Technical data

Overhaul

The cylinder head

1. Remove the “collets” and valve springs using a valve

bow. Remove the valves. Remove the valve stem seals.

Place the valves in the proper sequence in a valve

stand.

Valve guides

2. Check the wear of the valve guides by placing a new

valve in the guide. Use an indicator gauge and meas-

ure the clearance. Replace the guides if necessary.

Wear limits:

Inlet valve, max. clearance ............. 0.15 mm (.0059 in)

Outlet valve, max. clearance .......... 0.15 mm (.0059 in)

3. Use mandrel p/n 9995218 to press out the valve

guides. Oil the new valve guides externally and use

mandrel p/n 884559 to install them. Press down the

mandrel all the way down to the cylinder head. Ream

the valve guides if necessary.

4. Mill or ream the valve seats. The angle (C) should

be 45° (for 2003T, 30° for the inlet valve). The sealing

surface width (B) should be 1 ± 0.1 mm (0.039 ±

0.0039 in.) Grind the valves in a valve grinding ma-

chine. The angle (D), see Technical data. If the disc

thickness after grinding is less than 1.0 mm (0.039

in.) for 2001, 2002, 2003 or 0.8 mm (0.031 in.) for

2003T, the valves must be scrapped. Valves with

bent stems, or if the measurement (A) exceeds

2.5 mm (0.098 in.) must also be scrapped. Grind the

valve tip towards the rockers if necessary. Lap in the

valves using valve grinding paste and check the con-

tact area with marking dye.