P250-250S cap 06 (CYLINDER HEADVALVES).pdf
P250-250S cap 06 (CYLINDER HEADVALVES).pdf
P250-250S cap 06 (CYLINDER HEADVALVES).pdf
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6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S 25<strong>06</strong> .________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________6<strong>CYLINDER</strong> HEAD/VALVES________________________________________________________________________________SCHEMATIC DRAWING------------------------------------------------------------------------- 6- 1SERVICE INFORMATION----------------------------------------------------------------------- 6- 2TROUBLESHOOTING --------------------------------------------------------------------------- 6- 3<strong>CYLINDER</strong> HEAD COVER REMOVAL ------------------------------------------------------ 6- 4CAMSHAFT REMOVAL-------------------------------------------------------------------------- 6- 4<strong>CYLINDER</strong> HEAD REMOVAL------------------------------------------------------------------ 6- 6<strong>CYLINDER</strong> HEAD DISASSEMBLY ----------------------------------------------------------- 6- 7<strong>CYLINDER</strong> HEAD ASSEMBLY ---------------------------------------------------------------- 6- 8<strong>CYLINDER</strong> HEAD INSTALLATION ----------------------------------------------------------- 6- 9CAMSHAFT INSTALLATION------------------------------------------------------------------- 6-10<strong>CYLINDER</strong> HEAD COVER INSTALLATION ----------------------------------------------- 6-116-0
6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S <strong>250S</strong>CHEMATIC DRAWING6-1
6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S <strong>250S</strong>ERVICE INFORMATIONGENERAL INSTRUCTIONS• The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiatorand water jacket must be drained first.• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movableparts and valve arm sliding surfaces for initial lubrication.• The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages.Clean and unclog the oil passages before assembling the cylinder head.• After disassembly, clean the removed parts and dry them with compressed air before inspection.• After removal, mark and arrange the removed parts in order. When assembling, install them inthe reverse order of removal.SPECIFICATIONS Standard (mm) Service Limit (mm)Item PEOPLE/PEOPLE S PEOPLE/PEOPLE SValve clearance (cold)IN 0.10 ⎯EX 0.10 ⎯Cylinder head compression pressure 15kg/cm² ⎯Cylinder head warpage ⎯ 0.05Camshaft cam heightValve rocker arm I.D.IN 34.2987 34.14EX 34.1721 34.02IN 10.00~10.015 10.10EX 10.00~10.015 10.10Valve rocker arm shaft IN 9.972~9.987 9.9O.D. EX 9.972~9.987 9.9Valve seat widthValve stem O.D.Valve guide I.D.IN 1.2 1.8EX 1.2 1.8IN 4.990~4.975 4.925EX 4.970~4.955 4.915IN 5.00~5.012 5.03EX 5.00~5.012 5.03Valve stem-to-guide IN 0.010~0.037 0.08clearance EX 0.030~0.057 0.10TORQUE VALUESCylinder head <strong>cap</strong> nut 24.5N-m Apply engine oil to threadsValve clearance adjusting nut 8.8N-m Apply engine oil to threadsCylinder head cover bolt 7.8~11.8N-mSPECIAL TOOLValve spring compressorE04<strong>06</strong>-2
6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S 250TROUBLESHOOTING• The poor cylinder head operation can be diagnosed by a compression test or by tracing enginetop-end noises.Poor performance at idle speed• Compression too lowCompression too low• Incorrect valve clearance adjustment• Burned or bend valves• Incorrect valve timing• Broken valve spring• Poor valve and seat contact• Leaking cylinder head gasket• Warped or cracked cylinder head• Poorly installed spark plugWhite smoke from exhaust muffler• Worn valve stem or valve guide• Damaged valve stem oil sealAbnormal noise• Incorrect valve clearance adjustment• Sticking valve or broken valve spring• Damaged or worn camshaft• Worn cam chain tensioner• Worn camshaft and rocker armCompression too high• Excessive carbon build-up in combustionchamber6-3
6. <strong>CYLINDER</strong> HEAD/VALVES<strong>CYLINDER</strong> HEAD COVER REMOVALRemove the met-in box, carrier. (2-6)Remove the body cover, center cover andrear fender A. (2-6)Disconnect the secondary air inlet tubeconnector and breather hose (air cleaner).(5-2)Remove the cylinder head cover four boltsand two nuts attaching the secondary air inletduct.Remove the cylinder head cover.Cylinder Head CoverBoltPEOPLE/PEOPLE S 250BoltsNutsCAMSHAFT REMOVALTurn the A.C. generator flywheel so that the“T” mark on the flywheel aligns with the indexmark on the right crankcase cover.Hold the round hole on the camshaft gearfacing up and the location is the top deadcenter on the compression stroke.Remove the cam chain tensioner <strong>cap</strong> bolt.Turn the cam chain tensioner screwclockwise to tighten it.Remove the two bolts attaching cam chaintensioner and the tensioner.Cam Chain TensionerTensioner ScrewRound HoleFirst remove the two bolts between thecylinder head and cylinder.Then, remove the four <strong>cap</strong> nuts and washerson the camshaft holder. • Diagonally loosen the cylinder head<strong>cap</strong> nuts in 2 or 3 times.BoltsCap NutsBoltsCamshaft Holder6-4
6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S 250Remove the camshaft holder.Camshaft HolderRemove the dowel pins.Remove the camshaft gear from the camchain to remove the camshaft.Cam ChainDowel PinsCAMSHAFT INSPECTIONCheck each cam lobe for wear or damage.Measure the cam lobe height.Service Limits:IN: 34.14mm replace if belowEX:34.02mm replace if belowCamshaft GearCheck each camshaft bearing for play ordamage. Replace the camshaft assemblywith a new one if the bearings are noisy orhave excessive play.Camshaft Bearings6-5
6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S 250CAMSHAFT HOLDER DISASSEMBLYRemove the valve rocker arms.Valve Rocker ArmsCAMSHAFT HOLDER INSPECTIONInspect the camshaft holder, valve rockerarms and rocker arm shafts for wear ordamage.If the valve rocker arm contact surface isworn, check each cam lobe for wear ordamage.Rocker Arm ShaftsCamshaft HolderRocker Arm ShaftsMeasure the I.D. of each valve rocker arm.Service Limits: IN: 10.10mm replace if overEX: 10.10mm replace if overMeasure each rocker arm shaft O.D.Service Limits: IN: 9.90mm replace if belowEX: 9.90mm replace if below<strong>CYLINDER</strong> HEAD REMOVALFirst drain the coolant from the radiator andwater jacket, then remove the thermostatwater hose.Remove the camshaft. (6-4)Remove the carburetor and intake manifold.Remove the bolt attaching the thermostathousing and the thermostat housing.Remove the cylinder head.BoltThermostat6-6
6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S 250Remove the dowel pins and cylinder headgasket.Remove the cam chain guide.Remove all gasket material from the cylinderhead mating surface.Be careful not to drop any gasketmaterial into the engine.CylinderDowel PinsCam Chain GuideCylinder Head Gasket<strong>CYLINDER</strong> HEAD DISASSEMBLYRemove the valve spring cotters, retainers,springs, spring seats and valve stem sealsusing a valve spring compressor.• Be sure to compress the valve springswith a valve spring compressor.• Mark all disassembled parts to ensurecorrect reassembly.Cylinder HeadSpecialValve spring compressorE040Valve Spring CompressorCombustion ChamberRemove carbon deposits from the exhaustport and combustion chamber. Be careful not to damage the cylinderhead mating surface.6-7
6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S 250INSPECTION<strong>CYLINDER</strong> HEADCheck the spark plug hole and valve areas forcracks.Check the cylinder head for warpage with astraight edge and feeler gauge.Service Limit: 0.05mm repair or replace ifoverStraight EdgeFeeler GaugeVALVE SPRING FREE LENGTHMeasure the free length of the inner and outervalve springs.Service Limits:Inner (IN, EX) : 29.5mm replace if belowOuter (IN, EX): 39.5mm replace if belowVALVE /VALVE GUIDEInspect each valve for bending, burning,scratches or abnormal stem wear.Check valve movement in the guide.Measure each valve stem O.D.Service Limits: IN: 4.925mm replace if belowEX: 4.915mm replace ifbelow<strong>CYLINDER</strong> HEAD ASSEMBLYInstall the valve spring seats and stem seals.Lubricate each valve stem with engine oil andinsert the valves into the valve guides.Be sure to install new valve stem seals.SpecialValve spring compressor E040Valve Spring Compressor6-8
6. <strong>CYLINDER</strong> HEAD/VALVESTap the valve stems gently with a plastichammer to firmly seat the cotters.PEOPLE/PEOPLE S 250Plastic Hammer Be careful not to damage the valves.<strong>CYLINDER</strong> HEAD INSTALLATIONInstall the cam chain guide.Install the dowel pins and a new cylinderhead gasket.CylinderCylinder HeadDowel PinsInstall the cylinder head and take out the camchainCam Chain GuideCylinder Head GasketCam ChainAssemble the camshaft holder.First install the intake and exhaust valverocker arms; then install the rocker arm shafts.6-9• Install the exhaust valve rocker armshaft on the “EX” side of the camshaftholder and the exhaust rocker armshaft is shorter.• Clean the intake valve rocker arm shaftoff any grease before installation.• Align the cutout on the exhaust valverocker arm shaft with the bolt of thecamshaft holder.Valve Rocker ArmsCamshaft Holder
6. <strong>CYLINDER</strong> HEAD/VALVESPEOPLE/PEOPLE S 250CAMSHAFT INSTALLATIONTurn the A.C. generator flywheel so that the“T” mark on the flywheel aligns with the indexmark on the right crankcase cover.Keep the round hole on the camshaft gearfacing up and align the punch marks on thecamshaft gear with the cylinder head surface(Position the intake and exhaust cam lobesdown.) and install the cam chain over thecamshaft gear.Install the dowel pins.Cam ChainPunch MarksCam ChainCamshaft GearCamshaft GearDowel PinsInstall the camshaft holder, washers and nutson the camshaft holder.Tighten the four cylinder head nuts and thetwo bolts between the cylinder head andcylinder.Torque: Cylinder head <strong>cap</strong> nut: 24.5N-mCylinder & cylinder head bolt: 7.8~11.8N-m• Apply engine oil to the threads of thecylinder head <strong>cap</strong> nuts.• Diagonally tighten the cylinder head<strong>cap</strong> nuts in 2~3 times.• First tighten the cylinder head <strong>cap</strong> nutsand then tighten the bolts between thecylinder and cylinder head to avoidcracks.BoltsCamshaftCap NutsCamshaft Holder6-10
6. <strong>CYLINDER</strong> HEAD/VALVESTurn the cam chain tension screw counterclockwise to release it.PEOPLE/PEOPLE S 250Tensioner ScrewBoltsApply engine oil to a new O-ring and install it.Tighten the cam chain tension <strong>cap</strong> screw.O-ring Be sure to install the gasket into thegroove properly.<strong>CYLINDER</strong> HEAD COVER INSTALLATIONAdjust the valve clearance. (3-6)Install a new cylinder head cover O-ring andinstall the cylinder head cover.Be sure to install the O-ring into thegroove properly.O-ringCylinder Head CoverInstall and tighten the cylinder head coverbolts and nuts.Torque: 7.8~11.8N-mBolts6-11Cylinder Head CoverNuts
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