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10. CYLINDER HEAD/VALVES

SERVICE INFORMATION ···························10-2 CYLINDER HEAD COVER ························· 10-4

TROUBLESHOOTING·································10-2 CAMSHAFT················································· 10-5

COMPONENT LOCATION ··························10-3 CYLINDER HEAD ····································· 10-10

10
CYLINDER COMPRESSION TEST·············10-4 CAM CHAIN TENSIONER LIFTER··········· 10-20

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CYLINDER HEAD/VALVES
SERVICE INFORMATION
CYLINDER HEAD/VALVES

GENERAL
• This section covers service of the cylinder head, valves and camshafts.
• All the services covered in this section can be done 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.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Camshafts lubricating oil is fed through oil passages in the cylinder head and camshaft holder. Clean the oil passages before
assembling them.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.

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 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 (page 14-14).
Compression too low, hard starting or poor performance at low speed
• Valves:
– Incorrect valve clearance adjustment
– Burned or bent valve
– Incorrect valve timing
– Broken valve spring
– Uneven valve seating
• Cylinder head:
– Leaking or damaged cylinder head gasket
– Warped or cracked cylinder head
– Loose spark plug
• Worn cylinder, piston or piston rings (page 14-14)
Compression too high, overheating or knocking
• Excessive carbon build-up on piston crown or on combustion chamber
Excessive smoke
• Cylinder head:
– Worn valve stem or valve guide
– Damaged stem seal
• Worn cylinder, piston or piston rings (page 14-14)
Excessive noise
• Cylinder head:
– Incorrect valve clearance adjustment
– Sticking valve or broken valve spring
– Damaged or worn camshaft
– Loose or worn cam chain
– Worn or damaged cam chain
– Worn or damaged cam chain tensioner
– Worn cam sprocket teeth
• Worn cylinder, piston or piston rings (page 14-14)
Rough idle
• Low cylinder compression

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CYLINDER HEAD/VALVES
COMPONENT LOCATION
10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)

47 N·m (4.8 kgf·m, 35 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

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CYLINDER HEAD/VALVES
CYLINDER COMPRESSION TEST
Warm the engine to normal operating temperature.
Stop the engine and remove the all spark plug caps and
spark plugs (page 3-6).
Install a compression gauge [1] into the spark plug hole.
Turn the ignition switch ON with the engine stop switch
" ". [1]
Shift the transmission into neutral.
Open the throttle all the way and crank the engine with
the starter motor until the gauge reading stops rising.
The maximum reading is usually reached within 4 – 7
seconds.
Compression pressure:
1,500 kPa (15.3 kgf/cm2, 218 psi) at 300 min-1 (rpm)
Low compression can be caused by:
– Blown cylinder head gasket
– Improper valve clearance adjustment
– Valve leakage
– Worn piston rings or cylinder
High compression can be caused by:
– Carbon deposits in combustion chamber or on
piston head

CYLINDER HEAD COVER

REMOVAL/INSTALLATION

• The cylinder head cover can be serviced with the [3]

engine installed in the frame.
Disconnect the spark plug caps from the spark plugs
(page 3-6).
Remove the throttle body (page 7-13).
Disconnect the crankcase breather hose [1] from the
cylinder head cover.
Pull off the heat guard rubber [2] from the PAIR check
valve cover joints [3].

[1] [2]

Remove the cylinder head cover bolts [1] and mounting [1]/[2]
rubbers [2].
Remove the cylinder head cover [3] from the cylinder
head.

• Do not forcibly remove the dowel pins from the

cylinder head cover.

[3]

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CYLINDER HEAD/VALVES
Remove the cylinder head cover packing [1] from the
cylinder head cover. [1]
Installation is in the reverse order of removal.
TORQUE:
Cylinder head cover bolt:
10 N·m (1.0 kgf·m, 7 lbf·ft)

• Replace the cylinder head cover packing with a new

one.
• Install the cylinder head cover packing into the
groove in the cylinder head cover.
• Apply sealant (TB5211C manufactured by
ThreeBond, KE45 manufactured by Shin-Etsu
Silicone or an equivalent) to the cylinder head cover [3]
packing semi-circular areas as shown (8 places).
• Check the mounting rubbers [2] are in good
condition, replace them if necessary.
• Install the mounting rubbers with their "UP" mark [3]
facing up.
Adjust the throttle grip freeplay (page 3-4).

[2]

CAMSHAFT
REMOVAL

• The camshaft can be serviced with the engine

[1] [3]
installed in the frame.
Remove the cylinder head cover (page 10-4).
Make sure the No. 1 piston is at TDC (Top Dead
Center) on the compression stroke (page 3-6).
Remove the sealing bolt [1] and sealing washer [2].
Turn the cam chain tensioner lifter shaft fully in
(clockwise) and secure it using the special tool.
TOOL:
[3] Tensioner stopper 070MG-0010100

[2]

Be careful not to let If you replace the camshaft and/or cam sprocket, [3] [2]
the cam chain loosen the cam sprocket bolts [1].
guide bolts fall into
• Turn the crankshaft clockwise one full turn (360°),
the crankcase.
loosen the other cam sprocket bolts, then reset the
No.1 piston to the TDC (Top Dead Center) on the
compression stroke (page 3-6).
Remove the bolts [2] and cam chain guide B [3].

[1]

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CYLINDER HEAD/VALVES

From outside to inside, loosen the bolts in a crisscross

[1] [3] [4]
pattern in several steps or the camshaft holder might
break.
Be careful not to let Loosen the camshaft holder bolts [1] gradually in a
the camshaft holder crisscross pattern in 2 or 3 steps, and remove them and
bolts fall into the washers [2].
crankcase.
Remove the camshaft holders [3] with the dowel pins
from the cylinder head.
• Do not forcibly remove the dowel pins from the
camshaft holders.
Remove the camshafts [4] by removing the cam chain
from the cam sprockets.
[1]/[2]
• Attach a piece of wire to the cam chain to prevent it
from falling into the crankcase.
Remove the valve lifters [1] and shims [2].
[2]
• Be careful not to damage the valve lifter bore.
• Shim may stick to the inside of the valve lifter. Do
not allow the shims to fall into the crankcase.
• Mark all valve lifters and shims to ensure correct
reassembly in their original locations.
• The valve lifter can be easily removed with a valve
lapping tool or magnet.
• The shims can be easily removed with a tweezers or
magnet.

[1]

INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning or clogs in oil passages.
– Cam sprockets/camshafts
– Camshaft holders/dowel pins
– Cam chain guide B
Measure each part according to CYLINDER HEAD/
VALVES SPECIFICATIONS (page 1-7).
Replace any part if it is out of service limit.
CAMSHAFT RUNOUT
Support both sides of the camshaft (at journals) with V-
blocks and check the camshaft runout with a dial
gauge.

SERVICE LIMIT: 0.04 mm (0.002 in)

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CYLINDER HEAD/VALVES
CAMSHAFT OIL CLEARANCE
Wipe any oil from the journals of the camshaft, cylinder
[1]
head and camshaft holders.
Install the camshafts onto the cylinder head.
Lay a strip of plastigauge [1] lengthwise on top of each
camshaft journal avoiding the oil hole.

• Do not rotate the camshaft during inspection.

Be sure the dowel Install each camshaft holder to the correct locations [4] [4]/[5]
pins in the cam with the identification marks.
shaft holders are
– No mark: right camshaft holder [1]
aligned with the
– "R" mark: center camshaft holder [2]
holes in the cylinder
– "L" mark: left camshaft holder [3]
head.
Apply engine oil to the threads and seating surfaces of
the camshaft holder bolts [4].
Install the holder bolts and sealing washers [5].
Finger tighten the bolts.

[1]

[2] [3]

Gradually tighten the camshaft holder bolts until the

camshaft holders lightly contact the cylinder head
surface.

Failure to tighten the camshaft holder in a criss-cross

pattern might cause a camshaft holder to break.
Tighten all camshaft holder bolts in the numerical order
cast on the camshaft holders.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Remove the camshaft holders and measure the width

of each plastigauge.
The widest thickness determines the oil clearance.
SERVICE LIMIT: 0.10 mm (0.004 in)
When the service limits are exceeded, replace the
camshaft and recheck the oil clearance.
Replace the cylinder head and camshaft holders as a
set if the clearance still exceeds the service limit.

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CYLINDER HEAD/VALVES
INSTALLATION
Apply molybdenum oil solution to the outer surface of
each valve lifter [1]. [2]

Install the shims Install the shims [2] on the retainers and valve lifters
and valve lifters in into the valve lifter bores.
their original
locations.

[1]

Each camshaft has an identification mark.

• "IN" mark [1]: Intake camshaft
• "EX" mark [2]: Exhaust camshaft

[1] [2]

If the cam sprockets are removed, install the cam [2] [4]
sprockets onto the camshafts.
• Install the intake cam sprocket [1] with the timing
mark (IN) facing outward and the No.1 cam lobes [2]
facing up and out as shown.
• Install the exhaust cam sprocket [3] with the timing
mark (EX) facing outward and the No.1 cam lobes
[4] facing up and out as shown.
Clean and apply a locking agent to the cam sprocket
bolt threads.
Install the cam sprocket bolts [5].

[1] [5] [3]

Rotate the crankshaft clockwise slowly and align the "T"

mark [1] with the index notch [2] in the crankcase cover.

[1]

[2]

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CYLINDER HEAD/VALVES
Apply molybdenum oil solution to the camshaft journals, [2]
lobes and thrust surfaces.
Install the cam chain [1] over the cam sprockets of the [1]
intake [2] and exhaust [3] camshafts, making sure that
the timing marks [4] on the cam sprockets are flush with
the top surface [5] of the cylinder head.
• Install each camshaft to the correct locations with
the identification marks (page 10-8).
"IN" mark: Intake camshaft
"EX" mark: Exhaust camshaft

[3]

[5]

[4]

Coat new O-rings with oil and install them into the
grooves in the camshaft holders.
Apply molybdenum oil solution to the camshaft journals
of the camshaft holders.

Install each camshaft holder [1] to the correct locations

[1]
with the identification marks [2].
– No mark: right camshaft holder
– "R" mark: center camshaft holder
– "L" mark: left camshaft holder

[2]

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CYLINDER HEAD/VALVES
Apply engine oil to the camshaft holder bolt [1] threads
[1] [1]/[2]
and seating surface.
Install the camshaft holder bolts with new sealing
washers [2].

Failure to tighten the camshaft holder in a crisscross

pattern may cause the camshaft holder to break.
From inside to outside tighten the camshaft holder bolts
gradually until the camshaft holders seats on the
cylinder head.
Tighten the camshaft holder bolts in a crisscross
pattern in 2 or 3 steps to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the cam chain guide B [1]. [1] [2]
Be careful not to let Install and tighten the cam chain guide bolts [2]
the cam chain guide securely.
bolts fall into the
If the cam sprocket was removed from the camshaft,
crankcase.
apply a locking agent to the cam sprocket bolt [3]
threads.
Tighten the cam sprocket bolts to the specified torque.
TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)
Turn the crankshaft clockwise one full turn (360°) and
tighten the other cam sprocket bolts.

[3]

Remove the tensioner stopper [1] from the cam chain

[1] [2]
tensioner lifter.
Turn the crankshaft clockwise several times, and align
the "T" mark on the primary drive gear with the index
notch on the right crankcase cover (page 10-8).
Recheck the valve timing.
Inspect the valve clearance (page 3-6).
Install the sealing bolt [2] with a new sealing washer [3]
and tighten it securely.
Install the cylinder head cover (page 10-4).

[3]

CYLINDER HEAD
REMOVAL
Remove the following:
– Exhaust pipe/muffler (page 2-18)
– Throttle body (page 7-13)
– Camshaft (page 10-5)
Disconnect the ECT sensor 2P (Blue) connector [1] and
bleeding hose [2].

[2]

[1]

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CYLINDER HEAD/VALVES
Remove the bolts [1] and water hose joint A [2] from the
[3]
cylinder head.
Remove the O-ring [3] from the water hose joint A.

[1] [2]

Remove the 6 mm bolts [1]. [1] [2]

Loosen the 9 mm washer-bolts [2] in a crisscross
pattern in 2 or 3 steps, then remove them.
Remove the cylinder head [3].

• Attach a piece of wire to the cam chain to prevent it

from falling into the crankcase.
• Do not tap the cylinder head too hard and do not
damage the mating surface with a screwdriver.

[3]

Remove the dowel pins [1] and gasket [2].

[2]

[1]

Remove the starter clutch (page 11-13).

[2]/[3]
Remove the cam chain guide A [1].
Remove the washer bolt [2], collar [3] and cam chain
tensioner [4].
Remove the cam chain [5] and timing sprocket [6] from
the crankshaft.

[4]

[5]/[6] [1]

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CYLINDER HEAD/VALVES
DISASSEMBLY
Remove the following:
– Insulator (page 7-16)
– ECT sensor (page 4-38)
– Spark plugs (page 3-6)
Remove the air bleeding joint [1] and sealing washer [2]
from the cylinder head.

[1]

[2]

Remove the spark plugs from the cylinder head. [1]

Install the tappet hole protector [1] into the valve lifter
bore.
TOOL:
[1] Tappet hole protector 07HMG-MR70002

An equivalent tool can easily be made from a plastic 35

mm film container as shown.
TOP VIEW

5 mm 5 mm

31 mm

15 mm

25 mm I.D.(when
compressed)

To prevent loss of Remove the valve spring cotters [1] using the special [2]
tension, do not tools as shown.
compress the valve
springs more than TOOLS:
necessary to [2] Valve spring compressor 07757-0010000
remove the cotters. [3] Valve spring compressor [1]
attachment 07959-KM30101

[3]

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CYLINDER HEAD/VALVES
Mark all parts Remove the valve spring compressor and remove the
during disassembly following: [6]
so they can be
– Valve spring retainers [1]
placed back in their
– Valve springs [2]
original locations.
– Valves [3]
– Valve stem seals [4]
– Valve spring seats [5] [2]
Avoid damaging the Remove the carbon deposits from the combustion
cylinder mating chamber [6] and clean off the cylinder head gasket [1]
surface and valve surface.
seat surfaces. [5]
[4]
[3]

INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, burning or clogs in oil passages.
– Cylinder head
– Valve springs
– Valves
– Valve guides
– Cam chain
– Cam chain timing sprocket
– Cam chain guide A
– Cam chain tensioner
Measure each part and clearance according to
CYLINDER HEAD/VALVES SPECIFICATIONS (page
1-7).
Replace any part if it is out of service limit.
• Ream the valve guide using the valve guide reamer
to remove any carbon build up before measuring the
guide (page 10-14).
• Refer to valve seat inspection (page 10-15).

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CYLINDER HEAD/VALVES
VALVE GUIDE REPLACEMENT
Disassemble the cylinder head (page 10-12).
[2]
Chill new valve guides in a freezer for about 1 hour.

• Be sure to wear heavy gloves to avoid burns when

handling the heated cylinder head.
• Using a torch to heat the cylinder head may cause
warpage. [1]
Heat the cylinder head to 130 – 140°C (266 – 284°F)
with a hot plate or oven. Do not heat the cylinder head
beyond 150°C (302°F). Use temperature indicator
sticks, available from welding supply stores, to be sure
the cylinder head is heated to the proper temperature.
Support the cylinder head and drive the valve guides [1]
out of the cylinder head from the combustion chamber
side.
TOOL:
[2] Valve guide driver, 4.5 mm 07HMD-ML00101
Take out new valve guides [1] from the freezer.
While the cylinder head is still heated, drive new valve
guides from the camshaft side until the exposed height
is specified value.
TOOL:
[2] Valve guide adjusting driver 07743-0020000

SPECIFIED HEIGHT:
IN/EX: 12.70 – 13.00 mm (0.500 – 0.512 in)
Let the cylinder head cool to room temperature.

[1] [2]

Ream new valve guides after installation.

[1]

• Take care not to tilt or lean the reamer [1] in the

guide while reaming.
• Use cutting oil on the reamer during this operation.
Insert the reamer from the combustion chamber side of
the cylinder head and always rotate the reamer
clockwise.
TOOL:
Valve guide reamer, 4.5 mm 07HMH-ML00101
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve seat
(page 10-15).

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CYLINDER HEAD/VALVES
VALVE SEAT INSPECTION/REFACING
INSPECTION
Disassemble the cylinder head (page 10-12).
[1]
Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coat of Prussian Blue to the valve seats.
Tap the valve against the valve seat several times using
a hand-lapping tool [1], without rotating the valve to
make a clear pattern.
The valves cannot Remove the valve and inspect the valve seat face.
SEAT WIDTH
be ground. If the
The valve seat contact should be within the specified
valve face is
width and even all around the circumference.
burned, badly worn
or if it contacts the STANDARD: 0.90 – 1.10 mm (0.035 – 0.043 in)
seat unevenly, SERVICE LIMIT: 1.5 mm (0.06 in)
replace the valve.
If the valve seat width is not within specification, reface
the valve seat (page 10-15).
Inspect the valve seat face for:
• Damaged face:
– Replace the valve and reface the valve seat
• Uneven seat width:
– Bent or collapsed valve stem; Replace the valve
and reface the valve seat
• Contact area (too low or too high):
– Reface the valve seat

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CYLINDER HEAD/VALVES
REFACING
Reface the valve seat using the following tools.
TOOLS:
Cutter holder, 4.5 mm 07781-0010600
Seat cutter, 27.5 mm (IN, 45°) 07780-0010200
Seat cutter, 24 mm (EX, 45°) 07780-0010600
Flat cutter, 28 mm (IN, 32°) 07780-0012100
Flat cutter, 24 mm (EX, 32°) 07780-0012500
Interior cutter, 26 mm (IN, 60°) 07780-0014500
Interior cutter, 22 mm (EX, 60°) 07780-0014202

VALVE SEAT WIDTH:

0.90 – 1.10 mm (0.035 – 0.043 in)

• Follow the refacer manufacturer’s operating

Old seat width
instructions.
• Be careful not to grind the seat more than
necessary.
32°
1. Use a 45° seat cutter, remove any roughness or
irregularities from the seat.
2. Use a 32° flat cutter, remove the top 1/4 of the
existing valve seat material.
Old seat width
3. Use a 60° interior cutter, remove the bottom 1/4 of
the existing valve seat material.
4. Using a 45° seat cutter, cut the seat to the proper
width.
Make sure that all pitting and irregularities are
removed. 60°
5. After cutting the seat, apply lapping compound to the
valve face, and lap the valve using light pressure.

[1]
• Excessive lapping pressure may deform or damage
the seat.
• Change the angle of lapping tool [1] frequently to
prevent uneven seat wear.
• Do not allow lapping compound to enter the guides.
After lapping, wash any residual compound off the
cylinder head and valve and recheck the seat contact.
Assemble the cylinder head (page 10-17).

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CYLINDER HEAD/VALVES
ASSEMBLY
VALVE LIFTER
VALVE COTTERS AIR BLEEDING JOINT
12 N·m (1.2 kgf·m, 9 lbf·ft)
SHIM VALVE SPRING RETAINER

VALVE SPRING

VALVE STEM SEAL

VALVE SPRING SEAT

SEALING WASHER
VALVE GUIDE

INTAKE VALVE EXHAUST VALVE

Clean the cylinder head assembly with solvent and

blow through all oil passages with compressed air. [3]
Apply engine oil to the fitting area of new valve stem
seals [1].
Install the valve spring seats [2] and valve stem seals.
Combustion
Apply molybdenum oil solution to each valve stem end chamber side
and sliding surface.
Insert the valves [3] into the valve guides while turning [5]
them slowly to avoid damage to the valve stem seals. [2]
Install the valve spring [4] with the tightly wound coils
facing the combustion chamber.
Install the valve spring retainers [5]. [1] [4]

Grease the cotters Install the valve cotters [1] using the special tool. [3]
to ease installation.
To prevent loss of TOOLS:
tension, do not [2] Tappet hole protector 07HMG-MR70002
compress the valve [3] Valve spring compressor 07757-0010000
spring more than
[1]
[4] Valve spring compressor 07959-KM30101
necessary. attachment

[4] [2]

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CYLINDER HEAD/VALVES
Support the cylinder Place a suitable tool [1] onto the valve stem [2].
[1]
head above the
Tap the tool gently to seat the valve cotters firmly using
work bench surface
a hammer.
to prevent valve
damage.

[2]

Apply a locking agent to the bleeding joint [1] threads.

Install the bleeding joint with a new sealing washer [2]
to the cylinder head.
Tighten the bleeding joint to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the following:
– Insulator (page 7-16)
– ECT sensor (page 4-38) [1]
– Spark plugs (page 3-6)

[2]

INSTALLATION
Install the timing sprocket [1] by aligning the wide teeth
between the crankshaft and sprocket. [5] [4]
[3]
Install the cam chain [2].
Apply locking agent to the cam chain tensioner pivot Align
bolt [3] threads.
Install the cam chain tensioner [4], collar [5] and pivot
bolt.
Tighten the cam chain tensioner pivot bolt to the
specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) [2]

[1]

Install the cam chain guide A [1] while aligning its pins [1]
with the grooves in the cylinder and its end with the
groove in the crankcase.
Install the starter clutch (page 11-16).

Align

Align

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CYLINDER HEAD/VALVES
Install the dowel pins [1] and a new gasket [2].
[2]

[1]

Route the cam chain through the cylinder head and [3] [2]
install the cylinder head [1] onto the cylinder.
Clean the cylinder head 9 mm washer-bolts [2] in
solvent, and dry them thoroughly.
Apply molybdenum oil to the 9 mm washer-bolt threads
and seating surfaces.
Install and tighten the 9 mm washer-bolt in a crisscross
pattern in 2 or 3 steps to the specified torque.
TORQUE: 47 N·m (4.8 kgf·m, 35 lbf·ft)
Install and tighten the 6 mm bolts [3] securely.

[1]

Install a new O-ring [1] to the water hose joint A [2].

[1]
• Do not apply engine oil to the O-ring.
Install the water hose joint A into the cylinder head and
tighten the bolts [3].

[3] [2]

Connect the ECT sensor 2P (Blue) connector [1] and

bleeding hose [2].
Install the following:
– Camshaft (page 10-8)
– Throttle body (page 7-13)
– Exhaust pipe/muffler (page 2-18)

[2]

[1]

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CYLINDER HEAD/VALVES
CAM CHAIN TENSIONER LIFTER
REMOVAL/INSTALLATION

• The cam chain tensioner lifter can be serviced with

[1] [3]
the engine installed in the frame.
Remove the sealing bolt [1] and sealing washer [2].
Turn the cam chain tensioner lifter shaft fully in
(clockwise) and secure it using the special tool.
TOOL:
[3] Tensioner stopper 070MG-0010100
Remove the cam chain tensioner lifter mounting bolts
[4].

[2] [4]

Remove the cam chain tensioner lifter [1] and gasket [1]
[2].
Installation is in the reverse order of removal.

• Replace the gasket and sealing washer with new

ones.

[2]

INSPECTION
Check the cam chain tensioner lifter [1] operation: [2] [1]
– The cam chain tensioner lifter shaft [2] should not go
into the cam chain tensioner lifter body when it is
pushed.
– When it is turned clockwise with a tensioner stopper [3]
or a screwdriver [3], the cam chain tensioner lifter
shaft should be pulled into the cam chain tensioner
lifter body. The cam chain tensioner lifter shaft
should spring out of the cam chain tensioner lifter
body as soon as the stopper tool is released.

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