As you lift, note the location of the dowel pins and O-ring see illustration. If you do not have the tools, or do not desire to perform the honing operation, a dealer service department or motorcycle repair shop will generally do it for a reasonable fee. Place a new cylinder base gasket on the crankcase see illustration. Work slowly and do not nick or gouge the soft aluminum of the head. A wood or plastic hammer handle can be used to gently tap the cylinder down, but don't use too much force or the piston will be damaged. Repeat the procedure for the other piston.
This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure. Check the end of the stem for pitting and excessive wear and make sure the bevel is the specified width. Repeat the procedure until a satisfactory seal is obtained. Be sure to rotate the head every few strokes to avoid removing material unevenly. Use solvent to clean the valve and Wipe the seat area thoroughly with a solvent soaked cloth.
The gauge should be the same thickness as the cylinder head warp limit listed in this Chapter's Specifications. Push down on the cylinder, making sure the piston doesn't get cocked sideways, until the bottom of the cylinder liner slides down past the piston rings. Use an appropriate size deep socket to push the seals into place until they are properly seated. Remember to keep the parts for each valve together so they can be reinstalled in the same location. Four of the shorter nuts go on the rear cylinder head; the longer nuts and the remaining four short nuts go on the front cylinder head. Never reuse the old head gasket and don't use any type oilgasketsealant.
Measure the free length see illustration and compare it to this Chapter's Specifications. Slip the sprocket onto the camshaft over the dowel. If it's necessary to turn the crankshaft, hold the timing chain up while you're turning so it doesn't fall off the crankshaft sprocket and become jammed. Compressed air will speed the drying process and ensure that all holes and recessed areas are clean. Any springs that are shorter than specified have sagged and should not be reused. Refer to Section 8 for those procedures.
You may have to deburr the area around the groove to enable the pin to slide out use a triangular file for this procedure. The presence of any of the above conditions indicates the need for valve servicing. Carefully release the valve spring compressor and remove the spring and the valve from the 10. If the stem runout exceeds the value listed in this Chapter's Specifications, replace the valve. Use compressed air, if available, to blow out all the holes and passages.
Every Clymer motorcycle service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the motorcycle covered. Front cylinder head Refer to illustrations 8. Lubricate the cylinder thoroughly, turn on the drill and move the hone up and down in the cylinder at a pace which will produce a fine Crosshatch pattern on the cylinder wall with the Crosshatch lines intersecting at approximately a 60-degreeangle see illustration. If a lapping tool is not available, a piece of rubber or plastic hose can be slipped over the valve stem after the valve has been installed in the guide and used to turn the valve. Fabricate a piston pin removal tool from threaded stock, nuts, washers and a piece of pipe see illustration. Tighten the bolts and nuts evenly in several stages, in a criss-crosspattern, to the torque listed in this Chapter's Specifications.
Every Clymer motorcycle service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer motorcycle repair manuals are the cheapest way to keep your motorcycle running properly. Remove the O- ring from the base of the cylinder see illustration. However, disassembly, cleaning and inspection of the valves and related components can be done if the necessary special tools are available by the home mechanic. Wipe the oil out of the cylinder and repeat the procedure on the remaining cylinder. Instead, shut off the drill and continue moving the hone up and down in the cylinder until it comes to a complete stop, then compress the stones and withdraw the hone.
Mount the hone in the drill motor, compress the stones and slip the hone into the cylinder. If not, scribe an arrow into the piston crown before removal. By subtracting the stem diameter from the valve guide diameter, the valve stem-to-guideclearance is obtained. Be sure to use plenty of lubricant and do not take off any more material than is absolutely necessary to produce the desired effect. Insert a finger in the tensioner hole and push against the chain damper.
Do not use a wire brush mounted in a drill motor, or one with extremely stiff bristles, as the head material is soft and may be eroded away or scratched by the wire brush. Store the components in such a way that they can be returned to their original locations without getting mixed up. If it is not within the specified range, or if it varies around its circumference, valve service work is required. Lift the valve off the seat and turn it at regular intervals to distribute the lapping compound properly. Removal Refer to illustrations 12.