Service Information - Honda 2005 FOURTRAX FOREMAN TRX500 TM Service Manual

CYLINDER HEAD/VALVE
SERVICE INFORMATION
GENERAL
• This section covers service of the rocker arms, cylinder head, valves and camshaft. These services can be done with the
engine installed in the frame.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original
locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
• Rocker arm and valve lubricating oil is fed through oil passages in the cylinder head and head cover. Clean the oil pas-
sages before assembling cylinder head.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike
the cylinder head too hard during removal.
SPECIFICATIONS
Unit: mm (in)
ITEM
Cylinder compression at 380 rpm (min"
1
)
Valve clearance
Valve, valve
guide
Valve spring
Rocker arm
Camshaft
and cam
follower
Valve stem O.D.
Valve guide I.D.
Stem-to-guide clearance
Valve seat width
Free length
Arm I.D.
Shaft O.D.
Arm-to-shaft clearance
Cam lobe height
Cam follower O.D.
Follower bore I.D.
Follower-to-bore clearance
IN/EX
IN
EX
IN/EX
IN
EX
IN/EX
Inner
Outer
IN/EX
IN/EX
IN/EX
IN
EX
IN/EX
IN/EX
IN/EX
Cylinder head warpage
STANDARD
440 kPa (4.5 kgf/cm
3
, 64 psi)
0.15(0.006)
5.975 - 5.990 (0.2352 - 0.2358)
5.955 - 5.970 (0.2344 - 0.2350)
6.000 - 6.012 (0.2362 - 0.2366)
0.010-0.037(0.0004-0.0015)
0.030 - 0.057 (0.0012 - 0.0022)
1.2(0.05)
42.94(1.691)
43.63(1.718)
12.000 - 12.018 (0.4724 - 0.4731)
11.964 - 11.984 (0.4710 - 0.4718)
0.016 - 0.054 (0.0006 - 0.0021)
35.8315-35.9915(1.41069-1.41699)
35.5512-35.7112(1.39965-1.40595)
22.467 - 22.482 (0.8845 - 0.8851)
22.510 - 22.526 (0.8862 - 0.8868)
0.028 - 0.059 (0.0011 - 0.0023)
-
SERVICE LIMIT
-
-
5.95 (0.234)
5.93 (0.233)
6.02 (0.237)
0.12(0.005)
0.14(0.006)
1.5(0.06)
42.08 (1.657)
42.76 (1.683)
12.05(0.474)
11.92(0.469)
0.08 (0.003)
35.60 (1.402)
35.38(1.393)
22.46 (0.884)
22.54 (0.887)
0.07 (0.003)
0.10(0.004)
TORQUE VALUES
Cylinder head cap nut
Spark plug
Upper engine hanger nut (frame side)
Upper engine hanger bolt (engine side)
Cam sprocket bolt
Cam chain tensioner pivot bolt
39 N-m (4.0 kgf-m, 29 Ibfft) Apply engine oil to the threads and seating surface.
22 N-m (2.2 kgf-m, 16 Ibf-ft)
54 N-m (5.5 kgf-m, 40 Ibf-ft)
32 N-m (3.3 kgf-m, 24 Ibf-ft)
20 N-m (2.0 kgf-m, 15 Ibf-ft) Apply locking agent to the threads.
12 N-m (1.2 kgf-m, 9 Ibf-ft) Apply locking agent to the threads.
8-4