1-ii Table of Contents
Repair Instructions .............................................. 1C-*
ECM Removal and Installation............................ 1C-*
CKP Sensor Inspection ....................................... 1C-*
CKP Sensor Removal and Installation ................ 1C-*
IAP Sensor Inspection......................................... 1C-*
IAP Sensor Removal and Installation.................. 1C-*
TP Sensor Inspection.......................................... 1C-*
TP Sensor Adjustment ........................................ 1C-*
TP Sensor Removal and Installation................... 1C-*
ECT Sensor Inspection ....................................... 1C-*
ECT Sensor Removal and Installation ................ 1C-*
Speed Sensor Inspection .................................... 1C-*
Speed Sensor Removal and Installation ............. 1C-*
IAT Sensor Inspection......................................... 1C-*
IAT Sensor Removal and Installation.................. 1C-*
TO Sensor Inspection ......................................... 1C-*
TO Sensor Removal and Installation .................. 1C-*
STP Sensor Inspection ....................................... 1C-*
STP Sensor Adjustment...................................... 1C-*
STP Sensor Removal and Installation ................ 1C-*
ISC Valve Inspection........................................... 1C-*
ISC Valve Removal and Installation.................... 1C-*
ISC Valve Pre-set (AN400/ZK7).......................... 1C-*
ISC Valve Preset and Opening Initialization
(AN400/ZK8) ..................................................... 1C-*
HO2 Sensor Inspection ....................................... 1C-*
HO2 Sensor Removal and Installation ................ 1C-*
Specifications....................................................... 1C-*
Service Data........................................................ 1C-*
Tightening Torque Specifications........................ 1C-*
Special Tools and Equipment ............................. 1C-*
Special Tool ........................................................ 1C-*
Engine Mechanical .................................. 1D-1
Precautions........................................................... 1D-*
Precautions for Engine Mechanical..................... 1D-*
Schematic and Routing Diagram........................1D-1
Camshaft and Sprocket Assembly Diagram ....... 1D-*
Throttle Cable Routing Diagram.......................... 1D-*
Throttle Cable Routing Diagram (AN400/A/
ZAK9)................................................................1D-1
Diagnostic Information and Procedures............ 1D-*
Compression Pressure Check ............................ 1D-*
Repair Instructions ..............................................1D-2
Engine Components Removable with the
Engine in Place ................................................. 1D-*
Engine Assembly Removal and Installation ........ 1D-*
Crankcase bracket Removal and Installation...... 1D-*
Crankcase bracket Inspection............................. 1D-*
Air Cleaner Box Removal and Installation........... 1D-*
Air Cleaner Element Inspection........................... 1D-*
Air Cleaner Drain Plug Inspection ....................... 1D-*
Throttle Cable Removal and Installation ............. 1D-*
Throttle Cable Adjustment................................... 1D-*
Throttle Body Components ................................. 1D-*
Throttle Body Construction.................................. 1D-*
Throttle Body Removal and Installation .............. 1D-*
Throttle Body Disassembly and Assembly.......... 1D-*
Throttle Body Inspection and Cleaning ............... 1D-*
Engine Top Side Disassembly ............................ 1D-*
Engine Top Side Assembly ................................. 1D-*
Camshaft Inspection ........................................... 1D-*
Cam Chain Tension Adjuster Inspection............. 1D-*
Cam Chain Guide Inspection .............................. 1D-*
Cylinder Head Disassembly and Reassembly .... 1D-*
Cylinder Head and Related Parts Inspection ...... 1D-*
Valve Guide Replacement .................................. 1D-*
Valve Seat Repair ............................................... 1D-*
Cylinder Disassembly and Assembly .................. 1D-*
Cylinder Inspection.............................................. 1D-*
Piston Ring Removal and Installation ................. 1D-*
Piston and Related Parts Inspection ................... 1D-*
Engine Bottom Side Disassembly ....................... 1D-*
Engine Bottom Side Assembly............................ 1D-*
Cam Chain Tensioner Inspection........................ 1D-*
Conrod and Crankshaft Inspection...................... 1D-*
Width Between Crankshaft Webs ....................... 1D-*
Bearing Inspection .............................................. 1D-*
Bearing Removal and Installation ....................... 1D-*
Rear Suspension Mounting Bushing Removal
and Installation .................................................. 1D-*
Engine Bottom Side Assembly (AN400/A/
ZAK9) ................................................................1D-2
Specifications.......................................................1D-3
Service Data........................................................ 1D-*
Tightening Torque Specifications........................1D-3
Special Tools and Equipment .............................1D-3
Recommended Service Material .........................1D-3
Engine Lubrication System ..................... 1E-*
Precautions........................................................... 1E-*
Precautions for Engine Oil .................................. 1E-*
Schematic and Routing Diagram ........................ 1E-*
Engine Lubrication System Chart Diagram ......... 1E-*
Engine Lubrication Circuit Diagram..................... 1E-*
Diagnostic Information and Procedures............ 1E-*
Engine Lubrication Symptom Diagnosis ............. 1E-*
Oil Pressure Check ............................................. 1E-*
Repair Instructions .............................................. 1E-*
Engine Oil and Filter Replacement ..................... 1E-*
Oil Sump Filter Removal and Installation ............ 1E-*
Oil Sump Filter Cleaning ..................................... 1E-*
Oil Pump Removal and Installation ..................... 1E-*
Oil Pump Inspection ............................................ 1E-*
Piston Cooling Nozzle Removal and
Installation ......................................................... 1E-*
Piston Cooling Nozzle Inspection........................ 1E-*
Specifications....................................................... 1E-*
Service Data........................................................ 1E-*
Tightening Torque Specifications........................ 1E-*
Special Tools and Equipment ............................. 1E-*
Special Tool ........................................................ 1E-*
Engine Cooling System ........................... 1F-*
Precautions............................................................1F-*
Engine Cooling System Warning .........................1F-*
General Description ..............................................1F-*
Cooling System Description .................................1F-*
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