1-ii Table of Contents
Oil Pressure Regulator Inspection ...................... 1E-5
Oil Pan / Oil Sump Filter Cleaning ......................1E-6
Oil Pressure Switch Removal and Installation ....1E-6
Oil Pressure Switch Inspection ........................... 1E-7
Oil Jet (For the Cylinder Head)
Removal and Installation...................................1E-7
Oil Jet (For the Piston Cooling and
Transmission) Removal and Installation ...........1E-7
Oil Jet Inspection.................................................1E-8
Oil Pump Removal and Installation ..................... 1E-8
Oil Pump Inspection ............................................1E-8
Specifications.......................................................1E-9
Service Data........................................................ 1E-9
Tightening Torque Specifications........................1E-9
Special Tools and Equipment .............................1E-9
Recommended Service Material .........................1E-9
Special Tool ........................................................ 1E-9
Engine Cooling System ...........................1F-1
Precautions........................................................... 1F-1
Engine Cooling System Warning ........................ 1F-1
Precautions for Engine Oil .................................. 1F-1
General Description ............................................. 1F-2
Engine Cooling System Description.................... 1F-2
Schematic and Routing Diagram........................ 1F-3
Cylinder Head Cooling System Chart Diagram... 1F-3
Diagnostic Information and Procedures............ 1F-4
Engine Cooling Symptom Diagnosis................... 1F-4
Repair Instructions .............................................. 1F-5
Engine Cooling System Components ................. 1F-5
Oil Cooler and Oil Cooler Hose Components ..... 1F-6
Oil Cooler and Oil Cooler Hose Construction...... 1F-7
Oil Cooler / Oil Cooler Hose Removal
and Installation .................................................. 1F-8
Engine Cooling Hose Removal
and Installation .................................................. 1F-9
Oil Pump / Oil Pressure Regulator Removal
and Installation ................................................ 1F-10
Oil Nozzle Removal and Installation ................. 1F-10
Oil Return Pipe (Cylinder Side) Removal
and Installation ................................................ 1F-11
Oil Return Pipe (Crankcase Side) Removal
and Installation ................................................ 1F-11
Engine Cooling System Inspection ................... 1F-11
Oil Cooler Cleaning ........................................... 1F-12
Specifications..................................................... 1F-13
Service Data...................................................... 1F-13
Tightening Torque Specifications...................... 1F-13
Special Tools and Equipment ........................... 1F-13
Recommended Service Material ....................... 1F-13
Fuel System ............................................. 1G-1
Precautions.......................................................... 1G-1
Precautions for Fuel System .............................. 1G-1
General Description ............................................ 1G-2
I.D. No. Location ................................................ 1G-2
Fuel System Description .................................... 1G-2
Schematic and Routing Diagram....................... 1G-9
Carburetor Hose Routing Diagram..................... 1G-9
Fuel Tank Drain Hose and Breather Hose
Routing Diagram ............................................ 1G-10
Throttle Cable / Starter Cable
Routing Diagram ............................................ 1G-11
Diagnostic Information and Procedures......... 1G-12
Carburetor Symptom Diagnosis ....................... 1G-12
Repair Instructions ........................................... 1G-13
Fuel Tank Construction .................................... 1G-13
Fuel Tank Removal and Installation................. 1G-14
Fuel Valve Removal and Installation................ 1G-14
Fuel Filter Inspection and Cleaning.................. 1G-15
Fuel Level Gauge Removal and Installation .... 1G-15
Fuel Level Gauge Inspection ........................... 1G-16
Throttle Cable Removal and Installation .......... 1G-16
Throttle Cable Inspection ................................. 1G-16
Throttle Cable Play Inspection
and Adjustment .............................................. 1G-16
Starter Cable Removal and Installation............ 1G-16
Starter Cable Inspection................................... 1G-16
Carburetor Components................................... 1G-17
Carburetor Assembly Removal
and Installation ............................................... 1G-19
Carburetor Disassembly................................... 1G-20
Carburetor Assembly ....................................... 1G-23
Float Height Inspection and Adjustment .......... 1G-24
Carburetor Inspection and Cleaning ................ 1G-25
Carburetor Heater Inspection (For E-02, 19) ... 1G-26
TP Sensor Inspection....................................... 1G-26
TP Sensor Replacement .................................. 1G-27
Carburetor Synchronization ............................. 1G-28
Engine Idle Speed Inspection .......................... 1G-29
Fuel Line Inspection ......................................... 1G-29
Air Cleaner Element Removal
and Installation ............................................... 1G-29
Air Cleaner Element Inspection
and Cleaning .................................................. 1G-29
Specifications.................................................... 1G-30
Service Data..................................................... 1G-30
Tightening Torque Specifications..................... 1G-30
Special Tools and Equipment .......................... 1G-31
Recommended Service Material ...................... 1G-31
Special Tool ..................................................... 1G-31
Ignition System........................................ 1H-1
Schematic and Routing Diagram ........................1H-1
Ignition System Diagram .....................................1H-1
Diagnostic Information and Procedures............1H-2
Ignition System Symptom Diagnosis...................1H-2
No Spark or Poor Spark ......................................1H-3
Repair Instructions ..............................................1H-4
Ignition Coil and Spark Plug Cap Components...1H-4
Spark Plug Removal and Installation ..................1H-4
Spark Plug Inspection and Cleaning ...................1H-4
Ignition Coil Inspection ........................................1H-4
Ignition Coil Assembly Removal
and Installation ..................................................1H-6
Spark Plug Removal and Installation ..................1H-6
Spark Plug Inspection .........................................1H-6
CKP Sensor Inspection .......................................1H-6
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