Cylinder Head Removal

RADIATOR PIPES, CARBURETOR JOINT, AND OIL DELIVERY PIPE

1.  Remove:
• Radiator pipe 1
• Cover (Right) 2

2.  Drain the coolant (in the cylinder) by removing drain bolts 3  

3. Remove;
• Water pump joint 1
• Radiator pipes 2
• Carburetor joints
• Bypass hose 3

4.  Remove:
• Oil delivery pipe union bolts 1
• Copper washers
• Cylinder head side covers 2

5.  Loosen the cam chain tensioner end plug 3

6.  Remove the cam chain tensioner assembly 4

CYLINDER HEAD AND CYLINDER

1. Remove the cylinder head cover

NOTE:
Piston and cylinder can be removed, when necessary, without removing the camshaft.

The main steps are as follows.
 • Disconnect the cam chain using Cam Chain Cutter 1 (90890-01112).

• Remove the cylinder head nuts in the camshaft case using Hexagon Wrench 2 .
• Remove the cam shaft, cam shaft case and cylinder head as assembly.

2. Remove:
• Cam chain guide (Upper) 1
• Camshaft cap (I3) 2
• Camshaft cap (E3) 3
• Dowel pins

3.  Remove:
• Cam chain sprocket bolts 1 Use 2 2 mm (0.88 in) wrench to hold camshaft.
• Camshaft caps (I1, I2, I4, E1,E2, E4)
• Dowel pins
• Camshafts
• Cam chain guide (Front) 1

4.  Remove:
• Cylinder head nut
• Cylinder head

NOTE:
Follow the numerical order shown in photo, start by loosening each nut 1 /4 turn until all are loose.

5. Remove:
• Cylinder head gasket 1
• Dowel pins 2
• Cylinder
• Oil delivery pipes 3
• Cylinder base gasket
• Dowel pins