CYLINDER HEAD ASSEMBLY

VALVE COTTERS

SPRING

SPRING RETAINER

SPRING SEAT

INSULATOR

ІІПг

STEM SEAL

VALVE GUIDE

3? O-RING

After ’07:

WATER HOSE JOINT

INTAKE VALVE

EXHAUST VALVE

Blow out all oil passages in the cylinder head with compressed air.

Install the spring seat and new stem seal.

Lubricate the valve stem sliding surface with molyb­denum oil solution.

Insert the valves into the guide while turning it slowly to avoid damage to the stem seal.

INTAKE VALVE

EXHAUST VALVE SPRING

CYLINDER HEAD ASSEMBLY

Install the valve springs with the tightly wound coils facing the combustion chamber.

CYLINDER HEAD ASSEMBLY

VALVE SPRING COMPRESSOR

Grease the cotters to ease installation.

To prevent loss of tension, do not compress the valve springs more than necessary.

COTTERS

CYLINDER HEAD ASSEMBLY

Install the spring retainer.

NOTE.

Do not confuse the intake spring retainers and exhaust spring retainers. The intake spring retainer has a flat surface and the exhaust spring retainer has a chamfered edge.

Install the valve cotters using the special tools as shown.

TOOLS:

Valve spring compressor 07757-0010000

Valve spring compressor

attachment 07959-KM30101

NOTE:

Do not confuse the intake cotters and exhaust cot­ters. The intake cotters are long and exhaust cotters are short.

ATTACHMENT

Support the cylinder head so the valve heads do not contact anything that may damage them.

CYLINDER HEAD ASSEMBLY

Tap the valve stems gently with two plastic ham­mers as shown to seat the cotters firmly.

’05 — ’07:

SCREW

12.0 ±1.0 mm (0.47 ±0.04 in)

INSULATOR After ’07: SCREW

CYLINDER HEAD ASSEMBLY

Install the carburetor insulator to the cylinder head by aligning the groove of the carburetor insulator with the tab of the cylinder head.

Tighten the carburetor insulator band screw so the distance between the band ends is follow:

— ’05 — ’07: 12.0 ± 1.0 mm (0.47 ± 0.04 in)

INSULATOR Align

9.0 ± 1.0 mm (0.35 ±0.04 in)

CYLINDER HEAD ASSEMBLY

O-RING

BOLT

CYLINDER HEAD ASSEMBLY

— After ’07: 9.0 ±1.0 mm (0.35 ±0.04 in)

Install a new O-ring to the water hose joint.

Install the water hose joint to the cylinder head. Install and tighten the bolt securely.

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