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Removal
Remove the cylinder head cover. See the Cylinder Head Covers topic for more information.
Note the positions of the rocker arms and shafts so that they can be returned to their original positions.
Remove the rocker arm shaft cap bolts and sealing washers with a 14 mm socket. The 2002 – 2004 models do not have these cap bolts.
On the 2002 – 2004 models have rocker arm shaft bolts inside the cylinder head cover. Remove these bolts on these models.
On the models with rocker arm shaft cap bolts, thread an M8 bolt into the rocker arm shaft. pull on the bolt to slide the rocker arm shaft out of the cylinder head cover.
Remove the rocker arm shaft. The rocker arms on the 2002 – 2004 models have O-rings. Inspect the O-rings and replace them as needed.
Remove the wave washers.
Remove the rocker arms.
Inspection
Inspect the rocker arms for signs of wear and damage. If the rocker arm cam follower are damaged also inspect the camshaft. See the Camshafts topic for more information.
Measure the inside diameter of the rocker arms with vernier calipers. Measure in several spots.
Rocker Arm Inside Diameter: 12.000 – 12.018 mm (0.4724 – 0.4731 in.)
Service Limit: 12.05 mm (0.474 in).
Inspect the rocker arm shafts for damage and wear. Measure the outside diameter of the shafts where the rocker arms ride with vernier calipers or a micrometer. Measure in several spots.
Rocker Shaft Diameter
2002 – 2004: 11.973 – 11.984 mm (0.4714 – 0.4718 in.)
Service Limit: 11.95 mm (0.470 in.)
2005 and newer: 11.983 – 11.994 mm (0.4717 – 0.4722 in.)
Service Limit: 11.96 mm (0.471 in.)
Replace the rocker arm components as needed.
Installation
Install O-rings to the rocker arm shafts on the 2002 – 2004 models.
Apply fresh engine oil to the rocker arms and shafts.
When installing the rocker arms and shafts make sure to return them to their original positions.
Set the rocker arms and wave washers in place in the cylinder head cover. The wave washers sit on the camshaft sprocket side.
Insert the rocker arm shafts through the cylinder head cover and rocker arms. On the 2002 – 2004 models line up the threaded holes in the shafts with the holes in the cylinder head cover.
Insert the rocker arm shaft bolts on 2002 – 2004 models. Tighten the bolts to specification.
Rocker Shaft Bolts
2002 – 2003, 700cc 2004: 8.8 N-m, 0.9 kgf-m, 78 in-lb
Install the rocker arm shaft cap bolts and sealing washers on the 2005 and newer models. Tighten the rocker arm cap bolts to specification with a 14 mm socket.
Rocker Shaft Cap Bolts
2005 – 2011, 700cc 2005 – 2006: 20 N-m, 2.0 kgf-m, 14 in-lb
Install the cylinder head cover. See the Cylinder Head Covers topic for more information.