8. Cylinder Head/Valves > | Service information 8-1 Camshaft Removal as | Troubleshooting 8-1 Camshaft Installation 87 | Cylinder Head Cover Removal/installation 8-2 Cylinder Head Removal/installation 89 | Cylinder Head Cover Disassembly/ Cylinder Head Disassembly/Assembly 8-10 Assembly B4 Sevice Information ‘This section covers service of the cylinder head, valves. camshaft, rocker arms and sub-rocker arms. This service can be one with the engine in the frame. + Camshaft lubricating ail is fed through oil passages in the cylinder head, Clean the oil passages before assembling the cylinger head. + Clean all disassembled parts with clean solvent and dry them by blowing off compressed air before inspection, + When disassembling, mark and store the disassembled parts to ensure that they are reinstalleg in their proper locations. Troubleshooting + Engine top-end problems usually affect engine performance. This can be diegnosed by a compression or leak down test, or by trating noises to the top-end with a sounding rod or stethoscope. + I performance is poor at low speeds, check for white smoke in the erankease breather tube. If the tube is smoky, check for 2 seized piston ring, Compression Too Low, Hard Starting or Poor Performance Excessive Smoke at Low Speed + Cylinder head + Valves = Worn valve stem or valve guide ~ incorrect valve adjustment — Damaged stem seal ~ Burned or bent valves, = Incorrect valve timing Excessive Noise — Broken valve spring + Cylinder head — Uneven valve seating = Incorrect valve adjustment + Cylinder head = Sticking valve or broken vaive spring Leaking or damaged head gasket = Darnaged or worn camshaft Warped or cracked cylinder head Loose or worn cam chain — Worn or damaged cam chain Compression Too High. Overheating or Knocking — Wern or damaged cam chain tensioner + Excessive carbon built-up in eylinder head or on top of = Worn cam sprocket teeth piston = Worn rocker arm andior shaft 8-1Cylinder Head/Valves Cylinder Head Cover Removal/Installation 61 — Qwveo 8-2Cylinder Head/Valv NOTE Belore removal, turn the crankshaft and align the “T" mark on the flywheel withthe index notch on the crankcase cover when on the compression stroke Ipage 3-5) Requisite Service + Carburetor removaliinstallation (page 5-4) Procedure aw Rename ] Romovel Order | Hastatioion sn the reverse order of removal (1) | Breather tube boat £2) nsutter bot i (2) | Carburetor insulatri0-ring wn | ta) rock 2 18) | Seating washer | a | (6) | Pipe stay bolt ) 2 17) | Of pss Pipe i {8) | Upper engine hanger plate | 2 | Installation (page 6-5) (8) | Cvtnder nead cover bot (10 mm hess) 2-—rL Loosen the two bolts indicated by dotted line enclosure co) (8 ramheash Tr J] Remove these bots etter removing the evlinder heed (111) Cynder nead cover assembiy | 1 | Stine oytnter ned cover othe inateside an remove i Disessembiylossembly (nape 8-4 (12)) Gosker 1 {18}, Bowe! in 2 8-3Cylinder Head/Valves Cylinder Head Cover Disassembly/Assembly 3 Q 727.20 7) ee 8-4 ¢Cylinder Head/Valves mped with its letter cede in the I Requisite Service jon as shown. Install properly + Note the locations of the wave washer + Cylinder head cover removallinstallation ipage 8-2) Procedure T Remarks | Removal Order (1) | Exnoust subrrocker arm shaft 12) | Copper washer (3) | Exhaust subocker srmiwave washer (5) | Copper wosher (6) | iteke sot rocker armiwave wesher (3) Rocker orm shot (8) Copper washer (9) _ Rocke arm | rstatienon in he vverse order of emt 8-5Cylinder Head/Valves Camshaft Removal | fof mechanic's wite to the chain to prevent it from being dropped into the crankcase. Remove with cam sprocket. Installation (page 8-7) Mechanic's wise & Requisite Service + Cylinder head remove [page 8-2) Procedure Qty | Remarks: | Removal Order 11) | Tenstoner shat ot : (2) | Cam sprocket bolt 2_| Push down the tensioner’s lever using the screw driver | © | nainsert tne pin ofthe tensioner holser (07973 te30008 ito the hole ofthe tensioner 28 shown Siowly fleece the tensioner unt tool resets against the | | evinge ead casing. «21 | Cam sprocketcern chain 1 | Remove them frm the com shaft farge ta) | Cam ehetn 1 | Deraithe com chain for the sprocket and attach a piece | 48) | Camshatt assembly (6) | Camshaft bearing (7) | Com chain tensioner shaft 1 | Push down the tensioner’s lever and remove the cam | ‘chain tensioner holder. (8) | Cam chain tensionecireturn spring Ww (9) | Bearing setting pin 2 110) Stopper/spring wn 8-6Cylinder Head/Valves Camshaft Installation Release the cam chain tensioner (page 8°6I. > ms 7 Install the camshaft assembly through the cam chain and remove the mechanic's wire from the cam chain. Remove the crankshaft hole cap and timing hele cap. Turn the crankshaft counterclockwise and align the "'T"” mark on the flywheel with the index notch on the left crankcase cover Place the camshaft into its correct position with the cam lobes all facing down. Install the chain onto the cam sprocket so that the timing > ‘marks on the sprocket align with the upper surface of the cylinder head, Install the cam sprocket onto the camshaft flare NOTE + Do not turn the sprocket when installing it onto the | 9 camshaft flange, | (0) "OUT" MARK 1) CAMSHAFT ASSEMBLY. N \ fy |) @ mechanic's abe wine (2) "T" MARK (1) TIMING MARKS (2) CAM LOBES 8-7Cylinder Head/Valves Align the cam sprocket bolt hole with camshatt hole, Install and tighten the ane bolt loosely. then turn the crankshaft and install the second bolt. Torque both bolts. Torque: 20 Nem 2.0 kg-m, 14 ftlb) Push down the tensioner's lever using the screw driver and: remove the tensioner holderCylinder Head/Valves Cylinder Head Removal/Installation ) Qo (si Requisite Service + Camshatt removal (page 8.6) + Camshaftinstallation (pege 8-7) Procedure Oy Remarks Removal Order Instalation isin the reverse order of removal (1) | Cylinder head nut 2 (2) | Cylinder head boltiwasher 66 (3) | Gesker 1 Do dowel in 2 (5) | Cylinder head assembly 1__| Dissssembiy/assembly (page @-10) 8-9a NOTE + Mark ail parts during disassembly so they can be placed back their original positions. + Remove carbon depesits from the combustion chamber and clean off the head gasket surface before assembly. For valve guide replacement, see section 9 of the Common Service Manual. Req ite Service + Cylinder Head Removal/installation (page 8-2) Procedure ay Remarks sembly Order Assembly isin the ceverse order of dsassemb (11 Valve spring cotter 8 | + Use valve spring compressor (07757 0010000). {To prevent lose of tension, 30 not compress the valve spring mare than necessary (2) | Valve spring retainer ja | (3) | Outer spring | 4 | Axinsaion instal withthe narrow piten end fasing down (4) | Inner spring (4 | (5) | Ovter spring seat | 4 (6) | Intake valve 2 (7) | Exhaust valve | 2 (8) | Valve stem | 4 {9) | Valve guide 4 | suse valve guige mover, 6.6 mm (077420010200) 101] Oving 4 8-10