KAWASAKI FC150V ENGINE MANUAL Table of Contents – Page 1 of 3 GENERAL INFORMATION MECHANICAL SYSTEM ELECTRICAL SYSTEM GENERAL SPECIFICATIONS WIRING DIAGRAM ELECTRIC STARTER MODEL PERIODIC MAINTENANCE TROUBLE SHOOTING ENGINE - HARD STARTING ENGINE - MALFUNCTIONS AT LOW SPEED ENGINE - ERRATICAL RUN ENGINE - EXCESSIVE OIL CONSUMPTION ENGINE - LOW POWER ENGINE - EXCESSIVE FUEL CONSUMPTION ENGINE - MALFUNCTIONS OF STOPPING TORQUE SPECIFICATIONS CONTROL SYSTEM GOVERNOR LEVER SETTING THROTTLE CABLE INSTALLATION FA
KAWASAKI FC150V ENGINE MANUAL Table of Contents – Page 2 of 3 ELECTRIC STARTER & CHARGING TROUBLE SHOOTING STARTER MOTOR CHECK COMPONENTS RING GEAR CHECK STARTER MOTOR REASSEMBLY STATOR OUTPUT IGNITION SYSTEM TYPE OF IGNITION SYSTEM SPARK CHECK CONTROL UNIT CHECK IGNITION COIL CHECK FLYWHEEL REMOVAL FLYWHEEL INSTALLATION IGNITION COIL AIR-GAP ADJUSTMENT INTERMEDIATE CONNECTOR INSTALLATION THROTTLE-LEVER-LINKED ENGINE SWITCH BAND-BRAKE-LINKED ENGINE SWITCH CYLINDER HEAD COMPRESSION CHECK REMOVAL MAINTENANCE
KAWASAKI FC150V ENGINE MANUAL Table of Contents – Page 3 of 3 CAMSHAFT REMOVAL VISUAL CHECK SERVICE LIMIT INSTALLATION PISTON & CON-ROD REMOVAL PISTON AND PISTON RING VISUAL CHECK PISTON CLEANING PISTON SERVICE LIMIT PISTON PIN SERVICE LIMIT PISTON RING SERVICE LIMIT PISTON RING INSTALLATION CON-ROD VISUAL CHECK CON-ROD SERVICE LIMIT PISTON AND CON-ROD ASSEMBLY PISTON/CON-ROD ASSY INSTALLATION CRANKSHAFT VISUAL CHECK SERVICE LIMIT INSTALLATION CRANK PIN RE-GRINDING GOVERNOR GOVERNOR GEAR CHECK AND REMOVAL G
=strokeair-cooled gasoline engine WORKSHOP MANUAL
FOREWORD This manual is designed for use by trained mechanics in a properly equipped shop. In order to perform the work efficiently and to avoid costly mistakes, read the text thoroughly, familiarize yourself with the procedures before starting work, and then do the work carefullyin a clean area. Whenever special tools or equipments are specified. do not use makeshift tools or equipment.
TABLE OF CONTENTS
PI STON PI STON PI STON PI STON P1STON PI STON GOVERNOR GOVERNOR GEAR CHECK AND REMOVAL GOVERNOR GEAR INSTALLATION GOVERNOR SHAFT INSTALLATION 60 60 60 60
1 1 G E N E R A L I N F O R M A T I ON Be familiar with OPERATOR’S MANUAL beforeservice. Lubrication Supply engine oilas specified even for a short test running to avoid any score in the engine, which may destroy the enginein the field use. Use clean engine oilin the case specified as just “coat oil” in this manual. Don’t use justany oil or grease. Some oils and greases in particular should be used onlyin certain applications andmay be harmful if used in an application for which they are not intended.
2 2 G E N E R A L I N F O R M A T I ON Force Common sense should dictatehow much forceis necessary in assembly and disassembly. I f a part seems especially difficult to removeor install, stop and check what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the heads.
3 3 GENERAL INFORMAT I ON Defective Component No Shock The electrical parts should never be sharply struck, Never replace a defective electrical component withwith a hammer, or dropped on a hard surface.Such out determining what caused the failure. If the failure was brought on by some other item or items, a shockto the partsmay damage them. they too must be repaired or replaced, or the new Electrical Leads replacement will fail again.
4 4 G E N E R A L S P E C I F I C A T I ONS ~ _ _ = . - FC15OV 1 Number 3200 rpm Mechanical cf. Note 4 Flyweight Type 0.55 L (1.16 US Pt) Capacity O i l Pan 1. 3 g . 37 us qt. Automatic (with Throttle Control) one Type with Dual Element ransistorized Flywheel Magneto V 0.5 A with Diode Per Canadaand USA Requirement 12 V 0.2 kW Bendix Type Mechanical Flyweight Band Brake on Flywheel Note : 1. Specifications are subjectto change without notice. 2. ACR = Automatic CompressionRelease.
5 5 W I R I ND GI A G R A M 1. Portion surrounded by hatching shows 1 KAWASAKI procurement parts. A: Engine B: Spark plug C: Ignition coil Charging coil Control unit Connector (3P) Stop switch Key switch Battery J: Discharge chute interlock switch K: Control lever 1: Starter D: E: P: G: H: I: Lead Color E.
6 6 PER I O D I C MA I N T E N A N C E To ensure satisfactory operation over extended period of time, engine requires normal maintenance at regular intervals. Chart below shows periodic maintenance. Suitable intervalis shown as (0). I NTERVAL MAINTENANCE Daily Every 25 hr Every 50 1. Check and add engine oi Check for looseor lost nuts and screws Check for fuel and oilleakage. Check battery electrolytelevel. Check and clean air intake screen. Clean engine switchand control panel on engine.
7 7 TROUBLE S H O O T I N G I Are sparks produced Remove spark plug and plug spark when check spark by crankis ing engine whilehav- YES ing the plug grounded against engineblock. Install spare plug to plug hole to avoid fuel spittingfrom the ha le. lead and engine block in state where plug cap is removed? Make sure to hold plug spark plug.
8 8 TROUBLE SHOOT,I N G I Faulty plug insulation. Remove spark plug and check spark by crankFouled electrodes. *Faulty hightensioncord.Rep ing engine whilehaving the plug grounded STRONG Incorrect ignition Correct coil air against engine block. Install spare plug to plug hole to avoid fuel spitting from the hole. 1ace To avoid electric shock, do not hold plug itself. Make sure to hold plug cap. * Overrichfuel in carburetorAdjust Is unusual smoke emitted out of muffler? slow system.
9 9 TROUBLE SHOOT I N G .Entry of dust or fuel pipe or fuel filter. .Air or vapourlock in fuelRemove 1 ine. *Plugged air vent fuel ofClean tank cap. *Plugged air/fuel passes in Clean carburetor. .Too littleopening ofcarb. Correct pilot air-screw. Problem in governor system Incorrect governor linkage Correct adjustment. Faultygovernor spring. Governorgearassymalfunc-Replace t ion. Rep 1ace Stale fuel. Excessive carbon depositin engine. Excessive engine load. Engine overheating.
10 10 TROUBLE SHOOT I NG Adjust load ~Carb. not properly adjusted. Adjust *Dirty or cloggedairintakeClean screens, shroud and engine fins. Carbon deposit in combust ion chamber. *Wrong spark plug. Clean Rep 1ace I NO- I *Too muchortoolittleoilCorrect in crankcase. Excessively contaminated Change lubricating oil. Clogged air cleaner. Clean Carbon deposit io exhaust Clean hole andmuffler. Carb.not properlyadjusted.Adjust Correct Is unusual ted out of Same asHARD STARTING.
11 11 TROUBLE SHOOT I NG (BANB D R A KM E ODEL) I Engine does not stop within 3 seconds when being braked. I Does engine stop within 10 seconds when being braked? *Faulty band brake. .Faulty switch lead. Faulty switchterminal. Dirty switch terminal. -+Faulty band brake. Faulty switch lead. *Faulty switch terminal. Dirty switch terminal.
12 12 TORQUE S P E C I F I C A T I O N S I FC150 12 N-m (105 lbf-in 7 N.m (60 lbf-in 7 N-m (60 lbf-in) 23 N-m (205 lbf-in) 45 N-m (33 lbf -ft) 6 N-m (50 lbf-in) __.___..___ 7 N-m (60 lbf-in) 3.5 N-m (30 lbf-in) 7 N-m (60 lbf-in) 7 N-m (60 lbf-in) 7 N.m.(60 lbf-in Governor arm nut 7 N-m (60 lbf-in) 7 N-m (60 lbf-in) 3.5 N.m (30 lbf-in 9.5 N-m 3 N-m 20-22 N-m 21 N-m Side drain plug 38 N-m (340 lbf-in) (with plane washer) Engine mounting BBC mounting bolt (M8) General bolt (85 lbf .
13 13 CONTROL S Y S T E M Whenever carburetor or governor lever is removed from engine and then installed again. adjust governor lever position. Install governor lever (A) on governor shaft (B) but do not tighten nut (C). Loosen nut (C) if it is tightened. Turn governor lever (A) counterclockwise or place throttle lever on dash in "FAST* position to opencarb. throttle valve fully. Turn governor shaft (B) counterclockwise to end of travel.
14 14 CONTROL S Y S T E M N O T E :Air cleaner mustbe installed to engine before starting. 1. Start and warm up engine withoutload. 2. Loosen two control plate bolts (I). 3. Align hole (B) of speed control lever (C) with hole (I)) of control plate (E) and insert 6 mm (0.24 in.) dia. orpin bolt 6 mm through two holes. ! N O T E :Make sure chokevalve is fully opened. 4. Adjust fast idle speed for specified rpm (see GENERAL SPECIFICATIONS) by moving control plate (E). 5.
15 15 CONTROL S Y S T E M 1. Turn carb. pilot screw (B) in until it just seats and then back out1 turn. 2. Start and warm up engine withoutload. 3. Move throttle lever on dash to "SLOW" position. 4. Adjust slow idle speed to specified rpm (see GENERAL SPECIFICATIONS) by moving throttle stop screw (A). Adjust pilot screw (B) until engine idles at maximum speed and then turn pilot screw out additional 1/4 turn. 6. Re-adjust slow idle speed to specifiedrpm. 5.
16 16 A I R CLEANER 1. Assemble related parts neatly to minimize airleakage. 2. Do not remove any parts constructingair passages when 3. running engine. Keep air passages free from grass and rubbish. E22FC03W2 Air cleaner maintenance is one of the most important items to keep engine performing well. Instruct users for following cautions. 1. FOAM ELEMENT must be lightly oiled to performas intendin engine oil and squeeze ed. Make sure to soak element excessive oil, after washed. 2.
17 17 CARBURETOR This carburetor is float type with adjustable pilot screw (idle mixture) and fixed main jet. N O T E :Refer to each parts catalog for detailed parts conf igulation.
18 18 CARBURETOR W A R N I N G :Gasoline is extremely flammable. Avoid fires dueto smokingor careless practices. 1. Shut fuel valve. 2. 3. Drain fuel from float chamber. Disconnect fuel line (C) from carburetor. Plug the fuel line opening immediatelyor drain fuel in the line into suitable container. 4. Disconnect breather tube (A) from intake pipe (B). 5. Disconnect adaptor (D) from intake pipe (B). 6. Remove bolts (E). c A UT 0 N :Do not lose collars in intake pipe bolt holes. 7.
19 19 CARBURETOR N 0 T E :Before removing float chamber, rotate float cham1/6 turns 2 or 3 ber clockwise and counterclockwise for times, pushing float chamber tocarb. body to release sticking of float chamber and rubbergasket. E24FCIOWI C A U T I 0 N :Remove mainjet before removing main nozzle. Main iet will interfere with main nozzle C A U T I 0 N : Do not clean jet orif ices and float valve seat with hard object.
20 C A U T I 0 N :Do not strike floatpin (A) to removeor holder (B). To remove of pin install it, to avoid breakage float pin, pull the transformed end (C) with pliers. To install float pin, push float pin transformed end until both coming off pin ends are at samelength. N O T E : Float (D) does not require check andadjustment. I I EZIFCIZWI CAUT I ONS: 1. Do not over-tighten small carb. components. Finger: tighten pilot screw. 2. Do not bend throttle and choke shaftswhen assembling. 3.
21 21 CARBURETOR 5. Hook throttle rod (HI, rod spring (I). choke rod (L), and choke rod spring (M) to carburetor levers. 6. Set related parts through the boltsin following sequence: Intake pipe Gasket for intake pipe Carburetor Gasket with round hole Insulator Gasket with square hole 7. Install the related parts on cylinder flange and tighten bolts to specifiedtorque. (See TORQUE SPECIFICATIONS.) 8. Connect adaptor (G) to air cleaner joint (P).
22 22 CARBURETOR 315510 5510C 6100C 150012541 12541 EZIPAOTWI
23 23 C O O L I NG S Y S T E M W A R N I N G :Gasoline is extremely flammable. Avoid fires dueto smokingor careless practices, Engine cover is removed together with fuel tank, tank cap, fuel valve, and fuel tank cover, 1. Shut fuel valve 2. 3. (A) and disconnect fuel line (B) from carburetor inlet. Open fuel valve and drain fuel into suitable container, Remove recoil starter. C A U T I O N : Do not lose washers(C) and collars (D). 4. Remove oil filler cap (E). 5.
24 24 COOLING SYSTEM : : : : : : : : .::, 1. Remove fuel tank cap (D). 2. Pull fuel valve knob (B) off from valve shaft (E) N 0 T E : Knob (B) is install ed on valve shaft (E) w i t h snap fit. 3. Disconnect fuel line (F) fiom fuel tank (C). 4. Remove fuel strainer (I) from fuel tank (C). I l J /;;\A--- 1 I w 5. Remove fuel tank cover (G). C AUT I ON : Do not lose collars (If). 6. Remove fuel valve (A). C A UT I 0 N : Do not disassemble fuel valve (A).
25 COOLING SYSTEM :‘:’ ::::: .:::: ,jjjj : : Assembly and installation are reverse of disassembly and removal. Note following points. 1. Apply locking agent on thread when replace stud for engine cover mounting. 2. Align notch (A) of oil filler with projection (B) of filler port. Make sure O-ring (C) is in place. 3. Coat a light film of oil on O-ring and install oil 4. filler. 5. Tighten screws in crisscross sequence and evenly to specified torque. Do not tighten screw completely at a time. 6.
26 26 RECO IL STARTER C A U T I 0 N :Do not wedge rope between reel and case. 1. P u l l handle out about 250 mm (10 in). Then hold rope in place with locking pliers or knot (A). 2. Pull knot in handle (B) out and untie it. W A R N I N G :Wear gloves during disassembling to avoid injury. 3. While carefully holding reel (C) and case (D), remove locking pliersor untie knot. 4. Unwind spring tension slowly.
27 27 RECO I L 'STARTER W A R N I N G :When removingreel (C), be careful that recoil spring under reel thedoes not fly loose and causes injury. The s p r i n gisunder great pressure. N O T E :There shouldbe no spring tension on reel when removing reel. If tension is felt, push reel back into place and gently "wiggle"it until reel can be easily removed. 8. Rotate reel (C) one-quarter turn clockwise from rest position where no tension canbe felt. Then, slowly lift reel straight up out of case.
28 28 RECO IL STARTER ! W A R N I N G ' : Wear gloves during recoil spring(M) installation to avoid injury. The recoil spring must be assembled with great pressure. _._- 1. Coat grease for high temperature application on recoil spring (A) and sliding surfaces. Set recoil spring (A) in reel (B) so that spring end (C) catches hook (D) in reel. 3. Wind recoil spring (A) into reel (B) counterclockwise. 4. Make sure that gap between springhook (E) and outside of reel boss (F) is 2 4 mm (0.08 0.16 in.).
29 29 RECO I L STARTER 7. Install spring (J) and pawl (K) into the respective groove. 8. Install retainer (M), covering pawl with "R* side groove. N O T E :Apply locking agent on screw (N). C A U T I 0 N :Do not over tighten screw(N). of pawl. tightening may disturb movement 9. Tighten screw (N) to specified torque. (See SPECIFICATIONS.) Over TORQUE 11. Pull rope out of case and install handle. 12. Check movement of pawl, pulling and returning rope. 13. Pull rope out to the end.
30 30 E L E C T R I C S T A R T E R k C H A R G l NG 1. Disconnect spark plug cap, and ground the cap terminal. test. 2. Turn key switch to "ON" position and check condition. W A R N I N G : Engine maybe cranked in this rotating Do any touch parts not and equipment during -_test. of engine C A U T I 0 N : If starter does not stopkey byswitch "OFF", disconnect negative lead from battery as soon as possible. (STARTER DOES NOTROTATE) I - Does pinion rotate? "-I I - @Weak or faulty battery.
31 31 E L E C T R I CS T A R T E R & C H A R G Nl G W A R N I N G :Disconnect negative (-) lead first and then positive (+) lead to prevent spark atterminal.'-' 1. Disconnect battery before removing electric starter from engine to avoid accidental runningof starter in handli ng. 2. Remove electric starter fromengine. W A R N I N G :The test room must be free from any flammable object. Keep away your body from pinion. I - C A U T I O N :Be careful not to deform electric starter body by holding.
32 32 E L E C T R I CS T A R T E R & C H A R G Nl G E28FC15WI 1. Coat multi purpose grease on reduction gears. 2. Do not miss putting shim on shaft in cover assy. E28FC24WI 1. Disconnect connector (A). 2. Start and warm up engine. 3. Set multimeter selector switch to2!jV DC posit ion. inal (B) 4. Connect tester positive prove with stator term and negative prove with crankcase. 5. Run engine at 3,000 rpm and check voltage. If voltage is less than 8V, replace stator.
33 I G N I T I ON S Y S T E M Transistor controlled ignition system is used for these engines and this system consistsof following components. 1. Ignitioncoil 2. Control unit 3. Flywheel (with permanent magnet) These componentsdo not mechanically contact and periodic maintenance is not required.
34 34 I GN IT I O N S Y S T E M 1. Set multimeter selector switch toR x position. 2. Check resistance between terminal (A) and case (B). If resistance is out of specified value, replace control unit. C A U T I 0 N : Do not useMegger. I .CONTROLUNITRES I STANCE Case (B) Terminal (A) Case (B) N 0 T E :This check may not cover every defect. E30FCOSW2 r 1. Check resistance between the pointsas specified. 2. If resistance is out of specified value, replace ignition coil.
35 35 IGNITION S Y S T E M 1. Remove starting pulley and engine cover assy. (See ENGINE COVERREMOVAL. ) 2. Avoiding flow-out of engine oil, place engine on bench so that flywheel faces sideward. 3. Put soft metal piece on shaft end to avoid demage and strike metal piece sharply until flywheel comes loose. ESOFCIIWI 1. Before installing flywheel, remove grease and oil from taper part of crankshaft and taper hole of flywheel. 2. Make sure key is in place when installing flywheel. 3.
36 36 I GN I T I O N S Y S T E M Engine switch linked with throttle lever is equipped on control pannel of engine and operated as follows: 1. When control lever (A) is positioned at slow idle, fast idle, or choke, control lever is far from engine switch tang (B). 2. When control lever (A) is pulled beyond slow idle posi(B) and tion, the lever contacts with engine switch tang grounds ignition circuit. C A U T I 0 N : Check and clean engine switch tang area to keep good contact. 3.
37 31 CYL I N D E R H E A D 1. Remove spark plug and set compression gauge to plug hole. 2. Crank engine with recoilor electric starter several times and check highest reading. If highest reading is less than 343 kPa (50 psi), check engine in accordance with TROUBLESHOOTING. N O T E :Battery should be fully charged this for test. E32FCOSWI 1. Disconnect plug cap from sparkplug. 2. Remove rocker cover. 3. Remove cyl.head. 4.
38 38 CVL I N D E R H E A D C A U T I 0 N :Gasket is coated with special sealant. Do not damage surfaceof gasket during installation. If surface coating is damaged, replace gasket. 1. Rotate crankshaft until piston comes upat highest position in compression stroke. 2. Install push rods in their respective position in cylinder. 3. Place head gasket and cyl. head assy on cyl. block. 4. Make sure both spherical ends of push rods are in place on rocker arms and tappets.
39 39 VALVE When any part relatedto valve clearance is changed or modified for defect correction,or after engine has been used for long period, adjust valve clearance. N O T E :Do adjustment while engine is cold. 1. Turn crankshaft until piston comes up at highest position in compression stroke. 2. Check clearance between valve stem and rocker arm with feeler gauge (A).
40 40 VALVE ACR is device to release compression during engine start, for easy cranking. 1. Remove rocker cover. Remove spark plug to ease hand cranking. 3. Make sure valve clearance is as specified. (See VALVE CLEARANCEADJUSTMENT. 4. Rotate crankshaft slowlyin usual direction observing movement of exhaust valve (A) and rocker arm (B). 2. If exhaust valve doesnot open more than 0.50 mm (0.02 in.) briefly just after intake valve closes. ACR mechanism on camshaftis faulty. (See CAMSHAFT VISUALCHECK.
41 41 VALVE N O T E :Mark push rods so they are placedin their original positions in re-installing. 1. Remove push rods. 2. Unscrew lock nuts (A) and pivots (B), and then remove rocker arms (C). 3. Place screw head of valve spring compressor (D) on the valve head andSI ip jaw ofcompressor between spring(E) and retainer (F). 4. Compress spring and remove retainer (F) with needle nose pliers. 5. Remove compressor and valve spring.
42 42 1. Check valve head for excessive deposit andgas leakage. 2. Remove carbon from valve head withwi-re brush. 3. Check valve head for warped face (A) dent on face and margine (B) of less than 0.5 mm (0.020 in.). If valve head has above defect, replace valve, N 0 T E :Excessive depositis caused by leaded gasoline, and deposit triggersgas leakage causing valve defects. Therefore unleaded gasolineis recommended. 4.
43 43 VALVE 1. Check diameter of valve stem in area covered by valve guide at several points withmicrometer. I f diameter is less than MIN. replace valve. V A L V ES T E MD I A . 2. MIN Check bend of valve stem at center part with V blocks (A) and dial indicator (B). If bend (dial gauge reading) of valve is stem more replace valve. than 0.03 mm (0.0012 in. C A U T I 0 N : Do not try to grind or recondition valve face. I f valve face is worn or damaged, replace it. E33FC I8W2 1.
44 44 VALVE If valve does not contact all way around with seat, lap valve into seat. 1. Coat fine lapping compound sparingly on valveface. 2. Rotate valve in circular motion with valve lapper (A). N 0 T E : Lapping mark should appear or on near center of va 1 ve face. 3. Check valve every 8 to 10 strokes and continue lapping until uniform ring appears on valve seat all around. way 4. After lapping, wash parts in solvent to remove compound. Dry parts thoroughly. E33FC2OW2 1. Reface enough 2.
45 45 VALVE 1. Use valve guide cleaner to cleani nside of valve guides. 2. Check inside diameter of valve gu 11de at several points with inside micrometer. If diameter is more than MAX, rep ace cyl. head. VALVE GUIDE I N S I D E D I A. M A X Intake 5.550 mm (0.2185 in. Exhaust 5.560 mm (0.2189 in. E33FC22W2 (A with push rod), (B with pivot). wi th valve stem), and (C If necessary, replace rocker arm. E33FC23WI 1. Check bend of push rod at center part withV blocks (A) and dial indicator (B).
46 46 C R A N K C A S CE O V E R W A R N I N G : Be careful not to burn yourself by oil. 1. Drain engine o i l to suitable container. 2. Remove rust and burr from edgeof PTO shaft step. 3. Loosen screws, and tap parts near dowel alternately with soft mallet. E34PCOIWI 1. Check inside diameter of PTO bearing (A) at several points with inside micrometer. If diameter is more than 25.100 mm (0.9882 .in.), replace crankcasecover. 2.
47 47 CRANKCASE COVER 0 1 ':L SEAL REPLACEMENT I f oil leakage through oil sealis observed or seal lip is damaged, replace oil seal. 1. Remove oil seal by tapping it out with screw driver or punch. 2. Placing spring held seal lip (A) inside, push oil seal into housing until seal outside surface becomes flush with housing end (C). 3. Before final assembly, pack some amount of grease for high temperature applicationinto space between seal1 ip (A:) and dust 1 ip (B).
48 48 CAMSHAFT 1. Place cyl. block upside down on bench. Rotate crankshaft (A) until timing marks (B, C) on 2. 3. crankshaft gear (D) and camshaft gear (E) align, to avoid interference between tappets and camshaft in removal. Remove tappets, and mark them so they can be placed in their original position in re-installing. E35FC06WI Check cam gear for worn or broken teeth. If excessively worn or broken teeth are observed, replace camshaft. Check movement and damage of ACR mechanism on camshaft.
49 49 C A M S HAF T 2. Check cam lobe height with vernier calipers, If lobe height is less than 22.80 mm (0.898 in.). replace camshaft. E35FC08W2 1. Place cyl. block upside down on bench. 2. 3. 4. Install tappets in their respective positionsand push them all the way intoguide to avoid interference with camshaft in assembling. Rotate crankshaft until piston is at highest position. Aligning timing marks (A) and (B), install camshaft into crankcase.
50 50 P I STON 4t CON-ROD C A U T I 0 N :Remove any carbon or ridge at top of cyl. bore to avoid piston ring breakage in. removing. 1. Rotate crankshaft (A) to expose con-rod bolts (B). cap. 2. Loosen con-rod bolts and remove con-rod 3. Push piston and con-rod out through top of cylinder. 4. Remove piston fromcon-rod. 5. Remove piston ringsfrom piston with ring expander(C).
51 51 PI STON & CON-ROD Appearance of piston and piston ringsshows condition of engine in running. If excessive damage is observed, replace piston and/or piston rings and remove cause of such damage. I 1. Rings of wrong size or rings having improper end gap w i l l not fit to shape of cylinder. This causes high oil consumption and excessive blowby. Check ring end gap and arrange end as gapshown in PISTON RING INSTALLATION. 2.
52 52 PI S T O N & CON-ROD C A U T I 0 N :Do not use caustic cleaning solution or wire brush to clean piston. 1. Remove all deposits from piston. 2. Clean carbon from piston ring grooves with ring groove cleaner. If cleaning tool is not available. use old piston ring breaking into suitable size. 3. Make sure oil return passages in ring groove are open. E 3 6 F C 1 3 WI 1. Check clearance between ring groove and ring using new ring and feeler gauge. If clearance is more than 0.10 mm (0.004 in.
53 53 PI S T O N & CON-ROD 1. Check thickness of piston ring at several points with micrometer. I f thickness is less than 1.40 am (0.0551 in.), replace piston ring. for top and second rings 2. Check piston ring end gap with feeler gauge, insta.11ing each ring squarely in cylinder at approx. 25 mm (1 in.) from top. If gap is more-than MAX, replace piston ring. PISTON RING END GAP MAX 1.0 mm (0.04 in. Second Top 1.5 mm (0.06 in. E 3 6 P C I6W2 1. Use ring expander. N 0 T E :Face up 2. 3.
54 54 PI STON & CON-ROD Check con-rod especially big end for wearing, scratching, scoring, and/or discoloring. Abnormal wearing and scratching are causedby foreign particle(s) in oil. Clean engine inside and changeoil. Check air cleaner. and clean or replace damaged one. If con-rod and/or crankshaft are used again, remove ridges on their surfacecarefully. Scoring and discoloring are symptom ofpoor lubricating and/or over heating.
Assemble con-rod big end aligning pilot grooves (A), Check inner diameter of big end at several points with inside micrometer. E 3 6 F C I9W2 1. Aligning mark " A " (A) on piston head with "MADE IN JAPAN" on con-rod, assemble piston overcon-rod. 2. Coat a light film of oil on piston pin and insert pin through piston andcon-rod. 3. Install retaining rings in each grooves firmly. C A U T I 0 N : Do not re-use retaining ring removed.
56 56 1. Set ring compressor (B) over piston, flushing with piston top, with projection (A) on compressor toward top of piston. 2. Tighten compressor with wrench (C), then loosen it slightly. 3. Coat a light film of oil on cyl. bore. 4. Rotate crankshaft with crank pin in lowest pos it ion. 5. Aligning mark (A) on piston head toward flywheel side, instal1 piston/conrod assy into cyl inder. 6. Leading big end of con-rod to crank pin, push piston down further. 7.
57 57 CRANKSHAFT Check crank pin part and bearing journals for score, wear, or corrosion. If crank pin partshows any damage, carefully check con-rod big end and repair or replace con-rod and/or crankshaft. (See CON-ROD VISUAL CHECK. ) Check crank gear for worn or broken teeth. If excessively worn or broken teeth are observed, replace crank gear.
58 58 CRANKSHAFT 2. Check outside diameterof crank pin (A) at several points withmicrometer. If outside diameteris less than 27.920 mm (1.0992 in.), replace crankshaft. 3. Check run out of crankshaft at both bearing journals with dial indicator (A), setting crankshaft to alignment jig (B). If total reading of run out is more than 0.20 mm (0.008 in.), replace crankshaft. E37FCO7W3 1. Install key (A) as shown. 2. Install crank gear (B) as timing mark facing outside. 3.
-59 59 CRANKSHAFT 1. Re-grind crank pinto 0.5 mm under size. 22.95023.00 27.467 1.5 -24.00 mm (0.9035 0.9055 in. 27.480 mm (1.0814 1.0819 in.) 1.8 mm (0.0590.071 24.10 mm (0.945 in. 0.949 in. ) N O T E :Crank pin must be concentric and parallel within 0.005 mm (0.0002 in.) full indicator reading, and surface must be finished very smooth with super finishing stone. C A U T I 0 N :If crank pin is re-ground, under-size con- rod must be used to keep specified clearance.
60 60 GOVERNOR 1. Check governor gear assy for wear and damage,as installed in crankcase cover. C A U T I 0 N :Do not remove governor gear assy from crankcase cover exceot to reolace~ I f once removed. it cannot be re-used. 2. If governor gear assy (A) must be replaced, remove it with proper size screw drivers(B). C A U T I 0 N : Do not damage gasket surface by screw drivers. E39FC04W2 1. Place sleeve (A) into governor gear assy (B).
61 61 LUBR I C A T I NG S Y S T E M -20°c -10°c 0°c IO°c 20°c 30°c 40°C N O T E :Detergent engine oil delays formation of gum and varnish. Do not add any additives to detergentoil. 2. Select oil viscosity depending on expected environmental temperature as shown. -4°F 14°F 32°F 5O°F 68°F 86’°F 104°F E4OPCOIWI If slinger is damaged, replace it. E4OFCIOWI Function of breather is to keep vacuumin crankcase avoiding oil being forcedout of engine.
62 62 LUBR I C A T I N G S Y S T E M 1. Check valve and valve seat for any damage such as crack or wear. 2. Install reed valve (A) and back plate (B) on inspection tool (C), and check gap between reed valve (A) and tool surface (C) with feeler gauge. If gap is more than 0.2 mm (0.008 in.). or replace valve.
63 63 CYL I __- 1. Visually check cyl. block for scored bore, broken fin, or other damages. If unrepairable damage is observed, replace cy]. block. 2. Check inside diameter at 10 mm (0.4 in.) from top in directions of parallel and right angle to crankshaft, with inside micrometer. I f inside diameter and/or out of round are more than MAX, resize cyl. bore or replace cyl. block. CYL. B O R IEN S I D D EIA. CYL.
64 64 CYL I N D E R / C R A N K C A S E 2. Hone cylinder to final size as shown on right table following procedure shown below. C A U T I 0 N : Consider shrinkage ofcyl. bore for 0.0060.008 mm (0.0002-0.0003 in.) after cooling down from honing heat. F.S. : F. S. 0.25 mm 65.230 (2.5681 0.50 mm 65.48065.500 mm (2.5779 2.5787 in. 0.75 mm 65.73065.750 mm (2.5878 2.5886 in. Final Size N 0 T E : Use honing stone recommended by hone manufacturer. 65.250 mm 2.5689 in. (1) A1ign centers of cyl.
65 65 C Y L INDER/CRANKCASE C A U T I ON :Do not removeball bearing from housing except replacing. 1. Clean ball bearing with high flash point solvent. 2. Pour engine oil to bearing. 3. Rotate bearing inner race slowly by hand. If anyroughness is felt andit can re-cleaning, replace ball bearing. not be removed by E4IFC03WI 1. Remove oil seal preceding ball bearing replacement. r- Do not re-use removed oil seal. 2. Push out ball bearing with bearing driver. 3.
66 66 CY NDER/CRANKCASE If inside diameter is more than 14.070 mm (0.5539 in. ), repllace cy1 inder/crankcase.
67 67 B A N DB R A K E In the brake system, shoe (B) operated by lever (A) brakes flywheel (C) to stop engine quickly when brake control lever on equipment is moved to stop position. At the same time, engine switch tang(F) contacts with lever (A) to ground ignition circuit. The operations are as follows: 1. Starting When brake controllever on equipment is moved to start position, control cable (D) pulls lever (A) to release shoe (B) from flywheel (C) and to release engine switch tang (F) from lever (A).
68 68 B A N DB R A K E 1. Do not remove brake shoe (B) from stud (G) except when replacing theshoe. 2. If stud (G)is removed to replace shoe (B), apply locking agent on the thread when reinstalling stud. the in installation. ire adjustment 3. Shoe (B) does not requ E43FC02WI Operate brake controllever on equipment and check brake cable for any slack. If necessary, adjust brakecable connect ion. 1. Release brake control lever on equipment. 2.
