Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component.
Center of engine
Item |
Removal |
Inspection |
Installation |
Air cleaner element | Refer to “air cleaner element removal and installation” . | Refer to “air cleaner element inspection” in section 0b . | Refer to “air cleaner element removal and installation” . |
Pair control solenoid valve | Refer to “pair control solenoid valve removal and installation” in section 1b . | Refer to “pair system inspection” in section 1b . | Refer to “pair control solenoid valve removal and installation” in section 1b . |
Cylinder head cover | Refer to “engine top side disassembly” . |
— |
Refer to “engine top side assembly” . |
Camshafts | Refer to “engine top side disassembly” . | Refer to “camshaft inspection” . | Refer to “engine top side assembly” . |
Throttle body | Refer to “throttle body removal and installation” . | Refer to “camshaft inspection” . | Refer to “throttle body removal and installation” . |
Thermostat | Refer to “thermostat removal and installation” in section 1f . | Refer to “thermostat inspection” in section 1f . | Refer to “thermostat removal and installation” in section 1f . |
Crankcase breather cover | Refer to “crankcase breather (pcv) hose / reed valve / cover removal and installation” in section 1b . | Refer to “crankcase breather (pcv) cover inspection” in section 1b . | Refer to “crankcase breather (pcv) hose / reed valve / cover removal and installation” in section 1b . |
Starter motor | Refer to “starter motor removal and installation” in section 1i . | Refer to “starter motor inspection” in section 1i . | Refer to “starter motor removal and installation” in section 1i . |
Oil filter | Refer to “engine oil and filter replacement” in section 0b . |
— |
Refer to “engine oil and filter replacement” in section 0b . |
Oil cooler | Refer to “oil cooler / oil cooler hose removal and installation” in section 1e . |
— |
Refer to “oil cooler / oil cooler hose removal and installation” in section 1e . |
Exhaust pipe/muffler | Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k . | Refer to “exhaust system inspection” in section 1k . | Refer to “muffler / muffler chamber / exhaust pipe removal and installation” in section 1k . |
Engine right side
Item |
Removal |
Inspection |
Installation |
Cam chain tension adjuster | Refer to “engine top side disassembly” . | Refer to “cam chain tension adjuster inspection” . | Refer to “engine top side assembly” . |
Clutch cover | Refer to “clutch removal” in section 5c . |
— |
Refer to “clutch installation” in section 5c . |
Clutch plates | Refer to “clutch removal” in section 5c . | Refer to “clutch parts inspection” in section 5c . | Refer to “clutch installation” in section 5c . |
Clutch sleeve hub | Refer to “clutch removal” in section 5c . |
— |
Refer to “clutch installation” in section 5c . |
Primary driven gear | Refer to “clutch removal” in section 5c . | Refer to “clutch parts inspection” in section 5c . | Refer to “clutch installation” in section 5c . |
Oil pump drive sprocket | Refer to “engine bottom side disassembly” . |
— |
Refer to “engine bottom side assembly” (page 1d- 56). |
Gearshift shaft | Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b . | Refer to “gearshift linkage inspection” in section 5b . | Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b . |
Ckp sensor rotor/cam chain drive sprocket | Refer to “engine bottom side disassembly” . |
— |
Refer to “engine bottom side assembly” (page 1d- 56). |
Cam chain tensioner | Refer to “engine bottom side disassembly” . | Refer to “cam chain tensioner inspection” . | Refer to “engine bottom side assembly” (page 1d- 56). |
Ckp sensor | Refer to “ckp sensor removal and installation” in section 1c . | Refer to “ckp sensor inspection” in section 1c . | Refer to “ckp sensor removal and installation” in section 1c . |
Starter idle gear | Refer to “starter clutch removal and installation” in section 1i . |
— |
Refer to “starter clutch removal and installation” in section 1i . |
Starter clutch | Refer to “starter clutch removal and installation” in section 1i . | Refer to “starter clutch inspection” in section 1i . | Refer to “starter clutch removal and installation” in section 1i . |
Starter torque limiter | Refer to “starter torque limiter removal and installation” in section 1i . | Refer to “starter torque limiter inspection” in section 1i . | Refer to “starter torque limiter removal and installation” in section 1i . |
Engine left side
Item |
Removal |
Inspection |
Installation |
Speed sensor | Refer to “speed sensor removal and installation” in section 9c . | Refer to “speed sensor inspection” in section 9c . | Refer to “speed sensor removal and installation” in section 9c . |
Engine sprocket | Refer to “engine sprocket removal and installation” in section 3a . | Refer to “drive chain related parts inspection” in section 3a . | Refer to “engine sprocket removal and installation” in section 3a . |
Drive chain | Refer to “drive chain replacement” in section 3a . | Refer to “drive chain inspection and adjustment” in section 0b . | Refer to “drive chain replacement” in section 3a . |
Gear position switch | Refer to “gear position (gp) switch removal and installation” in section 5b . | Refer to “gear position (gp) switch inspection” in section 5b . | Refer to “gear position (gp) switch removal and installation” in section 5b . |
Generator cover | Refer to “generator removal and installation” in section 1j . | — | Refer to “generator removal and installation” in section 1j . |
Generator rotor | Refer to “generator removal and installation” in section 1j . | — | Refer to “generator removal and installation” in section 1j . |
Water pump | Refer to “water pump removal and installation” in section 1f . | Refer to “water pump related parts inspection” in section 1f . | Refer to “water pump removal and installation” in section 1f . |
Oil pressure switch | Refer to “oil pressure switch removal and installation” in section 1e . | Refer to “oil pressure indicator inspection” in section 9c . | Refer to “oil pressure switch removal and installation” in section 1e . |
Oil jet inspection
Refer to “oil jet removal and installation” .
Oil jet
Make sure that the oil jets are not clogged. If they are
clogged, clean their oil passage using a wire of the
proper size and compressed air.
Piston cooling jet
Oil jet (for transmission)
Oil jet (for cam chain te ...
Precautions
Precautions for driveline / axle
Refer to “general precautions” in section 00 (page 00-1).
Never inspect or
adjust the drive chain while the engine is running.
Caution
do not use trichloroethylene, gasoline or such similar
solvent. These fluids will d ...
Excva pulley inspection
Inspect the excva pulley in the following procedures:
remove the excva pulley. Refer to “excv cable removal and installation”
.
Visually inspect the excva pulley for wear and
damage. If there is anything unusual, replace the
pulley with a new one.
Install the pulle ...