CYLINDER HEAD AND VALVE MECHANISM
18) Supply the engine cooling water from the water tank.
19) Connect the cable to the negative terminal of the battery.
20) Start up the engine and check to make sure that there is no
water leakage from any part. Then check the cooling water
level.
6 – 8
CYLINDER HEAD AND VALVE MECHANISM
INSPECTION
CYLINDER HEAD
Flatness
[mm]
Part Maintenance standard Service limit
Axial direction 0.05, max. 0.20
Perpendicular direction 0.02, max. 0.20
EHV2-017
VALVE INSERT
Valve and valve insert contacting length
[mm]
Part Maintenance standard Service limit
Intake 2.7 - 2.9 3.4
Exhaust 2.8 - 3.1 3.5
ES-85
VALVE
Distance between the valve and the bottom surface
of the cylinder head
Check the value measured before disassembling the cylinder
head.
[mm]
Part Maintenance standard Service limit
Intake 0.58 - 1.07 —
Exhaust 0.58 - 1.12 —
Valve head dimension
[mm]
Part Maintenance standard Service limit
Intake 2.0 1.8
Exhaust 1.5 1.3
EHV2-018
6 – 10
CYLINDER HEAD AND VALVE MECHANISM
VALVE ROCKER AND RELATED PARTS
Rocker shaft outside diameter
[mm]
Maintenance standard Service limit
24.99 - 25.00 24.90
EHV3-013
Rocker shaft runout
[mm]
Maintenance standard Service limit
0.03, max. 0.05
ES-91
Valve rocker bushing inside diameter
[mm]
Maintenance standard Service limit
25.02 - 25.04 25.10
EHV1-020
Clearance between the valve rocker bushing and
rocker shaft
[mm]
Maintenance standard Service limit
0.02 - 0.06 0.2
Valve rocker spring free length
[mm]
Part Maintenance standard Service limit
Inside 112.0 —
Valve rocker 29.0 —
ES-87
6 – 12
CYLINDER HEAD AND VALVE MECHANISM
Valve rocker spring tension
[kg]
Maintenance
Part Service limit Remarks
standard
When compressed to 82
Inside 4.6 3.6
mm
When compressed to 11
Valve rocker 4.6 3.6
mm
EHV3-011
PUSH ROD
Deviation
Measure the deviation while supporting the center of the
spherical surfaces at both ends of the push rod.
[mm]
Maintenance standard Service limit
0.3, max. 0.5
E4-14
CAM FOLLOWER
Outside diameter
[mm]
Maintenance standard Service limit
23.94 - 23.97 23.85
EHV3-015
Clearance between the cam follower and cam fol-
lower hole
[mm]
Maintenance standard Service limit
0.03 - 0.08 0.20
6 – 13
CYLINDER HEAD AND VALVE MECHANISM
REPAIR AND REPLACEMENT
CORRECTING THE CYLINDER HEAD
Using a surface grinder, grind the cylinder head. The amount of
grinding should not exceed 0.5 mm.
[mm]
Maintenance standard
Item Service limit (B)
(A)
Cylinder head height 110 109.5
ER6-107
CORRECTING VALVE
1) Using a valve refacer, repair the valve face portion. If the
thickness of the valve face exceeds the service limit after
repaired, replace it with a new one.
Note:
• There should be no stepped wear on the valve face.
[mm]
Maintenance
Item Service limit
standard ES-95
Intake 44°30′ - 45° —
Valve face angle
Exhaust 44°30′ - 45° —
Valve head Intake 2.0 1.8
thickness Exhaust 1.5 1.3
2) Using a valve refacer or oil stone, repair the valve stem end.
Note:
• Finish the valve stem end surface to be perpendicular to
the axis. Also, the finished surface should have no
scrape marks or scratches.
ES-94
6 – 14
CYLINDER HEAD AND VALVE MECHANISM
CORRECTING THE VALVE INSERT
1) Using a valve seat grinder, repair the seat surface of the
valve insert.
Note:
• There should be no stepped wear on the seat surface of
the valve insert.
Maintenance
Item Service limit
standard
Seat surface Intake 45° - 45°15′ —
ER-108
angle Exhaust 45° - 45°15′ —
REPLACING VALVE INSERT
1) Using a valve insert remover (special tool), remove the
intake and exhaust valve inserts.
Item Part number
Valve insert puller 99660 97002
EP6-110
2) Fit the intake and exhaust valve inserts. Make sure to cold-fit
them.
Cold-fitting procedure
• Keep the valve insert in dry ice for more than five minutes.
Use of alcohol will improve the cooling effect.
Note:
• Do not touch the cold valve insert or dry ice directly, or
it will cause chilblains.
EHV3-018
6 – 15
CYLINDER HEAD AND VALVE MECHANISM
2) Apply a coat of engine oil to the valve stem, then insert the
valve into the valve guide. With the lapping rod coming into
contact with the valve head, lap the valve by rotating it while
lightly tapping the valve insert.
3) After completing the lapping operation, wash the lapping
compound away, and then apply engine oil to the seating
surface, and perform lapping with oil.
4) After oil lapping, coat the contacting surface of the valve with
red lead and repeat lapping operation in the same manner
as previously done with the grinding compound, then check
the condition of the valve surface. Repeat lapping until the ER6-109
valve surface is properly corrected.
[mm]
Maintenance
Item Service limit
standard
Valve and valve Intake 2.7 - 2.9 3.4
insert contacting
dimension Exhaust 2.8 - 3.1 3.5
ES-85
REPLACING VALVE GUIDE
1) Using a valve guide remover (special tool), drive out the
valve guide from the bottom side of the cylinder head.
Item Part number
Intake 99667 95000
Valve guide remover
Exhaust 99667 96000
ER4-4
2) Using a valve guide replacer (special tool), drive the valve
guide perpendicularly into place until the lower end of the
tool just touches the surface of the cylinder head.
Item Part number
Intake 99666 97003
Valve guide replacer
Exhaust 99666 97004
EHV2-026
3) After driving in the valve guide, finish the inside diameter to
the maintenance standard with a reamer (special tool).
Item Part number
Intake 99662 96000
Reamer
Exhaust 99662 97000
EHV3-023
6 – 17
