FR651V, FR691V, FR730V FS651V, FS691V, FS730V FX651V, FX691V, FX730V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual
Quick Reference Guide This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.
FR651V, FR691V, FR730V FS651V, FS691V, FS730V FX651V, FX691V, FX730V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
LIST OF ABBREVIATIONS A ampere(s) ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L after bottom dead center alternating current lb m min pound(s) after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) N Pa PS psi r rpm TDC TIR V W meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s)
EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems (EM) in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. 1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase.
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................
1-2 GENERAL INFORMATION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work. Especially note the following (1) Dirt Before removal and disassembly, clean the engine.
GENERAL INFORMATION 1-3 Before Servicing (12)Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.
1-4 GENERAL INFORMATION Before Servicing “Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
GENERAL INFORMATION 1-5 Model Identification FX Models FR Models
1-6 GENERAL INFORMATION Model Identification FS Models Cylinder Number Designation: No.1 Cylinder is the left-hand cylinder viewed from the inlet pipe. No.2 Cylinder is the right-hand cylinder viewed from the inlet pipe.
GENERAL INFORMATION 1-7 General Specifications Item Type of Engine Cylinder Layout Bore × Stroke Piston Displacement Direction of Rotation Compression Release Low Idle Speed High Idle Speed Ignition System RFI Starting System: FR and FS Models FX Models Charging System: FS and FX Models FR Models Spark Plug Carburetor: FR and FS Models FX Models Fuel Pump Air Cleaner: FR Models FS Models FX Models Governor Lubrication System Oil Filter Oil Capacity (when engine is completely dry) Cooling System Dimensions (
PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Specifications ......................................................................................................................... Special Tools ..........................................
2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals. The bullet mark ( ) designates that the corresponding item should be performed at that interval. Some adjustments require the use of special tools or other equipment.
PERIODIC MAINTENANCE 2-3 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: EO: Apply oil to the threads. L: Apply a non-permanent locking agent to the threads. Lh: Left-hand threads. S: Tighten the fasteners following the specified sequence.
2-4 PERIODIC MAINTENANCE Torque and Locking Agent Fastener 46 14.7 5.9 Torque kgf·m 4.7 1.5 0.60 ft·lb 34 11 52 in·lb 22 11 2.2 1.1 16 97 in·lb 6.9 5.9 0.70 0.60 61 in·lb 52 in·lb 5.9 0.60 52 in·lb 8.8 0.90 78 in·lb 9.8 27.4 3.9 3.9 5.9 1.0 2.8 0.40 0.40 0.60 87 in·lb 20 35 in·lb 35 in·lb 52 in·lb 2.0 0.20 18 in·lb 19.6 2.0 14 3.95 0.40 35 in·lb 56 5.9 22 3.4 5.7 0.60 2.2 0.
PERIODIC MAINTENANCE 2-5 Specifications Item Fuel System Idle Speed (1): Low Idle Speed (Carburetor idle rpm) Low Idle Speed (Governor idle rpm) High Idle Speed Air Cleaner: Type: FR Models FS and FX Models Pre-cleaner: FR Models FS Models FX Models Second-stage cleaner: FS Models FX Models Engine Top End Valve Clearance: Inlet, Exhaust Valve Seating Surface Angle: Inlet, Exhaust Valve Seating Surface Width: Inlet Exhaust Lubrication System Engine Oil: Type Viscosity Capacity Level Electrical System Spark P
2-6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter, 45° 57001-1116 35: Valve Seat Cutter, 45° 57001-1187 30: Valve Seat Cutter, 32° 57001-1121 35: Valve Seat Cutter, 32° 57001-1199 33: Valve Seat Cutter Holder Bar: 57001-1128 Valve Seat Cutter Holder, 57001-1360 6:
PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures Fuel System NOTE ○High and low idle speeds may vary depending on the equipment on which the engine is used. Refer to the equipment specification. Low Idle Speed Adjustment all possible external loads from the engine. • Disconnect Start the engine and warm it up thoroughly. • WARNING Always keep your hands clear of the moving parts. the throttle lever at a dash to the idle position.
2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Always keep your hands clear of the moving parts. the locknut [A], and unscrew the high idle set • Loosen screw [B] few turns. the throttle lever on dash to obtain the specified high • Move idle speed and leave it there. High Idle Speed 3 600 r/min (rpm) the high idle set screw so that the end of it just • Turn touches the speed control lever [C], and tighten the lock • nut. Check the idle speed, and readjust the idle speed if necessary.
PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned, and each air cleaner element should be replaced with new ones at the maintenance time as shown in the maintenance chart. NOTE ○Operating in dusty condition may require more frequent maintenance than above. FX Models Remove the elements (see Element Removal in the Fuel System chapter). Replace the primary element [A] every 250 hrs.
2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Housing (Cap and Body) Inspection FX Models Remove: Elements (see Element Removal in the Fuel System chapter) Air Cleaner Housing (see Air Cleaner Body and Bracket Removal in the Fuel System chapter) Clean the housing with detergent and water and dry the housing thoroughly. Check the housing for deformation or other damage. ○Seal the housing well and permit only filtered air to reach the carburetor.
PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures No.1 Cylinder ○The left projection [A] on the flywheel is faced with the right leg [B] on the #1 ignition coil [C] as shown in the figure. ○Check the inlet and exhaust valves are closed completely, if not, turn the flywheel one turn (360°) clockwise and face the left projection with the right leg again. No.2 Cylinder ○The left projection [A] on the flywheel is faced with the right leg [B] on the #2 ignition coil [C] as shown in the figure.
2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures the adjusting bolt with a spanner [A], tighten the • Holding adjusting locknut [B] to the specified torque. Torque - Valve Clearance Adjusting Locknuts: 11 N·m (1.1 kgf·m, 87 in·lb) not overtighten the valve clearance adjusting locknuts. • Do After the valve clearance adjustment, measure the valve • clearance again. Readjust the valve clearance if necessary.
PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Seat Cutter Operating Cares 1. This valve seat cutter is designed only for valve seat repair. Therefore the cutter must not be used for other purposes. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures the seat with machinist’s dye. • Coat Fit a 45° • guide. cutter [A] to the holder and slide it into the valve ○Resurface the valve seat with a 45° cutter, removing only enough material to produce a smooth and concentric seat. CAUTION Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head.
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures lapping is completed, wash all parts in solvent to • When remove lapping compound. Dry the parts thoroughly. the position of the lapping mark on the valve face. • Note The lapping mark should appear on or near the center of • the valve face. When the engine is assembled, be sure to adjust the valve clearances (see Valve Clearance Adjustment). Lubrication System Engine Oil Level Inspection the engine on a level surface.
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures the oil filler cap and pour in the specified type • Remove and the amount of oil. Engine Oil: Grade: SF, SG, SH, SJ or SL Class Viscosity: SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 Capacity: [When the oil filter is not removed] 1.8 L (1.9 US qt) [When the oil filter is removed] 2.1 L (2.2 US qt) the O-ring [A] on the oil filler cap for damage. Re• Check place the oil filler cap assembly if O-ring is damaged.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection pull the plug cap from the spark plug, and re• Carefully move the spark plug. If the plug is oily or has carbon built up on it, clean the plug using a high-flash point solvent and a wire brush or other suitable tools. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked replace the plug with a new one. Use the standard spark plug or its equivalent.
FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Governor Link Mechanism...................................................................................................... Control Panel Assembly Removal .....................................
3-2 FUEL SYSTEM Exploded View FX Models
FUEL SYSTEM 3-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 Fastener Air Cleaner Bracket Mounting Bolts Air Cleaner Holder Bracket Bolts Carburetor and Inlet Pipe Mounting Bolts Carburetor and Inlet Pipe Mounting Nuts Choke Valve Screws Cover Plate Screw Drain Screw Float Chamber Mounting Screws Inlet Manifold Bolts Throttle Valve Screws N·m 5.9 5.9 5.9 5.9 0.93 2.4 2.0 3.9 5.9 0.93 R: Replacement Parts S: Tighten the fasteners following the specified sequence. Torque kgf·m 0.60 0.60 0.60 0.60 0.095 0.24 0.
3-4 FUEL SYSTEM Exploded View FR651V, FR691V, FR730V, FS651V, FS691V, FS730V Models
FUEL SYSTEM 3-5 Exploded View No. Fastener 1 2 3 4 5 Carburetor and Inlet Pipe Mounting Nuts Control Panel and Inlet Pipe Mounting Bolt Inlet Manifold Bolts Main Jet Solenoid Valve Throttle Lever Mounting Screw (FR651V, FR691V, FS651V, FS691V Models) Throttle Valve Screws 6 7 N·m 5.9 5.9 5.9 2.3 4.5 Torque kgf·m 0.60 0.60 0.60 0.23 0.46 ft·lb 52 in·lb 52 in·lb 52 in·lb 20 in·lb 40 in·lb 0.68 0.069 6.0 in·lb L 0.68 0.069 6.0 in·lb L 8. FR730V and FS730V Models 9.
3-6 FUEL SYSTEM Exploded View
FUEL SYSTEM 3-7 Exploded View No. 1 2 3 4 Fastener Control Panel Mounting Bolt Governor Arm Clamp Nut Governor Arm Joint Bolt Governor Shaft Plate Screws 5. FR and FS Models EO: Apply engine oil. Lh: Left-hand threads. R: Replacement Parts N·m 5.9 7.8 5.9 2.0 Torque kgf·m 0.60 0.80 0.60 0.
3-8 FUEL SYSTEM Specifications Item Carburetor Specifications: Make/Type: FR651V and FS651V FR691V and FS691V FR730V and FS730V FX651V FX691V FX730V Throttle Bore Diameter: FR and FS Models FX Models Venturi Diameter: FR and FS Models FX Models Main Jet (MJ): FR and FS Models FX Models Pilot Jet (PJ): FR and FS Models FX Models Pilot Air Screw Turns out (PS) (Idle Mixture Screw Turns Out): FR and FS Models FX Models Float Level Idle Speed: (1) Low Idle Speed (Carburetor idle rpm) Low Idle Speed (Governor id
FUEL SYSTEM 3-9 Specifications Fuel (2) Fuel Requirement US, Canada Other Countries Fuel Pump Type Governor Type Unleaded regular grade gasoline Using a minimum of 87 octane by antiknock index is recommended. Antiknock Index: (RON + MON)/2 RON = Research Octane Number MON = Motor Octane Number Using a minimum of 91 octane by RON is recommended. Pulse-diaphragm pump Flyweight all speed governor (1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.
3-10 FUEL SYSTEM Governor Link Mechanism Control Panel Assembly Removal FX Models Remove: Inlet Pipe Mounting Bolt [A] and Nut [B] Control Panel Mounting Bolt [C] Choke Spring [D] Control Panel Assembly [E] Governor Spring [F] • FR and FS Models Remove: Control Panel and Inlet Pipe Mounting Bolt [A] Carburetor and Inlet Pipe Mounting Nut [B] Control Panel Mounting Bolt [C] Choke Spring [D] Control Panel Assembly [E] Governor Spring [F] • Control Panel Assembly Installation installing the control panel
FUEL SYSTEM 3-11 Governor Link Mechanism FR and FS Models Install the governor spring [A], control panel assembly [B] and choke spring [C]. Tighten: • • Torque - Control Panel Mounting Bolt [D]: 5.9 N·m (0.60 kgf·m, 52 in·lb) Carburetor and Inlet Pipe Mounting Nut [E]: 5.9 N·m (0.60 kgf·m, 52 in·lb) Control Panel and Inlet Pipe Mounting Bolt [F]: 5.9 N·m (0.
3-12 FUEL SYSTEM Governor Link Mechanism • Remove the bolt [A] to separate the governor arms [B]. Governor Arm Installation the inside governor arm [A] onto the governor shaft • Install [B]. sure the link spring [C] around the throttle link rod [D] • Be is in place and that it pulls the outside governor arm [E] • and throttle lever [F] each other. Tighten: Torque - Governor Arm Clamp Nut [G]: 7.8 N·m (0.
FUEL SYSTEM 3-13 Governor Link Mechanism Governor Assembly Installation the snap ring into the groove securely. • Fit Turn governor plate by hand and check that the steel • balls the and governor plate operate freely. Replace spring pin [A] with a new one. • Be sure totheinstall the washer [B] and pin. • 2.0 ∼ 2.3 mm (0.079 ∼ 0.091 in.) [C] Governor Assembly Inspection check all governor parts for wear or damage. • Visually If any parts are worn or damaged, replace them with new ones.
3-14 FUEL SYSTEM Carburetor Fuel and Air Flow FX Models The main system of the carburetor consists of the main jet [A], valve seat [B], main nozzle [C], and the main air passage [D] (main air jet [E]). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel flows through the main jet and into the main nozzle, where it is joined by air from the main air passage (main air orifice).
FUEL SYSTEM 3-15 Carburetor The pilot system includes the pilot jet [F], pilot screw [G] (Idle mixture screw), pilot outlet [H], and the bypass holes [I]. The pilot system meters the fuel/air mixture while the engine is idling and running under a light load. Under these conditions there is very little air flow through the carburetor bore; so little that it is not enough to draw fuel through the main system of the carburetor and atomize it.
3-16 FUEL SYSTEM Carburetor FR and FS Models The main system of the carburetor consists of the main jet [A], main nozzle [B], and the main air passage [C] (main air jet [D]). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel flows through the main jet and into the main nozzle, where it is joined by air from the main air passage (main air jet).
FUEL SYSTEM 3-17 Carburetor Fuel Shut Off Solenoid Valve To avoid after firing when stopping the engine, a solenoid actuated fuel shut off solenoid valve [A] is installed in the carburetor bowl. The valve shuts off the fuel supply to the main jets [B] simultaneously when the switch key turned to the “OFF” position. The valve opens automatically when the switch key is turned to the “Run” position.
3-18 FUEL SYSTEM Carburetor Main Jet Replacement FX Models Close the fuel shut off valve in the equipment. Remove the carburetor (see Carburetor Removal). Drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber (see Fuel System Cleanliness Inspection in the Periodic Maintenance chapter). Unscrew the chamber screws [A] and take off the float chamber [B]. • • • • • Remove the float assembly [A] from the float chamber.
FUEL SYSTEM 3-19 Carburetor the main jet [A] with a new one for altitude ex• Replace pected (see High Altitude Operation). the new O-ring [B] to the main jet. • Install the suitable rod [C], press the main jet until they are • Using bottomed to the spacer [D]. the carburetor (see Carburetor Disassem• Assemble bly/Assembly). FR and FS Models Close the fuel shut off valve in the equipment. Remove the carburetor (see Carburetor Removal).
3-20 FUEL SYSTEM Carburetor Inlet Pipe Removal FX Models Remove: Air Cleaner (see Air Cleaner Body and Bracket Removal) Control Panel Assembly (see Control Panel Assembly Removal) Inlet Pipe Mounting Bolt [A] and Nut [B] Ground Lead [C] Clamp [D] Breather Hose [E] Inlet Pipe [F] • FR and FS Models Remove: Element Assembly (see Element Removal) Control Panel Assembly (see Control Panel Assembly Removal) Inlet Pipe Mounting Nut [A] Ground Lead [B] Clamp [C] Breather Hose [D] Inlet Pipe [E] • Inlet Pipe In
FUEL SYSTEM 3-21 Carburetor the breather hose [A] so that the clamp knob [B] • Connect faces the downward. the removed parts (see appropriate chapters). • Install FX Models [C] FR and FS Models [D] Carburetor Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the engine switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
3-22 FUEL SYSTEM Carburetor the throttle link spring [A] at the throttle shaft lever • Unhook clip end [B] with a long nose plier. the throttle link rod [C] from the throttle shaft lever • Unhook clip end. the carburetor.
FUEL SYSTEM 3-23 Carburetor Carburetor Installation the mating surface of the carburetor and inlet man• Clean ifold. the gaskets [A] with new ones. • Replace Install the [B], carburetor [C] and gaskets se• quence as insulator shown in the figure. dielectric grease to the solenoid valve connector. • Apply the solenoid valve connector. •○Connect The tongue [D] of the gaskets face the PTO side (FX Models only).
3-24 FUEL SYSTEM Carburetor the throttle link rod [A] and spring [B] to the throttle • Install shaft lever clip [C]. NOTE ○Take care not to bend the throttle link rod during installation. sure the link spring around the throttle link rod is • Make in place and that it pulls the governor arm and carburetor throttle shaft lever toward each other. FX Models [D] FR and FS Models [E] the fuel tube [A] fully so that the clamp knob [B] • Install faces the downward.
FUEL SYSTEM 3-25 Carburetor Carburetor Disassembly/Assembly FX Models Refer to the illustration shown for disassembly and assembly. There are several passage plugs (ball plugs) in the carburetor body. Do not remove. Before disassembly, mark the out side of choke and throttle valves for assembling them. Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side. Drive the float pin into the carburetor body.
3-26 FUEL SYSTEM Carburetor FR651V, FR691V, FS651V, FS691V Models Refer to the illustration shown for disassembly and assembly. There are several passage plugs (ball plugs) in the carburetor body. Do not remove. Before disassembly, mark the out side of choke and throttle valves for assembling them. Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side. Drive the float pin into the carburetor body.
FUEL SYSTEM 3-27 Carburetor FR730V and FS730V Models Refer to the illustration shown for disassembly and assembly. There are several passage plugs (ball plugs) in the carburetor body. Do not remove. Before disassembly, mark the out side of choke and throttle valves for assembling them. Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side. Drive the float pin into the carburetor body.
3-28 FUEL SYSTEM Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the carburetors. CAUTION Do not use compressed air on an assembled carburetor, or the floats may be crushed by the pressure.
FUEL SYSTEM 3-29 Carburetor Carburetor Inspection WARNING Gasoline is extremely flammable and can be explosive under certain. Turn the engine switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the carburetor body for damage. Flange sealing • Inspect surfaces should be smooth and free of burns and nicks.
3-30 FUEL SYSTEM Carburetor the float valve for excessive wear or damage. The • Inspect tip should be smooth, without any grooves, scratches, or tears. The rod at the other end of the needle should move smoothly when push in and released. [A] Good [B] Not Good If either the needle or the seat is worn or damaged, replace the float assembly and carburetor body as a set with a new one. the tapered portion [A] of the pilot screw [B] for • Inspect wear or damage.
FUEL SYSTEM 3-31 Inlet Manifold Inlet Manifold Removal the engine shroud (see Engine Shroud Removal • Remove in the Cooling System chapter) the inlet manifold mounting bolts [A]. • Unscrew Remove the inlet manifold [B] and gaskets. • FX Models [C] FR and FS Models [D] Inlet Manifold Installation the inlet manifold gaskets [A] with new ones. • Replace Clean the • ifolds.
3-32 FUEL SYSTEM Inlet Manifold Inlet Manifold Inspection the intake manifold for cracks or porous casting. • Inspect Cracks not to the eye may be detected by using a • metal crackvisible detection system (Visual color check: com- • monly found at automotive parts store.). If a crack is present in the inlet manifold, replace it. Inspect the gasket surfaces for burrs and nicks.
FUEL SYSTEM 3-33 Fuel Pump, Fuel Filter The diaphragm in the fuel pump operates by the pulse generated in the crankcase, and the fuel pump supplies fuel to the carburetor. The fuel pump disassembly is not recommended, if any damage for the pump is noticed replace it with a new one. Fuel Pump Removal • Remove: Fuel Tubes [A] Pulse Tube [B] Screws [C] Fuel Pump [D] Fuel Pump Installation the fuel tubes [A] and pulse tube [B] fully. • Connect Tighten the fuel pump mounting screws [C].
3-34 FUEL SYSTEM Fuel Pump, Fuel Filter Fuel Flow Test WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the engine switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the fuel pump outlet nozzle from the tube. • Disconnect Connect a suitable [A] to the outlet nozzle. • Run the lower end ofhose the into a container. • Start the engine, check thehose fuel flow.
FUEL SYSTEM 3-35 Air Cleaner Element Removal FX Models Unhook the two retaining clamps [A] and remove the cap [B] from the air cleaner body. • • Remove the primary element [A]. • Remove the secondary element [A]. FR and FS Models Open the air cleaner cover [A]. • the clamp [A]. • Loosen Remove the inlet hose [B] together with the element as• sembly [C].
3-36 FUEL SYSTEM Air Cleaner the clamp [A]. • Loosen Remove: • Inlet Hose [B] Foam Element [C] (FS Models only) Element Installation FX Models Slide the secondary element and primary element into place in the air cleaner body. Install the cap direction as shown in the figure. Upside [A] 41° [B] Fasten the two retaining clamps [C]. • • • FR and FS Models Install the form element [A] to the paper element [B] (FS Models only).
FUEL SYSTEM 3-37 Air Cleaner the inlet hose [A], and tighten the clamp [B]. •○Install Check that the element [C] is horizontally installed. • Install the inlet hose [A], and tighten the clamp [B]. • Close the air cleaner cover [A]. Element Cleaning and Inspection Air cleaner elements are not recommended to be cleaned, and each air cleaner element should be replaced with new ones. Refer to the Element Cleaning and Inspection in the Periodic Maintenance chapter.
3-38 FUEL SYSTEM Air Cleaner • Remove: Bolts [A] Bracket [B] Air Cleaner Body and Bracket Installation FX Models Install the air cleaner bracket [A]. Tighten: • • Torque - Air Cleaner Bracket Mounting Bolts [B]: 5.9 N·m (0.60 kgf·m, 52 in·lb) the air cleaner body [A] onto the lower bracket so that • Set the air inlet duct [B] is facing upward. the inlet hose [C], and tighten the clamp [D]. • Install the upper bracket [E]. • Install Tighten: • Torque - Air Cleaner Holder Bracket Bolts [F]: 5.9 N·m (0.
COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................................................................................................................ Cooling Fan ............................................................................................................................ Cooling Fan Removal ....................................................................................................... Cooling Fan Installation .......................................
4-2 COOLING SYSTEM Exploded View
COOLING SYSTEM 4-3 Exploded View No. 1 2 3 4 5 6 7 8 Fastener Cooling Fan Plate Mounting Bolts Cooling Fan Screen Bolts Engine Shroud Bolts (FX Models) Engine Shroud Bolts (FR and FS Models) Fan Housing Bolts (FX Models) Fan Housing Bolts (FR and FS Models) Flywheel Bolt Guard Mounting Bolts (FX Models) N·m 8.8 5.9 5.9 8.8 5.9 8.8 56 5.9 Torque kgf·m 0.90 0.60 0.60 0.90 0.60 0.90 5.7 0.60 9. FR Models 10. FS Models 11.
4-4 COOLING SYSTEM Cooling Fan Cooling Fan Removal to the Flywheel and Stator Coil Removal in the Elec• Refer trical System chapter. Cooling Fan Installation to the Flywheel and Stator Coil Installation in the • Refer Electrical System chapter. Cooling Fan Inspection the fan housing (see Flywheel and Stator Coil • Remove Removal in the Electrical System chapter). inspect the blades [A] in the cooling fan. • Visually If they have any crack, warp or damage, replace the cool- • ing fan with a new one.
COOLING SYSTEM 4-5 Engine Shroud Engine Shroud Removal • Remove: Spark Plug Cap (see Ignition Coil Removal in the Electrical System chapter) Carburetor (see Carburetor Removal) Engine Shroud Bolts [A] Engine Shroud [B] FR and FS Models Cut off the band [A]. • Engine Shroud Installation FX Models Install the engine shroud [A]. Tighten: • • Torque - Engine Shroud Bolts [B]: 5.9 N·m (0.
4-6 COOLING SYSTEM Engine Shroud FR and FS Models Install the engine shrouds. • NOTE ○Bend the engine shroud (regulator side) [A] only within the shown range. • • 70° [B] Attach the stator coil lead, ignition coil lead and solenoid valve connector lead to the engine shroud with the band. Tighten: Torque - Engine Shroud Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Cylinder Head......................................
5-2 ENGINE TOP END Exploded View
ENGINE TOP END 5-3 Exploded View No. 1 2 3 4 5 6 7 Fastener Connecting Rod Big End Cap Bolts Cylinder Head Bolts (L = 50 mm) Cylinder Head Bolts (L = 60 mm) Rocker Arm Bracket Bolts Rocker Cover Bolts Spark Plugs Valve Clearance Adjusting Locknuts N·m 9.8 46 46 14.7 5.9 22 11 EO: Apply engine oil. L: Apply a non-parmanent locking agent. MO: Apply molybdenum disulfide oil. R: Replacement Parts S: Tighten the fasteners following the specified sequence. Torque kgf·m 1.0 4.7 4.7 1.5 0.60 2.2 1.
5-4 ENGINE TOP END Specifications Item Cylinder Head: Cylinder Compression (MIN) Cylinder Head Warp Valves: Valve Head Thickness: Inlet, Exhaust Valve Stem Runout: Inlet, Exhaust Valve Stem Diameter: Inlet Exhaust Valve Guide Inside Diameter: Inlet, Exhaust Valve Spring Free Length: Inlet, Exhaust Rocker Arm Push Rod Runout: Inlet, Exhaust Rocker Shaft Outside Diameter: Inlet, Exhaust Rocker Arm Inside Diameter: Inlet, Exhaust Cylinder, Piston: Piston Diameter Piston Ring/Groove Clearance: Top Second Pisto
ENGINE TOP END 5-5 Specifications Item Valve Clearance: Inlet, Exhaust Valve Seating Surface Angle: Inlet, Exhaust Valve Seating Surface Width: Inlet Exhaust Valves Guide Inside Diameter: Inlet, Exhaust Cylinder Inside Diameter: Standard Cylinder 0.50 mm Oversize Cylinder Standard 0.05 ∼ 0.10 mm (0.0020 ∼ 0.039 in.) 45° 1.2 ∼ 1.8 mm (0.047 ∼ 0.071 in.) 0.8 ∼ 1.6 mm (0.031 ∼ 0.063 in.) 6.000 ∼ 6.012 mm (0.2362 ∼ 0.2367 in.) 77.98 ∼ 78.00 mm (3.070 ∼ 3.071 in.) 78.48 ∼ 78.50 mm (3.090 ∼ 3.091 in.
5-6 ENGINE TOP END Special Tools 67 ∼ Piston Ring Pliers: 57001-115 Piston Ring Compressor Belt, 57001-1097 Compression Gauge, 20 kgf/cm²: 57001-221 Compression Gauge Adapter, M14 × 1.
ENGINE TOP END 5-7 Cylinder Head Compression Measurement measuring compression, do the following. •○Before Be sure the battery is fully charged. ○Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help sealing the compression as it does during normal running. ○Stop the engine. Disconnect the spark plug caps of each cylinder and remove the spark plugs. Attach the compression gauge assembly firmly into one plug hole.
5-8 ENGINE TOP END Cylinder Head Cylinder Head Assembly Removal • Remove: Inlet Manifold (see Inlet Manifold Removal in the Fuel • • System chapter) Spark Plugs (see Spark Plug Removal in the Electrical System chapter) Unscrew the rocker cover bolts in the order shown [1 to 5]. Remove the cover [A] and the gasket. removing the #1, #2 cylinder head, set each pis• When ton at the top dead center (T.D.C) [A] of the compression stroke.
ENGINE TOP END 5-9 Cylinder Head each piston at the T.D.C [A] of the compression • Set stroke. new gaskets and the cylinder head assemblies on • Put each cylinder. NOTE ○As the head gaskets are coated with sealing agents, be careful not to damage the surfaces. the cylinder head bolts following the tightening • Tighten sequence as shown in the figure. Torque - Cylinder Head Bolts: 46 N·m (4.7 kgf·m, 34 ft·lb) CAUTION A torque wrench must be used to assure proper torque.
5-10 ENGINE TOP END Cylinder Head Push Rod Installation each piston at the T.D.C of the compression stroke. • Set Apply • rod. engine oil to the both ends and shaft of the push the push rods in their original positions of the tappet • Install hollow [A]. that both inlet and exhaust push rods on each • Check cylinder are at lowest position on the cam lobes. If the • • • piston is not at the T.D.C of the compression stroke, turn the flywheel clockwise one turn (360°) and reset each piston at the T.D.
ENGINE TOP END 5-11 Cylinder Head • Remove: Push Rod (see Push Rod Removal) Rocker Arm Bracket Bolts [A] Rocker Arm Bracket [B] the cylinder head assembly (see Cylinder Head • Remove Assembly Removal). the valve head in the combustion chamber with • Support a suitable block. remove the collets [A], push down the valve retainer • To [B] with suitable tool and remove the collets. • Remove the valve retainer, spring [C] and valve [D] . • Remove the stem seals [A].
5-12 ENGINE TOP END Cylinder Head the rocker arm brackets [A] so that bracket hollows • Install [B] fit to the cylinder head projections [C]. a non-permanent locking agent to the rocker arm • Apply bracket bolts, and tighten them. Torque - Rocker Arm Bracket Bolts: 14.7 N·m (1.5 kgf·m, 11 ft·lb) • Install the push rods (see Push Rod Installation). the rocker arm [A] so that the hollow side [B] • Position faces push rod. engine oil to the collars [A].
ENGINE TOP END 5-13 Cylinder Head Cylinder Head Inspection a straightedge [A] across the mating surface of the • Lay head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and head. If warp exceeds the service limit, repair the head by lapping the mating surface with emery paper secured to a surface plate (first No. 200, than No. 400). If the mating surface is badly damaged, replace the cylinder head. Cylinder Head Warp Service Limit: 0.05 mm (0.
5-14 ENGINE TOP END Valves Valve Clearance Inspection to the Valve Clearance Inspection in the Periodic • Refer Maintenance chapter. Valve Clearance Adjustment to the Valve Clearance Adjustment in the Periodic • Refer Maintenance chapter. Valve Seat Inspection to the Valve Seat Inspection in the Periodic Mainte• Refer nance chapter. Valve Seat Repair to the Valve Seat Repair in the Periodic Mainte• Refer nance chapter.
ENGINE TOP END 5-15 Valves Valve Guide Inside Diameter a small bore gauge or a micrometer to measure the • Use inside diameter [A] of the valve guide [B] at three positions down the guide length. If the measurement is more than the service limit, replace the cylinder head with a new one. Valve Guide Inside Diameter Service Limit: Inlet, Exhaust 6.08 mm (0.239 in.) Valve Spring Inspection the valve spring for pitting, cracks, rusting, and • Inspect burns. Replace the spring with a new one if necessary.
5-16 ENGINE TOP END Cylinder, Piston Piston Removal • Remove: Cylinder Head Assembly (see Cylinder Head Assembly • • Removal) Crankcase Cover (see Crankcase Cover Removal in the Camshaft/Crankshaft chapter) Camshaft (see Camshaft, Tappet Removal in the Camshaft/Crankshaft chapter) Turn the crankshaft to expose the connecting rod cap bolts [A]. Remove the bolts and take off the connecting rod caps [B]. NOTE ○Note the positions of the connecting rod caps for reinstalling the caps.
ENGINE TOP END 5-17 Cylinder, Piston • Remove the top and second rings with piston ring pliers. Special Tool - Piston Ring Pliers: 57001-115 the special tool is not available, carefully spread the ring • Ifopening with your thumbs, then push up to the opposite • side of the ring [A] to remove it. Remove the 3-piece oil ring with your thumbs in the same manner.
5-18 ENGINE TOP END Cylinder, Piston engine oil to the piston pins. • Apply Assemble the pistons onto the connecting rods as follow. •○No.1 Cylinder Piston; align the arrow mark on the piston head with opposite “K” Mark on the connecting rod to face the flywheel side. ○No.2 Cylinder Piston; align the arrow mark on the piston crown with the “K” mark on the connecting rod. ○Both marks must face the flywheel side. No.1 cylinder Piston [A] No.
ENGINE TOP END 5-19 Cylinder, Piston CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state, so they must be replaced together as a set. molybdenum disulfide oil solution oil to the inner • Apply surface [A] of the connecting rod big end [B] and caps [C]. ○The molybdenum disulfide oil solution is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10:1).
5-20 ENGINE TOP END Cylinder, Piston the piston ring grooves [A] with a broken piston ring • Clean or other suitable tools. CAUTION Be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement. Piston Ring and Ring Groove Wear the piston (see Piston Cleaning). • Clean Visually inspect the piston rings and ring grooves. • If the piston rings are worn unevenly or damaged, replace • them with new ones.
ENGINE TOP END 5-21 Cylinder, Piston Piston Ring End Gap the piston rings (see Piston Removal). • Remove Push each at a time) in the cylinder bore to a • point close toringthe(one bottom of the cylinder bore. ○Use the piston to push it in to be sure it is square. the gap [A] between the ends of the ring [B] with • Measure a thickness gauge. If the end gap of any ring is greater than the service limit, replace the entire set of rings with new ones. Piston Ring End Gap Service Limit: Top 0.6 mm (0.024 in.
5-22 ENGINE TOP END Cylinder, Piston Piston Diameter the outside diameter [A] of the piston 11 mm • Measure (0.43 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin hole. If the measurement is less than the service limit, replace the piston with a new one. Piston Diameter Service Limit: 77.79 mm (3.063 in.) Cylinder Inside Diameter and measure the cylinder inside diameter.
ENGINE TOP END 5-23 Cylinder, Piston Change to a honing stone for finishing, the final bore diameter should be as shown in the table. Be sure the correct stone is used and the stone is not worn. Clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket. Anchor the cylinder (block) on the drill press table before honing. Align the center of the cylinder bore to the press center. Set the press to operate from 200 ∼ 250 rpm.
LUBRICATION SYSTEM 6-1 Lubrication System Table of Contents Exploded View........................................................................................................................ Engine Oil Flow Chart............................................................................................................. Specifications ......................................................................................................................... Special Tools ...................................
6-2 LUBRICATION SYSTEM Exploded View
LUBRICATION SYSTEM 6-3 Exploded View No. 1 2 3 Fastener Engine Oil Drain Plug Oil Filler Mounting Bolt (FX Models) Oil Filter Mounting Bolt (FR and FS Models) Oil Pump Cover Plate Bolts EO: Apply engine oil. G: Apply grease. R: Replacement Parts N·m 6.9 5.9 8.8 5.9 Torque kgf·m 0.70 0.60 0.90 0.
6-4 LUBRICATION SYSTEM Engine Oil Flow Chart
LUBRICATION SYSTEM 6-5 Specifications Item Engine Oil: Grade Viscosity Capacity: When the oil filter is not removed When the oil filter is removed Level Oil Pressure Standard SF, SG, SH, SJ or SL class SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 1.8 L (1.9 US qt) 2.1 L (2.
6-6 LUBRICATION SYSTEM Special Tools Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT 1/8: 57001-1033
LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter CAUTION Engine operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident. Engine Oil Level Inspection to the Engine Oil Level Inspection in the Periodic • Refer Maintenance chapter. Engine Oil Change to the Engine Oil Change in the Periodic Mainte• Refer nance chapter. Oil Filter Removal to the Oil Filter Replacement in the Periodic Main• Refer tenance chapter.
6-8 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase. The oil is pumped to a replaceable oil filter cartridge, through the engine’s oil passages to lubricate internal components, and return to the crankcase.
LUBRICATION SYSTEM 6-9 Oil Pump, Relief Valve Oil Pump, Relief Valve Removal • Remove: Crankcase Cover (see Crankcase Cover Removal in the Camshaft/Crankshaft chapter) Governor Shaft (see Governor Shaft Removal in the Fuel System chapter) Bolts [A] Pump Cover Plate [B] • Remove: Inner Rotor [A] Outer Rotor [B] Spring [C] Relief Valve Ball [D] Oil Pump, Relief Valve Installation the rotor housing with engine oil for initial lubrication. • Fill Install the outer [A] and inner rotor [B].
6-10 LUBRICATION SYSTEM Oil Pump, Relief Valve the outside diameter [A] of the outer rotor with a • Measure micrometer at several points. If the rotor diameter is less than the service limit, replace both the inner and outer rotor with new ones. Outer Rotor Outside Diameter Service Limit: 52.31 mm (2.059 in.) the thickness [B] of the outer rotor with a mi• Measure crometer at several points. If the rotor thickness is less than the service limit, replace both the inner and outer rotor with new ones.
LUBRICATION SYSTEM 6-11 Oil Screen Oil Screen Removal the oil pump cover plate (see Oil Pump, Relief • Remove Valve Removal). • Remove the oil screen [A]. Oil Screen Installation the oil screen thoroughly whenever it is removed • Clean for any reason (see Cleaning and Inspection). the oil screen [A] in position. • Insert the oil pump cover plate (see Oil Pump, Relief • Install Valve Installation).
CAMSHAFT/CRANKSHAFT 7-1 Camshaft/Crankshaft Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tool ............................................................................................................................ Crankcase ..............................
7-2 CAMSHAFT/CRANKSHAFT Exploded View
CAMSHAFT/CRANKSHAFT 7-3 Exploded View No. 1 2 3 4 5 6 Fastener Connecting Rod Big End Cap Bolts Crankcase Cover Bolts Crankcase Cover Oil Passage Plugs Crankcase Oil Passage Plugs Breather Chamber Cover Bolts Breather Valve Mounting Screw N·m 9.8 27.4 3.9 3.9 5.9 2.0 EO: Apply engine oil. G: Apply grease. L: Apply a non-parmanent locking agent. Mi: Apply mineral oil. MO: Apply molybdenum disulfide oil. R: Replacement Parts S: Tighten the fasteners following the specified sequence. Torque kgf·m 1.0 2.
7-4 CAMSHAFT/CRANKSHAFT Specifications Item Camshaft, Tappet: Cam Lobe Height: Inlet Exhaust Camshaft Journal Diameter: PTO Side Flywheel Side Camshaft Bearing Inside Diameter: Service Limit 29.36 mm (1.156 in.) 29.36 mm (1.156 in.) 15.99 mm (0.630 in.) 15.99 mm (0.630 in.
CAMSHAFT/CRANKSHAFT 7-5 Special Tool Bearing Driver Set: 57001-1129
7-6 CAMSHAFT/CRANKSHAFT Crankcase Crankcase Cover Removal the engine on a clean surface while parts are being • Set removed. the engine oil (see Engine Oil Change in the Peri• Drain odic Maintenance chapter).
CAMSHAFT/CRANKSHAFT 7-7 Crankcase Crankcase Cover Assembly the old gasket from the mating surfaces of the • Chip crankcase and cover. compressed air, blow out the oil passage in the • Using crankcase cover. a high-flash point solvent, clean off the mating sur• With faces of the crankcase and the cover, and wipe them dry.
7-8 CAMSHAFT/CRANKSHAFT Crankcase to see that the dowel pins [A], O-rings [B] and plas• Check tic pipe [C] are in place on the crankcase. the crankcase cover and tighten the crankcase • Install cover bolts following the tightening sequence as shown in the figure. Torque - Crankcase Cover Bolts: 27.4 N·m (2.8 kgf·m, 20 ft·lb) ○Do not turn one screw down completely before the others, • as it may cause the crankcase cover to warp. Install the removed parts (see appropriate chapters).
CAMSHAFT/CRANKSHAFT 7-9 Crankcase sure to replace any oil seal with a new one if removed. •○Be Apply mineral oil to the crankshaft oil seal outside. ○Install the oil seal so that the marks [A] face out. ○Thoroughly pack high-temperature grease to 60% volume • into the space [B] between the dust lip [C] and seal lip [D]. Press in the new oil seal using a press or suitable tools until it is flush with flange surface [E] or maximum 1 mm (0.04 in.) lower than the flange surface. Do not damage the seal lip.
7-10 CAMSHAFT/CRANKSHAFT Breather The function of the breather is to create a negative pressure in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emission control system is used to prevent blow-by gases from emitting in the air. The blow-by gases are led to the breather chamber through the crankcase and camshaft.
CAMSHAFT/CRANKSHAFT 7-11 Breather FR and FS Models
7-12 CAMSHAFT/CRANKSHAFT Breather Breather Valve Removal • Remove: Stator Coil (see Flywheel and Stator Coil Removal in the • • Electrical System chapter) Unscrew the bolts [A] and remove the clamps [B]. Remove the breather chamber cover [C] and gasket. • Remove: Breather Pipe [A] (see Breather Pipe Removal) Screw [B] Back Plate [C] Reed Valve [D] Breather Valve Installation center of the valve seat with center of the reed valve • Align and back plate.
CAMSHAFT/CRANKSHAFT 7-13 Breather Breather Valve Inspection the reed valve [A] for breakage, crack or distor• Inspect tion, replace it with a new one if necessary. the plate [B] for damage or rough contact surface, • Inspect replace it with a new one if necessary. the valve seating surface. The surface should be • Inspect no nicks or burrs. Breather Pipe Removal • Remove: Breather Chamber Cover (see Breather Valve Removal) Breather Pipe [A] Breather Pipe Installation the breather pipe [A].
7-14 CAMSHAFT/CRANKSHAFT Camshaft, Tappet Camshaft, Tappet Removal the engine on a clean surface while parts are re• Set moved. the engine oil (see Engine Oil Change in the Peri• Drain odic Maintenance chapter). • Remove: Crankcase Cover (see Crankcase Cover Removal) Cylinder Head Assembly (see Cylinder Head Assembly Removal in the Engine Top End chapter) the crankcase upside down so that the tappets will • Turn fall away from the cam lobes. • Pull the camshaft [A] out of the crankcase.
CAMSHAFT/CRANKSHAFT 7-15 Camshaft, Tappet Camshaft Assembly the governor assembly (see Governor Assembly • Install Installation in the Fuel System chapter). assembling the camshaft, check the following items. •○After The governor plate [A] must move freely. ○While shaking the camshaft, check if the ACR weight [B] swings smoothly. Camshaft Inspection the camshaft gear [A] for pitting, fatigue cracks, • Check burrs or any evidence of improper tooth contact.
7-16 CAMSHAFT/CRANKSHAFT Camshaft, Tappet the inside diameter [A] of the camshaft insert on • Measure the crankcase cover at several points. If the inside diameter is more than the service limit, replace the crankcase cover with a new one. Camshaft Bearing Inside Diameter (Crankcase Cover) Service Limit: 16.119 mm (0.6346 in.
CAMSHAFT/CRANKSHAFT 7-17 Crankshaft, Connecting Rod Connecting Rod Removal the piston (see Piston Removal in the Engine • Remove Top End chapter). Connecting Rod Installation the piston (see Piston Installation in the Engine Top • Install End chapter). Crankshaft Removal • Remove: Camshaft (see Camshaft, Tappet Removal) • Connecting Rod and Pistons (see Piston Removal in the Engine Top End chapter) Pull the crankshaft [A] out of the crankcase.
7-18 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Connecting Rod Bend/Twist the connecting rod bend. •○Measure Select an arbor [A] of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. ○Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor through the connecting rod small end. ○On a surface plate, set the big-end arbor on V blocks.
CAMSHAFT/CRANKSHAFT 7-19 Crankshaft, Connecting Rod the crankpin width [A] with a dial caliper. • Measure If the crankpin width is more than the service limit, replace the crankshaft with a new one. Crankpin Width Service Limit: 44.7 mm (1.76 in.) Connecting Rod Big End Bearing/Crankpin Wear a light film of engine oil on the threads of the cap • Apply bolts. the cap bolts and tighten the bolts to the speci• Install fied torque (see Piston Installation in the Engine Top End • chapter).
7-20 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Crankshaft Main Journal/Wear both main journals at several points around the • Measure journal circumference. If the journal diameter is less than the service limit, replace the crankshaft with a new one. Crankshaft Journal Diameter Service Limit: PTO Side [A] 39.90 mm (1.571 in.) Flywheel Side [B] 39.88 mm (1.570 in.
STARTER SYSTEM 8-1 Starter System Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Electric Starter System ........................................................................................................... Starter Motor Removal...................................
8-2 STARTER SYSTEM Exploded View
STARTER SYSTEM 8-3 Exploded View No. Fastener 1 Starter Motor Mounting Bolts Starter Motor Through Bolts (FR and FS Models) 2 3. FR and FS Models G: Apply grease. R: Replacement Parts N·m 19.6 Torque kgf·m 2.0 ft·lb 14 3.95 0.
8-4 STARTER SYSTEM Specifications Item Electric Starter System Starter Motor: Carbon Brush Lengh: FX Models FR and FS Models Commutator Groove Depth: FX Models FR and FS Models Commutator Diameter: FX Models FR and FS Models Commutator Runout: FX Models FR and FS Models Standard Service Limit 10.0 mm (0.39 in.) ––– 6.0 mm (0.24 in.) 10.16 mm (0.4 in.) 0.6 mm (0.02 in.) ––– 0.2 mm (0.008 in.) 1.27 mm (0.05 in.) 28.0 mm (1.10 in.) ––– 27.0 mm (1.06 in.) 31.369 mm (1.235 in.) ––– ––– 0.4 mm (0.
STARTER SYSTEM 8-5 Electric Starter System Starter Motor Removal the wire. • Disconnect Remove the mounting bolts [A] and pull the starter motor • [B] from the engine with the switch lead attached. FX Models [C] FR and FS Models [D] Starter Motor Installation the starter motor and engine mounting flanges to • Clean ensure good electrical contact and tighten the mounting bolts. ○Install the hook [A] so that the stopper [B] of the hook contacts the crankcase. Torque - Starter Motor Mounting Bolts: 19.
8-6 STARTER SYSTEM Electric Starter System the continuity of the solenoid when activated. •○Measure Set the hand tester selector switch to the R × 1 Ω position and connect the leads across the large terminals [A] as shown in the figure. ○Turn the engine switch to the START (II) position and read the tester. If the solenoid does not click or if the tester reads more than 0 Ω the solenoid is faulty. Replace it.
STARTER SYSTEM 8-7 Electric Starter System Starter Motor Test ○Always NOTE inspect the Starter Solenoid and Circuit Test section before starting following procedures. the starter motor (see Starter Motor Removal). • Remove Hold the starter motor with a vice. • CAUTION Be careful not to deform the starter motor body when holding it with a vice.
8-8 STARTER SYSTEM Electric Starter System • Remove the insulator [A]. the springs [A]. • Remove Free the brushes [B] from the brush holder [C]. • • Remove: Brush Holder [A] Yoke [B] the armature assembly [A] with pinion gear fork • Remove [B]. the front stopper [A]. • Remove Push the • ring [C]. rear stopper [B] downward and remove the snap the rear stopper and pinion clutch [D] from the arma• Pull ture shaft.
STARTER SYSTEM 8-9 Electric Starter System FR and FS Models Remove: Through Bolts [A] Brush Plate Assembly [B] • • Remove: York [A] Nut [B] Washer [C] Spring [D] Pinion Gear [E] Rubber Damper [F] Collar [G] End Cover [H] Starter Motor Assembly FX Models Apply a small amount of grease to the armature shaft [A] as shown in the figure. Do not reuse the snap ring [B]. Replace it with a new one. • • the boots [A], grommet [B] and rubber insert [C] • Inspect for visible damage.
8-10 STARTER SYSTEM Electric Starter System the pinion clutch [A]. • Install Install the • outside. rear stopper [B] so that the hollow side face the the snap ring [C] to the groove of the shaft. • Install Slide the stopper until the stopping with the snap ring. • Install therear front • face the inside. stopper [D] so that the smaller diameter grease to the pinion gear fork fingers. • Apply Assemble the pinion gear fork [E] as shown in the figure.
STARTER SYSTEM 8-11 Electric Starter System • Install the insulator [A]. the end cover so that the slit [A] fit the groove [B] • Install of the grommet. • Tighten the through bolts. the hook on the starter solenoid with the hook [A] • Engage on the pinion gear fork [B]. • Tighten the solenoid mounting nut. FR and FS Models Using the suitable tool, hold the brushes. Install the armature assembly to the brush plate assembly.
8-12 STARTER SYSTEM Electric Starter System grease to the armature shaft. • Apply Install the end cover so that the slit [A] fit the projection • [B] of the yoke. • Tighten: Torque - Starter Motor Through Bolts: kgf·m, 35 in·lb) 3.95 N·m (0.40 • Install: Collar [A] • • Rubber Damper [B] Pinion Gear [C] Spring [D] Washer [E] Make sure that grease does not attach to the contact portion between the collar and the rubber damper.
STARTER SYSTEM 8-13 Electric Starter System Armature Inspection the surface of the commutator [A]. • Inspect If it is scratched or dirty, polish it with a piece of very fine emery cloth [B], and clean out the grooves. the depth of the grooves between the commu• Measure tator segments. If the grooves are shallower than the specified limit, replace the armature with a new one. If the grooves are only dirty, clean them carefully. Commutator Groove Depth Standard: FX Models 0.6 mm (0.02 in.
8-14 STARTER SYSTEM Electric Starter System the armature winding resistance. •○Measure Set the multimeter selector switch to the R × 1 Ω position and check the resistance between each segment and all the others. If the resistance it too high or even infinite, the armature winding has an open circuit. Replace the starter motor. Armature Winding Resistance Close ∼ 0 Ω the multimeter selector switch to the R × 1 kΩ position • Set and measure the resistance between the commutator and the armature shaft.
STARTER SYSTEM 8-15 Electric Starter System the multimeter selector switch to the R × 1 Ω posi• Set tion and measure the resistance between the negative brushes and starter motor yoke. If the meter dose not read close ∼ 0 Ω, the yoke assembly is faulty. Replace it. FX Models [A] FR and FS Models [B] Negative Brush to Ground Resistance Close ∼ 0 Ω Pinion Clutch Inspection FX Models Remove the pinion clutch. Turn the pinion gear [A] by hand.
ELECTRICAL SYSTEM 9-1 Electrical System Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tool ............................................................................................................................ Wiring Dagram...............................
9-2 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 9-3 Exploded View Torque No. 1 2 3 4 Fastener Flywheel Bolt Ignition Coil Bolts Spark Plugs Stator Coil Screws 6. FR and FS Models 7. FS Models 8. FS and FX Models G: Apply dielectric grease. N·m kgf·m ft·lb 56 5.9 5.7 0.60 41 52 in·lb 22 3.4 2.2 0.
9-4 ELECTRICAL SYSTEM Specifications Item Charging System Regulated Output Voltage Stator Coil Resistance Unregulated Stator Output Regulator Resistance Ignition System Ignition Coil: Air Gap Primary Winding Resistance Secondary Winding Resistance Spark Plug Plug Gap Standard 14.1 V DC 0.1 ∼ 0.14 Ω 26 ∼ 34 V AC/3 000 rpm in the text 0.2 ∼ 0.4 mm (0.008 ∼ 0.016 in.) in the text in the text NGK BPR4ES 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.
ELECTRICAL SYSTEM 9-5 Special Tool Hand Tester: 57001-1394
9-6 ELECTRICAL SYSTEM Wiring Dagram FX Models
ELECTRICAL SYSTEM 9-7 Wiring Dagram FR Models
9-8 ELECTRICAL SYSTEM Wiring Dagram FS Models
ELECTRICAL SYSTEM 9-9 Precautions There are a number of important precautions that you must follow when servicing electrical systems. Learn and observe all the rules below. ○Do not reverse the battery cable connections. This will burn out the diodes in the electrical parts. ○Always check the battery condition before judging other parts of the electrical system. A fully charged battery is necessary for conducting accurate electrical system tests.
9-10 ELECTRICAL SYSTEM Charging System Flywheel and Stator Coil Removal FX Models Remove: Air Cleaner (see Air Cleaner Body and Bracket Removal in the Fuel System chapter) Fuel Pump (see Fuel Pump Removal in the Fuel System chapter) Stator Coil Lead Connector (see Regulator Removal) Bolts [A] and Guard [B] • FS Models Remove: Element Assembly (see Element Removal in the Fuel System chapter) Fuel Pump (see Fuel Pump Removal in the Fuel System chapter) Stator Coil Lead Connector (see Regulator Removal) Scre
ELECTRICAL SYSTEM 9-11 Charging System FR Models Remove: Paper Element (see Element Removal in the Fuel System chapter) Fuel Pump (see Fuel Pump Removal in the Fuel System chapter) Bolts [A] Fan Housing [B] Cooling Fan Screen Bolts Cooling Fan Screen • • Remove: Ignition Coils (see Ignition Coil Removal) Bolts [A] Plate [B] Cooling Fan [C] the flywheel with a suitable tool [A], remove the fly• Hold wheel bolt [B] and washer. • Remove the bracket [C].
9-12 ELECTRICAL SYSTEM Charging System FR and FS Models Cut off the band [A]. FR Models [B] FS Models [C] • Flywheel and Stator Coil Installation the stator coil and hold the stator coil lead to the • Install clamp. • Tighten: Torque - Stator Coil Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb) a cleaning fluid, clean off any oil or dirt on the fol• Using lowing portions and dry them with a clean cloth.
ELECTRICAL SYSTEM 9-13 Charging System the fan [A]. • Install Install the • on the fan.plate [B] so that the slits [C] fit to the bosses [D] • Tighten: Torque - Cooling Fan Plate Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) FX Models Attach the stator coil lead [A], ignition coil lead [B] and solenoid valve connector lead [C] to the engine shroud clamp [D] as shown in the figure.
9-14 ELECTRICAL SYSTEM Charging System FS Models For the , note the following. Install the fan housing. Tighten: • • • Torque - Fan Housing Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) the screen. • Install • Tighten: Torque - Cooling Fan Screen Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) the guard. • Install Screw the screw rivets. • FR Models For the , note the following. Install the screen. Tighten: • • • Torque - Cooling Fan Screen Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) the fan housing.
ELECTRICAL SYSTEM 9-15 Charging System Stator Coil Resistance the stator coil lead connector [A]. • Disconnect Measure the coil resistance. •(Electric Starterstator Model) ○Connect an ohmmeter between stator pins [B]. Stator Coil Resistance 0.1 ∼ 0.14 Ω • If the measured value is not within the specification, replace the stator coil with a new one.
9-16 ELECTRICAL SYSTEM Charging System Regulator Installation FX Models Install the regulator [A]. Tighten the regulator mounting screws [B]. Apply dielectric grease to the regulator terminals [C]. Connect the stator coil lead connector [D]. • • • • FS Models Install: Regulator [A] Ground Lead [B] Tighten the regulator mounting screws [C]. Apply dielectric grease to the regulator terminals [D]. Connect the stator coil lead connector [E].
ELECTRICAL SYSTEM 9-17 Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs.
9-18 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal • Remove: Fan Housing (see Flywheel and Stator Coil Removal) Spark Plug Cap [A] Bolts [B] Stop Switch Lead Connector [C] Ignition Coil [D] Ignition Coil Installation the ignition coil on the crankcase so that the stop • Install switch lead connector [A] face the upward, and tighten bolt [B] first, then tighten bolt [C].
ELECTRICAL SYSTEM 9-19 Ignition System Ignition Coil Inspection the ignition coil (see Ignition Coil Removal). • Remove Measure the winding resistance as follows. •○Set the hand tester to the R × 1 kΩ range. Special Tool - Hand Tester: 57001-1394 ○Measure the ignition coil winding resistance as shown in the table.
TROUBLESHOOTING 10-1 Troubleshooting Table of Contents Engine Troubleshooting Guide ............................................................................................... Starter Motor Troubleshooting Guide .....................................................................................
10-2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions, check if the way the engine is used is correct. If the engine malfunctions even if the engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubleshooting procedures. Do not unnecessarily disassemble the carburetor, the magneto or the engine unless it has been found to be the cause of malfunctioning.
TROUBLESHOOTING 10-3 Engine Troubleshooting Guide
10-4 TROUBLESHOOTING Engine Troubleshooting Guide
TROUBLESHOOTING 10-5 Engine Troubleshooting Guide
10-6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1. Disconnect spark plug caps from the spark plugs. 2. Turn engine switch to “START” position and check condition. WARNING Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test. CAUTION If starter does not stop by engine switch OFF, disconnect negative (–) cable from battery as soon as possible.
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