6. CYLINDER HEAD/VALVES Pulsar CK 125 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 5.42mm replace if below EX 5.40mm replace if below Measure each valve guide I.D. Service Limits: IN: 5.505mm replace if over EX: 5.525mm replace if over Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem- to-guide clearance. Service Limits: IN: 0.035mm EX: 0.055mm · If the stem-to-guide clearance exceeds the service limits, replace the guides. · Reface the valve seats whenever the valve guides are replaced. CYLINDER HEAD ASSEMBLY Stem Seal Valve Stem Lubricate each valve stem with engine oil and insert the valves into the valve guides. Apply engine oil to the valve stem seals and install them into the valve guides. Be sure to install new valve stem seals. Install the valve spring seats, washers, inner and outer springs, and retainers. Compress the valve springs using the valve Valve Spring Compressor Valve Spring spring compressor, then install the valve Attachment Compressor cotters. · Use the valve spring compressor to compress the springs and do not damage the cylinder head surface. · Install the cotters with the pointed ends facing down. Special Valve Spring Compressor E040 6-6