Automotive Manual PDF

Before installing a big bore kit, you should first install a high volume oil pump. A high volume oil pump will deliver up to 300% more oil to your top end which will only help preserve the life of your engine. To install the big bore kit you will need to:
1. Stuff a CLEAN rag behind the piston to seal off the crankcase.
2. Install a c-clip into one side of the piston. When installing the c-clip, compress the c-clip just enough to get it into the piston. Note the position of the c-clip once it is installed.
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Following is the step for installation the PowerFlow Kit for Honda CRF:
Step 1 – Remove OEM inner sealing ring, connection tube, and outside air boot sealing ring. Refer to owners manual.
Step 2 - Before installing Twin Air Inner Sealing Ring, apply a bead of silicone sealant into the machined groove on the Twin Air Inner Sealing Ring.
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1. Install the drill jig into the case by setting the jig into the servo. Retain the jig in the case with the servo’s snap-ring.
2. Drop the 9/16” guide into the jig. It doesn’t matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8” Allen screw.
3. Ream out the bore using the 9/16” reamer, applying ample lubrication.* DO NOT REAM ABOVE 500 RPM.
4. Replace the 9/16” reamer guide with the 5/8” guide, and the 9/16” reamer with the 5/8” reamer.
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1. Install the drill jig into the case by setting the jig into the servo. Retain the jig in the case with the servo’s snap-ring.
2. Drop the 9/16” guide into the jig. It doesn’t matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8” Allen screw.
3. Ream out the bore using the 9/16” reamer, applying ample lubrication.* DO NOT REAM ABOVE 500 RPM.
4. Replace the 9/16” reamer guide with the 5/8” guide, and the 9/16” reamer with the 5/8” reamer.
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1. Install the drill jig into the case by setting the jig into the servo. Retain the jig in the case with the servo’s snap-ring.
2. Drop the 9/16” guide into the jig. It doesn’t matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8” Allen screw.
3. Ream out the bore using the 9/16” reamer, applying ample lubrication.* DO NOT REAM ABOVE 500 RPM.
4. Replace the 9/16” reamer guide with the 5/8” guide, and the 9/16” reamer with the 5/8” reamer.
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Suitable for use on the following vehicles:
1.6 Diesel Engine - 4 Cylinder 1608cc OHC
1. Follow workshop manual instructions to remove the camshaft cover and the timing belt cover.
2. Turn the engine (in the normal direction of rotation) until the timing mark on the injection pump sprocket lines up with the cast lug on the timing cover.
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Connecting Rod
1. Install one piston pin clip into the clip groove in the piston.
2. Assemble the piston and the connecting rod, a ligning the oil groove in the large end of connecting rod opposite the “F” mark on the piston.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin from the side opposite the clip.
5. Tap the piston pin in with the SST until the pin contacts the clip. If the pin cannot be installed easily, replace the connecting (more…)

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1. Remove negative battery cable, then positive battery cable from the battery. If equipped, the Supplemental Restraint System will be deactivated when the battery is disconnected.
SteeRIng extenSIon
2. Remove the nut and bolt holding the steering column to the steering shaft located in the engine compartment about 8 inches down from the firewall. Mark the two shafts for realignment.
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1. Remove negative battery cable, then positive battery cable from the battery. If equipped, the Supplemental Restraint System will be deactivated when the battery is disconnected.
STEERING
2. Lock the steering wheel.
3. Located under the dash, remove the bolt that connects the steering shaft universal joint to the steering column and separate the steering shaft from the steering column.
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Tires, by nature, wear out over time. Due to the large number of factors involved (such as speed, road conditions, inflation, vehicle maintenance, your driving habits, temperature), it is impossible to predict a firm figure for expected tread life. Tires should be inspected regularly and replaced when the tire is worn down. 1. Checking for Wear Tires are worn out when there is just 1.6-mm (2/32-inch) tread depth remaining. This can be measured with an inexpensive tread depth gauge, available at most auto supply stores. In the absence of a gauge, here are two quick methods to check to see if your tires are worn down to the point of replacement.
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