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ENGINE TOP END 5-1
5
Engine Top End
Table of Contents
Exploded View........................................................................................................................ 5-2
Specifications ......................................................................................................................... 5-4
Special Tools .......................................................................................................................... 5-5
Cylinder Head......................................................................................................................... 5-7
Cylinder Compression Measurement................................................................................ 5-7
Cylinder Head Removal .................................................................................................... 5-7
Cylinder Head Installation ................................................................................................. 5-8
Cylinder Head Warp.......................................................................................................... 5-9
Rocker Shaft and Rocker Arm................................................................................................ 5-10
Rocker Arm Components Removal .................................................................................. 5-10
Rocker Arm Components Installation ............................................................................... 5-10
Rocker Arm Components Disassembly ............................................................................ 5-11
Rocker Arm Components Assembly ................................................................................. 5-11
Rocker Arm/Shaft Wear .................................................................................................... 5-11
Valve Lifters ............................................................................................................................ 5-13
Valve Lifter Removal ......................................................................................................... 5-13
Valve Lifter Installation ...................................................................................................... 5-13
Valve Lifter Inspection....................................................................................................... 5-13
Valves ..................................................................................................................................... 5-14
Valve Clearance Inspection .............................................................................................. 5-14
Valve Clearance Adjustment............................................................................................. 5-14
Valve Removal .................................................................................................................. 5-14
Valve Installation ...............................................................................................................5-14
Valve Guide Removal ....................................................................................................... 5-15
Valve Guide Installation .................................................................................................... 5-15
Valve Seat Inspection ....................................................................................................... 5-15
Valve Seat Repair ............................................................................................................. 5-16
Valve Spring Free Length ................................................................................................. 5-21
Valve Head Thickness ...................................................................................................... 5-21
Valve Stem Diameter ........................................................................................................ 5-21
Valve Guide Inspection ..................................................................................................... 5-21
Measuring Valve/Guide Clearance ................................................................................... 5-22
Valve Stem Cap Inspection............................................................................................... 5-22
Exhaust Pipe and Muffler ....................................................................................................... 5-23
Exhaust Pipe Removal...................................................................................................... 5-23
Muffler Removal................................................................................................................ 5-23
Exhaust Pipe and Muffler Installation................................................................................ 5-24
Exhaust Pipe and Muffler Inspection ................................................................................ 5-24
Spark Arrester Cleaning.................................................................................................... 5-24
- Utility Vehicle 1
- Service Manual 1
- Quick Reference Guide 3
- LIST OF ABBREVIATIONS 6
- COUNTRY AND AREA CODES 6
- EMISSION CONTROL INFORMATION 7
- (US Model only) 8
- Foreword 9
- General Information 11
- 1-2 GENERAL INFORMATION 12
- GENERAL INFORMATION 1-3 13
- 1-4 GENERAL INFORMATION 14
- GENERAL INFORMATION 1-5 15
- 1-6 GENERAL INFORMATION 16
- GENERAL INFORMATION 1-7 17
- 1-8 GENERAL INFORMATION 18
- GENERAL INFORMATION 1-9 19
- 1-10 GENERAL INFORMATION 20
- GENERAL INFORMAT ION 1-11 21
- Periodic Maintenance 23
- 2-2 PERIODIC MAINTENANCE 24
- PERIODIC MAINTENANCE 2-3 25
- 2-4 PERIODIC MAINTENANCE 26
- PERIODIC MAINTENANCE 2-5 27
- 2-6 PERIODIC MAINTENANCE 28
- PERIODIC MAINTENANCE 2-7 29
- 2-8 PERIODIC MAINTENANCE 30
- PERIODIC MAINTENANCE 2-9 31
- 2-10 PERIODIC MAINTENANCE 32
- PERIODIC MAINTENANCE 2-11 33
- 2-12 PERIODIC MAINTENANCE 34
- PERIODIC MAINTENANCE 2-13 35
- 2-14 PERIODIC MAINTENANCE 36
- PERIODIC MAINTENANCE 2-15 37
- 2-16 PERIODIC MAINTENANCE 38
- PERIODIC MAINTENANCE 2-17 39
- 2-18 PERIODIC MAINTENANCE 40
- PERIODIC MAINTENANCE 2-19 41
- 2-20 PERIODIC MAINTENANCE 42
- PERIODIC MAINTENANCE 2-21 43
- 2-22 PERIODIC MAINTENANCE 44
- PERIODIC MAINTENANCE 2-23 45
- 2-24 PERIODIC MAINTENANCE 46
- PERIODIC MAINTENANCE 2-25 47
- 2-26 PERIODIC MAINTENANCE 48
- PERIODIC MAINTENANCE 2-27 49
- 2-28 PERIODIC MAINTENANCE 50
- PERIODIC MAINTENANCE 2-29 51
- 2-30 PERIODIC MAINTENANCE 52
- PERIODIC MAINTENANCE 2-31 53
- 2-32 PERIODIC MAINTENANCE 54
- PERIODIC MAINTENANCE 2-33 55
- 2-34 PERIODIC MAINTENANCE 56
- PERIODIC MAINTENANCE 2-35 57
- 2-36 PERIODIC MAINTENANCE 58
- PERIODIC MAINTENANCE 2-37 59
- 2-38 PERIODIC MAINTENANCE 60
- PERIODIC MAINTENANCE 2-39 61
- 2-40 PERIODIC MAINTENANCE 62
- PERIODIC MAINTENANCE 2-41 63
- 2-42 PERIODIC MAINTENANCE 64
- PERIODIC MAINTENANCE 2-43 65
- 2-44 PERIODIC MAINTENANCE 66
- PERIODIC MAINTENANCE 2-45 67
- 2-46 PERIODIC MAINTENANCE 68
- PERIODIC MAINTENANCE 2-47 69
- Fuel System 71
- 3-2 FUEL SYSTEM 72
- FUEL SYSTEM 3-3 73
- 3-4 FUEL SYSTEM 74
- FUEL SYSTEM 3-5 75
- 3-6 FUEL SYSTEM 76
- FUEL SYSTEM 3-7 77
- 3-8 FUEL SYSTEM 78
- FUEL SYSTEM 3-9 79
- 3-10 FUEL SYSTEM 80
- FUEL SYSTEM 3-11 81
- 3-12 FUEL SYSTEM 82
- FUEL SYSTEM 3-13 83
- 3-14 FUEL SYSTEM 84
- FUEL SYSTEM 3-15 85
- 3-16 FUEL SYSTEM 86
- FUEL SYSTEM 3-17 87
- 3-18 FUEL SYSTEM 88
- FUEL SYSTEM 3-19 89
- 3-20 FUEL SYSTEM 90
- FUEL SYSTEM 3-21 91
- 3-22 FUEL SYSTEM 92
- FUEL SYSTEM 3-23 93
- 3-24 FUEL SYSTEM 94
- FUEL SYSTEM 3-25 95
- 3-26 FUEL SYSTEM 96
- FUEL SYSTEM 3-27 97
- 3-28 FUEL SYSTEM 98
- FUEL SYSTEM 3-29 99
- 3-30 FUEL SYSTEM 100
- FUEL SYSTEM 3-31 101
- 3-32 FUEL SYSTEM 102
- Cooling S ystem 103
- 4-2 COOLING SYSTEM 104
- COOLING SYSTEM 4-3 105
- 4-4 COOLING SYSTEM 106
- COOLING SYSTEM 4-5 107
- 4-6 COOLING SYSTEM 108
- COOLING SYSTEM 4-7 109
- 4-8 COOLING SYSTEM 110
- COOLING SYSTEM 4-9 111
- 4-10 COOLING SYSTEM 112
- COOLING SYSTEM 4-11 113
- 4-12 COOLING SYSTEM 114
- COOLING SYSTEM 4-13 115
- 4-14 COOLING SYSTEM 116
- Engine Top End 117
- 5-2 ENGINE TOP END 118
- ENGINE TOP END 5-3 119
- 5-4 ENGINE TOP END 120
- ENGINE TOP END 5-5 121
- 5-6 ENGINE TOP END 122
- ENGINE TOP END 5-7 123
- 5-8 ENGINE TOP END 124
- ENGINE TOP END 5-9 125
- 5-10 ENGINE TOP END 126
- ENGINE TOP END 5-11 127
- 5-12 ENGINE TOP END 128
- ENGINE TOP END 5-13 129
- 5-14 ENGINE TOP END 130
- ENGINE TOP END 5-15 131
- 5-16 ENGINE TOP END 132
- ENGINE TOP END 5-17 133
- 5-18 ENGINE TOP END 134
- ENGINE TOP END 5-19 135
- 5-20 ENGINE TOP END 136
- ENGINE TOP END 5-21 137
- 5-22 ENGINE TOP END 138
- ENGINE TOP END 5-23 139
- 5-24 ENGINE TOP END 140
- Converter System 141
- 6-2 CONVERTER SYSTEM 142
- CONVERTER SYSTEM 6-3 143
- 6-4 CONVERTER SYSTEM 144
- CONVERTER SYSTEM 6-5 145
- 6-6 CONVERTER SYSTEM 146
- CONVERTER SYSTEM 6 -7 147
- 6-8 CONVERTER SYSTEM 148
- CONVERTER SYSTEM 6-9 149
- 6-10 CONVERTER SYSTEM 150
- CONVERTER SYSTEM 6-11 151
- 6-12 CONVERTER SYSTEM 152
- CONVERTER SYSTEM 6-13 153
- 6-14 CONVERTER SYSTEM 154
- CONVERTER SYSTEM 6-15 155
- 6-16 CONVERTER SYSTEM 156
- CONVERTER SYSTEM 6-17 157
- 6-18 CONVERTER SYSTEM 158
- CONVERTER SYSTEM 6-19 159
- 6-20 CONVERTER SYSTEM 160
- CONVERTER SYSTEM 6-21 161
- 6-22 CONVERTER SYSTEM 162
- CONVERTER SYSTEM 6-23 163
- 6-24 CONVERTER SYSTEM 164
- CONVERTER SYSTEM 6-25 165
- 6-26 CONVERTER SYSTEM 166
- CONVERTER SYSTEM 6-27 167
- Engine Lubrication S ystem 169
- 7-2 ENGINE LUBRICATION SYSTEM 170
- ENGINE LUBRICATION SYSTEM 7-3 171
- 7-4 ENGINE LUBRICATION SYSTEM 172
- Special Tools and Sealant 173
- 7-6 ENGINE LUBRICATION SYSTEM 174
- ENGINE LUBRICATION SYSTEM 7-7 175
- 7-8 ENGINE LUBRICATION SYSTEM 176
- ENGINE LUBRICATION SYSTEM 7-9 177
- Oil Pump 178
- Relief Valve 179
- Oil Pressure Measurement 180
- Oil Pressure Switch 181
- Oil Nozzle 182
- Engine Removal/Installation 183
- Exploded View 184
- Special Tool 186
- Crankshaft/Crankcase 191
- 9-2 C RANKSHAFT/CRANKCASE 192
- CRANKSHAFT/CRANKCASE 9-3 193
- 9-4 C RANKSHAFT/CRANKCASE 194
- CRANKSHAFT/CRANKCASE 9-5 195
- 9-6 C RANKSHAFT/CRANKCASE 196
- CRANKSHAFT/CRANKCASE 9-7 197
- 9-8 C RANKSHAFT/CRANKCASE 198
- CRANKSHAFT/CRANKCASE 9-9 199
- 9-10 CRANKSHAFT/CRANKCASE 200
- CRANKSHAFT/CRANKCASE 9-11 201
- 9-12 CRANKSHAFT/CRANKCASE 202
- CRANKSHAFT/CRANKCASE 9-13 203
- 9-14 CRANKSHAFT/CRANKCASE 204
- CRANKSHAFT/CRANKCASE 9-15 205
- 9-16 CRANKSHAFT/CRANKCASE 206
- CRANKSHAFT/CRANKCASE 9-17 207
- 9-18 CRANKSHAFT/CRANKCASE 208
- CRANKSHAFT/CRANKCASE 9-19 209
- 9-20 CRANKSHAFT/CRANKCASE 210
- CRANKSHAFT/CRANKCASE 9-21 211
- 9-22 CRANKSHAFT/CRANKCASE 212
- CRANKSHAFT/CRANKCASE 9-23 213
- 9-24 CRANKSHAFT/CRANKCASE 214
- CRANKSHAFT/CRANKCASE 9-25 215
- 9-26 CRANKSHAFT/CRANKCASE 216
- CRANKSHAFT/CRANKCASE 9-27 217
- 9-28 CRANKSHAFT/CRANKCASE 218
- CRANKSHAFT/CRANKCASE 9-29 219
- 9-30 CRANKSHAFT/CRANKCASE 220
- CRANKSHAFT/CRANKCASE 9-31 221
- 9-32 CRANKSHAFT/CRANKCASE 222
- CRANKSHAFT/CRANKCASE 9-33 223
- Transmission 225
- 10-2 TRANSMISSION 226
- TRANSMISSION 10-3 227
- 10-4 TRANSMISSION 228
- TRANSMISSION 10-5 229
- 10-6 TRANSMISSION 230
- TRANSMISSION 10-7 231
- 10-8 TRANSMISSION 232
- TRANSMISSION 10-9 233
- 10-10 TRANSMISSION 234
- TRANSMISSION 10-11 235
- 10-12 TRANSMISSION 236
- TRANSMISSION 10-13 237
- 10-14 TRANSMISSION 238
- TRANSMISSION 10-15 239
- 10-16 TRANSMISSION 240
- TRANSMISSION 10-17 241
- 10-18 TRANSMISSION 242
- TRANSMISSION 10-19 243
- 10-20 TRANSMISSION 244
- TRANSMISSION 10-21 245
- 10-22 TRANSMISSION 246
- TRANSMISSION 10-23 247
- 10-24 TRANSMISSION 248
- TRANSMISSION 10-25 249
- 10-26 TRANSMISSION 250
- TRANSMISSION 10-27 251
- 10-28 TRANSMISSION 252
- TRANSMISSION 10-29 253
- 10-30 TRANSMISSION 254
- TRANSMISSION 10-31 255
- 10-32 TRANSMISSION 256
- TRANSMISSION 10-33 257
- 10-34 TRANSMISSION 258
- TRANSMISSION 10-35 259
- Wheels/Tires 261
- 11-2 WHEELS/TIRES 262
- WHEELS/TIRES 11-3 263
- 11-4 WHEELS/TIRES 264
- WHEELS/TIRES 11-5 265
- 11-6 WHEELS/TIRES 266
- WHEELS/TIRES 11-7 267
- 11-8 WHEELS/TIRES 268
- WHEELS/TIRES 11-9 269
- 11-10 WHEELS/TIRES 270
- Final Drive 271
- 12-2 FINAL DRIVE 272
- FINAL DRIVE 12-3 273
- 12-4 FINAL DRIVE 274
- FINAL DRIVE 12-5 275
- 12-6 FINAL DRIVE 276
- FINAL DRIVE 12-7 277
- 12-8 FINAL DRIVE 278
- FINAL DRIVE 12-9 279
- 12-10 FINAL DRIVE 280
- FINAL DRIVE 12-11 281
- 12-12 FINAL DRIVE 282
- FINAL DRIVE 12-13 283
- 12-14 FINAL DRIVE 284
- FINAL DRIVE 12-15 285
- 12-16 FINAL DRIVE 286
- FINAL DRIVE 12-17 287
- 12-18 FINAL DRIVE 288
- FINAL DRIVE 12-19 289
- 12-20 FINAL DRIVE 290
- FINAL DRIVE 12-21 291
- 12-22 FINAL DRIVE 292
- FINAL DRIVE 12-23 293
- 12-24 FINAL DRIVE 294
- FINAL DRIVE 12-25 295
- 12-26 FINAL DRIVE 296
- FINAL DRIVE 12-27 297
- 12-28 FINAL DRIVE 298
- FINAL DRIVE 12-29 299
- 12-30 FINAL DRIVE 300
- FINAL DRIVE 12-31 301
- 12-32 FINAL DRIVE 302
- FINAL DRIVE 12-33 303
- 12-34 FINAL DRIVE 304
- FINAL DRIVE 12-35 305
- 12-36 FINAL DRIVE 306
- FINAL DRIVE 12-37 307
- 12-38 FINAL DRIVE 308
- FINAL DRIVE 12-39 309
- 12-40 FINAL DRIVE 310
- Table of Contents 311
- 13-2 BRAKES 312
- BRAKES 13-3 313
- 13-4 BRAKES 314
- BRAKES 13-5 315
- 13-6 BRAKES 316
- BRAKES 13-7 317
- 13-8 BRAKES 318
- BRAKES 13-9 319
- 13-10 BRAKES 320
- BRAKES 13-11 321
- 13-12 BRAKES 322
- BRAKES 13-13 323
- 13-14 BRAKES 324
- BRAKES 13-15 325
- 13-16 BRAKES 326
- BRAKES 13-17 327
- 13-18 BRAKES 328
- BRAKES 13-19 329
- 13-20 BRAKES 330
- BRAKES 13-21 331
- 13-22 BRAKES 332
- BRAKES 13-23 333
- Suspension 335
- 14-2 SUSPENSION 336
- SUSPENSION 14-3 337
- 14-4 SUSPENSION 338
- SUSPENSION 14-5 339
- 14-6 SUSPENSION 340
- SUSPENSION 14-7 341
- 14-8 SUSPENSION 342
- SUSPENSION 14-9 343
- 14-10 SUSPENSION 344
- SUSPENSION 14-11 345
- 14-12 SUSPENSION 346
- SUSPENSION 14-13 347
- 14-14 SUSPENSION 348
- Steering 349
- 15-2 STEERING 350
- STEERING 15-3 351
- 15-4 STEERING 352
- STEERING 15-5 353
- 15-6 STEERING 354
- STEERING 15-7 355
- 15-8 STEERING 356
- STEERING 15-9 357
- 15-10 STEERING 358
- STEERING 15-11 359
- 15-12 STEERING 360
- STEERING 15-13 361
- 15-14 STEERING 362
- STEERING 15-15 363
- 15-16 STEERING 364
- STEERING 15-17 365
- 15-18 STEERING 366
- STEERING 15-19 367
- 15-20 STEERING 368
- STEERING 15-21 369
- 15-22 STEERING 370
- STEERING 15-23 371
- 15-24 STEERING 372
- STEERING 15-25 373
- 15-26 STEERING 374
- STEERING 15-27 375
- 15-28 STEERING 376
- STEERING 15-29 377
- 15-30 STEERING 378
- STEERING 15-31 379
- 15-32 STEERING 380
- STEERING 15-33 381
- 15-34 STEERING 382
- STEERING 15-35 383
- 15-36 STEERING 384
- STEERING 15-37 385
- 15-38 STEERING 386
- STEERING 15-39 387
- 15-40 STEERING 388
- STEERING 15-41 389
- 15-42 STEERING 390
- STEERING 15-43 391
- 15-44 STEERING 392
- STEERING 15-45 393
- 15-46 STEERING 394
- STEERING 15-47 395
- 15-48 STEERING 396
- STEERING 15-49 397
- 15-50 STEERING 398
- STEERING 15-51 399
- 15-52 STEERING 400
- 16-2 FRAME 402
- FRAME 16-3 403
- 16-4 FRAME 404
- FRAME 16-5 405
- 16-6 FRAME 406
- FRAME 16-7 407
- 16-8 FRAME 408
- FRAME 16-9 409
- 16-10 FRAME 410
- FRAME 16-11 411
- 16-12 FRAME 412
- FRAME 16-13 413
- 16-14 FRAME 414
- FRAME 16-15 415
- 16-16 FRAME 416
- FRAME 16-17 417
- 16-18 FRAME 418
- FRAME 16-19 419
- 16-20 FRAME 420
- Electrical System 421
- 17-2 ELECTRICAL SYSTEM 422
- ELECTRICAL SYSTEM 17-3 423
- 17-4 ELECTRICAL SYSTEM 424
- ELECTRICAL SYSTEM 17-5 425
- 17-6 ELECTRICAL SYSTEM 426
- ELECTRICAL SYSTEM 17-7 427
- 17-8 ELECTRICAL SYSTEM 428
- ELECTRICAL SYSTEM 17-9 429
- 17-10 ELECTRICAL SYSTEM 430
- ELECTRICAL SYSTEM 17-11 431
- 17-12 ELECTRICAL SYSTEM 432
- ELECTRICAL SYSTEM 17-13 433
- 17-14 ELECTRICAL SYSTEM 434
- ELECTRICAL SYSTEM 17-15 435
- 17-16 ELECTRICAL SYSTEM 436
- ELECTRICAL SYSTEM 17-17 437
- 17-18 ELECTRICAL SYSTEM 438
- ELECTRICAL SYSTEM 17-19 439
- 17-20 ELECTRICAL SYSTEM 440
- ELECTRICAL SYSTEM 17-21 441
- 17-22 ELECTRICAL SYSTEM 442
- ELECTRICAL SYSTEM 17-23 443
- 17-24 ELECTRICAL SYSTEM 444
- ELECTRICAL SYSTEM 17-25 445
- 17-26 ELECTRICAL SYSTEM 446
- ELECTRICAL SYSTEM 17-27 447
- 17-28 ELECTRICAL SYSTEM 448
- ELECTRICAL SYSTEM 17-29 449
- 17-30 ELECTRICAL SYSTEM 450
- ELECTRICAL SYSTEM 17-31 451
- 17-32 ELECTRICAL SYSTEM 452
- ELECTRICAL SYSTEM 17-33 453
- 17-34 ELECTRICAL SYSTEM 454
- ELECTRICAL SYSTEM 17-35 455
- 17-36 ELECTRICAL SYSTEM 456
- ELECTRICAL SYSTEM 17-37 457
- 17-38 ELECTRICAL SYSTEM 458
- ELECTRICAL SYSTEM 17-39 459
- 17-40 ELECTRICAL SYSTEM 460
- ELECTRICAL SYSTEM 17-41 461
- 17-42 ELECTRICAL SYSTEM 462
- ELECTRICAL SYSTEM 17-43 463
- 17-44 ELECTRICAL SYSTEM 464
- ELECTRICAL SYSTEM 17-45 465
- 17-46 ELECTRICAL SYSTEM 466
- ELECTRICAL SYSTEM 17-47 467
- 17-48 ELECTRICAL SYSTEM 468
- ELECTRICAL SYSTEM 17-49 469
- 17-50 ELECTRICAL SYSTEM 470
- ELECTRICAL SYSTEM 17-51 471
- 17-52 ELECTRICAL SYSTEM 472
- ELECTRICAL SYSTEM 17-53 473
- 17-54 ELECTRICAL SYSTEM 474
- ELECTRICAL SYSTEM 17-55 475
- 17-56 ELECTRICAL SYSTEM 476
- ELECTRICAL SYSTEM 17-57 477
- 17-58 ELECTRICAL SYSTEM 478
- Appendix 479
- 18-2 APPENDIX 480
- APPENDIX 18-3 481
- 18-4 APPENDIX 482
- APPENDIX 18-5 483
- 18-6 APPENDIX 484
- APPENDIX 18-7 485
- 18-8 APPENDIX 486
- APPENDIX 18-9 487
- 18-10 APPENDIX 488
- APPENDIX 18-11 489
- 18-12 APPENDIX 490
- APPENDIX 18-13 491
- 18-14 APPENDIX 492
- APPENDIX 18-15 493
- 18-16 APPENDIX 494
- APPENDIX 18-17 495
- 18-18 APPENDIX 496
- APPENDIX 18-19 497
- 18-20 APPENDIX 498
- APPENDIX 18-21 499
- 18-22 APPENDIX 500
- APPENDIX 18-23 501
- 18-24 APPENDIX 502
- APPENDIX 18-25 503
- 18-26 APPENDIX 504
- APPENDIX 18-27 505
- □8B500001 506
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