COMPONENT LOCATION
'05 - '07 shown:
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• This section covers service of the camshaft, cylinder head and valves. These services can be done with the engine installed in the frame.
• During disassembly, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Camshaft lubrication oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the cylinder head.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
_______________________________________________________________________________________________________ Unit: mm (in)
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ITEM |
STANDARD |
SERVICE LIMIT |
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Cylinder compression |
402 к Pa (4.1 kgf/cm2, 58 psi) at 360 rpm |
- |
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Cylinder head warpage |
- |
0.05 (0.002) |
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Decompressor clearance |
'05 - '07 |
Ex valve clearance + 0.35 mm (0.014) |
- |
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Valve and valve guide |
Valve clearance |
IN |
0.16 ±0.03 (0.006 ±0.001) |
- |
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EX |
0.28 ±0.03 (0.011 ±0.001) |
- |
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Valve stem O. D. |
IN |
5.475-5.490 (0.2156-0.2161) |
- |
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EX |
4.965 - 4.980 (0.1955 - 0.1961) |
4.96 (0.195) |
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Valve guide I. D. |
IN |
5.500-5.512 (0.2165-0.2170) |
5.552 (0.2186) |
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EX |
5.000 - 5.012 (0.1969 - 0.1973) |
5.052 (0.1989) |
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Stem-to-guide clearance |
IN |
0.010 - 0.037 (0.0004 - 0.0015) |
- |
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EX |
0.020 - 0.047 (0.0008 - 0.0019) |
- |
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Valve guide projection above cylinder head |
IN |
16.1 - 16.3 (0.63-0.64) |
- |
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EX |
17.9-18.1 (0.70-0.71) |
- |
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Valve seat width |
IN |
1.1 -1.3 (0.04-0.05) |
2.0 (0.08) |
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EX |
1.3-1.5 (0.05-0.06) |
2.0 (0.08) |
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Valve spring free length |
IN |
40.68(1.602) |
39.7 (1.56) |
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EX |
42.82 (1.686) |
41.9 (1.65) |
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Rocker arm |
Rocker arm I. D. |
12.000 - 12.018 (0.4724-0.4731) |
12.05 (0.474) |
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Rocker arm shaft O. D. |
11.967 - 11.975 (0.4711 - 0.4715) |
11.92 (0.469) |
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Rocker arm-to-shaft clearance |
0.025 - 0.051 (0.0010 - 0.0020) |
0.10 (0.004) |
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Camshaft |
Cam lobe height |
IN |
36.890 - 37.130 (1.4524 - 1.4618) |
36.890 (1.4524) |
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EX |
35.063 - 35.303 (1.3804 - 1.3899) |
35.063 (1.3804) |
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Valve lifter O. D. |
25.978 - 25.993 (1.0228 - 1.0233) |
25.97 (1.022) |
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Valve lifter bore I. D. |
26.010 - 26.026 (1.0240 - 1.0246) |
26.04(1.025) |
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Apply locking agent to the threads |
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Cylinder head cover bolt |
10 |
N-m |
(1.0 |
kgf-m, |
7 Ibf-ft) |
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Camshaft holder mounting bolt |
14 |
N-m |
(1.4 |
kgf-m, |
10 Ibf-ft) |
Apply |
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Decompressor cam mounting bolt |
24 |
N-m |
(2.4 |
kgf-m, |
18 Ibf-ft) |
Apply |
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('05 - '07) |
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Cam sprocket bolt |
20 |
N-m |
(2.0 |
kgf-m. |
15 Ibf-ft) |
Apply |
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Decompressor lifter arm mounting |
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nut ('05 - '07) |
22 |
N-m |
(2.2 |
kgf-m, |
16 Ibf-ft) |
Apply |
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Cylinder head nut |
66 |
N-m |
(6.7 |
kgf-m, |
49 Ibf-ft) |
Apply |
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Cam chain tensioner bolt |
12 |
N-m |
(1-2 |
kgf-m, |
9 Ibf-ft) |
Apply |
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Crankshaft hole cap |
15 |
N-m |
(1.5 |
kgf-m. |
11 Ibf-ft) |
Apply |
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Engine mounting nut (upper) |
54 |
N-m |
(5.5 |
kgf-m. |
40 Ibf-ft) |
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Engine hanger plate bolt |
26 |
N-m |
(2.7 |
kgf-m. |
19 Ibf-ft) |
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Spark plug |
22 |
N-m |
(2.2 |
kgf-m, |
16 Ibf-ft) |
TOOLS
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Interior cutter, 34 mm (60°, EX) 07780-0014700 or equivalent commercially available in U. S.A. |
Cutter holder, 5.0 mm 07781-0010400 or equivalent commercially available in U. S.A. |
Driver 07749-0010000 |
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Attachment, 07746-00102 |
37 x 40 mm 00 |
Pilot, 20 mm 07746-0040500 |
Cutter holder, 5.5 mm 07781-0010101 or equivalent commercially available in U. S.A. |
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Tensioner stopper 070MG-0010100 or 07AMG-001A100 (U. S.A. only) |
Cam sprocket holder ('05 - '07) 07AMB-MEBA100 (U. S.A. only) |
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• Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test or by tracing top-end noise with a sounding rod stethoscope.
• 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.
Compression too low, hard starting or poor performance at low speed
• Valves:
- Incorrect valve adjustment
- Burned or bent valves
- Incorrect valve timing
- Weak valve spring
- Uneven valve seating
- Valve stuck open
• Cylinder head:
- Leaking or damaged cylinder head gasket
- Warped or cracked cylinder head
• Loose spark plug
• Faulty cylinder, piston or piston rings
• Faulty decompressor system
Compression too high
• Excessive carbon build-up in cylinder head or top of piston Excessive smoke
• Worn valve stem or valve guide
• Damaged stem seal
• Cylinder, piston or piston rings problem
Excessive noise
• Incorrect valve adjustment
• Sticking valve or broken valve spring
• Worn or damaged camshaft
• Worn or damaged valve lifter
• Worn or loose cam chain
• Worn or damaged cam chain tensioner
• Worn cam sprocket teeth
• Cylinder, piston or piston rings problem
Rough idle
• Low cylinder compression
