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EBS30439
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
ECB01851
NOTICE
Do not use a sharp instrument; otherwise,
the following may be damaged or scratched:
• Spark plug bore threads
• Valve seats
2. Check:
• Cylinder head
Damage/scratches → Replace.
• Cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
Warpage limit
0.03 mm (0.0012 in)
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a. Place a straightedge "1" and a thickness
gauge "2" across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
CYLINDER HEAD, CYLINDER, AND PISTON
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1
2
TIP
To ensure an even surface, rotate the cylinder
head several times.
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EBS30147
CHECKING THE CYLINDER AND PISTON
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches → Replace the cylinder,
and replace the piston and piston rings as a
set.
2. Measure:
• Piston-to-cylinder clearance
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a. Measure the cylinder bore "C" with the cylin-
der bore gauge.
TIP
Measure the cylinder bore "C" by taking side-to-
side and front-to-back measurements of the cyl-
inder.
"C" = maximum of D
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Taper (front-to-back) = maximum difference be-
tween D
, D
1
Taper (side-to-side) = maximum difference be-
tween D
, D
2
Out of round (top) = difference between D
Out of round (middle) = difference between D
D
4
Out of round (bottom) = difference between D
D
6
5-23
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Bore
103.000–103.020 mm (4.0551–
4.0559 in)
Wear limit
103.080 mm (4.0583 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
, D
, D
, D
, D
1
2
3
4
, D
3
5
, D
4
6
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, D
5
6
, D
1
2
,
3
,
5
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