Service manual
4-3
ENG
CYLINDER HEAD, CYLINDER AND PISTON
CYLINDER HEAD, CYLINDER AND PISTON
Job name/Part name
Cylinder head, Cylinder and piston
removal
Engine
Muffler/Gasket
Air shroud 2
Spark plug
Cylinder head/Cylinder head gasket
Cylinder
Piston pin clip
Piston pin/ Bearing
Piston
Piston ring set
Cylinder gasket
Remarks
Remove the parts in the order.
Refer to the “ENGINE REMOVAL” sec-
tion
Reverse the removal procedure for in-
stallation.
Order
1
2
3
4
5
6
7
8
9
10
Q’ty
1/1
1
1
1/1
1
2
1/1
1
1
1
4
5
6
7
10
1
2
3
26Nm(2.6 m.kg, 18.2 ft.lb)
T
R
.
.
14Nm(1.4 m.kg, 10 ft.lb)
T
R
.
.
9Nm(0.9 m.kg,6.5 ft.lb)
T
R
.
.
New
New
New
E
8
9
CYLINDER HEAD, CYLINDER AND PISTON
4-4
ENG
PISTON PIN AND PISTON REMOVAL
1. Remove:
8 Piston pin clip 1
NOTE:
Before removing the piston pin clip, cover the
crankcase with a clean rag so you will not acci-
dentally drop the clip into the crankcase.
2. Remove:
8 Piston pin 1
8 Piston 2
8 Piston pin bearing 3
cC
Do not use a hammer to drive the piston pin
out.
CYLINDER HEAD INSPECTION
1. Eliminate:
8 Carbon deposits
Use a rounded scrapper 1.
2. Inspect:
8 Cylinder head warpage
Out of specification∅Re-surface.
*************************************
Warpage measurement and re-surfacement
steps:
8 Attach a straight edge 1 and a thickness
gauge 2 on the cylinder head.
8 Measure the warpage limit.
Warpage limit:
0.03 mm(0.0012 in)
8 If the warpage is out of specification, reface
the cylinder head.
NOTE:
Rotate the head severai tires to avoid remov-
ing too much material from one side.
*************************************
CYLINDER HEAD, CYLINDER, PISTON
2
1
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section
title(s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates
a disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described se-
quentially.
8
4
5
7
1
3
26