Kawasaki KLE500 (2004) [141/401] Engine top end 5 29
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Kawasaki KLE500 (2004) [141/401] Engine top end 5 29

Kawasaki KLE500 (2004) [141/401] Engine top end 5 29
ENGINE TOP END 5-29
Valves
•
Measure the outside diameter (O.D.) of the seating sur-
face with a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○
Remove all pittings of flaws from 45° ground surface.
○
After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° grinding operation easier.
○
When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter of the seating surface is too large,
make the 32° grind described below.
If the outside diameter [A] of the seating surface is within
the specified range, measure the seat width as described
below.
•
Grind the seat at a 32° angle [ B] until the seat O.D. is
within the specified range.
○
To make the 32° grind, fit a 32° cutter to the holder, and
slide it into the valve guide.
○
Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
CAUTION
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
○
After making the 32° grind, return to the seat O.D. mea-
surement step above.
•
To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
O.D. measurement step above.
If the seat width is too wide, make the 60° [A] grind de-
scribed below.
If the seat width i s within the specified range, lap the valve
to the s eat as described below.
•
Grind the seat at a 60° angle until the seat width is within
the specified range.
○
To make the 60° grind, fit a 60° cutter to the holder, and
slide it into the valve guide.
○
Turn the holder, while pressing down lightly.
○
After making the 60° grind, return to the seat width mea-
surement step above.
Correct Width [B]

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