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
5.59
ENGINE
5
Crankcase Assembly
1. Prepare upper and lower crankcase and install all
components as described on page 5.51 through page 5.57.
2. Inspect crankshaft seals to be sure they are aligned flush
with ends of crankcase.
3. Be sure balance shaft end plugs are installed with retaining
flange fitted in the grooves of crankcase.
4. Be sure oil passage tube is installed with new O-rings
(page 5.53).
5. Clean crankcase mating surfaces to remove all oil and
grease.
6. Apply a thin, continuous film of crankcase sealant PN
2871557 to upper and lower crankcase mating surfaces as
shown on page 5.58. Do not allow sealant to dry before
assembly.
7. Apply engine oil to crankshaft main bearings in the lower
crankcase half.
8. Carefully place lower crankcase on upper case, making sure
the oil supply tube and oil pump drive gear are aligned.
9. Tap with a rubber hammer to seat cases together.
10. Install all crankcase bolts and tighten all lightly by hand.
11. Inspect mating surfaces to be sure they are joined properly.
Investigate the cause of any gaps.
12. Torque all crankcase in sequence shown on page 5.58 to
final torque value, then repeat the sequence to verify final
torque.
13. Install cylinder head (page 5.35).
WATER PUMP
Water Pump Impeller Removal
IMPORTANT: Water pump impeller removal is not
required to remove the stator cover. If engine service
does not include water pump repair, leave the water
pump cover assembled to the stator cover and
remove as an assembly.
NOTE: The water pump impeller can be removed
without removing the engine.
See Chapter 4 “Cooling System” for procedure.
Water Pump Mechanical Seal Replacement /
Coupler Shaft & Bearing Replacement
IMPORTANT: Water pump mechanical seal removal is
not required to service the engine or to remove the
stator cover. If engine service does not include water
pump repair, remove the stator cover as an assembly.
NOTE: The water pump mechanical seal, coupler
shaft, and bearing can be serviced without removing
the engine.
See Chapter 4 “Cooling System” for procedure.