DIAGNOSIS AND REPAIR WORKFLOW
Work Flow (With GR8-1200 NI)
STARTING SYSTEM DIAGNOSIS WITH GR8-1200 NI
To test the starting system, use the following special service tool:
NOTE: Refer to the diagnostic station Instruction Manual for proper starting system diagnosis procedures
OVERALL SEQUENCE

DETAILED FLOW
NOTE: To ensure a complete and thorough diagnosis, the battery, starter motor and generator test segments must be done as a set from start to finish.
1.DIAGNOSIS WITH MULTITASKING BATTERY AND ELECTRICAL DIAGNOSTIC STATION GR8-1200 NI
Perform the starting system test with Multitasking battery and electrical diagnostic station GR8-1200 NI. For details and operating instructions, refer to diagnostic station Instruction Manual.
2.CRANKING CHECK
Check that the starter motor operates properly.
3.ENGINE START CHECK
Check that the engine starts.
4.STARTER MOTOR ACTIVATION
Check that the starter motor operates.
5.COMPARISON BETWEEN ENGINE COOLANT AND CRANKING VOLTAGE
Compare the engine coolant temperature and verify the cranking voltage is within specifications.
Minimum Specification of Cranking Voltage Referencing Coolant Temperature

6.STARTER OPERATION
Check the starter operation.
7."B" TERMINAL CIRCUIT INSPECTION
Check "B" terminal circuit.
8."S" CONNECTOR CIRCUIT INSPECTION
Check "S" connector circuit.
9.ENGINE ROTATION STATUS
Check that the engine can be rotated by hand.
Work Flow (Without GR8-1200 NI)
OVERALL SEQUENCE

DETAILED FLOW
NOTE: If any malfunction is found, immediately disconnect the battery cable from the negative terminal.
1.CHECK ENGINE START
Crank the engine and check that the engine starts.
2.CHECK THAT THE STARTER MOTOR STOPS
Check that the starter motor stops after starting the engine.
3.CHECK THAT THE ENGINE TURNS WHEN CRANKING
Check that the engine turns when cranking.
4.CHECK THE ENGINE SPEED WHEN CRANKING
Check that the engine speed is not low when cranking.
5.CHECK STARTER MOTOR ACTIVATION
Check that the starter motor runs at cranking.
6.CHECK POWER SUPPLY CIRCUIT
Check the following conditions:
7.CHECK STARTING SYSTEM WIRING
Check the following:
Starting system
System descriptionOil Seal
Removal and Installation of Valve Oil Seal
REMOVAL
Turn crankshaft until the cylinder requiring new oil seals is at
TDC. This will prevent valve from dropping into cylinder.
CAUTION: When rotating crankshaft, be
careful to avoid scarring the front cover with the timing chain.
Remove ...
Unit removal and installation
TRANSAXLE ASSEMBLY
Exploded View
Air breather hose
CVT fluid level gauge
CVT fluid charging pipe
O-ring
Copper sealing washer
Fluid cooler tube
Transaxle assembly
A. Refer to INSTALLATION.
...
Intake sensor
Removal and Installation
REMOVAL
Remove the evaporator (2). Refer to HA-48, "EVAPORATOR:
Removal and Installation".
Release the intake sensor clip (A), then remove the intake sensor
(1).
CAUTION:
Mark the mounting position of the intake sensor.
Do not damage the evapo ...