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Feb./15/ 07

Check every valve for bending, baking, and damage.

Measure the external diameter of the valve stem at the point, where it slides

against the guide, with a micrometer.

Replace the bent, scratched or damaged valve stem.


Service limit: for IN: 4.92 mm, for EX: 4.90 mm

  

Replace the bent, scratched or damaged valve stem with a new one.

Inspection of Valve Spring Retainer

Replace it with a new one if its damaged.

Inspection of Valve Seat:

Remove carbon sediment in the cylinder head combustion chamber and 

valve.

Dissolve red lead primer with oil or the like, and apply it to the valve faces 

evenly.

      

Strike the valves once and lightly with a valve punner to rotate them.

Wipe off the red lead primer on the valve faces, and strike the valves once

and lightly with the valve punner without rotating them, and inspect the 

contact surfaces.

If there is a scratch on the valve seat, modify the seat.

If the contact width is wide, narrow, in a high or low position, modify the 

seat.

  

Ask a specialist shop in internal combustion for the modification work.

Inspection of Rocker Arm:

      

Check the rocker arms for scratches, damages and jamming.

Measure the internal diameter of the rocker arms.

      

If the internal diameter is more than 10.05, replace the rocker arm.

Scratch on

the seat

Slanted valve

Contacting at

a low place

Contacting at

a high place

Check this portion

for wearout

Summary of Contents for Super head STAGE-1 kit

Page 1: ...which may cause technical troubles Install an oil cooler when necessary Engine oil must be API SF or higher class such as SAE 10W 40 15W 50 which are our recommendations Change the sprocket with the...

Page 2: ...mproper installation because of insufficient skill and knowledge could lead to parts breakage and subsequently to accidents Before doing work make sure your bike is secure on level ground for safety s...

Page 3: ...3 2 01 12 0105 SET No Part Name Qty Repair Part Item No Qty 1 Cylinder head assembly 1 SP H 149 T101 1 2 Exhaust pipe gasket 1 00 01 0027 2 Alumi Special 5 g 1 00 01 0001 1 Kit Contents Please order r...

Page 4: ...he camshaft and install the camshaft to the cylinder head with the cam shaft s cam top facing downwards Securely tighten the temporarily tightened cylinder head mounting bolt Specified torque 12 N m 1...

Page 5: ...ng the bolt hole on the camshaft with the cam sprocket tighten two hex bolts loosely At this point fix a knock bolt black bolt on the intake side In case of installing to an Ape or XR50 Motard based m...

Page 6: ...Item Stock Service Limit Remarks Valve clearance IN 0 08 0 03mm When cold Valve clearance EX 0 08 0 03mm When cold Distortion of cylinder head 0 05mm Replace Internal diameter of valve rocker arm 10 0...

Page 7: ...he valve faces evenly Strike the valves once and lightly with a valve punner to rotate them Wipe off the red lead primer on the valve faces and strike the valves once and lightly with the valve punner...

Page 8: ...tches cracks and damages Measure the height of cam tops Check here for scratches cracks and damages When the outer free length of valve spring is below 33 change it When the inner free length of valve...

Page 9: ...racing Crankcases need processing If you have purchased a cylinder head only Item No 01 03 0741 please study to purchase parts for bore up referring to this reference data In the case of using a stoc...

Page 10: ...1 please study to purchase bore and stroke up parts referring to this reference data Select a cam Super Head kit Select a cylinder 57 cylinder kit 57 plated cylinder kit for racing Crankcases need pro...

Page 11: ...alone Item No 01 03 0741 please select a cylinder and crank shaft kits referring to this reference data In case this kit is to be installed on Ape and XR50 Motard the above mentioned parts are needed...

Page 12: ...der Kit 59 4 SCUT Cylinder Kit 62 If you have purchased a cylinder head only of Item No 01 03 0741 please study to purchase parts for bore up referring to this reference list exclusivsely for a stock...

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