Service Manual

ENGINE TOP END 5-1

Engine Top End

Table of Contents

Exploded View........................................................................................................................ 5-2

Specifications ......................................................................................................................... 5-4

Special Tools .......................................................................................................................... 5-6

Cylinder Head......................................................................................................................... 5-7

Compression Measurement.............................................................................................. 5-7

Cylinder Head Assembly Removal ................................................................................... 5-8

Cylinder Head Assembly Installation ................................................................................ 5-8

Push Rod Removal........................................................................................................... 5-9

Push Rod Installation........................................................................................................ 5-10

Push Rod Inspection......................................................................................................... 5-10

Valve Mechanism Removal/Installation ............................................................................ 5-10

Cylinder Head Cleaning.................................................................................................... 5-12

Cylinder Head Inspection.................................................................................................. 5-13

Rocker Arm Inspection...................................................................................................... 5-13

Valves..................................................................................................................................... 5-14

Valve Clearance Inspection .............................................................................................. 5-14

Valve Clearance Adjustment............................................................................................. 5-14

Valve Seat Inspection ....................................................................................................... 5-14

Valve Seat Repair ............................................................................................................. 5-14

Valve Head Thickness ...................................................................................................... 5-14

Valve Stem Runout ........................................................................................................... 5-14

Valve Stem Diameter ........................................................................................................ 5-14

Valve Guide Inside Diameter ............................................................................................ 5-15

Valve Spring Inspection .................................................................................................... 5-15

Cylinder, Piston....................................................................................................................... 5-16

Piston Removal................................................................................................................. 5-16

Piston Installation..............................................................................................................5-17

Piston/Cylinder Seizure..................................................................................................... 5-19

Piston Cleaning................................................................................................................. 5-19

Piston Ring and Ring

Groove Wear..................................................................................

5-20

Piston Ring End Gap ........................................................................................................ 5-21

Piston Pin, Piston Pin Hole, and Connecting Rod Wear................................................... 5-21

Piston Diameter

................................................................................................................

5-22

Cylinder Inside Diameter................................................................................................... 5-22

Cylinder Boring and Honing.............................................................................................. 5-22