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
6.17
TRANSMISSION
6
Exploded View, Continued.
Ref. Qty. Description Ref. Qty. Description
1. 2 Plug, M18 48. 1 Gearcase, Main
2. 1 Plug w/Magnet, M18 49. 1 Bell Housing
3. 19 Screw, M8 50. 1 Park Pawl
4. 2 Screw, M6 51. 1 Gear, Sector 38T
5. 4 Screw, M10 52. 1 Detent Bullet
6. 4 Screw, M6 53. 1 Cup, Belleville
7. 1 Nut, Nylon Lock, 5/16-24 54. 1 Trust Spacer, Compensator
8. 1 Nut, M18 55. 1 Output Shaft
9. 1 Washer, Thrust 56. 1 Reverse Shaft, 53T
10. 1 Washer, Thrust 57. 1 Input Shaft, 25T
11. 1 Washer, Belleville 58. 1 Gear, Compensator
12. 2 Dowel Pin 59. 1 Cam, Compensator
13. 1 E-Ring 60. 1 Gear, Helical, 42T
14. 2 Retaining Ring 61. 2 Vent Tube
15. 1 Retaining Ring 62. 1 Gear, 67T
16. 1 Retaining Ring 63. 1 Sprocket, 48T
17. 1 Retaining Ring 64. 1 Sprocket, 23T
18. 1 Retaining Ring 65. 1 Shift Shaft, Bellcrank
19. 1 Retaining Ring 66. 1 Rail, Shift Shaft
20. 1 Retaining Ring 67. 1 Detent Plug
21. 1 Washer, Thrust 68. 1 Rail, Park Shaft
22. 1 Washer, Thrust 69. 1 Engagement Dog, Low
23. 2 Shim 70. 1 Engagement Dog, Reverse/Low
24. 1 Shim 71. 1 Bushing Sleeve
25. 1 Washer, Thrust 72. 1 Shaft, Compensator
26. 1 Shim 73. 1 Shift Fork
27. 1 Shim 74. 1 Engagement Dog, High
28. 6 Washer, Belleville 75. 2 Pipe, Knock
29. 1 Washer, Thrust 76. 1 Shift Fork
30. 1 Collar 77. 1 Switch Shaft
31. 3 Ball Bearing 78. 1 PTL, Subassembly
32. 1 Ball Bearing 81. 1 Bellcrank, 15T Spline
33. 1 Ball Bearing 82. 1 Oil Deflector
34. 1 Ball Bearing 83. 1 Bearing Cover
35. 1 Ball Bearing 85. 1 Silent Chain
36. 1 Needle Bearing 86. 1 Silent Chain
37. 1 Ball Bearing 87. 1 Switch, Rotary
38. 1 Needle Bearing 88. 1 O-Ring
39. 1 Needle Bearing 89. 1 O-Ring
40. 1 Ball Bearing 90. 1 O-Ring
41. 1 Flanged Bearing 91. 2 Seal, Triple Lip
42. 1 Torsion Spring, Park Pawl 92. 1 O-Ring
43. 1 Compression Spring 93. 1 O-Ring
44. 1 Compression Spring 94. 2 Seal, Triple Lip
45. 1 Wave Spring 95. 1 Seal, Triple Lip
46. 1 Compression Spring 97. 1 Speed Sensor
47. 1 Gearcase, Cover 98. 1 Coupler