Honda Cbr150r 2002-2009

ENGGIINNEE REMOV ALl/lINST ALLATIOONN

Looosseenn the lock nut and adjusting nut, then remove the
cluuttcchh cable fromm the clutch cable guide.
Disconnect the clutchh cable endd fromm the clutchh lifter arm.

-

Loooosseenn the rear axle nut, RR/IL drive chaaiinn adjusting lock
nuuttss anndd adjusting nutss..
Puusshhthe rear wheel forward and make a drive chainn slack
fully.

RReemmoovvee the two bolts and sprocket coveerr..

Reemmoovvee the fixingg plate bolts, fixing platee and drive
sprocckkeett..

http://www.motorcycle.in.th 77--33

ENGINEE REMOV ALI/INSTAALLATIOONN
Support the engine using a jack or other adjustable sup-
port to ease of engine hanger bolts remoovvaall..
Remmoovvee the front engine hanger nut andd bolt.
Remmoovvee the four bolts andd engine hanger plateess..

Loosseenn the rear engine hanger nuts.
Remmoovveethe rear engine hanger bolts/nuts andd engine fromm
the frame.

Notee the directionn of the hanger boltss..

ENGINNEE INNSSTTALLATIO0NN

NOTTEE::
Ussee a floor jack or other adjustable support to carefully
maneeuuvveerr the enginee into placcee..

Plaaccee the engine into the frame, andd insttaallll the rear enginee
hanger bolts fromm the left sidee..
Temporarily, insttaallll the rear engine hanger nuts.

CAUTION::
BBe ccareful not to ddammaaggee tthhee frraammee..

77--44 http://www.motorcycle.in.th

ENNGGIINNEE REMOV ALl/lINST ALLATIOONN

Inssttaalllthe engine hanger platess andd four bolts, andd tighten
the bolttss..
Inssttaalll the front engine hanger bolt andd nut, andd tighten
the nnuut to the specified torque.

TORQQUUEE:: 599 N·.m (66..00 kggff·m, 43 IbfN.ftt))

lTigighhtteen the rearr engine hunger nutssto the specifieedd torque.
TORQQUUEE:: 59 N·.m (66..00 kggff·m, 43 IbfN.ftt))

Inssttaalll the drive sprocket onto the counteerrsshhaafftt..
Inssttaalll the drive chaaiinn onto the drive sprockeett.

Inssttaallll the fixingg platee andd lock the platee by turning itt..

http://www.motorcycle.in.th 7-55

ENGINNEE REMOV ALl/lINSTAALLLLATIlOONN
Applyy locking agent to the threeaaddss of the fixing plate bolts.

Tighten the fixing plate bolts to the specified torqquuee..
TORQUE: 9.88 N.'m (1.0 kgff·mm,. 7 lIbbHf.ft1)

Sett the drive sprocket cover to the left crankcaassee.
lTgighhttenn the cover bolts securerryy..

Adjust the drive chaaiinn slackk (paaggee 3-1155))..
Tighten the rear axle nut to thee specified torque.
TORQUEE: 59 N'mm (6.0 kggff·m., 43 IbfH.ft1)

7--66 http://www.motorcycle.in.th

ENGINNEE REMOV ALl/lINSTAALLLLAATlION

Connect the clutcchh cable endd to the clutch lifter arm, then
install the clutchh cable to the clutch cable guide.

Insttaallll the radiator hoseess andd tighten the banndd screwss..

Instaallll the gearshift arm by adjusting the change pedal BOLT
height as shown.
Instaallll and tighten the gearshift arm pincchh bol:t..

http://www.motorcycle.in.th 7-77

ENNGGIINNEE RREEMMOOVV ALi/INST ALLATIOONN

CConnect thee nneeuutral swwiittcchh anndd alternator connectors.

Connect the vacuum tube to the PAIRR controll valve and
air inj eccttiioonn hose to the PAIRR check valve cover.
Installl the followwiinngg::
-stasrtaterrter motor terminaall and ground cablee (paaggee 1199--99))
-cacrabrubruerteotror (page 5-1133))
- aiar ir cleaner housinngg (pagee 5-4))
- fufeulel tank (pagee 55--33)1
- lelfet ft middllee cowwll (pagee 2-4))
-spsaprakrk pluug caap (pagee 3--88))
-exehxahuasutst system (pagee 2-77))
Fill and bleed the coolingg system (page 6--55)1.,
Adjust the clutch lever free play (page 3-211))..

7-88 http://www.motorcycle.in.th

CLUTCH/lGEARRSSHHIlFFTT LINKKAAGGEE

74 N·m (7.5 kgf·m, 54Ibf·ft)
12 N.m (1.2 kgf.m, 9 Ibf.ft)

64 NN·.mm (6.55 kkggff.m, 47 Ibbff·fWt) 4

8-00 http://www.motorcycle.in.th

8. CLUTCH/GEARSHlIFT LINKAGGEE

SERVICEE INFORMATION 8-11 GEARRSSHHIIFFTT LINKKAAGGEE 8-10
TROUBLLEESSHHOOOOTTIINNGG
RIGHHTT CRANKCCAASSEE COVER 8-22 PRIMARY DRIVVEE GEAR 8-12
REMOVALL
CLUTTCCHH LIFTTEERR ARM INSTALLLLAATTIIOONN 8-13
CLUTCH
88--33 RIGHHTT CRANKKCCAASSEE COVER

88-44 INSTALLAATTIIOONN 8-13

SERVIlCE INNFFOORRMMAT1IO0NN

GENERRAALL

This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in
the frame.
Transmission oil viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or
the motorcycle creeps with clutch disengaged, inspect the transmission oil level before servicing the clutch system.

lIDSPECIFICATIONS
Unit· mm (in) -

Clutch ITTEEMM SSTTAANNDDAARRDD SERVICE LIMMIITT

Leverr free play I AA I -100-- 20 (3//88-1133/1/166)) ---
Spring free length IBB
Discc thickness 37.6 (1.48) 36.66 (1.44)
10O..D0. 3.1 (0.12)
Platee warpoagae 11I.D0. 3..55-33.6.6(0(0.1.13388-0- .10.4124)2) 2.60 (0.10022))
Outer guide 0.2 (0.0088))
-2.92 - 3.08 (0..111155- 0.121) 22.93 (0.9033))
Outer 1I..D0. 17.04 (0.6711))
-_ _- 23.06 (0.9088))
I Mainshaft 0O..0D. at clutch outer guide
22.959 -- 22.98800 (0.9039 -- 0.9047) I7 6 . 196.39355/(00..66666677)

16..999911 --1177.0.0009 (0.6689 -- 0.6696)

30.000-30.002211 (1.11881111--11.1.1881199))

I 16.996 -- 16.984 (0.6680 -- 0.6687)

TORQUE VALUES 122 N·mm (1.22 kgff.mm, 9 Ibf·.fftt)) Apply a lockinngg agent to the threads
122 N·mm (1.2 kggff·m, 9I1bbff·.fRt) Apply oill to the threads and seating surface
Shift drum stopper arm bolt 744 N·mm (7.55 kggff·m, 54IIbbf·ffWt) Apply oill to the threads and seating surface
Gearshift cam platee bolt 64 NN·mm (6.55 kggff·m, 47 Ibbff·fWt)
Clutch center lock nut
Primary drive gear lock nut

http://www.motorcycle.in.th 88--11

CCLLUUTTCCHHl/GGEEAARRSSHHlIFFTT LLINKAGE 0077GGMB -- KT7010011

TTOOOOLS 007716--0002002101000

CClutch cceenntteerr hoollddeerr
LLock nnut wwrreenncchh,, 220 xx 224 mmm

TROUBLESHOOTlING

Faulty clutch operation can usually be corrected by adjusting the clutch system.

Clutch slips when accelerating -Transmission jjuummppss out off gear
Incorrect clutch adjuussttmmeenntt Damaged stopper arm

* Worn clutch disc . Damaged stopper plate
* Weak clutch springs Loosee stopper plate bolt

-Motorcycle creepss with clutch disengaaggeedd Gearshift pedaall will not returnn
Incorrect clutch adjustment * Weak or broken gearshift spindle return spring
Clutch plate warped • Bent gearshift spindle
* Faulty clutch lifter

Hardd to shift

- Damaggeedd gearshift spindle
- Damagedd stopper plate and ppinn
- Loosee stopper platee bolt

Incorrect clutch adjustment

88--22 http://www.motorcycle.in.th

CLUTCHl/GEARSHlIFT LINKAGE

RIGHT CRANKCASE COVER REMOVAL ~
CAHtEEND
Drain the engine oil (paggee 3-1111l).
Drain the coolant (page 6--55)1.,

Disconnect the clutch cable end from the clutch lifter arm..

Loosseennthe hose bandd screws and disconnect the radiator
hoses.

Removvee the ten bolts, clamp andd right crankccaassee cover..

Remmoovvee the gasket anndd doweell pinss..

http://www.motorcycle.in.th 8-3

CLUTCHl/GEARSHIlFT LINKAGGEE
CLUTCH LIFTER ARM

Remove the lifter piece and return spring.

Remove the clutch lifter arm/spindle.

Check the following:
--lliiffteter r arm spindle for wear or damage
-rerteutrunrn spring for fatigue or damage

Replaaccee the dust seall if necesaallllyy..

UFTf:R ARM/SPINDLE

CLUTCH

REMOVVAALL

Remmoovveethe clutch lifter bearingg andd clutch lifter plate bolts.
NOOTTEE:
LLoooosseenn the clutcchh lifterr platee bboollttss inn a cirsscross ppaattteernn

iinn 2 -- 33 steps.

RReemmoovvee the lifter ppllaattee anndd cluuttcchh springs.

Innssttaalll the cluuttcchh center hhoolddeerr anndd tighten thee fou r bolts.
HHoolldd the cluuttcchh asssseemmbbllyy..

RReemmoovvee the cluttcchh center lock nuutt anndd washer ussinngg the
speecciiaall tool.

TTOOOOLLS: 0077GGMMBB -- KKTT7700110011
CClluuttcchh cceenntteerr hhoollddeerr 0077771166 -- 00002200110000
lLoocckk nnuutt wwrreench, 2200 x 2244 mrnmrn

RReemmoovvee thhee ffoour bboollttss, cclluuttcchh cceenntteerr hhoollddeerr aanndd cluuttcchh
aasssembly.

88--44 http://www.motorcycle.in.th

CLUTCHl/GEARSHIlFT LINKAGE

Remove the clutch outeerr guide and washer from mainshaft.

DISASSEMBLl YY _____ -

Remove the clutch center, washer, judder spring, spring CLLUUTTCCHH DISC B
seat, clutch discs and plates.
Removee the pressuree plate. PRESSURE
PLATE
IINNSSPECTION
-e9 CLLUUTTCCHHDISC A
Clutcchh lifter bearingg
Turn the inner recee of the lifter bearinngg with your fingeerr..
The bearing should turn smoothly and freely without ex-
cessive play.
If necessaryy, replace the bearing.

http://www.motorcycle.in.th 8-5

CLUTCHl/GEARSHIlFT LINKAGEE

Clutch spring
Check the clutch spring for fatigue or other damage..
Measure the clutch spring free length.
SERVICE LIMMIITT: 36.6 rmnmm (1.4444 in1)

Clutch disc oDISSCCA DISC B

Check the clutch discs for signs of scoring or discolora- 0
tion.

[~I[~I

Measure the thickness of the discs.

SERVVICCEE LIMITS: Disscc AA- - 33..11 mmmrn (0.122 Iin))
Disscc B-- 22.600 mmmm (00..110022Iin)1

NOOTTEE::
RepDllaaccee the discs andd pdlaates as a set.

CClluuttcchh plaattee DISC
PLA
CChheecckkthee pllaattee for excceessssiivveewwaarrppaaggee or discoloration.
CChheecckkthee pllaatteewarpage onn a suurrffaaccee ussiinngg a feeler gauggee.

SSEERRVVIICCEELLIIMMIITT: 00.22 mmmrn((00..000088iin1l

88--66 http://www.motorcycle.in.th

CClluutch cceenntteerr CCLUTCHl/GEARSHIlFT LLINKAGE

CChheecck tthhee ggrrooooves oofftthhee cclluuttcch cceenntteerrffoorrddaammaaggee oorrwweeaarr CLUTCH CeNT R
ccaauused bbyy tthhe cclluutch pplates.
Replace iiff necessary.

Clutch outer CLUTCH OUTER

Check the clutch outer for nicks, indentations or abnormal
wearr made by the clutch discs.
Check the serrated teeth of the primary driven gear for
wear or damage.

Clutch outer guide

Measure the clutch outer guide.

SERVICE LIMMIITT:: 1I.D.0..:: 17.04 mmmm (0..667711 inn))
O0..0D..:: 222..9933 mmmm ((00..990033inn))

OlJTHGUID

Judder spring9, springg seat

Checckkthe judder springg andd spring seat for distortion, wear
or damage.

SF'AING S Ai

MMaalinnsshhaaft

MMeeaassuurree thhee mmaaiinnsshhaafftt 0O.D0.. aatt thhee cclluuttcchh oouutteerr gguuiiddee..
SSEERRVVIICCEE LLIIMMIITT::1166..993355mmmm ((00..66666677Iinn))

http://www.motorcycle.in.th 88--77

CLUTCH/GEARSHIFT LINKAAGGEE

ASSEMBLY CLUTTCCHH DISK A
CLUTCH DISK B
CLUTCH SPRINGS

SPRING SEAT

LOCK NUT CLUTCH CLUTCH OUTER
CENTER
... .-. .
PRESSSSUURREE PLATTEE

InstaIlIl ttthhheee cpplrrueetsscsshhuuddrreeiissPcpcssllaaaattenenddI.innppttllhhaaeetteeccsslluuaattllcctteehhrrnnooaauutttteeeerllryy...Iinn the clutch ~~
IInnssttaall the clutch
shall~woInusttearl.l the clutc CLUTTCCHH DISSCC B

. A into the
~oInustetar.ll the tabbss ooff
'0""" '"' ", "'h 0"",. 'D'~ ,slots of the clutch
ooouuutttessiirdd. ee(DcisIluucttccAAhhhhddaaiiSsssCcllaaArrggieenrrto1I.D.0th.. etthhsaahnnaDDllIoiSswCc

sBl)ots of the c U d side facing ou .

IIBInnn)ssstttaaallllllll ttthhheee jJs.upUddnr.ddineegrr ssseeppaarriittnn,, gwwg aawWssii.hhttheerr·Iitaasnntaddpccelluurettccdhhsccideeennttfeearrc..ing out.

v CLUTCH DISC A

88--88 http://www.motorcycle.in.th

CLUTCH/lGGEEAARRSSHHIlFFTT LINKAAGGEE

INSTTAALLLLAATTIIOONN

Insttaalll the washerr..
Apply molybdenum oil solution to the clutch outer guide.
Inssttaalllthe washer andd clutch outer guide to the main shaft.

Insttaallll the clutch assembly.

Inssttaalll the clutch center holder and tighten the four bolts.
Inssttaalll the washer and lock nut.
Holdd the clutchh assembly and tighten the lock nut to the
specified torque.

TOOLS: 07GMMBB -- KKTT7700110011
Clutch center holdeerr 017716 -- 00200110000
Lockk nnuut wrench,. 20 x 24 mmmm

TORQUE: 74 N·.mm (7.55 kggff·m., 544IbI bf-ffWt)

Removve the four bolts and clutchh center holder.

Insttaalll the clutcchh springs, lifter plate,. four bolts and clutchh
lifter bearing.

NOTEE::
Tighteenn the lifter platee bolts inn a crisscross pattern inn 2 - 33
stepnss.

http://www.motorcycle.in.th 8-9

CCLLUUTTCCHH//GGEEAARRSSHHIIFFTT LLIINNKKAAGGEE

GEARSHHIIFFTT LLIINNKKAAGGEE

RREEMMOOVVAALL

RReemmoovvee tthhee ffoolllloowwiinngg::
--gegaerasrhsihftift aarrmm
--rigrihgtht ccrraannkkccaasseeccoovveerr ((ppaaggee88--33) )
--clcultucthch aasssseemmbbllyy ((ppaaggee 88--44))
RReemmoovvee tthhee bboolltt,, wwaasshheerr aanndd ggeeaarrsshhiifftt ccaamm ppllaattee.
RReemmoovvee thhee ppiinnss frroomm thhee sshhiifftt ddrrum.

RReemmoovvee tthhee bboollt, wwaasher, ssttooppppeerr aarrmm aanndd rreettuurrnn sspprriinngg.
RReemmoovveetthhee ggeeaarrsshhiifftt ssppiinnddllee..
CChheecckk tthhee ggeeaarrsshhiifftt ccaamm ppllaattee aanndd ssttooppppeerr aarrmm ffoorr wweear
oorr ddaammaaggee..
CChheecckk tthhee ssttooppppeerr aarrmm rreettuurrnn sspprriinngg foorr ffaattiigguuee oorr ddaamm--
aaggee..

CChheecckktthhee ggeeaarrsshhiifftt ssppiinnddlleeffoorr vveenntt oorr ddaammaaggee..

IINNSSTTAALLLLAATTIIOONN

AAppppllyy mmoollyybbddeennuumm ooiill ssoolluuttiioonn ttoo tthhee ggeeaarrsshhiifftt ssppiinnddllee
sshhaaffttaannddiinnssttaall ltthheeggeeaarrsshhiiffttssppiinnddlleettootthheeggeeaarrsshhiiffttrreettuurrnn
sspprriinngg ppiinn..

88--1100 http://www.motorcycle.in.th

CLUTCH/lGEAARRSSHHIlFFTT LINKAAGGEE

Instaallll the returrnn sprinngg,, washer (betwweeeenn the arm and
spring), stopper arm and bolt, and tighten the bolt to the
specifieedd torque.

TORQUUEE:: 12 N·.m 11.2 kgff·.m,.9 Ibf-.ft)

Lower the stopper arm and install the pins.
Instaallll the gearshift cam plate by aligning the pin hole inn
the cam platee with the pin.

Apply locking agent to the gearshift cam plate bolt threads.
Instaallll the bolt and tighten it to the specifiedd torque.

TORQUEE:: 12 N.·m (1.2 kgf·.m,.9 1IbbHf.ht)

Instaallll the following:
-cluctlucthch assembly (page 8-99))
-rigrihgtht crankccaassee cover (paggee 8-14)
-gegaerasrhsihftift arm

http://www.motorcycle.in.th 88--1111

CLUTCH/lGEARSHIlFT LINNKKAAGGEE

PRIMARRYYDRIVEE GEAR

RREEMMOOVVAALL

Remmoove the oill pumpp (paaggee 4-33))..

Remmoovvee the four bolts, lifter platee andd clutcchh springs.
Insttaallll the clutcchh center holder andd tighten the bolts.

Remove the primary drive gear lock nut andd washer while
holding the clutchh center holder.

TOOL: G77GGMMB0 -- KKTT7700110011
Cluttcchh centterr hoolldderr
07716 -- 0020100
LLoocckk nut wrench., 20 x 24 mmmm

Remmoovvee the clutchh assembly (paaggee 8-4)..

Remove the primary drive gear.

Remove the woodruff keyy..

INSSTTAALLLLAATTIIOONN

Inssttaalll the washer.
Inssttaallll the woodruff keyy onto the crankshaft.

Inssttaalll the primary drive gear by aligningg the groove with
the woodruff keeyy..

Inssttaalll the clutchh assembly (paaggee 8--99))..

Apply enginee oill to the threadss andd seating surface of the
primary drive gear lock nut andd instaallll it with the washer.
HHoolldd the clutcchh assembly usingg the clutchh center holder.
Tightteenn the primary drive gear lock nut to the specifiedd
torque.

TORQUE:: 64 N.'m (6.5 kkgf'.mm,. 47 IbfH.ftt)

Remmoovvee the four bolts andd clutcchh center holder.
Inssttaallll the clutchh springs andd lifter plate.
Tightteenn the four bolttss..

Inssttaalll the following:
- oiol il pumpp (paaggee 4-66))
- rigrihgtht crankkccaassee cover (paggee 8-14)

8--1122 http://www.motorcycle.in.th

CLUTCH/lGEARSHIlFT LINKKAAGGEE

CLUTCH LIFTER ARM INSTALLLAATTIIOONN

Apply molybdenum oill solution to the lifter arm spindle.
Insert the returnn spring to the lifter arm spindle.
Align the cover hole andd cut-out of the lifter arm spindle
by turning the lifter arm spindle.

Apply engine oill to the lifter piecee..
Insert the lifter piecee to the cover holee and lifter arm
spindle.

RIGHT CRANKCCAASSEECOVER
INSTALLLLAATTIIOONN

Inssttaalll the new gasket andd dowel pins.

Insttaallll the right crankkccaassee cover, clamp and ten boltss..
Tighteenn the bolts secureellyy..

http://www.motorcycle.in.th 8-1133

CLUTCH/lGEARSHIlFT LINNKKAAGGEE

Connneecct thheewater hoosseessannddtighten the hoossee baannddsccrreewwss..

Connect the clutch cable end to the lifter arm. ~ o
Adjust the clutch lever free play (paaggee 3--22)1..
C UTCHCAB
Inssttaalll the under cowwll (pagee 22--33))..
Fillll andd bleeeedd the cooling systemm (paaggee 6-5)..
Fillll the recommmeennddeedd engine oill (paaggee 3-1100))..

8-144 http://www.motorcycle.in.th

ALTERNATORIlSTARTER CLUTCH

SYSTEM DIAGRAM

99--00 http://www.motorcycle.in.th

9. ALTERNATOORR/STARTER CLUTCH

- ___~ ~

SERVICE INFORMATIOONN 9-1 STARTER CLUTCH 99- 4
9-7
TROUBLESHOOTING 9-1 FLYWHEEELL INSTALLATION
9-8
LEFT CRANKCASE COVER REMOVAL 99-2 LEFT CRANKCASE COVER
INSTALLATION
ALTERNATOR/KSTTATTOORfl 99--22

FLYWHEEELL REMOV AL 9-3

SERVICE INFORMATIOONN

GENERAALL

- This section covers service of the alternator staattoorr,, flywheel and startteerr clutch. All service can be done with the

-- engine installed in the frame.
Refer to section 17 foorr alternator stator inspection.

Refer to section 19 foorr starter motor servicing.

TORQUE VALUES 10 N·m (1.0 kgff·mm, 7IIbbff·.ft) Applyy a locking agent to the threads --==-"-
64 N·m 1(66..55 kgff.mm, 47 Ibf.·ftt)) AApply oill to thhee thhrreeaads and seeaattiing surfaacee
Stator bolt 30 N.·m (3.11 kgf·mm,, 22 Ibf.·ft) Apply a locking agent to the threads
Flywheeell nut 5.2 N.·m (0.53 kgff·mm, 3.8 Ibf.·ft) Apply a locking agent to the threads
Starter clutch bolt
Ignition pulse generator bolt

TOOLS 07725-0040000
07KMC-HE00100
Flywheell holder
Rotor puller

TROUBLESHOOTING

Engginee does not turn

- Faulty starter clutch.

• Damaged reductioonn gear/shaft.

http://www.motorcycle.in.th 99--11

ALTERNNAATTOORW/SSTTARTER CLUTCH

LEFT CRANKCCAASSEE COVER REMOVAALL

Disconnect the alternator 4P connector (pagee 17-7)..
Removee the drive sprocket cover (paggee 7-33))..
Remoovvee the bolts, washer and left crankccaassee coverr..

Remoovvee the gasket and dowel pins.

ALTERRNATOR/STATOR UlSE GENE.RATOR MOtJ liNG BOLTS

STATOR REMOVAL

Removee the two ignition pluse generator mounting bolts
and ignition pluse generator.
Remove the three stator mounting bolts and wire
grommet, then remove the stator from the left crankcaassee
cover.

99--22 http://www.motorcycle.in.th

STATOR INSTTAALLLLAATTIIOONN ALLTTEERRNNAATTOORRISETTARTER CLUUTTCCHH

LEFT CRANNKKCCAASSEE COVER

Plaaccee the stator into the left crankccaassee coveerr.. PULSE GENERATOR MOUNTING BO TS
Apply liquuiidd sealant to the wire grommet seatinngg surface
and instaallll the grommet into the cover groove.

Apply lockinngg agent to the ignition pulssee generator andd
stator mounting bolts threads.
Rouuttee the wire properly andd tighten theetwo ignition pulssee
generator mounting boltss..

TORQUE: 5.2 N.'m (0.5533 kgff'm, 33..88 Ibf-.ft)

Tighteenn the three stator mounting bolts.

TORQUE: 1100 N'.mm (11..00 kgff'm, 7 Ibf-.ft)

FLYWHEEL REMOVALL

Remoovvee the left crannkkccaassee cover (paggee 9-2))..

Holldd the flywheel with the speciaall tooll andd looseenn the fly-
wheel nut.

TOOL:: 07725 -- 00004400000000
Flywhheeeell holder

Remmoovvee the flywheel nut andd washer.

http://www.motorcycle.in.th 99--33

ALTERNAATTOORR/E5TAARTER CLUTCH

Remoovvee the flywheel usingg the special tool.

TOOOLL:: 07KMMCC -- HEEO00O1IO0O0
Rotor puller

Remove the woodrufff keyy..

STARTER CLUTCHH DR Io;EN GEAR.

REMOOVVAALL

Remove the flywheel (paaggee99--33)). .
Remmoovvee the starter reduccttiioonn gear.

Remmoovvee the starter driven gear while turningg it coun-
terclockwise.

99--44 http://www.motorcycle.in.th

Hold the flywheel with the special tool and remove the ALTERNATOORW/STTARTER CLUTCH
starteerr clutch bolts. FLVl.o,'HfEL HOLO A

TOOL: 07725 -- Q0Q044Q0O0Q0Q0
Flywheel holder

Remove the startteerr clutch assemblyy from the flywheel.

Remove the sprag clutch from the starter clutch outer.

IBOLTS

INSPPEECCTTIIOONN REOUCTION GEAR

Check the starter reductionn gear for wear or damage.

Checkk the starter clutcchh outer andd sprag clutcchh for abnor- C IJTCH OUTER SPRAG CLUTe
maall wear or damage.

CChheecckk the starter driveenn gear teeth for wear or dammaaggee.

STARTE~ D~I

http://www.motorcycle.in.th 9-5

ALTTEERRNNAATTOORR/EST ARTER CLUUTTCCHH CLIJTCtl OUTEfI

INSTAALLLLAATTIIOONN

Apply enginee oill to the sprag clutchh rollliinngg surface.
Instaallll the spraagg clutchh into the starter clutchh outer with
the flange side facing the flywheeell side..

$ I'JijAGC UTei'!

Apply lockinngg agent to the starter clutcchh bolt threaddss.. LYWHEe L 01.0 R
Inssttaallll the starter clutcchh assembly onto the flywheeell andd
insttaallll the boltss..
Hoollddthe flywheeel with the speecciiaall tool and tighten the bolts
to the specciiffiieedd torque.

TOOL: 077772255-00004400000000
Flywwhheeell hollddeerr

TORQUE: 3300 N'mm (33..11 kggff·mm. 2221IbHf.ftil

Installl the starter drivveenn gear whilee turning it Ofi.IV£ N G' AR
counterclocckkwwiissee..

Make sure that the starter driven gear turns counterclock-
wise smoothly andd does not turn clockwise.

Inssttaallll the flywheel (paaggee 9-77))..

9-66 http://www.motorcycle.in.th

ALTERRNNAATTOORR/EST ARTER CLUTCH

Apply engine oil to the starter reduction gear bothh journal.
Inssttaalll the starter reductioonn gear.

FLYWHEEELL INSTALLATIONN

Cleeaann any oil from the tapered portions of the crankshaft
andd flwywvheel.
Inssttaallll the woodruff key inn the crankshaft key groove.

Innssttaalllthe flywheel on the crankshaft, aligning the key way
with the woodruff key.

Apply oill to the flywheel nut threads and seating surface,
andd insttaallll the washer and nut.

Hoolldd the flywheel with the special tool and tighten the nnuut

to the speccifieedd torque.

TOOL: 07725 -00004400000000
Flywwhheeeell holder

TORQUE: 64 Nv'mn (6..55 kggff'm, 47 IbfH.ftt)

Inssttaalll the left crankkccaassee cover (pagee 9-8))..

http://www.motorcycle.in.th 9-77

ALTTEERRNNAATTOORRISETARTEERR CLUTCHH

LEFT CRANKCASE COVER
INSTALLATION

Installl the dowel pin and a new gasket.

Installll the left crankcase covveerr..
Installll the washerr and bolttss, and tighten them securely.
Installll the drive sprocket cover (paggee 7--66))..
Connect the alternator 4P connector (paggee 17-7).

99--88 http://www.motorcycle.in.th

CYLINNDDEERR HEADDINVALVESS

10 N·.m (11..00kkggff.m,, 7IIbbff·.fftt))

12 N.m (1.2 kgf.m, 9 1bf.W

9 N.m 4 N·m (0.4. kggff·m,,
6.5 Ibf
2.9Ibf·ft)
29 N.m
~/~j
/~~

/'

100--00 http://www.motorcycle.in.th

10., CYLINDER HEADNALVES

SERVICE INFORMATION 10-11 VALVE GUIDE REPLACEMEENNTT 10-13
TROUBLESHOOTINNGG 10-2 VALVE SEAT INSPECTIOONN 10-14
CYLINDER COMPRESSION 10-3 VALVE SEAT REFACIINNGG 10-15
CYLINDER HEAD REMOVAL 10-4 CYLINDER HEAD ASSEMBLY 10-17
CAM CHAIN TENSIONER LIFTER 10-7 CYLINDER HEAD INSTALLATTIIOONN 10-19
CYLINDERR HEAD DISASSEMMBBLLYY 10-8

SERVVICE INNFORRMMAATTIIOONN

GENERAL

- This section covers service of the cylinder head, valves.
* The cylinnddeerr head and valves services can be done with the engine installed in the frame.

When disasssseemmbblliinngg,, mark and store the disassembled parts to ensure that they are reinstalled in theirr original

locatiioonnss..

Cleann all disassemblleedd parts with cleaning solvent and dry {them by blowing them off with compresseedd air before

inspectionn.. 1mm
* Cleann the oil passageess before assembling cylinder head.

Be carefull not to damage the mating surfaces when removing the cylinder head cover and cylinder head.

SPECIFICCAATTIIOONNSS Unit·: mm (inr )

IITTEEMM I ISTANDARDD SERVICE LIMIT

CEylinder compression 1,370 kpaa (13.9 kgf/cm'z, 197.7 psi)) ---

Cylinder head warpage 'at 680 minn' (rpm) 0.05 (0.002)
---
Valve, Valve clearance ---
valve guide +INN 0.16 ± 0.03 (0.006 f± 0.0011))
---
Valve stem 0O..D0. EX 0.25 f± 0.03 (0.010 ±f 0.00011))
3.7 (0.15)
INN 3.775 -- 3.790 (0.148866 -- 0.1449922))
EX 3.765 -- 3.780 (0.1482 -- 0.1488) 3.7 (0.155))

Valve guide JI..D. IN/EXX 3.800--3.38.18212 (0.14966--0.01.5150011) ) 3.89 (0.15533))
Stem-to-guidee clearance INN 0.075 (0.0002299))
EX 0.Q010 -- 0.037 (0.000044 -- 0.0001155)) 0.085 (0.0033)
0.,020 -- 0.0477 (0.00088-- 0.0001199))

Valve guide projection INN 15.5 (0.611)) ---
above cylinder head EEXX 13..11 (0.52) '
---

Valve seat width IN/EX 1.2 - 1.6 (0.05 - 0.06) 1.9 (0.07)

Valve spring free length IN/EX 39.7 (1.56) 38.5 (1.52)

Valve lifter 0.0. 22.478 - 22.493 (0.8850 - 0.8855) 22.47 (0.885)

Bore 1.0. 21.1 - 21.3 (0.83 - 0.84) 22.5 (0.89)

Camshaft Caamm lobee height IN 35.12 - 35.20 (1.383 - 1.386) 35.073 (1.3808)

Runout EX 34.71-34.79 (1.367 -1.370) 34.662 (1.3646)
0.02 (0.001)
--

Camshaft holder 1.0. IN/EX 17.000 - 17 .018 (0.6693 - 0.6700) 17.027 (0.6703)

Camshaft 0.0. IN/EX 16.966 -16.984 (0.6680 - 0.6687) 16.960 (0.6677)

Camshaft-to-camshaft IN/EX 0.Q16 - 0.052 (0.0006 - 0.0020) 0.067 (0.0026)
holder clearance

http://www.motorcycle.in.th 1100--11

CYLINDER HEADIVALVES 10 N·.m (1.0 kggff·m, 7 Ibf·.ft))
8.8 NN·mm (0.9 kgf.·mm,, 6.5 Ibf.4ft) Apply a locking agent to the threads
TORQUE VALUES 4.2 N·m (0.43 kgf.·m, 3.11IIbbff·.fft)
12 NN·.mm (1.2 kgf.·mm,, 9I1bbf·f.fht)) Apply oil to the threads and seatingg surface
Cylinder head cover bolt 30 N.·m (3..11 kgf.·mm,, 22 Ibf·.ft)) Apply oil to the threads and seating surface
Camm sprocket bolt
Camm chainn tensioner plug
Camshaft holder bolt
Cylinder headd nut

TOOOLLSS 077577 -00001100000000

Valve spring compressor 07JME -- KY20110000
Attachment 07GMD -- KT1700110000
Valve guide driver, 3.8 mrnmm 07JMH -- KYZ2O01IO0O0
Valve guide reamer
Valve seat cutter 07780 -- 001060000

Seat cutter, 24 mmm (44550" EX)) 07778800--0001100220000
Seat cutter, 27.5 mmm (44550" INN))
Flat cutter, 24 mmmm ((33220" EX)) 077800 -- 001250000
Fllaatt cutter, 277 Iml)mm ((33220" INN))
Interior cutter, 266 mmm (66000" INN)) 07778800-0001133330000
Interior cutter, 300 mmm (66000"EX)) 07778800-0001144550000
CCutter holder, 3.8 mmm 077778800-00001144000000
Tapet hoolee protector
07JMMHH -- KY2200220000
07JMG -- KY2200110000

TROUBLESHOOOOTTIINNGG

EEnngginee top--eenndd pproobblleemmss usually affect engine performance. Thessee cann bee diagnoosseedd by a compprreessssiioonn or leak

- dowwnn test, or by tracinngg engine noiseess to the top-endd with a sounding roodd stethoscope.
If the performmaannccee iss poor at low speeds, check for white smoke inn the crankccaassee breather tube. If the tube is smoky,

cheecckk for a seeiizzeedd pistoonn rinngg (secttiioonn 1111))..

CoommpprreeSsSsioonn toooo llooww,, hhaarrddssttarting or pooorr Excceessssiivveesmmookkee
* Worn valve stem or valve guide
-ppeerrffoorrmmaanncceeat llooww ssppeeeedd
Valves Damageedd stemm seaall
--Inccoorrrreecctt valvvee adjustment Faulty cylinder, pistoonn or piston rings (sectionn 11)
--BBuurrnneedd or bentt valves
--InIcnocorrrerecctt valve timiinngg -Excceessssiivveennooiissee
--BBrookkeenn valve sprinngg Cylinder Heeaadd
-WWeaekak valvee sprinngg --InIcnocorrerecctt valve clearance
* Cylinder heeaadd -StSictkicinkigng valve or brokenn valve spring
* Faulty cylinder or piston (secttiioonn 111))
-LeLaekaiknigng or damaged cylinder heaadd gasket
- WWaraprepded or craacckkeedd cylinder heaadd Rouugghh iddllee
LLoow cylinder compprreessssiioonn
CoommpprreeSsSsiioonnttoooo hhiigghh,, oovveerrhheeaattiinnggor kknnoocckkiinngg
EExxcceessssiivveeccaarrbboonn bbuuiilldd--uupp iinn cylinder heeaadd or onn top •* Innttaakkee air leaakk
of ppiissttoonn

1100--22 http://www.motorcycle.in.th

CYLLIINNDDEERR HEADIVAALLVVEESS

CYLINDER COMPRESSIlONN

I!'M'M'

• «Iftthhee engiinnee must be runnniinngg to doo soomme woorrkk, make
surre that thhee area is welll-vvennttiillaatteedd.. Never ruunn thhee en-
ginne in an enclosed arreeaa..

• Thheeexhaust coonnttaaiinnsspoisonous carrbboonnmonoxide gas

that may cauussee lossss of coonnsscciioouussnneessssand may lead to

deatthh..

Warmm upp the enginee to normaall operating temperatuurree..
Stop the engine.

Remmoovvee the spark pluugg (paaggee 33--66)). .

Inssttaalll the compreessssiioonn gauge into the spark plugg hole.
Opeenn the throttle alll the way andd crank the engine with
the starter motor unttiill the gauge readdiinngg stopss rising.

STAANNDDAARRDD: 1,370 kkPPaa (1133..99 kkggff//ccmm2z,,19977..77)) at 668800 rrppmm

If compressssiioonn iss high, it indiccaatteess that carbboonn deposits
havee accummuullaatteeddonn the combustion chamber and/oorrthe
pistonn crown.

If compprreessssiioonn iss lloww, pour 3 -- 5 cc (00..11 -- 0.2 o02z)) of cleann

engine oill into the cylinder through the spark plug hole
andd recheecckk the compreessssiioonn..

If the compreessssiioonn increases fromm the previous value,
check the cylinder, pistonn andd pisttoonn ringgss..

Leaakkiinngg cylinder heaadd gaskett

- Worn pisttoonn rinngg
Worn cylinder andd pistoonn

If compreessssiioonn is the same as the previous value, check
the valves for leakage.

http://www.motorcycle.in.th 10-33

CYLINDER HEAD/NVAALVES

CYLINDER HEAD REMOVAL

CYLINDERR HEAD COVER REMOVAL

Remove the followinngg::
-rigrihgtht and left middle cowl (page 2-4)
-fufeulel tank (page 5--33))
Remove the two bolts and radiator with wateerr hoosses
installed.
Disconnect the upper radiator hose from the cylinder head.

Disconnect the vacuumm tube.
Remove the bolt and PAIR control valve.
Disconnect the air injection hose from the PAIRRcheckkvalve
cover.

Remoovvee the two bolts andd rubberr washers.

RReemmoovvee the cylinder heeaadd cover, gasket, dowweell piinn andd CYliNDER H AD COVER
O--rriinngg..

1100-4 http://www.motorcycle.in.th

CYLINDER HEADINVAALLVVES

CAMSHAFT REMOVAL

Removvee the following::

-- under cowl (page 2-3))

-cycliynldinedrer head cover (page 10-4)

Remove the timing hole cap and crankshaft hole cap.

Turn the crankshaft counterclockwise and align the index
line of the '"TT"OO mark on the flywheel with the index notch
on the left crankcassee cover.

The index lines on the cam sprockets must be flush with
the cylinder headd surface as shown.

Make sure the pistonn is at TODC (Topp ODeadCCeenntteer) on the
compresssiioonn stroke.

If the pistonn is at TODC on the exhaust stoke, rotate the

crankshaft countercloocckkwwiissee 36000" ((11 fu!ll turn) and align

the "'TT"" mark with index notch. .

Remmoovvee the camm chaiinn ttensioner lifter plug.
Turnn the tensioner shaft clockwiissee with the stopper tool
(page 100--88))too retract the tensioner; then insert the stopper
fully to holldd the tensioner inn the fully retraacctteedd position.

Reemmoovvee thee caamm sprocket boollttss.. 100--55
NOOTTEE:
BBee caarreeffuull nott to lett thee sprocket boollttss falll inttoo the crank--
caassee.

http://www.motorcycle.in.th

CYYLLIINNDDEERRHEAADDIIVVAALLVVEESS CA SPROCKETS

RReemmoovvee thee ccaamm sspprroocckkeettss ooff thhee ccaammsshhaafftt flangeess.
RReemmoovveethee sspprroocckkeets froomm thee ccaamm cchhaain.
Attach a pieeccee of wire to the ccaamm cchhaaiinn to prevveenntt iitt fromm
falling inttoo the craannkkccaassee..

Remmoovvee the two bolts andd camm chainn guide.

Inspect the camm chainn slipper surface of the camm chaiinn
guide for wear or damage andd repilaccee if necessary.

Remove the camshaft hOolldder bolts,, camshaft holders,
dowel pins and camshafts.

NOTE:
Do not forcibly remove the dowel pins from the camshaft
holders..

CYLINDER HEAD REMOVAL

Drain the coolant (pagee 6-5))..
Remove the radiator (pagee 6-8))..

Remove the following:
-cacmasmhsahfat ft (pagee 10-5))
-exehxahuasutst system (pagee 2--55))
-cacrabrubruertoetror assembllyy (pagee 5-4)

Remove the valve lifters and shims.

NOTE :
• Be careful not to damage the valve lifter bore..
• Shim may stick to the inside off the valve lifter. Do not

- alloow the shims to fall into the crankcase. '
Mark aall valve lifters and shims t o ensure correecctt
reassembly in theeiirr original locatioonnss..
* The valve lifter can be easily removed with a valve

- lapping tool or magnet.
The shims can be easily removed with a tweezers or
magnet.

10-6 http://www.motorcycle.in.th

CYLINNDDEERR HEAADDINVALVESS

RReemmoovvee thhee ccyyllinnddeerr hheeaadd bboollttss..
LLoooosseenn thee ccyylinder hheeaadd nnuuttss inn a ccrriissssccrroossss ppaatttteerrnn iinn 2
to 33 ssteps, anndd remmoovvee them anndd washers.

RReemmoovvee the cylinder heeaadd..

Removvee the gasket andd doweell pins.

CAM CHAIN TENSIONERR LIFTER 10-7

REMOVAL

Remove the two bolts and cam chain tensioner lifter.

INSPEECCTTIIOONN

Remove the tensioonneerr lifter plug.
Check the lifter operaattiioonn::
-ThTehe tensioner shaft should not go into the body when it

is pusheedd..
-WWhehnen it is turned clockwise with a scrreewwddrriivveerr,, the

teennssiioonneerr shaft should be pulled into the body.TThhesshhaafftt
spring out off the body as soon as the screewwddrriivveerr is
released.

http://www.motorcycle.in.th

CYLINDEERR HEEAADDIIVVAALLVVEESS 16.5 mm

Makkee a tensioner shaft stopper tooll out of a thin piece of
steeell (0.8 mmrn thicckk)) usinngg the diagram.

8.5mm 3.5mm

INSTALLLLAATTIIOONN \

Turnn the tensioner shaft clockwwiisseewith the stopper tool to
retract the tensioner, thenn insert the stopper fu llIy to hold
the tensioner inn the fully retraacctteedd position.

STOPPER TOOL

Inssttaalll a new gasket onn the camm chaiinn tensioner lifter..
Inssttaalllthe tensioner lifter intoo the cylinder andd tighten the
mounting bolts.

Remmoovvee the stopper tooll fromm the tensioner lifterr..
Apply oill to the new aO--rriinng.
Inssttaalll the lifter plug with a new aO--rriinngg andd tighten it..

TORQUEE:: 4.2 N·.mm (00..4433kkggff·.mm,, 3..11 IbfH.ftt))

CYLINDER HEAD DISASSEMBLY

Looseenn the baanndd screw andd removvee the carburetor
insulator.
Disconnect the vacuuumm tubes.

100--88 http://www.motorcycle.in.th

CYLINDDEERR HEADIVAALLVVEESS

Remmoovvee the boolt., radiator hossee joint andd aO--rriinngg..

J OINT

While compreessssiinngg the valve spring with the valvee spring
compressor., remoovvee the valve cotters.

CAAUUTTIIOONN::

Too prevent loss of tenssion, doo not compresss the valvee
swprriinngg moore tthhaann neceessssaarryyto removee the cootiteerss..

TOOOOLL: 07757 -- 000110o0o0o0O
Valvvee spprriinngg coommpprressor

Valvvee sspprriinngg coommpprreessssoorratttacchhmmeenntt07JMMEE-- KY200110000

Tapett hhoollee prroottecttoorr 07JJMMGG-- KY20100

vALVE: SPAltIOC'l COMPAESSOFl

Loosseenn the valve spring compressor andd remmoovvee the fol-- 1 STEM SEAL
lowing:
-spsrpinrigng retaaiinneerrss SPRINGG SEAT
-vavlavleve springs
-spsrpinrigng seats :a.\a!SSPPRRlING
--intakkec andd exhaust valve @
-vavlavleve stemm seaall "---- COTTER

NOOTTEE::

Mark alll disassembled parrttss to ensure correct reassemm--
blyv.

Remmoovvee the carbboonn deeppOoSsits fromm the combustion cham- COMBASTION CHAMBER
beerr..
Cleeaann off any gasket materials fromm the cylinder headd
surface.

NNOOTTEE::
Beeiinngg careeffuull not to damage the gasket surfacee..

http://www.motorcycle.in.th 10-99

CYLLIINNDDEERR HHEAADDIVAALLVVEES
INNSSPPEECCTTIIOONN

Cammsshhaafft/lcamshaft hholder
RReemmoovvee thee snap rinngg anndd righhtt cammsshhaafftt hhoolddeerr..

R.IGH CAMSHAn HOLDER SNAP RING

Measure thee cammsshhaafftt holder I.DD..
SEERRVVIICCEE LLIIMMIITT::1177..002277 mmm (0.670033 iinn))

Measure the camshaaft O0.D0..
Calculatee the camshaafftt--ttoo--ccaammsshhaafftt holder cleaarraanncc;e.
SERVVICCEE LLIIMMIITT::16.9600 mmm (0.6667777 inn))
If the camshaft-too--ccaammsshhaafftt holder clearance exceeds the
servicee limit,. replaacceethe camshaft and left camshaft holder
as a set and rechecckk the camshaft clearance.
Replaacceethe right camshaft holderr if the camshaft clearance
still exceedss the service limiitt.

Measure the height of each cam lobe.
SERVICE LLIIMMIITT::

IN:: 35.073 mm (1.380088 inn))
EXX: 34.662 mm (1.36466 inn)

10-1100 http://www.motorcycle.in.th

CYLINDDEERR HEADIVAALLVVEESS

Support bothh ends of the camrnsshhaaffttwwiith V-blocks andd check
the camshaft runout with a dial indicator.

SERVICCEE LLIIMMITIT: 0.022 mmm (00..000011in)

Valve lifter
Check the valve lifter bore for scorinngg,, scratches or
damage.
Measuurree the eachh valve lifter bore 11..00..

SERVVIICCEE LLIIMMIITT::22.5 mmm (0.8899 in)

Check the valve lifter for scoring, scratchess or damage.
Measure the each valve lifter 0O.D0..
SERVVIICCEE LLIIMMIITT::22.47 mmm (0.885 in)

Valve spring 100--1111
Measure the valve spring length.

SERVICCEE LLIIMMIITT::38.5 mmm (1.5522 inn))

http://www.motorcycle.in.th

CYLLIINNDDEERR HEAADDIVAALLVVEESS

CCyylinder heeaadd
CChheecckk the spark pluugg hoollee anndd valve area for cracks.
CChheecckk the cylinder heeaadd for warpaggee with a straigghhtt edge
anndd a feeler gaauuggee..
SSEERRVVIICCEELLIIMMIITT::00.0055 mm (00..000022in))
NNOOTTEE::
BBee caarreeffuull not to dammaaggee the gasskkeett surfaaccee..

Valvee
Inssppeecctt the valvvee for trueness, burning, scraatcchheess or ab--
noorrmmaall stemm weaarr.
MMeeaassuurree the valvvee stemm 0O.D0.
SSEERRVVIICCEELLIIMMIITT:: INN/IEEXX: 33.7 mm (0.15 iinn))
Innsseerrtteaacchh valvvee intoo the valve guuiddee anndd check the valvee
mmoovveemmeennttinn the guide.

Valvvee guuiddee

NNOOTTEE::

~~ ~

• RReeaamm the valvvee guuiiddee to remmoovvee the caarrbboonn build-up
beefooree cheecckkiinngg the valvee guide.

* Alwaayyss roottaatteethe reammeerrclockkwwiissee,,neevveerrcouunntteerrcclloocckk--
wise whenn instaallinngg,, remmoovviinngg anndd reammiinngq..

TOOLL:: -07JJMMHH- KKYY2200110000
Valve guuiddee reamer

MMeeaassuurreeanndd reeccoorrddeaacchh valveeguuiiddee1I.D.0. withh a baalll gauge
or inssiiddee mmicromeeter.

SSEERRVVIICCEELLIIMMIITT::INN/IEEXX: 33.8899 mm (00.115533 inn))

CCaallccuullaattee the steemm--ttoo--gguuiiddeecleaarraannccee..

SSEERRVVIICCEELLIIMMIITT:: IINN: 0.075 mm (00..00002299inn))
EEXX: 0.085 mmmm (00..00003333 inn))

-NNOOTTEE:: /
Iftthe steemm--ttoo--gguuidideecleaarraanncceeexceeds the servviccee limit, /

deeteerrmmiinnee if a neww guidee with standaardd dimeennssioonnss
would bringg the cleaarraanncceewithhiinntolerraannccee..Ifso replaccee
the guides as neecceessssaarryy andd reeaammto ffiitt..
If the stemm--ttoo--gguuiiddeecleaarraannccee stiillll excceeeeddssthe service
limit with new guides, reppllaaccee the valve anndd guide,.
* RReeffaaccee the valvvee seat whenever new valve guides are

installed.

100--1122 http://www.motorcycle.in.th

VALVE GUIDE REPLLACCEEMMEENNTT CYLINDER HEADIVALLVVEESS

Chill the valve guides inn the freezer sectioonn of a refrigeraa-- e-
tor for about an hour.
I
'!i§OMMa
VAlVE GUID£ DRIVER
Wear insulated gloves t o avoiddburns when handling the
heateddcylinder head.

Heat the cylinder head to 1300°°CC -- 140°CC (275°FF -- 290°F)
with a hot plate or oven. Do not heat the cylinder head

beyondd 150°CC (300°°FF)).. Use temperature indicator sticks,
available from welding supply stores, to be sure the cylin-
der headd is heateedd to the proper temperaturee..

CAUTION:

• Usinngg a torch t o heat the cylinder head may cause
warping.

• Be careful n ot fto damage the mmaattiinnggsurface.

Support the cylinder head and drive the valve guides out
of the cylinder head from the combustion chamber side.

TOOL: 0077GGMMDD-- KT70110000
Valve guide driver, 33..88 mm

While the cylinder head is still heated, drive new valve VALVE GlIlDE DRIVER
guides inn the cylinder head from the camshaft side until
the exposed height is followingg dimensions.

TOOOLL: 077GGMMDD-- KT70110000
Valvoc guide driver, 33..88mm

VALVE GUIDE PROJECCTTIIOONN::
INN:: 115..55mm ((00..6611inn))
EX: 1133..11mm ((00..5522inn))

Let the cylinder head cool to room temperature.

Reaamm the new valve guides.

TOOOLL: 07JJMMHH-- KY22010000 VALVE GUtDE REAMER
Valve guide reamer

NOTE:

Take care not to tilt or lean the reamer innthe guide while
reaming. Otherwise, the valve is installed slanted, that
causes oil leakss from the stem seal and improper valve
seat contact and resulttss inn the valve seat refacinngg not
able to be performed.
Insert the reamer from the combustion chamber side
of the headd and always rotatee the reamer clockwise.
Usee cutting oil on the reamer during this operation.

Clean the cylinder head thoroughly to remove any metal
particleess after reaminngg and refacee the valve seat.

http://www.motorcycle.in.th 10-13

CYLINDER HEADD/NVALVESS

VALVE SEAT INSPECTIOONN

Cleann the intake and exhaust valves thoroughly to remove
the carbon deposits.

Apply light coating of Pruussssiiaann Bluee to the valve seats.
lLaappthe valves andd seatss usinngg a rubber hose or other hand
lappinngg tool..

Remoovveethe valve and inspect the width of each valve seat. VALVE SEAT
CONTACTT WIDTH
- -STANDAARRDD: 11.22- 1.6 mmmm (0..0055- 0.06 in)

SERVIICCEE LLIIMMIITT::11..99 mmmm (0.07 inn))
Valve seat width iss not within specification, refaacceethe valve
seat (paaggee 100--11551)..

CAAUUTTIIOONN:

Thhee vvallvvee ccannot be grroouunndd.. Htf a vvallvvee faccee ;is burned or
badly wwoorrnn or it ccoonntact thhe sseat uunnevvennllyy, replacce the

vvaallvvee..

DAMAGED FACCEE UNEVEN SEAT
WIDTHH

IIf the valve seat iss followinngg conditioonnss,, the seat must be TOO lLOOWW TOO HIGGHH
ground.

• Uneevveenn seat width:
-BeBnetnt or collappsseedd valve stem;
Reppllaaccee the valve and refaaccee the valve seat.

• Damageedd face:
-ReRpelapclaece the valve and refacee the valve seeaaft.

• CCoonnttaacctt aarreeaa (\ttoooo hhiigghh oorr ttoooo llooww aarreeaa))::

-- Reffaaccee the valvee seat.

I

10-1144 http://www.motorcycle.in.th

VALVE SEAT REFACINNGG CYLLIINNDDEERR HEAADDIVAALLVVEESS

Hondaa Valve Seaatt Cutteerrss,, a grinder or equivalent valve OLD SEAT WIDTH
seat refaacciinngg equipment aree recommmeennddeedd to correct a 32°
worn valve seaatt..
A
NNOOTTEE::
Followwthe refacceerr mannuuffaaccttuurree'’ssoperraattiinngg instructions.
BBee careeffuull not to go grindd the seat morree than necceess--
sary.

Usee a 45 degreeecutter to remove the roughnneessss or irregu-
larities fromm the seat.

NNOOTE:
Reeffaacceethe valvee seat with a 45 degree cutter when a valve
guide iss replaceedd..

TOOLLSS:: 07780-- 0010066o0O0
Seeaat cutter, 24 mmmrn (EEXX)) 07780- 0010220000
Seeaat cutter, 27.5 mrnmm (IN)) 07JJMHH-- KY2020000
Cutter holddeer,, 3.8 mrnmrn

Usiinngg 3322 degree cutter, remmoovvee 1/4 of the existing valve
seat material.

TOOLLSS:: 07780- 0012550000
Flaatt cutteer,, 24 mmmm (EXX) 07780- 0013330000
Flat cutter, 27 mmmm ((IINN)) 0O77JJMMHH-- KY2020000
Cutter holder, 3.8 mrnmrn

Usinngg 600 degree cutter, remoovvee the botttoomm 1/4 of the oill
seat.
Remmoovvee the cutter andd inspect the area youu have just ree--
moovveedd..

TOOLLSS:: 07780- 0014550000 I
Interior cutter, 26 mmmm (EXX) 077800-- 0O0O114O0O0O0
Interior cutteer,, 30 mrnmm (IN)) 07JJMHH-- KY2020000
Cutter holder, 3.8 mmmm

http://www.motorcycle.in.th 10-155

CYLINNDDEERR HEADIVVAALlVVEESS 1.2 -1.5 mm
(0.05 - 0.06 in)
Insttaalll a 45 degree seat cutter and cut the seat to proper
width.
Makee sure that all pitting and irregularities are removeedd..
Refinishh if necessary.

-STANDARDD SEAT WIDTH: 11.2 -- 11.66 rmnmm (0.05 - 00.066 in)

Apply thin coat of Prussiaann Blue to the valve seat. CONTAACCTT TOO HIGGHH OLD SEAT
Pressss the valve through the valve guide and onto the seat WIDTH
to make a clear pattern. ~.
I \_ _ _ _--..I 3322"0
NOTE: II
The locationn of the valve seat iinn relationn to the valvee face
iss very important for goodd sealing.

IIf the contact area iss too higghh onn the valve, the seat must
bee lowered usinngg a 3322 degree flat cutter.

If the contacctt area iss too low onn the valve, the seat must be
raiseedd usiinngg a 600 degreee inner cutterr..

Refinniisshh the seat to specifications, usinngg a 45 degree seat
cutter..

CONTAACCTT TOO LOW

OLD SEAT
WIDTH

CAAUUTTIOI ONN: 600
• Exxcceessssiivveellapppiinnggpprreessssuurreemmay ddeeffoorrmmoor ddaammaaggeetthhee G T 01

sseeaatt..
• CChhaannggeetthheeanngglleeof llapppiinngg ttoooollffrreqquuenttllyy toopprrevent

uunneevveenn sseeat wweeaarr..
• LLaappppiinngg ccoommppoouunndd ccaann ccaauussee ddaammaaggee if iit eenntteerrss bbee-

ttwweeeenn tthhee vvaallvveesstteemm and gouuiiddee..

After cuuttttiinngg the seaatt,, applyy laappppiinnggcompounndd too thee valve
faccee anndd laapp the vaallvvee ussiinngg lighhtt preessssuurree..
After laappppiinngg,, washh any reessiidduuaall commppoouunndd off the cylliinn--
der heaadd anndd valve.

Reecchheecckk thee seat coonnttaacctt after lappppiinngg..

1100--1166 http://www.motorcycle.in.th

CYLINNDDEERR HEAADD ASSEMBLY CYLINNDDEERR HEAADDINVALVES

RREETTAAIINNEERR VALVE LIFTER

\2) ~

SSHIMM ..0

SPRING SEAT

, ~JJ1 ~bINTAKE VALVE :!USTVALVE

Cleann the cylinder head assembly with solvent and blow SPRING SEAT
through all oil passaggeesswith compressed air. SPRl
Instaallll the valve spring seat and new valve stem seal.
Lubricate eachh valve stem with molybdenum oil. ) .\1SmlNG
Insert the intake and exhaust valve.into the valve guides.

To avoid damage to the seal, turn the valve slowly when
inserting..

@" -------.-COTTER STEM SEAL

Installll the valve springs with the blue painted side facing
up and the springs tightly wound coils should face toward
the combustion chamber.
Install the retainers.

CO . B.A.STION CHAMBER SIDe

http://www.motorcycle.in.th 10-17

CYLINDER HEADIVALVES

Compress the valve spring and install the valve cotters.

CAUTION:
Too prevenntt loss off tensioonn,, do not commpprress the vallvvee
spring more than necceessssaarryy..

TOOL: -0177577 - 001o0o0o0O0
Valve spring compressor
Attachment O077JMEE-- KY20100
Tapet hole protector
07JJMMGG-- KY20100

Tap the stems gently with two plastic hammer to firmly PLASTIC
seat the cotters. HAMMERS

CAUUTTIIOONN::
Supporrtt tthhe ccyyllinder hhead aboovvee thhe work bbench ssuurrffaaccee
to prevenntt vvaallvvee ddaammaaggee..

Apply coolannttto the new O-rriinnggand instaallll ittto the radiaattoorr
hosee joint.
Insttaallll the radiator hose joint to the cylinder heaadd andd
tighten the boltt..

CCoonnnneecctt the vacuuuumm tubeess..
Innssttaalll the carburetor insulator too the cylinder heeaadd by
alignniinngg the inssuullaattoorr groove with cylinder hheeaadd boossss anndd
tighteenn thee insulator bbaanndd sccrreeww..

100-1188 http://www.motorcycle.in.th

CYLINDERR HEADIVALVES

CYLINDER HEAD INSTALLATIOONN

Clean any gasket material from the cylinder mating sur-
faces..
NOTE:

Do not allow dust and dirt to enter the engine..

Make sure that the cam chain guide bosses are in the
grooves of the cylinder.
Installll the dowel pins and new gasket.

Routee the cam chain through the cylinder head and install
the cylinder head onto the cylinddeerr.
Apply oil to the threads and seating surface of the four
nuts and install them and washers.
TIighten the nuts to the specified torque inn the specified
sequenccee as shown.
TOORRQQUUEE: 30 NN·mm (3..11 kgf·.m, 22 Ibbff·Wtt)
Insttaallll and tighten the two bolts.

Inssttaalll the valve shims inn their originaall locations..
Coat the outer surfaces of the valve lifters with oil.
Inssttaalll the valve lifters inn their originnaall lifter bores, being
careeffuull not too damage the slidingg surfaces of the lifters
andd boreess..

CAMSHAFFTT INSTTAALLLLAATTIIOONN .-

Apply molybdenum oiill soluuttiioonn too thee cammsshhaafftt journals
anndd caamm lobes.

http://www.motorcycle.in.th 100--1199