Removing The Cylinder Head; Checking The Cylinder Head; Installing The Cylinder Head - Yamaha 2007 XP500 Service Manual

EAS15B420a

REMOVING THE CYLINDER HEAD

1. Remove:
Cylinder head bolts
G
Cylinder head nuts
G
NOTE:
Loosen the nuts and bolts in the proper se-
G
quence as shown.
Loosen each nut 1/2 of a turn at a time. After
G
all of the nuts are fully loosened, remove them.
EAS24160

CHECKING THE CYLINDER HEAD

1. Eliminate:
Combustion chamber carbon deposits
G
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
Spark plug bore threads
G
Valve seats
G
2. Check:
Cylinder head
G
Damage/scratches → Replace.
Cylinder head water jacket
G
Mineral deposits/rust → Eliminate.
3. Measure:
Cylinder head warpage
G
Out of specification → Resurface the cylinder
head.
Warpage limit
0.03 mm (0.0012 in)
MMMMMMMMMMMMMMMMMMMMMM
a. Place a straightedge "1" and a thickness
gauge "2" across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
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EAS15B422a

INSTALLING THE CYLINDER HEAD

1. Install:
Dowel pins
G
Cylinder head gasket
G
2. Install:
Cylinder head
G
NOTE:
Pass the timing chain through the timing chain
cavity.
3. Tighten:
Cylinder head nuts "1"
G
Cylinder head nut
35 Nm (3.5 m•kg, 25 ft•lb)
5-15
CYLINDER HEAD
New