Service Manual (KLZ1000C) — page 169 of 762
Engine Top End
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ENGINE TOP END 5-1
Engine Top End
Table of Contents
Exploded View................................... 5-2 Cylinder Head Warp Inspection ... 5-28
Exhaust System Identification ........... 5-6 Valves ................................................ 5-29
Specifications .................................... 5-8 Valve Clearance Inspection ......... 5-29
Special Tools and Sealants ............... 5-10 Valve Clearance Adjustment........ 5-29
Clean Air System............................... 5-13 Valve Removal ............................. 5-29
Air Suction Valve Removal........... 5-13 Valve Installation .......................... 5-29
Air Suction Valve Installation........ 5-13 Valve Guide Removal .................. 5-29
Air Suction Valve Inspection ........
Air Switching Valve Removal .......
5-14
5-14
Valve Guide Installation ...............
Valve-to-Guide Clearance
5-30 5
Air Switching Valve Installation .... 5-15 Measurement (Wobble
Air Switching Valve Operation Method) ..................................... 5-31
Test............................................ 5-15 Valve Seat Inspection .................. 5-31
Air Switching Valve Unit Test ....... 5-15 Valve Seat Repair ........................ 5-32
Clean Air System Hose Cylinder, Pistons................................ 5-37
Inspection.................................. 5-15 Cylinder Removal......................... 5-37
Cylinder Head Cover ......................... 5-16 Cylinder Installation...................... 5-37
Cylinder Head Cover Removal .... 5-16 Piston Removal............................ 5-38
Cylinder Head Cover Installation . 5-16 Piston Installation......................... 5-39
Camshaft Chain Tensioner ................ 5-18 Cylinder Wear Inspection............. 5-39
Camshaft Chain Tensioner Piston Wear Inspection ................ 5-40
Removal .................................... 5-18 Piston Ring, Piston Ring Groove
Camshaft Chain Tensioner Wear Inspection ........................ 5-40
Installation ................................. 5-18 Piston Ring Groove Width
Camshaft, Camshaft Chain ............... 5-19 Inspection.................................. 5-40
Camshaft Removal ...................... 5-19 Piston Ring Thickness Inspection 5-41
Camshaft Installation ................... 5-20 Piston Ring End Gap Inspection .. 5-41
Camshaft, Camshaft Cap Wear Throttle Body Assy Holder................. 5-42
Inspection.................................. 5-23 Throttle Body Assy Holder
Camshaft Runout Inspection........ 5-23 Removal .................................... 5-42
Cam Wear Inspection .................. 5-24 Throttle Body Assy Holder
Camshaft Chain Removal ............ 5-24 Installation ................................. 5-42
Cylinder Head.................................... 5-25 Muffler................................................ 5-43
Cylinder Compression Muffler Body Removal.................. 5-43
Measurement ............................ 5-25 Muffler Body Installation............... 5-44
Cylinder Head Removal ............... 5-26 Exhaust Pipe Removal................. 5-45
Cylinder Head Installation ............ 5-27 Exhaust Pipe Installation.............. 5-45