1-ii Table of Contents
Repair Instructions ..............................................1C-1
ECM Removal and Installation............................1C-1
CKP Sensor Inspection .......................................1C-1
CKP Sensor Removal and Installation ................1C-1
IAP Sensor Inspection.........................................1C-2
IAP Sensor Removal and Installation..................1C-2
TP Sensor Inspection..........................................1C-2
TP Sensor Adjustment ........................................1C-2
TP Sensor Removal and Installation...................1C-3
ECT Sensor Inspection .......................................1C-3
ECT Sensor Removal and Installation ................1C-3
Speed Sensor Inspection ....................................1C-3
Speed Sensor Removal and Installation .............1C-4
IAT Sensor Inspection.........................................1C-4
IAT Sensor Removal and Installation..................1C-4
TO Sensor Inspection .........................................1C-4
TO Sensor Removal and Installation ..................1C-5
STP Sensor Inspection .......................................1C-5
STP Sensor Adjustment......................................1C-5
STP Sensor Removal and Installation ................1C-6
ISC Valve Inspection...........................................1C-6
ISC Valve Removal and Installation....................1C-6
HO2 Sensor Inspection .......................................1C-6
HO2 Sensor Removal and Installation ................1C-6
Specifications.......................................................1C-7
Service Data........................................................1C-7
Tightening Torque Specifications........................1C-7
Special Tools and Equipment .............................1C-7
Special Tool ........................................................1C-7
Engine Mechanical .................................. 1D-1
Precautions...........................................................1D-1
Precautions for Engine Mechanical.....................1D-1
Schematic and Routing Diagram........................1D-1
Camshaft and Sprocket Assembly Diagram .......1D-1
Throttle Cable Routing Diagram..........................1D-2
Diagnostic Information and Procedures............1D-3
Compression Pressure Check ............................1D-3
Repair Instructions ..............................................1D-4
Engine Components Removable with the
Engine in Place .................................................1D-4
Engine Assembly Removal and Installation ........1D-6
Crankcase bracket Removal and Installation......1D-9
Crankcase bracket Inspection.............................1D-9
Air Cleaner Box Removal and Installation...........1D-9
Air Cleaner Element Inspection.........................1D-10
Air Cleaner Drain Plug Inspection .....................1D-10
Throttle Cable Removal and Installation ...........1D-10
Throttle Cable Adjustment.................................1D-10
Throttle Body Components ...............................1D-11
Throttle Body Construction................................1D-12
Throttle Body Removal and Installation ............1D-13
Throttle Body Disassembly and Assembly........1D-13
Throttle Body Inspection and Cleaning .............1D-15
Engine Top Side Disassembly ..........................1D-16
Engine Top Side Assembly ...............................1D-18
Camshaft Inspection .........................................1D-22
Cam Chain Tension Adjuster Inspection...........1D-24
Cam Chain Guide Inspection ............................1D-25
Cylinder Head Disassembly and Reassembly ..1D-25
Cylinder Head Related Parts Inspection ...........1D-29
Valve Guide Replacement ................................1D-32
Valve Seat Repair .............................................1D-33
Cylinder Disassembly and Assembly ................1D-33
Cylinder Inspection............................................1D-34
Piston Ring Removal and Installation ...............1D-34
Piston and Related Parts Inspection .................1D-35
Engine Bottom Side Disassembly .....................1D-37
Engine Bottom Side Assembly ..........................1D-44
Cam Chain Tensioner Inspection......................1D-51
Conrod and Crankshaft Inspection....................1D-51
Width Between Crankshaft Webs .....................1D-52
Bearing Inspection ............................................1D-52
Bearing Removal and Installation .....................1D-52
Rear Suspension Mounting Bushing Removal
and Installation ................................................1D-54
Specifications.....................................................1D-55
Service Data......................................................1D-55
Tightening Torque Specifications......................1D-57
Special Tools and Equipment ...........................1D-58
Recommended Service Material .......................1D-58
Special Tool ......................................................1D-58
Engine Lubrication System .................... 1E-1
Precautions...........................................................1E-1
Precautions for Engine Oil ..................................1E-1
Schematic and Routing Diagram ........................1E-1
Engine Lubrication System Chart Diagram .........1E-1
Engine Lubrication Circuit 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 Sump Filter Removal and Installation ............1E-4
Oil Sump Filter Cleaning .....................................1E-4
Oil Pump Removal and Installation .....................1E-5
Oil Pump Inspection ............................................1E-5
Piston Cooling Nozzle Removal and
Installation .........................................................1E-5
Piston Cooling Nozzle Inspection........................1E-6
Specifications.......................................................1E-6
Service Data........................................................1E-6
Tightening Torque Specifications........................1E-6
Special Tools and Equipment .............................1E-7
Special Tool ........................................................1E-7
Engine Cooling System ...........................1F-1
Precautions........................................................... 1F-1
Engine Cooling System Warning ........................ 1F-1
General Description ............................................. 1F-1
Cooling System Description ................................ 1F-1
Engine Coolant Description................................. 1F-1
Cooling Fan Thermo-Switch Description............. 1F-2
Engine Coolant Temperature Sensor
Description ........................................................ 1F-3
Schematic and Routing Diagram ........................ 1F-4
Cooling Circuit Diagram ...................................... 1F-4
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