Table of Contents 1- i
1
Section 1
CONTENTS
Engine
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Engine.......................................... 1-1
Engine General Information and
Diagnosis ................................................. 1A-1
Diagnostic Information and Procedures............1A-1
Engine Symptom Diagnosis ................................ 1A-1
Emission Control Devices ...................... 1B-1
Precautions...........................................................1B-1
Precautions for Emission Control Devices .......... 1B-1
General Description .............................................1B-1
Carburetor System Description ........................... 1B-1
Repair Instructions ..............................................1B-2
Crankcase Breather (PCV) Hose Inspection.......1B-2
Crankcase Breather (PCV) Hose Removal
and Installation.................................................. 1B-2
Engine Mechanical .................................. 1D-1
Schematic and Routing Diagram........................1D-1
Throttle Cable Routing Diagram..........................1D-1
Diagnostic Information and Procedures............1D-2
Engine Mechanical Symptom Diagnosis.............1D-2
Compression Pressure Check ............................1D-2
Repair Instructions ..............................................1D-3
Engine Components Removable with the
Engine in Place .................................................1D-3
Air Cleaner Element Removal and Installation ....1D-4
Air Cleaner Element Inspection and Cleaning ....1D-4
Air Cleaner Box Removal and Installation...........1D-4
Engine Assembly Removal .................................1D-5
Engine Assembly Installation ..............................1D-8
Engine Top Side Disassembly ............................1D-9
Engine Top Side Assembly ...............................1D-12
Cylinder Head Cover Disassembly and
Assembly ........................................................1D-19
Cylinder Head Cover Relate Parts Inspection...1D-20
Cylinder Head Disassembly and Assembly ......1D-21
Cylinder Head Related Parts Inspection ...........1D-22
Valve Guide Replacement ................................1D-25
Valve Seat Repair .............................................1D-27
Camshaft Inspection .........................................1D-27
Cam Chain Tension Adjuster Inspection...........1D-29
Cam Chain Tensioner Inspection......................1D-29
Cam Chain Guide Inspection ............................1D-29
Cylinder Inspection............................................1D-29
Piston Ring Removal and Installation ...............1D-30
Piston and Piston Ring Inspection ....................1D-31
Engine Bottom Side Disassembly .....................1D-33
Engine Bottom Side Assembly..........................1D-42
Conrod and Crankshaft Inspection....................1D-57
Width Between Crankshaft Webs .....................1D-58
Crankshaft Oil Seal Inspection..........................1D-58
Bearing Inspection ............................................1D-58
Bearing Removal and Installation .....................1D-59
Specifications.....................................................1D-66
Service Data (LT-A400/F, LT-F400/F) ..............1D-66
Tightening Torque Specifications......................1D-68
Special Tools and Equipment ...........................1D-68
Recommended Service Material .......................1D-68
Special Tool ......................................................1D-68
Engine Lubrication System .................... 1E-1
Precautions...........................................................1E-1
Precautions for Engine Oil ..................................1E-1
Schematic and Routing Diagram........................1E-1
Engine Lubrication System Chart Diagram .........1E-1
Cylinder Head Cooling System Chart
Diagram.............................................................1E-3
Diagnostic Information and Procedures............1E-3
Engine Lubrication Symptom Diagnosis .............1E-3
Oil Pressure Check .............................................1E-3
Repair Instructions ..............................................1E-5
Engine Oil and Filter Replacement .....................1E-5
Engine Oil Level Inspection.................................1E-5
Oil Sump Filter Removal and Installation ............1E-5
Oil Sump Filter Inspection and Cleaning.............1E-6
Oil Jet Removal and Installation (LT-F400/F) .....1E-6
Oil Jet Inspection (LT-F400/F) ............................1E-6
Oil Pump Drive Gear / Oil Pump Removal and
Installation .........................................................1E-6
Oil Pump Inspection ............................................1E-8
Oil Cooler And Oil Hose Components.................1E-9
Oil Cooler / Oil Cooler Hose Inspection and
Cleaning ............................................................1E-9
Oil Cooler / Oil Cooler Hose Removal and
Installation .......................................................1E-10
Oil Cooler Cleaning ...........................................1E-11
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