Bad Boy 1500 - Valve Stem Replacement

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SERVICE MANUAL
Cylinder / Head Valve
Cylinder Head Inspection:
CAUTION
• Before measuring the valve guide, clean carbon
deposits with reamer.
• Tool: 5.0 mm valve guide reamer
• Measure and record each valve guide inner
diameters.
Service limit: 5.03 mm
Valve Stem Replacement:
• Heat cylinder head to 100-150° Celsius
(212° - 302° Fahrenheit) with heated plate or oven.
CAUTION
• Do not apply torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed.
Wear gloves to protect your hands when heating.
Valve guide driver
5.0mm
• Hold the cylinder head, and then press out
old valve guide from combustion chamber side.
Tool: Valve guide driver: 5.0 mm
CAUTION
• Check for deformation after valve guide is
pressed in.
• When pressing in the new valve guide, cylinder
head must be kept 100-150°C
(212° - 302° Fahrenheit).
• Valve guide
height should
be 13 mm.
• Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
• Wait for the cylinder head cooling down to room
temperature, and then correct the new valve guide
with reamer.