5-6 ENGINE TOP END

Exhaust System Identification

Exhaust Pipe Mark Position [A]

Premuffler Chamber Mark Position [A]

ENGINE TOP END 5-7

Exhaust System Identification

Muffler Body Mark Position [A]

Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C]

Honeycomb Type Catalyst Positions [A]

5-8 ENGINE TOP END

Specifications

Item				Standard					Service Limit
Camshafts
Cam Height:
Exhaust	33.143			33.257 mm (1.3048				1.3093 in.)	33.04 mm (1.301 in.)
Inlet	34.543			34.657 mm (1.3600				1.3644 in.)	34.44 mm (1.356 in.)
Camshaft Journal/Camshaft	0.038			0.081 mm (0.0015			0.0032 in.)		0.17 mm (0.0067 in.)
Cap Clearance
Camshaft Journal Diameter	23.940			23.962 mm (0.9425				0.9434 in.)	23.91 mm (0.941 in.)
Camshaft Bearing Inside				24.021 mm (0.9449				0.9457 in.)	24.08 mm (0.948 in.)
	24.000
Diameter
Camshaft Runout	TIR 0.02 mm (0.0008 in.) or less								TIR 0.1 mm (0.004 in.)
Cylinder Head
Cylinder Compression	(Usable Range)
	980	1 498 kPa (10.0 15.3 kgf/cm²,							– – –
	142	217 psi) at 240 r/min (rpm)
Cylinder Head Warp	– – –								0.05 mm (0.002 in.)
Valves
Valve Clearance:
Exhaust	0.24		0.31 mm (0.0094			0.0122 in.)			– – –
Inlet	0.13		0.19 mm (0.0051			0.0075 in.)			– – –
Valve Head Thickness:
Exhaust	1.0 mm (0.039 in.)								0.5 mm (0.020 in.)
Inlet	0.5 mm (0.020 in.)								0.3 mm (0.012 in.)
Valve Stem Bend	TIR 0.01 mm (0.0004 in.) or less								TIR 0.05 mm (0.002 in.)
Valve Stem Diameter:
Exhaust	3.955			3.970 mm (0.1557			0.1563 in.)		3.94 mm (0.155 in.)
Inlet	3.975			3.990 mm (0.1565			0.1571 in.)		3.96 mm (0.156 in.)
Valve Guide Inside Diameter:
Exhaust	4.000			4.012 mm (0.1575			0.1580 in.)		4.08 mm (0.161 in.)
Inlet	4.000			4.012 mm (0.1575			0.1580 in.)		4.08 mm (0.161 in.)
Valve/Valve Guide
Clearance (Wobble Method):
	0.08		0.16 mm (0.0031
Exhaust						0.0063 in.)			0.40 mm (0.016 in.)
Inlet	0.03		0.10 mm (0.0012			0.0039 in.)			0.34 mm (0.013 in.)
Valve Seat Cutting Angle	32°, 45°, 60°								– – –
Valve Seating Surface:
Width:
Exhaust	0.8	1.2 mm (0.031			0.047 in.)				– – –
Inlet	0.5	1.0 mm (0.020			0.039 in.)				– – –
Outside Diameter:
Exhaust	22.8		23.0 mm (0.898			0.906 in.)			– – –
Inlet	26.93			27.13 mm (1.060			1.068 in.)		– – –
Valve Spring Free Length:
Exhaust	40.81 mm (1.607 in.)								39.5 mm (1.555 in.)
Inlet	38.46 mm (1.514 in.)								37.1 mm (1.461 in.)

ENGINE TOP END 5-9

Special Tools and Sealant

Compression Gauge, 20 kgf/cm²: 57001-221

Valve Seat Cutter Holder Bar: 57001-1128

Valve Spring Compressor Assembly: 57001-241

Valve Spring Compressor Adapter, 20: 57001-1154

Valve Seat Cutter, 45° - 24.5: 57001-1113

Valve Seat Cutter, 45° - 30: 57001-1187

Valve Seat Cutter, 32° - 25: 57001-1118

Valve Guide Arbor, 4: 57001-1273

Valve Seat Cutter, 32° - 30: 57001-1120

Valve Guide Reamer, 4: 57001-1274

5-10 ENGINE TOP END

Special Tools and Sealant

Valve Seat Cutter Holder,		4:		Compression Gauge Adapter, M10 × 1.0:
57001-1275			57001-1601

Valve Seat Cutter, 60° - 25: 57001-1328

L-Shape Hose: 57001-1606

Valve Seat Cutter, 60° - 27: 57001-1409

Attachment C: 57001-1624

Valve Guide Driver:		Kawasaki Bond (Silicone Sealant):
57001-1564	92104-0004