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- 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 REMOVAL FLYWHEEL CHECK CHECK CONTROL UNIT CHECK FLYWHEEL INSTALLATION IGNITION COIL AIR-GAP ADJUSTMENT FLYWHEEL HOUSING INSTALLATION CHECK AND CLEANING

SECTION 3 - AIR CLEANER AIR CLEANER SERVICE AIR CLEANER HOUSING INSPECTION AIR CLEANER INSTALLATION

SECTION 4 - CARBURETOR OPERATION CARBURETOR REMOVAL AND DISASSEMBLY CARBURETOR CLEANING CARBURETOR INSPECTION CARBURETOR ASSEMBLY CARBURETOR INSTALLATION CARBURETOR ADJUSTMENT

SECTION 5 - REMOVAL (GOVERNOR RELATED) GOVERNOR GEAR DISASSEMBLY 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 CABLE INSTALLATION AND ADJUSTMENT CHOKE ADJUSTMENT MAXIMUM SPEED ADJUSTMENT IDLE SPEED ADJUSTMENT

SECTION 6 - COMPRESSION COMPRESSION CHECK HEAD AND HEAD REMOVAL TIGHTENING PROCEDURE CYLINDER HEAD CHECK AND REPAIR VALVE AND SPRING REMOVAL VALVE SPRING INSPECTION TO ANALYZE VALVE VALVE INSPECTION VALVE GUIDE CHECK AND REPLACEMENT VALVE SEAT RECONDITIONING CLEARANCE CHECK AND REPAIR

SECTION 7 - LUBRICATION LUBRICATION OIL WARNING SYSTEM FULL FLOW (OPTIONAL) CAPACITIES OIL RECOMMENDATION OIL LEVEL CHECK OIL CHANGE BREATHER CHECK OIL PUMP INSPECTION OIL PUMP INSTALLATION

SECTION 8 - , , AND CON-ROD PISTON AND CON-ROD REMOVAL PISTON INSPECTION PISTON RING THICKNESS INSPECTION PISTON RING END GAP INSPECTION PISTON PIN AND PIN HOLE DIA. INSPECTION CON-ROD INSPECTION PISTON AND CON-ROD ASSEMBLY PISTON RING INSTALLATION PISTON AND CON-ROD ASSY INSTALLATION KAWASAKI FB460V ENGINE MANUAL

Table of Contents – Page 3 of 3

SECTION 9-- AND 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 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 INSPECTION PLAIN BEARING INSPECTION BALL BEARING INSTALLATION OIL SEAL REPLACEMENT (PTO SIDE)

SECTION 11 - ELECTRIC AND CHARGE STARTER MOTOR CIRCUIT STARTER SYSTEM CHECK STARTER MOTOR CHECK STARTER SOLENOID TEST STARTER MOTOR DISASSEMBLY STARTER MOTOR INSPECTION BRUSH HOLDER CHECK PINION CLUTCH INSPECTION STARTER MOTOR REASSEMBLY CHARGING SYSTEM CHECK TROUBLESHOOTING

SECTION 12 - RECOIL STARTER RECOIL STARTER DISASSEMBLY RECOIL STARTER REASSEMBLY RECOIL STARTER INSPECTION 4-stroke air-cooled gasolineengine FOREWORD

This manual is designed for use by trained mecha- The term "Replace"and some abbreviations are nics in a properly equipped shop. used as follows: In order to perform the work efficiently and to avoidcostly mistakes,read the text, thorough- Replace - usually means replace with a new part. ly familiarize yourself with the procedures before startingwork, and then do the work carefully MIN = Minimum in a cleanarea. Whenever special tools or equip- MAX = Maximum ment are specified, do not use makeshift tools or Ass'y = Assembly equipment.Precision measurements can only STD = Standard bemade if the proper instruments areused, and I Ilust. = Illustration the use of substitute tools mayadversely affect Spec. = Specification(s) safe operation. PTO = Powertake off Approx. = Approximately (Approximate) Whenever you see these WARNING and CAUTION Carb. = Carburetor symbols, heed their instructions! Con-rod = Always follow safe operating andmaintenance Cyl. = Cylinder practices.

WARNING: Thiswarning symbol identifies All rights reserved. No part of thispublication special instructions or procedureswhich, if not maybe reproduced, stored in a retrieval system, correctly followed, could result in fire, personal or transmitted in any formor by anymeans, injury, or loss of life. electronic mechanical photocopying, recording or otherwise, without the priorwritten permission of EngineDivision/Kawasaki Heavy Industries, CAUTION: This identifies special instructions Ltd. No liability canbe accepted for anyinac- or procedureswhich, if not strictly observed, curacies or omissions in this publication, although could result in equipment damage or destruction. everypossible care has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without prior NOTE: Indicates message or points of partic- notice or obligation. Illustrations in this publi- ularinterest for more efficient andconvenient cation are intended for reference use only and may operation. not depict actual model component parts. TABLE OF CONTENTS /-

Section 1 Section 5 GENERAL INFORMATION GOVERNOR

Before Servicing ...... 1-1 Removal (Governor Related) ...... 5-1 Specifications...... 1-3 Governor Gear Disassembly ...... 5-1 Performance Curves ...... 1-4 Governor Gear Inspection ...... 5-2 Dimensional Specifications ...... 1-5 Governor Reassembly ...... 5-2 Periodic Maintenance ...... 1-7 Reassembly (Governor Related) ...... 5-2 4-Stroke Engine Theory ...... 1-7 Linkage Adjustment ...... 5-2 Construction (Internal Component) ...... 1-8 Throttle Cable Installation and Fuel System and Operation ...... 1-9 Adjustment ...... 5-3 Electrical System ...... 1-10 Choke Adjustment ...... 5-3 Preliminary Engine Checks ...... 1-11 Maximum Speed Adjustment ...... 5-3 TroubleShooting ...... 1-13 Idle Speed Adjustment ...... 5-3 Tune-upProcedure ...... 1-17 Overhaul Procedure ...... 1-17

Section 2 IGNITION Section 6 COMPRESSION Ignition System ...... 2-1 Spark Check ...... 2.1 Compression Check ...... 6-1 Flywheel Removal ...... 2.1 Cylinder Head and Removal ...6-1 Flywheel Check ...... 2.2 Cylinder Head Tightening Procedure ...... 6-1 Ignition Coil Check ...... 2-3 Cylinder Head Check and Repair ...... 6-2 Control Unit Check ...... 2-3 Valve and Spring Removal ...... 6-2 Flywheel Installation ...... 2-3 Valve Spring Inspection ...... 6-2 Ignition Coil Air-gap Adjustment ...... 2-3 To Analyze Valve ...... 6-2 Flywheel HousingInstallation ...... 2-4 Valve Inspection ...... 6-2 Spark Plug Check and Cleaning ...... 2.4 Valve Guide Check and Replacement...... 6-3 Valve Seat Reconditioning ...... 6-4 Tappet Clearance Check and Repair ...... 6-6 Section 3 AlR-CLEANER

Air cleaner Service ...... 3.1 Air cleaner Housing Inspection ...... 3.1 Air cleaner Installation 3.1 ...... Section 7 LUBRICATION

Section 4 Lubrication ...... 7-1 CARBURETOR Oil Warning System...... 7-1 Full Flow Oil Filter ...... 7-1 Carburetor Operation ...... 4.1 Capacities ...... 7-1 Carburetor Removal and Disassembly ...... 4.1 Oil Recommendation ...... 7-2 Carburetor Cleaning ...... 4-2 Oil Level Check ...... 7-2 Carburetor Inspection ...... 4.2 Oil Change ...... 7-2 Carburetor Assembly ...... 4.2 Breather Check ...... 7-2 Carburetor Installation ...... 4-3 Oil Pump Inspection ...... 7-3 Carburetor Adjustment ...... 4-3 Oil Pump Installation ...... 7-3 Section 8 Section 12 PISTON.PISTON RING. AND CON-ROD RECOILSTARTER

Piston and Con-rod Removal ...... 8-1 Recoil Starter Disassembly ...... 12-1 Piston Inspection ...... 8.2 RecoilStarter Reassembly ...... 12-1 Piston Ring Thickness Inspection ...... 8-2 Recoil Starter Inspection ...... 12-2 Piston Ring EndGap Inspection ...... 8-3 Piston Pin and Pin Hole Dia. Inspection .....8-3 Con-rod Inspection ...... 8-4 Piston and Con-rod Assembly...... 8-5 Piston Ring Installation ...... 8-5 Piston and Con-rod Assembly Installation ... 8-5

Section 9 CRANKSHAFT AND CAMSHAFT

Crankshaft and Camshaft Removal...... 9-1 Crankshaft Inspection ...... 9-1 Under Size Con-rod ...... 9-2 Link Rod Inspection ...... 9-2 BushingReplacement ...... 9-2 Balance Weight Inspection ...... 9-3 Balancer Guide Inspection ...... 9-3 Camshaft Inspection ...... 9-3 Crankshaft and Camshaft Installation ...... 9-4 Crankcase Cover Installation ...... 9-5 Crankshaft End Play...... 9-5 Crankshaft End Play Adjustment...... 9-5

Section 10 CYLINDER BLOCK AND BEARING

Cylinder Block Inspectionand Repair ...... 10-1 Ball Bearing Removing ...... 10-2 Ball Bearing Inspection ...... 10-2 Plain Bearing Inspection ...... 10-2 Ball Bearing Installation ...... 10-3 Oil Seal Replacement ...... 10-3 Section 11 ELECTRICSTARTER AND CHARGE

Starter Motor Circuit ...... 11-1 Starter System Check ...... 11-1 Starter Motor Check ...... 11-2 Starter Solenoid Test ...... 11-2 Starter Motor Diassembly ...... 11-3 Starter Motor Inspection ...... 11-4 Brush Holder Check ...... 11-7 Pinion Clutch Inspection ...... 11-7 Starter Motor Reassembly ...... 11-7 Charging System Check ...... 11-7 Trouble Shooting ...... 11-9 1-1 GENERAL INFORMATION Section 1 GENERAL INFORMATION

BEFORE SERVICING Force Common sense should dictate howmuch force is necessary in assemblyand disassembly. If a Before starting to service a engine carefully read part seems especially difficult to remove or install, theapplicable section to eliminate unnecessary stop and examine what may becausing the pro- work. However, a detailedaccount has limi- blem.Whenever tapping is necessary, tap lightly tations; a certainamount of basicknowledge using a woodenor plastic-faced mallet. Use an is required for successful work.Especially note impact driver for screws (particularly for the re- the following: moval of screws held by a lacking agent) in order to avoid damaging the heads. Lubricant Don't use just any oil or grease.Some oils and greases in particular should be used only in certain applications and may be harmful if used in an ap- plication for which they are not intended. Mechanical Systems: Battery Ground Before performing anydisassembly operations Adjustments onthe equipment, remove the ground (-) lead Adjustmentsshall bemade in accordance with from the battery to preventthe possibility of thePeriodic Maintenance Chart or whenever accidentally turning the engine over while partially troubleshootingor presence of symptoms indi- disassembled. cate that adjustments may be required. Lubrication Edges Enginewear is generally at its maximum while Watch for sharpedges, especially duringmajor the engine is warming up and beforeall the rubbing enginedisassembly and assembly. Protect your surfaces have an adequate lubricative film. During hands with gloves or a piece of thick cloth when assembly, oil or grease (whicheveris more suitable) lifting the engine or turning it over. should be applied to any rubbing surfave which its lubricative film. Old greaseand dirty Dirt has lost oil should becleaned off. Deteriorated grease Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or other has lost its lubricative quality andmay contain abrasive foreign particles. parts, will work as an abrasive and shorten the life of the engine. For the same reason, before install- Press ing a new part, clean offany dust or metal fillings. A part installed using a press or driver, such as a seal, should first be coated with oil on its outer or Tightening Sequence innercircumference so that it will go into place Where there is a tightening sequence indicated in smoothly. this Service Manual, 'the bolts,nuts, or screws must be tightened in the order and method indicat- Oil Seal, Grease Seal ed. When installing a part with several bolts, nuts, Replace any oil or grease seals that were removed or screws, they should all be started in their holes with newones, as removalgenerally damages and tightened to a shug fit. Thentighten them seals. A seal guide is required for certain oil or evenly,according to thetightening sequence, to grease seals during installation to avoid damage the specifiedtorque. This is to avoid distortion to the seal lips.Before a shaft passes through a of the part and/or causing gas or oil leakage. seal, apply a little lubricant, preferably high tem- Conversely,when loosening the bolts, nuts, or perature grease, to thelips to reduce rubber-to- screws,loosen all of themabout a quarter of a metal friction. turn and then remove them. Gasket, O-ring Torque When in doubt as to the condition of a gasket or Thetorque valuesgiven in this Service Manual O-ring,replace it. with a newone. The mating shouldalways be adhered to. Either too little surfaces around the gasket should be free of for- or too much torque may lead to serious damage. eign matter and perfectly smooth to avoid oil or Use a good quality, reliable torque wrench. compression leaks. GENERAL INFORMATION 1-2

Liquid Gasket and Non-permanent Locking Agent Theelectrical parts should neverbe struck Follow manufacturer's directions for cleaning and sharply, as with a hammer, or allowed to fall preparing surfaceswhere these compounds will be on a hard surface.Such a shock to the parts used. Apply sparingly.Excessive amounts may can damage them. block engine oil passages and cause serious damage. Do not disconnectthe battery leads or any An example of a non-permanent locking agent otherelectrical connections when the igni- commonly,available in North America is Loctite tion switch is on, or while the engine is run- Lock'n Seal (Blue). ning, unless specifically noted. Ball Bearing Installation When installing a ball bearing, thebearing race Neverkeep thestarter engaged if thestarter which is affected by friction should be pushed by motor will not turn over, or the current may a suitable driver. This prevents severe stress on the burn out the starter motor windings. balls and races, and prevents races and balls from Never replace a defective electrical component beingdented. Press a ball bearing until it stops without determining what caused the failure. at the stop in the hole oron the shaft. If the failure was brought on by some other Circlip, Retaining Ring item or items, they too must berepaired or Renewany circlips and retaining rings that were replaced, or the new replacement will fail. removed, as removal weakens and deforms them. Makesure all connectors in the circuit are When installing circlips and retaining rings, take cleanand tight, andexamine wires for signs care to compress orexpand them only enough of burning,fraying, etc. Poorwires and bad to install them. connections will affect electrical systemope- ration. High Flash-point Solvent Ahigh flash-point solvent is recommended to Measure coil and winding resistance when the reduce fire danger. Acommercial solvent com- part is cold (at room temperature). monly available in North America is Stoddard All theelectrical leadsare eithersingle-color solvent(generic name). Always follow manufac- or two-color and, with only a few exceptions, turer and containerdirections regarding the use of must be connected to leads of the same color. any solvent. When solderingor unsoldering connections, Molybdenum Disulfide ) Grease do not use a soldering iron of more than 40 Thismanual makes reference to molybdenum wattscapacity. Use 16 gauge (0.062 in.) disulfide grease in the assembly of certain engine 60/40 resincore solder when reconnecting andchassis parts. Alwayscheck manufacturer wiring. recommendationsbefore 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 shockhazards when working onelectrical equipment. Work in a clean, dry environment withdry hands. Formax- imum shockhazard protection,connect the equipment ground terminal to an earth ground. Do not reverse the battery leadconnections. This will burn out the diodes in the electrical parts. Always check battery condition beforecon- demningother parts of an electrical system. A fully charged battery is a must for conduct- ing accurate electrical system tests. 1-3 GENERALINFORMATION SPECI FlCATlONS

ENGINE MODEL FB460V ENGINE TYPE Forced Air Cooled, Vertical Shaft, 4-Stroke Gasoline Engine NUMBER OF CYLINDER 1 PISTON DISPLACEMENT 460 cc (28.1 cu.in.) x STROKE 89 mm x 74 mm (3.50 in. x 2.91 in.) 6.4 : 1

MAX. OUTPUT 12.5/3,600 r.p.m. (with JX156-K112-01 ) MAX. TORQUE 2.78 kg-m/2,300 r.p.m. (20.1 ft-lbs/2,300 r.p.m.) MIN. SPECIFIC FUEL CONSUMPTION RATIO 315 gr/hp-hr (0.694 Ibs/hp-hr)

DIRECTION OF ROTATION Counter-Clockwise Facing thePTO Shaft FAST IDLE SPEED SETTING 3,350 r.p.m. SLOW IDLE SPEED SETTING 1,400 r.p.m.

LUBRICATION Pressurised Lubrication BALANCING Reciprocating Weight THROTTLE CONTROL Remote Cable CHOKE CONTROL Automatic STARTER Electric Starter or Recoil Starter CARBURETOR Float Type Fixed Main Jet IGNITION Transistorized-Fly-WheelMagneto (Point Less) CHARGING COIL 12V-13A with Regulator (Electric Starter Model RFI per Canada and U.S.A. Requirement GOVERNOR Mechanical Governor OIL FILLAND DIP STICK Extended Above Engine OIL DRAIN with Extention Pipe COOLING AIR INLET Rotating Screen with Periphery Blade Protector COOLING SHROUDS Noise Suppresive Layered Sheet AIR CLEANER Semi Cyclone Type with Dual Element

LUBRICANT API Service Classification : SD, SE, SE/CC, SF Class At temperatures below 0°C (32°F) : SAE 5W-20 At temperatures above 0°C (32°F) : SAE 30 FUEL Regular Grade Leaded or Unleaded Gasoline

(Electric Starter Model) (Recoil Starter Model)

DIMENSION (H x W x L) 307mm 381 x mm 419.5 x mm 356 mm 365 x mm 511 x mm (12.08 in. x 15.00 in. x 16.51 in.) (14.01 in. x 14.37 in. x 20.12 in. NET WEIGHT 36 kg (79.36 Ibs) 36 kg (79.36 Ibs)

OPTIONAL PARTS Oil Warning System, Full Flow Oil Filter

Specifications and dimensions are subjectto change without notice. GENERAL INFORMATION 1-4 PERFORMANCECURVES

FB46OV WOT PERFORMANCE (SAE J607a) TORQUE kgm ft- Ibs

2.6 18 2.4

gr/hp.hrIbs/hp.hr

300

2000 3000 3600 4000 ENGINE SPEED r.p.m.

The ratings shown herein are established in accordance with Society of Automotive Engineers Code J607a. Powercurves are corrected to standard conditions of sea level barometer and temperature of 15.6°C (60" F) and are developed from laboratory test engines equipped with standard air cleaner andmuffler. The "Maximum B.H.P." curve represents performance of laboratory test engines. Production engines will develop not less than 95% of the "Maximum B.H.P." whentested after run-in to reduce friction and after cleanout of , with valves, carburetorand ignition systemadjusted to laboratory standards. Engine power will decrease 3.5% for each 305m (1,000 ft.) above sea level and 1% for each 5.6°C (10°F) above standard temperature of 15.6°C (60°F). 1-5 GENERALINFORMATION DIMENSIONALSPECIFICATIONS (Recoil Starter Model)

276 143.5 276 I GENERALINFORMATION 1-6

(Electric Starter Model) 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 at regular intervals. The chart below showsperiodic inspectionand maintenance required and suitable interval designatedwith

Electric start models only. Perform these operations after the first 5 hours of use, then at the recommended interval. Clean the air cleaner element more often when operating under dusty conditions.

Fuel Use regular grade leaded or unleaded. CAUTION: Gasohol is not recommended. Don't use additives, such as carburetor cleaners, de-icers, or moisture-removingliquids in the gasoline. Don't mix oil with gasoline. Always use a clean container. Engine Oil Use API classification SF, SE/CC, SE or SD. Use SAE 30 at temperatures above 0°C(32°F) and SAE 5W-20 at temperatures below 0°C (32°F). Don't put additives in the oil. 4-STROKEENGINE THEORY KAWASAKI FG Series engines are of the same basic "4-stroke cycle design" as used in automobiles, trucks and . There are four strokes to one complete power cycle. 1. Stroke: The piston goes down, creating a vacuum in the cylinder which draws gas through open intake valve into the space above piston. 2. Compression Stroke: The piston comes up with both valves closed, highly compressing the gas into the space left between the top of the piston and cyl- inder head. 3. Power Stroke: At this point themagneto sends high tension current to the spark plug, firing or exploding the compressed gas and driving the piston down. 4. Exhaust Stroke: Exhaust valve opens and the upward stroke of the piston forces out all of the burnt gases, thus completing the power cycle. GENERAL INFORMATION 1-8 CONSTRUCTION (INTERNAL COMPONENT)

1. Cylinder head 12. Wristpin 2. Gasket 13. Linkrod 3. Ignition coil 14. Adjust shim 4. Ring gear 15. Oil seal 5. Rotating screen 16. Crankshaft 6. Flywheel nut 17. Crankgear 7. Flywheel with blades 18. Connecting rod 8. Charging stater coil 19. Piston 9. Ballbearing 20. Piston pin 10. Balance weight 21. Snap ring 1 1. Support shaft 22. Pistonrings

11 A. Intake valve B. Exhaust valve 12 C. Valve guide D. Valve rotater E. Valve spring F. Springretainer 13 G. Tappet H. Oil pump I. Governor assembly J. Camshaft K. Breathervalve \14

The intake andexhaust valve guideare fitted Internal components for FB460V engine with a bushing. The cylinder block and bush- consist of the piston, connecting rod, camshaft, ings can be reamed out to install service valve crankshaft,reciprocating balancer,, guide bushings and standard size valves, when oil pump and governor. valve guidewear exceeds theservice-limit. Pressurized oil directly lubricates the PTO journal,, and linkrod journals. A satellite exhaustvalve with a rotator is A balance weight is mountedon crankshaft used to prolong the life of the exhaust valve. withlink rodsand reciprocating balance is accomplished in theexact line of the piston The functionof thebreather is to create a motion. vaccum in the crankcase which prevents oil The flyweight governorgoverns all speed from being forced out of the engine through ranges. piston rings, oil seals, or . Oil laden air Oversize andrings 0.25 mm, 0.5 mm, in the crankcase passes through a maze created 0.75 mm (0.01 in., 0.02 in., 0.03 in.) areavail- by the reedvalve and expansion chambers able. wherethe oil is separated from theair and Camshaft is gear-driven by thecrankshaft. drained back to the crankcase. The air passes The camshaft lobs operate against the tappets, through a hose out to the aircleaner. which raise and lower valves. 1-9 GENERAL INFORMATION FUEL SYSTEM AND OPERATION n

n

1. Atomospheric pressure 8. Needle valve 15. Throttle valve 2. Air cleaner 9. Tongue 16. Venturi 3. Paper element 10. Main jet 17. Intake valve 4. Foam element 11. Bolt 18. Lower pressure 5. Intake pipe 12. Gasket 19. Piston 6. Choke valve 13. Float bowl 20. Starter motor 7. Main nozzle 14. Float 21. Control plate

Fuelenters the carburetor bowl throughthe Atomospheric pressure in the bowl forces needle valve contolled by the float. The down- fuel up the main nozzleinto the venturi, where wardmovement of thepiston on the intake thefuel mixes with airmoving through the n stroke creates negative pressure in the cylinder. venturi. The choke valve controls the amount Atomospheric pressureforces out side air of airentering the venturi during starting throughthe air cleanerand venturi into the operation. engine. Heigh speed air in the venturi creates negative The throttle valve controls the fuel-air mixture pressure. entering theengine. GENERAL INFORMATION 1-10 ELECTRICALSYSTEM

The electrical system for FB460Vconsists of an solenoid and startingmotor. ignition system, electric starting system, charging Thecharging system consists of a flywheel system and monitor system (optional). stator and regulator to convert AC current to DC current. The stator out put is 12 amps at The ignition systemincludes a flywheel, igni- 3,350 rpm. tion coil, control unit, spark plug andengine The monitor system consists of an oil pressure stop switch (recoil starter model only). sensor (oil switch), oil pressure warning lamp Thestarter system includes a keyswitch, and charge lamp. Wiring Diagram FB46OV-AS. Model (Bendix StarterMotor) FB46OV-BS. Model (Shiftlever StarterMotor)

ENGINE ENGINE

Spark plug

I Control unit

Key switch

OFF RUN START

FB460V. (Recoil-Starter Model) Specifications Ignition System

~-

ignition NGK BMR4A or CHAMPION RCJ-8 0.6 to 0.7 mm

Control unit I resistance See CONTROL UNIT CHECK 1-1 1 GENERAL INFORMATION Electric StarterSystem (Bendix-type) PRELIMINARY ENGINE CHECKS I ITEM 1 Battery rating 12 V/35A.H. or more completeA diagnosis of engine malfunctions One tenth of battery capacity Max chargingappears in this section. current However, the majorityof engineproblems is Starter-rating 12 V - 0.8 KW normally due to ignition or fuel system diffi- Brush lengthmm(0.4712 in.) (MINI I culties. Commutator 0.2 mm (0.008 in.) (MINI groove depth 1. If engine willnot start with gasoline in the Commutator 32 mm (1.26 in.) (MINI diameter tank,remove spark plug and check spark by cranking engine while having the plug touched Commutator 0.3 mm (0.012 in.) (MAX) Run-out against . Current draw 12 V, 7000 rpm (MINI60A (MAX) WARNING: To avoid fire, do not hold spark plug in close positions to the plug hole. Keep the plug as far away as possible from the plug hole. To avoid an electric shock, do not hold the plug itself. Make sure to hold the plug cap. Electric Starter System (Shiftlever-type) I 1-1. If there is goodspark between electrodes, the ignition system is in good condition. Battery rating 12 A.H. / 35 A.H. or more Max charging One-tenth of battery capacity current Starter-rating 12 V - 0.75 KW Brush length 6 (0.24mm in.) (MIN) I Commutatorrnm0.2 (0.008 in.) (MIN) I groove depth Commutator 27 mm(1.10 in.) (MAX) diameter Commutator0.4 mm (0.016 in.) (MAX) run-out I Currentdraw 11.5 V, 6000 rpm (MINI test 50A (MAX)

Charging System 1-2. If there is no or a very weak spark, clean the I ITEM I I plug andregap to 0.6 to 0.7mm (0.024 to Stator output Approx. 12 amps-0 rpm 0.028 in.). Replace the plug if it's electrodes No-load voltage 34.5 V / 3350 rpm (MIN) are of worn. 1-3. If there is still no spark refer to "IGNITION" Regulator-type 12V system, constant voltage, regulator section. Regulator See Regulator Inspection resistance A 2. If engine still fails to start,check the fuel system for the tank to carburetor to besure gas is getting to carburetor. Checkcarb. adjustments and be sure choke and throttle controls are working properly. Monitor System Refer to Section 4 for carb. information. 3. Check for a plugged air cleaner.Clean orre- place if necessary.

4. If engine still willnot start, or starts but does not run properly, perform the compres- sion test that follows, and refer to "Diagnose Malfunction" in this Section. GENERALINFORMATION 1-12

5. Testcompression when engine loses power or runs erratically and fuel and ignition systems adjustments do not correct the problem.

CAUTION: Disconnect spark plug cap to prevent engine from starting during compression test.

6. engine with electric or recoil starter and check the compression force.

7. If compression is low, it is usuallythe result of one or more of following: Leaking cyl. head gasket. Warped cyl. head. Worn piston rings. Worn cyl. bore. Damaged piston. Burned or warped valves. Improper valve clearance. Broken valve springs.

8.Use a compressiongauge and test compres- sion by:

8-1. Removespark plug andscrew compression gauge into the plug hole securely.

8-2. Crankengine with electricor recoil starter and take highest pressure gauge reading.

8-3. Cylinder compression should not be less than 380 KPa (55 psi). 8-4. If compressionreading is too high,check for carbon built up in combustion chamber. 1-13 GENERAL INFORMATION

TROUBLE SHOOTING points. This chart describes typical troubleshooting If enginemalfunctions, check if the way the en-procedures. gine is used is correct. If engine malfunctions Do not unnecessarilydisassemble carburetor, even if engine is used correctly, systematicallymagneto or engineunless it hasbeen found to be carry out troubleshooting starting with simple the cause of malfunctioning.

[Engine hard to start]

Remove spark plug and I checkspark bycrank- ing engine while having the plug touched again- st engine block.

WARNING: between hightension Keep the plug as far leadand engine block away as possible from in the state where plug the plug hole. To avoid an electric shock, do not hold the plug itself. ,Makesure to hold the Aresparks produced plug cap. between hightension leadand engine block when control unit is replaced?

gap Demagnetized fly- Replace wheel

Make startingattempts NO- number of times and then removespark into fuel pipe or filter plug andobserve elec- [odes. tank cap Are they wet? Plugged fuel line Clean

Y ES-, turn thecrankshaft without loading

in float bowl

Worn piston/piston rings t Replace Stuck piston rings Clean or replace Check carb. fuel line. Worn cyl. bore Bore or replace Check for plugged air passage. tightening Check float level. seat Plunge-upby valve Adjust valve clearance Warped cyl. head Broken valve springReplace Stuck valve Cleanor grind Replace GENERAL INFORMATION 1-14

[Engine loss power]

Adjust level or add

Excessiveengine load.Adjustload

screens, shroudingand engine fins.

chamber.

Is the ignition spark NO- Replaceplug. spark Wrong normal? FaultyReplaceplug. spark Fau lty controlFaulty unit. Replace Fau lty ignitionFaulty coil Replace Faulty hightension cord. Adjust gap Armatureair gap incorrect. Replace Demagnetizedflywheel.Correct

Is lubricatingcondition NO- normal? in crankcase.

bricating oil.

Is unusualsmoke emit- YES Cleancleaner. Pluggedair ted out of muffler? @Carbondeposit in hole and muffler. not properly Too much oilin crankcase. Adjust level

-I_-- -I_--

compression suffici- Is Hard. ent?

[Engine runs erratically]

fuel pipe or .

Problem in thegovern- I or system justment. Faulty governorspring.Replace

tioning. 1-15 GENERAL INFORMATION

[Engine malfunctions at high speed]

Is revolutionfluctuation of relatively large period pro- ducedwhen a load is appli- fuel filter or fuel pipe

[Engine malfunctions at low speed]

Remove spark plug and check Faulty plug insulation Replace spark by cranking engine electrodesFouled Clean while having the plug touch- Faultycontrolunit Replace ed against engine block. Faultyignition coil Replace Faulty hightension cord Replace Incorrectarmature air gap Correct WARNING: Keep the plug as far away as possible from the plug hole. To avoid an electric shock, do nothold the plug it- self. Makesure to hold the plug cap. J t Is unusualsmoke emitted Overrichfuel in slow system Turn off pilot air jet by out of muffler? a minor extent NO

Directly andgradually open Disassemble andclean throttle valve byhand. Does the revolutiondrop ordoes engine stall at a certain position?

Is suckedair throughRetightencar- buretor flange? buretor Replace gasket Damaged t Are valve nor-clearances of Adjust valve clearances m al values? mal Wrong YES t Is alignment oftiming gear Largelydeviated valve tim- alignment of marks correct? ing timing gear marks GENERALINFORMATION 1-16

[Fuel consumption is excessive] r High fuel level in carb. Is compression sufficient? -Adjust float chamber (including overflow) Delay is -Adjust High idling R.P.M. -Adjust Incompleteopening of choke choke valve Excessivelybacked off - burator pilot air screw

Replace Stuck piston -Clean or replace Worn cylinder bore -Bore or replace insufficient cyl. head tigh- teness Faulty valve seat contact Plunge-up of valve -Adjust valve clearance Wrong valve timing -Adjust Broken valve spring -Replace Stuck valve -Clean or grind

[Oil consumption is excessive]

YES- Plugged oil ring groove -Clean High oil level -Adjust Faulty valve seat contact Worn valve stems and valve guides Oil leakagealong governor -Replace shaft Oil leakage from oil seal -Replace Oil leakage from mounting -Replace gasket surface Oil leakage from drain plug -Retighten or replace gasket Clogged breather valve -Clean Drain-back hole in tappet -Clean chamber plugged Incorrect oil viscosity -Correct Worn piston rings Replace Stuck piston rings Clean or replace Worn cylinder bore Bore or replace Replace [Eng ine runs erratically] runs [Engine Carb. not properly adjust- ed Spark plug fould, pitted, or adjust or gapped incorrectly Carb. flange leaking at gas- or replace ket Carb. bodyand throttle shaft warn Restricted gas tank vent -Clean Governor mulfunctioning -Adjust [En gine backfires] [Engine Tighten

head gasket.

valve

[En gine knocks] [Engine Stale fuel Change Excessivecarbon deposit in Clean

Excessive engine load Adjust Engine overheating See low on power Faulty control unit Replace engine 1-17GENERAL INFORMATION TUNE-UPPROCEDURE OVERHAUL PROCEDURE

A "Tune-Up" (see the steps below) would normal- The following overhaulprocedure is intended to ly be performed on relatively new engines brought help you in systematic and sequential method of in for minor difficulties. By performing these repairing a Kawasaki FB46OV engine. Efficiency is steps you will either besure the engine is func- obtained when the repair operationsare performed tion properly or will know if andwhat major in the samesequence every time.The exact repairs should be performed. procedure will vary according to the engine model Thesteps are also covered in the OVERHAUL being repaired. PROCEDUREand will normally be performed This table can also be used as an index. as a part of the complete overhall. Fordetail information onhow to perform each operation refer to thesection and page number Remove , clean tank and lines. listed. Check oil level and drain. Remove air cleaner,check for proper servicing. DISASSEMBLY Drain engine oil Remove recoil starter,flywheel housing, and shrouds. Air cleaner assy Inspectrope, recoilstarter assembly or Muffler ass'y __ pinion clutch (electric starter). Carburetor,heat shield plate and gas- ket. Intake pipe. Clean cooling fins and entire engine. Rock flywheel to check compression. Carburetor and linkage. Disassemble carburetor. I______- Removecarb., disassemble and inspect Electric starter for wear or damage.Wash in solvent, replaceparts as necessaryand assemble. starter Recoil Set initial adjustment. Dip stick and blower housing Spin flywheel to check compression Inspect inlet and exhaust flange for dam- aged gaskets. Spark plug-adjust gap, inspect. clean and I Checkgovernor linkage, spring, and speed Rope starter pulley. control lever for damage or wear,also Adjust armature airgap. check adjustment. Tappetchamber cover and Remove flywheel, check for seal leakage, pipe connector both flywheel and PTO shaft sides. Cylinder head and gasket Check flywheel key for damage. Check valve-to- tappet clearance valve Check coil and control unit, inspect all and spring. wires for breaks damaged insulation. Flywheel_- Be sure lead wires do not touch flywheel. Breather Check stop switch and lead. Ignition coiland control unit Install flywheel. Set air gap.Check for Starter motor disassembly spark. Recoil starter disassembly Remove cyl. head,check gasket, remove Governor control base plate and sparkplug, and clean carbon, inspect governor arm valves for seating. Crankcase cover Damaged oil seal Install cyl. head, torque to thespecified torque, set spark plug gap or replace Damaged governor gear ass'y the plug if necessary. Oil pump and relief valve Camshaft and gear Replace oil andfuel, check mufflerfor restrictions ordamage. Tappets Con-rod and piston Adjust speed control linkageand cable Balance weight support shaft if used, for correct operation. Crankshaft and balance weight Run and adjust idle (mixture), and MAX ass'y speed. Disassemble crankshaft ass'y I GENERAL INFORMATION 1-18

Section DISASSEMBLY 9 Crankshaft inspect and check 10 Cylinder check bore, main bearings, 6 valve guides and valve seats. Disassemble connecting rod and piston. 8 Check piston, rings, connectingrod, piston pin.

I Section R EPAl R Resize cylinder bore to next over size. Replace valve guide intake, exhaust. Reface valves and seats and lap. I Replace main bearings. Replace oil seals. Replace governor gear ass'y. Cylinder head repair 2 Replace flywheel ring gear. 9 Replace bushing link rod.

Section REASSEMBLY Assemblecrankshaft, linkrod and balance weight. 9 Crankshaft ass'y and balance weight support shaft Piston, piston pin, rings 8 Connecting rod sub ass'y 9 Tappets, camshaft 5 Governor gear ass’y 7 9 Crankcase cover 5 Valves, valve springs, retainers Adjust valve tappet clearance. 6 Tappetchamber cover, breather pipe connector 7 Breather reed valve and cover lgnition coil ~- Control unit Charging stator coil 2 Flywheel and pulley Adjust air gap : armature to flywheel. Check spark. Cylinder head and gasket Cylinder head and cylinder cover Blower housing. Oil dip stick Inlet pipe. Governor control base plate. 2-1 IGNITION Section 2 IGNITION

IGNITION SYSTEM SPARK CHECK

A controlled ignition system is used for Removespark plug andcheck spark by cranking FB46OV. This systemconsists of the following engine whilehaving the plug touched against components. engine block. Ignition coil unit Control unit (Igniter) Permanentmagnet flywheel Keep the plug as far away as Spark plug possible from the plug hole. To avoid an electric shock do not hold the plug itself. Makesure to The ignition coil unit is mounted outside the fly- hold the plug cap. wheel on the cylinder block. Since thetransistor ignition system contains no mechanical parts, no wear occurs and no periodic maintenance is required except for the spark plug. If there is goodspark between electrodes, the ignition system is in good condition. Principle of Operation

: Primarycoil : Transistor : Secondarycoil : Transistor : Control Resister F : Flywheel CU : Control Unit (Igniter) SP : Sparkplug If there is noor very weakspark, clean spark : Control Resister SW : Stop switch plug andregap to 0.6 to 0.7mm (0.024 to 0.028 in.). Replace spark plug if electrodes are worn. See "Spark Plug Check and Cleaning" section. When voltage at point (A) is plus, base current ) flows into Transistor ). Thenthe Transistor is turned "ON"and allows large amplified current to flow, during which the Transistor does not operate because Resister ( ) lowers valtage at point C. As the flywheel continues to rotate,AC power is further generated in the primary coil (L, ). Thenthe Transistor ) is turned "ON" by high voltageat point (C). FLYWHEELREMOVAL As soon as the Transistor ) isturned "ON", the base current ) through (R, ) to 1. Remove spiral case. (Flywheel housing) Transistor ) changes its flow to ) and to 2. Disconnect spark plug cap from spark plug. Transistor thus the Transistor ) is 3. 'Carefully remove the wire out of spiral case. turned "OFF" because of voltage drop at point (B). CAUTION: Flywheel nut has a left-hand thread. This sudden current changeinduces high voltage within the secondary coil (L,), which 4. Place a pry baragainst the thick root of the fires thespark plug. blades to prevent the blades from breaking off. 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 hammerand bar, strike ring gear evenly to remove it.

7. Remove and inspect flywheel key. Replace the key if it is bent or sheared. 8. Inspectcrankshaft taper for nicksor burrs. If necessary, finish taperusing fine emery paper.

FLYWHEELCHECK drill 5/16 deep (4-6) drill holes gear

CAUTION: Do not give impact to , as (3)Heat a new ring gear (C), evenly to an extent impact weakens magnetic force of it. that expansion by heating facilitates following 1. Put flywheel on a wooden surface. installation. 2. Hold a metal tool about 25mm (1 in.) away (4) With the bevelededge of the gearfaced up, from flywheel magnet. The metal tool should quickly install ring gear, quickly followed by be attractedby magnet. If magneticforce tapping ring gear evenly to insure good seating. is weak, replace flywheel.

New ring gear 2-3 IGNITION IGNITIONCOIL CHECK FB460V-BS. Model

1. Remove two mounting screwsand remove ignition coil. 2. Remove the plug cap from hightension cord. 3. Set KAWASAKI multimeter selector switch at BM1129 a specified range and connect leadsas shown in the chart below,. If meter reading falls within the values shown in the chart, the coil is func- tioning properly.

Spark plug leadPrimary terminal TerminalCore

Control Unit Resistance (AS. BS, Model) Terminal (A) I Terminal (A) Case (B) ON to

*Resistance value may vary with individual meters. *Do not use a megger. Core

Ignition Coil Resistance FLYWHEELINSTALLATION Connection I Resistance Be sure the key is in place when installing flywheel. I Primary terminal I 0.4 to 0.8 coi I (R x 1 Range)core To tighten flywheel nut, reverse the removal steps. Secondary Plug lead 10 to 18 Torque to spec. listed. coil (R x 1 Range)core Flywheel Nut Tightening Torque *Resistance value may vary with individual meters. 83 to 88N-m (62 to 65 ft-lbs)

CONTROL UNIT CHECK IGNITIONCOIL AlR-GAP 1. Unfasten connectors. ADJUSTMENT 2. Unscrew mounting screws and remove control unit. (1) Leave ignitioncoil mounting screwsloose 3. Set KAWASAKI multimeter selector switch at so the coil canbe moved for air gap adjust- Rx1 scaleand connect leads as shown in ment. the chart below. If meter reading falls within (2)Inserting a 0.3mm (0.012in.) AIR GAP- the valuesshown in the chart, the unit is thickness gauge (A) at eacharea in between functioning properly. coil legs on flywheel rim,move the coil to adjust AIR GAP. FB460V-AS. Model (3) Tighten mounting screws firmly.

White lead

(Ground lead) IGNITION 2-4

FLYWHEELHOUSING Electrodes INSTALLATION Shell 1. Install flywheel housing (E), rotating screen (B), Porcelain protector (D) and tighten screws. Gasket Terminal NOTE: The air gap (C) between contour blades (D) Seating material underscreen and flywheel housing (E) should be Reach not less than 1 mm (0.04 in.). Use washers (A) to adjust the airgap (C).

Adjust washer (A) Rotating screen (B) Protector (D) Air gap

Flywheel Flywheel housing Bracket The plug canbe cleaned using a high flash-point solventand a wirebrush or other suitable tool. If the spark plug electrodesare burn away or 2. Install cylinder headcover and tighten screws. damaged, or if theporcelain is cracked,replace the plug. Use the following spark plug. NOTE: Push cylinder headcover firmly against flywheel housing to eliminate cooling air leakage. Specified Spark Plug 3. Install dipstick and air cleaner assembly. Spark plug Gap NGK BMR-4A 0.6 to 0.7 mm CHAMPION RCJ-8 to 0.028 in.)

Spark Plug Gap SPARK PLUG CHECK (1) Measure the gap with a wire type thickness AND CLEANING gauge. If the gap is incorrect, carefully bend theouter electrode with a needlenose plier A spark plug consists of two electrodes (A) separat- to obtain the correctgap. ed from each otherby sparkgap (B). Theside electrode is connected to shell (C)of the spark plug. The center electrode is completely insulated Spark Plug Tightening Torque from theshell. 28 N-m (20 ft-lbs) The high voltage, produced in the secondary coil winding, is applied to thecenter electrode and causes a spark to jumpthe gap (B) to the side electrode.This spark ignites the fuel-air-mixture and starts thecombustion process in the cylinder.

Gapbetween electrodes affectsthe entire range of engine performance - starting, idling, accelerating, power and top speed. Sparkplugs must operate within a specific temperature range to givegood performance. 3-1 AIRCLEANER Section 3 AIR CLEANER

A properly serviced air cleaner protects theinternal AIR CLEANER HOUSING parts of the engine from dust particles in the air. INSPECTION If the aircleaner instructions are not carefully followed, the dirt anddust whichshould be 1. Check aircleaner housing for deformation or collected in the cleaner, will be drawn into the en- other damage. Thehousing must seal well gineand become a part of the oil film, which and permit only filtered air to reach carbure- is very detrimental to engine life; dirt in the oil tor. Replace the housing if damaged. forms an abrasive mixture which wears the moving 2. Check noforeign material is obstructing the parts. air passage. The air cleaner on every engine brought in for a check up or repair should be examined and servic- ed. An aircleaner element clogged with dirt chokes the air supply to the engine, resulting in an overly AIR CLEANER INSTALLATION rich fuel/air mixture and inefficient combustion. This inturn causesreduced engine power and overheatingdue to carbon build-up in combus- 1. Clean elements, housing, cover and other parts. tion chamber. 2. Elementsand housing must be installed cor- rectly. Do not run engine with air 3. Install O-ring, housing, elements cover, washers cleaner removed. and tighten wing bolts.

AIR CLEANER SERVICE

A FB460V engine is equipped with a heavy duty air cleaner which has dual elements and an element housing.

Remove two wing bolts and lift off aircleaner completely.

CAUTION: Do not clean the element with solvent or compressed air.

1. Foam Element Visuallyexamine element for turn, puncture andotherwise damaged. Replace element if necessary. Wash element in detergent and water and dry throughly. Immerse in newengine oil andsqueeze out excess.

2. Paper Element Cleanelement by tappinggently to remove 1. Wing bolt 5. Element (Paper) dust. If very dirty, wash in detergentand 2. Washers 6. Housing water,and dry throughly. Replace with a new 3. Cover 7. 0-Ring pa per elementpaperevery 300 hours. 4. Element (Foam) 8. Element housing CARBURETOR 4-1 Section 4 CARBURETOR

CARBURETOROPERATION engine draws fuel only from thatorifice. 3. During intermediateoperation, secondand 1. In the choke or start position, the choke valve third orifices areuncovered as the throttle is closed, and the only air entering the engine valveopens, and more fuel is allowed to mix enters throughopening around the valve. As with the air flowing into the engine. thestarting device is operated to start the 4. During high speed operation, the throttle valve engine, the airpressure in thecarburetor is is fully opened. Air flows throughthe car- reduced as airdrawn into the engine.Since buretor at high speed. the air passage is blocked by the choke valve, Theventuri, which decreases theair passage fuel is drawn from the main nozzle and from through carburetor, further accelerates the air both idle fuel discharge ports and mixes with flow. Thishigh speedmovement of the air the air that passes through the throttle valve. decreases theair pressure, and fuel is drawn This makes a very rich fuel mixture required to into the air stream thro gh themain nozzle start a Cold engine. that opens into venturi, mi ing with the air in 2. At idle a relatively smallamount of fuel is the air passage. As the en 'ne load increases, required to operate the engine. The throttle is air is automatically bled intothe main nozzle almostclosed, shutting off thefuel supply through the airjet located in the air horn. from all exceptthe one idle-fuel discharge This allows fuel to be metered freely from the orifice, so that thesuction created by the main nozzle and to be facilitated atomization.

Carburetor Specifications F B460V-ASF B46OV-BS

Main Jet

Pilot Jet # 47.5 #47.5 Pilot Screw (Turn out) 1-1/8 I 1 -1/8 Float Valve 1.5 mm (0.059 in.) 1.5 mm (0.059 in.)

Low Idle Speed 1350 to 1450 rpm 1350 to 1450 rpm

Fast Idle Speed 3275 to 3425rpm 3275 to 3425 rpm

Float parallel to carburetor body-to-bowl mating surface.

CARBURETORREMOVAL AND DISASSEMBLY

WARNING:Gasoline is dangerous. CAUTION: Do not bent the links or stretch. Avoid fires due to smoking or careless maintenance practices. 2. Pull carb.free, and gently twist carb. to free 1. Beforeremoving for repair,check for signs oflink rod. air leakage, or mounting gaskets that are loose, 3. Remove governor link rod and link spring. deteriorated, or otherwisedamaged. 4. Disassemble carb. (See illust. below). 4-2 CARBURETOR Disassembly Carburetor (See: Illustration) 2. Partsshould remain in cleaner for 1 or 2 hours. Remove and rinse with solvent.

NOTE:Rinse carb. body inhot water to neutralizecorrosive action of cleaner on aluminum.

3. Dry parts with compressed air. Be sure all holesare open. Do not userags or paper to dry parts. Lint may plug hole or passages.

CARBURETORINSPECTION

1. Inspect carb. body for damage.Flange sealing surfaces should be smooth andfree of burrs and nicks. 2. Replace gasket if necessary. 3. Inspect pilot screwand drain screw for wear at the seatingsurface. Inspect for weaksp- rings. 4. Inspect main jet, bleed pipe, main nozzle and pilot screw for damage. 5. Inspect inlet needle valve for wear or damage at the seating surface. 6. Inspect clip for damage.

NOTE:Inspect the other parts of carb. for wear, damage.

Ref. Parts Name Ref. Parts Name No. No. 1 Screw 16 Needle valve 2 Throttle valve 17 Float pin 3 Screw 18 Clip 4 Choke valve 19 Float chamber 5 Screw 20 Choke shaft CARBURETOR ASSEMBLY 6 Spring 21 Throttle shaft 7 Spring 22 Ring 8 Pilot screw 23 Seal Reassembly is the reverse of removal. Notethe 9 Pilot jet 24 Float following points: 10 Drain screw 25 Main nozzle 1. Install main nozzle, bleed pipe, and main jet by 11 Spring 26 Main jet turning clockwise into carb. body.Do not 12 27 Spring Washer over tighten screws. 13 28 Bolt Ring 2. Install pilot screw (mixture screw)and spring 14 Ring 29 Bleed pipe 15 Gasket 30 Spring finger tight. 3. Install pilot jet screw by turning it clockwise into carb. body. Do not over tighten. 4. Install float and float pin. CARBURETORCLEANING CAUTION: Do not push on float or, inlet needle CAUTION: Neverclean holes or passages with valve when adjustingfloat level. small drill bits or wire. 5.When carburetor is upside down, float surface 1. Place carb. body andcarb. parts in PT503 (A) must be parallel to carb. body (B). To cleaner or its equivalent.Do not put gaskets adjust float surface angle, bend tang (C)with and plastic parts in cleaner. needle-nose pliers. CARBURETOR 4-3 CARBURETOR ADJUSTMENT

WARNING: Gasoline is dangerous. Avoid fires due to smoking or careless maintenance practices.

Adjust Idle Mixture Air cleanermust be assembled to engine.

1. Turn idle mixture screw (B) inuntil it just seats, then back it out 1-1/8turns.

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 lever onequipment to "IDLE POSITION". 3. Use a tachometerand adjust throttle stop screw (A) to obtain 1,350 to 1,450 rpm by CARBURETORINSTALLATION turning it in or out while holding the end of the screw against carb. body. 1. Install throttle linkages (A) andchoke linkage 4. Adjust idle mixture screw (B) by turning (B) on carburetor. clockwise (lean) or counterclockwise (rich) to 2. Install breatherconnector (C)on intake pipe obtain the peak of idling. 5. Turn idlemixture screw (B) back out 1/4 (D). 3. Assembly3. gaskets (E), heatshield plate (F), turn more. carburetor (G), gasket (H) and intake pipe 6. Use a andreadjust throttle stop screw (A) to obtain and satisfy specified 1,350 (D). 4. Install carb. ass'y on inlet pipe (I) with through to 1,450 rpm idling. bolts (J). 7. Stopengine. 5-1 GOVERNOR Section 5 GOVERNOR

Thegovernor control regulates the enginespeed by 3. Remove through-bolts (J). changing thegovernor spring (1) tension, thus 4. Remove intakepipe (D), gasket (H), car- allowing thegovernor to control thecarb. throttle buretor (GI, heatshield plate (F) andgaskets at all timesandmaintain desiredany speed. (E). A FB46OV engine is equipped with a mechanical 5. Disconnectbreather connector from tappet g overnor. chamber cover.flyweight chamber type governor. If the engine is carrying a loadand running at rated speed, the speed will drop if theload in- creaseseven slightly. In responce to the decrease, governorweights (2) contact by corresponding amount.Their movement is transmittedthrough the sleeve (3) andgovernor shaft (4) to thearm (5). The arm then moves the link rod (6) (in the direction of the arrow) (7) which turns the throttle valve in the openingdirection. As speedincreases, it is sensed bythe governor (8), and therod turns the valve in theopposite direction. Thisaction/reaction sequencesoon creates a state of equilibrium whichallows the engine to run at nearly the samespeed as before while carrying a slightly greater load. Dumpingthe load suddenly will cause a rapid increase in speed. But the interaction of the 6. Remove link spring (A) and gently twist engine-governor-carb.protects the engine from carburetor to free throttle linkage (B) and over-revolution andspeed soon settles at a constantchoke linkage (C). Removelinkage. level.

Low speed position

High speed position

GOVERNORGEAR DISASSEMBLY REMOVAL(GOVERNOR RELATED) 1. Unscrew mounting bolts in the order specified 1. Remove air cleanerassembly.remove crankcaseand cover from crankcase. 2. Loosenclamp and disconnect fuel line from 2. If necessary,remove governor ass’y (A) with carburetor. a proper size screw driver. GOVERNOR 5-2

Reassembly is the reverse of removal. Note the following points: GOVERNOR GEARINSPECTION 1. Install governorlever (A) ongovernor shaft (B) and tighten nut (C)finger tight. 1. Inspectgovernor gear for worn anddamage. Replace as an unit, if wearand damage ex- ceed.

GOVERNOR REASSEMBLY

1. Install thrust washer (C)and stuffinto new governorass'y (E) to shortstationary shaft (A)until innerflange (D) fittedinto groove (B) of the shaft as shown.

CAUTION: The sleeve can not be installed after stuffed into the gear to the shaft. Do not reuse governor ass'y once removed. 2. The throttle and chokelinkages can not be 2. After installed,governor ass'y should rotate installedon the carburetor after the intake freely on the shaft. pipe was installed.

LINKAGEADJUSTMENT

1. Place throttle lever on dash in "FAST" posi- tion. (Equipment side) 2. Loosen nut (1), that holdsgovernor arm to governor shaft (2). 3. Turn governor shaft (2) clockwise to the end of travel by inserting needle (3) to shaft end hole and tighten nut (1).

NOTE: The throttle lever on the dash must be in "FAST" position when adjusting the governor.

4. Lower and raise throttle lever after adjustment to be sure linkage is not binding. 3. Install governor gear cover. 5. More throttle lever (on dash) up to "FAST" 4. Place a new gasket on crankcase cover and put position. Speed control lever (C)should be in smallamount of grease around oil seal lips. wideopen throttle position [aligned hole (B) 5. Lubricatecrankshaft bearing in crankcase and (D)], but not enough to move choke link cover with engine oil. (4). If adjustment is necessary,loosen cable 6. Suitably set the gear to bemeshed with clamp bolt (A)and adjust cable. gear when installing crankcase cover. 6. Retighten clamp bolt (A). 5-3 GOVERNOR

THROTTLE CABLE INSTALLATION MAXIMUM SPEEDADJUSTMENT ANDADJUSTMENT Start engine and allow it warm. Makesure that the throttle leverand cable on 1. Align hole (B) of speed control lever (C) equipmenthave the speed control linkages with with hole (D) of control plate (E) by moving engine. the lever; insert a (6 mm) 0.24 in.dia. pin 1. Leave cable clamp bolt (A) loose. (or a 6 mm bolt) through the two holes. 2. Align hole (B) of speed control lever (C) with 2. Leave two control-plate-tightening-bolts (I) hole (D) of control plate (E) moving the lever; loose. insert a (6 mm) 0.24 in. dia. pin (or a 6 mm 3. Use a tachometerand slide control plate (E) bolt) through the two holes. left or right to obtain specified 3,350 rpm. 3. Pull up outerhousing (F) ofthrottle cable Be sure that the carb. choke valve is fully until the inner cable (G) has almost no slack, opened during adjustment. and tighten the cable clampbolt. 4. Tighten two bolts (I) securely in a manner to 4. Remove the 6 mm dia. pin. avoid changing the specified speed. Be sure that carb.choke valve (H) is closed 5. Adjustchoke perprocedure previously men- completely when throttle lever on equipment tioned. is moved to "CHOKE"position. If not,per- 6. Remove the 6 mm dia. pin or bolt. form "CHOKEADJUSTMENT,, described 7. Stop engine. below. IDLE SPEEDADJUSTMENT

CHOKEADJUSTMENT Before the following procedure, carb. adjustment must be performed. 1. Align hole (B) of speed control lever (C) with (See CARBURETORADJUSTMENT) hole (D) of control plate (E) moving the lever; Start engine and allow it warm. insert a 6 mm (0.24 in.) dia. pin (or a 6 mm 1. Move throttle leveron equipment to farest dia. bolt) through the two holes. IDLE position and leave it there. 2. Turn in choke setting screw (K) until its end 2. Turning throttle stop screw (J) in or out to just begins to touch the tongue of lever (L). obtain specified idling 1,350 to 1,450 rpm. 3. Remove the 6 mm dia. pin or bolt. 3. Stop engine. COMPRESSION 6-1 Section 6 COMPRESSION

COMPRESSIONCHECK torque and maintain positive sealing of the com- bustion chamber. Before measuring compression pressure; 1. Remove cyl. head and gasket.

Check cyl. head to torque. Be sure battery is fully *- charged onelectric starter models. Start engine and allow it to warm up. During warm up, check for leaks around cyl. head gasket. Stop engine. 1. Removespark plug andscrews compression gauge into the plug hole securely. 2. Crank engine with recoil or electric starting for several seconds and take highest pressure gauge reading. Cylinder compressionshould not be less than 3 kg/cm² (43 psi). 3. If compressionreading is too high,check for carbon built up in combustion chamber. Carbondeposits in combustion chamber should beremoved every 100 to 200 hours of. use, or whenever cyl. head is removed. 4. If thecompression pressure is less than spe- CYLINDERHEAD TIGHTENING cified, it is usually the resultof one or more of: PROCEDURE Leaking cyl. head gasket. Warped cyl. head. CAUTION: Do not use a sealer of any kind on gas- Worn piston rings. ket. Damaged piston. Worn cyl. bore. 1. Coathead bolts threads with a light filmof Burned or warpedvalves. oil and install the bolts. Improper valve clearance. 2. Tighten screws down evenly by hand. Broken valve springs. 3. Use a torquewrench and tighten head bolts To a greatextent, compression can also be in the sequence as shown, and to the specified practically measured by: torque. Cylinder Head Tightening Torque Disconnectspark plug cap to prevent engine starting during compression test. 34 to 39 N-m (25to 29 ft-lbs) Be careful not to get your fingers caught in fly- L wheel fins during test. CAUTION: Do notturn onescrew downcom- Spinflywheel counter clockwise (flywheel side) pletely before the others, as it may cause a warped against the compressionstroke; a sharp rebound cyl. head. indicatessatisfactory compression. Slight or no rebound indicatespoor compression.

CYLINDERHEAD AND HEADGASKET REMOVAL

CAUTION: Always note the position of each cyl. head screw so they may be properly reassem- bled.

A FB46OV has 3-heat-resistant high-tension studs in the exhaust valve sidearea to prevent loss of 6-2 COMPRESSION CYLINDERHEAD CHECK VALVE SPRINGINSPECTION AND REPAl R 1. Clean cyl. head. 1. Inspect valve springs for damage.Replace springs if necessary. WARNING: Be alert to fire if combustible 2. Measure the freelength of springs. If shorter cleaner is used. than specified, replace spring.

2. Check cyl. headflatness by placing cyl. head Valve Spring Free Length (MIN) on a surface plate more than at six points. Intake I 43.3 mm (1.705in.) 3. Use a thickness gauge (A) to measure the Exhaust 39.0 mm (1.535in.) space between surface plate and cyl. head.

Cyl. Head Warp (MAX) TO ANALYZEVALVE 0.4in.) mm (0.01 5 I JI Whenleaded gasoline is used, excessive lead 4. If cyl. head is warpedmore than specified, depositson the exhaust valve arecaused by replace it. exhaust gas leakagepast the valve. This in- dicates the valve is not seating properly. Clean theseating face and lap the valve into the seat. If worn severly, grind the valve and reface the seat to correct condition. CAUTION: Besure to reset valve-to-tappet clear- ance after grinding valve.

Valvestem corrosion is caused bymoisture in the engine. Moisture in the fuel-air mixture orcombustion gases cancondense inside the enginewhen the engine is stopped and cools down. 5. If cyl. head is warped less thanthe specified Valvecorrosion can also occur during storage. limit, refacethe head surface by rubbingon Fogging or pouring oil in combustion chamber emerypaper (first: No. 200,then: No.400) beforestoring helps prevent valve corrosion. placed on a surface plate. Corroded or pitted valves collect deposits 6. Check cyl. headgasket for burn andtrace of and may cause sticking valves. gas leakage. Replace gasket if necessary. Replace badly corroded or pitted valves. Poor engine cooling due to dirt or obstructions is a common cause for overheating anengine VALVEAND SPRING REMOVAL and the valves. Remove flywheel housingand clean cooling fins. 1. To remove valves using a valvespring com- Othercauses for valves running hot are worn pressor (A), put screwhead of compressor valveguides or valve springs, incorrect valve over the valve head and slip lower jaw between clearance,lean fuel-air mixture and incorrect spring (B) and retainer (C). or overheated plug. 2. Compressspring. Remove retainer by a needle Use of old or stale gasoline is a common cause nose plier. Pull out valve. Removecompres- for sticky valves. Thisgummy deposit can sor and valve spring. beseen on the valve. When thiscondition exists,the carburetor may also contain gum deposits and will require a complete cleaning. CAUTION:Always usefresh gasoline and drain fuel tank,lines and carburetor before storing equipment.

VALVE INSPECTION

1. Removecarbon from valve head,face and stem with a power-operatedwire brush. Be sure carbon is removed and not merely burnish- ed. COMPRESSION 6-3

2. Check valve faces,heads and stem for de- fects. Look for bent valve stemsand exces- sive corrosioncausing pits on valve face or stem. 3. Replace valves with a warpedhead or with less than(0.6mm) 0.02 in. margin.Valve stemends should be ground square before checking valve-to-tappet clearance.

Valve Stem Diameter (MIN)

Valve Stem Diameter

7.91 2 mm (0.31 15 in.)

If anysingle measurement is less thanMIN, WarpedHead replace the valve. Worn or Improperly Ground ValveStems No Margin

Valve Stem Bend Check VALVEGUIDE CHECK ANDREPLACEMENT (1) Support valve in V blocks at each end of the stem. 1. Usevalve guide cleaner to clean the inside of valve guides. 2. Measureinside diameter of valve guide with inside micrometer at several points.

(2)Position a dial gauge perpendicular to the stem. (3) Turn valve andread the variation ondial gauge.

Valve Stem Bend (MAX) Valve Guide Reject Size 0.03 mm (0.0012 in.) (MAX)

Valve Guide Inside Diameter If the stembend is greaterthan MAX, replace valve. Intake 8.062(0.3174 mm in.)

Valve Stem Diameter Check 8.062 mm (0.3174 in.) (1) Measure the diameter of valve stem (A) in two directions at right angles, at fourdifferent Replace valve guide if insidediameter exceeds positions on thestem. MAX. 6-4 COMPRESSION

To Replace Valve Guide (4) Turning the remover bolt,drive new valve guide into the hole to proper depth. To Remove Valve Guide:

(1) Use a valve guide remover (A) to replace valve Valve Guide Depth h guide. (2) Fix valve guide remover on cylinder with bolts 30 mm (1.18 in.) and nuts. Exhaust 30 mmin.) (1.18 (3) Put a coat of engine oil to the remover bolt threadsand screw it in until the threads can be seen at valve guide lower end. (4) Install thrust washer (B) and nut (C) (left hand thread) to the remover bolt.

Draw out

(5) Use stanisol or kelosen lubricant to finish reaming by a valve guide reamer. (6) Turn to finish specified reamer (A) clockwise. (7) Throughly clean valve area before reassembling engine.

(5) Turn out the boltto remove valve guide bushing until it is completely removed from the guide.

To Install Valve Guide: (1) Use a valve guide remover to install valve guide. (2) Apply a coat of engine oil tothe outer surface of valve guide (A). (3) Install thrust washer (B) andnew valve guide (A) to the remover bolt and retain them with nut (C) as shown.

Draw in

VALVE SEAT RECONDITIONING

1. Inspect valve seats for damage. If seats are warped or distorted by beyond recondition- ing, replace cyl. block. Pitted or worn valve seats can be refaced. Lap valves to seats after refacing. 2. Torepair the seats; first use 45" cutter (A) then 30" to obtain standard valve seat width and 45" again to finish. Check the seat for good contact all the way around with machinist's dye. 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. Otherwisepeen over edge around entire in- sert.

Valve Lapping (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. Valve Seat Width STD (3) Use vacuum cup tool (A), to grip top of valve. I Valve Seat Width Rotate valve in a circular motion to lap to I I seat. Intake 1.0 to 1.6 mm (0.039to 0.063 in.) (4) Lift valve from seat every 8 to 10sstrokes, continuelapping operation until an uniform Exhaust 1.0 to 1.6 mm (0.039to 0.063 in.) ring appears aroundthe entire surface of valve face.

: Valve Sealing Width. See Table. : Valve Seat Angle. In.: 45°/ Ex.: 45" : ValveFace Angle. In.: 45°/ Ex.: 45° : ValveMargin. 0.6mm (0.02in.) MIN. (5)When lapping is completed,wash all theparts : Valve Narrowing Angle. In.: 30°/ Ex.: 30° in solvent to removelapping compound. Dry parts thoroughly. (6) Note position of lapping mark on valve face. 3. Follow "Valve Lapping"procedure to keepThe lappingmark should appear on or near the seat contact with the middle point of thecenter of the valve face. valve facevalve (as shown). (7) Check valve clearancelapping. after 6-6 COMPRESSION

TAPPET CLEARANCE CHECK 4. Install all parts related to valve repair. AND REPAIR Reassembly is the reverse of removal.

Since valve repairs change tappet clearance (valve- CAUTION: After installing valves andsprings, to-tappet), checkthe clearances (intake andex- checkretainers are positionedCorrectly. DO haustsides). Make Sure to do this whenengine not Use molybdenumdissulfied when installing is cold. valve in cyl. block. 1. Insert valves in their respective positions in cyl. block. 2. Turn crankshaft until piston is at highest position in compressionstroke. Then insert a thickness gauge (A) between valve stemsend and tappet to check tappet clearance.

Specified TappetClearance (Cold)

Tappet Clearance

3. If the clearance is less thanspecified, grind the end of valve stem to obtain the specified tappet clearance.

To Grind Valve Stem End: Place valve in valve lappingguide (A) andslide the stem end over oil stone back and forth. LUBRICATION 7-1 Section 7 LUBRICATION

LUBRICATION

Oil has four purposes. It cools,cleans, seals and lubricates. A pressurized lubrication systemused on the FB460V engine pressure-lubricates the crank pin, PTO main journal and balancer link.

TheFB46OV utilizes a camshaftdriven trochoid I I pump to pressurize the lubrication system. Oil is first drawnthrough a filtering screen (1) then the inlet (2) and into the pump chamber (3). Oil pressure is adjusted by a relief valve (8) to a value Oil pressure sensor of above (3 kg/cm² ) 42.6 psi at 3,000 rpm (Rated speed).The oil is then pumped to the PTO main journal (4)into crankshaft and lubricatesthe lower link rod (5),crank pin (6) andupper link FULL FLOW OILFILTER (Optional) rod journal (7). A portion of oil at the crank pin is passed through a metered orifice in the connect- TheFB46OV can accept an optional car- ing rod and is sprayed on the piston to cool the tridge type full flow oil filter (A) which can piston andprevent ringsticking. The return oil extend oil change intervals to as mush as 50 mists then lubricates the side ball bearing hours. (STD intervals: 25 hours) and others.

OILWARNING SYSTEM (Electric Starter Model only) CAPACIT IES Triggered bythe sensor (A), a warning light comes on whenpressure fallsbelow (0.3 Crankcase kg/cm² ) 4.26 psi lubrication problem. 1.4 (2.96 Pt US) (See ELECTRICAL SYSTEM) 7-2 LUBRICATION OILRECOMMENDATION BREATHER CHECK

Use a high quality detergentengine oil classified It is the breather's function to maintain a vacuum "API Service SF, SE/CC, SE, or SD". Detergent in the crankcase.The breather has a reed valve, engine oils keep the engine cleaner and delay the which limits the direction of air flow caused by formation of gumand vernish deposits. Nothing the piston movement of up and down. Air can should be added to the recommended oil. flow out ofthe crankcase, but the "one way valve" blocks the return flow, thus maintaining a vacuum Recommended SAE Viscosity Grades in the crankcase. I A partial vacuum must be maintained in the crank- Below Above Temperature case to prevent oil from beingforced outof 0°C (32°F) 0°C (32°F) I I I I engine, at the piston rings, oil seals and gaskets. Viscosity SAE 5W-20 SAE 30 The FB460V uses the combination of a reed valve and four expansionchambers (1 4) crankcase breather. Oil ladenair in the crankcasepasses through a maze by the reed valve and expansion OIL LEVEL CHECK chamberswhere the oil is separated from the air and drained back to the crankcase.The breather is vented through the air cleaner, to prevent dirt 1. Put engine on a level surface. from entering the crankcase. 2. Remove dipstick;wipe dipstick with a clean rag; insert dipstick into filler tube. 3. Let dipstick cap (A) threadsrest on topof the tube. Do not screw dipstick in. 4. Remove dipstick to check oil level. Add if necessary. DO NOT overfill. 5. Install and tighten dipstick. 6. Check oil level and add regularly before operat- ing equipment.

1. Inspect reed valve for stuck and binding. Full level 2. Inspectreed valve seating surface. They must not have any nicks or burrs. 3. Inspectreed valve for hair crack, distortion and broken.

OILCHANGE

Change oil after first 5 hours of operation. There- after 25 hours of operation;more often under dirty operating conditions. 1. Put engine on a level surface. 2. Remove oil drain plug,and drain oil while engine is warm. 3. Install drainplug. 4. .Remove dipstick and refill with new oil up to no higher than "Full" mark on dipstick. (See OI L LEVEL CHECK) 4. Check to besure venttube is not damaged 5. Install dipstick. and sealed properly. LUBRICATION 7-3 OIL PUMPINSPECTION

1. Removecrankcase cover from crankcase. (See Section 9 : Crankshaft Removal) 2. Measurecamshaft bearing on oil pump cover (A) with an insidemicrometer (B). The bearing is cast with oil pump cover and is not replaceable.

t

OIL PUMP INSTALLATION

1. Install inner and outer rotors together. 2. Install oil screen. 3. Put relief-valve ball on valve seat. 4. Install oil pump cover with relief valve spring Bearing Inside Diameter(MAX) and tighten cap screws to specified torque. 20.071 mm (0.7902 in.) I Pump Cover Tightening Torque

Replace pump cover, if insidediameter ex- 17 to 23 N-m (12 to 17 ft-lbs) ceeds MAX. ___-- After installation,the oil pumpshould rotate Remove oil pump coverand inspect oil screen 3. freely in the housing. for broken mesh. Replace it, if necessary. 4. Inspect relief ball valve seating, they must not 5. Install crankcase cover on block. have any nicks or burrs. (See Section 9 : Crankcase Cover Installation) 5. Measure free length of ball valve spring.

Free Length of Spring (MIN)

19.5 mm (0.768 in.) .______- I Replace spring if free length is less than MIN.

6. Inspectinner and outer oil pump rotors. Re- place rotors if wear or damage is excessive. NOTE: Do not unscrew bolts (1) whichtighten relief valve cover (2) and oil induction guide plate (3). These bolts are applied locking bond. 8-1 PISTON,PISTON RING, AND CON-ROD Section 8 PISTON, PISTON RING, AND CON-ROD

PISTON ANDCON-ROD REMOVAL To AnalyzePiston Ring Wear: (1) Rings of thewrong size or ringshaving im- 1. Removeany carbon or ridge at the topof proper end gap will not conform to the shape cyl. bore; this will helpprevent piston rings of cylinder. This results in high oil consump- from breaking. tion and excessive blow-by. 2. To remove piston and con-rod from engine, Ringend gaps should be staggered on piston rotate crankshaft (A) to expose con-rod bolts during installation. End gaps in alignment can (B)as shown. cause oil consumption and blow-by. 3. Remove rod bolts and con-rod cap. Light scuffing or scoring ofboth ringsand 4. Push piston and con-rod out through the top piston occurswhen unusually high friction of cylinder. and combustiontemperatures approach the melting pointof piston material.Probable causes of this condition one: Dirty cooling shroud and cyl. head. Lack of cylinder lubrication. Improper combustion. Wrong bearing or piston clearance. Toomuch oilin crankcasecausing fluid friction.

(2) An engineoperating at abnormally high tem- peratures may cause varnish, lacquer or carbon deposits to form in the piston grooves making the rings stick. When this happens, excessive oil consumption and blow-by will occur. Engineoverheating and ring sticking is usual- ly caused by one or more of: To Remove Piston From Con-Rod: Overloading. Incorrect ignition timing. (1) Remove piston pin snaprings with thin nose Lean fuel mixture. pliers and slideout piston pin. Dirty cooling fins. Incorrect oil. CAUTION: Do not reuse snap rings once removed. Low oil supply. Removal weakens and deforms the rings. Stale fuel.

(2) Remove piston rings one at a time, by slipping (3) Verticalscratches across piston ringsare due them over (A) ring lands.Use a ring expander to anabrasive in engine.Abrasives may be (A) toprevent damage to rings and piston. airborne, may have been left in engine during overhaul or maybe loose lead and carbon deposits. When this exists, check for one or more of: Damaged,collapsed or improperlyinstalled air cleaner. Loose connection or damaged gasket between air cleaner and carb. and cleaner air /- Air leak around carburetor-to-cyl. block gas- ket. Air leakage around throttle shaft. Failure to properly clean cyl. bore after reconditioning engine. Scratchesacross oil side rails (A) aredue to abrasive in engine oil. PISTON,PISTON RING, ANDCON-ROD 8-2 In this condition andmuch use, compression 4. Visuallyinspect rings andgrooves for uneven rings (B) will also be worn. wear or damage. Replace them if uneven wear Oil inner spacerwear (C)and distorsion may or damage are excessive. cause increase oil up by pumping action of oil ring. This results in high oil consumption, in- 5. Measure piston ring groove width. Use a creased deposit in combustion chamberand verniercaliper at several points aroundthe stick of rings. piston.

ring

Piston Ring GrooveWidth (MAX) Ring Groove Width I PISTONINSPECTION Top I 2.120 rnm (0.0835 in.) I 2.095 mm (0.0825 in.) No need to proceed with the stepsshown if cyl- --_-4.055 rnm (0.1596 in.) inder is to beresigned or visual inspection of piston showswear or scoring which require replacing - If the widthof any of the grooves is wider piston. than MAX at any point, replace piston. 1. Remove all deposits from piston. 6. Inspect piston for scoringorfractures at 2. Cleancarbon from pistonring grooves with a ring lands. ring groove cleaner.

CAUTION: Do not use a caustic cleaning solution or a wire brush to clean piston. PISTON RING THICKNESS INSPECTION 3. Be sure oil return passages in ring groovesare open. Use a micrometer to measure piston ring thickness at several points around rings. CAUTION: Neverclean piston head with engine assembled.Carbon particles willfall between piston and cylinder, and may cause severe seizure.

Piston Ring Thickness(MIN) 1.945 mm (0.0766 in.) 1.941 mm (0.0764 in.) 8-3 PISTON,PISTON RING, AND CON-ROD

NOTE: Difficult to exactly measure oil ring thick- Piston Pin Dia. (MIN) ness.Replace oil ring together with compression 20.978 mm (0.8259 in.) rings. I 1. Measureinside diameter of piston pin hole in piston with an inside micrometer at several PISTON RING END GAP INSPECTION points. 2. If insidediameter exceeds MAX, replacepis- 1. Insert each ring in cyl. boreand check end ton. gap. 2. Install ringsquarely in thebore to a point approx.(25mm) 1 in. down from the top of cylinder.

NOTE: Use piston to push it in to be sure it is square.

3. Check ring end gap with feeler gauge (A).

Piston Pin Hole Dia.(MAX) 21.028 mm (0.8279 in.) I To Analyze Piston Wear: Detonation cancause extensive an damage to piston, cyl. head,gasket or others.Deto- nation is abnormalcombustion causing ex- cessive temperatureand pressure in the com- End Gap (MAX) bustionchamber. Commonly called carbon 0.7 mm (0.028 in.) knock, spark knock or timing knock,deto- 0.7 mm (0.028 in.) nation occurs as the compressed fuel-air mixture ignitesspontaneously to interrupt the normal ignition. 4. If the end gap of any ring is greater than MAX, replace the entire set of rings. Following is a list of possiblecause for deto- nation: Lean fuel mixture. PISTON PIN AND PIN HOLE DIA. Low octane fuel. INSPECTION Advanced ignition timing. Engine lugging. Measure outsidediameter of piston pin (A) Build-up of carbon deposits on piston or cyl. with a micrometer at several points. head. If piston pin diameter is msallerthan MIN, Wrong cyl. head or milling of head increasing replace piston pin. compression ratio. Poor cooling. Pre-ignition is the ignitionof the fuel-air mixtureprior to regular ignition spark.Pre- ignition causes internal shock,resulting in pings, vibration, detonation andpower loss. .Severedamage to piston,rings and valves results from pre-ignition. Check following forcauses of pre-ignition: Internal carbon deposits. Incorrect spark plug. Broken ceramic in spark plug. Sharp edges on combustion chamber. Poor cooling. PISTON,PISTON RING, AND CON-ROD 8-4

Check con-rod and piston alignmentwhen piston shows a diagonal wear pattern extend- ing across the skirt of piston.Contact with the cyl. wall on bottomof skirt at left(or right) and ring lands on right (or left). A cylinder bored at anangle to crankshaft canalso cause improperring contact with cylinder. This condition causes: Rapid piston wear. Uneven piston wear. Excessive oil consumption.

CON-ROD INSPECTION

1. Cleanand inspect bearing surface on con-rod and cap. Replace parts if scored. 2. Measureinside diameter of the smallend of con-rod at several points by a telescoping gauge.

Big End Inside Dia.(MAX) 37.066 mm (1.4593 in.)

6. If insidediameter exceeds MAX, replacecon- rod.

NOTE: A bent or twisted con-rod must be re- placed.

Small End Inside Dia. (MAX) I 21.039 mm (0.8283 in.) To Analyze Con-RodWear: Check con-rod andcap for damageor unusual 3. If insidediameter is greater than specified, wear patterns. replace con-rod. Lack of lubrication orimproper lubrication 4. Place con-rod capover con-rod big end to cancause con-rod andcap to seize to crank- align pilot grooves (A) on the capand rod. shaft. Screwcap bolts and tighten bolts to the When rod and cap seize to crankshaft, the con- specified torque shown. rod and piston may both breakcausing other internal damage.Inspect theblock carefully Rod Cap Tightening Torque before rebuildingengine.

--I-- Con-rod and crankshaft damagecan result 19 to 20 N-m----_____ (14 to 15 ft-lbs) from: Engine run low on oil or without oil. Oil pump broken ordamage. 5. Measure theinside diameter of big end at Oil hole in con-rod plugged. several points by a telescoping gauge or inside Oil not changed regularly. micrometer. Bearing cap installed incorrectly. 8-5 PISTON,PISTON RING, AND CON-ROD

PISTON ANDCON-ROD ASSEMBLY TOP (chrom plated) 1. Aligning match mark " " on the piston head with "MADE IN JAPAN"on the con-rod, Second install piston over con-rod. 2. Coat piston pin with a light film of oil. Insert Oil pin through piston and con-rod. (three piece) 3. Install retainingrings in eachend of piston pin bore.Rings should be seated firmlyin Marking (R) facing UP retainer grooves in piston.

CAUTION: Do not reuse the ringswhich was removed.Removal weakens, deforms the rings 30' to 45' and could fall outand score the cyl. wall. 2nd and lower side

Top and upper side rail and gap

Position Ring End Gaps

PISTON AND CON-ROD ASSY INSTALLATION PISTON RINGINSTALLATION 1. TO INSTALL RINGS TO PISTON: Place ring compressor (B) over piston with 1. Be sure oil return holes are clean and carbon the projections (A) oncompressor toward is removed from all grooves. the top of piston. 2. Use a ring expander to install rings as illust- Pushcompressor down until it is flush with rated. the topof piston. Tightencompressor with a wrench (C), then loosen slightly.

3. Make sure rings are installedas shown. 4. Install top andsecond rings with the mark- ingsfacing up. (Oil ring steel rails have no "TOP" or "Bottom".) After installation, 2. Coat the inside of cyl. bore with a light film rings should rotate freely in the grooves. of oil. 5. Space top andsecond ring endgaps 180 de- 3. Align arrow mark (A) on piston head towards grees apart. flywheel endand install con-rod and piston 6. Spaceside rail andgaps 180° degrees a part ass'y through the top of cyl. bore.Push pis- respectively. See I Ilust. ton intocyl. bore with a hammer handle. PISTON,PISTON RING, ANDCON-ROD 8-6

4. Turn crankshaftgently and place crankpin in lowestposition. Then further insert piston into cylinderwhile leadingbig end bearing surface to placeabove crankpin. Turn cyl. block upside down onbench. 5. Coat theinside of big endbearing 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.

Con-Rod Bolt Tightening Torque r 19 to 20 N-m (14 to 15 ft-lbs)

CAUTION: Tighten rod screwssecurely. After tightening rod screws, con-rod should be able to movesideway on crankpin of shaft. A torque wrenchmust be used to preventloose or over- tight cap screws which may result in breakage and/ or scoringof rod. 9-1 CRANKSHAFTAND CAMSHAFT Section 9 CRANKSHAFT AND CAMSHAFT

CRANKSHAFTAND CAMSHAFT REMOVAL

1. To removecrankshaft from cyl.block, re- move rust or burrs from power take-off shaft end of crankshaft. 2. Lightly tappingthe both endsnear dowel alternately with a soft mallet,remove crank- case cover. 3. Turn cyl. block upside down on a bench. 4. Rotatecrankshaft until timing marks on crankshaft gear and cam gear align. 5. Pull out thecamshaft, then remove tappets. PTO Main Journal Dia. (MIN) NOTE: Align timing marks to prevent damage to tappets when removing camshaft. Mark tappets mm (1.3746 so they can be installed in their original guides during assembly. Mag. Side Journal Dia. (MIN)

6. Remove con-rod and piston. 34.945 mm (1.3757 in.) (See Section 8) Rotatecrankshaft gently until thecrank pin 7. If journal diameter is less thanMIN, replace positioned oppositeside of cylinder bore. crankshaft. 8. Removebalancer guide. 9. Remove crankshaft. 3. Measure con-rod big-end journal (A) at several point with a micrometer.

Con-Rod Big-End Journal Dia.(MIN)

36.934 mm (1.4541 in.)

CRANKSHAFTINSPECTION If journal diameter is less than MIN, replacecrank- shaft. 1. and inspect bearing surfaces On crank- 4. Measure crankshaft linkrod journals at several shaft for scored.Inspect crankshaft gear(s) points with a dial-caliper. for cracked,scored or brokenteeth. Re- place parts if necessary. LinkJournal Rod Dia. (MIN) 2. With a micrometer, measure both main journals 53.951 mm (2.12406 in.) at several points around journal circumference. CRANKSHAFTAND CAMSHAFT 9-2 If journalsdiameter is less thanMIN, replace 3.A-Surface must be concentric andparallel to crankshaft. each other within 0.005mm (0.0002 in.) full indicator reading. 5. TO CHECK CRANKSHAFT ALIGNMENT: Place crankshaft into an alignment jig, rotate NOTE: Finish should be very smooth; use a super crankshaftslowly, andmeasure total indicat- finishing stone. ed runout at locations shown.

Dial indicator \ LINKROD INSPECTION

1. Cleanand inspect bearing surfaces on link rod. If the bearingsurface of smallend is scored or damaged,replace the rod.Scored or damaged big endbearing (bushing) must be replaced witha new bushing. Turn crankshaft slowly 2. With a micrometer, measure both insidebear- ing surfaces at several points. Run Out (TIR) (MAX) 0.05 mm (0.002 in.)

If total run out exceeds MAX, replace crankshaft. e Crankshaft damagecan result from: Engine runs with low oil or without oil. Oil dipper broken or damaged. Oil hole in con-rod plugged. Oil not changed regularly. Bearing cap installed incorrectly.

UNDER-SIZECON-ROD

1. Con-rodjournal canaccept anunder-size Small End Inside Dia. (MAX) con-rod having36.5 mm (1.437 in.) dia. Re- 12.059 mm (0.4748 in.) grinding is requiredbefore usingthe under- size. 2. The final finishingdiameter should be 36.48 If theinside diameter exceeds MAX, replace to 36.467 mm (1.4362 to 1.4357 in.). the link rod. Big End (bushing) Inside Dia.(MAX) c r 54.121 mm (2.13074 in.) I- If theinside diameter is greater thanMAX, replace bushing.

R B BUSHINGREPLACEMENT

1. Place link rod on a bench plate (4) with radial oil-groove side up. Under size dimentional spec. 2. With a bearing driver (1), drive out bushing (2) as shown. D= 36.480 to 36.467 mm (1.4362 to 1.4357 in.) R= 2.30 to 2.70 mm (0.09to 0.1 1 in.) NOTE: Do not forgetthe direction of seam of B= 32.3 mm MAX (1.272 in. MAX) the shell to reinstall new one. 9-3 CRANKSHAFTAND CAMSHAFT BALANCER GUIDE -INSPECTION

1. Cleanand inspect bearing surface on theshaft for worn or damage, replace it if necessary. 2. Measurebearing surface diameter at several point, using a micrometer.

1. Bearing driver 3. Link rod 2. Big end bushing 4. Benchplate

3. Clean theparts in solvent throughly and dry them. Put a light coat of oil on a new bushing. 4. Re-installthe bushing using an arbor press or bearing driver. 5. Press-in thebushing 0.5 mm (0.02 in.)below flange surface (3). Support Shaft Dia. (MIN) I 25.927 mm (1.0208 in.) I

BALANCEWEIGHT INSPECTION If shaftdiameter is less thanMIN, replace support shaft.

1. Cleanand inspect bearing surface of bushing for worn or damage.Replace it, if necessary. CAMSHAFTINSPECTION 2. Wristpins (A) arepress fit on weight (B) strongly, and normally require no mainte- 1. Inspect camshaft for worn or broken teeth. nance. 2. Measure with a micrometer,camshaft bearing 3. With a inside micrometer or telescoping gauge, surfaces and camlobesat point shown. measure bearing surfaceof bushing (C). 3. Replace camshaft if worn or damaged.

Bushing Inside Dia. (MAX)

26.097 mm (1.02744 in.)

If insidediameter exceeds the MAX replace bushing. Bushing can be replaced as the same procedure as that of link rod bushing.

NOTE: Align oil hole on bushing and oil passage on weight, when installing service bushing. CRANKSHAFTAND CAMSHAFT 9-4 Bearing Surface Dia. (MIN) 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.

If bearingsurface diameter is less thanMIN, 2. Cover key wayon flywheel end of crankshaft replace camshaft. with a tape to prevent seal damagewhen installing crankshaft. 3. Put a light film of oil oncrankshaft bearing Lobe Height (MIN) surfaces. 4. Pack preferablyhigh temperature grease into oilseals. 5. Put crankpin at bottom dead center of engine. If lobe height is less than MIN for either lobe, Install crankshaft carefully. replace camshaft. 6. Align centerhole of balance weight and support shaft holein crankcase. 7. Install support shaft, O-ring and nuts. 8. Install con-rod and piston assembly. (See Section 8) 9. Install tappets in their respectiveguides from CRANKSHAFTAND CAMSHAFT which they were removed. INSTALLATION NOTE: Push tappets all the way in to valve guides to prevent damage to tappetswhen installing 1. Assemblecrankshaft, link rods,collares, gear camshaft. and balance weight as illustrated below. Install governorshaft and snap pin by properly positioning the shaft, pin and projection-stopper as illustrated. 16 17 18 I

7

8

1. Crankshaft 10. Washer 2. Crankcase 11. Support shaft 3. Oil seal 12. Stud 4. Ballbearing 13. Bushing 1. Case cover mounting face 5. Collar 14. Wrist pin 2. Crankcase 6. Balance weight 15. Link rod 3. Snap pin 7. Oi hole 16. Crankgear 4. Governor shaft 8. O-ring 17. Collar 5. Stopper (projection) 9. Nut 18. Bushing 6. Governor shaft in crankcase 9-5 CRANKSHAFTAND CAMSHAFT

Rotatecrankshaft until piston is positioned at CrankcaseCover TighteningTorque top deadcenter. Install camshaft with (A) aligned with mark (B) on crankshaft 17 to 23 N-m (12 to 17 ft-lbs) gear.

CRANKSHAFTEND PLAY

1. Measure crankshaftend play with a dial in- dicator. 2. Install dial indicator (A) oncrankshaft as shown.Move crankshaft in and out. End play mustbe 0.09 to 0.20 mm(0.035 to 0.0078 in.).

CRANKCASE COVER INSTALLATION

1. Cleangasket surface and put a newgasket on crankcase cover. 2. Pack preferablyhigh temperature grease into oil seal. 3. Lubricatecrankshaft bearing in case cover with engine oil. 4. Check governor weights closed.

NOTE:To make the installation easier,align oil pump shaft convexwith camshaft end groove.

5. Be sure to suitably set governorgear to be meshed with camgear when installing crank- case cover. CRANKSHAFTEND PLAY 6. Install crankcasecover and tighten capscrews ADJUSTMENT down evenly by hand. Use a torque wrench and tighten screws in the 1. The end play should be 0.09 to 0.2 mm (0.0035 squenceshown, and to thespecified torque. to 0.0078in.) with the 0.5mm (0.02 in.) Do not turn onescrew downcompletely be- gasketplaced in-between crankcase cover and fore theothers, as it maycause a warped crankcase. crankcase cover. 2. Check end play and adjust if necessary. 3. Measure3. depth (a); from crankcasecover mounting surface to PTO shaft bearing end as shown. 4.Measure depth (b);from crankgear end to crankcase gasket surface as shown. 5.Calculate (a-b), and select appropriately sized shim(s) from "AdjustingShim Table" to correctly adjust end play. 6. Insert the shim(s) to PTO shaftand install crankcase cover. 7. Shim sizes (thickness) are provided in the range of 1.74 mm (0.0685 in.) to 1.18 mm (0.0464 in.) in 0.07mm (0.0027 in.) increments as shown. CRANKSHAFTAND CAMSHAFT 9-6

G asket Crankshaft Gasket

Crankcase

bearing

Crankcase cover

Adjustment Shim Difference in depth : A-0 of Shim 1.92 to 1.99 mm 1.74mm 92025-2153 -___-_-(0.0755 to 0.0748 in.) (0.0685 in.) 1.85 to 1.92 mm 1.67 mm 92025-2152 (0.0728 to 0.0755 in.) (0.0657 in.) 1.78 to 1.85 mm 92025-2151 1.60 mm (0.0700 to 0.0728 in.) (0.0629 in.) 1.71 to 1.78 mm 1.53mm 92025-2 150 (0.0673 to 0.0700 in.) (0.0602 in.) 1.64 to 1.7 mm 1.46 mm 92025-2149 (0.0645 to 0.0673 in.) (0.0574 in.) 1.57 to 1.64 mm 1.39 mm 92025-2 148 (0.0618 to 0.0645 in.) (0.0547 in.) 1.50 to 1.57 mm 1.32 mm 92025-2 147 (0.0590 to 0.0618 in.) (0.0519 in.) 1.43 to 1.50 mm 1.25 mm 92025-2 146 (0.0562 to 0.0590 in.) (0.0492 in.) 1.36 to 1.43 mm 1.18 mm 92025-2145 (0.0535 to 0.0562 in.) (0.0464 in.) 10-1 CYLINDER BLOCKAND BEARING Section 10 CYLINDER BLOCK AND BEARING

CYLINDER BLOCK INSPECTION Resize cyl. bore canbe done by an autho- AND REPAl R rized repair shop or by using a drill press and honing tool. Use a stone recommended by the Visuallyinspect cyl. block, wheneverengine is honemanufacturer to produce the correct disassembled, to see if there are any cracks, strip- cyl. wall finish. ped bolt holes, broken fins, or cyl. wall is scored. 1. MACHINETHE BORE first according to Usean inside micrometer, or telescoping gauge the allowance table below. and micrometer to determine the size of cyl. bore.Measure parallel with crankshaft and at Bore Dia. right angles to crankshaft at top,center and 89.23 to 89.21 mm bottom of ring travel. 0.25 mm (3.5130 to 3.5122 in.) If cyl. bore is morethan the weartolerance 89.48 to 89.46 mm and/or the out of round, it must be resized. 0.50 mm (3.5228 to 3.5220 in.) 89.73 to 89.71 mm (3.5327 to 3.5319 in.)

2. TO FINISH THEBORE: Select anduse a suitablestone (normally driven by a drill press) CAUTION: Allow for a shrinkage (from the final size) of 0.006 to 0.008mm (0.00024 to 0.00031 in.) which will occur when engine cools down.

Final Bore Size Dia.SizeBoreFinal I 89.250 to 89.230 mm 0.25 mm (3.51378to 3.51299 in.) Cylinder Bore Wear Tolerance (MAX) 89.500 to 89.480 mm (3.52362 to 3.52283 in.) 0.076 mm (0.003 in.) 89.750 to 89.730 mm 0.75 mm (3.53346 to 3.53268 in.)

Out of Round Cylinder Bore(MAX) (1) Clean cylinder at top and bottom to remove 0.063 mm (0.0025 in.) burrs and pieces of base and head gasket. I I (2) Anchor cyl. block on drill press tablebefore honing. (3)Align center of the cyl. bore todrill press Standard BoreSize Dia. center. Set the press to operate from 200 to MAX MIN 250 rpm. (4) Connect drive shaft to hone and set stop on 89.000 mm 88.980 mm (3.5039 in.) (3.5031 in.) drill press so hone can only extend 20 to 25 mm (3/4 to 1 in.) from the top or bottom of cylinder. TO RESIZE Bore to Next Oversize: (5) Rotateadjusting nut(knob) on hone with Always resize to exactly0.25mm (0.010 in.) finger or small screw driver until stones contact or 0.50mm(0.02 in.) or 0.75mm (0.03 in.) over snuglyagainst cyl. wall at narrowest point. standard size as shown in table. DO NOT FORCE. If this is done accurately, the stock oversize rings (6) Turn stone by hand. If youcannot turn it, and pistons will fit perfectly and proper clearances hone is too tight, Loosenhone until it can will be maintained. be turned by hand. CYLINDER BLOCKAND BEARING 10-2

CAUTION: Be sure cylinder and hone are centered and alignedwith drive shaft and drill spindle.

(7) Coat inside of cylinder with honing oil. Start drill press.Move hone up and down in cyl- inder spprox. 20 cycles-per-minute. (8) Checkdiameter of cylinder regularlyduring honing, using an inside micrometer.

Stop drill press before measur- ing, and remove honefrom cylinder.

CAUTION: Finish should have a 40 to 60 degree Bearingdriver Ball bearing Crankcase cover cross-hatch pattern. Do not use solvent or gasoline.

(9) Clean cylinder thoroughly. Usesoap, warm waterand clean rags. Clean cyl. wall for a BALLBEARING INSPECTION "white glove"inspection. A clean white rag should not show soil from the cyl. wall. 1. Cleanbearing in highflash point solvent (10)Dry cylinder and coat with engine oil. throughly and dry it. 2. Spinbearing by handand check for play. Replacebearing if it is noisy,or does not smoothly spin, or has excessive play.

AXIAL RADIAL

PLAINBEARING INSPECTION

The camshaft bearings and PTO journal bearing are cast with the cyl. block and covers. CAUTION: Cylinder must be thoroughly cleaned Cylinder block andcovers should be replaced after honingto eliminate all grit. if scored or worn.

1. Measurecamshaft bearing on block with an inside micrometeror telescoping gauge.

BALLBEARING REMOVING

Ball bearingsare press-fit into crankcaseand case cover. 1. Remove oil seals on crankcase. Oil seal should not be reused once removed. 2. Place crankcase on a bench with oil seal side UP. 3. Using a bearingdriver, drive out bearings as shown. 10-3 CYLINDER BLOCKAND BEARING

Camshaft Bearing Inside Dia.(MAX)

16.068 mm (0.6326 in.)

Replace cyl.block, if insidediameter exceeds MAX.

2. MeasurePTO and camshaft bearings on covers with an inside micrometer or telescopinggauge.

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

Replacecrankcase cover or oil pump cover, if inside diameter exceeds MAX.

BALLBEARING INSTALLATION

1. Clean cylinder/crankcaseand the cover in highflash point solvent throughly and dry. 2. Put a light coat of oil on bearing surface. 3. Press-fit ball bearing into cyIinder/crankcase and the cover with an arbor or bearing driver.

OIL SEAL REPLACEMENT (PTO SIDE)

1. Remove oldoil seals bytapping them out with a screw-driver or punch from the inside. 2. Pack preferablyhigh temperature grease into a new oil seal. 3. Press-in oil seal with sharpedge ofoil seal lip towardinside of engine. (Dust seal lip outside.) 4. For flywheel side,press-in oil seal to be flush with housing. 5. For PTO side, press-in oil seal 0.5 mm (0.02 in.) below outside end mostface of PTO bearing. ELECTRICSTARTER AND CHARGE 11-1 Section 11 ELECTRIC STARTER AND CHARGE

STARTERMOTOR CIRCUIT STARTER STARTER SOLENOID MOTOR Thestarter motorcircuit includesthe engine switch, starter solenoid, battery and starter motor. When the engine switch is turned to (START) position (See WiringDiagram), a smallamount of currentflows through the switch and the solenoid.This current magnetizes thesolenoid core, whichthen pull theplunger to it, closing IGNITION solenoid contacts complete a circuit for the start- SWITCH er motor, and the starter armature rotates. At the same time plunger pull the shift lever end. The pinion linkaged to the other end of the lever slides on the armature shaft, engaging the pinion with flywheelring gear.Asengine fires and speedup, starterarmature is overrun,causing pinion to disengage.The key switch is returned STARTERSYSTEM CHECK to "I" (ON) position, cutting off thecranking system. If a startingproblem occurs,check engine thor- Starter motors used on FB46OV are a Bendix type oughly to besure engine is not the cause of the and shift lever type. problem. It is a goodpractice to removespark plug and rotate crankshaft by hand, to besure CAUTION: Because of a large amount of current, it rotatesfreely. Any , clutch orother load never hold engine switch in START position if of this nature will affect cranking performance. starter motor will not turn over, or current may The Trouble Shooting (1-17) tableshould aid burn out starter motor windings. you in diagnosing problems.

Wiring Diagram Bendix-Type (FB460V-AS Model) Shift Lever-Type (FB46OV-BS Model)

ENGINE

AV 20 11-2ELECTRIC STARTER AND CHARGE A shorted,open, or groundedarmature or STARTERMOTOR CHECK field coil. A defective starter motor switch. A performance test of starter motor can be made in the following manner. Needed for the test are: A tachometer capable of reading 20,000 rpm. A 12V 32Ah (or more) battery. An ammeter capable of reading 200 amperes. STARTERSOLENOID TEST WARNING: Battery electrolyte is poisonous andcorrosive. It is injurious to eyes, skinand Use the same procedure for starter relay test for clothing. Handle it carefully. If electrolyte is spill- the Bendix starter and shift lever starter. ed, flush immediately with a solution of one part baking soda to four parts water. 1. Disconnect lead (A) tostarter motor as shown.

1.Connect starter motor, battery andammeter as shown in illust.

A I

(Wiring diagram for performance test) 2. Measure the continuityof solenoidwhen Starter motor should not beloaded. The activated. test shouldbe quickly conducted, as the 3. Set a multimeter selectorswitch to rating is 30 seconds. position andconnect leads across the large terminals. 2. Inserttachometer in the end of starter motor and activate startermotor. A starter motor in good condition will be within the follow- ing spec.

Bendix Type (FB460V-AS Model)

Terminalvoltage 12 v Startermotor rpm 7,000 rpm (MIN) Currentdraw (A) 60 A (MAX)

Shift Lever Type (FB46OV-BS Model)

Terminalvoltage 11.5 V Starter motor rpm 6,000 rpm (MIN) Currentdraw (A) 50 A (MAX) 4. Turn engineswitch to START andread the meter. If not, check for the following and correct If solenoid does not click or if the meter reads if necessary: morethan continuity, solenoid is faulty. A binding or seizing condition in the starter Replace it. motor bearings. If solenoidmakes a single clicking sound, 'Starter motor brushes sticking in brush hold- the meterread continuity, and pinion gear ers. moves outward (shift leversolenoid only), A dirty or wornarmature commutator or solenoidand the rest of the starter circuit brushes. are good. ELECTRICSTARTER AND CHARGE 11-3 If solenoid clicks once but the meterdoes STARTERMOTOR DISASSEMBLY not read continuity, solenoid is faulty. Re- place it. (Bendix Type) If solenoiddoes not click at all, proceed with following. 5. Disconnectlead (BW) and set multimeter to position and connect leads as shown.

2

If the meter does not read close to continuity, solenoid is faulty. Replace it. If the meterreads close to continuity, sole- noid may be good. Check the voltage to sole- noidfrom engine switch. Set multimeter selectorswitch to 25VDC position and connect it as shown.

Name Parts Name Parts No. 1 Pinion stopper set 2 Pinion ass'y 3 Front cover 4 Front cover metal 5 Thrust washers 6 Armature 7 Brush holder ass'y 8 Brush (-)

6. Turn engineswitch to START andread the For disassembly, follow the steps below. meter. If themeter reads battery voltage, the cir- 1. Pinion stopper set (1) cuit, is good. If solenoidwould not click in 2. Pinion ass'y (2) the previous tests, it is faulty. Replace it. 3. Through bolts (14) and screws (15) If the meterreads much less than battery 4. Rear cover ( 1 1) voltage or no voltage at all, either the wiring 5. Brush holder ass'y (7) or engine switch is faulty. 6. Brush (10) and brush springs (9) 7. Yoke ass'y (16) 7. Test engine switch. 8. Armature (16) 8. Inspect the wiring shown carefully for damaged 9. Thrust washers (5) or broken wires and replace as required. 10. Front cover (11) 11-4 ELECTRIC STARTER AND CHARGE (Shift Lever Type)

Measure commutator outsidediameter at several points around diameter circumference, using a vanier caliper.

Ref, Ref Parts Name Parts Name No. No. 1 Front cover 10 Brush spring 2 Washer 11 Insulator 3 Stopper 12 Rear cover 4 Snap ring 13 Bolt 5 Clutch ass'y 14 Solenoid 6 Shift lever 15 Nut 7 Armature 16 Nut Commutator Outside Dia.(MIN)

I_-- 8 Brush holder 17 Yoke ass'y Bendix Type 32 mm (1.26 in.) 9 Brush lever Type 27 mm (1.10 in.)

For disassembly, follow the steps below. If outsidediameter is less than (MIN), replace armature. 1. Nut (16) Measure depth of grooves between commutator 2. Nuts and solenoid (14), (15) segments. 3. Long bolts (13) 4. Rear cover (12) Commutator Groove Depth(MIN) 5. Insulator (11) 6. Brush holder and spring (8),(10) 0.2 mm (0.01 in.) 7. Yoke ass'y (9), (17) Shift lever Type 0.2 mm (0.01 in ) 8. Shift lever (6) 9. Armature (7) 10. Washer (2) 11. Stoppers and snapring (3),(4) 12. Clutch ass'y (5)

STARTERMOTOR INSPECTION

1. ArmatureInspection

Inspectsurface of commutator. 2. Segment If it has a scratch or is dirty, polish it with a 3. Good piece of very fine emerypaper (No.5000 to 4. 0.2 mm (0.08 in.) limit No.6000). 5. Insulating Material ELECTRICSTARTER AND CHARGE 11-5 If grooves are shallower than (MIN), under cut insulatingmaterial to standarddepth using a thin file.

Standard Groove Depth Bendix Type 0.5 to 0.8 mm (0.02to 0.03 in.) Shift lever Type 0.5 to 0.6mm (0.02to 0.023 in.)

If groovesare only dirty, clean them carefully. Support armature in tail stock at each,end of shaft as shown. Position dial indicator per- pendicular to commutator. Turn armature slowly and read run-out on dial indicator. rCommutator-to-Shaft Resistance (52) If resistance is less than infinite, armature is shorted. Test armature windings for shorts. Place armature on a growler. Hold a thin metal strip (e.g., hack saw blade) on top of armature.

Commutator Run-Out (MAX) Bendix Type 0.3 mm (0.012 in.) I Shift lever Type 0.4 mm (0.016 in.) I

If run-out is greaterthan (MAX), turn down commutator or replace startermotor. Set multimeter selector switch to R x posi- tion andcheck resistance between each seg- ment and all the others.

Turn on growlerand rotate armature .one complete turn. If metal strip vibrates, windings are internally shorted to each other and starter motor must be replaced.

2. Brush Length Check Measure overall lengthof each brush.

Armature WindingResistance Very Low

If resistance is too high or even infinite, arma- ture winding hasan open circuit. Replace starter motor. Set multimeter selectorswitch to R x position and measure resistance between com- mutator and armature shaft. 11-6 ELECTRICSTARTER AND CHARGE Brush LengthBrush (M IN) Terminal-to-GroundResistance

Shift lever Type 6 mm (0.24 in.) If resistance is less than infinite.field coil is If brushesare shorterthan (MIN), replaceshorted to ground.Replace yoke assembly. them. 4-2 Shift lever-Type Starter Motor Set multimeter selectorswitch to R x Brush Spring Check3.Spring Brush positionresistancebetweenmeasure and field Inspectbrush spring for damage.Replace coils‘terminals (A). springs if necessary. If brushspring are able to snap the brushes firmlyinto place, they maybe considered serviceable. If they cannot, replace them.

4. Field Coil Check 4- 1 Bendix-Type StarterMotor Set multimeter selector switch to R x posi- tion andmeasure resistance between field coils’ terminals (A).

Terminal-to-Terminal Resistance

Very Low

If there is continuity field coil is still good. If resistance is greater thanindicated above (no continuity). Replace yoke assembly. Set multimeter selectorswitch to R x position and measure resistance between yoke (A) and one terminal of each coil (B).

Terminal-to-Terminal Resistance (52 Very Low

If resistance is greaterthan indicated above (no continuity),replace yoke assembly. Set multimeter selectorswitch to R x 1 position and measure resistance between yoke (A) and one terminal of each coil (B).

Terminal-to-YokeResistance

I Very Low I

If resistance is greater than indicated above (no continuity), replace yoke ass‘y. Set multimeter selector switch to R x 1 position and measure resistance between posi- tibe brush (A) and starter motor yoke (B). ELECTRICSTARTER AND CHARGE 11-7

Positive Brush-to-YokeResistance If any irregularity is noted, pinion clutch should be replaced.

If resistance is less than infinite, positive brush STARTERMOTOR REASSEMBLY is horted to ground.Replace entirepositive brush ass’y (C). Reassembly is the reverse order of disassembly. Note thefollowing points. Apply multi-purpose glease to: BRUSH HOLDER CHECK Sliding surface of pinion and shaft’s spline. Dust seal lip. (Bendix-Typeonly) Metal holding shaft at front and rear cover. Set multimeter selectorswitch to R x 1 Do not reuse retaining ring on shaft, which position andmeasure resistance between was removed. brush holder (A) and its base (B). Removalweaken and deform the retaining ring.

Charging System A charging system produces the current required to maintain thebattery in good state of charge.

Thecharging system consist of a flywheel magnet, charging coil (stater) and regulator. Thecharging coil output current is rectified (changed from AC to DC)and is maintained constant voltagefor battery charging. Rated speed of AC generator is 3,350 rpm, and at lower speedsavailable output will bere- Positive BrushHolder-to-Ground Resistance ) duced relatively.

CHARGINGSYSTEM CHECK If resistance is less than infinite, replacebrush holder. Be sure to perform more basic checksfirst such as; 1. Battery defectiveor not charged. 2. Eroded or loose terminals or connections. 3. Cracked insulation or brocken wires. 4. Wire groundingout the system. PINIONCLUTCH INSPECTION 5. Defective switch. Condition Found (Battery Run Down) Rotate pinion manually. Check battery polarity. Negative (-) side of While rotating pinion in direction of normal battery should be grounded to engine or frame operation,smoothly reverse the direction of (equipment),positive (+) side of battery to rotation to confirm that it locks. regurator charge lead. (See IIlustration) 11-8 ELECTRICSTARTER AND CHARGE If the wiring is reversed, regulator will be Stater UnregulatedOut Put (MIN) damaged. 34.5 volts 3,350 rpm AC generator

3.4w If voltage is less than specified, replace stater.

Regulator Resistance Measurement Remove all the wires from regulator. Set multimeter selectorswitch to R x 1 position. Connecttester leads to regulatorconnecter CHG monitor terminals using the table below. The resistance value should be specified.

OHM Meter Readings Connected Between d Key SW.

Out Put Test Start engine and allow it to warm up complete- ly. Set multimeter selector switch to the 25V DC position. (Use KAWASAKI multimeter) Connectmeter positive (+) lead to battery positive (+) terminal, andnegative (-) meter lead to battery negative (-) terminal.

Run engine at rated RPM (3,350rpm), meter shouleshow a minimum of 12 amps. If not, the system is defective and thecomponents (by KAWASAKI TESTER) of the system should be checked.

Test Stater Out Put Start engine and allow it to warm up complete- ly. Disconnect coupler from charging circuit. Connectvoltmeter leads to staterlead ter- minals on coupler. Run engine at rated RPM (3,350 rpm). Output voltage should beas specified below. CHG monitor Stater

If resistance is not as specified,replace the regulator.

NOTE: Resistance value may vary with individual meters. ELECTRICSTARTER AND CHARGE 11-9 TROUBLESHOOTING

Inspection Item Remedy t

Does crankshaft rotate? Does starter rotate? terminals for Correct connection or

Check and repair wir- Is operating sound pro- ing to solenoid switch. duced out of starter’s Wiring connection Yes ->- Repair or replace sole- noid switch.

Check return spring for permanent defor- mation and check pin- ion for dragging. Correct meshing of Faulty pinion and ring gear andreplace ring gearor satisfac- pinion and/ or ring gear.

I Yes /Make connection and No Replace motor terminal of independ- Check pinion‘s ent starter. Does motor (field coil or armature). clutchfor damage,and run? replace if necessary. I

Faulty solenoid switch

Faulty (rotation Check battery charge Charge or replace the Is rotation normal? isslow) andalso check battery terminals for disconnec- Correct connection or and corrosion, corrosion corrosion, tion and at battery terminals. Yes Faulty If abnormal (Immedi- Check ignition system engine oil is satisfac-Change engine oil. ately disconnectcable fromof the battery.)

‘Motor fails to stop even starter is replaced with Repairreplace or start- when key switch is new one? turned to OFF position.

t No I Inspect interior of engine. I 12-1 RECOILSTARTER Section 12 RECOIL STARTER

RECOILSTARTER DISASSEMBLY 6. Remove bolt (A) and ratchedcover (B).

1. Pull handle out about 10 to 12 inches or until notch (A) in pulley is nearrope hole. Hold rope in place with knot (B).

7. Remove pawls (A) and spring (B).

2. Pry knotout of handleand untie it. Pull handle off rope. 3. While carefully holding rotating parts with one hand, untie knot (B) with the other. 4. Pull rope in through rope hole (A) in housing and hold it in notch (B) in reel (C). 5. Allow springtension slowly to unwind recoil 8. Removereel. mechanism. CAUTION: Do not let therope wedgebetween theand reel the housing. Be careful that springdoes not fly loose and injure you. It is under great pressure. Turn reelone-quarter turn counterclockwise past the rest position where no tension canbe felt. Now, slowly lift reel straight up out ofhousing.

NOTE: Thereshould be no springtension on reel whenremoving reel. If tension is felt, push reel back into placeand gently "wiggle" it until reel may be easily removed.

9. If necessary,remove spring.

RECOILSTARTER REASSEMBLY

Assembly is reverse of disassembly. Note the following points. RECOILSTARTER 12-2 If spring wasremoved, it must be installed Pawls (A) mustbe installed as shown for as shown. If it is not installedcorrectly, proper starter operation. starter will not operate properly.

//\WARNING: Spring must be put under great pressure during installation. Weargloves to avoid injury.

1. Lightly glease spring (A).

Install coil spring (A), ratchedcover (B) and tighten bolt (C).

If rope was unwound from reel, it must be woundclockwise (as shown) for correct starter operation.

Rotate reelthree turns counterclockwise to preload the spring. Pullrope in throughrope hole in housing and install handle.

RECOILSTARTER INSPECTION

Disassemble recoilstarter. Immerse only metalparts in a bath of high Set reel into place so that slots (A) onspring flash-point solvent. case catch on tabs (B) on reel. CAUTION: Do not cleanany non-metalicparts in solvent as they may be damaged.

Use compressed air to dry cleaned components. Check starterpawls for chips or excessive wear. Check starterrope for excessivewear or fraying. Check condition of recoilspring andratched cover spring. Inspectsprings for breaks, rust, distortion, or weakened condition.