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CYLINDER HEAD/VALVES
AGILITY 125
7-0
7. CYLINDER HEAD/VALVES
AGILITY 125
CAMSHAFT INSTALLATION................7-9
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The cylinder head can be serviced with the engine installed in the frame.
When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable
parts, valve arm and camshaft sliding surfaces for initial lubrication.
The camshaft is 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 in
the reverse order of removal.
SPECIFICATIONS
Item
IN
Valve clearance (cold)
EX
Cylinder head compression pressure
Cylinder head warpage
IN
Camshaft cam height
EX
IN
Valve rocker arm I.D.
EX
Valve rocker arm shaft
IN
O.D.
EX
IN
Valve seat width
EX
IN
Valve stem O.D.
EX
IN
Valve guide I.D.
EX
Valve stem-to-guide
IN
clearance
EX
7-1
Standard (mm)
0.12
0.12
13kg/cm
29.803
29.5637
10.00010.015
10.00010.015
9.9729.987
9.9729.987
1.0
1.0
4.9754.990
4.9554.970
5.0005.012
5.0005.012
0.0100.037
0.0300.057
29.40
29.16
10.10
10.10
9.91
9.91
1.8
1.8
4.90
4.90
5.03
5.03
0.08
0.10
7. CYLINDER HEAD/VALVES
TORQUE VALUES
Cylinder head nut
Valve clearance adjusting nut
Stud bolt
2.0kg-m
0.9kg-m
0.9~1.1kg-m
AGILITY 125
SPECIAL TOOLS
Valve spring compressor
TROUBLESHOOTING
The poor cylinder head operation can be diagnosed by a compression test or by tracing engine
top-end noises.
Poor performance at idle speed
Compression too low
Compression 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 plug
7-2
7. CYLINDER HEAD/VALVES
AGILITY 125
Cylinder Head Cover
CAMSHAFT REMOVAL
Remove the center cover.
Remove the four cylinder head cover bolts
to remove the cylinder head cover.
Remove the two nuts attaching the
secondary air inlet tube.
O-ring
Screw
Tensioner Screw
Camshaft Gear
Round Hole
7-3
Punch Marks
7. CYLINDER HEAD/VALVES
AGILITY 125
Nut
Bolt
Washer
Camshaft Holder
Camshaft
Dowel Pins
Cam Chain
Camshaft Gear
CAMSHAFT INSPECTION
Check each cam lobe for wear or damage.
Measure the cam lobe height.
Service Limits:
IN : 29.40mm replace if below
EX: 29.16mm replace if below
7-4
7. CYLINDER HEAD/VALVES
AGILITY 125
Camshaft Bearings
Rocker Arm
Camshaft Holder
7-5
5mm Bolt
7. CYLINDER HEAD/VALVES
CYLINDER HEAD REMOVE
AGILITY 125
Intake Manifold
Cylinder Head
Bolts
Dowel Pins
7-6
7. CYLINDER HEAD/VALVES
CYLINDER HEAD DISASSEMBLY
Remove the valve spring cotters, retainers,
springs, spring seats and valve stem seals
using a valve spring compressor.
INSPECTION
CYLINDER HEAD
Check the spark plug hole and valve areas for
cracks.
Check the cylinder head for warpage with a
straight edge and feeler gauge.
Service Limit: 0.05mm repair or replace if
over
7-7
AGILITY 125
Valve Spring Compressor
7. CYLINDER HEAD/VALVES
AGILITY 125
7-8
7. CYLINDER HEAD/VALVES
AGILITY 125
Dowel Pins
Gasket
Stud Bolts
Cylinder Head
Camshaft Holder
7-9
7. CYLINDER HEAD/VALVES
CAMSHAFT INSTALLATION
AGILITY 125
Cam Chain
Camshaft Gear
Dowel Pins
Punch Marks
Camshaft Holder
Nut
Washer
Tensioner Screw
7-10
7. CYLINDER HEAD/VALVES
AGILITY 125
O-ring
7-11