POWERHEAD. Section 4A - Cylinder Head. Rocker Shaft and Rocker Arm... 4A-21 Camshaft... 4A-22 Cylinder Head... 4A-24

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1 POWERHEAD Section 4A - Cylinder Hed CYLINDER HEAD Tle of Contents Specifictions A-2 Specil Tools A-4 Cylinder Hed A-6 Intke/Exhust Vlves A-8 Cmshft/Oil Pump A-10 Torque Sequence A-12 Cylinder Hed A-12 Vlve Clernce A-13 Checking Vlve Clernce A-13 Adjusting Vlve Clernce A-15 Preprtion for Cylinder Hed Removl.... 4A-17 Cylinder Hed Removl A-18 Cylinder Hed Disssemly A-19 Clening nd Inspection A-21 Rocker Shft nd Rocker Arm A-21 Cmshft A-22 Cylinder Hed A-24 Vlves A-30 Vlve Springs A-31 Cylinder Hed Ressemly A-32 Vlve Instlltion A-32 Cmshft Oil Sel Instlltion A-34 Cmshft Instlltion A-34 Rocker Arm Shft Assemly A-36 Rocker Arm Shft Instlltion A-36 Cylinder Hed Gsket A-37 Cylinder Hed Instlltion A-37 Cylinder Hed Cover Instlltion A-38 4 A R2 DECEMBER 2001 Pge 4A-1

2 Specifictions Cmshft Dimensions Intke A Exhust A Intke B Exhust B A in. ( mm) in. ( mm) in. ( mm) in. ( mm) CAMSHAFT Run-out Limit B Cmshft Bering Dimeter in. (0.1 mm) in. ( mm) Free Length Tilt Limit in. ( mm) Less thn in. (1.7 mm) VALVE SPRING Compressed Pressure (Instlled) Intke Exhust Tilt Limit (Intke & Exhust) Dir. of Winding (Intke & Exhust) ls. ( kg) ls. ( kg) in. (1.1 mm) Left Hnd Pge 4A R2 DECEMBER 2001

3 Wrp Limit in. (0.1 mm) CYLINDER HEAD * Lines indicte stright edge mesurement Cmshft Bore Inside Dimeter in. ( mm) VALVES Vlve/Vlve Set/Vlve Guides: Vlve Clernce (cold) Intke Exhust Vlve Dimensions: A Hed Dimeter Intke Exhust B Fce Width Intke Exhust C Set Width Intke Exhust D Mrgin Thickness Intke Exhust Stem Outside Dimeter Intke Exhust Guide Inside Dimeter Intke Exhust Stem To Guide Clernce Intke Exhust Stem Run-out Limit (mx.) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. ( mm) in. (0.016 mm) R2 DECEMBER 2001 Pge 4A-3

4 Vlve Dimensions B C D A Hed Dimeter Fce Width Set Width Mrgin Thickness ROCKER SHAFT ROCKER ARM Outside Dimeter in. ( mm) Inside Dimeter of Bore ( mm) Specil Tools 1. Flywheel Holder P/N M 2. Vlve Guide Remover P/N A1 3. Vlve Guide Instller Bushing P/N A1 Pge 4A R2 DECEMBER 2001

5 4. Vlve Guide Remer P/N A1 CYLINDER HEAD 5. Vlve Spring Compressor P/N A R2 DECEMBER 2001 Pge 4A-5

6 CYLINDER HEAD CYLINDER HEAD stroke Outord Oil Pge 4A R2 DECEMBER 2001

7 CYLINDER HEAD TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 CYLINDER HEAD (ELECTRIC) 1 CYLINDER HEAD (MANUAL) 1 1 CYLINDER HEAD 2 4 GUIDE 3 4 CIRCLIP 4 2 ANODE 5 2 GROMMET 6 2 COVER 7 2 SCREW (M6 x 20) SCREW GASKET 10 1 OIL SEAL 11 1 O RING 12 1 COVER 13 1 DECAL-Servicing Referrl 14 1 DECAL-Engine Oil/Vlve Clernce 15 1 GASKET 16 5 SCREW (M6 x 20) SCREW (M6 x 25) SCREW (M9 x 1.5 x 95) DOWEL PIN 20 1 PLUG 21 1 O RING R2 DECEMBER 2001 Pge 4A-7

8 INTAKE/EXHAUST VALVES stroke Outord Oil Pge 4A R2 DECEMBER 2001

9 INTAKE/EXHAUST VALVES TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 2 EXHAUST VALVE 2 2 INTAKE VALVE 3 4 SEAT Vlve Spring 4 4 SEAL Vlve Stem 5 4 VALVE SPRING Outer 6 4 RETAINER Vlve Spring 7 8 KEY 8 4 ROCKER ARM 9 4 SCREW 10 4 NUT ROCKER SHAFT 12 2 PLUG 13 2 BRACKET 14 1 SPRING 15 3 SCREW (M8 x 30) R2 DECEMBER 2001 Pge 4A-9

10 CAMSHAFT/OIL PUMP stroke Outord Oil Loctite 222 Thred Locker Pge 4A R2 DECEMBER 2001

11 CAMSHAFT/OIL PUMP TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 SCREW (M8 x 40) WASHER 3 1 BELT 4 1 GEAR-Driven 5 1 DOWEL PIN 1 CAMSHAFT (ELECTRIC) 6 1 CAMSHAFT (MANUAL) 7 1 PIN 8 1 OIL PUMP ASSEMBLY 9 1 O RING 10 1 O RING 11 1 O RING 12 4 SCREW (M6 x 35) R2 DECEMBER 2001 Pge 4A-11

12 Torque Sequence Cylinder Hed Center Screws (6) -Cylinder hed Flnge Screws (3) Cylinder Hed Screw Torque Center Screws Qty. 6 (Lrger Di. M9) 1st: 17 l. ft. (23 N m) 2nd: 34.5 l. ft. (47 N m) Cyl. Hed Flnge Screws Qty. 3 (Smller Di. M6) 1st: 53 l. in. (6 N m) 2nd: 106 l. in. (12 N m) Pge 4A R2 DECEMBER 2001

13 Vlve Clernce CYLINDER HEAD NOTE: Vlves should e djusted when engine is cold. WARNING Engine could possily strt when turning flywheel during djustment. To prevent this type of ccidentl engine strting nd possile serious injury, lwys remove sprk plug leds from sprk plugs. 1. Remove flywheel cover (refer to Section 2A - Ignition). 2. Remove cylinder hed cover (refer to Cylinder Hed Removl). Checking Vlve Clernce IMPORTANT: Timing elt must e properly instlled with timing mrks on the drive ger nd the driven ger ligned with corresponding mrks on powerhed. 1. Position the driven ger for cylinder #1 or #2 (see instructions following). 2. Mesure the vlve clernce using feeler guge. If out of specifiction refer to Adjusting Vlves following. () () Intke Vlve () Exhust Vlve () Vlve Clernce Specifictions (Cold) in. ( mm) in. ( mm) R2 DECEMBER 2001 Pge 4A-13

14 POSITIONING OF TOP CYLINDER (#1) Position the #1 piston (top) t top ded center (TDC) on the compression stroke. 1. Rotte the driven ger clockwise to lign the 1 mrk on the driven ger with the cylinder hed mrk. 1 -Cylinder Hed Mrk -Driven Ger Mrk POSITIONING OF BOTTOM CYLINDER (#2) Position the #2 piston (ottom) t top ded center (TDC) on the compression stroke. 1. Rotte the driven ger clockwise 180 to lign the mrk on the driven ger with the cylinder hed mrk. 1 -Cylinder Hed Mrk -Driven Ger Mrk Pge 4A R2 DECEMBER 2001

15 Adjusting Vlve Clernce CYLINDER HEAD d c -#1 Intke -#1 Exhust c -#2 Intke d-#2 Exhust 1. Loosen locknut. -Locknut R2 DECEMBER 2001 Pge 4A-15

16 2. Insert the feeler guge (specifiction size) etween the vlve stem nd vlve djusting screw. -Feeler Guge 3. Adjust the vlve djusting screw ginst the feeler guge using screwdriver until slight resistnce is felt on the feeler guge. 4. Tighten nut to specified torque with guge inserted. Vlve Adjusting Nut Torque 120 l. in. (13.5 N m) 5. Re-check the vlve clernce nd redjust if necessry. 6. Reinstll the cylinder hed nd flywheel cover. Tighten screws to the specified torque. Pge 4A R2 DECEMBER 2001

17 Preprtion for Cylinder Hed Removl CYLINDER HEAD 1. Remove ottom cowl. -Screws (7) 2. Remove flywheel cover or mnul strter (see section 8). -Screws (4) Refer to section 2A for removl of the following components.. Timing elt. Ignition Coil c. Sprk plug 4. Refer to section 3A for removl of fuel pump R2 DECEMBER 2001 Pge 4A-17

18 Cylinder Hed Removl 1. Remove cylinder hed cover screws. 2. Remove cylinder hed cover. -Cylinder Hed Cover -Screws (5) Remove cylinder hed mounting screws. Seprte cylinder hed from cylinder lock Screws (9) Pge 4A R2 DECEMBER 2001

19 Cylinder Hed Disssemly CYLINDER HEAD 1. Hold driven ger using tool nd remove screw nd flt wsher. Remove driven ger M -Holder M Remove screws securing rocker rm to cylinder hed. Remove rocker rm nd retiners. 3. Remove retining screw. c -Screws (3) -Rocker Arm c -Retining Screw R2 DECEMBER 2001 Pge 4A-19

20 4. Remove oil sel nd cmshft. -Oil Sel -Cmshft 5. Remove vlve springs with spring compressor A Vlve Spring Compressor P/N A1 Pge 4A R2 DECEMBER 2001

21 Clening nd Inspection CYLINDER HEAD Rocker Shft nd Rocker Arm 1. Check rocker rm for pitting (), clogging (), or wer (c). Replce if necessry. Mesure rocker shft outside dimeter (d) nd rocker rm inside dimeter (e). Replce if out of specifiction. d c e Rocker Shft Outside Dimeter in. ( mm) Rocker Arm Inside Dimeter in. ( mm) R2 DECEMBER 2001 Pge 4A-21

22 Cmshft Mnul strt models re equipped with cm shft feturing compression relese mechnism. The compression relief mechnism releses percentge of the cylinder compression during engine crnking which lowers the strter rope pull force. At crnking speeds (RPM) the cm shft decompression levers rest ginst the side of the exhust cm loes, protruding out from the hel of the loe. This protrusion contcts the exhust vlve rocker rms during the compression stroke, slightly opening the exhust vlve. With the increse of centrifugl force t engine running speeds, the decompression levers swing out of contct with the exhust vlve rocker rms, llowing the exhust vlves to operte normlly (fully closed) during the compression stroke. -Exhust Vlve Rocker Arm -Decompression Lever 1. Inspect the cmshft for pitting, het discolortion, scrtches nd for the following mesurements. Replce cmshft if worn or not within specifiction. 2. Inspect the compression relief cm lever (if equipped) for free movement. Replce cmshft if necessry. -Compression Relief Cm Pge 4A R2 DECEMBER 2001

23 3. Mesure the cm loe length () nd width (). CYLINDER HEAD Cm Loe Specifictions Intke Exhust Intke Exhust in. ( mm) in. ( mm) in. ( mm) in. ( mm) 4. Mesure the cmshft ore dimeters () nd cmshft ering dimeters ( nd c) Cmshft Bore Inside Dimeter in. ( mm) Cmshft Bering Dimeter in. ( mm) R2 DECEMBER 2001 Pge 4A-23

24 Cylinder Hed 1. Inspect the cylinder hed for minerl deposits/corrosion in the wter pssge wys, clen ny deposits/corrosion oserved. 2. Inspect the cylinder hed for cron deposits in comustion chmer (use round scrper to clen wy deposits). Be creful not to scrtch or remove mteril Using stright edge nd thickness guge inspect cylinder hed for wrpge. Replce cylinder hed if out of specifiction Cylinder Hed Wrpge Limit in. (0.1 mm) Pge 4A R2 DECEMBER 2001

25 VALVE GUIDE INSPECTION CYLINDER HEAD 1. Mesure the vlve guide ore (). If vlve guide wer is out of specifiction, replce the vlve guide Vlve Guide Inside Dimeter Intke Vlve in. Exhust Vlve ( mm) VALVE GUIDE REPLACEMENT 1. Het the cylinder hed in n oven to 390 F (200 C). This will help to ese guide removl nd instlltion nd to mintin correct interference fit. 2. Remove the vlve guide using vlve guide remover. -Vlve Guide Remover ( A1) R2 DECEMBER 2001 Pge 4A-25

26 3. Instll the new vlve guide nd circlip using vlve guide instller ushing long with the vlve guide remover. -Vlve Guide Remover ( A1) -Vlve Guide Instller Bushing ( A1) After instlling the vlve guide, rem the vlve guide using vlve guide remer to otin proper stem-to-guide clernce. -Vlve Guide Remer ( A1) Pge 4A R2 DECEMBER 2001

27 VALVE SEAT RECONDITIONING CYLINDER HEAD Clen the cron deposits from the comustion chmers nd vlve sets nd check for pitting. Severl different types of equipment re ville for reseting vlve sets. Follow the equipment mnufcturer s instructions. Mesure vlve set width (). Resurfce the vlve set if not in specifiction Vlve Set Width Specifiction Intke Vlve in. Exhust Vlve ( mm) Refce vlve set, use 60, 45, 15 vlve set cutter. NOTE: When twisting cutter, keep n even downwrd pressure to prevent chtter mrks R2 DECEMBER 2001 Pge 4A-27

28 NOTE: If resurfcing the vlve sets is required, resurfce the vlve sets to the specified ngles shown in chrt. c Vlve Set Angle Specifictions c 60 Condition: The vlve set is centered on vlve fce ut it is too wide Vlve Set Cutter Set Desired Results Use 15 Cutter To reduce vlve set Lightly 60 Cutter width Pge 4A R2 DECEMBER 2001

29 Condition: The vlve set is in the middle of the vlve fce ut it is too nrrow. CYLINDER HEAD Vlve Set Cutter Set Desired Results Use 45 Cutter To chieve uniform vlve set width Condition: Vlve set is too nrrow nd it is ner vlve mrgin Vlve Set Cutter Set Desired Results Use 15 Cutter, First To center the set nd to 45 Cutter chieve its Width Condition: Vlve set is too nrrow nd is locted ner the ottom edge of the vlve fce Vlve Set Cutter Set Desired Results Use 60 Cutter, First To center the set nd to in- 45 Cutter crese its Width R2 DECEMBER 2001 Pge 4A-29

30 Vlves 1. Clen the cron deposits from the vlve. Discrd ny crcked, wrped, or urned vlves. 2. Mesure the vlve stem dimeter to check for wer. Replce vlves if not within specifiction Vlve Stem Dimeter Intke Vlve in. ( mm) Exhust Vlve in. ( mm) 3. Check the vlve fce for pitting. Vlves fces tht re pitted must e refced. NOTE: Severl different types of equipment re ville for refcing vlves. Follow the equipment mnufcturer s instructions. NOTE: After refcing the vlve set or replcing the vlve nd vlve guide, the vlve set nd vlve fce should e lpped. 4. Check the mrgin thickness () of the vlves fter the vlves hve een ground. Any vlve with mrgin thickness of less thn the specifiction, should e replced Intke Vlve Exhust Vlve Mrgin Thickness in. ( mm) in. ( mm) Pge 4A R2 DECEMBER 2001

31 5. Mesure vlve stem runout. Replce if out of specifiction. CYLINDER HEAD Intke Vlve Exhust Vlve Vlve Stem Runout Limit (Mx.) in. (0.016 mm) Vlve Springs 1. Check ech spring under lod on spring tester. Replce ny wek springs Check free length limit of ech spring. Replce vlve springs if not in specifiction Vlve Spring Free Length in. ( mm) R2 DECEMBER 2001 Pge 4A-31

32 3. Check ech spring on flt surfce using squre. Rotte spring nd check spce etween the top coil nd squre. Replce vlve springs if not in specifiction Vlve Spring Tilt Specifiction Less thn 0.06 in. (1.7 mm) Cylinder Hed Ressemly Vlve Instlltion INTAKE AND EXHAUST VALVE COMPONENTS c d e f -Vlve -Spring Set c -Vlve Sel d-vlve Spring e -Spring Retiner f -Vlve Keepers Pge 4A R2 DECEMBER 2001

33 INSTALLING VALVES 1. Alwys use new vlve sels. 2. Apply engine oil to the vlves nd vlve sets. 3. Instll vlves s shown. CYLINDER HEAD A1 c -End of the Vlve Spring with the Pre-Compressed Coils gets Instlled Towrds the Cylinder Hed -Use Spring Compressor Tool ( A1) to Compress the Springs for Instlltion c -Compress the Spring nd Retiner nd Instll the Vlve Keepers Around the Vlve Stem. You My hve to Tp Lightly on End of Vlve to Set the Keepers R2 DECEMBER 2001 Pge 4A-33

34 Cmshft Oil Sel Instlltion 1. If removed, instll Oil Sel. Position sel so prt numer side in fcing outwrd. Press sel in until it mkes contct with the inside flt surfce. Cmshft Instlltion -Upper Cmshft Oil Sel 1. Apply engine oil to the min journls (3 plces) on the cmshft. 2. Slide cmshft into cylinder hed (threded end towrds driven ger). 3. Instll cmshft retining screw. Tighten screw to the specified torque. -Cmshft Retining Screw Cmshft Retining Screw Torque 57 l. in. (6.5 N m) Pge 4A R2 DECEMBER 2001

35 4. Plce driven ger on cmshft so lignment pin is in hole. Hold ger with tool ( M) nd fsten with wsher nd screw. Tighten screw to the specified torque. 5. Remove ny oil from the cmshft loes nd pply Moly Grese to the lift portion of the loes. Otin Moly Grese from locl source. NOTE: Rotte cmshft fter ssemly to ensure it rottes smoothly. d c M -Alignment Pin -Driven Ger c -Wsher d-screw Driven Ger Screw Torque (d) 28 l. ft. (38 N m) R2 DECEMBER 2001 Pge 4A-35

36 Rocker Arm Shft Assemly 1. Apply engine oil to the rocker shft nd rms. 2. Locte the end of the rocker shft tht gets instlled towrds driven ger (oil holes will line-up with the mting oil holes in the cylinder hed). 3. Slide the rocker rms onto rocker shft s shown. -Rocker Shft -Rocker Arms Rocker Arm Shft Instlltion 1. Instll the rocker rm shft ssemly s shown. Tighten screws to the specified torque. NOTE: Leve ll djustment screws loose t this time. -Rocker Arm Retiner (3) -Mounting Screws (3) Rocker Arm Shft Mounting Screw Torque 13 l. ft. (18 N m) Pge 4A R2 DECEMBER 2001

37 Cylinder Hed Gsket 1. Instll cylinder hed gsket nd dowel pins. CYLINDER HEAD -Dowel Pin (2) -Gsket Cylinder Hed Instlltion 1. Apply engine oil to the threds of ech screw nd set surfce. 2. Fsten cylinder hed with screws shown Center Screws (6) -Cylinder Hed Flnge Screws (3) R2 DECEMBER 2001 Pge 4A-37

38 3. Torque screws in sequence nd in two steps Cylinder Hed Screw Torque Center Screws Qty. 6 (Lrger Di. M9) 1st: 17 l. ft. (23 N m) 2nd: 34.7 l. ft. (47 N m) Cyl. Hed Flnge Screws Qty. 3 (Smller Di. M6) 1st: 53 l. in. (6 N m) 2nd: 106 l. in. (12 N m) Cylinder Hed Cover Instlltion 1. Instll cover sel into groove. 2. Instll cylinder hed cover. Secure cylinder hed cover with screws. -Cylinder Hed Cover -Screws (5) Cylinder Hed Cover Screw Torque 70 l. in. (8 N m) Pge 4A R2 DECEMBER 2001

39 3. Refer to section 2A for instlltion of the following components.. Timing elt. Ignition Coil c. Sprk plugs 4. Refer to section 3A for instlltion of fuel pump. 5. Instll flywheel cover or mnul strter (if equipped). CYLINDER HEAD Secure ottom cowl. -Screws (6) -Screw (M6x60) R2 DECEMBER 2001 Pge 4A-39

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