KAWASAKI FD620D 4-STROKE LIQUID COOLED ENGINE SERVICE MANUAL Table of Contents – Page 1 of 2 GENERAL INFORMATION BEFORE SERVICING MODEL IDENTIFICATION GENERAL SPECIFICATIONS PERIODIC MAINTENANCE CHART EXCEPT U.S. PERIODIC MAINTENANCE CHART FOR U.S.
KAWASAKI FD620D 4-STROKE LIQUID COOLED ENGINE SERVICE MANUAL Table of Contents – Page 2 of 2 CAMSHAFT / CRANKSHAFT EXPLODED VIEW SPECIFICATIONS CRANKCASE BREATHER CAMSHAFT TAPPET CRANKSHAFT, CONNECTING ROD ELECTRICAL SYSTEM EXPLODED VIEW SPECIFICATIONS SPECIAL TOOLS WIRING DIAGRAM WIRE HARNESS PRECAUTIONS CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER SYSTEM TROUBLESHOOTING ENGINE TROUBLESHOOTING GUIDE STARTER MOTOR TROUBLESHOOTING GUIDE
4-stroke liquid-cooled *y v-twin gasoline engine Service Manual
O-l Kawasaki FD62QD 4-stroke liquid 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 Department/Consumer Products Group/Kawasaki Heavy Industries, Ltd., Japan. .
o-2 This warning may apply to any of the following components or any assembly containing one or more of these components:Brake Shoes or Pads Clutch Friction Material Gaskets Insulators 1 SAFETY INSTRUCTIONS l Operate if possible out of doors or in a well ventilated place. l Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped. l lf possible, dampen before cutting or drilling.
m o-3 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 toofs, and workshop procedures must be understood in order to carry out maintenance and Whenever the owner has ‘repair satisfactorily.
This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. I NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation. l Indicates a procedural step or work to be done. olndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or NOTE.
Quick Reference Guide 1 General Information I 1 1 Fuel System I2 ( Cooling System I3 1 Engine Top End I Lubrication System ( Camshaft / Crankshaft 1 Electric System I Trouble Shooting - This quick reference guide will assist you in locating a desired topic or procedure. 0 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.
GENERAL INFORMATION l-l II1 General Information Table of Contents Before Servicing ......................................................................................................... Model Identification .................................................................................................... General Specifications ............................................ . ................................................... Periodic Maintenance Chart except U.S .....................................
1-2 Before GENERAL INFORMATION 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 - (12) Oil Seal, 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.
l-4 GENERAL KAWASAKI INFORMATION Multimeter: KAWASAKI Multimeter (P/N 3951 OO-9803A) meter of other type may indicate different value.
GENERAL Model Identification Cylinder Number Designation: No.1 Cyl. is the right-hand cylinder viewed from the flywheel. No.2 Cyl. is the left-hand cylinder viewed from the flywheel.
1-6 GENERAL General INFORMATION Specifications FD620D Items Type of engine Bore x Stroke Piston displacement Max. output Direction of rotation Low idle speed except U.S. Low idle speed for U.S. High idle speed except U.S. High idle speed for U.S.
GENERAL Periodic Maintenance Chart except INFORMATION l-7 U.S. 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 (0) designates that the corresponding item should be performed at that interval. Some adjustments require the use of special tools or other equipment.
1-8 GENERAL Periodic INFORMATION Maintenance Chart for U.S. 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 (0) designates that the corresponding item should be performed at that interval. Some adjustments require the use of special tools or other equipment.
GENERAL Torque and Locking Letters used in the “Remarks” L M 0 S l-9 Agent The following tables list the tightening locking agent or liquid gasket. L, INFORMATION column torque for the major fasteners, and the parts requiring use of a non-permanent mean* : Apply a non-permanent locking agent to the threads. : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. : Apply an oil to the threads, seated surface, or washer.
FUEL SYSTEM Fuel System Table of Contents 2-2 Exploded View .......................................................................................................................... .......................................................................................................................... 2-4 Specifications.. 2-5 Governor Link Mechanism ....................................................................................................... 2-5 ...............................................
2-2 FUEL Exploded SYSTEM View Tl: 2.00 N-m (0.20kg-m,17.0 in-lb) (Stopper Screw) T2: 1.16 N-m (0.13 kg-m, 10.3 in-lb) (Drain Screw) T3: 0.66 N-m (0.90 kg-m, 7.6 in-lb) (Throttle Valve Screws) T4: 9.80 N-m (1 .OO kg-m, 87.0 In-lb) (Solenoid Valve) T5: 1.00 N-m (0.10 kg-m, 8.9 in-lb) (Main Jet) T6: 2.94 N-m (0.30 Kg-m, 26.0 In-lb) (Air Hone Mounting Screws) T7: 1.00 N-m (0.10 kg-m, 8.9 in-lb) (Pilot Ah Jet) T8: 0.88 N-m (0.90 kg-m, 7.8 in-lb) (Choke Valve Screw) l8: 1.00 N-m (0.10 kg-m, 8.
FUEL . 4 Tl: 7.6 N-m (0.
2-4 FUEL SYSTEM Specifications Standard Item Carburetor Specifications: Make/type Main bore diameter Venturi diameter Main jet (MJ) Pilot jet (PJ) Main air jet (MAJ) Pilot air jet (PAJ) Pilot Screw turns out (PS) (Idle mixture screw turns out) Float level Idle Speed except U.S. Low idle speed High idle speed Idle Speed for U.S. Low idle speed High idle speed TEIKEI/FD22K-1 A 26 mm (1.02 in) 22 mm (0.87 in) #112 #58 #1.8 #0.
FUEL Governor Link Mechanism Control Panel Assembly/Removal 0 Remove: Air Cleaner (see Air Cleaner) Muffler (see Muffler Assembly Removal) Carburetor(see Carburetor Removal) OUnscrew the M6 mounting screws (A) and take off the control panel assembly (B) while unhooking the governor spring (C) end loop at the middle of the governor arm(D). NOTE 0 Note the position of the different length of the screws. The longer screw has a collar (E) between control panel and the crankcase.
2-6 FUEL SYSTEM Governor Assembly Removal @Split the crankcase (see Crankcase Splitting in the Camshaft/Crankshaft chapter). @Remove the governor assembly (A) with the sleeve (B) by prying the gear with’ two proper size screw drivers. OTo avoid damaging the parting surface of the casecover, use a suitable soft mats (C) as shown. ACAUTION Do not remove the governor assembly unless it is necessary. It has been removed, it must be replaced. oRemove Once the thrust washer.
FUEL l The oil seal must be assembled, with seal lip towards inside of the engine. l Press in the oil seal 1 .Omm (0.04 in) below the crankcase surface. 4. Projections 5. Crankcase 1. Governor Shaft 2. Oil Seal 3. Shaft Arm Governor Shaft Installation Notes l install the governor shaft (A) by properly between projections (B) as shown positioning (see above PHOTO). shaft arm NOTE olnstall the governor crankcase. shaft l Check that the governor - .
2-8 FUEL SYSTEM Carburetor Fuel and Air Flow The main system of the carburetor consists of the main jet, main nozzle, and the main air passage (main air jet). 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 Idle Mixture Screw (Pilot Screw) and Idle Speed AcQustment ACAlJTtON Do not attempt to adjust idle mixture screw with air cleaner removed l Stop the engine. @Turn the idle mixture screw (A) all the way in until it seats lightly. ACAlJTfON Do not turn tfte idle mixture screw in too far or the carburetor will be damaged and require replacement body @Back the idle mixture screw out the specified number of turns (1 3/4). This setting is approximately correct.
2-10 FUEL SYSTEM Always keep your hands clear of the moving parts. l Move the throttle lever on dash in the fast idle position and leave it there. @Loosen two M6 control panel mounting bolts enough to move the control panel assembly. l Carefully move the control panel assembly left or right to obtain the specified fast idle speed. *Tighten the M6 Mounting bolts. Fast Speed 3600 f 75 rpm l Check the idle speed, and readjust the idle speed if necessary.
FUEL f uef System Cleanliness inspection Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition 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. l Place a suitable drain hose (B) under the drain screw (A) on the carburetor. l Run the lower end of the hose into a container.
2-12 FUEL Disassembly SYSTEM Assembly Notes @Refer to the illustration shown for disassembly and assembly. @There are a number of the plate or boll plugs in the carburetor. None of these should be removed. @Turn in the idle mixture screw and count the number of turns until it seats fully but not tightly, and then remove the screw. This is to set the screw to its original position when assembling.
FUEL SYSTEM 2-13 0 Disassemble the carburetor. l immerse all the carburetor metal parts in a carburetor cleaning solution and clean them. l Rinse the carburetor parts in water and dry them with compressed air. l Do not use a rags or paper to dry parts. Lint may plug the holes or passages. 0 Blow air through the holes and fuel passages with the compressed air. All holes must be open. l Assemble the carburetor.
2-14 FUEL SYSTEM @Inspect the tapered portion (B) of the screw for wear or damage. *If the pilot screw (A) is worn or damaged, on the taper portion, replace it. l Check the spring for weakened condition, replace it, if necessary. Fuel Shut- Off Solenoid Valve Test @Unscrew the fuel shut off valve and remove the valve. @Connect a 12 VDC source to the solenoid as shown. *If the actuate solenoid plunger (Needle Valve) does not pop in when the Test Voltage is applied, replace it.
FUEL Intake Manifold Removal: 0 Remove: Air Cleaner Carburetor Control Panel Assembly @Drain the coolant in the engine (see coolant Draining) l Unscrew the manifold mounting bolts in numerical sequence, l/4 turn at a time, until all bolts are loose. *If the mounting bolts removal sequence is not followed, manifold mating surfaces may be warped. 0 Remove the manifold and gaskets. A. No.1 C.yi. Head B. No. 2 Cyl. Head Installation C. Gaskets D.
2-16 FUEL SYSTEM Fuel Pump l_,l “” The optional location fuel pump (A) is not installed in the engine when shipped. The fuel pump must be installed onto an equipment as inlet and outlet pipes are horizontal or vertical (Outlet is up side). l The fuel pump cannot be disassembled ,if any damage for the pump is appeared replace it with a new one. Fuel Pump Test Before this test, be sure the battery is fully charged. explosive. lniurv could result. Do not expose to spark or flame.
FUEL Air Cleaner Element Removal ORemove the wing bolts, washers and air cleaner case. l Take off the air cleaner elements from the body. A. Wing Bolts B. Washers C. Case D. Elements E. Body Element Installation Notes l install the elements correctly on the air cleaner body. l The elements can be installed either way on the air cleaner body. sure the elements Element Cleaning is inplace Be on the air cleaner body. and Inspection NOTE 0 In dusty areas, the elements should the recommended intervals.
2-18 FUEL SYSTEM Cleaner Body and Bracket Removal *Remove the cleaner body mounting washers. screws, spring washers and plain NOTE 0 Do not let the screws, spring washers and plain washers fall into the carburetor bore. *Pull the breather hose off the pipe at the back of the body, and remove the cleaner body. @Unscrew the carburetor mounting nuts, then take off the bracket. A. B. C. D. Screws Spring Washers Plain Washers Body E. Bracket F. Breather Hose G. Pipe H.
COOLING SYSTEM 3-1 Cooling System i Table of Contents Exploded View ............................................................................................................ Specifications .............................................................................................................. Cooling System ........................................................................................................... Coolant.. ........................................................................
3-2 COOLING ExDloded SYSTEM View b T3 D: Apply G: Apply 2 Apply agent engine oil grease a non-permanent to the threads locking Tl: 27 N-m (2.8 kg-m, 20 Mb) (Therm0 Switch) T2: 20 N-m (2.0 kg-m, 14.5 &lb) (Fan Shafl Nut) T3: 21 N-m (2.1 kg-m, 15.
COOLING Tl: SYSTEM 2.0 N-m (0.2 kg-m, 17 In-lb) in-lb) (Finger Tight) T2: 14 N-m (1.
3-4 COOLING SYSTEM Specifications item Standard ‘Coolant: Type Color Mixed ratio Freezing point Total amount Radiator Cap Relief Pressure: Pressure valve (positive) Vacuum Valve (negative) Permanent type of antifreeze for aluminum engine and radiator Green 50% solution of ethylene glycol -35°C (-31 “F) 2.7 L (0.7 us gallon) 73.3 to 102.7 kPa (10.6 to 14.9 psi) 4.90 kPa (0.
COOLING Cooling System This engine is equipped with a highly efficient pressurized cooling system using a thermostat to maintain an optimum operating temperature. Coolant bypasses the closed thermostat when cold until operating temperature is attained, causing the engine to warm up more quickly. If the coolant temperature becomes too high, a therm0 switch on the engine activates the coolant warning lamp to alert the operator or cooling problem. 1. Water Pump 2. Cylinder Jackets 3. Cylinder Heads 4.
3-6 COOLING SYSTEM Coolant Coolant Deterioration @Visually inspect the coolant in the radiator. Olf whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. 0 If the coolant gives off an abnormal smell when changing, check for a cooling system leak. It may be caused by exhaust gas leaking in to the cooling system.
COOLING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Since coolant is harmful to the human body, do not use for drinking. ORemove the radiator cap (A) as follows. 0 First turn the cap counterclockwise to the first stop and wait there for a few seconds. OPush down the cap, then turn the cap counterclockwise to the next stop. 0 Lift off the cap. l Place a suitable container under the radiator.
3-8 COOLING Original Type: SYSTEM Coolant Color: Mixed ratio: Freezing Point: Total amount: Permanent type antifreeze for aluminum and radiator Green 50% solution of ethylene giycoi -35°C (-31°F) 2.7L (0.7 U.S. gallon) engine Air Bleeding Before putting the engine into operation, any air trapped in the cooling system must be removed as follows. 0 Remove the radiator cap. @Fill the radiator up to the radiator filler neck with coolant. l Check the cooling system for leaks. l install the radiator cap.
COOLING Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumulations is not removed, it will clog up the water passage and considerably reduce the efficiency of the cooling system. 0 Drain the cooling system. OFill the cooling system with fresh water mixed with a flushing compound.
3-10 COOLING Water SYSTEM Pump Water Pump Removal 0 Remove: Muffler (see Muffler Assembly Removal) 0 Loosen the hose clamp (A) and disconnect the radiator hose (B) at the coolant inlet port of of the water pump (C). l Loosen the tube clamp (D), and pull off the coolant by-pass tube (E). @Unscrew the water pump mounting bolts, and remove the water pump assembly. NOTE 0 Note the position of different in their original positions.
COOLING Internal Parts - Mechanlcal 1. Mating Ring (Floating 2. Cup Gasket (Chusion 3. Seal Ring 4. Bellows 5. Spring Retainer 6. Coil Spring 7. Casing 8. Cartridge SYSTEM Seal Seat) Ring) Pump Parts Inspection @Clean All parts except plastic and rubber parts in a bath of high flash-point solvent and dry them compressed air. Clean non-metal parts with detergent and water, and dry them. l inspect the pump housing for damage. Mating surfaces should be smooth and free of burrs and nicks.
3-12 COOLING SYSTEM OWhen installing the impeller (4) sub assembly to the housing(5). coat mating surfaces between the mating ring and seal ring (6) with a clean water. @To avoid oil seal damage, coat thin film of engine oil on the pump shaft (7). and then carefully insert pump shaft into the housing. Radiatdr Removal Always allow the engine to cool before removing the radiator cap. Then remove the cap slowly and carefully to avoid a possible fast discharge of hot coolant which could cause severe burns.
CO.OLlNG l lf the air passages of the radiator unremoval obstructions or radiator with a new one. *If a radiator leak is detected, follows: 1. Install the radiator cap, and (1). Attach an air hose (4) 2. Pressurize the inside of the to 70 kpa (7 to 10 psi). 3. Submerge the radiator in indicate the location of the 4.
3-14 COOLING SYSTEM Radiator Hose Inspection l ln accordance with the Periodic Maintenance Chart, visually inspect the hoses (A) for signs of deterioration. Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or swollen. 0 Replace any damaged hose. NOTE 0 Hoses can deteriorated on the inside and still appear to be in good condition on the outside. Radiator Hose installation Notes l install the radiator hoses being careful to follow Exploded View).
I---_-.-_‘- /L COOLING Cooling Fan, Fan Belt The only service on the cooling fan is to be sure the fan blades are not deformed, and the blade tips are far enough from the air duct to not strike the duct. The fan belt should be neither too tight nor too loose. Belt Tension Check 0 Remove: Radiator (see Radiator Removal) l Measure the belt tension using a proper belt tension gauges (1). Follow the manufacturer’s instructions for use of the belt tension gauge.
3-16 COOLING SYSTEM Removal 0 Remove: Radiator (see Radiator Removal) 0 Remove the radiator brackets (E). 0 Disconnect the wire tie (D) which binding the pressure switch, pulser coil and primary ignition coil leads to the radiator bracket (E). 0 Disconnect the therm0 switch (A) lead and coolant bypass tube(B). ORemove the therm0 switch. 0 Unscrew the bracket mounting bolts (C) and nuts (F), then remove the radiator mounting brackets.
COOLING Fan Bearing Removal 0 Remove: Fan Mounting Bracket (4) l Unscrew the fan shaft nut (1). and remove the shaft (3) and washer (2). l To check the ball bearing (5), rotate the bearing slowly by finger; if any roughness is noted, the bearing should Do not allow a flame or heating element the oil. Heat the oil in a well-ventilated procedure to avoid burns. be replaced. to come in direct contact with area.
3-18 COOLING SYSTEM Thermostat This cooling system is equipped with a thermostat to maintain a Coolant bypasses the closed thermooptimum operating temperature. stat when cold until operating temperature is attained, Thermostat Removal 0 Remove Radiator (see Radiator Removal) Cooling Fan (see Cooling Fan Removal) @Loosen the hose clamp (A) and disconnect the radiator hose (B) at the thermostat cover. l Unscrew the thermostat cover bolts (C), and remove the cover. l Take off the thermostat (D).
COOLING Therm0 Switch When coolant temperature rises above 111 “C (232’F), the therm0 switch detects this and turns on a warning light on dash. Whenever you start the engine, make sure the warning light is not on in started engine. If the warning light comes on, stop the engine immediately, and check the cooling system for over heating.
ENGINE TOP END 4-l Engine Top End I4 Table of Contents Exploded View ............................................................................................................ .............................................................................................................. Specifications Special Tools .............................................................................................................. Cylinder Head.. .............................................................
4-2 ENGINE Exoloded TOP END View Tl: 8.8 N-m (0.9 kg-m, 78 in-lb) 12: 21.0 N-m (2.
ENGINE ll: L: TOP END 21 N-m (2.1 kg-m, 15 tt-lb) Apply a non-permanent kxktng agent to the threads.
4-4 ENGINE TOP END Soecifications Item Cylinder Head: Cylinder compression (M IN) Cylinder head warp Valves: Valve seating surface width Valve head thickness Valve stem run out Valve stem diameter Valve spring free length Rocker arm push rod runout Rocker shaft outside diameter Rocker arm bearing inside diameter clearance Piston ring thickness Piston ring end gap Piston pin outside diameter Piston pin hole inside diameter Connecting rod small end inside diameter Cylinder inside diameter: Intake, Exha
ENGINE Special Compression TOP Tools Gauge Assembly, Piston Ring Pliers: 57001-I Ml 4 x 1.
4-6 ENGINE Cylinder TOP END Head Compression Measurement l Before measuring compression, do the following. 0 Be sure the battery is fully charged. OThoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running. OStop the engine. @Disconnect the spark plug caps of each cylinder and remove the spark plugs. @Attach the compression gauge assembly (A) (Special Tool: 57001-I 23) firmly into the one plug hole.
I-, ENGINE l Loosen the cylinder head bolts l/4 turn in the sequence shown. ACAlJllON If the above procedure warped during removal. ORepeat the sequence head assembly. Is not followed, I the cylinder until all bolts are removed head may be and lift off the cylinder NOTE 0 Mark the push-rods so they can be installed in their original position during assembly. 0 Note the position of the special bolt (A) for reinstalling the cylinder head. (No.2 Cyl.
. ENGINE 4-8 TOP Push Rod Installation END Notes @Align (RI ) mark on the flywheel (1) with (A) mark on the breather chamber cover (2) turning the flywheel clockwise. l install the push rods in their original positions on each cylinder. OTo install the push rod in a correct position on the tappet, insert the push rod so end of the push rod is sliding down along inside wall of the crankcase and position the push rod end on to the tappet.
ENGINE l Support the valve head in the combustion chamber with a suitable block. l To remove the spring retainer (A), push down the retainer with thumbs and shift (C) the retainer to a side hole (6) on the retainer. 0 Remove the spring and valve. @Remove the stem seals (A) and bottom spring retainers (C). NOTE 0 It is not necessary to remove the stem seal unless it is being replaced. 0 Bottom spring retainer can only be removed with stem seal. 0 Valve guide (B) is not replaceable, do no rernove it. .
I - -- _..~---4-10 ENGINE TOP END l Check the cylinder head for cracks or other damage. l Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25% kelosene and 75% light engine oil. @Wipe the area dry and immediately apply a coating of zinc oxide dissolved in wood alcohol. If a cracks is present, the coating will become discolored at the defective area. *If a cracks is present in the cylinder head, replace it. l inspect the gasket surface for burrs and nicks.
. ENGINE TOP END 4-11 Valves Clearance Inspection NOTE 0 Valve clearance temperature). must be checked when the engine is cold (at room ORemove the rocker chamber cover (see Cylinder Head Removal). l Place the piston at top dead center (TDC) of the compression stroke turning the crankshaft clockwise facing the flywheel. No. 1 Cylinder: OAlign (!,) mark on the flywheel (1) with (A) mark on the breather chamber cover (2) as shown.
4-12 ENGINE TOP END NOTE OFor designing an adjustment dimensional specifications. 1: 2: 3: 4: 5: 6: 8.80 to 9.00 mm 3.85 to 4.25 mm 2.80 to 3.00 mm 2.00 to 2.50 mm M5 PO.5 screw Rocker Arm tools, refer to the following (0.346 to 0.354 in) (0.15 to 0.17 in) (0.11 to 0.12 in) (0.08 to 0.10 in) Valve Seat Inspection 0 Remove the valve. 0 Inspect the valve seats for damage. *If the seats are warped or distorted by beyond reconditioning, replace the cylinder head.
ENGINE 2. 3. Do not drop may fall off. Do not fail grinding the to the cutter or hit the valve seat cutter, or the diamond 4-13 to apply engine oil to the valve seat cutter before seat surface. Also wash off ground particles sticking with washing oil. I 0 Do not use a wire brush to remove the metalparticles It will take off the diamond particles. from the cutter. Setting the valve seat cutter holder. in position, operate the cutter with one hand. Do not apply too much force to the diamond portion.
4-14 ENGINE TOP END l Coat the seat with machinist’s dye. OFit a 45 o cutter (A) to the holder and slide it into the valve guide. OResurface the valve seat with a 45 a cutter, removing only enough material to produce a smooth and concentric seat. ACAlJllON Do not grind the seat too much. Overgrlndlng will reduce valve clearance by slnklng the valve Into the head. H the valve sinks too far Into the head, It will be lmposslble to adlust the clearance and the cylinder head must be replaced.
I ENGINE TOP END Valve Head Thickness !-k-J / ! j 0 Remove the valve. l Measure the thickness of the valve head. *if the valve head thickness (valve margin) limit, replace the valve. I Valve Head Thkzkness Service Limit (IN, EX): I (1) is less than the service 0.6 mm (0.024 In) Valve Stem Run Out l Support the valve in V blocks at each end of the stem. a dial gauge perpendicular to the stem. *Turn the valve and read the variation on the dial gauge.
4-16 ENGINE Cylinder, TOP Pistorn END ... Piston Removal OSplit the 0 Remove @Turn the ORemove crankcase (see Camshatft/Crankshaft chapter). the camshiaft (see Camshaft/Crankshaft chapter). crankshaft to expose the connecting rod cap bolts. the bolts and take off the connecting rod caps. A. Cap Bolts B. Caps C. Pry Points l Push the connectilng connecting irod end into the cylinder. rod out of the cylinder.
ENGINE Piston Installation TOP Notes *Oil Ring Installation: OFirst install the expander in the piston oil ring groove so that the explander ends butt together. 0 Install the upper and lower steel rails. There is no UP or Down to the rails. They can be installed either way. A. Expander ends l install the chrome-plated top ring and second ring with “N” mark facing up. The rings should turn freely in the grooves. @Align the piston and rings with the piston ring end gap as shown. 1. 2. 3. 4.
4-18 ENGINE - TOP Piston/Cylinder END Seizure l In case of seizure, remove the piston. l Visually inspect the cylinder and piston damage. *If there is only light damage, srnooth the piston with #400 emery cloth. Remove the small aluminum deposits from the cylinder with #400 emery cloth or light honing. *If the damage is severe, the both cylinders must be bored oversize and an oversized pistons installed. Piston Cleaning ORemove t the piston (and pistonrings (see Piston and Ring Removal).
ENGINE *If the piston ring/groove replace the piston. Piston Ring/Groove clearance is greater than the specified value, Clesrance Servke Limit 0.15 mm (0.005 in) 0.12 mm (0.005 in) Top Second NOTE 0 The oil ring ring groove is a three clearance piece and assembled thickness, ring. visually Difficult inspect to measure only. the l Measure the piston ring thickness. o Use a micrometer to measure at several points around the rings.
4-20 ENGINE TOP END Piston Pin, Piston Pih Hole, and Connecting Rod Wear @Remove the piston pin. l Measure the diameter of the piston pin with a micrometer at several points. *If the outside diameter is less than service limit, replace the piston pin. Piston Pln Outslde Diameter Servke Llml: 16.975 mm (0.6682 In) l Measure the inside diameter of the piston pin hole at several points on both side. Use a dial bore gauge. *If the inside diameter is more than the service limit, replace the piston.
ENGINE 0.25 mm Oversize: Service Limit: 76.25ll mm (3.0020 in) 76.317 mm (3.0046 in) 0.5 mm Oversize: Service Limit: 76.500 mm (3.0118 in) 76.567 mm (3.0144 In) 0.75 mm Oversize: Servke Limit 76.750 mm (3.0217 in) 76.817 mm (3.0242 in) TOP END 4-21 Cylinder Bore Out-of-Round Standard: 0.01 mm (0.0004 in) Servke Limit: 0.056 mm (0.0022 in) Cylinder Boring Fine Boring Bore Dlameter and Honing Always resize to exactly ‘0.25 mm (0.01 in), or 0.5 mm (0.02 in), 0 75 mm (0.
4-22 ENGINE TOP END NOTE Do not use gasoline. kerosene. or commercial solvent to clean the cylinder bore. These fluids only wash all r’he oil from the cylinder wall. They do not remov(e the metal pa.rticles produced during honing. 0 l Clean the cylinder l thoroughly. Use soap warm water and clean rags. Clean the cylinder wall for “white glove” inspection. A clean white rag should not show soil from the cylinder wall. Dry the cylinder and coat with a engine oil. I AKAUllON I The cylinder all grit.
ENGINE TOP END Muffler .-. Muffler Assembly Remo wal l Unscrew the exhaust pipe mounting nuts, and remove the spring washes and engine hook (B) [No. 2 Cylinder(C)]. Use a penetrating oil if necessary to breaking threads. ORemove the bolts on the muffler bracket and take off the muffler assembly. 0 Do not use unnecessary force on the exhaust pipes when removing thle muffler assembly, or they could become damaged or distored.
LUBRICATION - Lubrication SYSTEM 5-l System Table of Contents [-I1 -5 , I.., _,,.-. E.xploded View ........................................................................................................... Engine Oil Flow Chart.. ............................................................................................... ............................................................................................................. Specifications Engine Oil and Oil Filter.. .....................
5-2 LUBRICATION Exploded View SYSTEM d T2 l-l: 15.0 N-m (1.5 kg-m, 11.0 Mb) T2: 23.0 N-m (2.3 kg-m, 16.5 R-lb) 0: Apply engine oil G: Apply grease L: Apply a non-pewmanent to lhe lhreads.
LUBRICATION Engine Oil Flow r-.
5-4 LUBRICATION SYSTEM SDecif ications ---.
LUBRICATION Engine Oil and Oil Filter ACAUTION - Engine operation with InsuHklent, deteriorated, or contaminated engine oil WIN cause accelerated wear and may result in engine t- seizure and accident. Oil Level lnspec~ion l Place the engine on a level surface and check the oil level. l Clean area arourrd the dipstick (A) before removing it. @Remove the dipstick and wipe it with a clean cloth. into tube (6) following the tube bend and let it’s plug firmly fit into the tube, then check the oil level.
5-6 LUBRICATION SYSTEM Oil Change l Change oil after first 210 hours of operation. Thereafter change oil every 100 hours. @Check that there is oil in the crankcase. l Start and warm up the engine so the oil will drain easily. Stop the engine. 0 Place the engine on a level surface. @Tilt the engine and place a suitable container under the engine. ORemove the drain plug (A), and let the oil drain completely. Be careful with not oli being drrrined. 1youM”eraly.
LUBRICATION Oil Fitter Installation Notes *Apply a thin coat of grease ‘to the seal (A). 0 Install a new fiiltelr. OTurn the filter until the setal contacts mounting surface (6) of the engine. Then turn the filter BY HAND(S) 3/4 turn more. aRun the engine at slow idle speed 2 minutes. Check for leaks around the engine. l Stop the engine. Check the oil level (see Oil Level Check). Add oil only to the “H” mark on the dipstick.
5-8 LUBRlCATlON Pressurized SYSTEM 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 lo lubricate internal components, and return to the crankcase. A bypass valve is incorporated in the oil filter to allow oil to circulate if the filter becomes clogged.
LUBRICATION Oil Pump and Relief Valve Removal l Split the crankcase (see Camshaft/Crankshaft chapter). *Unscrew the mounting screws and take off the oil pump parts assembly (pump gear, pump cover plate, pump shaft, pins and rotors). @Take off the relief valve spring and ball. l Disassemble the ,pump par& assembly 1. 2. 3. 4. 5. Pins Pump Gear Mounting Bolts Outer Rotor Inner Rotor Installation 6. Pump 7. Relief 8. Spring 9. Pump 10.
5-10 LUBRICATION SYSTEM l Measure the inside diameter (A) of the pump housing with a inside micrometer at several points. *If the inside diameter is more than the service limit, replace the crankcase cover. Pump Housing Inside Diameter Service Limit: 40..901 mm (1.9093 in) 0 Measure the depth (6) of the puimp housing with a depth micrometer at several points. *If any of measurement is more than the service limrt, replace the crankcase cover. Pump HousIng Depth Sanka Limit: 10.290 mm (0.
LUBRICATION *If cleaning does not solve the problem, replace the relief valve parts. *If necessary, put the ball in position and lightly tap the ball with ;a suitable tools to form a perfect seat. 0 Measure free length (A) of the spring with a vernier Cdiper. It If the free length of the spring is less than the service limit, replace the spring. Free Len@h d Spring Senke Limit: 19.90 mlm (0.
5-12 LUBRICATION Oil Screen SYSTEM Filter Removal l Spiite the crankcase and remove the crankcase cover (see Camshaft/Crankcase chapter). *Unscrew the mounting screws (A) and remove the filter chamber cover (B) with oil induction pipe.. l Pick up the filter screen. installation Notes l Clean the oil filter screen (A) thoroughly whenever it is removed any reason. l Insert the screen in position and install the chamber cover. l install the screws and tighten them securely.
I CAMSHAFT/CRANKSHAFT 6-l Camshaft/Crankshaft Table of Contents Exploded View ........................................................................................................... Specifications .............................................................................................................. Crankcase .................................................................................................................... Splitting.. ..........................................................
6-2 CAMSHAFT/CRANKSHAFT Exdoded View ll: 21.0 N-m (2.1 kg-m, 15 Mb) T2: 21 .O N-m (2.
CAMSHAFT/CRANKSHAFT Item j L, Camshaft, Tappet: Cam lobe height Camshaft journal diameter Camshaft bearing inside diameter Crankshaft, Connecting Rod: Connecting rod bend Connecting rod twist Connecting rod big end width Crankpin width Connecting. rod big end inside dia. Crankpin outside diameter Crankshaft runout Crankshaft journal diameter Crankcase: PTO shaft bearing inside diameter Water pump shaft bearing inside dia. Crankshaft journal bearing Inside dia.
6-4 CAMSHAFT/CRANKSHAFT Crankcase Splilthg l Set the engine on a clean surface while parts are being removed. 0 Remove (see appropriate chapter).
CAMSHAFT/CRANKSHAFT OCheck that the governor weights are closed. 0 Be sure to suitably set the governor gear to be meshed with the cam gear and the oil pump gear to be meshed with the crank gear when installing crankcase cover. Do not force the crankcase cover into position. Gear train: viewed from PTO skle 0 Note the position ot dltterent length ot the bolts. Olnstall the crankcase cover and tlghten the case cover bolts to the spscffled toque (see Exploded Vlew) In the sequence as shown.
6-6 CAMSHAFT/CRANKSHAFT l A cracked or porous casting are not visible to eve, an evidence of leakage of the coolant from suspected area are found, replace the crankcase (block). *If a coolant leakage from the push rod compartment is appeared replace the crankcase (block). l Measure the inside diameter (A) of the PTO shaft bearing on the crankcase cover at several points. This bearing is not replaceable. Replace the crankcase cover if the inside diameter is more than the service limit.
CAMSHAFT/CRANKSHAFT l The service bushing is to be reinstalled using a bushing tool as shown. l Coat the bushing and flange surface with light film of oil, press in the new bushing flush with the flange surface. is required. l No finish reaming 1. Flange Surface 2. New Bushing for Designing Bushing 3. Bushing 4. Support Tools 1. Bushing Inside Diameter (MIN) 33.997 mm (1.3385 in.) 2. Housing Inside Diameter (MIN) 38.000 mm (1.4961 in.) 3. Bushing Width 26.0 mm (1.02 in.) 4. Bushing Counter Sunk 1 .
6-8 CAMSHAFT/CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevent oil from being forced out of the engine through the piston rings, oil seals or gaskets. The breather has a reed valve (C), which limits the direction of air flow caused by the piston moving up and down. Air can flow out of the crankcase,but the one way reed valve blocks return flow. It thus maintains a vacuum in the crankcase.
I II CAMSHAFT/CRANKSHAFT Camshaft Tappet - Removal l split the crankcase (see Crankcase Splitting). l Turn the crankcase up side down so that the tappets will fall away from the cam lobes. l Pull the camshaft out of the crankcase. NOTE 0 Before removing, align the punch mark (A) on the crankgear the projection (B) on the camgear. ORemove the tappets and mark them so they can be installed original positions during assembly. Installation with in their Notes l Apply engine oil to the following.
6-10 CAMSHAFT/CRANKSHAFT l Measure the inside diameter of the camshaft bearing (A) on the crankcase at several points. This bearing is not replaceable. Replace the crankcase if the inside diameter more than the service limit. Camshatt Bearing Service Llmlt: Inside Dlameter 16.066 mm (0.6326 in.) l Measure the inside diameter of the can ishaft bearing crankcase cover at several points. This bearing is not replacable. Replace the crankcase inside diameter is more than the service limit.
CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Crankshaft, Connecting Connecting Rod Removal Rod Rod Removal/Installation: ORemove the connecting Rod during the piston Removal in the Engine TOD End chapter). Connecting Rod Installation removal (see Piston Notes l See Piston l l l l l l l Installation Notes in the Engine Top End chapter for assembling the piston onto the connecting rod and insert the assembly into the cylinder. Turn the crankshaft until the crankpin is lowest position.
6-12 CAMSHAFT/CRANKSHAFT Crankshaft, Connecting Rod Inspection/Maintenance: Cleaningllnspection OAfter removing, clean the crankshaft and connecting rods with a high flash-point solvent and dry them with compressed air. l inspect the teeth of the crankgear for pitting, fatigue cracks, burrs and evidence of improper tooth contact. Replace the gear if necessary.
CAMSHAFT/CRANKSHAFT Crankpln Width Service Limit: Connecting 44.5 mm (1.75 in) Rod Big End BearinglCrankpin Wear 0 Place the connecting rod cap over its big end to align the pilot grooves on the cap and rod. l Coat a light film of oil on the thread of the cap bolts. l install the cap bolts and tighten bolts to the specified torque (see Exploded View). l Measure the inside.diameter (A) of big end at several points with a telescoping gauge or inside micrometer.
6-14 CAMSHAFT/CRANKSHAFT Crankshaft Main Journal1 Wear l With a micrometer, measure the both main journals at several points around the journal circumference. *If the journal diameter (A) is less than the service limit, replace the crankshaft with a new one. PTO Main Journal Service Limit: Dlameter 33.909 mm (1.3350 in) Flywheel Skle Journal Diameter Service LimB: 33.909mm (1.3350 In) Crankpin Resizing Crankpin can be to accept 33.5 mm (1.3189 in) dia under size connecting rod.
I ELECTRICAL SYSTEM 7-1 Electrical System Table of Contents /- Exploded View ............................................................................................................ Specifications .............................................................................................................. Special Tools ............................................................................................................... Wiring Diagram ......................................................
7-2 ELECTRICAL Exploded SYSTEM View T5 -0 Tl : 110.0 N-m (11.0 kg-m, 80.0 Mb) T2 : 27.0 N-m (2.8 kg-m, 20.0 H-lb) (Therm0 Switch) T3 : 25.0 N-m (2.5 kg-m, 18.0 fl-lb) T4 : 15.0 N-m (1.5 kg-m, 11.0 Mb) (Oil Pressure Switch) T5 : 8.8 N-m (1 .O kg-m, 7.
ELECTRICAL SYSTEM Specifications Item Charging Limit System: Regulated output voltage Alternator stator coil resistance Unregulated stator output Regulator resistance Ignition Service Standard ----- Battery voltage to 15V DC 0.11 to 0.
7-4 ELECTRICAL Special Tools KAWASAKI Muttimeter (PIN 3951008803A) SYSTEM
m ELECTRICAL Wirina Diaaram Revised ts WBODY TARM 2965867 2971044 a b L.
7-6 ELECTRICAL Wire Harness SYSTEM WIRE-HARNESS No.1 Cylinder Ignition lgni ter Coil Terminal 4P Connector Connectors No.
I ELECTRICAL SYSTEM I IGNITER I-- 4P Connector (Pin) Y0 GW0 I -I x&b xPQ ___- 1115 _-_----- I IGNITER \ Key Switch -- lI- d7 Wiring IgnitionCoil an Diagram PULSERCOILS lgni ter 4P Connector (Socket) k m 03 Color Code P : Pink WL: White Blue Y : Yellow GW: Green White 7-7
7-8 ELECTRICAL SYSTEM WIRE-HARNESS Yellow/White IO lgnlrer ‘,, ---;---. --- I / Connector Starter Solenoid Terminal Oil . Pressure Switch, IllI- VOLTAGE REGULATOR CHG Monitor (Green) Lamp (MAX): 12V-3.
ELECTRICAL Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ODo not reverse the battery lead connections. This will burn out the diodes in the electrical parts. OAlways check battery condition before condemning other parts of an dectrical system. A fully charged battery is a must for conducting accurate electrical system tests.
7-10 ELECTRICAL Charging Alternator SYSTEM System Rotor and Stator Removal l Remove the followings. Radiator Cooling Fan Starter Motor Pulser Coils Fan Drive Sheave/Hub OHold the rotor (flywheel) with a suitable tools, remove mounting nut. Alternator rotor (Flywheel): 0 Using a flywheel puller, remove the flywheel. A.
ELECTRICAL Charging System Operational Inspection l Check battery condition. / L- I- NOTE OAlways check battery condition before condemning other parts of the charging system. The baitery must be fully charged in order to conduct accurate charging system tests. l Warm up the engine to bring the components up to their normal operating temperatures. l Measure regulated output voltage at various engine speeds. 0 Connect a voltmeter across the battery terminals.
7-12 ELECTRICAL Regulator SYSTEM Resistance @Set the KAWASAKI multimeter selector switch to the R x 100 fl position. @Connect the test leads to the points shown on the chart and read the resistance. *If the resistance is not as specified replace the regulator. NOTE This voltage regulator 0 is an open type one. B. 6P Connector A. Regulator Range: R x 100 f2 t-1 TESTER (+I -1 - 1 -- By KAWASAKI TESTER -2 + Key.SW CHG.M 1 Okf2 l.
r ELECTRICAL Ignition SYSTEM 7-13 System Key Switch 1T ll2V.B Puls er Coilj -=- flsnition Coil + No2 Cylinder Pulser Coil t Ignition Time: 23” f 2’ BTBC Crankpin Center Direction F I ywheeI No1 Cylinder Center Line No1 Cylinder Pulser Coil \Leading edse Transistor controlled battery ignition system is used in this engine. This ignition system is essentially a battery-ignition coil system where the battery surpplies the current to the primary circuit in the system.
7-14 ELECTRtCAL SYSTEM Pulser Coil Removal 0 Remove: Radiator and its Brackets Flywheel Cover Cooling Fan and its Brackets @Disconnect the wire ties. @Unscrew the pulser coil mounting screws and pull the pulser coils out of the cylinder block and leave them there. l Disconnect the 4P coupler of the pulser coil leads end. @Take off the pulser coils and its wire leads together. A. Pulser Coils B. Wire Tie Installation C. Mounting Screws Notes 0 Installation is the reverse of removal.
I ELECTRICAL Igniter jL SYSTEM 7-15 Inspection ORemove the igniter. 0 Unfasten the igniter lead connectors. 0 Unscrew the mounting screws and remove the igniter. A. Igniter B. Lead Connectors (4P Couplers) C. Mounting Screws @To inspect the igniter resistance, perform the following. l Set the KAWASAKI multimeter selector switch to the R x 1 kf2 position. l Connect the test leads to the points shown on the chart and drawing and read the resistance.
7-16 ELECTNCAL Ignition SYSTEM Coil inspection ORemove the ignition coils. 0 Disconnect the plug caps. 0 Disconnect the primary coil lead terminals. 0 Unscrew the mounting bolts and take off the ignition coils. A. Ignition Coils B. Plug Caps C. Mounting Bolts D. Primary Coil Lead Terminals (Not Cylinder’s Ignition Coil Shown) @Unfasten the plug cap from the high tension lead. l Set the KAWASAKI multimeter selector switch to the specified range.
ELECTRICAL Spark Plug Gap Inspection 0 Measure the gap with a wire-type thickness gauge. *If the gap is incorrect, carefully bend the side electrode tool to obtain the correct gap. Spark Plug Gap Standard: 0.6 to 0.7 mm (0.024 to 0.
7-18 Electric ELECTRICAL Starter SYSTEM System Starter Il.40tor Removal l Disconnect the wires shown (A). ORemove the mounting bolts (C) and pull the engine with the switch lead (B) attached Starter Motor starter motor from the Installation @Clean the starter motor and engine mounting electrical contact and tighten the mounting torque (see Exploded View).
ELECTRICAL @Set the multimeter to the R x 1 fI position and connect the leads as shown. *If the meter does not read close to 0 n, the solenoid is faulty. Replace it. *If the meter reads close to 0 R, the solenoid may be good. Check the voltage to the solenoid from the engine switch. A, Switch Terminal B. To Ground l Set the multimeter selector switch to the 25 VDC position and connect it as shown. l Turn the engine switch to the START ( 11) position and read the meter.
m 7-20 ELECTRICAL SYSTEM l Connect the starter motor, battery and ammeter as shown. NOTE OStarter motor should not be loaded. conducted, as the rating is 30 seconds. The test should be quickly l Active the starter motor. The starter motor in good condition will be within following specifications. 11.5v Terminal Voltage Starter Motor RPM 6 000 (MIN) Current Draw (A) 50 (MAX) *If not, check for the following and correct if necessary. OA binding or seizing condition in the starter motor bearings.
ELECTRICAL 0 Pull the armature A. Armature B. Thrust Washer from the yoke. C. Front Stopper l Slide the thrust washer from the front of the shaft. l Separate the front and rear stoppers each other using a screw driver and remove the front stopper. l Push the rear stopper down the shaft and remove the snap ring. l Slide the stopper and pinion gear from the armature shaft. D. Rear Stopper A. Thrust Washer E. Pinion Gear B. Front Stopper C.
7-22 ELECTRICAL SYSTEM l inspect the rubber insert (B) and/or boot (A) for visible damage. *If they are damaged, 0 Fit the notch the yoke. replace them. (A) in the (-) lead grommet onto the projection (B) on l Grease the pinion gear fork fingers. @Set the pinion gear fork so that the fingers fit into the groove in the gear. OFit the notch (A) in the yoke onto the projection (B) on the pinion gear fork. l Engage the hook (A) on the starter solenoid with the hook (A) on the pinion gear fork.
c ELECTRICAL Brush Spring Inspection l inspection the brush springs for pitting, cracks, rusting and burrs. Replace the spring if necessary. l inspect the springs for weakened conditions and distortion. Replace the springs if necessary. *If the brush springs are able to press the brushes firmly into place, they may be considered serviceable. If they cannot, replace them. Armature Inspection 0 Inspect the surface of the commutator.
7-24 ELECTRICAL SYSTEM 0 Measure the armature winding resistance. OSet the multimeter selector switch to the R x 1 n 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 to 0 0 OSet the multimeter selector switch to the R x 1 kf2 position and measure the resistance between the commutator and the armature shaft.
ELECTRICAL Pinion Clutch Inspection t ORemove the pinion clutch. @Turn the pinion gear by hand. The pinion gear should turn counterclockwise freely, but should not turn clockwise (+) . *If the pinion clutch does not operate as it should, or if it makes noise, replace the pinion clutch.
TROUBLESHOOTING 8-l Troubleshooting Table of Contents Engine Starter Guide.. ................................................................................ Troubleshooting Motor Troubleshooting Guide ........................................................................ .
8-2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions, check if the way the engine is used is correct. If engine malfunctions even if engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes procedures. Do not unnecessary magneto or engine unless cause of malfunctioning.
8-4 TROUBLESHOOTING Problem system [Engine in the governor malfunctions at high speed] pn--YES relatrvely l Plugged air hole in tank cap. @Entry of dust and air into fuel filter or fuel pipe. large period produced i [Engine malfunctions at low speed] Remove spark plug and check spark by cranking engine while having the plug touched against engine block. n! - Clean - Clean F - WEAK - l- LSTRONG- 0 Fouled l Faulty @Faulty 0 Faulty l Faulty . electrodes. igniter. ignition coil.
TROUBLESHOOTING [Fuel consumption Is compression is excessive] @High fuel level in carb. float chamber (including overflow). 0 Faulty igniter. l High idling R.P.M. l Choke partially closed. 0 Excessively backed off carburetor pilot screw. sufficient? l Worn piston/piston rings. @Stuck piston. l Worn cylinder bore. l Insufficient cyl. head tightness. l Faulty valve seat contact. l Plunge-up of valve. l Wrong valve timing. 0 Broken valve spring. l Stuck valve.
8-6 TROUBLESHOOTING [c0e’ant ‘eakagel 1 -yf;d~;~*““‘“. failure l Mechanical - of radiator. 0 Cracked or porous casting. l Loose stud bolts and cap screw. l Engine overheating. water 0 Damaged pump sealings. l Improperly installed gasket. 1 l Mulfunction radiator cap.
TROUBLESHOOTING Starter Motor 1. Disconnect terminal. 2. Turn engine condition. Troubleshooting spark switch plug Guide cap, and to “START” ground position the cap and check Engine may be cranked in this test. rotating and disconnect [STARTER DOES NOT 8-7 parts of engine negative (-) lead Do not touch any during test. equipment from battery as soon as ROTATE] ~rfj-“” ~~/~~ YES 0 Weak battery. @Faulty leads or connection (Solenoid to motor).
