LUBRICATION SYSTEM

SERVICE TOOLS

Description Part Number Page

ADAPTER HOSE········· ·· ·· ·· ··
DISCONNECT T00L ···
· ·· ·· ·· ···
PRESSURE GAUGE ····· ·· ·· ·· ··

SERVICE PRODUCTS

Description Part Number Page

LOCTITE243 (BLUE) ··
···
····
···
COMPONENTS
ENGINE LUBRICATION CIRCUIT

1. Camshaft bearings
2. 0il pressure switch
3. 0il filter
4. 0il pressure regulator valve
5. 0il strainer
6. 0il pump
7. Crankshaft main bearings
8. Crankshaft support bearing
9. Connecting rod' bearings
 -Refill engine with recommended engine oil Refer
INSPECTION to OIL LEVEL VERIFICATION in the PERIODIC
MAINTENANCE PROCEDURES subsection.
ENGINE OIL PRESSURE -Check for high oil consumption ,refer to HIGH
NOTE : The engine oil pressure test should be OIL CONSUMPTION in the TROUBLESHOOT
Done with a warm engine100°C(212°F) and the -ING subsection.
recommended oil. -Check for engine oil leaks. For leak indicator
Remove the oil pressure switch. Refer to OIL hole,refer to COOLING SYSYTEM
PRESSURE SWICH in this subsection. INSPECTION in the PERIODIC MINTENANCE
Use the pressure gauge with the proper adapter PROCEFURES subsection.Rapair if necessary.
hose. 2. Use of unsuitable engine oil type.
-Replace engine oil by the recommended engine
REQUIRED TOOL 0il.
PRESSURE GAUGE 3. Clogged oil filter.
(P/N529 035 709) -Replace oil and oil fi1ter at the same time.
ADAPTER HOSE 4. Defective oil pressure switch.
(P/N529 035 652) -Test oil pressure switch, see procedure in this
subsection.
The engine oil pressure should be within the fol- 5. Defective or worn oil pump.
lowing values. -Check oil pump, see procedure in this subsection.
6. Defective engine oil pressure regulator.
OIL 1250 RPM 6000 RPM Check engine oil pressure regulator ,see procedure
PRESSURE in this subsection.
MINIMAL 70kPa(10PSI) 300kPa(44PSI) 7. Worn plain bearings in crankcase.
NOMINAL 150kPa(22PSI) 350kPa(51PSI) -Check plain bearings clearance, refer to
MAXIMA L 250kPa(36PSI) 450kPa(65PSI) BOTTOM subsection.
8. Clogged engine oil strainer.
1f the engine oi1 pressure is out of specifications, Check engine oil strainer, see procedure in this
check the points described in TROUBLESHOOT-- subsection.
INE in this subsection. OIL CONTAMINATION
Remove oil pressure gauge and adapter hose. 1. Defective water pump seal ring or rotary seal.
NOTE: To remove adapter hose from oil pressure - Check for oil or coolant leak from indicator hole
gauge, use the disconnect tool. near water pump, refer to COOLING SYSTEM
INSPECTION in the PERIODIC MAINTENCE
REQUIED TOOL PROCEFURES subsection. Replace seal if
necessary.
DISCINNECT TOOL
2. Cylinder head or cylinder base gasket leak
(P/N 529 035 714
-Retighten cylinder head to specified torque, refer
to TOP END subsection .replace gasket if
Reinstall the oil pressure switch,
tightening does not solve the problem.
TROUBLESHOOTING 3.Engine internal damage.
-Repair engine.
LOW 0R N0 OIL PRESSURE 4.Oil cooler gasket leak.
-Replace oil cooler gasket and change engine oil.
1. Oil level is too low.
HIGH OIL CONSUMPTION
1. Leaking breather oil seal.
-Check if the oil seal of the breather is brittle, hard
or damaged. Refer to BOTTOM END subsection.
2. Valve stem seals worn or damaged.
-Replace valve stem seals.
3. Worn piston rings(blue exhaust smoke).
-Replace piston rings.

PROCEDURES 1. 0il cooler

2. Gasket
OIL COOLER
Oil Cooler Inspection
Oil Cooler Access Check oil cooler for cracks or other damage.
Refer to BODY and remove: Replace if necessary.
- Upper console Oil Cooler Installation
- Lower console For installation, reverse the remova1 procedure.
- RH lateral console panel Pay attention to the following details.
- RH inner panel Wipe off any oil and coolant spillage.
- Fuel tank cowl. Install a NEW gasket.
Refer to PERIODIC MAINTENCE
Oil Cooler Removal PROCEDURES subsection and carry out the
Refer to the PERIODIC MAINTENCE following:
PROCEDURES subsection to: - Refill engine oil with recommended oil and at
- Drain engine oil. the proper oil lever.
- Drain engine coolant. - Refill and bleed cooling system.
Remove oil cooler retaining screws.
OIL PRESSURE SWITCH (OPS)
Oil Pressure Switch Location
The oil pressure switch is located at engine MAG
side above the magneto cover.

1 .Retaining screws
2. Oil cooler

Place rags or towels under oil cooler to catch re-

maining oil and coolant.
Remove oi1 cooler and discard gasket. 7. 0il oressi1re switch
 Oil Pressure Switch Access If resistance values are incorrect, replace the oil
Refer to BODY and remove: pressure switch.
- Upper console If the values are correct, check wiring.
- Lower console Oil Pressure Switch Removal
- RH lateral console panel Unplug the oil pressure switch connector.
- RH inner panel Unscrew and remove oil pressure switch.
- Fuel tank cowl. Oil Pressure Switch Installation
Oil Pressure Switch Activation Tighten oil pressure switch to specified torque.
The oil pressure switch activates when the engine OIL PRESSURE SWITCH
oil pressure is lower than the operating pressure. Service product LOCTITE243 (BLUE)
OIL PRESSURE SWITCH OPEATING PRESSURE (P/N293 800 060)
30kpa ±10kap (4.35PSI ±1.45 PSI) Tightening torque 12N·m±1 N·m
(106lbf·in±9lbf·in)
To check the function of the oil pressure switch,
an oil pressure test has to be performed. Refer to ENGINE OIL PRESSURE REGULATOR
ENGINE OIL PRESSURE in this subsection. Oil Pressure Regulator Location
lf the engine oil pressure is good perform the oil The oil pressure regulator is located on the engine
pressure switch resistance test. magneto side(inside magneto cover).
Oil Pressure Switch Resistance Test
Disconnect the connector from the oil pressure
switch.
Use a multimeter to check the resistance between
as shown.
OPS ENGINE ENGINE
CONNECTOR NOT RUNNING
RUNNING
PIN RESISTANCE(Ω)
Close to 0Ω Infinite(open) when
4 Engine (normally pressure
ground reaches 30kPa±10kPa
(4.35PSl±1.45PSl) 1. Engine oil ρressure regulator

NOTE: The oil pressure regulator system works

when the oil pressure exceeds 400kPa (58PSl).
Oil Pressure Regulator Access
Refer to BODY and remove:
- Upper console
- Lower console
- RH lateral console panel
- RH inner panel
- Fuel tank cowl.
Oil Pressure Regulator Removal
Remove plug screw and pull oil pressure regulator
out.

1. Oil pump

Oil Pump Removal

1. Plug screw Remove the PT0 cover. Refer to PTO COVER in
2. Gasket ring the BOTTOM END subsection.
3. Pressure regulator housing 1. Remove:
4. Spring - Retaining ring
5. Pressure regulator valve _ Oil pump gear
- Needle pin
Oil Pressure Regulator Inspection - Thrust washer.
Inspect pressure regulator housing and valve for
scoring or other damages.
Check spring for free length.

SPRING FREE LENGTH

NEW NOMINAL 39mm(1535in)
SERVICE LIMIT 37 mm(1457in)

NOTE: Replace worn or damaged components.

Clean bore and thread in the magneto housing
from metal shavings and other contaminations.
Oil Pressure Regulator Installation 1.Thrust washer
For installation, reverse the removal procedure. 2. Needle pin
Pay attention to the following details. 3.Oil pump gear
NOTE: At installation always replace the gasket 4. Retaining ring
ring of the plug screw by a new one.
2. Remove oil pump cover screws and pull
OIL PUMP oil pump cover out..
Oil Pump Location
The oil pump is located on the engine PT0 side
(behind PT0 cover).
1. Retaining screws
2. Oil pump cover 1. Oil pump bore
2. Outer rotor
3. Remove oil pump shaft with needle pin and 3. Oil pump shaft
inner rotor. 4. Needle pin
4. Remove outer rotor. 5. Inner rotor

Check inner rotor for corrosion pin holes or other

damages. If so, replace oil pump shaft assembly.

1. Outer rotor 1. Pittings on the teeth

2. Needle pin
3. Oil pump shaft Using a feeler gauge, measure the clearance of
4. Inner rotor inner and outer rotors as shown.

Oil Pump Inspection CLEARANCE OF INNER AND OUTER ROTOR

Inspect oil pump and oil pump cover bore for SERNICE LIMIT 0.25mm (.0098in)
marks, scratches or other damages. Check for
scratches in crankcase between outer rotor and
oil pump bore. lf so, replace damaged parts.
Check oil pump cover for damages and for surface
straightness with a straightedge.
1. Outer rotor
2. Inner rotor OIL PUMP COVER- MEASUREMENT "B″
A. 0.25mm (.0098in)
Substract measurement ''B" from measurement "A"
If clearance of inner and outer rotors exceeds the to obtain axial clearance.
Tolerance, replace oil pump rotors. Ensure to also
check oil pump cover. If damaged, replace the OIL PUMP AXIAL CLEARANCE
complete oil pump assembly. SERVICE LIMIT 0.2 mm(.0079in)
If clearance between outer rotor and its bore in
crankcase exceeds the tolerance, replace the NOTE: When the axial clearance of the oil pump
complete oil pump rotors and/or the crankcase. shaft assembly increases, the oil pressure de-
Using a depth gauge, measure the axial clearance creases.
of the oil pump as shown. Oil Pump Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: When installing the oil pump rotors, make
sure both markings are on the outer side.

OIL PUMP- MEASUREMENT "A″ TYPICAL

1. Markings
After reinstallation of the remaining parts, check
for smooth operation of the oil pump assembly.
Oil Pump Final Test
After engine is completely reassembled, start
engine and make sure oil pressure is within
specifications (refer to ENGINE OIL PRESSIRE
in this subsection).
ENGINE OIL STRAINER REED VALVE
Oil Strainer Location The engine is equipped with a reed valve which
The engine oil strainer is located between both prevents accumulation of larger oil quantities in
crankcase halves. the crankcase. The reed valve is fitted into the
Oil Strainer Removal crankcase.
Separate crankcase halves .Refer to BOTTOM
END subsection.
Remove screws and retaining plate.
Pull out engine oil strainer.

1. Reed valve
2. Stopper
3. Screws

1. Engine oil strainer Reed Valve Removal

2. Retaining plate Remove:
3. Screws -PTO cover (refer to PTO COVER in the
BOTTOM END subsection)
Oil Strainer Cleaning and Inspection - Reed valve retaining screws
Clean engine oil strainer with a part cleaner then - Stopper plate
use an air gun to dry it. - Reed valve.

▲WARNING Reed Valve Inspection

Always wear eye protector. Chemicals can Check reed valve for cracks or other damage.
cause a rash break out and injure your eyes. Replace reed valve if damaged.

Check engine oil strainer for cracks or other Reed Valve Installation
damage. Replace if damaged. The installation is the reverse of the removal
Oil Strainer Installation procedure.
The installation is the reverse of the removal
procedure. REED VALVE RETAINING SCREW
Tightening torque 10N·m±1N·m
OIL STRAINER RETAINING SCREWS (89lbf·in±9lbf·in)
Service product LOCTITE243 (BLUE)
(P/N293 800 060)
Tightening torque 6N·m± 0.7N·m
(53lbf·in±6lbf·in)
COOLING SYSTEM
SERVICE TOOLS
Description Part Number Page
BLIND HOLE PULLER KIT ·············· ··
HANDLE ···· ······
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LARGE HOSE PINCHER ·· ········
· ·······
OIL SEAL PUSHER ····
··················
ROTARY SEAL PUSHER PLATE · ······· ···
SEAL PUSHER · ··
·······
············· ···

SERVICE PRODUCTS
Description
DOW CORNING111 ·· ··
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LOCTITE243 (BLUE) ·····
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RADIATOR
800R Engine
RADIATOR
1000R Engine
WATER PUMP
800R Engine
WATER PUMP
1000R Engine
GENERAL Thermostat Removal
NOTICE Never start engine without coolant. 800R Models
Some engine parts such as the rotary seal on 1. Install a hose pincher on both radiator hoses
the water pump shaft can be damaged. REQUIRED TOOL
LARGE HOSE PINCHER
PROCEDURES
(P/N 520 032 500)
THERMOSTAT 2. Drain remainder of cooling system, refer to
The thermostat is a single action type. PERIODIC MAINTENANCE PROCEDURES
Thermostat Location subsection.
800R Model 3. Remove thermostat housing screws and re-
The thermostat is located in the thermostat housing move thermostat cover.
at the top of the front cylinder(RH side).

TYPICAL-THERMOSTAL LOCATION 800R THERMOSTAT LOCATION FRONT CYLINDER

MODEL HEAD
1. Front cylinder 1. Thermostat cover
2. Thermostat housing 2. Thermostat housing
3. Cover screws
1000 Models 4. Bleed screw
The thermostat is mounted in-line in the cooling
system circuit. 4. Pull thermostat and gasket from thermostat
housing.

THERMOSTAT LOCATION –RH FRONT

WHELL WELL ACCESS TYPICAL
1. ln-line thermostat 1. Thermostat with gasket
1000 Models THERMOSTAT OPENING TEMPERATURE
1. Install a hose pincher on both radiator hoses MODELS STARTS TO OPEN FULLY OPEN
800R 65°C(149°F) 75°C(167°F)
REQUIRED TOOL 1000 65°C(149°F) 88°C(190°F)
LARGE HOSE PINCHER
(P/N 520 032 500) Replace thermostat if it does not begin to open at
specified temperature.
Check if gasket is brittle, hard or damaged. lf so,
replace gasket.
Thermostat Installation
800R Models
For installation, reverse the removal procedure Pay
attention to the following.

THERMOSTAT COVER INSTALLATION

GASKET PRODUCT TIGHTENING
TIRQUE
1. Install hose pincher from LH side New LOCTITE 6N·m± 0.6N·m
2. Install hose pincher from RH side 243 (BLUE) (53lbf·in±5lbf·in)
(P/N293800060)
2. Drain remainder of cooling system, refer to on screws
PERIDOC MAIN PROCEDURES subsection.
3. Remove Oetiker clamps that secure hoses to 1000 Models
thermostat. Reverse removal procedures.
4. Remove thermostat. All Models
Refill cooling system.
Bleed cooling system, refer to PERIDOC MAIN
PROCEDURES subsection.
NOTICE The cooling system must be bled as
specified.
Check for coolant leaks.
RADATIR
Radiator inspection
Check radiating fins for clogging or damage.
Remove insects, mud or other obstructions with
compressed air or low pressure water.
Radiator Removal
1. Clamps 1. Install a hose pincher on both radiator hoses.
2. Thermostat
REQUIRED TOOL
Thermostat Test LARGE HOSE PINCHER
To check thermostat, put it in water and heat the (P/N 520 032 500)
water.
 NOTE :Turning steering to LH stop or removing
LH front wheel assembly provides greater access
for radiator removal.
9. Carefu1ly remove radiator through LH wheel
well.
Radiator Installation
1. For installation, reverse the removal procedure
however, pay attention to the following details.
2. install the rubber bushings between bottom of
radiator and radiator support.
1. Install hose pincher from LH side 3. Ensure the vent hose on the cooling fan motor
2. Install hose pincher from RH side is properly routed as illustrated.

2. Lift front of vehicle to extend suspension.

3. Remove the following parts from the radiator:
- Radiator inlet hose (LH upper)
- Radiator outlet hose (RH lower)
- Radiator mounting screws (2 at top of radiator).
4. Disconnect cooling fan electrical connector.
5. Remove cooling fan vent hose from frame.
6. Remove the2 forward air filter housing RADIATOR – REAR VIEW
mounting screws. 1. Radiator mounting screws
NOTE: This will make room for lifting the radiator 2. Lower mounting bushings
off its lower mounting bushings. 3. Radiator fan electrical connector
4. Fan motor vent hose
NOTE: Cooling fan vent hose must pass over the
top RH frame member, then be inserted down into
the RH vertical bumper tube.
NOTICE If the vent hose on the cooling fan motor
is not properly routed, the fan motor may be
damaged due to improper venting.

1. Forward air filter housing mounting screws to

remove

Model Equipped with a Winch

7. Remove the winch, refer to LIGHTS , GAUGE
AND ACCESSORIES subsection.
All Models
8. Lift radiator and tilt its lower end towards the 1. Cooling fan vent hose
front of the vehicle. 2. RH top frame member
3. RH vertical bumper tube
4. Fill radiator with the recommended coolant. RADIATOR COOLING FAN
Refer to PERIODIC MAINTENANCE Radiator Cooling Fan Operation
PROCEDUTE subsection. The ECM controls the radiator cooling fan via the
5. Bleed the cooling system, refer to inputs of the coolant temperature sensor (CTS) and
MAINTENANCE PROCEDUTE subsection. the manifold air pressure and temperature sensor
NOTICE The cooling system must be bled as (MAPTS). Refer to the following table.
specified.
6. Check for coolant leaks from radiator and
hoses.
COOLANT TEMPERATURE
SENSOR (CTS)
Refer to ELECTRONIC FUEL INJECTION (EFI)
subsection.
RADIATOR C00LING FAN RELAY
(R1)
Relay Installation
(Radiator Cooling Fan)
NOTE: Relay may be inverted by 180° at
installation and it will work correctly. Ensure to
align tabs of relay with terminals of fuse holder at
installation.

1. R1: Radiator coo1ing fan relay

Relay Operation Test

(Radiator Cooling Fan)

The easiest way to check the relay is to remove

it and temporarily substitute with the accessory
relay. If the radiator cooling fan operates, replace
the relay.
 ENGINE INTAKE COOLING CHECK ENGINE MESSAGE IN LIMP HOME
TEMPERATURE TEMPERATURE FAN LIGHT MULTIFUNCTION MODE
GAUGE
— 88°C(190°F) Turns ON — — —

— 85°C(185°F) Turn OFF — — —

96°C(205°F) — Turns ON — — —
962°C(198°F) — Turn OFF — — —
115°C(239°F) — ON Turns ON -Check engine —
-Hl Temp
118°C(244°F) — ON Flashes Limp Home Engine
limited to4000

Radiator Cooling Fan Fuse Location

The fuse is located in the fuse box underneath the
dashboard on the driver's side.

1. Cooling fan activation button

lf fan turns on, check CTS, wiring harness and
connectors. If al1 parts are good, replace the ECM.
1ffan does not turn on when the Cooling Fan but-
ton is pressed, refer to the following
troubleshooting chart.
1. Cooling fan fuse

Radiator Cooling Fan Test

1. Connect the vehicle to B.U.D.S., refer to
COMMUNICATION TOOLS AND B.U.D.S. for
procedure and connector location.
2. In B.U.D.S. software, select the following:
- Read Data button
- Activation tab
- ECM tab
- Cooling Fan button.
 COOLING FAN TROUBLESH00TING CHART
WATER PUMP HOUSING
Is fan working? YES→ Everything is 0K
NO Water Pump Housing Location
Check "Relay driver YES→ Replace fuse Is 1t is located on the engine MAG side (RH side of
fuse(5A) and fan fuse fan working? engine).
(30A). Is fuse burnt? Water Pump Housing Access
NO Remove fuel tank. Refer to FUEL SYSTEM
Bypass fan relay R1 subsection.
箭头 Water Pump Housing Removal
Fan turns? YES→ Replace relay Is
fan working? △WARNING
NO To avoid potential burns, do not remove the
Apply12 Vdc to fan radiator cap or loosen the coolant drain plug if the
connector engine is hot.
箭头
Fan turns? NO→ Replace fan Drain cooling system. Refer to PERIDIC
Is fan working? MAINTENANCE PROCEDURES subsection.
YES Remove radiator outlet hose from water pump
housing.
Check CTS
Remove screws retaining water pump housing.
箭头
CTS works ? NO→ Replace CTS
Is fan working?
YES
Check wiring harness
and connectors
箭头
Harness and NO→ Repair or replace
connectors good? defective part(s)
YES
Try a new ECM → Is fan working?

1. Coolant drain plug

Radiator Cooling Fan Removal 2. Sealing ring,
1. Disconnect fan motor electrical connector.
3. Screws
2. Remove fan motor vent tube from vehicle
4. Water pump housing
frame.
3. Remove 4 fan retaining screws.
Pul1 water pump housing to remove it.
4. Remove the radiator fan.
Water Pump Housing Inspection
Radiator Cooling Fan Installation Check if gasket is brittle, hard or damaged and re-
For the installation, reverse the removal procedure.
place as necessary.
 Water Pump Impeller Inspection
Check impeller for cracks or other damage. Re-
place impeller if damaged.
Water Pump Impeller Installation
The installation is the opposite of the removal
procedure.
NOTICE Be careful not to damage impeller fins
during installation.
TYPICAL
1. Gasket
WATER PUMP SHAFT AND SEALS
Use these guidelines to service these parts
Water Pump Housing Installation
The installation is the opposite of the removal DEFECTIVE RART ACTION
procedure. Rotary seal Replace:
NOTICE To prevent leaking ,take care that the - Rotary seal
gasket is exactly in groove when you reinstall - Oil seal
the water pump housing. ( assembled engine )
Tighten screws of water pump housing in a criss Oil seal Replace:
cross sequence to specification. -Rotary seal
- Oil seal
TIGHTENING TORQUE ( assembled engine )
Water pump housing 10N·m±1 N.m Water pump shaft Replace:
screws (89lbf·in±9lbf·in) - Water pump
shaft assembly
(including rotary seal)
WATER PUMP IMPELLER
- Oil seal
Water Pump Lmpeller Removal (engine disassembled)
Remove water pump housing.
Unscrew impeller. NOTICE Rotary seal must be replaced if water
pump shaft is to be replaced.
Water Pump Seals Replacement
(Assembled Engine)
NOTE: Read and thoroughly understand the en-
tire procedure before starting it.
Seals Removal
Remove water pump housing, refer to WATER
PUMP HOUSING in this subsection.
1. Remove the following parts, see procedure in
this subsection.
1. Turn counterclockwise unscrew - WATER PUMP HOUSING
- WATER PUMP IMPELLER
NOTICE Water pump shaft and impeller have 2. Carefully pry out inner part of the rotary seal
right-hand threads. Remove by turning using 2 screwdrivers.
counterclockwise and install by turning clockwise.
7. Inner part of rotary seal

1. Small chisel

4. Use 2 screwdrivers and carefully remove the

outer part of the rotary seal.

TYPICAL – INNER PARTS OF ROTARY SEAL

REMOVED
3. Carefully bend down the outer part of rotary seal
lip using a smal1 chisel.

7. Screwdrivers

NOTICE Be careful not to damage the crankcase

while removing outer part of the rotary seal.
5. Thoroughly remove carefully sealing residue
and burr of rotary seal using a scraper.
NOTICE Be careful not to damage water pump
shaft.

1. Pull on screws to remove seal

8. Check water pump shaft axial play. lf not
adequate, engine must be disassembled to replace
the water pump shaft.
9. Clean oil seal seat.

1. Scraper

6. Install 2 wooden screws in the seal

Seals Installation
1. Apply engine oi1 on water pump shaft.
2. Apply grease to the lips of the oil seal.
3. Carefully install the oil seal over the water pump
1. Wooden screws shaft.
2. Oil seal 4. Push the oil seal into the water pump cavity.

7. Remove oil seal from crankcase by pulling REOUIRED TOOL

screws with pliers. 17mm(11/16in) deep socket
OIL SEAL INSTALLATION
1. Rotary seal
5. Ensure that the oi1 seal is properly seated in 2. M8 robust flat washer (P/N 420 227 935)
water pump cavity. 3. M8×1.25 nut (P/N 233 281 414)

11. Remove M8 nut.

NOTE: The robust M8 flat washer remains on
water pump shaft.
12. Install rotary seal installation tools on
crankcase as follows.
REQUIRED TOOLS
ROTARY SEAL PUSHER PLATE
(P/N529 036 130)
4×M6×85 screws(P/N420440347)
4×tubes70mm(2.75in)
TYPICAL SEAL PUSHER(P/N529 035 766)
1. Oil seal proper/y seated

6. Apply engine oil on water pump shaft.

7. Place rotary seal onto water pump shaft and pull
out water pump shaft by hand.

NOTICE Do not install the rotary seal completely

into the crankcase to prevent the water pump shaft
plastic gear from breaking. Push it partia1ly in then
pull the shaft. ROTARY SEAL PUSHER PLATE (P/N529 036
8. Place a robust M8 flat washer (P/N420227935) 130)
onto water pump shaft.
9. Install a M8×1.25 nut onto water pump shaft by
hand.
10. Then thread nut1-1/2 turns to pull the shaft into
rotary seal.

SEAL PUSHER (P/N529 035 766)

 SEAL PUSHER INSTALLTION
ROTARY SEAL PUSHER PLATE ASSEMBLY 1. Seal pus1lerai1gneol with pusher bolt
1. 4×tubes (70mm(2.75in) length)
2. 4×screws M6×85 12.5 lighten the pusher bolt by hand until it stops
3. Plane surface on pus1ler bolt against the sea1 pusher.
13. Carefully thread the pusher bolt1-1/2 turns.
NOTE: Make sure pusher bolt has a plane surface. 14. Ensure that the rotary seal is going straight into
12.1 Apply a little grease at the end of tool pusher crankcase.
bolt. 15. Remove rotary seal installation tools from
12.2 Ensure that pusher bolt is completely crankcase.
unscrewed. Repeat the steps9to15 until rotary sea1 is
12.3 Instal1 rotary seal pusher plate on crankcase completely seated in the crankcase.
by tightening M6 screws. 16. Remove tools from crankcase.

NOTICE Do not use pneumatic or electric tools for

tightening screws.

ROTARY SEAL PROPERLY SEATED ON CRANKCASE

17. Carry out the final adjustment of the water

ROTARY SEAL PUSHER PLATE INSTALLTION pump shaft as follows.
1. Rotary seal pusher plate 17.1 lnstal1 M8×1.25 nut(P/N233 281 414) onto
2. Tube (70mm (2.75in)length) water pump shaft.
3. M6×85 screw 17.2 Carefully thread M8 nut until the rotary seal
4. Pusher bolt is flush with the end of water pump shaft threads.

12.4 Install seal pusher between rotary seal

pusher plate and water pump shaft.
WATER PUMP SHAFT PROPERYL ADJUSTED WISH 1. Water pump shaft
ROTARY SEAL 2. Crankcase MAG side

NOTICE The water pump shaft must be properly 3. Remove outer part of rotary seal.
adjusted with rotary seal.
The water pump shaft must move freely while REQUIED TOOL
pushing it toward the crankcase. BLAND HOLE PULLER KIT
18. Install the following parts, see procedure in this (P/N 529 036 056)
subsection
- WATER PUMP IMPELLER
- WATER PUMP HOUSING 4. Install expander snugly against outer part of
19. Refill and bleed cooling system. Refer to rotary seal and pu11 seal out.
PERIODIC MAINTENANCE PRODUCEDURES
subsection.
20. Check cooling system for leaks
Water Pump Shaft and Seals
Replacement (Disassembled Engine)
Water Pump Shaft and Seals Removal
1. Remove the following parts:
- WATER PUMP HOUSING
- WATER PUMP IMPELLER
- WATER PUMP GEARS
2. Push out water pump shaft with inner portion of
rotary seal from inside of crankcase MAG side.
TYPICAL
REQUIED TOOL
Soft hammer 5. Remove oil seal from inside of crankcase MAG
side using a pusher tool.
NOTICE Be careful not to damage the rotary
seal surface in crankcase.
 .
1.Handle
2. Pusher

When installing the oil seal on the pusher, make

sure the sealing lip points outwards.
Push NEW oil seal in place.
1. Oil seal
2. Machined surface for rotary seal

1. Oil seal
OIL SEAL REMOVAL-FROM INSIDE 2. Installer handle with oil seal pusher
CRANKCASE MAG SIDE Apply DOW CORNING 111 (P/N413 707 000) on
1. Orifices for oil seal removal Sealing lip of the oil seal.

Water Pump Shaft and Seals Installation

The installation is there verse of the removal
procedure. However, pay attention to the
following.
Use tightening torque values specified in the
exploded view.
NOTE: Never apply oil on the press fit area of the
oil seal and rotary seal.
Clean rotary seal surface of any old sealant.
Install oil seal.
1. Sealing lip
REQUIED TOOL 2. Oil seal properly installed
OIL SEAL PUSHER (P/N 529035757) Apply engine oil on the water pump shaft and
HANDLE (P/N 420877650) intermediate shaft.
Slide NEW water pump shaft assembly into
crankcase.
 REQUIED TOOL
WATER PUMP GEARS
SEAL PUSHER
(P/N 529035766) Water Pump Gears Identification

7. Surface where rotary seal is pushed by tool 1. Water pump shaft

2. Water pump gear
Water Pump Shaft Assembly 3. Water pump intermediate drive gear
4. Water pump intermediate shaft
NOTICE Never use a hammer for rotary seal 5. Water pump drive gear (see BOTTOM END
installation. Only use a press to avoid damaging subsection
the ceramic component.
Water Pump Gears Inspection
Water Pump Gear
Inspect water pump gear for wear and damage on
the snap mechanism to the needle pin. Replace if
damaged.

1. Water pump shaft with rotary seal

2. Water pump seal installer

NOTICE After installation, water pump shaft with

rotary seal must rotate freely.
CRANKCASE MAG SIDE
7. Circlip
2. Water pump gear
Water Pump Intermediate Drive Gear
Check water pump intermediate drive gear for
wear or broken teeth. Replace if damaged.
 CRANKCASE MAG SIDE
CRANKCASE PTO SIDE 1. Water pump gear
1. Water pump Intermediate drive gear 2. Needle pin
2. Circlip 3. Thrust Washer
3. Water pump intermediate shaft
4. Crankcase PTO side Water Pump Intermediate Drive Gear
1. Remove clrclip retaining water pump
intermediate drive gear and discard it.
Water Pump Drive Gear
See BOTTOM subsection,
Water Pump Gears Removal
Water Pump Gear
1. Remove circlip retaining water pump gear and
discard it.

CRANKCASE PTO SIDE

1. Water pump intermediate drive gear
2. Circlip
3. Water pump intermediate shaft
4. Crankcase PTO side

2. Remove the following parts:

CRANKCASE MAG SIDE - Water pump intermediate drive gear
1. Circlip - Needle pin. .
2. Water pump gear Water Pump Drive Gear
See BOTTOM END subsection.
2. Remove the following parts Water Pump Gears Installation
- Water pump gear Water Pump Gear
- Needle pin Install the following parts on water pump shaft.
- Thrust washer. - Thrust washer
- Needle pin Install NEW circlip to retain water pump
- Water pump gear. intermediate drive gear.
NOTICE Never use the circlip a second time.
NOTICE A missing thrust washer will cause a Always install a NEW one.
leaking rotary seal. Water Pump Drive Gear
See BOTTOM END subsection.

1. Water pump gear

2. Needle pin
3. Thrust washer

NOTE: Ensure water pump gear snaps properly

onto needle pin.
Install NEW circlip to retain water pump gear.
NOTICE Never use the circlip a second time.
Always install a NEW one.

1.Circlip
2. Water pump gear

Water Pump Intermediate Drive Gear

Install the following parts on water pump
intermediate shaft.
- Needle pin
- Water pump intermediate drive gear.
MAGNETO SYSTEM
SERVICE TOOLS

_Description Part Number Page

BACK PROBE TEST WIRES
CRANKSHAFT LOCKING BOLT
CRANKSHAFT PROTECTOR
FLUKE115 MULITIMETER
MAGNET0 PULLER

SERVICE PRODUCTS
Description Part Number Page
DREL BOND SEALING COMPOUND
LOCTITE243 (BLUE)
LOCTITE648 (GREEN)
LOCTITE767 (ANTISEIZE LUBRICANT)
LOCTITE CHISEL (GASKET REMOVER)
PULLEY FLANGE CLEANER
PROCEDURES Magneto Cover Inspection and

MAGNETO COVER Cleaning

Magneto Cover Access Check magneto cover for cracks or other damage.
Remove fuel tank, refer to FUEL TANK AND Replace if necessary.
FUEL PUMP NOTE: Clean all metal components in a
Magneto Cover Removal nonferrous metal cleaner. Use LOCTITE CHISEL
Drain engine oil (refer to PERIODIC (GAS- KET REMOVER) (P/N413 708 500), or
MAINTENANCE PROCDURES subsection). suitable equivalent.
Remove crankshaft position sensor (CPS) and cut
tie raps. ▲WARNING
Remove dipstick and oi1 level tube with 0-rings. Wear safety glasses and work in a well ventilated
area when working with strong chemical
products. Also wear suitable nonabsorbent gloves
to protect your hands.

Magneto Cover Installation

For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: Install a NEW magneto cover gasket.
Apply DREI BOND SEALING COMPOUND
(P/N420 297 906) on stator cable grommet as
1. Dipstick shown in next illustration.
2. Oil level tube
3. Crank position sensor (CPS)
4. O-rings
Remove magneto cover retaining screws

1. Stator cable grommet (apply Drei Bond sealing

compound

1. Magneto cover Tighten screws using the following sequence

2. Retaining crews

Pull out magneto cover.

NOTE: If required, remove stator and harness from
magneto cover.
 TYPICAL

TIGHTENING SEQUENCE 3. If any reading is out of specification, replace

stator.
MANGENTO COVER SCREW 4. Re-plug connectors properly.
Tightening torque 10N.m±1N.m Stator Static Test: Insulation
（89lbf.in±9lbf.in） 1. Disconnect the stator connector from the voltage
regulator/rectifier.
Refill engine with recommended oi1. 2. Connect multimeter between any YELLOW
wire(on stator connector) and engine ground.
STATOR
Stator Connector Access REQUIED TOOL
NOTE: The stator is directly connected to the FLUKE115 MULTIMETER
voltage regulator/rectifier. (P/N529 035 868)
Stator Static Test: Continuity
1. Disconnect the stator connector from the voltage
regulator/rectifier. TEST PROBES RESISTANCE@
2. Check resistance between YELLOW wires. 20°C(68°F)
Any YELLOW wire Infinite(open circuit)
REQUIED TOOL and engine ground
FLUKE115 MULTIMETER
(P/N529 035 868)

TERMINAL RESISTANCE@
20°C(68°F)
1 and2
1 and3 0.15 - 0.30Ω
2 and3
3. If there is a resistance or continuity, the stator
coils and/or the wiring is shorted to ground and
needs to be repaired or replaced.
4. Re-plug connectors properly.
Stator Dynamic Test: AC Voltage
Output
1. Disconnect stator connector at voltage
regulator/rectifier.
2. Start engine.
3. Check AC voltage output as follow:

REQUIRED TOOL 1. Holding strip screws

BACK PROBE TEST WIRES 2. Wire holding strip
(P/N529 036 063) 3. Stator retaining screws
4. Stator
FLUKE 115 MULTIMETER
(P/N529 035 868) Stator Inspection
Check stator windings and insulation for cracks or
other damages. lf damaged replace it.
4. Read voltage as per following table. Check if stator wires are brittle, hard or otherwise
damaged.
TEST ENGINE TERMINAL VOLTAGE Stator Installation
SPEED For installation, reverse the removal procedure.
1 and 2 15 Vac However, pay attention to the following.
4000 RPM 1 and 3 MINIMUM NOTICE When installing the stator take care to
2 and 3 route wires properly and install retaining strip.
NOTE: There is only one position for the stator
5. If voltage is lower than specification, replace (notch in the magneto housing cover).
stator.
6. Re-plug connectors properly.
Stator Removal
Remove MAGENTO COVER. See procedure in
this subsection.
Remove screws securing the wire holding strip.
Remove stator retaining screws then the stator.

1. Threads for cable holding strip

2. Notch for stator
 HOLDING STRIP SCREWS NOTE: Use grease to place protector on crank-
Service product LOCTITE243 (BLUE) shaft end prior to screw on the magneto puller.
(P/N293 800 060)
Tightening torque 4N·m± 0.5N·m
(35lbf·in±4lbf·in)

STATOR RETAINING SCREWS

Tightening torque 11N·m± 1N·m
(97lbf·in±9lbf·in)

HOLDING STRIP SCREWS

Service product
LOCTITE243 (BLUE)
(P/N293 800 060) 1. Rotor
2. Magneto puller

Tightening torque Screw magneto puller bolt to remove rotor.

4N·m± 0.5N·m Rotor Inspection
(35lbf·in±4lbf·in) Check inner side of rotor for scratches or other
damage.
Blow pressurized air in the rotor oil bore and make
ROTOR sure it is not clogged.
Rotor Removal
Remove MAGNETO COVER. See procedure in
this subsection.
Lock crankshaft(refer to CRANKSHAFT
LOCKING PROCEDURE in the BOTTOM END
subsection).

REQUIRED TOOL
CRANKSHAFT LOCKING
BOLT (P/N 529035617)

Heat screw in order to break the Loctite.

Remove screw and washer securing rotor to 1. Rotor
crankshaft. 2. Oil bole
Remove rotor.
Check keyway of the rotor for wear or damages.
Check if trigger wheel teeth are bent or otherwise
REQUIRED TOOL
damaged.
MAGNET0 PULLER
Check woodruff key and keyway on the crank-
(P/N529 035 748)
shaft for wear or damages.
CRANKSHAFT PROTECTOR
Replace parts as necessary.
(P/N529 036 034)
Rotor Installation Rotate starter double gear counterclockwise to
For installation, reverse the removal procedure. align intermediate gear teeth with sprag clutch
However, pay attention to the following. gear.
Use PULLEY FLANGE CLEANER (P/N413 711
809) to clean following:
- Crank shaft taper
- Oil passage in crank shaft taper
- Thread in crankshaft
- Rotor taper
- Oil bore in rotor.
NOTICE Taper on crankshaft and rotor must be
free of grease.

1. Starter double gear

2. Sprag clutch gear
3. Intermediate gear
ROTOR RETAINING SCREW
Service product LOCTITE648 (GREEN)
(P/N413 711 400)
150N·m±10N·m
1. Crankshaft (MAG side) Tightening torque (111 lbf·ft±7lbf·ft)
2. Oil passage
3. Threads
SPRAG CLUTCH
Oil sprag clutch and instal1 sprag clutch gear. Sprag Clutch Removal
Remove MAGENTO CIVER. See procedure in
this subsection.
Heat screws in order to break the Loctite.
Loosen sprag clutch housing screws located inside
rotor.

1. Sprag clutch
2. Sprag clutch housing
3. Sprag clutch gear
4. Apply engine oil here
1. Rotor
Slide rotor onto crankshaft. The woodruff key and 2. Sprag clutch housing screws
the keyway must be aligned. Remove rotor(refer to/11'07-0/li'in this subsection).
Remove sprag clutch gear. Apply LOCTITE648 (GREEN) (P/N413 711 400)
Remove sprag clutch housing screws and sprag on threads of sprag clutch housing screws.
clutch housing. Install screws but do not torque yet.
Apply engine oil on sprag clutch and sprag clutch
gear needle bearing.

1. Sprag clutch housing screws

2. Rotor
3. Sprag cluth
4. Sprag clutch housing

1. Sprag clutch
Sprag Clutch Inspection 2. Sprag clutch housing
Inspect sprag clutch and sprag clutch housing for 3. Sprag clutch gear
wear and damage. 4. Apply engine oil here
Also check the collar of the sprag clutch gear.
Rotate sprag clutch gear in sprag clutch. Insta11 rotor, refer to ROTOR in this subsection.
NOTE: Sprag clutch must lock in Tighten sprag clutch housing screws to
counterclockwise direction. specification.

SPRAG CLITCH HOUSING SCREW

30N·m±2N·m
Tightening torque (22 lbf·ft±1lbf·ft)

SPRAG CLUTCH GEAR

Sprag Clutch Gear Removal
Remove ROTOR. See procedure in this
subsection.
Pul1 sprag clutch gear out of the rotor.
SPRAG CLUTCH FUNCTION TEST
1. Lock

NOTE: Sprag clutch, housing and gear must be

replaced at the same time, if damaged.
Sprag Clutch Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
 Starter Drive Gear Removal
Remove MAGENTO COVER. See procedure in
this subsection.
Remove location pins, starter double gear and
intermediate gear.

1. Rotor
2. Spfag clutch gear

Sprag Clutch Gear Inspection

Inspect gear, especially teeth and sprag clutch
Collar, for wear and other damage.
Check needle bearing condition. Replace sprag 1. Intermediate gear
clutch gear if necessary. 2. Starter double gear
3. Starter gear
4. Location pins

Starter Drive Gear Inspection

Inspect gears and location pins for wear and dam-
age.
Replace parts as necessary.
Starter Drive Gear Installation
The installation is the reverse of the removal
Procedure. Pay attention to the following details.
INSPECT Apply LOCTITE 767 (ANTISEIZE
1. Teeth LUBRICANT) (p1N2g3 8oo o7o) on starter gear
2. Collar before installing the starter double gear.
3. Needle bearing Apply engine oil on location pins.

Sprag Clutch Gear Installation

The installation is the reverse of the removal
Procedure.
NOTE: Apply engine oil on needle bearing and
Collar of sprag clutch gear.

STARTER DRIVE GEARS

Starter Drive Gear Location
The starter drive gears are located on the engine
MAG side behind the magneto cover.
INTAKE MANIFOLD
 2. Release fuel pressure by running engine until it
PROCEDURES runs out of gas.
PLENUM BRACKET 3. Disconnect the fuel hoses at the fuel injectors ,
Plenum Bracket Installation refer to ELECTRON FUEL INJECTION (EFI).
On Cylinder1, install the plenum bracket using the △CAUTION The fuel hose may still be under
appropriate mounting holes. pressure.
4. Disconnect fuel injectors electrical connectors .
5. Remove plenum adapter elbow.

1. Mounting holes for the 1000 engine 1. Plenum adapter elbow

2. Mounting holes for the 800R engine 2. Remove retaining screws
Tighten plenum bracket retaining screws to 3. Remove clamps
specification
6. Remove intake manifold from engine
PLENUM BRACKET RETAINING SCREWS
Tightening torque 10N·m±1 N·m
(89lbf·in±9lbf·in)

INTAKE MANIFOLD
Intake Manifold Access
Refer to BODY and remove the lower console .
Intake Manifold Removal
1. Disable fuel pump using B.U.D.S. Select the
ECM and Activation tabs, then click on Disabled
in the fuel pump area.
SOME PARTS REMOVED FOR CLARITY
1 Intake manifold
2. Remove retaining screws (×4)

Intake Manifold Inspection

Check intake manifold for cracks, warping at
flanges or any other damage. Replace if necessary.

1.Click “Dosable”
Intake Manifold Installation
The installation is the reverse of the removal
procedure. However, pay attention to the
followin9.
Tighten intake manifold retaining screws to
specified torque one cylinder at a time.

INTAKE MANIFOLD RETAINING SCREWS

Tightening torque 20N·m±2.5N·m
(15lbf·ft 士 2 lbf·ft)

Tighten elbow retaining screws to specification.

INTAKE MANIFOLD RETAINING SCREWS

Tightening torque 10N·m±1N·m
(89lbf·ft 士 9 lbf·ft)

Tighten intake manifold clamps to specification.

INTAKE MANIFOLD RETAINING SCREWS

Tightening torque 0.7N·m±0.1N·m
(6lbf·ft 士 1 lbf·ft)

Enable fue1 pump using B.U.D.S.

TOP END
SERVICE TOOLS
Description Part Number Page
CRANKSHAFT LOCKING BOLT
ENGINE LEAK DOWN TEST KIT
PISTON CIRCLIP INSTALLER..
PISTON CIRCLIP INSTALLER..
PISTON RING COMPRESSOR
TDC DIAL INDICATOR
VALVE GUIDEINSTALLER
VALVE GUIDE REMOVER5 MM
VALVE SPRING COMPRESSOR CUP
VALIVE SPRING COMPRESSOR

SERVICE TOOLS- OTHER SUPPLIER

Description Part Number Page
SNAP-ON PLIERS

SERVICE PRODUCTS
Description Part Number Page
LOCTITE767 (ANTISEIZE LUBRICANT)
CYLINDER HEAD NO.1
CYLINDER HEAD NO.2
CYLINDER AND PISTONS
 △WARING
GENERAL
Always respect this order for disassembly;
Special reference are made in the text for disconnect BLACK (-) cable first.
procedures which are different for cylinder no. 1
and cylinder no. 2. Remove radiator cap.
△WARING
To prevent burning yourself only remove the
radiator cap by wearing the appropriate safety
equipment.

Unplug spark plug cable.

Clean spark plug area and remove spark plug from
cylinder head.

1. Cylinder 1 (front)
2. Cylinder 2 (rear)

When diagnosing an engine problem, always

perform a cylinder leak test.
NOTE: Even though the following procedures do
not require the engine removal, many illustrations
show the engine out of the vehicle for more clarity. 1. Spark plug cable
IMPORTANT: Note position of parts on 2. Spark plug
disassembly. This may help to find the root cause
of a problem. A component that is not replaced Remove valve cover.
should be reinstalled in the same position as
originally mounted.

INSPECTION
LEAK TEST
Before performing the cylinder leak test , verify
the following:
- Clamp(s) tightness
- Radiator and hoses.
NOTE: For best accuracy, the leak test should be
done with the engine at normal operating 1. Valve cover screws
temperature. 2. Valve cover
△WARING
Prevent burning yourself on hot engine parts. Rotate crankshaft until piston is at ignition TDC.
Preparation To turn crankshaft, there are two possible
Disconnect battery procedures.
First Procedure
Turn the drive pulley.
Second Procedure
1. Remove plug screw with 0-ring from magneto
cover.
2. Use a14 mm Allen key and turn crankshaft.
NOTICE Turn only clockwise to avoid loosening
of magneto flywheel Allen screw.
Set the piston to precisely ignition TDC.
 REQIRED TOOL NOTE: All testers have specific instructions on
TDCDIAL INFICATOR gauge operation and required pressure.
(P/N 414 104 700) Install gauge adapter into previously cleaned spark
plug hole.
Supply combustion chamber with air pressure.

1. Dial gauge

NOTE: If a dial gauge is not available , use a

screw driver or another similarly suitable tool.
NOTICE Do not scratch or damage piston/ TYPICAL
cylinder surface. 1. Leak tester
NOTE: At ignition TDC the marks on the camshaft 2. Air supply hose
timing gear have to be parallel to cylinder head Note the amount or percentage of leakage
base as per following illustration. (depending on tester).
LEAKAGE ENGINE
PERCENTAGE CONDIT1ON
0% to15% Excellent condition
16% to25% Good condition
26% to40% Fair condition; reduced
engine performance
41% and higher Poor condition , diagnose
and repair engine
NOTE: To make sure there is no false reading due
to a valves not perfectly seated, tap each valve
adjustment screw (on the rocker) using a soft
1. Marks on camshaft timing gear hammer.
2. Cylinder 1leaol base Diagnosis
Listen for air leaks .
Leak Test
_ Air escaping in intake port/throttle body means
REQIRED TOOL leaking intake valve(s).
ENGINE LEAK _ Air escaping in exhaust port means leaking
DOWN TEST KIT exhaust valve(s).
(P/N 529 035 661) _ Air bubbles in the coolant (radiator) means
leaking cylinder head gasket.
Connect leak tester to adequate air supply _ Air/coolant escaping from cylinder/head means
Set needle of measuring gauge to zero. damaged gasket(s) and/or loosened screws.
- Air escaping into crankcase area means
excessively worn cylinder and/or broken piston
rings.
-Air/oil escaping from crankcase means damaged
gasket and/or loosened screws(refer to BOTTOM
END subsection).
NOTE: For all the checkpoints mentioned above,
see the appropriate engine section to diagnose and
repair the engine.
Reassembly 1. Valve cover
Reverse the preparation procedure. Ensure to 2. Gasket
respect torque values and use of appropriate
Products / lubricants. Refer to exploded views in Repeat the procedure for the other valve cover if
other subsections of this manual as required. required.
Valve Cover Inspection
PROCEDURES Check the gasket on the valve cover if it is brittle,
VALVE COVER cracked or hard. If so, replace the gasket.
Valve Cover Access Valve Cover Installation
Refer to BADY and remove: For installation, reverse the removal procedure.
- Upper console Tighten valve cover retaining screws to specified
- Lower console torque in a criss -cross sequence.
- LH and RH lateral console panels.
Valve Cover Removal VALE COVER RETAINING SCREW
Remove valve cover screws of valve cover. Tightening torque 7N · m ± 0.8N · m
(62lbf·ft 士 7 lbf·ft)

ROCKER ARM
Rocker Arm Removal
Remove valve cover.
Refer to TIMING CHAIN subsection and remove
the following parts:
- Timing chain tensioner
- Camshaft timing gear.
Remove pan head screw and camshaft retaining
1. Valve cover screws plate.
2. Valve cover

Remove valve cover and gasket

1. Camshaft retaining plate
2. Pan head screw 1. Rocker arm (exhaust side)
3. Cylinder head' 2. Rocker arm (intake side )
3. Thrust washers
Remove rocker arm shafts
NOTICE Pay attention not to lose thrust washers
or drop them into the timing chain compartment.

1. 2 thrust washers
2. Rocker arm (exhaust side)
1. Rocker arm shaft 3. Cylinder head (spark plug side)
2. Rocker arm (exhaust side) 4. Big taper to spark plug side
3. Rocker arm (intake side )
4. Adjustment screw Rocker Arm Inspection
5. lock nut Inspect each rocker arm for cracks and scored
friction surfaces. If so, replace rocker arm
Remove rocker arm assembly(exhaust side and assembly. Check the rocker arm rollers for free
intake side) with adjustment screws and lock nut movement, wear and excessive radial play.
Remove thrust washers. Replace rocker arm assembly if necessary.
 ROCKER ARM SHAFT DIAMETER
NEW 12.00mm to12.018mm
(.4724in to.4731 in)

SERVICE LIMIT 11.990mm(.472in)

Any area worn excessively will require parts

replacement.
1. Rocker arm (exhaust side) Rocker Arm Installation
2. Roller NOTE: Use the same procedure for exhaust and
3. Bore for rocker arm shaft intake rocker arm.
Apply engine oil on rocker arm shaft.
Measure rocker arm bore diameter. If diameter is Install the rocker arm shafts with the chamfered
out of specification, change the rocker arm edge first and use following procedure.
assembly. Insert a rocker arm pin through rocker arm pin
bore.
ROCKER ARM BORE DIAMETER Install a thrust washer at timing chain side, then
NEW 12.036mm to12.050mm the proper rocker arm(exhaust side or intake side).
.4739in to.4744in) Push in rocker arm shaft until its chamfer reaches
SERVICE LIMIT 12.060 mm (.4748in) the end of rocker arm bore.

Check adjustment screws for free movement,

cracks and/or excessive play.

1. Free movement of adjustment screw top

Rocker Arm Shaft Inspection 1. Rocker arm shaft

Check for scored friction surfaces; if so, replace 2. Thrust washer (timing chain side)
parts. 3. Thrust washer (spark plug side)
Measure rocker arm shaft diameter
Place the other thrust washer and push rocker arm
shaft to end position.
Install the camshaft retaining plate.
Adjust valve clearance, refer to PEROODIC
MAINTENANCE PROCEDURE
A. Measure rocker arm shaft diameter here
CAMSHAFT
NOTE: The engine is equipped with two different
camshafts.

1. Camshaft retaining plate

2. Pan head screw
3. Cylinder head

Remove rocker arms (see ROCKER ARM in this

1. Intake cam subsection).
2. Exhaust cam Remove the camshaft.
3. Camshaft of cylinder1 NOTE: For removal rotate camshaft so that
4. Camshaft of cylinder1 intake/ exhaust lobe shows to upper side of
5. Flat spot cylinder head.

Camshaft Removal
The removal procedure is the same for both
camshafts.
NOTICE Each camshaft is different in design.
Thus, it is important not to mix up any parts of the
camshaft assembly with that of the other cylinder.
Keep parts as a group.

Remove valve cover(see VALVE COVER in this

subsection).
Refer to TIMING CHAIN subsection and remove 1. Camshaft retaining plate
the following parts: 2. Area for camshaft lobes
- Timing chain tensioner 3. Camshaft
- Camshaft timing gear.
Remove the camshaft retaining plate. Camshaft Inspection
Camshaft Lobe Inspection
Check each lobe for scoring, scuffing, cracks or
other signs of wear.
Measure camshaft lobe height using a micrometer
A. Camshaft lobe (exhaust valves) A. Camshaft lobe (exhaust valves)
B. Camshaft lobe (intake valves) B. Camshaft lobe (intake valves)
C. Camshaft journal (timing chain side) C. Camshaft journal (timing chain side)
D. Camshaft journal (spark plug side) D. Camshaft journal (spark plug side)

CAMSHAFT LOBE (EXHAUST) CAMSHAFT JOURNAL

32.950mm to33.150 mm (TIMING CHAIN SIDE)
NEW
800R (1.2972in to1.3051 in) 34.959mm to34.975mm
NEW
ENGINE SERVICE 32.930 mm(1 2965 in) (1 3763 in to1 .377 in)
LIMIT SERVICE LIMIT 34.950 mm(1 .376 in)
32.860 mm to33.060 mm
NEW
1000 (1.294in to1.302in) CAMSHAFT JOURNAL
ENGINE SERVICE 32.840 mm(1 .293in) (SPARK PLUG SIDE)
LIMIT 21 959 mm to21 980 mm
NEW
(.8645in to.8654in)
SERVICE LIMIT 21 .950 mm(.8642 in)
CAMSHAFT LOBE (INTAKE)
NEW 32.890mm to33.090 mm Camshaft Installation
800R (1.2949in to1.3028 in) For installation, reverse the removal procedure.
ENGINE SERVICE 32.870 mm(1. 2941 in) Pay attention to the following details.
LIMIT NOTICE The camshafts are not identical in
NEW 32.960 mm to33.160 mm design. Do not invert the camshafts during
1000 (1.298in to1.306in) assembly. Any mix-up of the components will lead
ENGINE SERVICE 32.940 mm(1 .297in) to engine damage.
LIMIT Place the camshaft retaining plate in the slot of the
camshaft.
Measure camshaft bearing in cylinder head . Refer
to CYLINDER HEAD INSPECTION in this
subsection.
Camshaft Journal Inspection
Check each journal for scoring, scuffing, cracks or
other signs of wear.
Measure camshaft journal using a micrometer .
 NOTE: Before removing cylinder head, blow out
remaining coolant by air pressure. During cylinder
head removal, the remaining coolant in cylinder
head could overflow into the engine and a little
quantity of coolant could drop into the engine. In
this case, the engine oil will be contaminated.
Disconnect spark plug wire.
Disconnect temperature sensor connector, located
at rear cylinder head.
Remove the valve cover and its gasket (see
1. Direction of movement VALVECOVER in this subsection).
2. Camshaft retaining plate Refer to TIMING CHAIN subsection and remove
3. Slot retaining camshaft the following parts:
- Timing chain tensioner
For other parts, refer to proper installation - Camshaft timing gear.
procedure. First remove the M6 cylinder he1id screws, then
CYLINER HEAD the M10 cylinder head screws.
Cylinder Head Access
Refer to BODY and remove:
- Lower console
- LH and RH lateral console panels.
Remove LH passenger handhold bar.

1. Cylinder head screws M 10

2. Cylinder head screws M 6

Pull up cylinder head.

Remove timing chain guide (fixed).
LH PASSENGER HANDHOLD BAR Remove and discard the cylinder head gasket,

On cylinder2, remove the shift cable bracket.

Refer to INTAKE MANIFOLD subsection to
remove following parts:
- Plenum, for cylinder 1
- Intake manifold.
Cylinder Head Removal
The removal procedure is the same for both
cylinder heads.
Drain coolant. Refer to ENGINE COOLANT
REPLACEMENT in the PERIODIC
MAINTENANCE PRODURES subsection.
1. Cylinder head A. Cam shaft bearing (timing chain side)
2. Timing chain B. Cam shaft bearing (spark plug side)
3. Chain guide (fixed)
4. Cylinder head l gasket CAMSHAFT BEARING
(TIMING CHAIN SIDE)
Cylinder Head Inspection 35.000 mm to35.025mm
NEW
Inspect timing chain guide (fixed) for wear, cracks (1.378in to1.3789in)
or other damages. Replace if necessary. SERVICE
35.040 mm(1 3795 in)
Check for cracks between valve seats, if so, LIMIT
replace cylinder head. CAMSHAFT BEARING (SPARK PLUG SIDE)
Check mating surface between cylinder and 22.000mm to22.021 mm
NEW
cylinder head for contamination. If so, clean both (.8661 in to.867in)
surfaces. SERVICE
Clean oil support through the cylinder head from 22.040 mm(.8677 in)
LIMIT
contamination.
Cylinder Head Installation
NOTE: Never invert front and rear cylinder heads.
0n the800R, cylinder heads are not identica1.
For installation, reverse the removal procedure.
Pay attention to the following details.
Ensure dowel pins are in place.
NOTICE Timing chain guide (fixed) has to be
fixed between cylinder and cylinder head.

1. Oil port to lubricate camshaft lobes intake

/exhaust
2. Oil supply to camshaft bearing journal (timing
chain side)
3. Oil supply to camshaft bearing journal (spark
plug side)
Cylinder Head Camshaft Bearing Inspection
Measure camshaft bearing in cylinder head.
 TIGHTENCE SEQUENCE-M10 CYLINDER HEAD
TYPICAL SCREWS
1. Timing chain guide (tensioner side) mounted in
crankcase M10 CYLINDER HEAD SCREWS
2. Timing chain guide (fixed) between cylinder ,and Tightening torque 20N·m±1N·m
cylinder head (step1) (15lbf·ft±1 lbf·ft)

Install a NEW cylinder head gasket. M10 CYLINDER HEAD SCREWS

Install cylinder head screws in correct position. Tightening torque 180°＋/－5°
(step2)
NOTICE Cylinder head screws have different sizes
and lengths. Tighten M6 cylinder head screws as per following
specification.

1. M6 Screws

1. Location no. 1 Check timing chain guide (tensioner side) for

2. Location no. 2 movement.
CYLINDER HEAD SCREW IDENTIFICATION On cylinder1, install the plenum bracket, refer to
800R engine Location no. 1 M10×140 INTAKE MANIFOLD subsection.
Location no. 2 M6×85
1000 engine Location no. 1 M10×159
Location no. 2 M6×105

Tighten M10 cylinder head screws FIRST as per

following specifications.
VALVE SPRINGS
Valve Spring Removal
Refer to following procedures in this subsection to
remove:
- CAMSHAFT
- CYLINDER
Compress valve spring.

REQUIRED TOOL
VALVE SPRING COMPRESSOR
(P/N529 035 724) 1. Valve spring compressor clamp
VALVE SPRING COMPRESSOR 2. Valve spring compressor cup
CUP (P/N529 035 764) 3. Valve cotter

△WARNING Remove tools and withdraw valve spring retainer

Always wear safety glasses when disassembling and valve spring.
valve springs. Be careful when unlocking valves.
Components could fly away because of the strong
spring preload.

1. Valve spring retainer

2. Valve spring

LOCATE VALVE SPRING COMPRESSOR CLAMP IN Valve Spring Inspection

CENTER OF THE VALVE Check valve spring for visible damage. lf so, re-
place valve spring.
Remove valve cotters, Check valve spring for free length and
straightness.
 VA LVES
Valve Removal
Remove valve spring, see VALVE SPRING in this
subsection.
Push valve stem, then pull valves (intake and
exhaust) out of valve guide.

A. Valve spring length

VALVE SPRING FREE LENGTH

NEW 40.81 mm(1.607in)
SERVICE LIMIT 39.00 mm(1 535in)

Replace valve springs if not within specifications.

Valve Spring Installation
For installation, reverse the removal procedure.
Pay attention to the following deta11s.
Colored area of the valve spring must be placed on
top. 1. Intake valve 31mm
To ease installation of cotters, apply oil or grease 2. Exhaust valve 27 mm
on them so that they remain in place while Remove valve stem seal and discard it
releasing the spring.
NOTE: Valve cotter must be properly engaged in REQUIED TOOL
valve stem grooves. SNAP-ON PLIERS(P/N YA 8230)

1. Position of the valve spring

2. Valve cotter

After spring is installed, ensure it is properly

locked by tapping on valve stem end with a soft
hammer so that valve opens and closes a few
times. Valve Inspection
Whenever valves are removed always inspect
NOTICE An improperly 1ocked valve spring will valve guides. Refer to VALVE GUIEDS in this
cause engine damage. subsection.
 VALVE STEM DIAMETER
Valve Stem Seal
EXHAUST VALVE
Always install NEW seals whenever valves are NEW 4.956mm to4.970 mm
removed. (.1951 in to.1957in)
Valve SERVICE LIMIT 4.930mm(.1941 in)
Inspect valve surface, check for abnormal stem INTAKE VALVE
wear and bending. If out of specification, replace NEW 4.966mm to4.980 mm
by a new one. (.1955in to.1961 in)
SERVICE LIMIT 4.930mm(.1941 in)
Valve Face and Seat

VALVE OUT OF ROUND 1. Valve seat

(INTAKE AND EXHAUST VALVES) 2. Exhaust valve contaminated area
NEW 0.005mm(.0002 in) 3. Valve face (contact surface to valve seat)
SERVICE LIMIT 0.06 mm(.0024in)
Check valve face and seat for burning or pittings
Valve Stem and replace valve or cylinder head if there are
Measure valve stem in three places using a signs of damage.
micrometer . Ensure to seat valves properly. Apply some lapping
Replace valve if valve stem is out of specification compound to valve face and work valve on 1ts seat
or has other damages such as wear or friction with a lapping tool (see VALVE GUIDEA in this
surface. subsection).
Measure valve face contact width.
NOTE: The location of contact area should be in
center of valve seat.
Measure valve seat width using a caliper .

VALVE SEAT CONTACT WIDTH

EXHAUST VALVE
NEW 1.25mm to1.55mm
(.049in to.061 in)
SERVICE LIMIT 2.00 mm(.079 in)
A. Valve stem diameter INTAKE VALVE
NEW 1.05mm to1.35mm
(.041 in to.053in)
SERVICE LIMIT 1.80mm(.071 in)
If valve seat contact width is too wide or has dark VALVE GUIDES
spots, replace the cylinder head. Valve Guide Inspection
Always replace valve stem seals whenever valve
guides are removed.
Measure valve guide in three places using a small
bore gauge.
NOTE: Clean valve guide to remove carbon
deposits before measuring.
Replace valve guide if it is out of specification or
has other damages such as wear or friction surface.
VALVE GUIDE DIAMETER
(INTAKE AND EXHAUST VALVES
NEW 4.998mm to5.018mm
A. Valve face contact width (.1968in to.1976in)
B. Valve seat contact width SERVICE LIMIT SERVICE LIMIT
5.050 mm(.1988 in)
Valve Installation Valve Guide Removal
For installation, reverse the removal procedure. Refer to following procedures in this subsection to
Pay attention to the following details. remove:
Install a NEW valve stem seal. Make sure thrust - Cylinder head
washer is installed before installing seal. - Valves.
Apply engine oil on valve stem and insta1l it. NOTE: Clean valve guide area from contamination
NOTICE Be careful when valve stem is passed before removal.
through sealing lips of valve stem Drive the valve guide out of cylinder head.
sea1.
REQUIED TOOL
Hammer
VALVE GUIDE
REMOVER 5 MM

1. Thrust washer
2. Sealing lips of valve stem seal

To ease installation of cotters, apply oil or grease

on them so that they remain in place while
releasing the spring.
After spring is installed, ensure it is properly
locked by tapping on valve stem end with a soft 1. Valve guide remover
hammer so that valve opens and c1oses a few 2. Valve guide
times. Valve Guide Installation
NOTICE An improperly locked valve spring wi1l For installation, reverse the removal procedure.
cause engine damage. Pay attention to the following details.
Clean the valve guide bore before reinstalling the
valve guide into cylinder head.
Install valve guide.

REQUIED TOOL
VALVE GUIDE
INSTALLER

1. Valve seat
2. Valve face (contact surface to valve seat)
3. Turn valve while pushing against cylinder head
A. Valve seat angle 45°

NOTE: Ensure to seat valves properly. Apply

marking paste to ease checking contact pattern.
Repeat procedure until valve seat/valve face fits
1. Valve guide installer together.
2. Valve guide CYLINDER
Cylinder Removal
NOTE: Apply LOCTITE767 (ANTISEIZE Refer to TUMING CHAIN subsection and remove
LUBRICANT) (P/N293 800 070) on valve guide the following parts:
prior to install it into the cylinder head. - Timing chain tensioner
NOTICE Push valve guide in the cold cylinder - Camshaft timing gear.
head as per following illustration. Remove the cylinder head (see CYLINDER
HEAD in this subsection).
Pull cylinder.
Discard cylinder base gaskets.

1. Thrust surface of cylinder head

2. Valve guide
A. Measurement from thrust surface to valve guide
top
VALVE GUIDE(MEASUREMENT“A”) 1. Cylinder
NEW 14.00mm to14.40mm 2. Piston assembly
(.5512 in to .5669 in) 3. Cylinder base gasket
4. Camshaft timing chain
Apply some lapping compound to valve face and
work valve on its seat with a lapping tool.
 Cylinder Inspection
Check cylinder for cracks, scoring and wear ridges
on the top and bottom of the cylinder. If so, replace
cylinder.
Cylinder Taper
Measure cylinder bore at3 recommended positions.

A. Perpendicular to crankshaft axis

B. Parallel to crankshaft axis

CYLINDER OUT 0F ROUND

NEW (MAXIMUM) 0.015mm(.0006in)
SERVICE LIMIT 0.020 mm(.0008 in)

A. First measurement (from cylinder bottom) Cylinder Installation

B. Second measurement For installation, reverse the removal procedure.
C. Third measurement Pay attention to the following details.
NOTICE Always replace cylinder base gasket
CYLINDER TAPER MEASUREMENTS before installing the cylinder.
ENGINE MEASUREMENT SPECIFICATION NOTE: Make sure piston rings are properly spaced,
A 5mm(.197in) refer to PISTION in this subsection.
800R engine B 63mm(2.48in) Apply engine oil:
C 32 mm(1 26in) - In the bottom area of the cylinder bore
A 5mm(.197 in) - On the piston rings
1000 engine B 58 mm(2.283 in) - On the compressor tool.
C 52 mm(2.047 in) Compress piston rings.

CYLINDER TAPER SPECIFICATION REQUIED TOOL

NEW (MAXIMUM) 0.038mm(.0015in) PISTON RING COMPRESSOR
SERVICE LIMIT 0.090 mm(.0035in)

Distance between measurements should not exceed First mount cylinder 2.

the service limit mentioned above. Otherwise, NOTE: The cylinder can not be pushed fully over
replace cylinder and piston rings. the piston unless the piston is located at TDC.
Cylinder Out of Round Then remove the CRANKSHAFT LOCKING
Measure cylinder diameter in piston axis direction BOLIT (P/N529 035 617).
from top of cylinder . Take another measurement Crank the engine further and position piston1 at
90° from first one and compare . TDC.
NOTE: Take the same measuring points like Mount cylinder 1.
described in CYLINDER TAPER above. Put timing chain through the chain pit then put the
cylinder in place.
 1. Piston circlip
NOTE: The removal of both piston circlips is not
necessary to remove piston pin.
Push piston pin out of piston.
1. Piston ring compressor tool
2. Piston
3. Cylinder

NOTICE Chain guide has to be fixed between

cylinder and cylinder head.
NOTE: After both cylinders are installed, turn
crankshaft until piston of cylinder2 is at TDC and
lock crankshaft. Refer to CRANKSHAFT
BOTTOM END subsection. 1. Piston
Install cylinder head and the other parts in 2. Piston pin
accordance with the proper installation procedures.
Detach piston from connecting rod.
PISTON
Piston Inspection
Piston Removal Inspect piston for scoring, cracking or other
Refer to following procedures in this subsection to damages. Replace piston and piston rings if
remove: necessary.
- Cylinder head Using a micrometer, measure piston at8mm (.315in)
- Cylinder. perpendicularly (90°) to piston pin.
Place a rag under piston and in the area of timing
chain compartment.

△WARNING
Piston circlips are spring loaded

Remove one piston circlip and discard it.

1. Measuring perpendicularly (90°) to piston pin
A. 8mrn (375in)
1. Use the micrometer to set the cylinder bore
The measured dimension should be as described in gauge
the following tables. If not, replace piston. 2. Dial bore gauge

PISTON MEASUREMENT
NEW 90.950 mm to90.966mm
(3.5807in to3.5813in)
SERVICE LIMIT 90.850 mm(3.577 in)

Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston
dimension.

TYPICAL
1. Indicator set to 0(zero)

Position the dial bore gauge20 mm (.787 in) above

cylinder base, measuring perpendicularly (90°) to
piston pin axis.
Read the measurement on the cylinder bore gauge.
The result is the exact piston/cylinder wall
1. Micrometer set to the piston dimension clearance.
PISTON/CYLINDER CLEARANCE
With the micrometer set to the dimension, adjust a NEW 0.027mm to 0.057 mm
cylinder bore gauge to the micrometer dimension (.0011 in to.0022in)
and set the indicator to 0(zero). SERVICE LIMIT 0.100 mm(.0039 in)
NOTE: Make sure used piston is not worn.
If clearance exceeds specified tolerance, replace
piston by a new one and measure piston/cylinder
clearance again.
NOTE: Make sure the cylinder bore gauge
indicator is set exactly at the same position as with
the micrometer, otherwise the reading will be false.
Connecting Rod/Piston Pin Clearance CONNECTING ROD SMALL END DIAMETER
Using synthetic abrasive woven, clean piston pin 800R
from deposits . NEW 20.010 mm to20.020 mm
Inspect piston pin for scoring, cracking or other (.7878in to.7882in)
damages. SERVICE LIMIT 20.060 mm(.7898 in)
Measure piston pin . See the following illustration 1000
for the proper measurement positions. NEW 20.010 mm to20.020 mm
(.7878in to.7882in)
SERVICE LIMIT 20.050 mm(.7894in)

Replace connecting rod if diameter of connecting

rod sma1l end is out of specifications. Refer to
BOTTOM END subsection for removal procedure.
Compare measurements to obtain the connecting
rod/piston pin clearance.
A. Piston pin diameter
CONNECTING ROD/
PISTON PIN DIAMETER PISTON PIN CLEARANCE
800R SERVICE LIMIT 0.080mm(.0031 in)
NEW 19.996mm to20.000 mm
(.7872in to.7874in) Piston Installation
SERVICE LIMIT 19.980 mm(.7866 in) For installation, reverse the removal procedure.
1000 Pay attention to the following details.
NEW 21.996mm to22.000 mm Apply engine oi1 on the piston pin.
(.866in to.8661 in) 1nsert piston pin into piston and connecting rod.
SERVICE LIMIT 21 .980 mm(.8654in) For each cylinder, Install piston with the punched
arrow on piston dome is pointing toward the rear
Replace piston pin if diameter is out of side of the engine.
specifications. Front cylinder: Mark on top of piston must show
Measure inside diameter of connecting rod small to intake side.
end bushing . Rear cylinder: Mark on top of piston must show
to exhaust side.

1. Bore gauge
2. Connecting rod
 1. Circlip
2. Sleeve
3. Assembly jig from piston clip installer

1. Piston of cylinder 1 Push taper side of assembly jig until circlip reaches
2. Mark on piston must show to intake side of middle of sleeve.
cylinder 1 Align sleeve with piston pin axis and push
3. Piston of cylinder 2 assembly jig until circlip engages in piston.
4. Mark on piston must show to exhaust side of
cylinder 2
Use the piston appropriate circlip installer to
assemble the NEW piston circlip as per following
procedure:

ENGINE TYPE TOOL

800R PISTON CIRCLIP
INSTALLER
1000 PISTON CIRCLIP
INSTALLER
1. Hold piston while pushing circlip in place
2. Sleeve
3. Assembly jig
4. Direction to push circlip

NOTE: Take care that the hook of the piston circlip

TYPICAL is positioned properly.

NOTICE Always replace disassembled piston

circlip(s) by NEW ones. Place a rag on cylinder
base to avoid dropping the circlip inside the
engine.
Place circlip in sleeve as per following illustration.
 1. Piston
2. Feeler gauge

CORRECT POSITION OF THE PISTON CIRCLIP Ring End Gap

RING/PISTON GR00VE CLEARANCE
UPPER COMPRESSION RING
PISTON RINGS
NEW 0.20 mm to 0.40 mm
Ring Removal (.008in to.016in)
Remove the piston (see PISTON in this SERVICE LIMIT 0.60 mm(.024in)
subsection). LOWER COMPRESSION RING
Ring Inspection NEW 0.20 mm to 0.40mm
Ring/Piston Groove Clearance (.008in to.016in)
Using a feeler gauge measure each ring/piston SERVICE LIMIT 0.70 mm(.028 in)
groove clearance . If the clearance is too large, the OIL SCRAPER RING
piston and the piston rings should be replaced. NEW 0.20 mm to 0.70mm
(.008in to.028in)
RING END GAP SERVICE LIMIT 1 .00 mm(.039in)
UPPER COMPRESSION RING To measure the ring end gap place the ring in the
NEW 0.03mm to 0.07mm cylinder in the area of 8mmto16mm (5/16in
(.0012in to.0028in) to5/8in) from top of cylinder.
SERVICE LIMIT 0.150mm(.0059in) NOTE: In order to correctly position the ring in the
LOWER COMPRESSION RING cylinder, use piston as a pusher.
NEW 0.02 mm to 0.06mm Using a feeler gauge, check ring end gap. Replace
(.0008in to.0024in) ring if gap exceeds above described specified
SERVICE LIMIT 0.150mm(.0059in) tolerance.
OIL SCRAPER RING Ring Installation
NEW 0.01 mm to 0.18mm For installation, reverse the removal procedure.
(.0004in to.0071 in) Pay attention to the following details.
SERVICE LIMIT 0.250mm(.0098in) NOTE: Use a ring expander to prevent breakage
during installation. The oil ring must be installed
by hand.
NOTE: First install spring and then rings of oil
scraper ring.
Install the oil scraper ring first, then the lower
compression ring with the word “N” and “TOP”
facing up, then the upper compression ring with
the word “N” and “TOP” facing up.
1. Upper compression ring
2. Lower compression ring
3. 0il scraper ring

NOTICE Ensure that top and second rings are not

interchanged.

Check that rings rotate smoothly after installation.

Space the piston ring end gaps120° apart and do
not align the gaps with the piston pin bore or the
thrust side axis.

1. DO NOT align ring gap with piston thrust side

axis
2. DO NOT align ring gap with piston pin bore
axis
A. 120°
TIMING CHAIN

SERVICE TOOLS
Description Part Number Page

CAMSHAFT TIMING TOOL

CRANKSHAFT TDC POSITION TOOL

SERVICE PRODUCTS
Description Part Number Page
LOCTITE243 (BLUE)
TIMING CHAIN
GENERAL
IMPORTANT: Note position of parts on
disassembly. This may help to find the root cause
of a problem. A component that is not replaced
should be reinstalled in the same position as
originally mounted.
TROUBLESHAOOTONG
UNUSUAL ENGINE NOISE OR VIBRATION
1. IMPROPER VALVE CLEARANCE
ADJUSTMENT AND/OR WORN OUT ROCKER
ARM(S) 800R Engine-(FRONT CYLINDER SHOWN)
-Readjust valve clearance and/or replace defective 1. Timing chain tensioner
part(s), refer to TOP END subsection.
2. DEFECTIVE CHAIN TENSIONER 1000 Engine
-Replace chain tensioner The timing chain tensioner is located in the
3. WORN OUTTIMING CHAIN GUIDE(S) cylinder.
-Replace chain guide(s)
4. STRETCHED TIMING CHAIN OR WORN
OUT TIMING GEARS
-Replace timing chain and timing gears.
5. LOOSE TIMING GEAR RETAINING
SCREWS
-Retighten screws to recommender torque.
6. INCORRECT CAMSHAFT TIMING
-Replace damaged components and readjust
camshaft timing.

ENGINE LACKS ACCELERATION OR 800R Engine-(FRONT CYLINDER SHOWN)

POWER 1. Timing chain tensioner
1. INCORRECT CAMSHAFT TIMING
_Replace damaged components and readjust Timing Chain Tensioner Removal
camshaft timing. 1. Make sure the respective cylinder is set to TDC
ignition. Refer to CAMSHAFT TIMING GEARS
PROCEDURES in this subsection.
TIMING CHAIN TENSIONERS 2. Carefully unscrew chain tensioner plug and
Timing Chain Tensioner Location release spring tension.
800R Engine △CAUTION Tensioner is spring loaded.
The timing chain tensioner is located in the 3. Remove:
cylinder head. - O-ring
- Spring
- Chain tensioner plunger
 Timing Chain Tensioner Installation
1. For installation, reverse the removal procedure.
However, pay attention to the following.
NOTE: Before installing the chain tensioner make
sure, that the camshaft timing gear can be moved
back and forth.

1. Chain tensioner plug

2. O-ring
3. Spring
4. Chain tensioner plunger

4. Remove:
- Chain tensioner housing retaining screws
- Chain tensioner housing
- O-ring. MOVE GEAR BACK AND FORTH

2. Apply engine oil on the plunger before

insta1lation.
3. Slightly turn the camshaft timing gear in order
to get the timing chain play on the tensioner side.
4. Slightly screw the plunger in until the timing
chain allows no more back and forth movement of
the camshaft timing gear.
5. Screw the plunger in an additional 1/8 turn to
reach the required specified torque.
TIMING CHAIN TENSIONER ADJUSTMENT
1. Screws (TORQUE)
2. Chain tensioner housing 0.1 N·m(.9lbf·in)
3. O-ring, NOTICE Improper adjustment of the timing chain
will lead to severe engine damage.
Timing Chain Tensioner Inspection 6. Fit the spring on one side into the slot of the
Check the chain tensioner housing and plug for plug and on the other side into the plunger.
cracks or other damages. Replace if necessary. NOTE: Turn spring only clockwise in order to fit
Check chain tensioner plunger for free movement the spring end into the notch of the plunger to
and/or scoring. avoid loosening the plunger during spring
Check if 0-rings are brittle, cracked or hard. installation. Do not pre1oad the spring.
Replace if necessary. NOTE: Do not forget to place the 0-ring on chain
Check spring condition. Replace if bent, broken or tensioner plug.
worn. 7. Then compress the spring and screw the plug in.
NOTE: To avoid overstressed timing chain, the Camshaft Timing Gear Installation
plug must engage into threads within the first full For installation, reverse the removal procedure.
turn. Pay attention to the following details.
8. Remove locking tool and install all other 1. Clean mating surface and threads of camshaft
removed parts. prior installing camshaft timing gear.
9. Finally, tighten the plug.
CAMSHAFT TIMING GEARS
Camshaft Timing Gear Removal
Remove the valve cover , refer to TOP END sub
section.
Turn crankshaft to TDC ignition of the respective
cylinder and lock magneto flywheel, see
CAMSHAFT TIMING in this subsection.
Unscrew timing chain tensioner. Refer to TIMING
CHAIN TENSIONERS in this subsection.
Remove camshaft timing gear retaining screws.
1. Mating surface on camshaft
2. Threads for camshaft screws

2. Crankshaft must be set to TDC ignition position

before installing the timing chain, refer to
CAMSHAFT TIMING in this subsection.
3. Insta1l the camshaft timing tool on the cylinder
head.
REQUIED TOOL
CAMSHAFT TIMING TOOL

NOTE: Align tube of camshaft adjustment tool

properly with machined radius on cylinder head.
1. Camshaft timing gear retaining screws
2. Camshaft timing gear

Remove the camshaft timing gear.

NOTE: Secure timing chain with a piece of wire.
Camshaft Timing Gear Inspection
Check camshaft timing gear for wear or
deterioration.
If gear is worn or damaged, replace it as a set with
the timing chain.
For crankshaft gear, refer to BOTTOM END
subsection, see CRANKSHAFT. CAMSHAFT TIMING TOOL INSTALLED
1. Tube (camshaft adjustment tool)
2. Machined radius (camshaft adjustment tool)
3. Cylinder head
4. Set camshaft to TDC ignition position by 7. Install and tighten camshaft timing gear
aligning the camshaft flange flat spot with the tool retaining screws to specified torque.
lever.
NOTE: In addition, to ensure proper camshaft
timing, press camshaft adjustment tool lever
downwards.

1. Camshaft timing gear

2. Timing gear retaining screws
PRESS TOOL LEVER DOWN
1. Lever CAMSHAFTTIMING GEAR RETAINING
2. Flat spot SCREWS
3. Camshaft Service product LOCTITE243 (BLUE)
Tightening torque 10N·m±1N·m
NOTICE Crankshaft and camshaft must be locked (89lbf·in 士 9lbf·in)
at TDC ignition position to place camshaft timing
gear and timing chain in the proper position. 8. Remove the CAMSHAFTTIMING TOOL
5. Place camshaft timing gear along with the Camshaft Timing
timing chain on the camshaft. NOTE: If a piston (of cylinder1 or2) is set to TDC
NOTE: The printed marks on the camshaft timing ignition, the camshaft timing gear of the opposite
gear must be parallel to the cylinder head base. cylinder must be in the following position.

1. Timing chain
2. Camshaft timing gear TYPICAL
3. Printed marks on camshaft timing gear 1. Cylinder head base
2. Marks on timing gear of the opposite cylinder
6. Install and adjust timing chain tensioner , refer
to TIMING CHAIN TENSIONERS in this Camshaft Timing Piston No. 2 (rear)
subsection. 1. Remove spark plugs of both cylinders
2. Remove valve covers of both cylinders.
3. Remove the plug and 0-ring of magneto cover.

1. Allen key74mm

1. Plug 5.1 The rear piston is at TDC when it's index mark
2. O-ring on the magneto flywheel is aligned with notch in
the magneto cover.
4. Remove the crankshaft position sensor (CPS),

1. CPS PISTON N0. 2 AT TDC

2. Screw 1. Mark “2” on magneto flywheel
2. Notch on magneto cover
5. Set piston no. 2to TDC ignition by turning the 3. Crankshaft position sensor location
crankshaft.
5.2 Confirm printed marks on the camshaft timing
REQUIED TOOL gear are parallel to cylinder head base, in the lower
Allen key 14mm position.
NOTE: If printed marks on camshaft timing gear
are not as specified, turn crankshaft 360°.
NOTE: In this position the piston is set to TDC
ignition.
TYPICAL – PISTON AT TDC IGNTION CYLINDER 1 AT TDC IGNTION
1. Printed marks on camshaft timing gear 1. Mark “1” on magneto flywheel
2. Cylinder head base 2. Notch on magneto cover
3. Location of crankshaft position sensor
6. Install the crankshaft TDC position tool to lock
crankshaft in position. Refer to CRANKSHAFT 3.2 Confirm printed marks on the camshaft timing
TDC POSITION TOOL in this subsection. gear are parallel with cylinder head base, in the
Camshaft Timing Piston No. 1 (front) lowest position.
1. Set piston no. 2 (rear) to TDC ignition, see NOTE: In this position the piston is set to TDC
CRANKSHAFT TIMING PISTON NO. 2(READ) ignition.
in this subsection.
2. Remove crankshaft TDC position tool.
3. To set front piston no. 1 to TDC ignition turn
crankshaft 280° counterclockwise.
REQUIED TOOL
Allen key 14mm

TYPICAL – PISTON AT TDC IGNTION

1. Printed marks on camshaft timing gear
2. Cylinder head base

TURN CRANKSHAFT 280°COIUNTERCLOCKWISE Crankshaft TDC Position Tool Installation

1. Allen key14 mm Install tool in magneto cover CPS bore.

3.1 The front piston is at TDC when it's index

mark on the magneto flywheel is aligned with the
notch in the magneto cover.
 REQUIED TOOL
CRANKSHAFT TDC POSITION
TOOL

NOTE: Make sure to match the teeth on the

crankshaft TDC position tool with the magneto
rotor.

1. Magneto cover
2. TDC position tool

TIMING CHAIN
The engine is equipped with two timing chains.
- MAG side timing chain is located behind the
magneto cover.
- PT0 side timing chain is located behind the PT0
1. Crankshaft TDC position tool teeth (end view) cover.
Timing Chain Removal (MAG Side)
Refer to MAGENTO SYSTEM subsection and
remove following parts:
- Magneto cover
- Rotor
- Sprag clutch gear.
Refer to TOP END subsection and remove
following parts:
- Valve cover.
Refer to following procedures in this subsection
and remove following parts:
- Chain tensioner
MAGNETO COVER - Camshaft timing gear.
1. Crankshaft TDC position tool installed in CPS Remove timing chain guide (tensioner side) and
bore lower timing chain guide.

NOTICE Tool must be fully inserted

 1. Timing chain
1. Timing chain 2. Lower timing chain guide
2. Lower timing chain guide 3. Timing chain guide (tensioner side)
3. Timing chain guide (tensioner side)
Carefully pull the timing chain sideward and down
NOTE: Mark the operating direction of the timing from the crankcase.
chain and check for excessive radial play before NOTE: Mark the operating direction of the timing
removal. Refer to TIMING CHAIN chain and check for excessive radial play before
INSPECTION. removal. Refer to TIMING CHAIN
Carefully pull the timing chain downwards and INSPECTION.
sideways, then out of the crankcase. Timing Chain Inspection
Timing Chain Removal (PTO Side) Inspection is the same for both timing chains.
Refer to BOTTOM END subsection and remove Check timing chain on camshaft timing gear for
following parts: excessive radial play.
- PTO cover
- Breather gear
- Intermediate gear.
Refer to PTO END subsection and remove
following parts:
- Valve cover.
Refer to following procedures in this subsection
and remove following parts:
- Chain tensioner
- Camshaft timing gear.
Remove timing chain guide (tensioner side) and
lower timing chain guide.

CHECK TIMING CHAIN RADIAL PLAY

Check chain condition for wear and teeth

condition.
 Refer to TIMING CHAIN in this subsection
Timing Chain Guide Inspection
(Tensioner Side)
Check timing chain guide for wear, cracks or de-
forming. Replace if necessary.
1. Timing chain Timing Chain Guide Inspection
(Tensioner Side)
If chain is excessively worn or damaged, replace it The installation is the reverse of the removal
as a set (camshaft timing gear and timing chain). procedure.
Check timing chain guides for wear, cracks or
deforming. Replace as required. TIMING CHAIN GUIDE BEARING SCREW
NOTE: Check also the timing chain guide Service product LOCTITE243 (BLUE)
(tensioner side). Tightening torque 10N·m 士 1 N·m
Timing Chain Installation (89lbf·in±9lbf·in)
The installation is essentially the reverse of the
removal procedure, but pay attention to the
following details.
NOTE: Installation is the same for both timing
chains.
Install timing chain with camshaft timing gear.
NOTE: Ensure to carry out proper valve timing,
refer to CAMSHAFT TIMING GEARS in this
subsection.
NOTICE Improper valve timing will damage
engine components.

TIMING CHAIN GUIDE

(TENSIONER SIDE)

1. Timing chain guide (tensioner side)

2. Bearing screw

Timing Chain Guide Removal

(Tensioner Side)
BOTTOM END

SERVICE TOOLS
Description Part Number Page

CRANKCASE SUPPORT MAG/PT0

CRANKSHAFT LOCKING BOLT
DRIVE SHAFT OIL SEALINSTALLER
DRIVE SHAFT OIL SEAL PROTECTOR_ PLAIN BEARING REMOVER/INSTALLER PLAIN
BEARING REMOVER/INSTALLER
PT0 COVER OIL SEAL INSTALLER

SERVICE PRODUCTS
Description Part Number Page
LOCTITE243 (BLUE)
LOCTITE5910
LOCTITE CHISEL (GASKET REMOVER)
ENGINE DRIVE SHAFT
CRANKCASE AND PTO COVER
CRANKSHAFT
GENERAL
IMPORTANT: Note position of parts on
disassembly. This may help to find the root cause
of a problem. A component that is not replaced
should be reinsta1led in the same position as
originally mounted.
PROCEDURES
ENGINE DRIVE SHAFT
NOTE: The engine drive shaft transmits the power
from the gearbox to the front differentia1 and is 1. Bearing cover front drive side
located inside the crankcase. 2. Circlip
Engine Drive Shaft Removal 3. Drive shaft
Remove the engine. Refer to ENGINE REMOVAL
AND INSTALLATION subsection. Engine Drive Shaft Removal
Rear Bearing Cover Removal Split crankcase , refer to CRANKCASE in this
Detach gearbox from engine, refer to GEARBOX subsection.
AND 4×4 COUPING UNIT subsection. Remove engine drive shaft from the crankcase.
At rear of engine, remove the bearing cover and its
O-ring.

1. Crankcase MAG side

2. Engine drive shaft
1. Bearing cover screws
2. O-ring Engine Drive Shaft Inspection
3. Bearing cover gearbox Replace oil seals and/or O-ring (bearing cover
gearbox side) if they are brittle , hard or damaged.
Front Bearing Cover Removal Check drive shaft bearings for contamination
Remove the bearing cover at the front of the and/or metal shavings. Check if bearings turn
engine. freely and smoothly. Replace if necessary.
NOTICE Check ends of the circlip for sharp edges
or burr before removing the drive shaft, to avoid
damaging the oil seal.
1. Bearing cover
2. Drive shaft bearing
Do not apply in excess as it will spread out inside
Check drive shaft for cracks, bend, pitting or other crankcase.
visible damages. NOTE: It is recommended to apply this specific
sealant as described here to get a uniform
Check drive shaft splines for wear or damages. application without lumps. If you do not use the
Check oil seal running surface of the drive shaft roller method, you may use your finger to
for scratches. Replace if necessary. uniformly distribute the sealant (using a finger
Engine Drive Shaft Installation w1ll not affect the adhesion).
The installation is the reverse of removal Rear Bearing Cover Installation
procedure. Pay attention to the following details. For bearing cover installation on gearbox side,
Clean all metal components in solvent. protect the oil seal to avoid damaging the sealing
Crankcase surfaces and bearing covers are best lip.
cleaned using a combination of LOCTITE REQUIED
CHISEL (GASKET REMOVER) (P/N413 708 ERIVE SHAFT OIL SEAL
500) and a brass brush. Brush a first pass in one
direction then make the final brushing
perpendicularly (90°) to the first pass.
NOTICE Do not wipe with rags. Use a new clean
hand towel only.
Use a suitable installer for installing bearings.
Use LOCTITE5910 (P/N293800 081) on mating
Su faces.
IMPORTANT: When beginning the application of
the bearing cover sealant, the assembly and the
first torquing should be done within10 minutes.
it is suggested to have all you need on hand to save 1. Drive shaft
time. 2. Bearing cover gearbox side
Use a plexiglass plate and apply some sealant on it. 3. O-ing
Use a soft rubber roller50mm-75mm (2in_ 3in), 4. Protection sleeve
available in arts products suppliers for printing,
and rol1 the sealant to get a thin uniform coat on
the plate (spread as necessary). When ready, apply
the sealant on bearing cover surfaces.
 REQUIED
Tightening torque 10N·m 士 1 N·m
(89lbf·in 士 9lbf·in)

Front Bearing Cover Installation

1. Bearing cover
2. Oil seal

5. Install drive shaft oil seal using the following

FRONT OF ENGINE
1. Water pump cover
2. Oil seal front side
3. Oil cover
4. Drive shaft

FRONT BEARING COVER SCREWS

Service product LOCTITE243 (BLUE)
(P/N293 800 060)
Tightening torque 10N·m 士 1 N·m
(89lbf·in 士 9lbf·in) 1. Bearing cover
2. Oil seal
Engine Drive Shaft Installation 3. Oil seal installer
Finally check for axial play of the drive shaft REQUIED
FRONT OIL SEAL ERIVE SHAFT OIL
(ENGINE DRIVE SHAFT) SEAL
Front Oil Seal Replacement 6. Reinstall remaining parts in the reverse order of
(Engine Drive Shaft) removal.
NOTE: The front oil sea1 can be replaced with the REAR OIL SEAL
engine installed. (ENGINE DRIVE SHAFT)
1. Remove front propeller shaft. Rear Oil Seal Replacement
2. Remove adapter sleeve between propeller shaft (Engine Drive Shaft)
and front engine drive shaft. 1. Remove rear bearing cover , refer to ENGINE
3. Remove the front bearing cover, refer to DRIVE SHAFT REMOVAL / INSTALLATION in
ENGINE DRIVE SHAFT REMOVAL / this subsection.
INSTALLATION in this subsection. 2. Remove drive shaft seal from bearing cover.
4. Remove drive shaft seal from bearing cover. 3. Remove 0-ring from bearing cover.
1. Bearing cover 1. O-ring
2. O-ring 2. Bearing cover

4. Install drive shaft oil seal using the fo1lowing 6. Reinstall remaining parts in the reverse order of
tool. removal.
PTO COVER OIL SEAL
To replace oil seal it is not necessary to remove
engine from vehicle.
PTO Oil Seal Removal
Refer to CONTINUOUSLY VARLABLE
TRAINSMISSION (CVT) subsection to remove
the following parts:
- CVT cover
- Drive pulley
- Driven pulley
- CVT air guide.
Remove oil seal with a small flat screwdriver.
1. Bearing cover NOTICE Avoid scoring surfaces with tool.
2. Oil seal
3. Oil seal installer

REQUIED
ERIVE SHAFT OIL
SEAL

5. Install O-ring in rear bearing cover.

1. PTO cover
2. Oil seal

PTO Oil Seal Inspection

Check oil seal running surface of crankshaft PT0
side for grooves. Replace if necessary.
PTO Oil Seal Installation
The installation is the reverse of the removal
procedure.
Pay attention to the following details.
NOTICE Oil seal must be installed with sealing lip
toward the engine.
Push oil seal in place.
REQUIED
PTO COVER OIL
SEAL

1. PTO cover
2. PTO cover screws
3. Vent hose nipple

PT0 Cover Inspection

Check the PT0 cover for cracks or other damage.
1. PTO cover Replace PT0 cover if damaged.
2. Oil seal installer Clean oil breather bore in PT0 cover from
3. Oil seal contaminations with part cleaner then use
pressurized air to dry it.
PTO COVER
PTO Cover Removal ▲WARNING
Refer to CONTINUOUSLY VARLABLE Always wear skin and eye protection. Chemicals
TRAINSMISSION (CVT) subsection to remove can cause skin rash, skin burns and severe eye
the following parts: injury.
- CVT cover
- Drive pulley Check surface of sealing sleeve for wear or other
- Driven pulley damages. Replace PT0 cover if damaged.
- CVT air guide.
Disconnect vent hose.
Remove PT0 cover screws and pul1 PTO cover.
 PLAIN BEARING TOOL
PLAIN BEARING
REMOVER / UNSTALLER

The PT0 cover has to be supported from below

with suitable support with straight surface, in order
to prevent damage of the sea11ng surface.

1. Oil breather bore

2. Surface of sealing sleeve

Check plain bearings for scorings or other

damages.
NOTE: Measure plain bearing inside diameter
(PTO cover) and compare to crankshaft journal
Diameter (PTO cover bearing). Refer to CRANK
SHAFT in this section. Replace if the
measurement is out of specification.

1. PTO cover
2. Plain bearing remover /installer

Plain Bearing Installation

NOTE: Do not lubricate plain bearings and/or PT0
cover for installation.
Install plain bearings in a cool PTO cover.
PLAIN BEARING TOOL
PLAIN BEARING
1. Plain bearing REMOVER / UNSTALLER
2. Oil bore
A. Measure plain bearing inside diameter NOTICE Mark position of oil bore on PTO cover
and on plain bearing remover/installer. Align mark
PLAIN BEARING INSIDE DIAMETER on plain bearing remover/installer with mark on
(PTO COVER) PTO cover.
SERVICE LIMIT 34.120 mm(1 .3433 in)

Plain Bearing Replacement (PTO Cover)

Plain Bearing Removal
NOTICE Unless otherwise instructed, never use a
hammer to install plain bearings. Use a press only.
Carefu1ly remove the PT0 oil seal with a
screwdriver, without damaging the PT0 cover.
Press out the plain bearings from the outside
towards the inside.
1. Mark position of oil bore on PTO cover
2. Mark position of oil bore on plain bearing
remove/installer

Carefully press-in the plain bearings in the same

direction as during disassembly, from the outside
towards the inside. Support PT0 cover with TIGHTENING SEQUENCE
suitable support with straight surface, in order to
prevent damage of the sealing surface. PTO COVER SCREW
NOTE: Wrong oil bore position will stop oil Tightening sequence 10N·m 士 1 N·m
supply to plain bearings and wil1 damage the (89lbf·in 士 9lbf·in)
engine.
NOTICE The partition of the plain bearings must DRIVEGEARS
be positioned near to oil bore in counterclockwise Drive Gears Location
direction. The engine is equipped with a breather gear which
prevents engine o11 coming out through the
breathing system into the air intake system. The
drive gears are located on the engine PT0 side
behind the PT0 cover.

1. Partition
2. PTO cover (inside)
3. Oil bore

PT0 Cover Installation

For installation, reverse the removal procedure.
Pay attention to the following details.
NOTE: At installation, replace PTO cover gasket
and oil seal.
Tighten PT0 cover screws following the illustrated
sequence.
1. Breather gear
2. Intermediate gear 1. Thrust washer
3. Water pump drive gear 2. Water pump drive gear
4. Oil pump drive gear 3. Needle pin

Drive Gears Removal Drive Gears Inspection

Remove PT0 cover (refer to IC)70 C0 産用. Intermediate Gear/0il Pump Drive Gear/Water
Withdraw intermediate gear and breather gear. Pump Drive Gear
Inspect gears for wear or other damage. Replace if
For oil pump drive gear removal, refer to OIL damaged.
PUMP in the LUERICATION subsection. Breather Gear
To remove water pump drive gear, pull the shaft Check if oil seal is brittle, hard or damaged.
assembly a bit out and turn it about one teeth until Replace if necessary.
it stays out.
Then push water pump drive gear in.

1. Breather gear
2. Oil seal

Step: Push gear in Inspect gear for wear or other damage.

1. Water pump drive gear Check ball bearing for excessive play and smooth
2. Intermediate shaft operation. Replace breather gear assembly if
necessary.
Remove needle pin and pull water pump drive gear Drive Gears Installation
out. The installation is essentially the reverse of the
Remove thrust washer from intermediate shaft. removal procedure.
Adequately oil the ball bearing of the breather
gear.
 - Water pump housing.
CRAN KCASE 11. Refer to LUBRICATION SYSTEM subsection
Crankcase Disassembly to remove following parts:
1. Refer to PEROIDIC MAINTENANCE -Oil filter
PROCEDURES subsection and: -Oil cooler
1.1 Drain cooling system. -Oil pump drive gear.
1.2 Drain engine oil. NOTE: Oil pump removal from crankcase is not
1.3 Drain gearbox oil. necessary, but recommended to see condition of oil
2. Lock crankshaft. Refer to CRANKSHAFT pump (refer to LUBRICATION SYSTEM
LICKING PROCEDURES in the this subsection. subsection).
3. Refer to COUNTINUOUSLY VARIABLE 12. Remove electric starter.
TRAINSMISSION (CVT) subsection to remove
following parts:
- CVT cover
- Drive pulley
- Driven pulley
- CVT air guide.
4. Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
5. Detach gearbox from engine. Refer to
GEARBOX AND 4×4 COUPLING UNIT .
6. Refer to MAGENTO SYSTEM subsection to 1. Electric starter
remove the following parts: 2. Screw
- Magneto cover
- Rotor with sprag clutch gear NOTE: Before splitting the crankcase, measure
- Starter drive gears. crankshaft axial play. Refer to CRANKSHAFT.
7. Refer to following procedures in this subsection Remove retaining screws of crankcase.
to remove the following parts:
- PTO cover
- Drive gears
- Bearing covers of engine drive shaft.
8. Refer tonM/~0 al-1l,4//Vsubsection to remove
following parts:
- Chain tensioners
- Camshaft timing gears
- Timing chains
- Timing chain guides.
9. Refer to TIMING CHAIN subsection to remove
following parts:
- Front cylinder head 1. Four screws M8x65
- Rear cylinder head 2. 13 screws M16x75
- Cylinders. 3. Two screws M6x25
10. Refer to C00i//VCSB 田 subsection to remove Carefully split crankcase halves by using a
following parts: screwdriver and a soft hammer.
 1. Engine oil strainer
NOTE: During disassembly, do not damage the 2. Retaining plate
sealing surfaces of the crankcase halves. 3. Screws
Pull crankshaft out of crankcase.
Remove the water pump intermediate shaft. Crankcase Cleaning

△WARNING
Use safety goggles to avoid eye injuries

Clean crankcase using a part cleaner.

Dry crankcase using compressed air .
Blow the oil supply lines.
Crankcase Inspection
Check crankcase halves for cracks or other dam-
age. Replace if damaged.
Check MAG and PTO plain bearings in for scoring
or other damages.
1. Water pump intermediate shaft

Remove engine oil strainer.

NOTE: Oil strainer removal for inspection and
cleaning is recommended. Refer to
LUBRICATION SYSTEM subsection.

1. Plain bearing

NOTE: Measure plain bearing inside diameter and

compare to PT0/MAG main journa1 diameters of
crankshaft (refer to CRANKSHAFT). Replace if
the measurements are out of specification.
 1. Plain Bearing PUSH PLAIN BEARING OUTSIDE
2. Oil bore 1. Crankcase half
A. Measure plain bearing inside diameter 2. plain bearing remover/installer
3. Crankcase support sleeve
MAIN BEARING INSIDE DIAMETER(PTO/MAG)
SERVICE LIMIT 42.100 mm(1 6575in) Plain Bearing Installation (Main)
NOTICE Unless otherwise instructed, never use
Plain Bearing Replacement (Main) hammer to install plain bearings. Use press only.
Plain Bearing Removal NOTE: Place the proper crankcase support sleeve
NOTICE Always support crankcase halves under crankcase halves before installing the plain
properly when plain bearings are removed. bearings (refer to BEARING REMOVAL
Damages to crankcase halves may occur if this PROCEDURE)
procedure is not performed correctly. Carefully press in the plain bearings in the same
NOTE: Always use a press for removal of plain direction as during disassembly, from the
bearings. crankcase inside towards the outside.
Carefully press the plain bearings out, from the During reassembly, make sure not to damage the
crankcase half inside towards the outside. sealing surfaces of the crankcase halves.
Install plain bearings in a cold crankcase.
REQUIED TOOLS NOTE: Do not lubricate plain bearings and/or
CRANKCASE crankcase for installation.
SUPPORT MAG/PTO Use an 0-ring ( φ 42xlmmto1.5mm
PLAIN BEARING (.04into.06in) thickness) to hold plain bearings in
REMOVER/INSTALLER place during installation .The O-ring will disappear
in the groove of the plain bearing
remover/installer.
NOTE: During disassembly, make sure not to Mark position of plain bearing oil bore on plain
damage the sealing surfaces of the crankcase bearing remover/installer.
halves. Mark position of oil bore on crankcase half.
Align mark on plain bearing remover/installer with
mark on crankcase half.
 1. Partition
1. Oil bore position marked on plain bearing 2. Oil bore
remover/installer 3. Crankcase half PTO (inside)
2. Plain bearing oil bore
3. Oil bore position marked on crankcase Crankcase Assembly
The assembly of crankcase is essentially the re-
NOTICE Misalignment of the plain bearing and verse of removal procedure. However, pay
crankcase oil bores will prevent proper oil supply attention to the following details.
to plain bearings. Install a NEW crankcase gasket.
Carefully press in the plain bearings from inside Oil the plain bearings before mounting the crank-
the crankcase towards the outside. shaft.
NOTICE The partition of the plain bearings in NOTICE Correctly reinstall crankshaft (refer to
crankcase half MAG side must be positioned near CRANKSHAFT)
to oil bore in clockwise direction. Properly reinstall engine oil strainer and screws.
Refer to LIBRICATION SYSTEM subsection.
Reinstall water pump intermediate shaft and gears.
Refer to WATER PUMP GEARS in the COOLING
SYSTEM subsection.
Tightening sequence for screws on crankcase is as
per following1llustration.

1. Crankcase half MAG (inside surface)

2. Partition
3. Oil bore

NOTICE The partition of the plain bearings in

crankcase half PT0 side must be positioned near to
oil bore in counterclockwise direction.
152 TIGHTENCE SEQUENCE
CRANKCASE SCREWS 3. Crankshaft position sensor.
Tightening torque- M6 10N·m±1N·m
(89lbf·in 士 9lbf·in)
-Tightening torque- M8 25N·m±3N·m
(18lbf·ft±2 lbf·ft)

CRANK SHAFT

1. Crankshaft pisition sensor

2. Screw

4. Plug screw and discard sealing ring

1. Crankcase MAG
2. Crankshaft

Crankshaft Locking Procedure

NOTE: When crankshaft is locked, the rear piston
no. 2 is at TDC. Crankshaft can not be locked at
piston no.1 TDC. 1. Sealing ring
NOTICE To see if the rear piston no. 2 is at TDC 2. Plug screw
ignition refer to CRANKSHAFT TIMING GEAR 3. Crankcase PTO side, front side
in the TIMING CHAIN subsection.
Remove: Use a14 mm Allen key to turn crankshaft until
1. Spark plug cables and spark plugs of both piston no. 2 is at TDC.
cylinders.
2. Plug screw and 0-ring of magneto cover.

1. Allen key14 mm
When rear piston is at TDC marks on magneto
1. Plug screw flywheel "2" and on the magneto cover are
2. O-ring aligned .
 Gradually insert the tool in the crankshaft groove.
Make sure that the tool tip enters the groove and
does not jam on the crankshaft balancer surface.
Crankshaft Removal
Refer to CRANKCASE
Crankshaft Inspection
NOTE: Check each bearing journal of crankshaft
for scoring, scuffing, cracks or other signs of wear.
NOTE: Replace crankshaft if the gears are worn or
otherwise damaged.
NOTICE Components out of specifications always
1. Mark“2”on magneto flywheel have to be replaced .If this is not observed, severe
2. Notch on magneto cover damage may be caused to the engine.
3. Crankshaft position sensor location

Use a screwdriver to check if the groove in the

crankshaft is aligned with the hole.

1. Crankshaft timing gears

1. Screw driver Crankshaft Axial Play

NOTE: Axial play needs to be measured before
Lock crankshaft splitting the crankcase.
Measure play on PT0 end, using a dial indicator.
REQUIED TOOL
CRANKSHAFT LOCKING Crankshaft Axial Play
NEW 0.200 mm to 0.500 mm
(.008in to.02in)
SERVICE LIMIT 0.600 mm(.024in)

If play is out of specification, replace crankcase

and/or crankshaft.
Connecting Rod Big End Axial Play
Using a feeler gauge, measure distance between
butting face of connecting rods and crankshaft
counterweight . If the distance exceeds specified
1. Crankshaft locking bolt tolerance, replace the crankshaft.
 1. Connecting rod screws

Measure crankpin . Compare to inside diameter of

connecting rod big end.

1. Crank shaft
2. Connecting rods
3. Feeler gauge

CONNECTING ROD BIG END AXIAL PLAV

NEW 0.200 mm to 0.500 mm
800R (.008in to.02in)
ENGINE SERVICE 0.600 mm(.024in)
LIMIT
NEW 0.250 mm to 0.550 mm 1. Micrometer
1000 (.01 in to.022in) 2. Crankpin area for plain bearing
ENGINE SERVICE 0.600 mm(.024in) CRANK PIN DIAMETER
LIMIT NEW 40.009mm to40.025mm
800R (1.5752in to1.5758in)
Connecting Rod/Piston Pin Clearance ENGINE SERVICE 39.990 mm(1 .5744in)
Refer to TOP END section. LIMIT
Connecting Rod Big End Radial Play NEW 41 .986 mm to42.010 mm
NOTE: prior to remove connecting rod from the 1000 (1 653in to1.6539in)
crankshaft, mark big end halves together to ensure ENGINE SERVICE 41 967mm(1 6522 in)
a correct reinstallation (cracked surface fits in only LIMIT
one position).
Remove connecting rods from crankshaft. If the crank pin diameter is out of specification,
NOTICE Connecting rod screws are not reusable. replace crankshaft.
Always discard screws and replace by NEW ones. To measure the connecting rod big end diameter,
It is recommended to install new plain bearings use the OLD connecting rod screws.
when reinstalling connecting rods. Install the OLD plain bearings as they were
mounted initia11y.
Carry out the tightening procedure described in
CRANKSHAFT ASSEMBLY in this subsection.
A. Connecting rod, big end plain bearing

CONNECTING ROD BIG END RADIAL

800R 40.100mm(1.5787in)
ENGINES SERVICE
1000 LIMIT 42.100mm(1.6575in) 1. Micrometer
ENGINES 2. Crankshaft area for PTO plain bearing
CRANKSHAFT MAIN BEARING JOURNAL
If connecting rod big end diameter is out of DIAMETER (MAG/PTO SIDE)
specification, replace plain bearings and recheck. NEW 42.016mm to42.040mm
CONNECTING ROD BIG END RADIAL (1.6542in to1.6551 in)
800R/1000 SERVICE 0.09mm(.0035in) SERVICE LIMIT 42.000mm(1.6535in)
ENGINES LIMIT

If connecting rod big end radial clearance is out of CRANKSHAFT RADIAL PLAY (MAG/PTO
specification, replace plain bearings and recheck. SIDE)
SERVICE LIMIT 0.07 mm(.0028in)
Crankshaft Radial Play MAG/PTO Side
Measure crankshaft on MAG/PTO side . Compare Crankshaft Radial Play
to inside diameter of MAG/PT0 plain bearing (PTO Cover Bearing)
(refer to CRANKCASE). Measure crankshaft journal diameter (PTO cover
bearing) . Compare to plain bearing inside
diameter (PTO cover). Refer to PTO COVER in
this subsection.

1. Micrometer
2. Crankshaft area for MAG plain bearing
 1. Half plain bearing of connecting rod big end
2. Split surface of the connecting rod
1. Micrometer 3. Nose of plain bearing in line with connecting
2. Crankshaft journal (PTO support bearing) rod groove

CRANKSHAFT JOURNAL DIAMETER Oil the plain bearing surface of the connecting rod
(PTO COVER BEARING) and crank pin before installation.
34.004mm to34.020 NOTICE Lower cap and rod must match together
NEW mm since there is a cracked surface.
(1.3387ln to1.3394in) Oil NEW connecting rod screws
SERVICE LIMIT 33.998 mm(1 3385in) NOTICE Always use NEW connecting rod screws
at final assembly. They are not reusable.
CRANKSHAFT RADIAL PLAY Thread screws in the connecting rods, then tighten
(PTO COVER BEARING) as per fo11owing procedure.
SERVICE LIMIT 0.10 mm(.0039 in) NOTICE Strictly adhere following instructions:
- Do not apply any thread locker.
If crankshaft journal diameter is out of - The running direction of the big end bearings and
specification, replace crankshaft. of the piston pins must not chan9e.
If crankshaft radial play (PTO cover bearing) out - Always perform each step on both connecting rod
of specification, replace plain bearings and -Failure to strictly follow procedure may cause
recheck. connecting rod screws to loosen and lead to Severe
engine damage.
Crankshaft Assembly
REQUODE TOOLS
For assembly, reverse the disassembly procedure. Torque wrench
Pay attention to following details. Angle torque wrench
Clean the split surface on both sides (cracked area)
carefully with compressed air.
Put plain bearings correctly in place.
 1. Connecting rod small ends
2. Connecting rod offset
3. Connecting rod screws

CONNECTING RODS SCREWS TIGHTENING

1. Angle torque wrench SEQUENCE
1 Tighten to1/2 of specified torque
800R Engine: 2 Tighten to30N·m±2N·m
NOTE: NEW connecting rods can be installed (22lbf·ft 士 1 lbf·ft)
either way. 3 Torque by an additional 90±5° turn using
an angle torque wrench
CONNECTING RODS SCREWS TIGHTENING
SEQUENCE Crankshaft Installation
1 Tighten to1/2 of specified torque For installation of crankshaft in crankcase reverse
2 Tighten to20N·m±2N·m the removal procedure. Pay attention to the fol_
(15lbf·ft±1 lbf·ft ) lowing details.
3 Torque by an additional 60 土 5° turn using Do not mix up the connecting rods of cylinders1
an angle torque wrench and2 during installation.
NOTICE Observe the correct installation position
1000 Engine: when fitting the crankshaft with the connecting
NOTICE Connecting rods are asymmetric. rods. The connecting rod MAG side has to face
There must be no gap between the small ends cylinder no. 1.
when they face each other.
1. Crankcase half MAG side
2. Connecting rod cylinder 1
3. Connecting rod cylinder 2
CONTINUOUSLY VARIABLE

TRANSMISSION (CVT)
SERVICE TOOLS

Description Part Number Page

CLUTCH HOLDER
CLUTCH PULLER.
PULLER/LOCKING TOOL

SERVICE PRODUCTS

Description Part Number Page

ISOFLEX GREASE TOPAS NB52

PULLEY FLANGE CLEANER
TRANSMISSION

Never touch CVT while engine is running.

never drive vehicle when variator cover is removed.
Subcomponent installation and assembly tolerances require strict adherence to procedures detailed.
Never use any type of impact wrench at drive pulley removal and installation.
The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch
assembly
These pulleys have metric threads. Do not SAE threads puller. Always tighten puller by hand to ensure that the
drive pulley has the same type of threads prior to fully tightening.

DRIVE BELT
Removal
Remove:
 Distance screws
 remove variator cover and gasket.

1. Variator cover
2. Distance screw
3. Gasket

NOTE:
Remove the center top screw last. This screw allows to
support the cover during removal.
Open driven pulley with the driven pulley expander.

Screw tool in the threaded hole of driven pulley and

tighten to open the pulley.

1. Driven pulley expander

2. Fixed sheave of driven pulley

To remove belt, slip the belt over the edge of fixed

sheave as shown.
INSPECTION
Inspect belt for cracks, fraying or abnormal wear.
Replace if necessary.

Drive belt width

Service limit 30.00mm(1.181 in)

Installation
For installation, reverse the removal procedure. Pay
attention to following details.

1. Word printed on belt

2. Drive pulley (front)
3. Driven pulley (rear)
4. Rotation direction
The maximum drive belt life span is obtained when the
drive belt has the proper rotation direction. Install it so
that the arrow printed on belt is pointing towards front
of the vehicle, viewed from top.

Install variator cover gasket.

Install the center top screw in first.
Tighten the distance screw as per following sequence.

DRIVE PULLEY

1. Belt
2. Drive pulley
3. Driven pulley

Removal
 remove variator cover and gasket.
 Remove belt
Block the drive pulley as followed.
Block drive pulley with the pulley holding tool.

1. Pulley holding tool

2. Torque wrench

When the drive pulley is blocked, mark sliding sheave

and governor cup to ensure correct reinstallation.

Unscrew the drive pulley screw (right hand thread),

then remove it as well as the conical spring washer and
thrust washer.

1. Drive pulley
2. Thrust washer
3. Drive pulley screw

Inspection
Drive pulley should be inspected annually for wear or
damages.
Check drive pulley for cracks and sliding contact
surface for excessive wear. Replace it if necessary.
Check one-way clutch bearing for excessive play and
smooth operation. Replace one-way clutch if necessary.

Installation
For installation, reverse the removal procedure. Pay attention to the following details.
Do not apply any lubricant on crankshaft and drive pulley tapers.
Clean pulley faces and shaft with dry cloth.
Install drive pulley on crankshaft extension.
Do not forget to place thrust washer
Never substitute conical spring washer and/ or screw with jobber ones. Always use genuine parts for this
particular case.
Install thrust washer with its concave side towards drive pulley then install drive pulley screw.
To torque the drive pulley screw, block the drive pulley. Refer at the beginning of this section.
When the drive pulley is blocked, torque screw to 100N.m.

DRIVEN PULLEY
Removal
 remove variator cover and gasket.
 Remove belt

Using the pulley holding tool, hold the driven pulley

during the removal of the driven pulley screw, do not
remove screw completely.

Put in tow STUD to Driven Pulley

1. Driven Pulley holding tool

2. Torque wrench

When the driven pulley is blocked, unscrew the driven

pulley screw.

1. Driven pulley
2. Thrust washer
3. Driven pulley screw

Inspection
Driven pulley should be inspected annually for wear or
damages.
Check sliding and fixed sheave for cracks and sliding
contact surface for excessive wear. Replace sliding
sheave if necessary.
Check sliding sheave bushings for cracks, scratch and
for free movement when assembled to sliding sheave.
Check ball bearing for free play and smooth operation.
Replace if necessary.

Installation
For installation, reverse the removal procedure. Pay attention to the following details.
Chamfer on inside diameter of the spacer must face engine side.
Clean pulley faces and shaft with dry cloth.
Driven pulley is a spring loaded system.
Always place washer at the time of driven pulley installation.
When the driven pulley is blocked, torque screw to 60N.m.

CVT AIR GUIDE

Removal
Remove:
 Variator cover
 Drive belt
 Drive pulley
 Driven pulley

Unscrew the clamps retaining the CVT air hoses

Remove CVT air guide.

Inspection
Clean CVT air guide from contamination.
Check O-rings if brittle, hard or damaged. Replace if
necessary.

1. CVT air guide

2. O-rings

Installation
For installation, reverse the removal procedure.
GEARBOX AND4X4 COUPLING UNIT
SERVICE TOOLS

Description Part Number Page

BLIND HOLE BEARING PULLER SET

COUNTERSHAFT OIL SEAL PUSHER
ECM ADAPTER TOOL
FLUKE115 MULTIMETER
OIL SEALINSTALLER (GEARBOX)
OIL SEALINSTALLER

SERVICE TOOLS- OTHER SUPPLIER

Description Part Number Page

BACK PROBE TEST WIRES

SERVICE PRODUCTS

Description Part Number Page

LOCTITE5910
LOCTITE CHISEL (GASKET REMOVER)
SUPER LUBE GREASE
GEARBOX COMPONENTS AND 4×4 COUPING MECHANISISM
 3. Damaged or worn gears.
GENEAL -Inspect gears for damages or missing teeth.
GEARBOX OVERVIEW Replace respective gears.
GEARINDICATION FAILS
1. Defective gearbox position sensor (GBPS)
-Perform a gearbox position sensor test.
-Damaged wires .Repair as required.
GEAR(S) IS (ARE) HARD TO SHIFT
1. Incorrect shifter cable adjustment.
-Adjust shifter cable (refer to SHIFTER CABLE in
SHIFTER subsection.
4 WHEEL DRIVEINDICATION FAILS
1. 4WD indicator switch failure .
1. Gearbox position sensor (GBPS) -Test 4WD indicator switch. Replace as required
2. Right cover -Bad contact. Check for corrosion or loose
3. Vehicle speed sensor (VSS) co11nector.
4. Actuator -Damaged wires. Repair as required
5. 4WD indicator switch 4 WHEEL DRIVE DOES NOT ENGAGE OR
DISENGAGE
1. Defective 4WD switch.
-Check 4WD switch operation.
2. Defective actuator.
-Test actuatol1.
3. Damaged or worn shifting fork or sleeve.
Remove actuator and inspect shifting fork and
sleeve.
PROCEDURES
VSS (VEHICLE SPEED SENSOR)
VSS Location
1. Center housing The vehicle speed sensor is located on the right
2. Left cover housing of the gearbox behind the actuator.
3. Countershaft
4. Output shaft
5. Shift shaft

TROUBLESHOOTING
UNUSUAL GEARBOX N0lSE AND/0R
VIBRATIONS
1. Low oil level in gearbox.
-Oil leakage from gearbox .Replace damaged(s)
and/or oil seal（s）
2. Defective bearings.
-Bearing(s) do(es) not turn smoothly. Replace
bearing(s).
 VSS INPUT VOLAGE TEST
TEST PROBES RESULIT
(KEY ON)
PIN A PIN C Battery
(RED wire) (BLACK/GREEN voltage
wire)

If voltage is not as specified, test positive and

ground separately.
VSS Signal Test
1. Tight housing of gearbox 1. Lift rear of vehicle so that rear wheels are off
2. Actuator the ground.
3. VSS (Vehicle Speed Sensor) 2. Set transmission to2WD and to Neutral.
3. Turn ignition switch 0N.
4. Back-probe the VSS connector and measure
VSS Access
voltage while slowly rotating rear wheels by hand.
To reach the VSS, remove the following parts
- Passenger seat REQUIRED TOOLS
- RH lateral console panel BACK PROBE TEST WIRES
- Fuel tank cowl. (P/N529 036 063)
VSS Wire Identification FLUKE115 MULTIMETER
FUNCTION PIN COLOR (P/N529 035 868)
12-volt input from A RED
fuse F5 VSS INPUT VOLAGE TEST
Speed signal B WHITE TEST PROBES RESULIT
(to ECM-A E1) (KEY ON)
Ground(to ECM-A C BLACK/GREEN PIN B PIN C Alternate reading
D4) (WHITE (BLACK/GREEN between battery
wire) wire) voltage and 0 Vdc
VSS Circuit Protection
CONDITION CIRCUIT PROTECTION NOTE: Since we measure pulsating voltage, the
Supplied with main Fuse5 of fuse block1 numeric display will continuously change. The
relay activated (from main relay R2) analog display may be easier to follow.

VSS Input Voltage Test

1. Turn ignition switch 0N.
2. Back-probe the VSS connector and measure
voltage.
REQUIRED TOOLS
BACK PROBE TEST WIRES
(P/N529 036 063)
FLUKE115 MULTIMETER
(P/N529 035 868) 1. Analog display
VSS Removal - Shift drum
Remove screw retaining the VSS - GBPS
- ECM.
1. Connect vehicle to the latest applicable version
Of B.U.D.S. software, refer to
COMMUNICATION TOOL AND B.U.D.S.
subsection.
NOTE: Ignition key must stay 0N during the reset
procedure. If the key is turned off, the procedure
must be carried out again.
2. In B.U.D.S., select the following:
- Read Data button
- Setting page tab
1. Screw - ECM tab.
2. VSS

Turn sensor and weave it out of the gearbox right

cover.

1. Read data button

2. Setting page tab
3. ECM tab

VSS Installation 3. Make sure that gearbox is set to NEUTRAL

For installation, reverse the removal procedure. position.
Pay attention to the following. 4. In the Gear Position Sensor Initialization field,
Apply SUPER LUBE GREASE (P/N293 550 030) click on the Reset button.
on VSS O-ring.

GBPS (GEARBOX POSITION

SENSOR)
GBPS Reset
When replacing the gearbox position sensor
(GBPS), it is required to reset (re-zero) its values
for proper operation. GEAR POSITION SENSOR INITIALIZATION
A reset must be carried out each time any of the 1. Reset button
following parts has been replaced: A message will be displayed if the operation is
- Gearbox assembly successful.
If an error occurred or the GBPS is not within the MULITIMETER VOLITAGE
allowed range while resetting, the ECM will PROBE POSITIONS
generate a fault code and will not accept the PIN1 and PIN3 of the
setting. GBPS connector
5. If a fault message is displayed, follow the 5 volts
instructions in the message(s).
6. Check for fault codes.
If a fault code is generated:
- Carry out the service action.
- Reset the fault code. If voltage is adequate, check GBPS
- Repeat the reset procedure. communication link (CAN).
7. Close and disconnect B.U.D.S. If there is no voltage, check each GBPS input as
NOTE: Do not turn ignition key OFF. follows.
8. Verify gears engagement. MULITIMETER VOLITAGE
8.1 With the vehicle on ground and in NEUTRAL PROBE POSITIONS
position, start engine. PIN1 connector(pin1)
8.2 During4-5 seconds, rev engine to2500±200 and battery ground
RPM.
8.3 Let engine returns to idle. 5 volts
8.4 Select an other position(P，R，H or L). Repeat
substeps8.2 and8.3 until all position are verified.
NOTE: The vehicle must be in movement to GBPS connector (pin3)
complete the procedure on R, H and L position. and battery + terminal

GBPS Access Battery voltage

To reach the GBPS sensor, remove the following
parts:
- Passenger seat
- RH lateral console panel If there is no voltage, check wires and connector
- Fuel tank cowl. pins. Replace or repair defective parts and reset
GBPS Input Voltage Test fault codes.
NOTE: Prior to conduct testing, check fault codes GBPS Communication Link Continuity Test
in B.U.D.S. Unplug connector ''A" from ECM and connect it to
Set shift lever in NEUTRAL position. the ECM ADAPTER TOOL (P/N529 036 166).
Back-probe the GBPS connector . MULITIMETER RESISTANCE
PROBE POSITIONS @20°C(68°F)
REQUOED TOOL GBPS connector(pin2)
BACK PROBE TEST and ECM adapter tool
WIRES (pin F4)
l Below1Ω
Test as follow
If resistance is out of specification, check wires
and connectors. Repair and reset fault codes.
4WDINDICATOR SWITCH
If resistance is good and the other tests succeeded, 4WDlndicator Switch Access
replace the GBPS and reset fault codes. To reach the4WD indicator switch, remove the
NOTE: The GBPS must be reset. fo1lowing parts:
GBPS Removal _ Passenger seat
Set shift lever in NEUTRAL position. - RH lateral console panel
Unplug GBPS connector. - Fuel tank cowl.
Remove screws and withdraw GBPS. 4WDlndicator Switch Removal
Disconnect 4WD indicator switch connector.

1. Screws 1. 4 WD indicator switch

2. Gearbox Position Sensor (GBPS) 2. Actuator
4WDlndicator Switch Test
GBPS Installation Measure switch resistance as follows
For installation, reverse the removal procedure.
Pay attention to the following details. SWITCH SWITCH WIRE RESISTANCE
Shift lever must be in the NEUTRAL position. POSITION
Align GBPS with the flat on the shift drum shaft. 2WD BLACK/ Engine Infinite (OL)
BEIGE ground

If the resistance is out of specification, replace the

4WD indicator switch.
4WDlndicator Switch Installation
For installation, reverse the removal procedure.
Pay attention to the following details.
Take care do not damage indicator switch threads
during installation.
Apply carefully some LOCTITE 5910(P/N293 800
081) on threads of indicator switch.
NOTICE Do not apply Loctite5910 on switch
1. flat on shift drum shaft plunger, as it will lead to switch malfunction.

Reset the GBPS. Refer to GBPS RESET in this

subsection.
 ACTUATOR
Actuator Access
To access the actuator, remove the fol1owing parts:
- Passenger seat
- RH lateral console panel
- Fuel tank cowl.
Remove screws securing fuel tank and move tank
on passenger's floor without disconnecting hoses
and connector from fuel pump.
Actuator Test
Check if the2WD/4WD selector works properly. 1. Actuator
Unplug actuator connector. 2. Washer
Turn ignition key ON. 3. Screw
Measure voltage as follows .
Pull the actuator out of housing.
REQUIRED TOOL
FLUKE 115 MULTIMETER Actuator Installation
Apply a small amount of SUPER LUBE GREASE
(P/N293 550 030) on actuator 0-ring.

SWITCH SWITCH WIRE VOLTAGE

POSITION
2WD WHITE/BLUE Battery
4WD WHITE/ WHITE voltage
BLACK

If the selector is out of specifications, check wires,

connectors and replace the selector if necessary.
If the selector is good, check the vehicle harness.
If the vehicle harness is good, replace the actuator. 1. Actuator0-ring
Actuator Removal Ensure coupling fork is in4WD position (toward
NOTE: Before beginning any servicing on the the front of vehicle).
actuator, make sure the vehicle is in4WD position.
No need to remove engine from vehicle.
Place a drain pan under actuator.
Remove actuator screws.
 If the front propeller shaft turns, the actuator is not
installed correctly. Remove actuator and reinstall
it.
Place ignition switch to 0N position and select the
2WD position.
Turn front wheel again. The front propeller shaft
should turn easily.
If the front propeller shaft does not turn, the
actuator is not installed correctly. Remove actuator
and reinstall it.
1. Coupling fork in 4WD position NOTICE Refill missing gearbox oil, refer to
GEARBOX OIL REPLACEMENT in PERIODIC
Align the actuator fork with the pin on couplin9 MAINTENANCE PROCEDURES subsection.
fork then push the actuator in the housing. See the Install all other removed parts. GEARBOX OIL
following illustration to position the actuator SEALS
correctly. Gearbox Oil Seal Replacement
Replace oil seals if they are brittle, hard or dam-
aged.
A small flat screwdriver can be used to remove
most of these oil seals.
NOTICE Avoid scoring parts during oil seal
removal.
When replacing an oil seal, take this opportunity to
inspect the following:
-Check bearings behind each oil seal for
contamination and/or metal shavings.
-Check oil seal running surfaces for scratches.
1. Actuator Countershaft Oil Seal
2. Aotuatorfor1l1 To replace the countershaft oil seal, remove:
3. Coupling fork -Drive and driven pulleys
-CVT air guide.
Rotate the actuator counterclockwise until it NOTE: When oil seal is removed also inspect
orients itself to mounting position. O-ring behind distance sleeve.
NOTICE Do not cut or break the actuator O-ring.
Install all actuator screws and tighten them.
ACTUATOR SCREWS
Tightening torque 25N.m±3N.m
（18 lbf.ft±2 lbf.ft

Connect actuator.
Lift the front of vehicle.
Turn front wheels. The front propeller shaft
should not turn(the PARK position must be 1. Countershaft oil seal
selected). 2. Distance sleeve
 REQUIRED TOOL
OIL SEAL INSTALLER
(GEARBOX) (P/N529 035 758)
HANDLE (P/N420877 650)

NOTICE Oil seal must be installed with sealing lip

toward gearbox.
Shift Drum Shaft Oil Seal
To replace the shift drum shaft oil seal, remove the
GBPS (GEARBOX POSITION SENSIR). See
procedure in this subsection.
1. Distance sleeve Use a suitable tube with the proper diameter to
2. O-ring install the oil seal.
NOTICE Oil seal must be installed with sealing lip
Install countershaft oil seal toward gearbox.
REQUIRED TOOL Output Shaft Oil Seal
COUNTERSHAFT OIL SEAL To replace the output shaft oil seal, proceed as
PISHER follows
Remove propeller shaft screw from gearbox out_
put shaft.
Remove rear final drive bolts.
Move the rear final drive rearward to dis1odge the
propeller shaft from the gearbox output shaft.

1. Countershaft oil seal

2. Oil seal installer

Shift Shaft Oil Seal

To replace the shift shaft oil seal, remove:
-RH lateral console panel and fue1 tank cowl, refer 1. Shift shaft oil seal
to BODY subsection. 2. Shift drum shaft oil seal
-Shift plate from shift shaft. 3. Output shaft oil seal
The shift shaft oil seal can be removed without
removing the gearbox from the vehicle. Punch a sharp screwdriver through oil seal for
Use a suitable tube with the proper diameter to removal.
install the oil seal. NOTE: Position screwdriver only in marked areas
If gearbox housing is apart, use following tools for to avoid damaging the ball bearing underneath oil
shift shaft oil seal installation. seal during removal.
 GEAR BOX
Gearbox Removal
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATUON for the
procedure.
Refer to COUNTINOUSLY VARIABLE
TRANSMISSION (CVT) subsection to remove
following parts:
1. Marked areas for removal - CVT cover
2. Output shaft oil seal - Drive and driven pulleys
- CVT air guide.
Before beginning the installation ensure gearbox is Drain gearbox. Refer to GEARBOX OIL
set to PARK position. REPLACEMENT in PERIODIC MAINTEANCE
Apply SUPER LUBE GREASE P/N293 550 030) PROCDURES subsection.
on sealing lips. Remove ACTIATOR see procedure in this
Apply engine oil on outer diameter of oil seal to subsection.
avoid damaging it during installation. Unscrew the four (4) nuts that attach the gearbox
Place oil seal on output shaft and install it using to the engine.
the following tools.

REQUIRED TOOL
OIL SEAL INSTALLER
(P/N529 036 204)
Flat washer (P/N250 200 102)
M12×1.25×35 hexagonal screw

LH SIDE OF ENGINE
1. Nut M8

1. Output shaft oil seal

2. Oil seal installer
3. Flat washer (P/N250 200 102)
4. M12×1.25×35 hexagonal screw
5. Apply engine oil on outer diameter of oil seal
RH SIDE OF ENGINE POSITION FOR SOFT HAMMER
1. Nut M8

Pull gearbox to separate it from engine.

Gearbox Disassembly
NOTE: During gearbox disassembly, inspect the
condition of each part closely.
Gearbox Left Cover
Set gearbox to NEUTRAL position.
Unscrew all bolts retaining the gearbox left cover.

POSITION FOR BIG FLAT SCREWDRIVER

Index Lever and Index Washer

Set gearbox to NEUTRAL position.
Remove screw retaining the index washer to the
shift drum.

1. 3 screws M6x35
2. 13 screws M6x55

Place the center housing on a wood stand, left

cover pointing upwards.
Using a big flat screwdriver and a soft hammer to
lift the left cover .
1. Screw
2. Index washer
Insert a flat screwdriver in the slot of index lever.
Turn screwdriver clockwise and remove index
washer.

1. Bearing pin
2. Reverse intermediate gear
3. Needle bearing
4. Thrust washers
1. Index lever Remove shift fork shaft.
2. Index washer Disengage shift forks from shift drum
3. Shaft drum

Remove the index lever with washer, step ring and

spring.

1. Shaft fork shaft

2. Shaft fork
3. Shaft drum
Remove main shaft assembly with shift fork.
1. Washer
2. Index lever
3. Step ring
4. Index spring

Main Shaft and Shift Forks

Remove bearing pin, reverse intermediate gear and
thrust washers.
NOTE: Take care not to lose lower thrust washer
during removal.
 1. Snap ring
1. Main shaft assembly 2. Free pinion (HIGH range gear)
2. Shift fork 3. Free pinion (LOW range gear)
4. Needle bearings
Remove shifting sleeve (HIGH range gear) and 5. Main shaft assembly
shift fork.
Remove from main shaft assembly:
- Snap ring (discard)
- Shifting sleeve (LOW/REVERSE range gear) -
Snap ring (discard)
- REVERSE range gear
- Needle bearing.

1. Shifting sleeve (HIGH range gear)

2. Shift fork

When required, remove from main shaft assembly:

- Snap ring (discard)
- HIGH range gear 1. Snap ring
- LOW range gear 2. Shifting sleeve (LOW/REVERSE range gear)
- Needle bearings. 3. Snap ring
4. Free pinion (REVERSE range gear)
5. Needle bearing
6. Main shaft assembly

Gearbox Right Cover

Remove ACTUATOR and GBPS (GEARBOX
POSITION SENSOR) see procedures in this
subsection.
Unscrew all bolts retaining the gearbox right cover.
 1. Shift shaft assembly

1. 5 Screws M8x55 Remove screw retaining the shifting intermediate

2. 2 Screws M6x85 gear.
3. 2 Screws M6x55
4. 8 Screws M6x35

To remove cover, use2 big screwdrivers

1. Screw
2. Washer
3. Intermediate gear
4. Dowel pin
POSITION FOR BIG FLAT SCREWDRIVER
Remove shift fork shaft.
Disengage shift forks from shift drum.

POSITION FOR BIG FLAT SCREWDRIVER

Shift Shaft and Shift Drum

Withdraw shift shaft assembly.
 1. Output shaft
2. 4×4 coupling sleeve
1. Shift fork shaft 3. Soft hammer
2. Shift fork
3. Shift drum Remove set screw, coupling fork shaft and
coupling fork from right cover.
Remove shift drum and thrust washer.

1. Set screw
2. Coupling fork shaft
1. Shift drum 3. Coupling fork
2. Thrust washer
Countershaft
Output Shaft and4×4 Coupling Mechanism Use a soft hammer to push out countershaft from
gearbox CVT side.
Remove output shaft from center housing and Remove distance sleeve and 0-ring.
withdraw4X4 coupling sleeve.
NOTICE Use a soft hammer to remove output
shaft.
 1. Ball bearing countershaft
2. Right cover
1. Counter shaft
2. Distance sleeve
3. O-ring

Gearbox Bearings
If necessary heat housing up to100°C(212°F)
before removing ball bearings.
△WARNING
Clean oil, outside and inside, from housing before
heating.

NOTICE Always support gearbox housings

properly when ball bearings are removed. 1. Screw
Housing damages may occur if this procedure is 2. Ball bearing countershaft
not performed correctly. 3. Ball bearing main shaft
To remove ball bearings of countershaft (right 4. Left cover
cover) and main shaft (left cover) use following
tool .

REQUIED TOOL
BLIND HILE BEARING

For ball bearings of countershaft (1eft cover) and

main shaft (center housing) push with a suitable
puller from outside in .

1. Ball bearing main shaft

2. Center housing
Gearbox Inspection
Always verify for the fol1owing when inspecting
gearbox components:
- Gear teeth damage
- Worn or scoured bearing surfaces
- Rounded engagement dogs and slots
- Worn shift fork engagement groove
- Worn splines on shafts and shifting sleeves.

Bearings
Check if ball bearings turn freely and smoothly.
Check all bearings, bearing points, tooth flanks and TYPICAL
taper grooves. 1. Inner splines
2. Engagement dogs
Free Pinions
NOTE: Always replace snap rings and use special Measure the width of shift fork engagement
pliers to install them. groove.
Check free pinions for wear.

TYPICAL
1. Micrometer TYPICAL
2. Free pinion 1. Shifting sleeve
DIAMETER FREE PINION A. Width of shift fork engagement groove
NEW 29.000 mm
to29.013mm WIDTH 0F SHIFT FORK ENGAGEMENT
(1.1417in to1.1422in) GROOVE
NEW 5.30 mm to5.40 mm
SERVICE LIMIT 29.015mm(1.1423in) (.209in to.213in)
SERVICE LIMIT 5.50mm(.217in)
Shifting Sleeves
Check shifting sleeves for worn inner splines and Shafts
rounded or damaged engagement dogs. Check bearing pin of reverse intermediate gear for
wear.
1. Bearing pin
A. Outer diameter
A. Bearing journal MAG side
BEARING PIN OUTER DIAMETER B. Free pinion bearing
NEW 24.987mm to25.000mm C .Bearing journal CVT side
(.984in to.984in)
SERVICE LIMIT 24.977 mm(.9833 in) MAIN SHAFT
FREE PINION BEARING
Check countershaft bearing journals for wear. NEW 24.987mm to25.000 mm
(.984in to.984in)
SERVICE LIMIT 24.984 mm(.984 in)
BEARING JOURNAL CVT/MAG SIDE
NEW 16.980mm to16.991 mm
(.669in to.669in)
SERVICE LIMIT 16.976mm(.668in)

Shift Shaft
Check shift shaft for worn splines and gears.
Check shift shaft spring for damages.
A. MAG side Shift Drum
B. Bearing journal CVT side NOTICE Do not disassemble shift drum.
Check if shifting gates move easily on shift drum
COUNTERSHAFT BEARING JOURNALS splines and check condition of springs.
MAG SIDE Check shift drum tracks for scouring or heavy wear,
NEW 19.977 mm to19.990 mm like rounded engagement slots.
(.786in to.787in)
SERVICE LIMIT 19.973 mm(.786in)
CVT SIDE
NEW 24.977mm to24.990mm
(.983in to.984in)
SERVICE LIMIT 24.970 mm(.983 in)

Check main shaft for wear

 Output Shaft
Check output shaft and its gear for cracks, bend,
pitting or other visible damages.
Check output shaft splines for wear or other
damages.
Check if the output shaft bearings turn freely and
smoothly.
Replace oil seal if brittle, hard or damaged.
4×4 Coupling Sleeve
1. Track for the low/reverse range gear shift fork Check splines of coupling sleeve for wear or other
2. Track for the high range gear shift fork damages.
3. Springs

Shift Forks
Check both shift forks for visible damage, wear or
bent shift fork claws.
Check engagement rollers for wear and smooth
movement.
Measure the shift fork claw thickness.

1. Inspect splines

Measure the coupling sleeve groove width

1. Micrometer
A. Shift fork claw thickness

SHIFT FORK CLAW THICKNESS A. Groove width

NEW 5.10 mm to5.20 mm
(.201 in to.205in) COUPLING SLEEVE GR00VE WIDTH

SERVICE LIMIT 5.00 mm(.197 in) NEW 5.25mm to5.35mm

(.207in to.211 in)
Shift Fork Shaft SERVICE LIMIT 5.50mm(.217in)
Check shift fork shaft for visible damage or wear.
Check if shift fork shaft is straight. Coupling Fork
Index Lever and Parking Lever Check coupling fork for visible damage, wear or
Index lever with roller must move freely. bent coupling fork claws.
Check parking lever for cracks or other damages. Check coupling fork claw thickness.