Thermostat

Thermostat Removal

_• Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).

_• Remove:

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

Thermostat Hosing Bolts [A] Thermostat Hosing [B]

_• Pull the thermostat [A] out of the cylinder head.

Thermostat Installation

_• Install the thermostat [A] in the cylinder head so that the air bleeder hole [B] is on top.

_• Install a new O-ring into the housing and apply grease it.

_• Tighten:

Torque - Thermostat Hosing Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

_• Fill the radiator with coolant (see Coolant Change in the

Periodic Maintenance chapter).

Thermostat Inspection

_• Remove the thermostat, and inspect the thermostat valve [A] at room temperature.

If the valve is open, replace the thermostat with a new one.

Thermostat

_• To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera-

ture of the water.

○^{The thermostat must be completely submerged and must}

not touch the container sides or bottom. Suspend an ac-

curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth. It must not touch the container, either.

If the measurement is out of the specified range, replace the thermostat with a new one.

Thermostat Valve Opening Temperature 80.5  83.5°C (177  182°F)

Hose and Pipes

Hose Installation

_• Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or

twisting.

_• Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter).

_• Install the clamp [A] as near as possible to the hose end

to clear the raised rib of the fitting. This will prevent the

hoses from working loose.

○^{The clamp screws should be positioned correctly to pre-}

vent the clamps from contacting the other parts.

Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m, 17 in·lb)

Hose Inspection

_• Refer to the Radiator Hose Damage and Installation Con- dition Inspection in the Periodic Maintenance chapter.

Water Temperature Sensor

Water Temperature Sensor Removal/Installation

_• Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.

Water Temperature Sensor [A]

Water Temperature Sensor Inspection

_• Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.

Engine Top End Table of Contents

Exploded View........................................................................................................................ 5-3

Exhaust System...................................................................................................................... 5-8

Specifications ......................................................................................................................... 5-10

Special Tools and Sealant ...................................................................................................... 5-12

Clean Air System.................................................................................................................... 5-14

Air Suction Valve Removal................................................................................................ 5-14

Air Suction Valve Installation............................................................................................. 5-14

Air Suction Valve Inspection ............................................................................................. 5-14 ₅

Air Switching Valve Removal ............................................................................................ 5-14

Air Switching Valve Installation ......................................................................................... 5-14

Air Switching Valve Operation Test ................................................................................... 5-15

Air Switching Valve Unit Test ............................................................................................ 5-15

Clean Air System Hose Inspection ................................................................................... 5-15

Cylinder Head Cover .............................................................................................................. 5-16

Cylinder Head Cover Removal ......................................................................................... 5-16

Cylinder Head Cover Installation ...................................................................................... 5-16

Camshaft Chain Tensioner ..................................................................................................... 5-18

Camshaft Chain Tensioner Removal ................................................................................ 5-18

Camshaft Chain Tensioner Installation ............................................................................. 5-18

Camshaft, Camshaft Chain .................................................................................................... 5-19

Camshaft Removal ........................................................................................................... 5-19

Camshaft Installation ........................................................................................................ 5-19

Camshaft and Sprocket Assembly.................................................................................... 5-22

Camshaft, Camshaft Cap Wear ........................................................................................ 5-22

Camshaft Runout .............................................................................................................. 5-23

Cam Wear......................................................................................................................... 5-23

Camshaft Chain Removal ................................................................................................. 5-23

Cylinder Head......................................................................................................................... 5-24

Cylinder Compression Measurement................................................................................ 5-24

Cylinder Head Removal .................................................................................................... 5-25

Cylinder Head Installation ................................................................................................. 5-26

Cylinder Head Warp.......................................................................................................... 5-28

Valves ..................................................................................................................................... 5-29

Valve Clearance Inspection .............................................................................................. 5-29

Valve Clearance Adjustment............................................................................................. 5-29

Valve Removal .................................................................................................................. 5-29

Valve Installation ............................................................................................................... 5-29

Valve Guide Removal ....................................................................................................... 5-29

Valve Guide Installation .................................................................................................... 5-30

Valve-to-Guide Clearance Measurement (Wobble Method) ............................................. 5-30

Valve Seat Inspection ....................................................................................................... 5-31

Valve Seat Repair ............................................................................................................. 5-31

Cylinder, Pistons..................................................................................................................... 5-36

Cylinder Removal.............................................................................................................. 5-36

Cylinder Installation........................................................................................................... 5-36

Piston Removal................................................................................................................. 5-36

Piston Installation.............................................................................................................. 5-37

Cylinder Wear ................................................................................................................... 5-38

Piston Wear ...................................................................................................................... 5-38

Piston Ring, Piston Ring Groove Wear............................................................................. 5-39

Piston Ring Groove Width................................................................................................. 5-39

Piston Ring Thickness ...................................................................................................... 5-39

Piston Ring End Gap ........................................................................................................ 5-40

Throttle Body Holder............................................................................................................... 5-41

Throttle Body Holder Installation....................................................................................... 5-41 Muffler..................................................................................................................................... 5-42

Muffler Body Removal....................................................................................................... 5-42

Exhaust Pipe Removal...................................................................................................... 5-42 Muffler Body and Exhaust Pipe Installation ...................................................................... 5-43

Dummy Page

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Air Suction Valve Cover Bolts	9.8	1.0	87 in·lb
2	Cylinder Head Cover Bolts	9.8	1.0	87 in·lb
3	Camshaft Cap Bolts	12	1.2	106 in·lb	S
4	Cylinder Head Bolts (M10 New Bolts)	54	5.5	40	MO, S
	Cylinder Head Bolts (M10 Used Bolts)	49	5.0	36	MO, S
5	Cylinder Head Bolts (M6)	12	1.2	106 in·lb	S
6	Throttle Body Holder Bolts	12	1.2	106 in·lb
7	Rear Camshaft Chain Guide Bolts	20	2.0	15	L
8	Camshaft Chain Tensioner Mounting Bolts	9.8	1.0	87 in·lb
9	Camshaft Chain Tensioner Cap Bolt	20	2.0	15
10	Spark Plugs	15	1.5	11
11	Camshaft Sprocket Bolts	15	1.5	11	L
12	Baffle Plate Bolts	5.9	0.60	52 in·lb

L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts

S: Follow the specified tightening sequence. SS: Apply silicone sealant.

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Cylinder Bolt (M8)	27.5	2.8	20	MO,S
2	Cylinder Nut (M10)	49	5.0	36	MO,S
3	Cylinder Bolts (M6)	12	1.2	106 in·lb	S
4	Exhaust Pipe Manifold Holder Nuts	17	1.7	12
5	Muffler Body Mounting Bolt (Front)	20	2.0	15
6	Muffler Body Mounting Bolt (Rear)	20	2.0	15

7. "R" marked side faces up.

8. "RN" marked side faces up.

9. Hollow mark faces forward.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts

S: Follow the specified tightening sequence.