KAWASAKI FB460V ENGINE MANUAL Table of Contents – Page 1 of 3 FOREWORD SECTION 1 - GENERAL INFORMATION BEFORE SERVICING PERFORMANCE CURVES DIMENSIONAL SPECIFICATIONS PERIODIC MAINTENANCE 4-STROKE ENGINE THEORY CONSTRUCTION (INTERNAL COMPONENT) FUEL SYSTEM AND OPERATION ELECTRICAL SYSTEM PRELIMINARY ENGINE CHECKS TROUBLE SHOOTING TUNE-UP PROCEDURE OVERHAUL PROCEDURE SECTION 2 - IGNITION IGNITION SYSTEM SPARK CHECK FLYWHEEL REMOVAL FLYWHEEL CHECK IGNITION COIL CHECK CONTROL UNIT CHECK FLYWHEEL INSTALLATION IG
KAWASAKI FB460V ENGINE MANUAL Table of Contents – Page 2 of 3 SECTION 5 - GOVERNOR - continued GOVERNOR GEAR INSPECTION GOVERNOR REASSEMBLY REASSEMBLY (GOVERNOR RELATED) LINKAGE ADJUSTMENT THROTTLE CABLE INSTALLATION AND ADJUSTMENT CHOKE ADJUSTMENT MAXIMUM SPEED ADJUSTMENT IDLE SPEED ADJUSTMENT SECTION 6 - COMPRESSION COMPRESSION CHECK CYLINDER HEAD AND HEAD GASKET REMOVAL CYLINDER HEAD TIGHTENING PROCEDURE CYLINDER HEAD CHECK AND REPAIR VALVE AND SPRING REMOVAL VALVE SPRING INSPECTION TO ANALYZE VALVE VALV
KAWASAKI FB460V ENGINE MANUAL Table of Contents – Page 3 of 3 SECTION 9--CRANKSHAFT AND CAMSHAFT CRANKSHAFT AND CAMSHAFT REMOVAL CRANKSHAFT INSPECTION UNDER-SIZE CON-ROD LINK ROD INSPECTION BUSHING REPLACEMENT BALANCE WEIGHT INSPECTION BALANCER GUIDE INSPECTION CAMSHAFT INSPECTION CRANKSHAFT AND CAMSHAFT INSTALLATION CRANKCASE COVER INSTALLATION CRANKSHAFT END PLAY CRANKSHAFT END PLAY ADJUSTMENT SECTION 10--CYLINDER BLOCK AND BEARING CYLINDER BLOCK INSPECTION AND REPAIR BALL BEARING REMOVING BALL BEARING IN
-stroke air-cooled gasolineengine
FOREWORD This manual is designed for use by trained mechanics in a properly equipped shop. In order to perform thework efficiently and to avoidcostly mistakes,read the text, thoroughly familiarize yourself with the procedures before startingwork,andthendo the work carefully tools or equipin a cleanarea.Wheneverspecial ment are specified, do not use makeshift tools or equipment.
TABLE OF CONTENTS Section 5 GOVERNOR Section 1 GENERAL INFORMATION ....................... 1-1 ......................... 1-3 .................... 1-4 ..... .........1-5 ................... 1-7 ..................1-7 ........ 1-8 .............. 1-9 ...................... 1-10 ............... 1-11 ...................... 1-13 ..................... 1-17 .................... 1-17 Before Servicing Specifications.
Section 8 PISTON.PISTONRING. AND CON-ROD ............. 8-1 ...................... 8.2 .......... 8-2 ...........8-3 .....8-3 ..................... 8-4 .............8-5 .................8-5 ... 8-5 Piston and Con-rod Removal Piston Inspection Piston Ring Thickness Inspection Piston Ring EndGap Inspection Piston Pin and Pin Hole Dia . Inspection Con-rod Inspection Piston and Con-rod Assembly Piston Ring Installation Piston and Con-rod Assembly Installation Section 9 CRANKSHAFT AND CAMSHAFT .........9-1 ..
1-1 GENERAL INFORMATION Section 1 GENERAL INFORMATION BEFORE SERVICING Beforestarting to service a engine carefully read theapplicablesection to eliminate unnecessary account has limiwork. However, a detailed amount of basic knowledge tations; a certain is required for successful work.Especiallynote the following: Force Common sense should dictate howmuchforce is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stopandexaminewhatmay becausing the problem.
GENERAL INFORMATION Liquid Gasket and Non-permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaceswherethesecompounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly,available in North America is Loctite Lock'n Seal (Blue). Ball Bearing Installation When installing a ball bearing, thebearing race which is affected by friction should bepushed by a suitable driver.
1-3 GENERAL INFORMATION SPECI FlCATlONS ENGINE MODEL FB460V ENGINE TYPE Forced Air Cooled, Vertical Shaft, 4-Stroke Gasoline Engine NUMBER OF CYLINDER 1 PISTON DISPLACEMENT BORE x STROKE 460 cc (28.1 cu.in.) 89 mm x 74 mm (3.50 in. x 2.91 in.) COMPRESSION RATIO 6.4 : 1 MAX. OUTPUT 12.5/3,600 r.p.m. (with JX156-K112-01 muffler) MAX. TORQUE 2.78 kg-m/2,300 r.p.m. (20.1 MIN. SPECIFIC FUEL CONSUMPTION RATIO 315 gr/hp-hr (0.
GENERAL INFORMATION PERFORMANCECURVES FB46OV WOT PERFORMANCE (SAE J607a) TORQUE kgm ft- Ibs 2.6 2.4 18 gr/hp.hr Ibs/hp.hr 300 2000 3000 ENGINE SPEED 3600 4000 r.p.m. The horsepower ratings shown herein are established in accordance with Society of Automotive Engineers Code J607a. Powercurvesare corrected to standard conditions of sea levelbarometerand temperature of 15.6°C (60" F) andaredeveloped from laboratory test engines equipped with standard air cleaner andmuffler. The "Maximum B.H.P.
1-5 GENERAL INFORMATION DIMENSIONALSPECIFICATIONS (Recoil Starter Model) 143.
GENERAL INFORMATION (Electric Starter Model) 1-6
1-7 GENERAL INFORMATION PERIODICMAINTENANCE Engine Serial Number The engine serial numberis located on thefront of the cylinder-head coverabove the spark plug. Periodic MaintenanceChart To ensure satisfactory operation over an extended period of time, the engine requires normal maintenance a t regular intervals. The chart below showsperiodic inspectionand maintenance required and suitable interval designated with Electric start models only.
GENERAL INFORMATION 1-8 CONSTRUCTION (INTERNAL COMPONENT) 1. 2. 3. 4. Cylinder head Gasket Ignition coil Ring gear 5. Rotating screen 6. Flywheel nut 7. Flywheel with blades 8. Charging stater coil 9. Ballbearing 10. Balance weight 1 1. Support shaft 12. 13. 14. 15. 16. Wristpin Linkrod Adjustshim Oil seal Crankshaft 17. Crankgear 18. Connecting rod 19. Piston 20. Piston pin 21. Snap ring 22. Pistonrings 11 12 13 \ A. B. C. Intake valve Exhaust valve Valve guide D. Valve rotater E.
1-9 GENERAL INFORMATION FUEL SYSTEM AND OPERATION n n 1. Atomospheric pressure 2. Air cleaner 3. Paper element 4. Foam element 5. Intake pipe 6. Choke valve 7. Main nozzle 8. Needle valve 9. Tongue 10. 11. 12. 13. 14. Main jet Bolt Gasket Float bowl Float Fuelentersthe carburetor bowl throughthe needle valve contolled by the float. The downwardmovement of thepistonontheintake stroke creates negative pressure in the cylinder.
GENERAL INFORMATION 1-10 ELECTRICALSYSTEM The electrical system for FB460Vconsists of an ignition system, electric starting system,charging system and monitor system (optional). solenoid and startingmotor. Thechargingsystemconsists of a flywheel stator and regulator to convert AC current to DC current. The stator out put is 12 amps a t 3,350 rpm. The monitor systemconsists of an oil pressure sensor (oil switch), oil pressure warninglamp and charge lamp.
1-1 1 GENERAL INFORMATION PRELIMINARY ENGINE CHECKS Electric StarterSystem (Bendix-type) I 1 ITEM Battery rating 12 V/35A.H. or more complete A diagnosis One tenth of battery capacity Max chargingappears in this section. current Starter-rating Brush length mm (0.47 12 Commutator groove depth Commutator diameter Commutator Run-out Current draw 12 V - 0.8 KW I in.) (MINI 0.2 mm (0.008 in.
GENERAL INFORMATION 5. Testcompressionwhenenginelosespower or runs erratically and fuel and ignition systems adjustments donot correct the problem. CAUTION: Disconnect spark plug cap to prevent engine from starting during compression test. 6. Crank engine with electric or recoil starter and check the compression force. 7. If compression is low, it is usuallytheresult of one or more of following: Leaking cyl. headgasket. Warped cyl. head. Worn piston rings. Worn cyl. bore. Damaged piston.
1-13 GENERAL INFORMATION TROUBLE SHOOTING points. This chart describes typical troubleshooting I f engine malfunctions, check if the way the enprocedures. Do not unnecessarily disassemble carburetor, gine is used is correct. If engine malfunctions even i f engine is used correctly, systematicallymagneto or engineunless it has been found to be carry out troubleshooting starting with simple the cause of malfunctioning.
GENERAL INFORMATION [Engine loss power] Adjust level or add Excessive engine load. Adjust load screens, shroudingandengine fins. chamber. Is the ignition spark normal? Is lubricating condition normal? NO- Replace plug. spark Wrong Faulty Replace plug. spark control Faulty unit. ignition Faulty coil Faulty high tension cord. Adjust Armature air gap incorrect. Demagnetized flywheel. Correct Replace Replace gap Replace NOin crankcase. bricating oil.
1-15 GENERAL INFORMATION [Engine malfunctions at high speed] Is revolutionfluctuationof relatively large period producedwhen a load is applifuel filter or fuel pipe [Engine malfunctions a t low speed] Faulty plug insulation electrodes Fouled Faulty control unit Faulty ignition coil Faulty high tension cord Incorrect armature air gap Remove spark plug and check spark by cranking engine whilehavingtheplug touched against engine block. WARNING: Keep the plug as far away as possible from the plug hole.
GENERAL INFORMATION [Fuel consumption is excessive] r Is compression sufficient? 1-16 High fuel level in carb. -Adjust float chamber (including overflow) Delay is ignition timing -Adjust High idling R.P.M. -Adjust choke Incomplete opening of choke valve Excessivelybacked off carburator pilot air screw Stuck piston Worn cylinder bore insufficient cyl.
1-17 GENERAL INFORMATION TUNE-UPPROCEDURE OVERHAUL PROCEDURE A "Tune-Up" (see the steps below) would normally be performed on relatively new engines brought in for minor difficulties. By performing these steps you will either besure the engine is function properly or will know if andwhatmajor repairs shouldbe performed. also covered in the OVERHAUL Thestepsare PROCEDURE and will normally be performed as a part of the complete overhall.
GENERAL INFORMATION DISASSEMBLY Section Crankshaft inspect and check 9 Cylinder checkbore,mainbearings, 10 valve guides and valve seats. 6 Disassemble connecting rod and piston. 8 I Section 2 9 Section 9 8 9 5 7 9 5 6 7 2 Check piston, rings, connectingrod, piston pin. R EPAl R Resize cylinder bore to next over size. Replace valve guide intake, exhaust. Reface valves and seats and lap. Replace main bearings. Replace oil seals. Replace governor gear ass'y.
2-1 IGNITION Section 2 IGNITION IGNITION SYSTEM SPARK CHECK A transistor controlled ignition system is used for FB46OV. This systemconsists of the following components. Ignition coil unit Control unit (Igniter) Permanentmagnet flywheel Spark plug Removespark plug andcheckspark engine while having the plug touched engine block. The ignition coil unit is mounted outside the flywheel on the cylinder block.
IGNITION 2-2 6. Remove flywheel with a flywheel puller (A). CAUTION: Do not cut flywheel by drilling too deep or too close. (2) By using a hammerandbar, strike ring gear evenly to remove it. 7. Removeandinspect flywheel key. Replace the key if it is bent or sheared. 8. Inspectcrankshafttaper for nicksorburrs. If necessary, finish taper using fine emery paper. FLYWHEELCHECK CAUTION: Do not give impact to magnet, as impact weakens magneticforce of it. 1. Put flywheel on a wooden surface. 2.
2-3 IGNITION IGNITIONCOIL FB460V-BS. Model CHECK 1. Remove two mounting screws and remove ignition coil. 2. Remove the plug cap from hightensioncord. 3. Set KAWASAKI multimeter selectorswitch a t a specified range and connect leadsas shown in the chart below,. I f meterreading falls within the values shown in the chart, the coil is functioning properly. BM1129 Terminal Core Spark plug lead Primary terminal Control Unit Resistance (AS.
IGNITION FLYWHEELHOUSING INSTALLATION 1. Install flywheel housing(E), rotating screen (B), protector (D) and tighten screws. NOTE: The air gap (C) between contour blades (D) underscreenand flywheel housing (E) should be not less than 1 mm (0.04 in.). Use washers (A) to adjust the airgap (C). 2-4 Electrodes Spark gap Shell Porcelain Gasket Terminal Seating material Reach Adjust washer (A) Rotating screen (B) Protector (D) Air gap Flywheel Flywheel housing Bracket 2.
3-1 AIR CLEANER Section 3 AIR CLEANER A properly serviced air cleaner protects theinternal parts of the engine from dust particles in the air. I f the aircleaner instructions are not carefully followed, the dirt and dust which should be collected in the cleaner, will be drawn into the ena part of the oil film, which gineandbecome is very detrimental to engine life; dirt in the oil forms an abrasive mixture which wears the moving parts.
CARBURETOR 4-1 Section 4 CARBURETOR CARBURETOROPERATION engine draws fuel only from thatorifice. second and third orifices areuncovered as the throttle valveopens,andmore fuel is allowed to mix with the airflowing into the engine. 4. During high speed operation, the throttle valve is fully opened. Air flows throughthe carburetor at high speed. Theventuri,which decreases theair passage through carburetor, further accelerates the air flow.
4-2 CARBURETOR Disassembly Carburetor (See: Illustration) in cleaner for 1 or 2 hours. Remove and rinse with solvent. should remain 2. Parts NOTE: Rinse carb. body inhot water to neutralize corrosive action of cleaner on aluminum. Be sure all holesareopen. Do not userags or paper to dry parts. Lint may plug hole or passages. 3. Dry parts with compressed air. CARBURETORINSPECTION 1. Inspect carb. body for damage.Flangesealing surfaces should be smooth andfree of burrs and nicks. 2.
CARBURETOR 4-3 CARBURETOR ADJUSTMENT WARNING: Gasoline is dangerous. Avoid fires due to smoking or careless maintenance practices. Adjust Idle Mixture Air cleaner must be assembled to engine. 1. Turn idle mixture screw (B) inuntil seats, then back it out 1-1/8turns. it just CAUTION: Do notturn the screw intoo far. The pointed end of valve seat is susceptible to damage. 2. Start and allow engine to warm. Move throttle CARBURETORINSTALLATION 1.
5-1 GOVERNOR Section 5 GOVERNOR Thegovernor control regulates the enginespeed by 3. Remove through-bolts (J). changing the governor spring (1) tension, thus 4. Remove intake pipe (D), gasket (H), carallowing thegovernor to control thecarb. throttle buretor (GI, heatshieldplate (F) andgaskets a t all times and maintain desired anyspeed. (E). A FB46OV engine is equipped with a mechanical 5. Disconnect breather connector from tappet cover. flyweight chamber type governor.
GOVERNOR 5-2 Reassembly is the reverse of removal. Note the following points: 1. Install governorlever (A) ongovernorshaft (B) and tighten nut (C)finger tight. GOVERNOR GEARINSPECTION 1. Inspectgovernorgear for worn anddamage. exReplace as an unit, if wearanddamage ceed. GOVERNOR REASSEMBLY 1. Install thrust washer (C)and stuffinto new (E) to shortstationaryshaft governorass'y (A)until innerflange (D) fittedinto groove (B) of the shaft as shown.
5-3 GOVERNOR THROTTLE CABLE INSTALLATION ANDADJUSTMENT Makesure that the throttle leverandcableon equipmenthave the speed control linkages with engine. 1. Leave cable clamp bolt (A) loose. 2. Align hole (B) of speed control lever (C) with hole (D) of control plate (E) moving the lever; insert a (6 mm) 0.24 in.dia. pin (or a 6 mm bolt) through thetwo holes. 3. Pull up outerhousing (F) ofthrottle cable until the inner cable (G) has almost no slack, and tighten the cable clampbolt. 4. Remove the 6 mm dia.
COMPRESSION 6-1 Section 6 COMPRESSION COMPRESSIONCHECK Before measuring compression pressure; Check cyl. head to torque. Be sure battery is fully charged onelectricstarter models. Start engine and allow it to warm up. During warm up, check for leaks around cyl. head gasket. Stop engine. 1. Remove spark plug and screws compression gauge into the plug hole securely. 2. Crank engine with recoil or electric starting for several seconds and take highest pressure gauge reading.
6-2 COMPRESSION CYLINDERHEAD AND REPAl R VALVE SPRINGINSPECTION CHECK 1. Clean cyl. head. WARNING: Be alert to fire if combustible cleaner is used. 1. Inspect valve springs for damage. Replace springs if necessary. 2. Measure the freelength of springs. I f shorter than specified, replace spring. Valve Spring Free Length 2. Check cyl. headflatness by placing cyl. head on a surface plate more thana t six points. 3. Use a thickness gauge (A) to measure the space between surface plate and cyl. head. Cyl.
COMPRESSION 6-3 2. Check valve faces, heads and stem for defects. Look for bent valve stemsandexcessive corrosioncausing pits on valve face or stem. 3. Replace valves with a warpedhead or with 0.02 in. margin. Valve less than (0.6mm) stem ends should be ground square before checking valve-to-tappet clearance. Valve Stem Diameter (MIN) Valve Stem Diameter 7.91 2 mm (0.3115 in.
6-4 COMPRESSION (4) Turning the remover bolt,drive new valve guide into the hole to proper depth. To Replace Valve Guide To Remove Valve Guide: (1 ) Use a valve guide remover (A) to replace valve guide. (2) Fix valve guide remover on cylinder with bolts and nuts. (3) Put a coat of engine oil to the remover bolt threadsandscrew it in until thethreads can be seen a t valve guide lower end. (4) Install thrust washer (B) and nut (C) (left hand thread) to the remover bolt. Valve Guide Depth h 30 mm (1.
COMPRESSION 6-5 D Right : Wrong CAUTION: Loosen valve seat can be turned or moved up or down. If this appears; Use a centerpunch to tighten insert at three points equally spaced. Otherwisepeenoveredgearound entire insert. Valve Lapping \ STD Valve SeatWidth I Valve Seat Width I ( 1 ) If the seat does not make propercontact, lap valve into the seat with a vacuum cup tool. (2) Coat face of valve sparingly with a fine lapping compound. (3) Use vacuum cup tool (A), to grip top of valve.
6-6 COMPRESSION TAPPET CLEARANCE CHECK AND REPAIR 4. Install all parts related to valve repair. Reassembly is the reverse of removal. Since valve repairs change tappet clearance (valveto-tappet), checktheclearances (intake andexhaustsides).MakeSure to do this whenengine is cold. 1. Insert valves in their respective positions in cyl. block. 2. Turn crankshaft until piston is a t highest position in compressionstroke.
LUBRICATION 7-1 Section 7 LUBRICATION LUBRICATION Oil has four purposes. It cools,cleans, seals and lubricates. A pressurized lubrication system used on the FB460V enginepressure-lubricates the crank pin, PTO main journal and balancer link. TheFB46OV utilizes a camshaftdriven trochoid pump to pressurize the lubrication system. Oil is first drawnthrough a filtering screen (1) then the inlet (2) and into the pump chamber (3).
7-2 LUBRICATION OILRECOMMENDATION BREATHER CHECK Use a high quality detergentengine oil classified "API Service SF, SE/CC, SE, or SD". Detergent engine oils keep the engine cleaner and delay the formation of gumandvernishdeposits. Nothing should be added to the recommended oil. It is the breather's function to maintain a vacuum a reed valve, in the crankcase.Thebreatherhas which limits the direction of air flow caused by the piston movement of up and down.
LUBRICATION 7-3 OIL PUMPINSPECTION 1. Remove crankcase cover from crankcase. (See Section 9 : Crankshaft Removal) 2. Measurecamshaftbearingon oil pump cover (B). The (A) with an inside micrometer bearing is cast with oil pump cover and is not replaceable. t OIL PUMP INSTALLATION 1. 2. 3. 4. Bearing Inside Diameter(MAX) I 20.071 mm (0.7902 in.) Pump CoverTightening Torque Replace pump cover, if inside diameter exceeds MAX. 17 to 23 N-m (12 to 17 ft-lbs) ___-- 3.
8-1 PISTON, PISTON RING, AND CON-ROD Section 8 PISTON, PISTON RING, AND PISTON ANDCON-RODREMOVAL 1. Removeanycarbon or ridge a t the topof cyl. bore; this will helpprevent piston rings from breaking. 2. T o remove piston and con-rod from engine, rotate crankshaft (A) to expose con-rod bolts (B)as shown. 3. Remove rod bolts and con-rod cap. 4. Push piston and con-rod out through the top of cylinder.
PISTON,PISTONRING, In this condition andmuchuse,compression rings (B) will also be worn. Oil inner spacerwear (C)and distorsion may causeincrease oil up by pumping action of oil ring.Thisresults in high oil consumption, increased deposit in combustion chamberand stick of rings. ANDCON-ROD 8-2 4. Visuallyinspectrings andgrooves for uneven wear or damage.Replacethem if uneven wear or damage are excessive. Use a a t several points aroundthe 5. Measure piston ring groove width. verniercaliper piston.
8-3 PISTON,PISTONRING, AND CON-ROD NOTE: Difficult to exactly measure oil ring thickness.Replace oil ring together with compression rings. PISTON RING END GAP INSPECTION 1. Insert each ring in cyl. boreandcheckend gap. 2. Install ringsquarely in thebore to a point approx.(25mm) 1 in. down from the top of cylinder. Piston Pin Dia. (MIN) 20.978 mm (0.8259 in.) I 1. Measureinsidediameter of piston pin hole in piston with aninside micrometer at several points. 2.
PISTON,PISTONRING, AND CON-ROD 8-4 Check con-rod and piston alignment when piston shows a diagonalwear pattern extending across the skirt of piston.Contact with the cyl. wall on bottomof skirt a t left(or right) and ring lands on right (or left). angle to crankshaft A cylinder bored a t an can also cause improperringcontact with cylinder. This condition causes: Rapid piston wear. Uneven piston wear. Excessive oil consumption. CON-ROD INSPECTION 1. Cleanandinspectbearingsurfaceon con-rod and cap.
8-5 PISTON, PISTON RING, PISTON ANDCON-ROD AND CON-ROD ASSEMBLY 1. Aligning match mark " " on the piston head the con-rod, with "MADE IN JAPAN"on install piston over con-rod. 2. Coat piston pin with a light film of oil. Insert pin through piston and con-rod. 3. Install retainingrings in eachend of piston pin bore.Ringsshouldbeseated firmlyin retainer grooves in piston. CAUTION: Do not reuse the ringswhich removed. Removal weakens, deforms the rings and could fall outand score the cyl. wall.
PISTON, PISTON RING, 4. Turn crankshaftgently and place crankpin in lowestposition.Then further insert piston into cylinderwhile leadingbigendbearing surface to place above crankpin. Turn cyl. block upside down onbench. 5. Coat theinside of big end bearing surface and cap screws with a light film of oil. 6. Install rod cap (A) so assembly pilot groove (B) align and tighten capscrews (C) to the specified torqueas shown.
9-1 CRANKSHAFT AND CAMSHAFT Section 9 CRANKSHAFT AND CAMSHAFT CRANKSHAFTANDCAMSHAFT REMOVAL 1. To remove crankshaft from cyl. block, remove rust or burrs from power take-off shaft end of crankshaft. 2. Lightly tappingthe both ends near dowel alternately with a soft mallet,removecrankcase cover. 3. Turn cyl. block upside down on a bench. 4. Rotate crankshaft until timing marks on crankshaft gear and cam gear align. 5. Pull out thecamshaft,thenremovetappets.
CRANKSHAFT AND CAMSHAFT I f journalsdiameter crankshaft. is less thanMIN,replace 5. TO CHECK CRANKSHAFT ALIGNMENT: Place crankshaft into an alignmentjig, rotate crankshaftslowly, andmeasure total indicated runout a t locations shown. Dial indicator 3.A-Surfacemustbe concentric andparallel to each other within 0.005 mm (0.0002 in.) full indicator reading. NOTE: Finish should be very smooth; use a super finishing stone. LINKROD \ 9-2 INSPECTION 1. Clean and inspect bearing surfaces on link rod.
9-3 CRANKSHAFTANDCAMSHAFT BALANCER GUIDE -INSPECTION 1. Cleanandinspectbearingsurface on theshaft for worn or damage, replace it if necessary. 2. Measurebearingsurfacediameter a t several point, using a micrometer. 1. Bearing driver 2. Big end bushing 3. Link rod 4. Benchplate 3. Clean theparts in solvent throughly and dry them. Put a light coat of oil on a new bushing. 4. Re-installthebushingusing an arbor press or bearing driver. 5. Press-in thebushing 0.5 mm (0.02 in.)below flange surface (3).
CRANKSHAFT AND CAMSHAFT NOTE: Radial oil-grooves of the link rods must be toward the outside of the crankwebs. Install balance weight to crankshaft withoil hole ( 7 ) facing flywheel side. Bearing Surface Dia.(MIN) If bearingsurfacediameter replace camshaft. is less thanMIN, Lobe Height (MIN) If lobe height is less than MIN for either lobe, replace camshaft. CRANKSHAFTANDCAMSHAFT INSTALLATION 1. Assemblecrankshaft, link rods,collares,gear and balance weight as illustrated below. 16 17 18 I 2.
9-5 CRANKSHAFTAND CAMSHAFT Rotate crankshaft until piston is positioned a t top dead center. Install camshaft with timing mark (A) aligned with mark (B) on crankshaft gear. Crankcase Cover Tightening Torque 17 to 23 N-m (12 to 17 ft-lbs) CRANKSHAFTENDPLAY 1. Measure crankshaftendplay with a dial indicator. 2. Install dial indicator (A) on crankshaft as shown. Move crankshaft in and out. End to play mustbe0.09 to 0.20 mm(0.035 0.0078 in.). CRANKCASE COVER INSTALLATION 1.
CRANKSHAFTAND CAMSHAFT Crankshaft Gasket Crankcase bearing Crankcase cover Adjustment Shim Difference in depth : A-0 of Shim 1.92 to 1.99 mm (0.0755 to 0.0748 in.) -___-_- 92025-2153 1.85 to 1.92 mm (0.0728 to 0.0755 in.) 92025-2152 1.78 to 1.85 mm (0.0700 to 0.0728 in.) 92025-2151 1.71 to 1.78 mm (0.0673 to 0.0700 in.) 92025-2 150 1.64 to 1.7 mm (0.0645 to 0.0673 in.) 92025-2149 1.46 mm (0.0574 in.) 1.57 to 1.64 mm (0.0618 to 0.0645 in.) 92025-2 148 1.39 mm (0.0547 in.) 1.50 to 1.
10-1 CYLINDER BLOCKANDBEARING Section 10 CYLINDER BLOCK AND BEARING CYLINDER BLOCK INSPECTION AND REPAl R Visuallyinspect cyl. block, wheneverengine is disassembled, to see if there areanycracks, stripped bolt holes, broken fins, or cyl. wall is scored. Usean inside micrometer, or telescoping gauge and micrometer to determine the size of cyl. bore.Measure parallel with crankshaft and a t right angles to crankshaft a t top,center and bottom of ring travel. weartolerance I f cyl.
CYLINDER BLOCKANDBEARING 10-2 CAUTION: Be sure cylinder and hone are centered and alignedwith drive shaft and drill spindle. (7) Coatinside of cylinder with honing oil. Start drill press.Movehone up and down in cylinder spprox. 20 cycles-per-minute. (8) Checkdiameter of cylinder regularlyduring honing, using an inside micrometer. Stop drill press before measuring, and remove honefrom cylinder. CAUTION: Finish should have a 40 to 60 degree cross-hatch pattern. Do not use solvent or gasoline.
10-3 CYLINDER BLOCKANDBEARING Camshaft Bearing Inside Dia.(MAX) 16.068 mm (0.6326 Replace cyl.block, MAX. in.) if insidediameterexceeds 2. MeasurePTOandcamshaftbearings on covers with an inside micrometer or telescoping gauge. 0.5mm (0.02 in.) PTO Bearing Inside Dia. (MAX) mm (1.3804 in.) Camshaft Bearing Inside Dia.(MAX) I 20.071 mm (0.7902 in.) I Replacecrankcasecover or oil pump cover, if inside diameter exceedsMAX. BALLBEARINGINSTALLATION 1.
ELECTRICSTARTER AND CHARGE 11-1 Section 11 ELECTRIC STARTER AND CHARGE STARTERMOTORCIRCUIT The starter motorcircuit includes the engine switch, starter solenoid, battery and starter motor. (START) When the engine switch is turned to a smallamount position (See WiringDiagram), of currentflowsthroughtheswitch and the solenoid.This current magnetizes thesolenoid core, whichthen pull theplunger to it, closing solenoid contacts complete a circuit for the starter motor, and the starter armature rotates.
11-2ELECTRICSTARTER STARTERMOTOR AND CHARGE A shorted,open, or groundedarmature field coil. A defective starter motor switch. CHECK A performance test of starter motor canbemade in the following manner. Needed for the test are: A tachometer capable of reading 20,000 rpm. A 12V32Ah (or more) battery. An ammeter capable of reading 200 amperes. WARNING: Battery electrolyte is poisonous andcorrosive. It is injurious to eyes, skinand clothing. Handle it carefully.
ELECTRICSTARTER AND CHARGE If solenoid clicks once but the meter does not read continuity, solenoid is faulty. Re- STARTERMOTORDISASSEMBLY place it. I f solenoiddoes not click a t all, proceed with following. (Bendix Type) 5. Disconnectlead (BW) and set multimeter to position and connect leads as shown. 2 I f the meterdoes not readclose to continuity, solenoid is faulty. Replace it. I f the meterreadsclose t o continuity, solenoid maybegood.Check the voltage to solenoid from engine switch.
11-4 ELECTRIC STARTER AND CHARGE (Shift Lever Type) Measure commutator outside diameter at several points around diameter circumference, using a vanier caliper. Ref, No. Parts Name Ref No. 1 Front cover 10 Parts Name Brush spring 2 Washer 11 Insulator 3 Stopper 12 Rear cover 4 Snap ring 13 Bolt 5 6 7 Clutch ass'y 14 Solenoid Shift lever 15 Nut Armature 16 Nut Brush holder 17 Yoke ass'y Commutator Outside Dia.
ELECTRICSTARTERANDCHARGE 11-5 I f groovesareshallower than (MIN), under cut insulatingmaterial to standarddepthusing a thin file. Standard Groove Depth Bendix Type 0.5 to 0.8mm (0.02to 0.03 in.) 0.5 to 0.6mm (0.02to 0.023 in.) Shift lever Type If groovesare only dirty, clean them carefully. Supportarmature in tail stock at each,end of shaft as shown. Position dial indicator perpendicular to commutator. Turn armature slowly and read run-out on dial indicator.
11-6 ELECTRICSTARTER AND CHARGE Length Brush (MIN) Shift lever Type I f brushes are them. Terminal-to-GroundResistance 6 mm (0.24 in.) shorter than I f resistance is less than infinite.field coil is to ground. Replace yoke assembly. (MIN), replace shorted 4-2 Shift lever-Type Starter Motor Set multimeter selector switch position resistance between measure and 3Spring . Brush Check Inspect brush spring for damage. Replace springs if necessary.
ELECTRICSTARTER AND CHARGE 11-7 I f any irregularity is noted, pinion clutch should be replaced. Positive Brush-to-YokeResistance I f resistance is less than infinite, positivebrush is horted to ground.Replace entirepositive brush ass’y (C). STARTERMOTOR REASSEMBLY Reassembly is the reverseorder of disassembly. Note thefollowing points. Apply multi-purposeglease to: Sliding surface of pinion and shaft’s spline. Dust seal lip. Metal holding shaft a t front and rear cover.
11-8 ELECTRICSTARTER AND CHARGE I f the wiring is reversed, regulator will be damaged. Stater UnregulatedOut Put (MIN) 34.5 volts 3,350 rpm AC generator 3.4w I f voltage is less than specified, replace stater. Regulator Resistance Measurement Remove all the wires from regulator. Set multimeter selectorswitch to R x 1 position. Connect tester leads to regulator connecter terminals using the table below. The resistance value should be specified.
ELECTRICSTARTER AND CHARGE 11-9 TROUBLESHOOTING Inspection Item Remedy t Does crankshaft rotate? Does starter rotate? Correct connection or terminals for ->- Is operating sound produced out of starter’s Yes Faulty I Wiring connection Repair or replace solenoid switch. Check return spring for permanent deformation and check pinion for dragging. Correct meshing of pinion and ring gear pinion and/ or ring gear.
12-1 RECOIL STARTER Section 12 RECOIL STARTER RECOILSTARTER DISASSEMBLY 6. Remove bolt (A) and ratched cover (B). 1. Pull handle out about 10 to 12 inches or until Hold notch (A) in pulley is nearropehole. rope in place with knot (B). 7. Removepawls (A) and spring (B). 2. Pry knotoutof handle off rope. handle and untie it. Pull 3. While carefully holding rotating parts with one hand, untie knot (B) with the other. 4.
RECOIL STARTER I f spring was removed, it must be installed as shown. If it is not installed correctly, starter will not operate properly. 12-2 Pawls (A) must be installed as shown for proper starter operation. //\WARNING: Spring must be put under great pressure during installation. Weargloves to avoid injury. 1. Lightly glease spring (A). Install coil spring (A), ratchedcover tighten bolt (C).
