Kawasaki WORKHORSE 250 (2003) [88/322] 24 engine top end
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Kawasaki WORKHORSE 250 (2003) [88/322] 24 engine top end

Kawasaki WORKHORSE 250 (2003) [88/322] 24 engine top end
4-24 ENGINE TOP END
Valves, Guides, Seats, Springs, Oil Seals
Valve Installation
•
If a new valve is to be used, check the valve-to-guide
clearance.
If there is too little clearance, ream the valve guide.
If there is too much clearance, install a new valve guide.
•
Check the valve seating.
•
After proper valve seating has been confirmed, replace
the valve stem oil seal [A].
•
Smear the valve stem end with a thin coat of molybdenum
disulfide engine assembly grease, and push the valve [B]
into the guide.
•
Put the spring seat [C] and the inner and outer springs [D]
in place.
○
Place the springs so that the closed coil end [E] of each
spring faces down.
•
Set the spring retainer [F] on the springs.
•
Use the valve spring compressor to press down the valve
spring retainer.
•
Install the split keepers [G], and slowly remove the spring
compressor. Be sure the keepers stay in place, holding
the retainer down.
•
Repeat the procedure for the other valve.
•
Install the removed parts to the cylinder head.
•
Install the cylinder head (see Cylinder Head Installation).
•
Adjust the valve clearance (see Valve Clearance Inspec-
tion).
Valve Visual Inspection
•
Inspect the valve head seating area [A] for erosion, nicks,
and warpage.
If the valve head seating area is warped, replace the
valve.
If the valve head seating area is eroded or nicked, it may
be possible to repair the valve on a valve refacing ma-
chine.
•
Inspect the stem [B] for obvious wear, discoloration, and
stem end [C] damage.
If the stem is obviously worn or discolored, replace the
valve.
If the stem end is damaged, it may be possible to repair
it on a v alve refacing machine.
Valve Guide Removal
•
Remove:
Valve(seeValveRemoval)
Valve Stem Oil Seal
•
Hammer lightly on the valve guide arbor [A] to remove the
guide from the top of the head.
Special Tool - Valve Guide Arbor, φ5.5 : 57001-1021

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