Engine
4
‐
10
Inspect
Valve Sealing:
(look for leaks at the seat)
Pour a combustion chamber
cleaner into the intake track.
Check the intake side (1), there
should be no leakage at the valve
seat (2).
If leakage is found, the valves and the
valve seats need to be ground and lapped.
Measure valve stem to valve guide
clearance.
Limit
Intake 0.12mm
Exhaust 0.14mm
Measure the margin thickness.
Both Intake and Exhaust
0.85 – 1.15 mm
Measure valve stem runout
Runout Limit: 0.01 mm
Whenever a valve is removed, always
replace the valve guide seal.
If the valve needs to be replaced, replace
the valve guide as well.
Measure the valve spring free length and
squareness.
Valve spring free length:
Intake: 32.5mm Exhaust: 36.2mm
Valve spring squareness:
Intake: 0.10mm Exhaust: 0.10mm
Measure the compressed spring force
Intake: 100.0 - 115.7 N at 27.5 mm
Exhaust: 120.6 - 138.3 N at 31.0 mm
Summary of Contents for Challenger 500
Page 1: ...SERVICE MANUAL Challenger 500 Challenger 700...
Page 50: ...500 UV Engine Specifications 2 10...
Page 51: ...500 UV Engine Specifications 2 1 1...
Page 52: ...500 UV Engine Specifications 2 12...
Page 53: ...500 UV Engine Specifications 2 13...
Page 209: ...Electrical 6 11 Ignition System Circuit Diagram 1 High tension coil 2 C D I 3 Magneto...
Page 213: ...Electrical 6 15 Electric Starting System...
Page 216: ...Electrical 6 18 Charging System...
Page 218: ...Electrical 6 20 Lighting System...
Page 219: ...Electrical 6 21 Signaling System...
Page 220: ...Electrical 6 22 Cooling System...
Page 221: ...Electrical 6 23 2WD 4WD Selecting System...
Page 244: ...MTD Products Inc Product Training and Education Department FORM NUMBER 769 10856 05 2015...