DR ALL-TERRAIN Service Manual download pdf (Page 212)

100

101

5-30 ENGINE TOP END

Cylinder Head

•

Apply molybdenum disulfide oil to the threads and seating

surface of the cylinder head bolts and both sides of the

washers.

•

Tighten the cylinder head bolts [A] following the tightening

sequence as shown.

First Torque - Cylinder Head Bolts (M10): 25 N·m (2.5

kgf·m, 18 ft·lb)

Final Torque - Cylinder Head Bolts (M10): 49 N·m (5.0

kgf·m, 36 ft·lb)

•

Tighten the cylinder head bolts (M6) [B].

Torque - Cylinder Head Bolts (M6): 9.8 N·m (1.0 kgf·m, 87

in·lb)

Cylinder Head Cleaning

•

Remove the cylinder head (see Cylinder Head Removal).

•

Scrape the carbon out of the combustion chamber and

exhaust port with a suitable tool.

•

Wash the head with a high-flash point solvent.

•

Blow out any particles which may obstruct the oil passage

in the cylinder head using compressed air.

Cylinder Head Warp Inspection

•

Clean the cylinder head (see Cylinder Head Cleaning).

•

Lay a straightedge across the lower surface of the cylinder

head.

•

Use a thickness gauge [A] to measure the space between

the straightedge [B] and the head at several locations.

Cylinder Head Warp

Service Li mit: 0.0 5 mm (0.002 in.)

If the cylinder head is warped more than the service limit,

replace it.

If the cylinder head is warped less than the service limit,

repair the head by lapping the lower surface with emery

paper secured to a surface plate (first N o. 200, then No.

400).

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DR ALL-TERRAIN Service Manual Page 212

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