8. CYLINDER HEAD/VALVES XCITING 500 8.
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8. CYLINDER HEAD/VALVES XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication. • The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages.
8. CYLINDER HEAD/VALVES XCITING 500 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.
8. CYLINDER HEAD/VALVES XCITING 500 CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug cap and remove the spark plug (page 3-7). Park Plug Cap Compression Gauge Install a compression gauge into the spark plug hole. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising. The maximum reading is usually reached 4 – 7 seconds.
8. CYLINDER HEAD/VALVES XCITING 500 Bolts CYLINDER HEAD COVER DISASSEMBLY Remove the floorboard (page 2-6). Remove the spark plug caps (page 8-4) Disconnect the crankcase breather hose from the cylinder head cover (page 7-3). Remove the four bolts and head cover. Cylinder Head Cover Remove the cylinder head cover packing. Remove the bolts and breather separator.
8. CYLINDER HEAD/VALVES XCITING 500 Gasket Remove the gasket. ASSEMBLY Assembly is in the reverse order of disassembly. Torque: Breather separator bolt: 13 N•m (1.3 kgf•m, 9 lbf•ft) Bolt Washer CAMSHAFT REMOVAL Remove the cylinder head cover (page 8-5). Turn the crankshaft clockwise and align the “T” mark on the flywheel with the index mark on the right crankcase cover (page 3-9). Remove the cam chain tensioner lifter sealing bolt, spring and sealing washer.
. CYLINDER HEAD/VALVES XCITING 500 Bolts Remove the two bolts and cam chain guide. Cam Chain Guide Loosen and remove the twelve camshaft holder bolts in a crisscross pattern in several steps, then remove the camshaft holders. Camshaft Holders ＊ Suspend the cam chain with a piece of wire to prevent the chain from falling into the crankcase.
8. CYLINDER HEAD/VALVES XCITING 500 INSPECTION Cam chain guide Inspect the am chain slipper surface of the cam chain guide for wear or damage. Spark Plug Cap Camshaft holder Inspect the bearing surface of each camshaft holder for scoring, scratches, or evidence of insufficient lubrication. Stop Pin Check the stop pin spring on the exhaust camshaft holder for damage. Replace the stop pin assembly with a new one if the spring is damage.
8. CYLINDER HEAD/VALVES Camshaft Support both ends of the camshaft with Vblocks and check the camshaft runout with a dial gauge. Service limit: 0.05 mm (0.002 in) Inspect camshaft lobes for pitting/scratches/blue discoloration. Measure the cam lobe height. Service Limits: IN : 37.11 mm (1.4844 in) EX: 36.86 mm (1.4744 in) If any defects are found, replace the camshaft with a new one, then inspect lubrication system. Check the decompression system by turning the decompressor cam on the exhaust camshaft.
8. CYLINDER HEAD/VALVES XCITING 500 Cam chain tensioner Check the one-way cam operation (tensioner) Unsmooth operation → Replace. Rocker Arms ROCKER ARMS REMOVAL Remove the camshaft (page 8-6) Remove the rocker arm shafts and washers, then remove the rocker arms. Rocker Arm Shafts/Washers Rocker Arm Shaft INSPECTION Rocker arm shaft Inspect the rocker arm shaft for blue discoloration or grooves. If any defects are found, replace the rocker arm shaft with a new one, then inspect lubrication system.
8. CYLINDER HEAD/VALVES XCITING 500 Rock Arm Inspect the rocker arm bore, cam lobe contact surface and adjuster surface for wear/pitting/scratches/blue discoloration. If any defects are found, replace the rocker arm shaft with a new one, then inspect lubrication system. Measure each rocker arm shaft O.D. Measure the I.D. of each rocker arm. Measure arm to shaft clearance. Replace as a set if out of specification. Service limits: 0.1 mm (0.
8. CYLINDER HEAD/VALVES Remove the two bolts, water joint, gasket and water stop collar. XCITING 500 Bolts Water Joint/Gasket/Water Stop Collar Remove the three bolts and cylinder head. Cylinder Head Bolts Remove the dowel pins and cylinder head gasket.
8. CYLINDER HEAD/VALVES DISSASEMBLY CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. XCITING 500 Valve Spring Compressor ＊ • Be sure to compress the valve springs with a valve spring compressor. • Mark all disassembled parts to ensure correct reassembly.
8. CYLINDER HEAD/VALVES XCITING 500 VALVE /VALVE GUIDE INSPECTION Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. Measure each valve stem O.D. Measure each valve guide I.D. Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stemto-guide clearance. Service limits: IN: 0.08 mm (0.0032 in) EX: 0.1 mm (0.
8. CYLINDER HEAD/VALVES XCITING 500 Measure compressed force (valve spring) and installed length. Replace if out of specification. Standard: Inner: 3.5 kg (at 28.7 mm, 1.148 in) Outer: 13 kg (at 31.43 mm, 1.2572 in) Measure the spring tilt. Replace if out of specification. Standard: Inner: 1.2 mm (0.048) Outer: 1.2 mm (0.048) ASSEMBLY Install the valve spring seats and oil seal. ＊ Be sure to install new oil seal. (2) Lubricate each valve with engine oil and insert the valves into the valve guides.
8. CYLINDER HEAD/VALVES XCITING 500 Tap the valve stems gently with a plastic hammer for 2～3 times to firmly seat the cotters. ＊ Be careful not to damage the valves. Dowel Pins CYLINDER HEAD INSTALLATION Install the dowel pins and new cylinder head gasket as shown. Gasket Cylinder Bolts Cylinder Head Install the cylinder head. Apply engine oil to the cylinder head bolt (9) threads. Install the two cylinder bolts and cylinder head bolt (9) but do not tighten them.
8. CYLINDER HEAD/VALVES Install the water stop collar, gasket and water joint. Install and tighten the two bolts to the specified torque. XCITING 500 Bolts Water Stop Collar Gasket Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft) Water Joint . Install gasket and pair reed valve. Install and tighten the four bolts securely. Pair Reed Valve Gasket Bolts O-ring Install the new O-rings onto the insulator and intake pipe.
8. CYLINDER HEAD/VALVES Install the insulator with the O-ring face the cylinder head. XCITING 500 Insulator O-ring Intake Pipe Install the intake pipe and tighten the two bolts securely. Bolts Rocker Arm Washer ROCKER ARM INSTALLATION Apply engine oil to the rocker arms and rocker arm shafts Install the rocker arms, rocker arm shafts and washers. Tighten the rocker arm shaft to the specified torque. Torque: 45 N•m (4.
8. CYLINDER HEAD/VALVES XCITING 500 CAMSHAFT INSTALLATION Turn the crankshaft clockwise, align the “T” mark on the flywheel with the index mark on the right crankcase cover (page 3-9). Apply molybdenum disulfide oil to the camshaft journals of the camshaft holder. Apply molybdenum disulfide oil to the camshaft journals of the cylinder head. Install the cam chain over the cam sprockets and then install the intake and exhaust camshafts. Punch Marks ＊ Install each camshafts to the correct locations.
8. CYLINDER HEAD/VALVES XCITING 500 Install intake and exhaust camshaft holders to the correct locations. ＊ Install each camshaft holders to the correct locations. “IN”: no stop pin. “EX”: has a stop pin. Apply engine oil to cylinder head bolt (No. 1 – 9) threads. Install and tighten the holder bolts (No. 1 – 9) in a crisscross pattern in four steps to the specified torque as follow diagram.
8. CYLINDER HEAD/VALVES XCITING 500 Install the common camshaft holder by arrow mark facing outside. Install and tighten the holder bolts (No. 10 – 13) in a crisscross pattern in four steps to the specified torque as follow diagram. ＊ Apply engine oil to cylinder head bolt (No. 10 – 13) threads. Tighten the bolts to the specified torque in sequence N•m (kgf•m, lbf•ft) (10) (11) (12) (13) Step 1 12 (1.2, 9) ← ← ← Step 2 23 (2.
8. CYLINDER HEAD/VALVES Install the cam chain guide and tighten the two bolts securely. XCITING 500 Bolts Cam Chain Guide Release the timing chain tensioner one-way cam and push the tensioner rod all the way in. Install the tensioner with a new gasket onto the cylinder. Install and tighten the tensioner bolts to specified torque. Cap Bolt Washer Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft) Install the spring, washer and timing chain tensioner cap bolt to specified torqur.
8. CYLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION XCITING 500 Cylinder Head Cover Packing Install the cylinder head packing into the groove of the cylinder head cover. Bolts Install the cylinder head cover onto the cylinder head and tighten the cylinder head cover bolts to the specified torque.
