Table of Contents 1- i
1
Section 1
CONTENTS
Engine
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Engine.......................................... 1-1
Engine General Information and
Diagnosis ................................................. 1A-1
Diagnostic Information and Procedures............1A-1
Engine Symptom Diagnosis ................................ 1A-1
Emission Control Devices ...................... 1B-1
Precautions...........................................................1B-1
Precautions for Emission Control Devices .......... 1B-1
General Description .............................................1B-1
Carburetor System Description ...........................1B-1
Crankcase Emission Control
System Description ........................................... 1B-2
Exhaust Emission Control System Description...1B-3
Noise Emission Control System Description.......1B-3
Schematic and Routing Diagram........................1B-4
PAIR System Hose Routing Diagram ................. 1B-4
Repair Instructions ..............................................1B-5
PAIR System Removal and Installation .............. 1B-5
PAIR System Inspection ..................................... 1B-6
PCV Hose Inspection .......................................... 1B-7
PCV Hose Removal and Installation................... 1B-7
Specifications.......................................................1B-8
Tightening Torque Specifications........................1B-8
Special Tools and Equipment .............................1B-8
Special Tool ........................................................ 1B-8
Engine Mechanical .................................. 1D-1
Schematic and Routing Diagram........................1D-1
Camshaft and Sprocket Assembly Diagram .......1D-1
Diagnostic Information and Procedures............1D-2
Compression Pressure Check ............................1D-2
Repair Instructions ..............................................1D-3
Engine Components Removable with
the Engine in Place ...........................................1D-3
Engine Assembly Removal .................................1D-5
Engine Assembly Installation ..............................1D-9
Air Cleaner Element Removal
and Installation................................................1D-12
Air Cleaner Element Inspection
and Cleaning...................................................1D-12
Engine Top Side Disassembly ..........................1D-12
Engine Top Side Assembly ...............................1D-15
Valve Clearance Inspection and Adjustment ....1D-25
Camshaft Inspection .........................................1D-25
Camshaft Sprocket Inspection ..........................1D-27
Camshaft Sprocket Removal and Installation ...1D-27
Cam Chain Tension Adjuster Inspection...........1D-28
Cam Chain Guide Removal and Installation .....1D-28
Cam Chain Guide Inspection ............................1D-29
Cam Chain Tensioner Inspection......................1D-29
Cylinder Head Disassembly and Assembly ......1D-30
Cylinder Head Related Parts Inspection ...........1D-33
Valve Guide Replacement ................................1D-36
Valve Seat Repair .............................................1D-38
Cylinder Inspection............................................1D-38
Piston Ring Components ..................................1D-39
Piston Ring Removal and Installation ...............1D-39
Piston and Piston Ring Inspection ....................1D-40
Engine Bottom Side Disassembly .....................1D-42
Engine Bottom Side Assembly..........................1D-48
Conrod Removal and Installation ......................1D-60
Conrod and Crankshaft Inspection....................1D-61
Conrod Crank Pin Bearing Inspection
and Selection ..................................................1D-62
Crankshaft Journal Bearing Inspection
and Selection ..................................................1D-64
Crankshaft Thrust Clearance Inspection
and Selection ..................................................1D-66
Specifications.....................................................1D-68
Service Data......................................................1D-68
Tightening Torque Specifications......................1D-70
Special Tools and Equipment ...........................1D-70
Recommended Service Material .......................1D-70
Special Tool ......................................................1D-71
Engine Lubrication System .................... 1E-1
Precautions...........................................................1E-1
Precautions for Engine Oil ..................................1E-1
Schematic and Routing Diagram........................1E-1
Engine Lubrication Circuit Diagram.....................1E-1
Engine Lubrication System Chart Diagram .........1E-2
Diagnostic Information and Procedures............1E-3
Engine Lubrication Symptom Diagnosis .............1E-3
Oil Pressure Check .............................................1E-3
Repair Instructions ..............................................1E-4
Engine Oil and Filter Replacement .....................1E-4
Oil Cooler / Oil Cooler Hose Removal
and Installation ..................................................1E-4
Oil Cooler / Oil Cooler Hose Inspection ..............1E-4
Oil Cooler Cleaning .............................................1E-4
Oil Pan / Oil Sump Filter / Oil Pressure
Regulator Removal and Installation ..................1E-4
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