How To Use This Manual
Besides describing the service maintenance tasks and the intervals at which they are to be performed, three basic levels of
service are presented in this manual: troubleshooting problems with the engine, engine top end service, and engine bottom
end service. The manner in which these instructions are used depends upon the tasks to be performed and the level of
disassembly and servicing required.
Troubleshooting And Special Tools
When diagnosing a specific problem with an engine or engine component, first see SECTION 3 - TROUBLESHOOTING AND
SPECIAL TOOLS. This section is designed to be used as a guide for diagnostics on the engine. This section provides potential
problem scenarios, potential causes for those problems, and action items to help with the repair. The section also provides a
list of Special Tools that are either useful or required in the diagnostics, service, and repair of the engine.
Remove External Assemblies
To prepare the engine for service, whether top or bottom end, first see SECTION 4 - REMOVE EXTERNAL ASSEMBLIES to
remove the muffler, air cleaner, etc. The order in which the topics are presented is the order in which the assemblies are most
easily removed from the engine.
Top End Service
If servicing only cylinder head components, see SECTION 5 - DISASSEMBLE ENGINE, TOP END DISASSEMBLY, and then
proceed to SECTION 6 - SERVICE ENGINE SUBASSEMBLIES, CYLINDER HEAD. When cylinder head service is complete,
see SECTION 7 - ASSEMBLE ENGINE, TOP END ASSEMBLY.
Bottom End Service
If servicing bottom end components, such as the piston, connecting rod, crankshaft, etc., first see SECTION 5 -
DISASSEMBLE ENGINE, TOP END DISASSEMBLY, and then proceed to BOTTOM END DISASSEMBLY in the same
section. When finished, move to SECTION 6 - SERVICE ENGINE SUBASSEMBLIES, and see PISTON AND CONNECTING
ROD; FLYWHEEL, CRANKSHAFT AND CAMSHAFT; and CRANKCASE AND CRANKCASE COVER, for all service
instructions. When bottom end service is complete, see SECTION 7 - ASSEMBLE ENGINE, BOTTOM END ASSEMBLY, and
then proceed to TOP END ASSEMBLY in the same section.
Install External Assemblies
When the top and bottom ends of the engine are assembled, see SECTION 8 - INSTALL EXTERNAL ASSEMBLIES to
complete the project. The order in which the topics are presented is the order in which the assemblies are most easily installed
on the engine. These instructions also include any cleaning, inspection, or adjustments that may be recommended.
Specifications
The final section of this manual, SECTION 9 - SPECIFICATIONS provides engine specifications, acceptable component wear
measurements, and torque specifications for the engine. While specifications for components to be serviced are listed within
the manual,a comprehensive list is also provided for quick reference.
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