3.1 CHAPTER 3 ENGINE 3 ENGINE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 CRANKSHAFT STRAIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 ENGINE LUBRICATION - EH50PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 OIL PRESSURE TEST - EH50PL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 OIL FLOW - EH46PL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 EH46PL OIL FLOW DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 EH46PL ENGINE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 COOLING SYSTEM LAYOUT AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 ENGINE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 CAM CHAIN TENSIONER / ROCKER ARM /CAMSHAFT REMOVAL . . . . . . . . . . . . . 3.14 CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 ROCKER ARM / SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 AUTOMATIC COMPRESSION RELEASE REMOVAL / INSPECTION . . . . . . . . . . . . . 3.17 AUTOMATIC COMPRESSION RELEASE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 3.17 CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CYLINDER HEAD EXPLODED VIEW, EH46PL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 CYLINDER HEAD WARPAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22 CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24 VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 CYLINDER / PISTON REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26 CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27 CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.27 HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29 PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29 PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30 CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30 STARTER DRIVE REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30 FLYWHEEL AND STATOR REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 3.31 CAM CHAIN / TENSIONER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31 ONE WAY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

3.2 ENGINE CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32 OIL PUMP REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32 OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33 COUNTER BALANCER SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . 3.34 CRANKSHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 CRANKCASE BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 OIL SEAL / MECHANICAL SEAL REMOVAL (ENGINE DISASSEMBLED) . . . . . . . . . 3.35 CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 END PLAY INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36 CRANKSHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36 COUNTER BALANCER SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 3.37 OIL PUMP SHAFT END PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37 ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 PUMP SHAFT OIL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 CRANKSHAFT / COUNTER BALANCE / OIL PUMP INSTALLATION . . . . . . . . . . . . . 3.38 CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 WATER PUMP MECHANICAL SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 WATER PUMP MECHANICAL SEAL REMOVAL (ENGINE INSTALLED) . . . . . . . . . . 3.39 ONE WAY VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40 CAM CHAIN DRIVE SPROCKET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40 TENSIONER BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40 PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40 PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41 CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41 CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42 CAM CHAIN / CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 CAMSHAFT TIMING ILLUSTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44 CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45 STATOR, FLYWHEEL AND STARTER DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . 3.45 ROCKER SHAFT / ROCKER ARM ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . 3.46 THERMOSTAT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46 OIL PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46 OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47 SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48 COOLING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

3.3 ENGINE 3 SPECIAL TOOLS SPECIFICATIONS Torque Specifications Engine Fastener Torque Patterns Tighten cylinder head, cylinder base, and crankcase fasteners in 3 steps following the sequence outlined below. PART NUMBER TOOL DESCRIPTION 2870390 Piston Support Block 2871043 Flywheel Puller 2871283 Crankshaft/Water Pump Seal Install Kit 5131135 Water Pump Install Kit 2870569 Crankshaft Truing Stand 2870975 Mity Vac™ Pressure Test Tool PV-43527 Oil Filter Wrench TORQUE SPECIFICATIONS Fastener Size EH46PLE ft. lbs. (Nm) Blind Plug (Oil Pressure) 1/8 PT (28tpi) 6.5-11 (9-15 Nm) Camshaft Sprocket 6mm 5-6.5 (7-9 Nm) Camshaft Chain Tensioner Lever 6mm 5-6.5 (7-9 Nm) Camshaft Chain Tensioner 6mm 5-6.5 (7-9 Nm) Camshaft Chain Tensioner Cap 11mm 6.5 (9 Nm) Throttle Body Adaptor 8mm 12-14 (16-20 Nm) Crankcase 8mm 14-15 (19-21 Nm) Crankshaft Slotted Nut (Cam Chain Drive Sprocket) 28mm 35-51 (47-69 Nm) Cylinder Base Bolts 10mm 6mm 45-49 (61-67 Nm) 6-8 (9-11 Nm) Cylinder Head Bolts 11mm 6mm Refer to Engine Assembly for torque procedure Drive Clutch Bolt 7/16 - 20 40 (55 Nm) Flywheel 16mm 58-72 (78-98 Nm) Oil Delivery Pipe 12mm 11-15 (15-21 Nm) Oil Drain Bolt (Crankcase) 14mm 14-17 (19-23 Nm) Oil Filter Pipe Fitting 20mm 36-43 (49-59 Nm) Hard Metal Oil Line Banjo Fitting N/A 11-16 (15-21 Nm) Oil Hose Fitting 1/8 Pipe Thread 6.5-11 (9-15 Nm) Oil Pump 6mm 5-6.5 (7-9 Nm) Oil Pump Case Screw 5mm 1.5-2 (2-3 Nm) One Way Valve 11mm 14-19 (20-25 Nm) Recoil Housing 6mm 5-6.5 (7-9 Nm) Rocker Cover 6mm 7-8 (9-11 Nm) Rocker Support 8mm 8-10 (11-13 Nm) Rocker Adjuster Screw 6mm 6-7 (8-10 Nm) Water Pump Impeller Nut 6mm 5-6.5 (7-9 Nm) Water Pump Housing Cover 6mm 5-6.5 (7-9 Nm) Stator Plate 6mm 5-6.5 (7-9 Nm) Starter Motor 6mm 5-6.5 (7-9 Nm) Spark Plug 14mm 9-11 (12-15 Nm) Thermistor -- 26 ± 2.1 (35 ± 3 Nm) 2 4 5 6 1 6 mm Cylinder Head 1 2 5 7 8 9 Crankcase 3 Cylinder Base Pattern 6 10 Pattern 3 4

3.4 ENGINE Engine Service Data Cylinder Head / Valve EH46PLE Rocker Arm Rocker arm ID .8669-.8678”(22.020-22.041 mm) Rocker shaft OD .8656-.8661 (21.987-22.0 mm) Rocker shaft Oil Clearance Std .0008-.0021” (.020-.054 mm) Limit .0039” (.10 mm) Camshaft Cam lobe height In Std 1.2884-1.2924" (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Ex Std 1.2884-1.2924" (32.726-32.826 mm) Limit 1.2766" (32.426 mm) Camshaft journal OD Mag 1.4935-1.4941" (37.935-37.950 mm) PTO 1.4935-1.4941" (37.935-37.950 mm) Camshaft journal bore ID Mag 1.4963-1.4970" (38.005-38.025 mm) PTO 1.4963-1.4970" (38.005-38.025 mm) Camshaft Oil clearance Std .0022-.0035" (.055-.090 mm) Limit .0039" (.10 mm) Cylinder Head Surface warpage limit .0020” (.05 mm) Standard height 3.870” (98.3 mm) Valve Seat Contacting width In Std .028" (.7 mm) Limit .055" (1.4 mm) Ex Std .039" (1.0 mm) Limit .071" (1.8 mm) Valve Guide Inner Diameter .2362-.2367" (6.0-6.012 mm) Protrusion above head .689-.709" (17.5-18.0 mm) Valve Margin thickness In Std .039" (1.0 mm) Limit .031" (.8 mm) Ex Std .047" (1.2 mm) Limit .031" (.8 mm) Valve Stem diameter In .2343-.2348" (5.950-5.965 mm) Ex .2341-.2346" (5.945-5.960 mm) Stem Oil clearance Std In .0014-.0024" (.035-.062 mm) Ex .0016-.0026" (.040-.067 mm) Limit .0059" (.15 mm) Overall length In 3.976" (101.0 mm) Ex 3.984" (101.2 mm) Valve Spring Overall length Std 1.654" (42.0 mm) Limit 1.575" (40.0 mm) Squareness Inner .075” (1.9 mm)

3.5 ENGINE 3 Engine Service Data KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off Side. Cylinder / Piston / Connecting Rod EH46PLE Cylinder Surface warpage limit (mating with cylinder head) .0020” (0.05 mm) Cylinder bore Std 3.6221-3.6228" (92.00-92.02 mm) Taper limit .0020” (0.050 mm) Out of round limit .0020” (0.050 mm) Piston clearance Std .0006-.0018" (0.015-0.045 mm) Limit .0024" (0.060 mm) Boring Limit .020” (.5 mm) Piston Outer diameter Std 3.6204-3.6215" (91.970-91.985 mm) .0098" (.25 mm) OS 3.6304-3.6310" (92.21-92.23 mm) .0197" (.50 mm) OS 3.6403-3.6407" (92.46-92.47 mm) Standard inner diameter of piston pin bore .9055-.9057" (23.0-23.006 mm) Piston Pin Outer diameter .9053-.9055” (22.994-23.0 mm) Standard clearance - piston pin to pin bore .0002- .0003” (.004- .008 mm) Degree of fit Piston Pin must be a push (by hand) fit at 68 o F (20 o C) Piston Ring Piston Ring Installed gap Top ring Std .0079-.0138" (.20-.36 mm) Limit .039" (1.0 mm) Second ring Std .0079-.0138" (.20-.36 mm) Limit .039" (1.0 mm) Oil ring Std .0079-.0276" (.20-.70 mm) Limit .059" (1.5 mm) Piston Ring Standard clearance - piston ring to ring groove Top ring Std .0016-.0031" (.040-.080 mm) Limit .0059" (.15 mm) Second ring Std .0012-.0028" (.030-.070 mm) Limit .0059" (.15 mm) Connecting Rod Connecting rod small end ID .9058 - .9063” (23.007 - 23.020 mm) Connecting rod small end radial clearance Std .0003-.0010" (.007-.026 mm) Limit .0020" (.05 mm) Connecting rod big end side clearance Std .0039-.0256" (.1-.65 mm) Limit .0315" (.80 mm) Connecting rod big end radial clearance Std .0004-.0015" (.011-.038 mm) Limit .0020" (.05 mm) Crankshaft Crankshaft runout limit .0024" (.06 mm)