Service Manual
GENERAL INFORMATION
1-2
Liquid
Gasket
and Non-permanent Locking Agent
Follow manufacturer's directions for cleaning and
preparing surfaces where these compounds 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, the bearing race
which
is
affected by friction should be pushed by
a
suitable driver. This prevents severe stress on the
balls and races, and prevents races and balls from
being dented. Press
a
ball bearing until
it
stops
at
the stop in the hole or on the shaft.
Circlip, Retaining Ring
Renew any circlips and retaining rings that were
removed,
as
removal weakens and deforms them.
When installing circlips and retaining rings, take
care to compress or expand them only enough
to install them.
High Flash-point Solvent
A high flash-point solvent
is
recommended to
reduce fire danger. A commercial solvent com-
monly available in North America
is
Stoddard
solvent (generic name). Always follow manufac-
turer and container directions regarding the use of
any solvent.
Molybdenum Disulfide
)
Grease
This manual makes reference to molybdenum
disulfide grease in the assembly of certain engine
and chassis parts. Always check manufacturer
recommendations before using such special lub-
ricants.
Engine Rotation
When turning the crankshaft by hand, always turn
it
in the direction of normal rotation; which
is
clockwise, viewed from the front (flywheel end)
of the engine. This will ensure proper adjustments.
Electrical
Systems:
Always minimize shock hazards when working
on electrical equipment. Work in
a
clean,
dry environment with dry hands. For max-
imum shock hazard protection, connect the
equipment ground terminal to an earth ground.
Do
not reverse the battery lead connections.
This will burn out the diodes in the electrical
parts.
Always check battery condition before con-
demning other parts of an electrical system.
A fully charged battery
is
a
must for conduct-
ing accurate electrical system
tests.
The electrical parts should never be struck
sharply,
as
with
a
hammer, or allowed to
fall
on
a
hard surface. Such
a
shock to the parts
can damage them.
Do
not disconnect the battery leads or any
other electrical connections when the igni-
tion switch
is
on, or while the engine
is
run-
ning, unless specifically noted.
Never keep the starter engaged
if
the starter
motor will not turn over, or the current may
burn out the starter motor windings.
Never replace
a
defective electrical component
without determining what caused the failure.
If the failure was brought on by some other
item or items, they too must be repaired or
replaced, or the new replacement will fail.
Make sure
all
connectors in the circuit are
clean and tight, and examine wires for signs
of burning, fraying,
etc.
Poor wires and bad
connections will affect electrical system ope-
ration.
Measure coil and winding resistance when the
part
is
cold
(at
room temperature).
All the electrical leads are either single-color
or two-color and, with only
a
few exceptions,
must
be
connected to leads of the same color.
When soldering or unsoldering connections,
do not use
a
soldering iron of more than
40
watts capacity. Use
16
gauge
(0.062
in.)
60/40
resin core solder when reconnecting
wiring.