Automotive Manual PDF

This kit is intended for use on 1993 and newer XR/CRF100’s using CDI ignition. Engine assembly requires special attention to detail. A new BBR Cylinder and piston kit have been supplied. The following measurments are critical to proper installation and performance.
Ring end gap: .012″ - .015″
Valve clearance: Intake: .002″ Exhaust: .003″
Piston to head clearance: .040″
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Ford 4.6L and 5.4L 3-valve engine cam phasers, how they work, their limitations, and how COMP uses them for making more power
What are cam phasers?
Ford’s cam phasers are specially designed, computer controlled cam gears that have the ability to adjust camshaft position while the engine is running. They are used on all 2005 and newer, 3-valve Ford modular engines. Since the modular engine uses two camshafts, one for each side of the engine, two cam phasers are used per engine.
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These lifters are engineered and manufactured to provide optimum performance and reliability. In order to take full advantage of the product, proper installation is required. Please follow the instructions below to insure complete satisfaction.

Pre-installation Considerations
Since the valve train in a typical overhead valve engine contains numerous components which may or may not be matched, care must be taken to avoid potential issues which may affect the overall performance of the lifters and the engine. These considerations can be best described in two categories: Mechanical Interference and Valve Train Geometry.
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Thank you for choosing COMP Cams® products! We know you have options in valve train component selection and we are proud to be your manufacturer of choice. Please read this instruction sheet carefully before beginning installation, and also take a moment to review the included limited warranty information.
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Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
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Swift DOHC uses hydraulic lifters. No adjustments are required.
Samurai & Sidekick
1) Remove valve cover. Rotate engine until zero degree (TDC) timing mark of timing belt cover is in line with timing mark on crankshaft pulley. See Fig. 1.
2) Ensure cylinder No. 1 is at TDC on compression stroke. Remove distributor cap. On Samurai and Sidekick (TBI), ensure rotor is pointed upward at distributor hold-down bolt and to No. 1 terminal of distributor cap. On Sidekick (MPI), ensure rotor is at about 1 o’clock position and pointed to No. 1 terminal of distributor cap. If rotor is not as described, rotate crankshaft 360 degrees.
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Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay.
VALVE CLEARANCE
NOTE: Adjust valve clearance with engine cold.
NOTE: If valve cover uses grommets below retaining nuts or bolts, keep grommets in order so they are installed in original locations during reassembly.
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Engine oil and filter renewal Exhaust system check Fluid leakage and engine electrical system check Fuel and brake line, hose and union check Fuel filter renewal Fuel system control linkage check Gearbox oil level check Headlight beam alignment check Hinge and catch lubrication Ignition timing check Intensive maintenance Introduction Light, direction indicator and horn check Lock, hinge and latch mechanism check Seat belt check Slow running adjustment Spark plug renewal Steering gear check Sunroof guide rails cleaning and lubrication Suspension check Timing belt renewal Valve clearance check
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This workshop manual contains repair instructions for the 2001, 2002 and 2003 engines. The instructions concerning overhauling describe the most suitable working method using the special tools listed under the heading “Special tools” . Both the engine designation and its serial number must be clearly stated in all correspondence concerning the engine and when ordering parts. We reserve the right to carry out design modifications and, for this reason, the contents of this manual cannot be regarded as binding.
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MOTORCYCLE SAFETY 32 ESSENTIAL INDIVIDUAL 2 Safe riding Rules COMPONENTS 2 Protective Apparel 32 Engine stop Button 2 Modifications 32 Switches 3 Loading and Accessories 34 FEATURES (Not required for operation) 34 Tool Bag 5 DESCRIPTION 5 Parts location 35 OPERATION 8 Parts Function 35 Pre-Ride -Inspection 10 MAJOR COMPONENTS (Information 36 Starting the Engine you need to operate this motorcycle) 38 Manual Starter Decompressor 10 Front Suspension 39 Flooded Engine 13 Rear Suspension 39 Break-In 17 Front Brake 40 Riding 19 Rear Brake 41 High Altitude Riding 21 Clutch 42 Braking 23 Fuel 43 Parking 25 Engine oil 43 Anti-Theft-Tips 27 Drive Chain 1 Tyres
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