Removal and Installation
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE V-BANK COVER
3. REMOVE INTAKE AIR CONNECTOR PIPE
4. REMOVE THROTTLE BODY
5. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
6. REMOVE WATER BYPASS PIPE
7. REMOVE REAR WATER BYPASS JOINT
8. REMOVE STARTER
a. Disconnect the starter connector.
b. Remove the nut, and disconnect the starter cable.
c. Remove the bolt, and disconnect the engine wire protector.
d. Remove the 2 bolts and starter.
INSTALLATION
1. INSTALL STARTER
a. Install the starter with the 2 bolts.
Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
b. Connect the starter cable with the nut.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
c. Install the engine wire protector to the starter with the bolt.
d. Connect the starter connector.
2. INSTALL REAR WATER BYPASS JOINT
3. INSTALL WATER BYPASS PIPE
4. INSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSTALL THROTTLE BODY
6. INSTALL INTAKE AIR CONNECTOR PIPE
7. FILL WITH ENGINE COOLANT
8. CHECK THAT ENGINE STARTS
9. START ENGINE AND CHECK FOR ENGINE COOLANT AND FUEL
10. INSTALL V-BANK COVER
REPLACEMENT
1. REPLACE FRONT BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new bearing.
SST 09820-00031
NOTE: Be careful of the installation direction.
2. REPLACE REAR BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using a press, press in a new bearing.
3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove the 3 nuts, end cover, gasket and plunger.
NOTE: Do not loosen the 3 stud bolts.
b. Using vernier calipers, measure the contact plate for depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
c. Remove the terminal kit parts.
1. Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block: 20 x 33 x 40 mm (0.79 x 1.30 x 1.57 in.)
Press force: 981 N (100 kgf, 221 lbf)
NOTE:
- Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied.
- If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
2. Using SST, loosen the terminal nuts.
SST 09810-38140
3. Terminal C:
Remove the terminal nut, washer, O-ring, terminal bolt and contact plate.
4. Terminal 30:
Remove the terminal nut, washer, O-ring, terminal bolt and contact plate.
d. Temporarily install these new terminal 30 kit parts:
1. Install the contact plate.
2. Install the terminal bolt.
3. Install the O-ring.
4. Install the washer.
5. Install the terminal nut.
e. Temporarily install these new terminal C kit parts:
1. Install the contact plate.
2. Install the terminal bolt.
3. Install the O-ring.
4. Install the washer.
5. Install the terminal nut.
f. Temporarily lighten the terminal nuts.
g. Tighten terminal nuts.
1. Put a wooden block on the contact plate and press it down with a hand press.
2. Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)
NOTE: If the nut is over tightened, it may cause cracks on the plastic frame.
h. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall the plunger, a new gasket and end cover with the 3 nuts.
Torque: 3.6 N.m (37 kgf.cm, 32 in.lbf)