TABLE OF CONTENTS Check Prior to Cylinder Head Removal.....................3-15 Check After Cylinder Head Removal.........................3-15 4.5 INTAKE AIR TEMPERATURE SENSOR (IAT) 3.7 STRIPPING MOTORCYCLE FOR SERVICE General...............................................................................4-7 Removal.............................................................................4-7 Installation..........................................................................4-7 General.............................................................................3-16 Engine Cradle and Stand.................................................3-17 4.6 ENGINE COOLANT TEMPERATURE SENSOR (ECT) 3.8 CAMSHAFTS, DRIVE CHAINS AND CAMSHAFT TIMING General...............................................................................4-9 Removal.............................................................................4-9 Installation..........................................................................4-9 General.............................................................................3-19 Camshaft and Secondary Timing Chain Removal............3-19 Inspection.........................................................................3-22 Lobe Surface Finish..................................................3-22 Camshaft Spalling.....................................................3-23 Primary Cam Drive Removal............................................3-24 Primary Cam Drive Installation.........................................3-24 Installation of Cams, Timing Chains and Camshaft Timing...............................................................................3-27 4.7 THROTTLE BODY AND FUEL RAIL Removal...........................................................................4-11 Installation........................................................................4-11 4.8 IDLE AIR CONTROL (IAC) General.............................................................................4-14 Removal...........................................................................4-14 Installation........................................................................4-14 3.9 CYLINDER HEAD Removal...........................................................................3-34 Disassembly.....................................................................3-35 Valve Seat Refacing.........................................................3-41 Head Assembly................................................................3-42 Installation........................................................................3-44 4.9 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) Removal...........................................................................4-15 Installation........................................................................4-15 3.10 UPPER AND LOWER CRANKCASE SEPARATION Rear Sensor..............................................................4-17 Crankshaft, Piston and Cylinder Liner Removal/Installation.........................................................3-50 3.12 OIL PUMP 4.11 FUEL INJECTORS Removal/Installation.........................................................3-64 General.............................................................................4-18 Removal...........................................................................4-18 Disassembly.....................................................................4-18 Fuel Injectors.............................................................4-18 Fuel Pressure Regulator...........................................4-18 Fuel Tubes.................................................................4-18 Assembly..........................................................................4-18 Fuel Injectors.............................................................4-18 Fuel Pressure Regulator...........................................4-19 Fuel Tubes.................................................................4-19 Installation........................................................................4-19 3.13 OIL FILTER MOUNT Removal/Installation.........................................................3-65 FUEL SYSTEM 4.1 SPECIFICATIONS:
FUEL SYSTEM Fastener Torque Values in this Chapter..............................4-1 General...............................................................................4-2 4.12 FUEL PUMP/FILTER/SENDER ASSEMBLY 4.2 ELECTRONIC FUEL INJECTION (EFI) Troubleshooting..................................................................4-3 4.3 FUEL TANK Removal...........................................................................4-20 Installation........................................................................4-21 Suction Side Fuel Filter....................................................4-22 Pressure Side Fuel Filter..................................................4-22 Removal....................................................................4-22 Installation.................................................................4-22 Fuel Pump........................................................................4-22 General......................................................................4-22 Removal....................................................................4-22 Installation.................................................................4-22 Removal.............................................................................4-4 Cleaning and Inspecting.....................................................4-5 Installation..........................................................................4-5 4.4 THROTTLE POSITION SENSOR (TP) General...............................................................................4-6 Removal.............................................................................4-6 Installation..........................................................................4-6 TABLE OF CONTENTS VII CRANKCAS ............................
D SERVICE r E 4.10 OXYGEN SE Removal........................ ...3-46 Front Sensor........... Rear Sensor........... Installation..................... Front Sensor...........