CYLINDER HEAD ASSEMBLY
VALVE COTTERS
SPRING |
SPRING RETAINER
SPRING SEAT
INSULATOR
ІІПг
STEM SEAL
VALVE GUIDE
3? O-RING
After '07:
WATER HOSE JOINT
INTAKE VALVE |
EXHAUST VALVE
Blow out all oil passages in the cylinder head with compressed air.
Install the spring seat and new stem seal.
Lubricate the valve stem sliding surface with molybdenum oil solution.
Insert the valves into the guide while turning it slowly to avoid damage to the stem seal.
INTAKE VALVE |
EXHAUST VALVE SPRING |
Install the valve springs with the tightly wound coils facing the combustion chamber.
VALVE SPRING COMPRESSOR |
Grease the cotters to ease installation. To prevent loss of tension, do not compress the valve springs more than necessary. |
COTTERS |
Install the spring retainer.
NOTE.
Do not confuse the intake spring retainers and exhaust spring retainers. The intake spring retainer has a flat surface and the exhaust spring retainer has a chamfered edge.
Install the valve cotters using the special tools as shown.
TOOLS:
Valve spring compressor 07757-0010000
Valve spring compressor
attachment 07959-KM30101
NOTE:
Do not confuse the intake cotters and exhaust cotters. The intake cotters are long and exhaust cotters are short.
ATTACHMENT |
Support the cylinder head so the valve heads do not contact anything that may damage them. |
Tap the valve stems gently with two plastic hammers as shown to seat the cotters firmly.
'05 - '07: |
SCREW |
12.0 ±1.0 mm (0.47 ±0.04 in) |
INSULATOR After '07: SCREW |
Install the carburetor insulator to the cylinder head by aligning the groove of the carburetor insulator with the tab of the cylinder head.
Tighten the carburetor insulator band screw so the distance between the band ends is follow:
- '05 - '07: 12.0 ± 1.0 mm (0.47 ± 0.04 in)
INSULATOR Align |
9.0 ± 1.0 mm (0.35 ±0.04 in) |
O-RING |
BOLT |
- After '07: 9.0 ±1.0 mm (0.35 ±0.04 in)
Install a new O-ring to the water hose joint.
Install the water hose joint to the cylinder head. Install and tighten the bolt securely.