Service Manual — page 251 of 715

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ENGINE TOP END 5-1

                                     Engine Top End
                                                   Table of Contents
Exploded View...................................         5-2      Cylinder Head Warp Inspection ...                      5-29
Exhaust System Identification ...........                5-6   Valves ................................................   5-30
Specifications ....................................      5-8      Valve Clearance Inspection .........                   5-30
Special Tools and Sealants ...............              5-10      Valve Clearance Adjustment........                     5-30
Clean Air System...............................         5-13      Valve Removal .............................            5-30
   Air Suction Valve Removal...........                 5-13      Valve Installation ..........................          5-30
   Air Suction Valve Installation........               5-13      Valve Guide Removal ..................                 5-30
   Air Suction Valve Inspection ........
   Air Switching Valve Removal .......
                                                        5-14
                                                        5-14
                                                                  Valve Guide Installation ...............
                                                                  Valve-to-Guide Clearance
                                                                                                                         5-31   5
   Air Switching Valve Installation ....                5-15        Measurement (Wobble
   Air Switching Valve Operation                                    Method) .....................................        5-32
     Test............................................   5-15      Valve Seat Inspection ..................               5-32
   Air Switching Valve Unit Test .......                5-15      Valve Seat Repair ........................             5-33
   Clean Air System Hose                                       Cylinder, Pistons................................         5-38
     Inspection..................................       5-15      Cylinder Removal.........................              5-38
Cylinder Head Cover .........................           5-16      Cylinder Installation......................            5-38
   Cylinder Head Cover Removal ....                     5-16      Piston Removal............................             5-39
   Cylinder Head Cover Installation .                   5-16      Piston Installation.........................           5-40
Camshaft Chain Tensioner ................               5-19      Cylinder Wear Inspection.............                  5-40
   Camshaft Chain Tensioner                                       Piston Wear Inspection ................                5-41
     Removal ....................................       5-19      Piston Ring, Piston Ring Groove
   Camshaft Chain Tensioner                                         Wear Inspection ........................             5-41
     Installation .................................     5-19      Piston Ring Groove Width
Camshaft, Camshaft Chain ...............                5-20        Inspection..................................         5-41
   Camshaft Removal ......................              5-20      Piston Ring Thickness Inspection                       5-42
   Camshaft Installation ...................            5-21      Piston Ring End Gap Inspection ..                      5-42
   Camshaft, Camshaft Cap Wear                                 Throttle Body Assy Holder.................                5-43
     Inspection..................................       5-24      Throttle Body Assy Holder
   Camshaft Runout Inspection........                   5-24        Removal ....................................         5-43
   Cam Wear Inspection ..................               5-25      Throttle Body Assy Holder
   Camshaft Chain Removal ............                  5-25        Installation .................................       5-43
Cylinder Head....................................       5-26   Muffler................................................   5-44
   Cylinder Compression                                           Muffler Body Removal..................                 5-44
     Measurement ............................           5-26      Muffler Body Installation...............               5-45
   Cylinder Head Removal ...............                5-27      Exhaust Pipe Removal.................                  5-46
   Cylinder Head Installation ............              5-28      Exhaust Pipe Installation..............                5-46