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
8.11
FINAL DRIVE
8
FRONT GEARCASE - CENTRALIZED HILLIARD
Exploded View
REF#DESCRIPTION QTY REF#DESCRIPTION QTY
1 O-Ring 1 21 Gearcase Housing 1
2 O-Ring 3 22 Pinion Neck Housing 1
3 O-Ring 1 23 Clutch Housing 1
4 Dowel Pin 1 24 Roll Cage Assembly 1
5 Expander 1 25 Hub Assembly (female) 1
6 Bearing 3 26 Hub Assembly (male) 1
7 Bushing 1 27 Cam 1
8 Bushing 1 28 Roller 20
9 Bushing 1 29 H-Clip Spring 20
10Oil Seal 230Bleeder Screw 2
11 Cap Plug 2 31 Thrust Button Assembly 1
12 Bolt, M6 3 32 Thrust Plate 1
13 Screw, M6 6 33 Pinion Gear 1
14 Fill Plug 1 34 Armature Plate (AWD) 1
15 Cap Screw, M6 4 35 Armature Plate (ADC) 1
16Screw, M4 436AWD Coil 1
17 Set Screw, M6 1 37 Piston 2
18 Cover Housing 1 38 Pump Assembly 1
19 Pinion Cover 1 39 Vent 1
20 Clutch Pack Assembly 2 40 Drain Plug, Magnetic 1
3
7
4
5
8
9
10
12
18
14
16
17
19
20
15
25
11
6
13
40
31
27
33
34
7-11 ft. lbs.
(9-15 Nm)
1
2
7-11 ft. lbs.
(9-15 Nm)
7-11 ft. lbs.
(9-15 Nm)
15 in. lbs.
(1.7 Nm)
21
22
23
24
26
29
28
32
30
35
36
37
39
38
8-10 ft. lbs.
(11-14 Nm)