COMPONENT LOCATION

’05 — ’07 shown:

COMPONENT LOCATION

SERVICE INFORMATION

GENERAL

• This section covers service of the camshaft, cylinder head and valves. These services can be done with the engine installed in the frame.

• During disassembly, 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.

• Camshaft lubrication oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the cylinder head.

• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.

SPECIFICATIONS

_______________________________________________________________________________________________________ Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Cylinder compression

402 к Pa (4.1 kgf/cm2, 58 psi) at 360 rpm

Cylinder head warpage

0.05 (0.002)

Decompressor clearance

’05 — ’07

Ex valve clearance + 0.35 mm (0.014)

Valve and valve guide

Valve clearance

IN

0.16 ±0.03 (0.006 ±0.001)

EX

0.28 ±0.03 (0.011 ±0.001)

Valve stem O. D.

IN

5.475-5.490 (0.2156-0.2161)

EX

4.965 — 4.980 (0.1955 — 0.1961)

4.96 (0.195)

Valve guide I. D.

IN

5.500-5.512 (0.2165-0.2170)

5.552 (0.2186)

EX

5.000 — 5.012 (0.1969 — 0.1973)

5.052 (0.1989)

Stem-to-guide clear­ance

IN

0.010 — 0.037 (0.0004 — 0.0015)

EX

0.020 — 0.047 (0.0008 — 0.0019)

Valve guide projec­tion above cylinder head

IN

16.1 — 16.3 (0.63-0.64)

EX

17.9-18.1 (0.70-0.71)

Valve seat width

IN

1.1 -1.3 (0.04-0.05)

2.0 (0.08)

EX

1.3-1.5 (0.05-0.06)

2.0 (0.08)

Valve spring free length

IN

40.68(1.602)

39.7 (1.56)

EX

42.82 (1.686)

41.9 (1.65)

Rocker arm

Rocker arm I. D.

12.000 — 12.018 (0.4724-0.4731)

12.05 (0.474)

Rocker arm shaft O. D.

11.967 — 11.975 (0.4711 — 0.4715)

11.92 (0.469)

Rocker arm-to-shaft clearance

0.025 — 0.051 (0.0010 — 0.0020)

0.10 (0.004)

Camshaft

Cam lobe height

IN

36.890 — 37.130 (1.4524 — 1.4618)

36.890 (1.4524)

EX

35.063 — 35.303 (1.3804 — 1.3899)

35.063 (1.3804)

Valve lifter O. D.

25.978 — 25.993 (1.0228 — 1.0233)

25.97 (1.022)

Valve lifter bore I. D.

26.010 — 26.026 (1.0240 — 1.0246)

26.04(1.025)

Apply locking agent to the threads

TORQUE VALUES

Cylinder head cover bolt

10

N-m

(1.0

kgf-m,

7 Ibf-ft)

Camshaft holder mounting bolt

14

N-m

(1.4

kgf-m,

10 Ibf-ft)

Apply

Decompressor cam mounting bolt

24

N-m

(2.4

kgf-m,

18 Ibf-ft)

Apply

(’05 — ’07)

Cam sprocket bolt

20

N-m

(2.0

kgf-m.

15 Ibf-ft)

Apply

Decompressor lifter arm mounting

nut (’05 — ’07)

22

N-m

(2.2

kgf-m,

16 Ibf-ft)

Apply

Cylinder head nut

66

N-m

(6.7

kgf-m,

49 Ibf-ft)

Apply

Cam chain tensioner bolt

12

N-m

(1-2

kgf-m,

9 Ibf-ft)

Apply

Crankshaft hole cap

15

N-m

(1.5

kgf-m.

11 Ibf-ft)

Apply

Engine mounting nut (upper)

54

N-m

(5.5

kgf-m.

40 Ibf-ft)

Engine hanger plate bolt

26

N-m

(2.7

kgf-m.

19 Ibf-ft)

Spark plug

22

N-m

(2.2

kgf-m,

16 Ibf-ft)

TOOLS

COMPONENT LOCATION

Interior cutter, 34 mm (60°, EX) 07780-0014700

or equivalent commercially avail­able in U. S.A.

Cutter holder, 5.0 mm 07781-0010400

or equivalent commercially avail­able in U. S.A.

Driver

07749-0010000

Attachment,

07746-00102

37 x 40 mm 00

Pilot, 20 mm 07746-0040500

Cutter holder, 5.5 mm 07781-0010101

or equivalent commercially avail­able in U. S.A.

Tensioner stopper 070MG-0010100

or 07AMG-001A100 (U. S.A. only)

Cam sprocket holder (’05 — ’07) 07AMB-MEBA100 (U. S.A. only)

TROUBLESHOOTING

• Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test or by tracing top-end noise 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.

Compression too low, hard starting or poor performance at low speed

• Valves:

— Incorrect valve adjustment

— Burned or bent valves

— Incorrect valve timing

— Weak valve spring

— Uneven valve seating

— Valve stuck open

• Cylinder head:

— Leaking or damaged cylinder head gasket

— Warped or cracked cylinder head

• Loose spark plug

• Faulty cylinder, piston or piston rings

• Faulty decompressor system

Compression too high

• Excessive carbon build-up in cylinder head or top of piston Excessive smoke

• Worn valve stem or valve guide

• Damaged stem seal

• Cylinder, piston or piston rings problem

Excessive noise

• Incorrect valve adjustment

• Sticking valve or broken valve spring

• Worn or damaged camshaft

• Worn or damaged valve lifter

• Worn or loose cam chain

• Worn or damaged cam chain tensioner

• Worn cam sprocket teeth

• Cylinder, piston or piston rings problem

Rough idle

• Low cylinder compression

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