90683-ZX2-003 Honda CLIP, WIRE HARNESS

Identify and mark all wires and harnesses before disconnecting to insure proper assembly.
3. Disconnect wire (1) from the alternator.
Cap or plug all fuel system openings to keep dirt and other foreign material out of the fuel system.
4. Disconnect fuel line (5).5. Remove the cotter pin from the pin holding rod (4) to the governor control lever. Disconnect rod (4) from the governor control lever.6. Loosen nut (3) holding rod (4) to support bracket (2) approximately one turn. Remove rod (4) from support bracket (2) and set it aside, clear of the engine.7. Remove the bolt holding rod assembly (6) to the governor control lever. Set rod assembly (6) aside, clear of the engine. 8. Disconnect tube assembly (8) for the cold starting aid.9. Disconnect two wires (7) from the coolant temperature senders10. Remove the bolts and three wiring harness supports (9). Move the wiring harness clear of the engine.11. Disconnect the wires from starting motor (10).12. Disconnect wires (11) from the oil pressure switch.13. Disconnect wires (12) from the oil pressure sender.
Viewed from beneath transmission.14. Remove the support clip from wiring harness (13) and transmission (14). Disconnect harness (13) at the connector located on the left side of transmission (14).15. Remove the nut connecting wiring harness (13) to sender (15). Move wiring harness (13) clear of transmission (14). 16. Remove the four bolts from the flange of hydraulic line (16) and filter assembly (17). Check the condition of the O-ring seal located beneath the flange of hydraulic line (16). Replace if needed.17. Remove line (18) from manifold (17).18. Remove the four bolts holding manifold (19) to filter assembly (17). Check the condition of the O-ring seal located beneath manifold (19). Replace if needed.19. Remove two bolts (20) from the housing of control cable assembly (21). Lift the housing up and pull the cable assembly clear of the transmission.20. Repeat step 19 for control cable assembly (22).21. Remove four bolts (23) from the base of filter assembly (17). Remove filter assembly (17). 22. Disconnect line (24) from transmission (14).
Viewed from beneath right side of flywheel housing.23. Remove two lines (25).
Viewed from beneath left side of flywheel housing.24. Remove two lines (26).25. Remove three supports (27) from lines (28).26. Disconnect two lines (28) from transmission (14). Position lines (28) clear of transmission (14).
Typical Example27. Remove a head bolt from the right rear side of the cylinder head. Install tooling (A) as shown. 28. Connect tooling (B) to the front engine lifting bracket. Connect a chain to tooling (A) and the rear engine lifting bracket. Support the engine and tooling with a hoist as shown. 29. Remove the nut, bolt and mount assembly (27) from each side of the front of the engine.
Typical Example30. Support transmission (14) with a hydraulic jack as shown.
Viewed from the right side of the machine.31. Disconnect lines (28) and (29).32. Remove the nut and bolt (30) from left and right side transmission mount assemblies (32).33. Use the hydraulic jack supporting the transmission to raise mount assemblies (32) clear of the machine frame.34. Remove bolts (31) from both mount assemblies (32). Remove left and right side transmission mount assemblies (32).35. Slowly lower the hydraulic jack clear of transmission (14).
Make a final check to be sure all removals and disconnections have been made from the engine and transmission.
36. Lift and move the engine far enough forward to remove the bolts from flange (33) located on the right side of the transmission. Remove flange (33).
Typical Example The engine and transmission must be slowly moved to the approximate angle shown to have enough clearance to be removed.37. Use tool (B) to put the engine and transmission into a position to be removed the frame. Remove the engine and transmission as a unit. The total weight of the engine and transmission is 923 kg (2050 lb). Use the following steps for installation of the engine and transmission.38. Connect tooling (B) to the front engine lifting bracket. Install tooling (A) to the right rear of the cylinder head. Connect a chain to tooling (A) and the rear engine lifting bracket. Support the engine with a hoist using tooling (A) and (B) as shown.39. Use tool (B) to put the engine and transmission into the approximate angle at which it was removed. Move the engine and transmission into position in front of the fire wall.40. Use a hydraulic jack to support the transmission. Use the hydraulic jack, the hoist and tooling (B) to move the engine and transmission into position in the frame.41. Move the engine forward far enough to install the bolts and flange (33) located on the right side of the transmission. Install flange (33). Move the engine back into position.42. Use the hydraulic jack to raise the transmission high enough to install bolts (31) and left and right side transmission mount assemblies (32). Tighten the bolts for mount assemblies (32) to a torque of 120 N m 14 (90 10 lb ft).43. Use the hydraulic jack to lower transmission (14) into position and install the nut and bolt (30) into left and right side transmission mount assemblies (32).44. Remove the hydraulic jack from beneath the machine.45. Use the hoist to position the engine and install the nut, bolt and mount assembly (27) onto each side of the front of the engine.46. Tighten the nuts for mount assemblies (32) and (27) to a torque of 360 47 N m (265 35 lb ft).47. Remove tooling (A) and tooling (B).48. Put 5P3931 Anti-Seize Compound on the threads of the head bolt that had been removed to install tooling (A). Install the head bolt and tighten to torque of 150 7 N m (110 5 lb ft).49. Reverse the procedures and steps 1 through 26 to complete the installation of the engine and transmission.50. Check all fluid reservoirs and fill to their correct levels. Refer to the Operation and Maintenance Manual for further information.End By:a. install drive shaft *b. install radiator and guardc. install mufflerd. install