Tools Required:6mm, 8mm, 10mm , 12mm and 14mm Sockets
8mm and 14mm Wrenches
Rachet Driver
Ratchet Extension
Screwdriver Phillips Tip
Step One: Remove 10mm bolts from rear seat hold down. Remove seat.
Step Two: Remove the two 8mm lower shroud bolts from each side of the tank. Remove the 8mm on top of the tank. Make sure fuel is turned to “OFF” on the petcock. Remove fuel line from petcock. Remove 8mm bolt holding petcock to frame. Remove rubber strap between subframe and tank. Remove tank and set on an empty 5 gallon bucket.
Step Three: Drain cooling system by loosening the 8mm bolt on the bottom of water pump assembly. (Note: The bolt with a copper washer.) Use a funnel and a clean drain pan to avoid spillage. Loosening the radiator cap will accelerate flow of coolant.
Step Four: Remove right side panel by removing 8mm bolt.
Step Five: Remove muffler by removing the upper 10mm muffler bolt, the lower 10mm muffler bolt and by loosening the 10mm muffler to header clamp bolt.
Step Six: Loosen clamp between rear of carburetor and airbox boot using a Phillips screwdriver.
Step Seven: Remove lower 12mm subframe bolts.
Step Eight: Loosen 10mm bolt on top of subframe.
Step Nine: Lift subframe from the rear and rotate it to a vertical position. Note: this will separate airbox boot from carburetor. Retighten 10mm upper subframe bolt to hold the subframe in this position.
Step Ten: Remove the two 12mm nuts holding the header to the head. Remove header.
Step Eleven: Using a 6mm socket, loosen hose clamp holding upper left radiator hose to the water inlet neck on head. Remove hose from water neck and move up and out of the way.
Step Twelve: Using an 8mm socket, remove bolt holding the water inlet neck to the head. Remove water inlet neck.
Step Thirteen: On X models equipped with AIS, remove 8mm bolt holding the air injector line to the head. Move line out of the way.
Step Fourteen: Using a 12mm socket and wrench, remove the two upper engine mounts. Using a 14mm socket and wrench remove the lower engine mount. Note: do not lose the steel, double washer assembly from the lower mount/head.
Step Fifteen: Loosen clamp on rubber boot between carburetor and head. Separate carburetor and boot from head.
Step Sixteen: On AIS equipped X models, separate the AIS vacuum line from the vacuum port on the inlet side of the head.
Step Seventeen: Release cam chain tension. Remove center 8mm bolt.
Using either the Honda tool (PN 07AMG-001A100) or a small flat blade screwdriver, turn the internal lifter clockwise until it bottoms out. Use a Vise-Grip to hold it in place.
Note: If you plan to replace the piston during this operation, remove the cam chain lifter as an assembly by just removing the two 8mm bolts, top and bottom. Pull entire assembly out.
Step Eighteen: Remove breather hose from the top of the valve cover. Be careful not to lose clamp.
Step Nineteen: Remove the two 10mm valve cover bolts.
Step Twenty: Remove cover by pulling upward from the back and lifting up at an angle.
Step TwentyOne: Remove the four 10mm bolts from the cam bearing caps.
Step TwentyTwo: Remove the cam bearing retainer caps by pulling upwards and wiggling slightly. Note: Be careful not to drop the bearing clips from the retainer caps.
Step TwentyThree: Slide the gearside bearing towards the Cam gear and let the Cam drop to gain clearance to remove chain from gear.
Step TwentyFour: Secure the cam chain with a piece of wire to the headtube of the frame. Note: keep a constant tension on the chain to avoid the chain coming off the crankshaft gear.
Step TwentyFive: Lift Cam out of the head.
Step TwentySix: Using an 8mm Box Wrench, loosen the two bolts on the left side of the head. Remove bolts.
Step TwentySeven: Using a 14mm Socket, remove the four head nuts from the studs.
Step TwentyEight: Use a telescopic magnet to remove the nuts and washers to avoid dropping them down inside the engine.
Step TwentyNine: Rock the head back and forth until it comes loose from the cylinder. Pull up and feed the chain through.
Step Thirty: Pull the head straight up and continue to feed the wire holding the chain through the head.
Step ThirtyOne: Remove the wire from the headtube and grab and support the wire beneath the head as you pull the head clear of the wire. Re-secure the wire to the headtube maintaining tension the whole time.
Step ThirtyTwo: Head is now removed from the engine and can now be bagged, bubble-wrapped, boxed and shipped to AS Racing for a proper service.
Now how about that piston???
