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HEAD/CYLINDER
Head and Cylinder Table of Contents
Introduction
An improperly assembled engine or motorcycle may fail while being ridden, causing possible
injury or harm to the rider.
Do not service or assemble an engine unless the mechanic is
certain of his skills and uses proper assembly procedure
. If the mechanic is in doubt, find
assistance from a trained professional!
Engine assembly requires clean parts; dirt or loose gasket material may clog oil passages
and starve an engine of oil. Dirt inside an engine may destroy bearings and gears.
Gasket surfaces may not seal if damaged or if they have remaining old gasket material on
them.
Do not use sealant on gaskets, sealants are not required and may leave excess material
inside the engine that may clog oil passages.
Lubricate all parts with engine oil during assembly.
Replace the following with new parts upon assembly of the head and cylinder:
Cylinder base gasket
Head gasket
Valve stem seals
Head joint O-ring
Piston circlips
All other parts must pass inspection and be suitable for service. Replace any part that is
out of specification, worn or damage.
HEAD REMOVAL AND INSPECTION
CYLINDER AND PISTON REMOVAL AND INSPECTION
CYLINDER AND PISTON INSTALLATION
HEAD ASSEMBLY
HEAD INSTALLATION
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