3-19
3
2. Using a calipers, measure the valve stem diame-
ter that it is within specifications.
DSC02201
NOTE: If the valve stem diameter is not within
specifications, the valve must be replaced.
MEASURING ROCKER ARM TO
SHAFT CLEARANCE
1. Using a calipers, measure the inside diameter of
the rocker arm. Record this measurement.
2. Using a micrometer, measure the outside diame-
ter of the rocker arm shaft. Subtract this mea-
surement from the rocker arm inside diameter.
The rocker arm to shaft clearance must not
exceed specifications.
HONING CYLINDER
1. Using a slide gauge and dial indicator, measure
the cylinder bore at three locations from top to
bottom; then repeat the measurements 90° from
the first measurements for a total of six mea-
surements. The variation (out-of-roundness) is
the difference between the highest and lowest
reading. Maximum variation (out-of-round-
ness) must not exceed specifications.
CC397D
2. Wash the cylinder in parts-cleaning solvent;
then inspect the cylinder wall for pitting, scor-
ing, scuffing, glazing, or corrosion. If marks are
found, repair the surface using a ball hone.
NOTE: To produce the proper 60° cross-hatch
pattern, use a low RPM drill (600 RPM) at the rate
of 30 strokes per minute. If honing oil is not avail-
able, use a lightweight petroleum-based oil. Thor-
oughly clean the cylinder after honing using mild
soap and hot water. Dry with compressed air; then
immediately apply oil to the cylinder bore. If the
bore is severely damaged or scored, replace the
cylinder.
3. If any measurement exceeds the specified limit,
the cylinder must be replaced.
MEASURING VALVE SPRINGS
Using a calipers, measure the free length of the
valve springs. If any spring is not within specifica-
tions, it must be replaced.
MEASURING CAMSHAFT LOBE
HEIGHT
1. Using a calipers, measure each cam lobe height.
ATV1013A
2. The lobe heights must be equal and must not
exceed minimum specifications.
INSTALLING VALVES
1. Apply grease to the inside surface of the valve
seals; then place a lower spring seat and valve
guide seal over each valve guide.
2. Insert each valve into its original valve location.
3. Install the valve springs with the painted end of
the spring facing away from the cylinder head.
NOTE: If the painted end is not visible, install the
ends of the springs with the closest coils toward
the head.
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