6.

CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250

6.
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CYLINDER HEAD/VALVES
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SCHEMATIC DRAWING------------------------------------------------------------------------- 6- 1

SERVICE INFORMATION----------------------------------------------------------------------- 6- 2

TROUBLESHOOTING --------------------------------------------------------------------------- 6- 3

CYLINDER HEAD COVER REMOVAL ------------------------------------------------------ 6- 4

CAMSHAFT REMOVAL-------------------------------------------------------------------------- 6- 4

CYLINDER HEAD REMOVAL------------------------------------------------------------------ 6- 6

CYLINDER HEAD DISASSEMBLY ----------------------------------------------------------- 6- 7

CYLINDER HEAD ASSEMBLY ---------------------------------------------------------------- 6- 8

CYLINDER HEAD INSTALLATION ----------------------------------------------------------- 6- 9

CAMSHAFT INSTALLATION ------------------------------------------------------------------- 6- 10

CYLINDER HEAD COVER INSTALLATION ----------------------------------------------- 6- 11

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6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250

SCHEMATIC DRAWING

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6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250

SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator
and water jacket must be drained first.
• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable
parts and valve arm sliding surfaces for initial lubrication.
• The valve rocker arms are 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 Standard (mm) Service Limit (mm)

Item PEOPLE/PEOPLE S PEOPLE/PEOPLE S
Valve clearance (cold) IN 0.10 ⎯
EX 0.10 ⎯
Cylinder head compression pressure 15kg/cm² ⎯
Cylinder head warpage ⎯ 0.05
Camshaft cam height IN 34.2987 34.14
EX 34.1721 34.02
Valve rocker arm I.D. IN 10.00～10.015 10.10
EX 10.00～10.015 10.10
Valve rocker arm shaft IN 9.972～9.987 9.9
O.D. EX 9.972～9.987 9.9
Valve seat width IN 1.2 1.8
EX 1.2 1.8
Valve stem O.D. IN 4.990～4.975 4.925
EX 4.970～4.955 4.915
Valve guide I.D. IN 5.00～5.012 5.03
EX 5.00～5.012 5.03
Valve stem-to-guide IN 0.010～0.037 0.08
clearance EX 0.030～0.057 0.10

TORQUE VALUES
Cylinder head cap nut 24.5N-m Apply engine oil to threads
Valve clearance adjusting nut 8.8N-m Apply engine oil to threads
Cylinder head cover bolt 7.8～11.8N-m

SPECIAL TOOL

Valve spring compressor E040

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6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250

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 White smoke from exhaust muffler

• Compression too low • Worn valve stem or valve guide
• Damaged valve stem oil seal
Compression too low
• Incorrect valve clearance adjustment Abnormal noise
• Burned or bend valves • Incorrect valve clearance adjustment
• Incorrect valve timing • Sticking valve or broken valve spring
• Broken valve spring • Damaged or worn camshaft
• Poor valve and seat contact • Worn cam chain tensioner
• Leaking cylinder head gasket • Worn camshaft and rocker arm
• Warped or cracked cylinder head
• Poorly installed spark plug

Compression too high

• Excessive carbon build-up in combustion
chamber

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6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250
Bolts

CYLINDER HEAD COVER REMOVAL

Remove the met-in box, carrier. (Ö2-6)
Remove the body cover, center cover and
rear fender A. (Ö2-6)
Disconnect the secondary air inlet tube
connector and breather hose (air cleaner).
(Ö5-2)
Remove the cylinder head cover four bolts
and two nuts attaching the secondary air inlet
duct.
Cylinder Head Cover Nuts
Remove the cylinder head cover.
Bolt

CAMSHAFT REMOVAL
Turn the A.C. generator flywheel so that the
“T” mark on the flywheel aligns with the index
mark on the right crankcase cover.
Hold the round hole on the camshaft gear
facing up and the location is the top dead
center on the compression stroke.
Remove the cam chain tensioner cap bolt.

Cam Chain Tensioner Round Hole

Tensioner Screw
Turn the cam chain tensioner screw
clockwise to tighten it.
Remove the two bolts attaching cam chain
tensioner and the tensioner.

Bolts
Cap Nuts
First remove the two bolts between the
cylinder head and cylinder.
Then, remove the four cap nuts and washers
on the camshaft holder.

＊ • Diagonally loosen the cylinder head

cap nuts in 2 or 3 times.

Bolts Camshaft Holder

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6. CYLINDER HEAD/VALVES PEOPLE/PEOPLE S 250

Camshaft Holder
Remove the camshaft holder.

Cam Chain Dowel Pins

Remove the dowel pins.
Remove the camshaft gear from the cam
chain to remove the camshaft.

Camshaft Gear
CAMSHAFT INSPECTION
Check each cam lobe for wear or damage.
Measure the cam lobe height.
Service Limits:
IN: 34.14mm replace if below
EX:34.02mm replace if below

Camshaft Bearings
Check each camshaft bearing for play or
damage. Replace the camshaft assembly
with a new one if the bearings are noisy or
have excessive play.

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CAMSHAFT HOLDER DISASSEMBLY Valve Rocker Arms

Remove the valve rocker arms.

Rocker Arm Shafts

Camshaft Holder
CAMSHAFT HOLDER INSPECTION
Inspect the camshaft holder, valve rocker
arms and rocker arm shafts for wear or
damage.
＊ If the valve rocker arm contact surface is
worn, check each cam lobe for wear or
damage.

Rocker Arm Shafts

Measure the I.D. of each valve rocker arm.

Service Limits: IN: 10.10mm replace if over
EX: 10.10mm replace if over
Measure each rocker arm shaft O.D.
Service Limits: IN: 9.90mm replace if below
EX: 9.90mm replace if below

CYLINDER HEAD REMOVAL Bolt

First drain the coolant from the radiator and
water jacket, then remove the thermostat
water hose.
Remove the camshaft. (Ö6-4)
Remove the carburetor and intake manifold.
Remove the bolt attaching the thermostat
housing and the thermostat housing.
Remove the cylinder head.

Thermostat

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Cylinder Dowel Pins

Remove the dowel pins and cylinder head
gasket.
Remove the cam chain guide.
Remove all gasket material from the cylinder
head mating surface.
＊ Be careful not to drop any gasket
material into the engine.

Cam Chain Guide Cylinder Head Gasket

Cylinder Head
CYLINDER HEAD DISASSEMBLY
Remove the valve spring cotters, retainers,
springs, spring seats and valve stem seals
using a valve spring compressor.
＊ • Be sure to compress the valve springs
with a valve spring compressor.
• Mark all disassembled parts to ensure
correct reassembly.

Special
Valve Spring Compressor
Valve spring compressor E040
Combustion Chamber
Remove carbon deposits from the exhaust
port and combustion chamber.

＊ Be careful not to damage the cylinder

head mating surface.

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Straight Edge
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

Feeler Gauge

VALVE SPRING FREE LENGTH

Measure the free length of the inner and outer
valve springs.
Service Limits:
Inner (IN, EX) : 29.5mm replace if below
Outer (IN, EX): 39.5mm replace if below

VALVE /VALVE GUIDE

Inspect each valve for bending, burning,
scratches or abnormal stem wear.
Check valve movement in the guide.
Measure each valve stem O.D.
Service Limits: IN: 4.925mm replace if below
EX: 4.915mm replace if
below

CYLINDER HEAD ASSEMBLY

Install the valve spring seats and stem seals.
Lubricate each valve stem with engine oil and
insert the valves into the valve guides.
Be sure to install new valve stem seals.
Special
Valve spring compressor E040

Valve Spring Compressor

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Plastic Hammer
Tap the valve stems gently with a plastic
hammer to firmly seat the cotters.

＊ Be careful not to damage the valves.

Cylinder Head
Cylinder Dowel Pins
CYLINDER HEAD INSTALLATION
Install the cam chain guide.
Install the dowel pins and a new cylinder
head gasket.

Cam Chain Guide Cylinder Head Gasket

Install the cylinder head and take out the cam
chain

Cam Chain
Valve Rocker Arms
Assemble the camshaft holder.
First install the intake and exhaust valve
rocker arms; then install the rocker arm shafts.
＊ • Install the exhaust valve rocker arm
shaft on the “EX” side of the camshaft
holder and the exhaust rocker arm
shaft is shorter.
• Clean the intake valve rocker arm shaft
off any grease before installation.
• Align the cutout on the exhaust valve
rocker arm shaft with the bolt of the
camshaft holder. Camshaft Holder

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Cam Chain Camshaft Gear

CAMSHAFT INSTALLATION
Turn the A.C. generator flywheel so that the
“T” mark on the flywheel aligns with the index
mark on the right crankcase cover.
Keep the round hole on the camshaft gear
facing up and align the punch marks on the
camshaft gear with the cylinder head surface
(Position the intake and exhaust cam lobes
down.) and install the cam chain over the
camshaft gear.

Punch Marks Camshaft Gear

Install the dowel pins. Cam Chain Dowel Pins

Camshaft
Cap Nuts
Install the camshaft holder, washers and nuts
on the camshaft holder.
Tighten the four cylinder head nuts and the
two bolts between the cylinder head and
cylinder.
Torque: Cylinder head cap nut: 24.5N-m
Cylinder & cylinder head bolt: 7.8～
11.8N-m
＊ • Apply engine oil to the threads of the
cylinder head cap nuts.
• Diagonally tighten the cylinder head Bolts Camshaft Holder
cap nuts in 2～3 times.
• First tighten the cylinder head cap nuts
and then tighten the bolts between the
cylinder and cylinder head to avoid
cracks.

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Tensioner Screw
Turn the cam chain tension screw counter
clockwise to release it.

Bolts
O-ring
Apply engine oil to a new O-ring and install it.
Tighten the cam chain tension cap screw.

＊ Be sure to install the gasket into the

groove properly.

O-ring
CYLINDER HEAD COVER INSTALLATION
Adjust the valve clearance. (Ö3-6)
Install a new cylinder head cover O-ring and
install the cylinder head cover.
＊ Be sure to install the O-ring into the
groove properly.

Cylinder Head Cover

Bolts
Install and tighten the cylinder head cover
bolts and nuts.
Torque: 7.8～11.8N-m

Cylinder Head Cover Nuts

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