ENGINE TOP END 5-1
Engine Top End
Table of Contents
Exploded View................................... |
5-2 |
Specifications .................................... |
5-6 |
Special Tools and Sealant ................. |
5-8 |
Clean Air System............................... |
5-10 |
Air Suction Valve Removal........... |
5-10 |
Air Suction Valve Installation........ |
5-10 |
Air Suction Valve Inspection ........ |
5-10 |
Vacuum Switch Valve Removal ... |
5-10 |
Vacuum Switch Valve Installation |
5-10 |
Vacuum Switch Valve Test ........... |
5-11 |
Clean Air System Hose |
|
Inspection.................................. |
5-11 |
Cylinder Head Cover ......................... |
5-12 |
Cylinder Head Cover Removal .... |
5-12 |
Cylinder Head Cover Installation . |
5-12 |
Camshaft Chain Tensioner ................ |
5-14 |
Camshaft Chain Tensioner |
|
Removal .................................... |
5-14 |
Camshaft Chain Tensioner |
|
Installation ................................. |
5-14 |
Camshaft, Camshaft Chain ............... |
5-15 |
Camshaft Removal ...................... |
5-15 |
Camshaft Installation ................... |
5-15 |
Camshaft, Camshaft Cap Wear ... |
5-16 |
Camshaft Runout......................... |
5-17 |
Cam Wear.................................... |
5-17 |
Camshaft Chain Removal............ |
5-17 |
Cylinder Head.................................... |
5-18 |
Cylinder Compression |
|
Measurement ............................ |
5-18 |
Cylinder Head Removal ............... |
5-19 |
Cylinder Head Installation ............ |
5-19 |
Cylinder Head Warp..................... |
5-20 |
|
|
Valves ................................................ |
5-21 |
|
|
Valve Clearance Inspection ......... |
5-21 |
|
|
.............................Valve Removal |
5-21 |
5 |
|
Valve Installation .......................... |
5-21 |
|
|
|
|
||
Valve Guide Removal .................. |
5-21 |
|
|
Valve Guide Installation ............... |
5-22 |
|
|
Valve-to-Guide Clearance |
|
|
|
Measurement (Wobble |
|
|
|
Method) ..................................... |
5-22 |
|
|
Valve Seat Inspection .................. |
5-23 |
|
|
Valve Seat Repair ........................ |
5-23 |
|
|
Cylinder, Pistons................................ |
5-28 |
|
|
Cylinder Removal......................... |
5-28 |
|
|
Cylinder Installation...................... |
5-28 |
|
|
Piston Removal............................ |
5-28 |
|
|
Piston Installation......................... |
5-29 |
|
|
Cylinder Wear .............................. |
5-30 |
|
|
Piston Wear ................................. |
5-30 |
|
|
Piston Ring, Piston Ring Groove |
|
|
|
Wear.......................................... |
5-31 |
|
|
Piston Ring Groove Width............ |
5-31 |
|
|
Piston Ring Thickness ................. |
5-31 |
|
|
Piston Ring End Gap ................... |
5-32 |
|
|
Throttle Body Holder.......................... |
5-33 |
|
|
Throttle Body Holder Installation.. |
5-33 |
|
|
Muffler................................................ |
5-34 |
|
|
Muffler Body Removal.................. |
5-34 |
|
|
Exhaust Pipe Removal................. |
5-34 |
|
|
Muffler Body and Exhaust Pipe |
|
|
|
Installation ................................. |
5-34 |
|
|
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
|
|
|
|
|
|
|
No. |
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||||
|
|
|
||||
1 |
Air suction valve cover bolts |
9.8 |
1.0 |
87 in·lb |
|
|
2 |
Cylinder head cover bolts |
9.8 |
1.0 |
87 in·lb |
S |
|
3 |
Camshaft cap bolts |
12 |
1.2 |
104 in·lb |
S |
|
4 |
Camshaft chain guide bolts |
12 |
1.2 |
104 in·lb |
S |
|
5 |
Cylinder head bolts (M10 new bolts) |
54 |
5.5 |
40 |
MO, S |
|
(Washer) |
||||||
|
|
|
|
|
||
5 |
Cylinder head bolts (M10 used bolts) |
49 |
5.0 |
36 |
MO, S |
|
(Washer) |
||||||
|
|
|
|
|
||
6 |
Cylinder head bolts (M6) |
12 |
1.2 |
104 in·lb |
S |
|
7 |
Cylinder head jacket plugs |
22 |
2.2 |
16 |
L |
|
8 |
Throttle body holder bolts |
13 |
1.3 |
113 in·lb |
|
|
9 |
Throttle body assy holder clamp bolts |
2.0 |
0.20 |
17 in·lb |
|
|
10 |
Camshaft sensor bolt |
12 |
1.2 |
104 in·lb |
|
|
11 |
Camshaft sensor rotor bolt |
12 |
1.2 |
104 in·lb |
L |
|
12 |
Front camshaft chain guide bolts (upper) |
25 |
2.5 |
18 |
|
|
13 |
Front camshaft chain guide bolts (lower) |
12 |
1.2 |
104 in·lb |
|
|
14 |
Rear camshaft chain guide bolts |
25 |
2.5 |
18 |
|
|
15 |
Camshaft chain tensioner mounting bolts |
11 |
1.1 |
95 in·lb |
|
|
16 |
Camshaft chain tensioner cap bolt |
28 |
2.9 |
21 |
|
|
17 |
Spark plugs |
13 |
1.3 |
113 in·lb |
|
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts
S: Follow the specific tightening sequence.
SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
5-4 ENGINE TOP END
Exploded View