3-23
3
Measuring Rocker Arm
(Inside Diameter)
1. Using a dial calipers, measure the inside diame-
ter of the rocker arm.
2. Acceptable inside diameter range must be
within specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diame-
ter of the rocker arm shaft.
2. Acceptable outside diameter range must be
within specifications.
Installing Valves
1. Apply grease to the inside surface of the valve
seals; then place a lower spring seat and valve
guide seal over each valve guide.
CC144D
2. Insert each valve into its original location.
3. Install the valve springs with the painted end of
the spring facing away from the cylinder head.
NOTE: If the paint is not visible, install the ends
of the springs with the closest wound coils toward
the head.
ATV-1011A
4. Place a spring retainer over the valve springs;
then using the valve spring compressor, com-
press the valve springs and install the valve cot-
ters.
CC132D
PISTON ASSEMBLY
NOTE: Whenever a piston, rings, or pin are out
of tolerance, they must be replaced.
Cleaning/Inspecting Piston
1. Using a non-metallic carbon removal tool,
remove any carbon buildup from the dome of
the piston.
2. Inspect the piston for cracks in the piston pin,
dome, and skirt areas.
3. Inspect the piston for seizure marks or scuffing.
Repair with #400 grit wet-or-dry sandpaper and
water or honing oil.
NOTE: If scuffing or seizure marks are too deep
to correct with the sandpaper, replace the piston.
4. Inspect the perimeter of each piston for signs of
excessive “blowby.” Excessive “blowby” indi-
cates worn piston rings or an out-of-round cylin-
der.
Removing Piston Rings
1. Starting with the top ring, slide one end of the
ring out of the ring-groove.
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