Service Manual
Table Of Contents
- GENERAL INFORMATION
- MAINTENANCE
- ELECTRONIC FUEL INJECTION
- SPECIAL TOOLS
- Part Numbers / Descriptions
- Fuel Pressure Gauge Kit - PU-43506-A
- Fuel Pressure Gauge Adaptor - PS-48762
- Throttle Position Sensor Tester Kit - 2201519
- Digital Wrench™ Diagnostic Software PU-47063
- Digital Wrench™ SmartLink Module Kit - PU-47471
- Digital Wrench™ - Diagnostic Connector
- Digital Wrench™ - Download Website
- FUEL TANK
- FUEL LINE
- EFI SERVICE NOTES
- EFI SYSTEM LAYOUT
- EFI COMPONENTS
- ELECTRONIC FUEL INJECTION
- ELECTRONIC CONTROL UNIT (ECU)
- FUEL PUMP
- FUEL PRESSURE REGULATOR
- FUEL INJECTORS
- CRANKSHAFT POSITION SENSOR (CPS)
- TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
- IDLE AIR CONTROL VALVE (IAC)
- THROTTLE POSITION SENSOR (TPS)
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- IGNITION COIL
- EFI DIAGNOSTICS
- FUEL SYSTEM TROUBLESHOOTING
- EFI SYSTEM BREAK-OUT DIAGRAMS
- Fuel Injector Circuit (PTO)
- Fuel Injector Circuit (MAG)
- Idle Air Control (IAC) Circuit
- Crankshaft Position Sensor (CPS) Circuit
- Fuel Pump / Fuel Level Sensor Circuit
- Fuel Pump Circuit
- Fuel Gauge Circuit
- Engine Coolant Temperature Sensor (ECT) Circuit
- Throttle Position Sensor (TPS) Circuit
- Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit
- Diagnostic Connector Circuit
- Diagnostic Connector Circuit (EPS Models)
- SPECIAL TOOLS
- COOLING SYSTEM
- ENGINE
- GENERAL INFORMATION - ENGINE
- ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
- Torque & Torque Sequence - Main Engine Components
- Valve Cover / Breather Valve
- Camshaft Carrier / Camshaft / Rocker Arm
- Cylinder Head / Valve / IAFM
- Valve & Spring Height Detail
- Piston / Connecting Rod
- Crankshaft
- Crankcase
- Crankcase - Upper
- Balance Shaft / Balance Shaft Timing
- Crankcase (Lower) With Oil Pump
- Water Pump Coupler
- Water Pump / Water Pump Coupler / Stator / Flywheel
- Drive Coupler (Rear) / Starter Gear
- ENGINE SERVICE
- ENGINE DISASSEMBLY AND INSPECTION
- Valve Cover / Breather Valve
- Rocker Carrier / Camshaft Removal
- Rocker Arm / Rocker Arm Shaft Inspection
- Camshaft / Camshaft Bore Inspection
- Cylinder Head Removal
- Cylinder Head Cleaning
- Cylinder Head Warp Inspection
- Cylinder Head
- Valve Inspection
- Combustion Chamber
- Valve Guide Removal / Installation
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Head Installation
- Camshaft / Carrier Assembly
- Camshaft / Camshaft Carrier Installation
- Camshaft Timing
- Cam Chain Tensioner Installation
- Camshaft Timing - Quick Reference
- Crankcase Disassembly
- Crankcase (Lower) / Oil Pump Disassembly
- Crankcase Disassembly (Upper)
- Piston / Connecting Rod Removal
- Counterbalance Shaft Removal / Inspection
- Counterbalance Split Gear Replacement
- Crankshaft / Cam Chain Removal
- Cam Chain / Sprocket Inspection
- Crankcase Inspection (Lower)
- Crankshaft Inspection
- Connecting Rod Inspection
- Connecting Rod Big End Bearing Selection
- Piston / Piston Ring Inspection
- Piston Ring Removal
- Piston Ring Installed Gap
- Piston Pin Bore Inspection
- Cylinder Inspection
- Piston-to-Cylinder Clearance
- Honing - Important Information
- ENGINE ASSEMBLY
- Crankcase Preparation - Upper
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Piston / Connecting Rod Installation
- Crankshaft Installation
- Oil Passage Tube
- Crankcase Assembly - Upper
- Balance Shaft Installation
- Balance Shaft Timing
- Crankcase Preparation (Lower)
- Crankcase Sealant and Torque Values
- Crankcase Assembly
- WATER PUMP
- TROUBLESHOOTING
- TRANSMISSION
- CLUTCHING (PVT)
- FINAL DRIVE
- BODY / FRAME
- STEERING / SUSPENSION
- BRAKES
5.26
ENGINE
ENGINE DISASSEMBLY AND
INSPECTION
Valve Cover / Breather Valve
1. Remove (2) breather housing bolts (A). Inspect bellows
(B) for cracks (not required for valve cover removal).
2. Remove (6) rocker cover bolts (C) and isolators (D).
3. Replace isolators and gasket (E) if oil leaks are evident.
Rocker Carrier / Camshaft Removal
1. Rotate engine in direction of rotation until pin (A) is facing
UP. Rotate cam another 60° to the 10:00 position to relieve
valve spring pressure from camshaft lobes.
2. Remove cam chain tensioner bolts evenly and remove
tensioner. Note “TOP” marked on plate for assembly.
3. Remove sprocket bolt and lift chain and sprocket off
camshaft. Secure cam chain with a wire (if cylinder head
will not be removed).
4. Loosen all cam carrier bolts evenly and lift carrier / rocker
arm assembly from cylinder head.
A
C
B
D
E
A
10:00
“TOP”