TABLE OF CONTENTS
02 – EXHAUST SYSTEM.......................................................................................... 51
377 AND 552 ENGINES ..................................................................................... 52
593, 593 HO, 593 HO SDI AND 793 HO ENGINES ...................................................... 53
TUNED PIPE.......................................................................................................... 54
MANIFOLD ........................................................................................................... 55
MUFFLER............................................................................................................. 55
03 – ENGINE REMOVAL AND INSTALLATION................................................................ 57
REMOVAL FROM VEHICLE......................................................................................... 59
INSPECTION.......................................................................................................... 63
INSTALLATION ....................................................................................................... 63
REMOVAL FROM VEHICLE......................................................................................... 65
INSPECTION.......................................................................................................... 69
INSTALLATION ....................................................................................................... 69
04 – MAGNETO SYSTEM......................................................................................... 71
GENERAL............................................................................................................. 76
MAGNETO FLYWHEEL.............................................................................................. 76
STATOR............................................................................................................... 78
CPS/TRIGGER COIL.................................................................................................. 78
05 – TOP END....................................................................................................... 81
TROUBLESHOOTING................................................................................................ 84
CLEANING............................................................................................................ 84
DISASSEMBLY ....................................................................................................... 84
INSPECTION.......................................................................................................... 86
ASSEMBLY ........................................................................................................... 86
TROUBLESHOOTING................................................................................................ 98
COMPONENT REMOVAL WITH THE ENGINE INSTALLED ...................................................... 98
CLEANING............................................................................................................ 98
RAVE VALVE BASIC OPERATION................................................................................... 98
DISASSEMBLY ....................................................................................................... 98
INSPECTION........................................................................................................ 103
ASSEMBLY ......................................................................................................... 104
06 – BOTTOM END ............................................................................................... 109
CLEANING.......................................................................................................... 112
DISASSEMBLY ..................................................................................................... 112
INSPECTION........................................................................................................ 113
ASSEMBLY ......................................................................................................... 113
BREAK-IN........................................................................................................... 118
CLEANING.......................................................................................................... 122
DISASSEMBLY ..................................................................................................... 122
INSPECTION........................................................................................................ 123
ASSEMBLY ......................................................................................................... 123
BREAK-IN........................................................................................................... 128
07 – ENGINE MEASUREMENT ................................................................................. 129
CYLINDER HEAD WARPAGE ..................................................................................... 129
CYLINDER TAPER.................................................................................................. 129
CYLINDER OUT OF ROUND...................................................................................... 129
COMBUSTIONCHAMBER VOLUME MEASUREMENT........................................................ 130
USED PISTON MEASUREMENT.................................................................................. 131
CYLINDER/PISTON CLEARANCE................................................................................. 131
RING/PISTON GROOVE CLEARANCE............................................................................ 133
RING END GAP..................................................................................................... 133
CRANKSHAFT DEFLECTION...................................................................................... 133
II
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