cylinder cam sprocket " " marks [1] facing outward and
flush with the top surface of the cylinder head.
CO SU
21 O
-20 BID
-01 HI

[1]
07 O
PR

10-18
 CYLINDER HEAD/VALVES
Always replace the Install the joint collars [1] and new O-rings [2] onto the
[1]
O-rings with new front cylinder head.
ones.

S.R DO
.L.
RS A
[3]

TO RIZ
MO TO
[2]

Install the camshaft holder A [1] to the front cylinder

[3] [2]

BA AU
head with the "IN" mark [2] facing to the intake side.
Install the camshaft Install the "I" marked camshaft holder B [3] onto the
holder B with their intake camshaft and the "E" marked camshaft holder B

DO O
bosses facing the [4] onto the exhaust camshaft.
holder A.

OR N
- C SO
.L. U [4] [1]
.R O
Apply engine oil to the threads and flange surfaces of
[3] [2]
the camshaft holder A/B flange bolts.
S S ÓN

Install new sealing washers [1] and camshaft holder A

flange bolts [2].
Tighten the camshaft holder A flange bolts in a
OR CI

crisscross pattern in two or more steps until the holder

rests lightly on the cylinder head surface.
OT IBU

Tighten the Tighten the camshaft holder B flange bolts [3] gradually
camshaft holder in two or more steps.
bolts, starting with
the bolts at the
AM R

dowel pins, in two or

OB IST

more steps.
[2] [1]/[2]
Tighten the Tighten the camshaft holder A flange bolts [1] to the
[2] [1]
specified torque, then the camshaft holder B flange
RD D

camshaft holder
bolts in a crisscross bolts [2].
pattern in 2 or 3
CO SU

steps. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[2]
21 O
-20 BID
-01 HI
07 O
PR

10-19
CYLINDER HEAD/VALVES
If the cam sprockets and/or CMP sensor rotor are
FRONT SIDE shown:
removed, tighten the cam sprocket bolts [1] to the
specified torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

S.R DO
Remove the tensioner stopper from the cam chain

.L.
tensioner lifter.
Install a new sealing washer and tighten the sealing bolt

RS A
securely (page 10-38).

TO RIZ
MO TO
[1]

Turn the crankshaft clockwise and align the "3T" mark

BA AU
[2]
[1] on the CKP sensor rotor with the index mark [2] on
the right crankcase cover.
Make sure that the No.3 piston is at TDC (Top Dead
Center) on the compression stroke.

DO O
Recheck the rear cylinder valve timing.

OR N
- C SO
.L. U [1]
.R O
With the No.3 piston is at TDC, make sure that the front
cylinder cam sprocket " " marks [1] facing outward
S S ÓN

and flush with the top surface of the cylinder head.

Install the cylinder head covers (page 10-6).
OR CI
OT IBU
AM R
OB IST

[1]

IF ONLY THE FRONT CYLINDER CAMSHAFT WAS

REMOVED:
RD D

Remove the rear cylinder head cover (page 10-6).

[2]
CO SU

Turn the crankshaft clockwise and align the "3T" mark

[1] on the CKP sensor rotor with the index mark [2] on
the right crankcase cover.
21 O

Make sure that the index lines [3] ("RE, "RI" marks) on
the rear cam sprockets are facing outward.
-20 BID

If they are not, turn the crankshaft clockwise one full

turn (360°) and realign the "3T" mark with the index
mark.
-01 HI
07 O

[1] [3]
PR

10-20
 CYLINDER HEAD/VALVES
Turn the crankshaft clockwise 1-1/4 turn (450°) and
[2]
align the "4T" mark [1] on the CKP sensor rotor with the
index mark [2] on the right crankcase cover.

S.R DO
.L.
RS A
TO RIZ
MO TO
[1]

Install the front cylinder intake and exhaust camshafts

BA AU
with the index lines [1] ("FI", "FE" marks) on the cam
sprocket facing outward.
Install the camshaft holders to the front cylinder head

DO O
following the same procedure as WHEN BOTH THE
FRONT AND REAR CAMSHAFTS WERE REMOVED

OR N
(page 10-16). [1]
If the cam sprockets are removed, tighten the cam

- C SO
sprocket bolts [2] to the specified torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

.L. U
Remove the tensioner stopper from the cam chain
tensioner lifter.
Install a new sealing washer and tighten the sealing bolt [2]
.R O
securely (page 10-38).
Recheck the valve timing.
S S ÓN

Install the cylinder head covers (page 10-6).

IF ONLY THE REAR CYLINDER CAMSHAFT WAS
OR CI

REMOVED:
Remove the front cylinder head cover (page 10-6).
[2] [3]
OT IBU

Turn the crankshaft clockwise and align the "4T" mark

[1] on the CKP sensor rotor with the index mark [2] on
the right crankcase cover.
AM R

Make sure that the index lines [3] ("FI", "FE" marks) on
the front cam sprockets are facing outward.
OB IST

If they are not, turn the crankshaft clockwise one full

turn (360°) and realign the "4T" mark with the index
mark.
RD D
CO SU

[1]

Turn the crankshaft clockwise 3/4 turn (270°) and align

[2]
21 O

the "3T" mark [1] on the CKP sensor rotor with the index
mark [2] on the right crankcase cover.
-20 BID
-01 HI
07 O
PR

[1]

10-21
CYLINDER HEAD/VALVES
Install the rear cylinder intake and exhaust camshafts
[2]
with the index lines [1] ("RI", "RE" marks) on the cam
sprocket facing outward.
Install the camshaft holders to the rear cylinder head

S.R DO
following the same procedure as WHEN BOTH THE
FRONT AND REAR CAMSHAFTS WERE REMOVED

.L.
(page 10-16).

RS A
If the cam sprockets and/or CMP sensor rotor are
removed, tighten the cam sprocket bolts [2] to the

TO RIZ
specified torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)

MO TO
Remove the tensioner stopper from the cam chain
tensioner lifter. [1]
Install a new sealing washer and tighten the sealing bolt

BA AU
securely (page 10-38).
Recheck the valve timing.
Install the cylinder head covers (page 10-6).

DO O
OR N
CYLINDER HEAD

- C SO
REMOVAL
Remove the following:
– Throttle body (page 7-14)

.L. U
– Front and rear camshafts (page 10-11)
– Cam chain tensioner lifters (page 10-38)
.R O
– Starter clutch (page 11-21)
Front: Disconnect the ECT sensor 3P (Gray) connector [1]
S S ÓN

FRONT: [1]
from the front cylinder head.
OR CI
OT IBU
AM R
OB IST

Rear: Remove the bolt [1] and CMP sensor [2] from the rear
RD D

REAR: [1]
cylinder head.
CO SU
21 O
-20 BID
-01 HI

[2]
07 O
PR

10-22
 CYLINDER HEAD/VALVES
Remove the bolts [1] and water joint [2] from the
[2]
cylinder head.

S.R DO
.L.
RS A
TO RIZ
MO TO
[1]

Remove the 6 mm flange bolts [1].

BA AU
[1] [2]
Loosen the 9 mm Remove the 9 mm special bolts/washers [2].
bolts in a crisscross
Remove the cylinder head [3].
pattern in 2 – 3

DO O
steps.

OR N
- C SO
.L. U [3]
.R O
Remove the gasket [1] and dowel pins [2].
[1] [3]/[4]
S S ÓN

Remove the oil through collar [3] and O-ring [4].

OR CI
OT IBU
AM R
OB IST

[2]

Remove the flange bolt [1] and front cam chain guide
[3]/[5] [4] [6]
RD D

[2].
Remove the flange bolt [3], front cam chain tensioner
CO SU

[4] and collar [5].

Remove the front cam chain [6].
21 O
-20 BID
-01 HI

[1] [2]
07 O
PR

10-23
CYLINDER HEAD/VALVES
Remove the flange bolt [1] and rear cam chain guide
[6] [2]
[2].
Remove the flange bolt [3], rear cam chain tensioner [4]
and collar [5].

S.R DO
Remove the rear cam chain [6] and timing sprocket [7]

.L.
from the crankshaft.

RS A
TO RIZ
MO TO
[4] [3]/[5] [7] [1]

DISASSEMBLY

BA AU
Remove the spark plugs (page 3-6).
FRONT Shown:
Loosen the band screws [1] and remove the insulators
[2]
[2] from the cylinder head.

DO O
Front: Remove the ECT sensor [3].

OR N
- C SO
.L. U
.R O
[3] [1] [2]
S S ÓN

Install the tappet hole protector [1] into the valve lifter
[1]
bore.

TOOL:
OR CI

Tappet hole protector 07HMG-MR70002

OT IBU
AM R
OB IST
RD D

Remove the normal side valve spring cotters using the

[1]
special tools as shown.
CO SU

TOOLS:
[1] Valve spring compressor 07757-0010000
[2] Valve spring compressor 07959-KM30101
21 O

attachment
-20 BID

To prevent loss of tension, do not compress the valve

springs more than necessary to remove the cotters.
-01 HI
07 O

[2]
PR

10-24
 CYLINDER HEAD/VALVES
Mark all parts Remove the following:
[6]
during disassembly
– Spring retainer [1]
so they can be
– Outer valve spring [2]
placed back in their
– Inner valve spring [3]

S.R DO
original locations.
– Valve [4] [3]
– Stem seal [5]

.L.
– Valve spring seat [6]

RS A
TO RIZ
[1]

MO TO
[2] [5] [4]

Remove the VTEC side valve spring cotters using the

[1]

BA AU
special tools as shown.

TOOLS:
[1] Valve spring compressor 07757-0010000

DO O
[2] Valve spring compressor 070ME-MCW0100
attachment

OR N
- C SO
To prevent loss of tension, do not compress the valve
springs more than necessary to remove the cotters.

.L. U [2]
.R O
Mark all parts Remove the following:
[5]
during disassembly
S S ÓN

– Spring retainer [1]

so they can be
– Inner valve spring [2]
placed back in their
– Valve [3]
original locations.
– Stem seal [4]
OR CI

– Valve spring seat [5] [2]

OT IBU
AM R
OB IST

[1] [4] [3]

INSPECTION
RD D

CYLINDER HEAD
Avoid damaging the Remove carbon deposits from the combustion chamber
CO SU

[1]
gasket surface. [1], being careful not to damage the gasket surface.
Check the spark plug hole and valve areas for cracks.
21 O
-20 BID
-01 HI
07 O
PR

10-25
CYLINDER HEAD/VALVES
Check the cylinder head for warpage with a straight
edge and feeler gauge.
SERVICE LIMIT: 0.10 mm (0.004 in)

S.R DO
.L.
RS A
TO RIZ
MO TO
VALVE SPRING

BA AU
Check the valve spring for fatigue or damage.
Measure the free length of normal side valve spring.

DO O
SERVICE LIMITS:
Spring A outer: 41.5 mm (1.63 in)

OR N
Spring A inner: 39.0 mm (1.54 in)
Replace the springs if they are shorter than the service

- C SO
limits.

.L. U
.R O
S S ÓN

Check the valve spring for fatigue or damage.

Measure the free length of VTEC side valve spring.
SERVICE LIMITS:
OR CI

Spring B outer: 53.2 mm (2.09 in)

Spring B inner: 38.3 mm (1.51 in)
OT IBU

Replace the springs if they are shorter than the service

limits.
AM R
OB IST
RD D

VALVE LIFTER
Inspect each valve lifter for scratches or abnormal
CO SU

wear.
Measure the each valve lifter O.D.
SERVICE LIMIT: 25.97 mm (1.022 in)
21 O
-20 BID
-01 HI
07 O
PR

10-26
 CYLINDER HEAD/VALVES
VALVE LIFTER BORE
Inspect each valve lifter bore for scratches or abnormal
wear.
Measure the each valve lifter bore I.D.

S.R DO
SERVICE LIMIT: 26.04 mm (1.025 in)

.L.
RS A
TO RIZ
MO TO
BA AU
CAM CHAIN TENSIONER/CAM CHAIN GUIDE
Inspect the cam chain tensioner [1] and cam chain
[2]
guide [2] for excessive wear or damage, replace them if

DO O
necessary.

OR N
- C SO
.L. U
.R O
[1]
S S ÓN

VALVE/VALVE GUIDE
Check that the valve moves smoothly in the guide.
OR CI

Inspect each valve for bending, burning or abnormal

stem wear.
OT IBU

Measure and record each valve stem O.D.

SERVICE LIMITS:
IN: 4.465 mm (0.1758 in)
EX: 4.455 mm (0.1754 in)
AM R
OB IST
RD D
CO SU

Ream the guides to remove any carbon deposits before

[1]
checking clearances.
Insert the reamer [1] from the combustion chamber side
21 O

of the head and always rotate the reamer clockwise.

TOOL:
-20 BID

Valve guide reamer, 4.5 mm 07HMH-ML00101

-01 HI
07 O
PR

10-27
CYLINDER HEAD/VALVES
Measure and record each valve guide I.D.
SERVICE LIMIT: IN/EX: 4.540 mm (0.1787 in)
Subtract each valve stem O.D. from the corresponding

S.R DO
guide I.D. to obtain the stem-to-guide clearance.

.L.
SERVICE LIMITS:
IN: 0.075 mm (0.0030 in)

RS A
EX: 0.085 mm (0.0033 in)

TO RIZ
Reface the valve If the stem-to-guide clearance is out of standard,
seats whenever the determine if a new guide with standard dimensions
valve guides are would bring the clearance within tolerance. If so,

MO TO
replaced (page 10- replace any guides as necessary and ream to fit.
29). If the stem-to-guide clearance is out of standard with
the new guides, replace the valves and guides.

BA AU
VALVE GUIDE REPLACEMENT
Chill the replacement valve guides in the freezer

DO O
[1]
section of a refrigerator for about an hour.
Heat the cylinder head to 100 – 150°C (212 – 300°F)

OR N
with a hot plate or oven.

- C SO
Do not use a torch to heat the cylinder head; it may
cause warping.

.L. U
Support the cylinder head and drive out the valve
guides from combustion chamber side of the cylinder
.R O
head.
TOOL:
S S ÓN

[1] Valve guide driver 07HMD-ML00101

Drive in the guide to the specified depth from the top of

OR CI

the cylinder head.

TOOL:
OT IBU

[1] Valve guide driver 07HMD-ML00101

SPECIFIED DEPTH:
Normal side: 12.15 – 12.50 mm (0.478 – 0.492 in)
AM R

VTEC side: 19.65 – 20.00 mm (0.774 – 0.787 in)

OB IST

Let the cylinder head cool to room temperature.

RD D

[1]
CO SU

Use cutting oil on Ream the new valve guide after installation.
[1]
the reamer during Insert the reamer [1] from the combustion chamber side
this operation of the head and also always rotate the reamer
clockwise.
21 O

TOOL:
-20 BID

Valve guide reamer, 4.5 mm 07HMH-ML00101

Clean the cylinder head thoroughly to remove any
metal particles.
-01 HI

Reface the valve seat (page 10-29).

07 O
PR

10-28
 CYLINDER HEAD/VALVES
VALVE SEAT INSPECTION/REFACING
Clean the intake and exhaust valves thoroughly to
[1]
remove carbon deposits.
Apply a light coating of Prussian Blue to the valve

S.R DO
seats.
Tap the valves and seats using a rubber hose or other

.L.
hand-lapping tool [1].

RS A
TO RIZ
MO TO
BA AU
Remove the valve and inspect the valve seat face.
The valve seat contact should be within the specified
width and even all around the circumference.

DO O
STANDARD: 0.90 – 1.10 mm (0.035 – 0.043 in)

OR N
SERVICE LIMIT:1.5 mm (0.06 in)

- C SO
If the seat width [1] is not within specification, reface the
valve seat (page 10-29).
Inspect the valve seat face for: [1]

.L. U
• Uneven seat width:
– Replace the valve and reface the valve seat.
.R O
• Damaged face:
– Replace the valve and reface the valve seat.
S S ÓN

The valves cannot be ground. If a valve face is burned

or badly worn or if it contacts the seat unevenly, replace
the valve.
OR CI

• Contact area (too high or too low)

– Reface the valve seat.
OT IBU

VALVE SEAT REFACING

Follow the refacing Valve seat cutters/grinders or equivalent valve seat
AM R

manufacturer's refacing equipment are recommended to correct worn

operating valve seats.
OB IST

instructions.
TOOLS:
Valve seat cutter, 29 mm (IN) 07780-0010300 45°
Valve seat cutter, 27.5 mm (EX) 07780-0010200
RD D

Cutter holder, 4.5 mm 07781-0010600

CO SU

TOOLS: 60°
Flat cutter, 30 mm (IN) 07780-0012200 32°
Flat cutter, 28 mm (EX) 07780-0012100
21 O

Cutter holder, 4.5 mm 07781-0010600

-20 BID

TOOLS:
Interior cutter, 30 mm (IN/EX) 07780-0014000
Cutter holder, 4.5 mm 07781-0010600
-01 HI
07 O
PR

10-29
CYLINDER HEAD/VALVES
After cutting the seat, apply lapping compound to the
[1]
valve face, and lap the valve using light pressure.

S.R DO
• Excessive lapping pressure may deform or damage
the seat.

.L.
• Change the angle of lapping tool [1] frequently to

RS A
prevent uneven seat wear.
• Do not allow lapping compound to enter the guides.

TO RIZ
After lapping, wash all residual compound off the
cylinder head and valve.

MO TO
ASSEMBLY

BA AU
FRONT CYLINDER HEAD (NORMAL VALVE SIDE):
COTTERS

DO O
INNER VALVE SPRING INTAKE STEM SEAL
VALVE LIFTER

OR N
OUTER VALVE SPRING SEAT
SPRING
VALVE GUIDE

- C SO
SHIM

.L. U
SPRING RETAINER
.R O
S S ÓN

EXHAUST VALVE
OR CI

EXHAUST STEM SEAL

OT IBU
AM R
OB IST

INTAKE VALVE
RD D
CO SU
21 O
-20 BID
-01 HI
07 O
PR

10-30
 CYLINDER HEAD/VALVES
FRONT CYLINDER HEAD (VTEC VALVE SIDE):

VALVE LIFTER
EXHAUST STEM SEAL

S.R DO
OUTER VALVE SPRING SPRING SEAT

.L.
VALVE GUIDE
SPRING RETAINER

RS A
TO RIZ
SLIDE PIN HOLDER

COTTERS

MO TO
INNER VALVE SPRING

BA AU
EXHAUST VALVE

DO O
OR N
INTAKE STEM SEAL

- C SO
.L. U
.R O
INTAKE VALVE
S S ÓN

REAR CYLINDER HEAD (NORMAL VALVE SIDE):

OR CI

VALVE LIFTER
SHIM
OT IBU

COTTERS
SPRING RETAINER
AM R

OUTER VALVE SPRING INNER VALVE SPRING

OB IST

EXHAUST STEM SEAL

RD D
CO SU

SPRING SEAT
21 O

VALVE GUIDE
-20 BID

INTAKE STEM SEAL

-01 HI
07 O
PR

EXHAUST VALVE INTAKE VALVE

10-31
CYLINDER HEAD/VALVES
REAR CYLINDER HEAD (VTEC VALVE SIDE):

SLIDE PIN HOLDER VALVE LIFTER

S.R DO
.L.
COTTERS OUTER VALVE SPRING

RS A
INNER VALVE SPRING

TO RIZ
SPRING RETAINER

MO TO
BA AU
EXHAUST STEM SEAL

DO O
SPRING SEAT

OR N
INTAKE STEM SEAL

- C SO
VALVE GUIDE

.L. U
.R O
EXHAUST VALVE INTAKE VALVE
S S ÓN

Remove the cylinder head orifice bolts [1] from the

[1]
cylinder head.
OR CI

Blow through all oil passages in the cylinder head with

compressed air.
OT IBU

Blow through air bleed hole in the bleed bolt with

compressed air.
Install the cylinder head orifice bolts to the specified
AM R

torque.
OB IST

TORQUE: 8 N·m (0.8 kgf·m, 5.9 lbf·ft)

RD D

Install the tappet hole protector [1] into the normal side
CO SU

[1]
valve lifter bore.
TOOL:
Tappet hole protector 07HMG-MR70002
21 O
-20 BID
-01 HI
07 O
PR

10-32
 CYLINDER HEAD/VALVES
Install the valve spring seats.
[1]
The intake stem seal has identification projections [1]
on the top surface.
Install intake [2] and exhaust stem seals [3] in their

S.R DO
proper position.

.L.
RS A
TO RIZ
MO TO
[2] [3]

Lubricate the normal side valve stems with

BA AU
molybdenum oil solution (page 1-17).
Insert the valve [1] into the valve guide while turning it
slowly to avoid damage to the stem seal.

DO O
Install the normal side inner [2] and outer valve springs [2]
[3] with the tightly wound coils facing the combustion

OR N
chamber side.
Install the valve spring retainer [4].

- C SO
[4]

.L. U [3] [1]

.R O
[3] [2]
S S ÓN
OR CI
OT IBU
AM R
OB IST

COMBUSTION CHAMBER SIDE

Grease the cotters Install the normal side valve cotters using the special
[1]
tool as shown.
RD D

to ease installation.
CO SU

To prevent loss of tension, do not compress the valve

spring more than necessary.
TOOLS:
21 O

[1] Valve spring compressor 07757-0010000

-20 BID

[2] Valve spring compressor

attachment 07959-KM30101
-01 HI

[2]
07 O
PR

10-33
CYLINDER HEAD/VALVES
Support the cylinder Tap the normal side valve stems gently with hammer [1]
[1]
head above the and shaft [2] as shown to firmly seat the cotters.
work bench surface
to prevent possible

S.R DO
valve damage. [2]

.L.
RS A
TO RIZ
MO TO
Lubricate the VTEC side valve stem sliding surface with

BA AU
molybdenum oil solution (page 1-17).
Insert the valve [1] into the valve guide while turning it
slowly to avoid damage to the stem seal.

DO O
Install the VTEC side inner valve springs [2] with the [2]
tightly wound coils facing the combustion chamber side.

OR N
Install the valve spring retainer [3].

- C SO
.L. U [3] [1]
.R O
[2]
S S ÓN
OR CI
OT IBU
AM R
OB IST

COMBUSTION CHAMBER SIDE

Grease the cotters Install the VTEC side valve cotters using the special
[1]
tool as shown.
RD D

to ease installation.
CO SU

To prevent loss of tension, do not compress the valve

spring more than necessary.
TOOLS:
21 O

[1] Valve spring compressor 07757-0010000

-20 BID

[2] Valve spring compressor

attachment 070ME-MCW0100
-01 HI

[2]
07 O
PR

10-34
 CYLINDER HEAD/VALVES
Support the cylinder Tap the VTEC side valve stems gently with hammer [1]
[1]
head above the and shaft [2] as shown to firmly seat the cotters.
work bench surface
to prevent possible

S.R DO
valve damage. [2]

.L.
RS A
TO RIZ
MO TO
Install the insulators [1] and tighten the band screws [2]
FRONT SIDE Shown:

BA AU
so that the insulator band distance is 10 ± 1 mm (0.4 ±
0.04 in). [1]
Front: Install and tighten the ECT sensor [3] to the specified

DO O
torque.
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)

OR N
Install the spark plugs (page 3-6).

- C SO
.L. U [3] [2] [1]
.R O
S S ÓN

10 ± 1 mm
(0.4 ± 0.04 in)
OR CI
OT IBU
AM R
OB IST

INSTALLATION
RD D

Note the installation Install the timing sprocket [1] by aligning the wide teeth
Align
direction of the between the crankshaft and sprocket.
CO SU

timing sprocket.
21 O
-20 BID
-01 HI

[1]
07 O
PR

10-35
CYLINDER HEAD/VALVES
Install the rear cam chain [1] onto the timing sprocket.
[1] [2]
Apply locking agent to the cam chain guide flange bolt
threads (page 1-11).
Install the rear cam chain guide [2] and flange bolt [3].

S.R DO
Apply locking agent to the cam chain tensioner flange

.L.
bolt threads (page 1-11).
Install the rear cam chain tensioner collar [4], tensioner

RS A
[5] and flange bolt [6].

TO RIZ
Tighten the cam chain guide and cam chain tensioner
flange bolts to the specified torque.
TORQUE: [3]

MO TO
Cam chain tensioner flange bolt:
26 N·m (2.7 kgf·m, 19 lbf·ft) [5] [4]/[6]
Cam chain guide flange bolt:

BA AU
12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the front cam chain [1] onto the timing sprocket.
[5] [1]
Apply locking agent to the cam chain guide flange bolt

DO O
threads (page 1-11). [4]/[6]
Install the front cam chain guide [2] and flange bolt [3].

OR N
Apply locking agent to the cam chain tensioner flange
bolt threads (page 1-11).

- C SO
Install the front cam chain tensioner collar [4], tensioner
[5] and flange bolt [6].
Tighten the cam chain guide and cam chain tensioner

.L. U
flange bolts to the specified torque.
.R O
TORQUE:
Cam chain tensioner flange bolt:
26 N·m (2.7 kgf·m, 19 lbf·ft) [3] [2]
S S ÓN

Cam chain guide flange bolt:

12 N·m (1.2 kgf·m, 9 lbf·ft)
OR CI

The cylinder head Install a new gasket [1] and dowel pins [2].
[1] [5] [3]/[4]
gasket has
Install the oil through collar [3] and a new O-ring [4].
identification mark
OT IBU

[5]. At installation,
install each gasket
in their proper
AM R

position.
OB IST
RD D
CO SU

[2]

Install the cylinder head [1] onto the cylinder block.

[3]
Apply engine oil to the threads and flange surface of the
21 O

9 mm special bolt/washers [2] and install them. [2]

-20 BID

Install the 6 mm flange bolts [3].

Tighten the 9 mm special bolts in a crisscross pattern in
2 – 3 steps to the specified torque.
-01 HI

TORQUE: 44 N·m (4.5 kgf·m, 32 lbf·ft)

Tighten the 6 mm flange bolts.
07 O
PR

[1]

10-36
 CYLINDER HEAD/VALVES
Install a new O-ring [1] into the groove of the water joint
[1] [2]
[2].

S.R DO
.L.
RS A
TO RIZ
MO TO
Install the water joint [1] to the cylinder head, then

BA AU
[1]
install and tighten the bolts [2].

DO O
OR N
- C SO
.L. U [2]
.R O
Front: Connect the ECT sensor 3P (Gray) connector [1].
FRONT: [1]
S S ÓN

Install the removed parts in the reverse order of

removal.
OR CI
OT IBU
AM R
OB IST

Rear: Apply engine oil to a new O-ring [1] and install it into the
REAR:
groove of the CMP sensor [2].
RD D

Install the CMP sensor and tighten the bolt.

CO SU

Install the removed parts in the reverse order of [1]

removal.
21 O
-20 BID
-01 HI

[2]
07 O
PR

10-37
CYLINDER HEAD/VALVES
CAM CHAIN TENSIONER LIFTER
REMOVAL
Front: Remove the throttle body (page 7-14).

S.R DO
[1]
Rear: Remove the right footpeg bracket bolts and heat guard

.L.
mounting bolt (page 2-15).

RS A
Remove the cam chain tensioner sealing bolt [1] and
sealing washer [2].

TO RIZ
MO TO
BA AU
[2]

Turn the cam chain tensioner lifter shaft fully in [4]

[2] [3]

DO O
(clockwise) and secure it using the tensioner stopper [1]
to prevent damaging the cam chain.

OR N
TOOL:
Tensioner stopper 070MG-0010100

- C SO
Be careful not to Remove the bolts [2] cam chain tensioner lifter [3] and
enter the dust and gasket [4].

.L. U
dirt to enter the
cylinder head.
.R O
S S ÓN

[1]

INSTALLATION
OR CI

Install the cam chain tensioner lifter [1] onto the cylinder
[2] [1]
head with a new gasket [2].
OT IBU
AM R
OB IST
RD D
CO SU

Install and tighten the mounting bolts [1].

[1]
Remove the tensioner stopper.
21 O

Install a new sealing washer [2] and tighten the sealing

-20 BID

bolt [3] securely.

Install the removed parts in the reverse order of
removal.
[3]
-01 HI
07 O
PR

[2]

10-38