Engine top side disassembly

It is unnecessary to remove the engine assembly from the frame when servicing the cylinder head cover and camshafts.

Note before servicing the engine top side components (until camshafts removal) with the engine in place, remove the following parts:

• air cleaner box
• throttle body

Other parts except for these “engine top side components” can not be serviced with the engine installed in the frame. Refer to “engine assembly removal” and “engine assembly installation” .

Caution identify the position of each removed part.

Organize the parts in their respective groups (e.G., Intake, exhaust) so that they can be reinstalled in their original positions.

Cylinder head cover

1. 1
   Remove the spark plugs. Refer to “ignition coil and spark plug removal and installation” in section 1h .
2. 2
   Remove the cylinder head cover (1) and its gasket.

   

3. Remove the dowel pins and o-rings.

Camshafts

1. Remove the valve timing inspection cap (1).

2. Turn the crankshaft to bring the line “a” on the ckp sensor rotor to the slit “b” of cap hole thread and also to bring the camshafts to the position as shown.

3. Remove the cam chain tension adjuster (2).

4. Remove the gasket (3).

1. 1
   Remove the cam chain guide no. 2 (4).
2. 2
   Remove the camshaft journal holders (5).

Caution

be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench in the descending order of numbers.

1. 1
   Remove the dowel pins.
2. 2
   Remove the intake camshaft (6) and exhaust camshaft (7).

   

Cylinder head Note

the cylinder head can not be serviced with the engine installed in the frame.

1. Disconnect the water bypass hose (1).

2. Remove the cylinder head bolts (m6) (2).

3. Remove the cylinder head bolts (m10) and washers.

Note

when loosening the cylinder head bolts, loosen each bolt little by little diagonally.

4. Remove the cylinder head.

5. Remove the dowel pins and cylinder head gasket (3).