Kawasaki FD671D, FD711DF, D750D, FD791D Service Manual

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FD671D/FD711D

FD750D

FD791D (DFI)

4–stroke liquid-cooled v-twin gasoline engine

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

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LIST OF ABBREVIATIONS

A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s)

AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch



C DC direct current rpm revolution(s) per minute F farad(s) TDC top dead center



F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) W watt(s) h hour(s) L liter(s)

degree(s) Celsius r revolution



ohm(s)

Read OWNER’S MANUAL before operating.

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EMISSION CONTROL INFORMATION

To protect the environment in which we live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board.

Crankcase Emission Control System

1. A sealed-type crankcase emission control system is used to eliminate blow-by gasses. The blow-by

gasses are led to a breather chamber through the crankcase and from there to the air cleaner.

Oil is separated from the gasses while passing through the inside of the breather chamber from the

crankcase, and then returned to the bottom of the crankcase.

2. Exhaust Emission Control System

The exhaust emission control system applied to this engine consists of a carburetor and an ignition

system having optimum ignition timing characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel

economy with a suitable air cleaner and exhaust system.

TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED

Federal law and California State law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below: Do not tamper with the original emission related part.

Carburetor and internal parts

•

Spark plugs

•

Magneto or electronic ignition system

•

Fuel ﬁlter element

•

Air cleaner elements

•

Crankcase

•

Cylinder heads

•

Breather chamber and internal parts

•

Intake pipe and tube

•

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Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufﬁcient experience or doubts as to his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualiﬁed mechanics.

In order to perform the work efﬁciently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are speciﬁed, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

To get the longest life out of your engine:

Follow the Periodic Maintenance Chart in the Service

•

Manual.

Be alert for problems and non-scheduled maintenance.

•

Use proper tools and genuine Kawasaki engine parts.

•

Genuine parts provided as spare parts are listed in the

Parts Catalog.

Follow the procedures in this manual carefully. Don’t

•

take shortcuts.

Remember to keep complete records of maintenance

•

and repair with dates and any new parts installed.

If you want spark plug information, for example, go to the Periodic Maintenance Chart ﬁrst. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Tableof Contents on the ﬁrst page of the chapter to ﬁnd the Spark Plug section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

This warning symbol identiﬁes special instruc-

tions or procedures which, if not correctly fol-

lowed, could result in personal injury, or loss of

life.

CAUTION

This caution symbol identiﬁes special instruc-

tions or procedures which, if not strictly ob-

served, could result in damage to or destruction

of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE



This note symbol indicates points of particular interest for more efﬁcient and convenient operation.

How to Use This Manual

In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.

The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations.

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Indicates a procedural step or work to be done.

•



Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or NOTE. Indicates a conditionalsteporwhataction to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will ﬁnd the instructions indicating which parts require speciﬁed tightening torque, oil, grease or a locking agent during assembly.

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GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing................................................................................................................................................................1-2

Model Identiﬁcation...........................................................................................................................................................1-4

General Speciﬁcations......................................................................................................................................................1-5

Periodic Maintenance Chart..............................................................................................................................................1-7

Torque and Locking Agent................................................................................................................................................1-8

Special Tools.....................................................................................................................................................................1-9

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1-2 GENERAL INFORMATION

Before Servicing

Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work.

Especially note the following:

(1) Dirt

Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or other parts, will work as an abrasive and shorten the life of engine. For the same reason, before installing a new part, clean off any dust or metal ﬁlings.

(2) Battery Ground

Remove the ground (—) lead from the battery before performing any disassembly operations on the equipment. This prevents: (a) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts.

(3) Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug ﬁt. Then tighten them evenly, in a staggered sequence. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely, when loosening the bolts, nuts, or screws, ﬁrst loosen all of them by about a quarter of a turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated.

(4) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.

(5) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difﬁcult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the heads.

(6) Edges

Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over.

(7) High-Flash Point Solvent

A high-ﬂash point solvent is recommended to reduce ﬁre danger. A commercial solvent commonly available in North America is Standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.

(8) Gasket, O-Ring

Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.

(9) Liquid Gasket, Non-Permanent Locking Agent

Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a nonpermanent locking agent commonly available in North America is Loctite Lock’n Seal (Blue).

(10) Press

A part installed using a press or driver, such as a journal, should ﬁrst be coated with oil on its outer or inner circumference so that it will go into place smoothly.

(11) Ball Bearing

When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft.

(12) Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.

When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.

(13) Seal Guide

A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high temperature grease on the lips to reduce rubber to metal friction.

(14) Circlip, Retaining Ring

Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.

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GENERAL INFORMATION 1-3

Before Servicing

(15) Cotter Pin

Replace any cotter pins that were removed with new ones, as removal deforms and breaks them.

(16) Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative ﬁlm. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative ﬁlm. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.

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 application for which they are not intended. This manual makes reference to molybdenum disulﬁde grease (MoS using such special lubricants.

(17) Electrical Wires

All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identiﬁed by ﬁrst the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color.

2) in the assembly of certain engine parts. Always check manufacturer recommendations before

(18) Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are removed. There replacement parts will be damaged or lose their original function once removed.

(19) Inspection

When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones.

Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure

(20) Speciﬁcations

Speciﬁcation terms are deﬁned as follows:

"Standards" show dimensions or performances which brand-new parts or systems have.

"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

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1-4 GENERAL INFORMATION

Model Identiﬁcation

Cylinder Number Designation:

No.1 Cyl. is on the oil ﬁlter side. No.2 Cyl. is on the electric starter side.

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GENERAL INFORMATION 1-5

General Speciﬁcations

Items

Type of engine Bore x Stroke 2-78 mm x 78 mm (3.07 in x 3.07 in)

Piston displacement 745 mL (45.5 cu. in) Direction of rotation Counterclockwise facing the PTO shaft end Low idle speed 1550 rpm High idle speed 3600 rpm Ignition system Transistorized-ﬂy wheel magneto RFI Per Canada and U.S.A. requirements Starting system Shift type electric starter Charging system 12 V - 20 amps with regulator Carburetor Float type, ﬁxed main jet Fuel pump Electro magnetic pump (in-line type) Air cleaner Dual stage element, dry type Governor All speed mechanical ﬂy weights Lubrication system Pressure feed by positive displacement pump

Oil ﬁlter Cartridge type full ﬂow ﬁlter Oil pressuer switch ON-OFF switch Oil capacity 2.0 L (2.1 US qt) [When oil ﬁlter is removed]

Cooling system Pressurized forced circulation type

Radiator 2-rows with louverless corrugated ﬁn (aluminum)

Dimensions (H x W x L ) 520 mm x 458 mm x 580 mm

Dry weight 58 kg (128 lb)

NOTE:Speciﬁcations are subject to change without notice.

Liquid-cooled, Horizontal shaft, OHV, 4-stroke, 90 gine.

(20.5 in x 17.9 in x 22.8 in)

FD671D, FD711D, FD750D



V-twin, Gasoline en-

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1-6 GENERAL INFORMATION

General Speciﬁcations

Items

Type of engine Bore x Stroke 2-78 mm x 78 mm (3.07 in x 3.07 in)

Piston displacement 745 mL (45.5 cu. in) Direction of rotation Counterclockwise facing the PTO shaft end Low idle speed 1550 rpm High idle speed 3600 rpm Ignition system Transistorized-ﬂy wheel magneto RFI Per Canada and U.S.A. requirements Starting system Shift type electric starter Charging system 12 V - 20 amps with regulator Fuel System DFI (Digital Fuel Injection) Fuel pump Electro magnetic pump (in-line type) Air cleaner Dual stage element, dry type Governor All speed mechanical ﬂy weights Lubrication system Pressure feed by positive displacement pump

Oil ﬁlter Cartridge type full ﬂow ﬁlter Oil pressuer switch ON-OFF switch Oil capacity 2.0 L (2.1 US qt) [When oil ﬁlter is removed]

Cooling system Pressurized forced circulation type

Radiator 2-rows with louverless corrugated ﬁn (aluminum)

Dimensions (H x W x L ) 520 mm x 458 mm x 580 mm

Dry weight 59 kg (130 lb)

NOTE:Speciﬁcations are subject to change without notice.

Liquid-cooled, Horizontal shaft, OHV, 4-stroke, 90 gine.

(20.5 in x 17.5 in x 22.8 in)

FD791D (DFI)



V-twin, Gasoline en-

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GENERAL INFORMATION 1-7

Periodic Maintenance Chart

To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals. The bullet mark (•) designates that the corresponding item should be performed at that interval.

Some adjustments require the use of special tools or other equipment. An electronic tachometer will facilitate setting idle and running speeds.

Always remove the spark plug cap from spark plug when servicing the engine to prevent accidental starting.

INTERVAL

MAINTENANCE Daily First Every Every Every Every Every Every

8 25 50 100 200 300 400

hr. hr. hr. hr. hr. hr. hr.

Check and add engine oil,

coolant and fuel

Check for loose or lost nuts and

screws Check for fuel, oil and coolant leakage Check battery electrolyte level Check or clean air intake screen Tighten nuts and screws Clean air cleaner foam element Clean air cleaner paper element Change engine oil Clean and regap spark plug Replace oil ﬁlter Replace air cleaner paper element

Clean conbustion chamber

K Check and adjust valve clearance K Clean and lap valve seating surface K Inspect radiator and hoses K Check fan belt conditions and tension K Change coolant

NOTE:The service intervals indicated are to be used as a guide. Service should be performed more frequently as

necessary by operating condition.

: Service more frequently under dusty conditions.

K: Have an authorized Kawasaki engine dealer perform those services.

•

• •

•

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1-8 GENERAL INFORMATION

Torque and Locking Agent

The following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent

locking agent or liquid gasket.

Letters used in the "Remarks" column mean:

L:Apply a non-permanent locking agent to the threads.

M:Apply a molybdenum disulﬁde lubricant (grease or oil) to the threads, seated surface, or washer.

O:Apply an oil to the threads, seated surface, or washer.

S:Tighten the fasteners following the speciﬁed sequence.

Fastener Torque Remarks

Fuel System:

Air Cleaner Wing Nut 3 0.3 26 in1lb Carburetor, Intake Pipe Mounting Bolts 12 1.2 106 in1lb Governor Arm Nut 8 0.8 69 in Fuel Shut-Off Solenoid Valve 7 0.7 61 in1lb Water Temperature Sensor 20 2.0 14

Cooling System:

Radiator Hoses Clamps Bolts (M6) 1.2 0.12 11 in1lb Radiator Mounting Bolts (M6) 6 0.6 52 in1lb Cooling Fan Shaft Nut 20 2.0 15 Water Pump Cover Bolts 20 2.0 15 S Thermo Switch 27 2.8 20 L

Engine Top End:

Cylinder Head Bolts 27 2.8 20 S Rocker Arm Bracket Mounting Bolts 22 2.2 16 Valve Clearance Adjusting Locknuts 11 1.1 96 in Spark Plugs 25 2.5 18

Lubrication System:

Oil Drain Plug 25 2.5 18 Oil Pressure Switch 15 1.5 11 L

Camshaft/Crankshaft:

Case Cover to Block Bolts 22 2.2 16 S Con-Rod Big End Cap Bolts 21 2.1 15 O

Electrical System:

Flywheel Bolt 56 5.7 41 Starter Motor Mounting Bolts 20 2.0 15

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a speciﬁc torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

kg1m ft1lb

Threads dia Torque

(mm) N1m kg1m ft1lb

5 3.4 0.35 30 in1lb 6 5.9 0.6 52 in1lb 8 15 1.5 11

10 20 2.0 15

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GENERAL INFORMATION 1-9

Special Tools

Compression Gauge: 57001–221

Piston Ring Pliers: 57001–115

Piston Ring Compression Grip: 57001–1095

Valve Seat Cutter Holder,

Valve Seat Cutter, 45

Valve Seat Cutter, 32– 33.0 : 57001–1199

7 : 57001–1126



35.0 : 57001–1116

–

Piston Ring Compression Belt, Ø67 -Ø79: 57001–1097

Valve Seat Cutter Holder Bar: 57001–1128

Compression Gauge Adapter M14 x 1.25: 57001–1159

Valve Seat Cutter, 32– 30 : 57001–1120

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1-10 GENERAL INFORMATION

Special Tools

Oil Filter Wrench : 57001–1249

Hand Tester: 57001–1394

Kawasaki Bond (Silicone Sealant) : 56019–120

Read Wire ECU Adapter: 57001–1500

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FUEL SYSTEM 2-1

Fuel System

Table of Contents

Exploded View............................................................2-3

Speciﬁcations.............................................................2-6

Governor Link Mechanism.........................................2-8

Control Panel Assembly Removal.......................2-8

Control Panel Assembly Installation....................2-8

Governor Arm Removal.......................................2-8

Governor Arm Installation....................................2-9

Governor Assembly Removal..............................2-9

Governor Assembly Installation...........................2-9

Governor Assembly Inspection...........................2-9

Governor Shaft Removal...................................2-10

Governor Shaft Installation................................2-10

Carburetor................................................................2-11

Fuel and Air Flow..............................................2-11

Fuel Shut Off Solenoid Valve ...........................2-11

Low Idle Speed Adjustment..............................2-12

High Idle Speed Adjustment..............................2-12

High Altitude Operation.....................................2-13

Main Jet Replacement.......................................2-13

Fuel System Cleanliness Inspection.................2-13

Carburetor Removal..........................................2-13

Carburetor Installation.......................................2-14

Carburetor Disassembly/Assembly....................2-15

Carburetor Cleaning..........................................2-16

Carburetor Inspection........................................2-16

Fuel Shut-Off Solenoid Valve Test....................2-17

Intake Manifold.........................................................2-18

Intake Manifold Removal...................................2-18

Intake Manifold Installation................................2-18

Intake Manifold Inspection.................................2-18

Fuel Pump................................................................2-19

Fuel Pump Test.................................................2-19

Air Cleaner...............................................................2-20

Element Removal..............................................2-20

Element Installation...........................................2-20

Element Cleaning and Inspection.....................2-20

Cleaner Body Removal......................................2-21

Cleaner Body Installation..................................2-21

Housing (Case and Body) Inspection...............2-21

Digital Fuel Injection (DFI) System..........................2-22

Governor Link Mechanism....................................2-22

Control Panel Assembly Removal.....................2-22

Control Panel Assembly Installation..................2-22

Governor Arm Removal.....................................2-22

Governor Arm Installation..................................2-23

Throttle body Assy................................................2-23

Throttle Body Assy Removal.............................2-23

Throttle Body Assy Installation..........................2-23

Throttle Body Assy Disassembly.......................2-24

Throttle Body Assy Assembly...........................2-24

Low Idle Speed Adjustment..............................2-24

High Idle Speed Adjustment..............................2-25

Intake Manifold (DFI)............................................2-25

Intake Manifold (DFI) Removal..........................2-25

Intake Manifold (DFI) Installation.......................2-26

DFI System...........................................................2-27

DFI System Wiring Diagram.................................2-28

Terminal Numbers of ECU Connectors................2-29

Safety Instruction for DFI System Servicing.........2-29

Electrical System...............................................2-29

Fuel System.......................................................2-29

Air System.........................................................2-29

Electrical Control Unit (ECU)................................2-30

ECU Removal....................................................2-30

ECU Connector Inspection................................2-30

ECU Ground Inspection....................................2-30

ECU Power Source Inspection..........................2-31

Fuel Pump.............................................................2-31

Fuel Pump Operation Inspection.......................2-31

Operating Voltage Inspection............................2-31

Fuel Flow Rate Inspection.................................2-32

Fuel Injectors (#1, #2)...........................................2-33

Fuel Injector Removal........................................2-33

Fuel Injector Installation....................................2-33

Power Source Voltage Inspection......................2-33

Output Voltage Inspection.................................2-33

Audible Inspection.............................................2-34

Injector Signal Test............................................2-34

Injector Resistance Inspection..........................2-35

Injector Unit Test................................................2-35

Fuel Pressure Regulator.......................................2-35

Fuel pressure Regulator Removal.....................2-35

Fuel Pressure Regulator Installation.................2-35

Fuel Pressure Regulator Inspection..................2-36

Self-Diagnosis.......................................................2-36

Self-Diagnosis Outline.......................................2-36

Self-Diagnosis Procedures................................2-36

How to Read Fault Codes.................................2-37

Inlet Air Temperature Sensor (Fault Code 12).....2-37

Removal.............................................................2-37

Installation..........................................................2-38

Output Voltage Inspection.................................2-38

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2-2 FUEL SYSTEM

Sensor Resistance inspection...........................2-39

Water Temperature Sensor (Fault Code 13)........2-39

Removal/Installation...........................................2-39

Output Voltage Inspection.................................2-39

Water Temperature Sensor Inspection..............2-40

Vacuum Sensor (Fault Code 21)..........................2-40

Removal/Installation...........................................2-40

Input Voltage Inspection....................................2-40

Output Voltage Inspection.................................2-41

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FUEL SYSTEM 2-3

Exploded View

1. Pilot Screw Assy

2. Pilot Jet

3. Main Jet (#105)

4. Main Jet (#105)

T1: 0.7 N1m (0.07 kg1m, 6 in1lb) T2: 2.0 N T4: 9.8 N T5: 12 N T6: 20 N T7: 1.7 N T8: 3.0 N

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m (0.2 kg1m, 17 in1lb)

m (1.0 kg1m, 87 in1lb)

m (1.2 kg1m, 106 in1lb)

m (2.0 kg1m, 15 ft1lb)

m (0.17 kg1m, 15 in1lb)

m (0.3 kg1m, 27 in1lb)

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2-4 FUEL SYSTEM

Exploded View

FD791D (DFI Model)

1. Throttle Body Assy

2. Electrical Control Unit (ECU)

3. Fuel Injectors

4. Fuel Pressure Regulator

5. Inlet Air Temperature Sensor

6. Water Temperature Sensor

7. Vacuum sensor

T1: 12 N1m (1.2 kg1m, 106 in1lb) T2: 3.0 N T3: 20 N T4: 9.8 N

m (0.3 kg1m, 27 in1lb)

m (2.0 kg1m, 15 ft1lb)

m (1.0 kg1m, 87 in1lb)

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FUEL SYSTEM 2-5

Exploded View

1. Other than DFI Model

T1: 8 N

m (0.8 kg1m, 69 in1lb)

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2-6 FUEL SYSTEM

Speciﬁcations

Item

FD671D FD711D FD750D

Caburetors Speciﬁcations:

Make/ type MIKUNI BW26 Throttle bore diameter 26 mm (1.02 in.) Venturi diameter 20 mm (0.79 in.) Main Jet (MJ) [R]: #102.5, [L]: #105 [R]: #110, [L]: #111.3 [R] and [L]: #106.3 Pilot jet (PJ) [R] and [L]: #41.3 [R] and [L]: #45 [R] and [L]: #43.8 Main air jet (MAJ) ø1.5 Pilot air jet (PAJ) ø0.8 Pilot air screw turns out (PS) [R]: 2, [L]: 2−1/4 [R]: 1−7/8, [L]: 1−3/4 [R]: 2−1/4, [L]: 2−3/8

(Idle mixture screw turns out)

Float level Float parallel to carburetor body

Idle Speed: (1)

Low idle speed 1550 rpm High idle speed 3600 rpm

Air Cleaner:

Type Dual stage ﬁltration system Pre-cleaner Foam element Two-stage cleaner Paper element

Fuel:

Fuel requirement Unleaded regular grade gasoline

Fuel Pump:

Type Electro-magnetic Pump (in-line type) Rated voltage 12 VDC Delivery (MIN) 400 mL (0.4 qt) / (MIN) at free ﬂow Shut-off deliver pressure 19.6 to 26.5 kPa (2.8 to 3.8 psi)

Governor:

Type Flyweight all speed governor

(1) Idle speeds may vary depending on each equipment. Refer to the equipment speciﬁcation. [R] means the right-side parts viewed from the choke valve. [L] means the left-side parts viewed from the choke valve.

Standard

21 mm (0.83 in.)

ø1.7

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FUEL SYSTEM 2-7

Speciﬁcations

Item

Digital Fuel Injection System

Idle Speed

Low idle speed 1550 rpm High idle speed 3600 rpm

Throttle Body Assy

Type Two barrel type Bore 20 mm (1.02 in)

ECU (Electronic Control Unit)

Type Digital memory type, sealed wih resin Usable engine speed 200

Pressure Regulator

Regulated fuel pressure 177 ± 5 kPa (1.8 ± 0.05 kg/cm

Vaccum Pressure Sensor:

Input voltage 4.75 5.25 V DC between BR/W and BK/R terminal Output voltage 3.46 3.82 V DC at standard atmospheric pressure (see this text for

Inlet Air Temperature Sensor

Resistance 5.29 6.47 kat 0C (32F)

Water Temperature Sensor

Resistance 2.21 2.69 k

Fuel Injectors

Nozzle type One spray type with 4 holes Resistance 12.5

Fuel Pump

Type Electro magnetic pump (in-line type) Discharge 120 mL or more/3 seconds at high idle speed (3600rpm)

4000 rpm

details)

2.21 2.69 k

0.133 0.163 k

0.290 0.354 kat 80

0.133 0.163 k



at 20C (68F)



at 80C (176F)



at 20C (68F)



at 110C (230F)

at 20C (68F)

Standard

FD791D (DFI Model)

, 25.6 ± 0.7 psi)



C (176F)

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2-8 FUEL SYSTEM

Governor Link Mechanism

Control Panel Assembly Removal

Remove:

•

Air Cleaner (see Air Cleaner Body Removal) Mufﬂer (see Mufﬂer Assembly Removal) Control Panel Mounting Bolts [A]

Remove the control panel assembly [A] while unhooking the governor

•

spring [B] end loop at the panel bracket. Clear the choke link rod end [C] from the choke lever.

•

Control Panel Assembly Installation

Before installing the control panel assembly, check to see that the

•

choke lever [A] and engine speed control lever [B] move smoothly in all directions. If any part is worn or damaged, replace the control panel assembly. After installation, adjust the low idle speed and high idle speed to the

•

speciﬁcations (see Low Idle Speed and High Idle Speed Adjustment).

Governor Arm Removal

Remove:

•

Control Panel Assembly

Loosen the clamp nut [A] and take off the governor arm [B].

•

Clear the throttle link rod [C] from the governor arm and choke lever.

•

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FUEL SYSTEM 2-9

Governor Link Mechanism

Governor Arm Installation

Insert the bracket [A] onto the governor shaft [B] thoroughly to the

•

bottom of the woodruff area of the shaft, and tighten the clamp nut [C].

Torque - Governor Arm Clamp Nut: 8 N1m (0.8 kg

Install the control panel assembly, and connect the bracket with the

•

governor spring [I]. Install the end of throttle link rod [H] with the link spring [G] around

•

it into the governor arm hole [K] and the other end into carburetor throttle lever [L] hole. Be sure the link spring around the throttle link rod is in place and that

•

it pulls the governor arm and throttle lever each other. Install the governor arm [D] on the bracket [A] with the bolt [F] and

•

washer by turning the bolt counterclockwise so the projection of the bracket ﬁts into the governor arm hole [E]. Loosen the bolt [F], and fully turn the bracket [A] counterclockwise

•

and hold it there. Turn the top end of the governor arm [D] counterclockwise to fully

•

open the carburetor throttle valve and tighten the bolt [F].

m, 69 in

lb)

Governor Assembly Removal

Remove:

•

Crankcase Cover (see Camshaft/Crankshaft chapter)

Remove the governor assembly [A] with the sleeve [B] by prying the

•

gear with two proper size screw drivers.

NOTE



To avoid damage to the surface of crankcase cover, use a suitable soft mats [C] as shown.

CAUTION

Do not remove the governor assembly unless it is necessary. Once it has been removed, it must be replaced.

Remove the thrust washer.

•

Governor Assembly Installation

Fit the sleeve into the governor assembly, and install them as a set.

•

NOTE



The sleeve and the governor assembly cannot be installed separately. Push the set onto the shaft until inner ﬂange snaps into the groove securely.

Sleeve [A] Governor Assembly [B] Inner Flange [C] Thrust Washer [D] Groove [E] Shaft [F]

Spin the governor assembly by hand and check that the ﬂyweights

•

operate freely and the center sleeve moves outward.

Governor Assembly Inspection



Visually check the assembly for wear and damage. If any parts is worm or damaged, replace the assembly.

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2-10 FUEL SYSTEM

Governor Link Mechanism

Governor Shaft Removal

Remove:

•

Camshaft (see Camshaft/Crankshaft chapter)

Unscrew the governor arm clamp nut, and remove the governor arm.

•

Remove the circlip [B] on the governor shaft [C], and remove the

•

governor shaft and washer [A].

NOTE



It is not necessary to remove the governor shaft unless it is being replaced.

Replace the oil seal only if the lip shows signs of leakage or it has

•

been damaged. The oil seal [A] must be assembled with seal lip towards inside of the

•

engine. Press in the oil seal 0

•

crankcase surface [C].

[D] Governor Shaft

1.0 mm (0.04 in.) [B] ﬂush or below the

Governor Shaft Installation

Apply engine oil to the governor shaft.

•

Insert the governor shaft into the crankcase and washer [A].

•

Fit the circlip [B] securely into the groove of governor shaft [C] as

•

shown. Check that the governor shaft moves freely in its operating range.

•

NOTE



If the oil seal is removed, reinstall it after the shaft is installed.

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FUEL SYSTEM 2-11

Carburetor

Fuel and Air Flow

The main system of the carburetor consists of the main jet [A], main nozzle [B], and the main air passage (main air jet) [C]. The main system meters fuel to the engine during moderate to heavy load conditions. Fuel ﬂows through the main jet and into the bleed pipe [D], where it is joined by air from the main air passage (main air jet). The resulting mixture ﬂows out the end of the main nozzle into the carburetor bore, where it is atomized by the high speed air ﬂow, and carried into the engine.

The pilot system includes the pilot jet [E], pilot screw (idle mixture screw) [C], pilot air jet [D], pilot outlet [F], and the bypass holes [G]. The pilot system meters the fuel/air mixture while the engine is idling and running under a light lead. Under these conditions there is very little air ﬂow through the carburetor bore; so little that it is not enough to draw fuel through the main system of the carburetor and atomize it. Instead, the fuel is drawn through the pilot system, since the nearly closed throttle valve [A] causes high speed air ﬂow past the pilot outlet and bypass holes (even at low engine speed).

B. Choke Valve

Fuel ﬂow in the pilot system is metered by the pilot jet. Air for better atomization is admitted via the pilot air jet in the mid-way of the carburetor. The fuel/air mixture passes into the bore of the carburetor downstream of the throttle valve through the bypass holes and pilot outlet. While the throttle valve is almost closed, it covers the small bypass holes opening into the bore from the pilot system. As the throttle valve begins to open, it uncovers the bypass holes, allowing more fuel/ air mixture to ﬂow. The extra ﬂow is needed because the engine starts to run faster as the throttle is opened. The pilot screw controls the amount of fuel/air mixture allowed through the pilot outlet, but dose not meter the bypass holes. A moderate amount of air comes in around the throttle valve at an idle, so adjusting the pilot screw changes the fuel/air ratio. Turning the pilot screw (idle mixture screw) out (counterclockwise) enriches the mixture; turning it in (clockwise) leans the mixture.

Fuel Shut Off Solenoid Valve

To avoid after ﬁring when stopping the engine, a solenoid actuated fuel shut off solenoid valve [A] is installed in the carburetor bowl. The valve shuts off the fuel supply to the main jet [B] simultaneously when the switch key turned to the “OFF” position.

The valve opens automatically when the switch key is turned to the “Run” position.

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2-12 FUEL SYSTEM

Carburetor

Low Idle Speed Adjustment

Disconnect all possible external loads from the engine.

•

Start the engine and warm it up thoroughly.

•

Always keep your hands clear of the moving parts.

Move the throttle lever on dash to the idle position.

•

Hold the throttle lever [A] on the carburetor in closed position (turn

•

the governer arm [B] clockwise all the way), and adjust the low idle speed screw [C] until the engine idles at speciﬁed speed.

Idle Speed (Carburetor idle rpm)

1450 rpm

Release the throttle lever and adjust the low idle speed set screw [D]

•

on the control plate to obtain the speciﬁed governed low idle speed.

Low Idle Speed (Governed idle rpm)

1550 rpm

High Idle Speed Adjustment

NOTE



High idle speed adjustment should be made after the idle speed adjustment is performed.

CAUTION

Do not adjust high idle speed with the air cleaner removed.

Start and warm up the engine thoroughly.

•

Always keep your hands clear of the moving parts.

Loosen the lock nut [A], and unscrew the high idle set screw [B] few

•

turns. Move the throttle lever on dash to obtain the speciﬁed high idle speed

•

and leave it there.

High Idle Speed

3 600 rpm

Turn the high idle set screw [B] so that the end of it just touches the

•

speed control lever [C], and tighten the lock nut [A]. Check the idle speed, and readjust the idle speed if necessary.

•

CAUTION

Be sure to make the idle and fast idle speeds respectively correspond to those of the equipment.

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FUEL SYSTEM 2-13

Carburetor

High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main-jet in the carburetor and correct idle speed.

[A] Main-jet [R] [B] Main-jet [L]

NOTE



The main jet high altitude kits are available if the equipment is to be used in the high altitudes. The main jet numbers are stamped on ends of the main jets.

High Altitude Main Jet

Altitude Main Jet No.

FD671D FD711D FD750D

1 000 m

3 000 ft)

(0 1 000 (3 000 2 000 m (6 000 ft) R: #97.5 R: #105 and higher L: #100 L: #106.3

2 000 m

6 000 ft)

R: #102.5 R: #110

L: #105 L: #111.3

R: #100 R: #107.5

L: #102.5 L: #108.8

R and L:

#106.3

R and L:

#103.8

R and L:

#101.3

Main Jet Replacement

Place the engine (equipment) on a level surface.

•

Close the fuel shut off valve in the equipment.

•

Drain the fuel in the carburetor completely by unscrewing the drain

•

screw [A] at the bottom of the ﬂoat chamber.

Remove the carburetor (see Carburetor Removal).

•

Unscrew the ﬂoat chamber screws and take off the ﬂoat chamber [B].

•

Using a proper blade screw driver, carefully replace the main jet [C]

•

with a new one for altitude expected.

Tighten the main jet to the speciﬁcation (see Carburetor Disassembly

•

Assembly Notes).

Torque - Main Jet: 0.7 N

Install the gasket and ﬂoat chamber.

•

Torque - Float Chamber Mounting Screw: 2.0 N1m (0.20 kg1m, 17 in1lb)

Fuel System Cleanliness Inspection

Gasoline is extremely ﬂammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of ﬂame or sparks; this includes any appliance with a pilot light.

Place a suitable pan under the drain screw [A] on the carburetor [B].

•

Turn out the drain screw a few turns to drain the carburetor and check

•

to see if water or dirt has accumulated in the carburetor.

Tighten the drain screw.

•

If any water or dirt come out, clean the carburetor (see Carburetor

•

Cleaning), and fuel tank, and check the fuel ﬁlter.

m (0.07 kg1m, 6 in1lb)

Carburetor Removal

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2-14 FUEL SYSTEM

Carburetor

Remove:

•

Air Cleaner and Related Parts (see Air Cleaner Removal) Radiator (see Radiator Removal) Cooling Fan and Fan Belt (see Cooling Fan and Fan Belt Removal)

Turn the fuel shut off valve to the OFF position.

•

Drain the carburetor.

•

Disconnect the fuel tube at the fuel inlet joint [A] of the carburetor.

•

Disconnect the solenoid valve lead terminal.

•

Unscrew the intake pipe and carburetor mounting bolts [B].

•

Unhook the throttle [C] and choke link rod [D] at the ends of their

•

arms while pull off the carburetor.

Carburetor Installation

Clean the mating surfaces of the carburetor, insulator and intake pipe,

•

and ﬁt new gaskets. Take care not to bend the throttle and choke link rods during

•

installation. Install the gaskets, insulator, carburetor and intake pipe with mounting

•

bolts and tighten them.

Torque - Carburetor and Intake Pipe Mounting Bolts: 12 N1m (1.2 kg

106 in

lb)

Be sure the fuel tube clip ends [A] face toward the intake-manifold[B]

•

as shown. Adjust idle speed.

•

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FUEL SYSTEM 2-15

Carburetor

Carburetor Disassembly/Assembly

Refer to the illustration shown for disassembly and assembly.

•

There are several passage plugs (ball plugs) in the carburetor body.

•

Do not remove.

Before disassembly, mark the out side of choke valve and throttle

•

valves for assembling them.

1. Limiter

2. Pilot Screw

3. Spring

4. Cover Assy

5. Choke Valve Assy

6. Throttle Valve Assy

7. Pilot Jet

8. Screw

9. Float Assy

10. Main Jet (R)

11. Main Jet (L)

12. Float Chamber Assy

Replace the pilot screw in accordance with the following procedure if

•

necessary.



Carefully mark the position of the pilot screw limiter on the carburetor

body so that it can be installed and set to its original position later.



Remove the limiter. Be careful not to turn pilot screw at this point.



Turn the pilot screw clockwise and count the number of turns until

screw is gently seated in the pilot passage. Record the number of

turns needed to closed the screw.



Turn out the pilot screw to replace it with a new one.



Install the new pilot screw until the screw is gently seated. Then open

the screw the same number of turns as recorded prior to removal.



Align the limiter with the mark on the carburetor body to install, taking

care not to turn the pilot screw.

Install the choke valve and throttle valve on the shaft as the out side

•

mark of them facing out side.

Drive in the ﬂoat pin so that the pin extends the same distance on

•

both side of the ﬂoat hinge bracket.

The fuel inlet valve seat is pressed into the carburetor body and is

•

not replaceable.

When assembling the carburetor parts which are attached to the

•

carburetor with the recommended tightening torque of a bolts and

screws. (see Exploded View)

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2-16 FUEL SYSTEM

Carburetor

Carburetor Cleaning

Clean the carburetor in a well-ventilated area, and take care that there is no spark or ﬂame anywhere near the working area; this include any appliance with a pilot light. Because of the danger of highly ﬂammable liquids, do not use gasoline or low ﬂash-point solvents to clean the carburetors.

CAUTION

Do not use compressed air on an assembled carburetor, the ﬂoat may be crushed by the pressure. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high ﬂash-point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.

Disassemble the carburetor.

•

Immerse all the carburetor metal parts in a carburetor cleaning

•

solution and clean them. Rinse the carburetor parts in water and dry them with compressed

•

air. Do not use rags or paper to dry parts. Lint may plug the holes or

•

passages. Blow air through the holes and fuel passages with the compressed

•

air. All holes must be open. Assemble the carburetor.

•

Carburetor Inspection

Gasoline is extremely ﬂammable and can be explosive under certain. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of ﬂame or sparks; this includes any appliance with a pilot light.

Inspect the carburetor body for damage. Flange sealing surfaces

•

should be smooth and free of burrs and nicks. Replace the gasket if necessary. Turn the throttle and choke shafts to check that the throttle and choke

•

butterﬂy valves move smoothly. If the valves do not move smoothly, replace the carburetor body and/ or throttle shaft and choke shaft assembly. Check that the gasket on the ﬂoat chamber.

•

If the gasket is not in good condition, replace it. Check the other parts of the carburetor for wear or damage. Replace

•

the part if necessary. Clean and check the ﬂoat level as follows.

•

CAUTION

Do not push down on the ﬂoat during ﬂoat level checking.

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FUEL SYSTEM 2-17

Carburetor

With the ﬂoat [A] assembly installed onto the carburetor body [B], hold

•

the carburetor upside down at an eye level. Gently support the ﬂoat

with a ﬁnger and bring it down slowly so that the ﬂoat arm tab [C]

just touches the ﬂoat valve [D]. The ﬂoat arm surface [E] should be

parallel [G] with the carburetor body mating surfaces [F].

If the ﬂoat position is not correct, bend the tab as required for correct

adjustment.

Inspect the ﬂoat valve for excessive wear or damage. The tip should

•

be smooth, without any grooves, scratches, or tears. The rod at the

other end of the needle should move smoothly when push in and

released.

If either the valve or the seat is worn or damaged, replace the ﬂoat

assembly and carburetor body as a set.

Inspect the tapered portion [A] of the pilot screw [B] for wear or

•

damage.

If the pilot screw is worn or damaged on the taper portion, replace it.

Check the spring for weakened condition, replace it, if necessary.

•

Fuel Shut-Off Solenoid Valve Test

Unscrew the fuel shut off valve and remove the valve.

•

Connect a 12 VDC source to the solenoid as shown.

•

If the actuate solenoid plunger (needle valve) does not pop in when

the test voltage is applied, replace it.

NOTE



If may be necessary to push the plunger slightly for the plunger to withdraw.

Install the gasket and the valve.

•

Torque - Fuel Shut-Off Solenoid Valve: 7 N1m (0.7 kg1m, 61 in1lb)

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2-18 FUEL SYSTEM

Intake Manifold

Intake Manifold Removal

Remove:

•

Air Cleaner (see Cleaner Body Removal) Carburetor Control Panel Assembly

Drain the coolant in the engine (see Coolant Draining).

•

Unscrew the manifold mounting bolts in numerical sequence, 1/4 turn

•

at a time, until all bolts are loose. If the mounting bolts removal sequence is not followed, manifold mating surfaces may be warped. Remove the manifold [A] and gaskets [B].

•

Intake Manifold Installation

Before assembling the manifold, install the cylinder heads on each

•

cylinder and tighten the head bolts (see Cylinder Head Installation). Place a new gaskets on each mating surface, and install the manifold.

•

Tighten the manifold mounting bolts in sequence 3 N

•

26 in

lb) at a time until the torque on each bolt is 20 N

15 ft

lb).

Torque - Intake Manifold Mounting Bolts: 20 N1m (2.0 kg

m (0.31 kg

m (2.0 kg

m, 15 ft

lb)

Intake Manifold Inspection

Visually inspect the coolant passage in the manifold for deposits

•

or corrosion in layers inside the passage, clean the passage if necessary. An improperly installed gaskets can cause coolant leakage and air

•

drawn into the induction passage. Check the gaskets for correct installation.

NOTE



Small coolant leaks appear only as a rust, corrosion or stain.

Inspect the intake manifold for cracks or porous casting.

•

Cracks not visible to the eye may be detected by coating the

•

suspected area with mixture of 25% kerosene and 75% light engine oil. Wipe the area dry and immediately apply a coating of zinc oxide

•

dissolved in wood alcohol. If a cracks is present, the coating will become discolored at the defective area. If a crack is present in the intake manifold, replace it. Inspect the gasket surfaces for burrs and nicks.

•

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FUEL SYSTEM 2-19

Fuel Pump

The fuel pump cannot be disassembled, if any damage for the pump is appeared replace it with a new one.

[A] Fuel Pump [B] Inlet Pipe [C] Outlet Pipe

Fuel Pump Test

Before this test, be sure the battery is fully charged.

Gasoline is extremely ﬂammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of ﬂame or sparks; this includes any appliance with a pilot light.

Disconnect and plug the fuel pump outlet pipe.

•

Connect proper pressure gauge to the fuel pump outlet pipe.

•

Turn the engine switch to the “RUN” position, the fuel pump will

•

operates. Record the pressure reading. Stop the fuel pump.

Remove the pressure gauge and connect the outlet fuel tube.

•

Disconnect the fuel pump outlet tube from the carburetor inlet.

•

Put the tube end in a graduated container.

•

Run the fuel pump for 30 seconds. Stop the fuel pump. Record the

•

container measurement.

Compare the readings to the speciﬁcations.

•

If low, check for clogged or damaged tubes, fuel ﬁlter, or fuel tank.

Replace faulty fuel pump.

Minimum Speciﬁcations

Fuel Pressure 19 kPa (2.76 psi) Fuel Flow 180 mL/30 seconds

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2-20 FUEL SYSTEM

Air Cleaner

Element Removal

Remove:

•

Air Cleaner Case Nut [A] Upper-case [B] Cleaner Case [C]

Remove:

•

Wing Nut [A] Foam Element [B] Paper Element [C]

Element Installation

Install the element correctly on the air cleaner body.

•

Be sure the paper element is in-place in the air cleaner body.

•

Be sure the foam element is in-place on the paper element body.

•

Element Cleaning and Inspection

NOTE



In dusty areas, the elements should be cleaned more frequently than the recommended intervals.

Because of the danger of highly ﬂammable liquids, do not use gasoline or a low ﬂash-point solvent to clean the element.

Remove the foam element [A] and the paper element [B].

•

Clean the foam element [A] in a bath of detergent and water, and let

•

the element air-dry thoroughly before install it.

Clean the paper element [B] by tapping it gently on a ﬂat surface to

•

remove dust. If the element is very dirty, replace it with a new one.

CAUTION

Do not use compressed air to clean the paper element. Do not oil the paper or foam element.

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FUEL SYSTEM 2-21

Air Cleaner

Cleaner Body Removal

Remove the elements. (see Element Removal)

•

Remove the cleaner body mounting bolts [A] and take off the cleaner

•

body [B].

Cleaner Body Installation

Replace the intake pipe gasket [A] with a new one.

•

Clean the mating surface of the cleaner body and intake pipe.

•

Install the cleaner body on the intake pipe and bracket.

•

Tighten the mounting bolts.

•

Torque - Cleaner Body Mounting Bolts: 9.8 N1m (1.0 kg

m, 87 in

lb)

Housing (Case and Body) Inspection

Clean the housing with detergent and water and dry thoroughly.

•

Check the housing for deformation or other damage. The housing

•

must seal well and permit only ﬁltered air to reach the carburetor.

If the housing is damaged, it must be replaced.

Check that no foreign material is obstructing the air passage.

•

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2-22 FUEL SYSTEM

Digital Fuel Injection (DFI) System Governor Link Mechanism

Control Panel Assembly Removal

Remove:

•

Air Cleaner (see Air Cleaner Body Removal) Mufﬂer (see Mufﬂer Assembly Removal) Control Panel Mounting Bolts [A]

Remove the control panel assembly [A] while unhooking the governor

•

spring [B] end loop at the panel bracket.

Control Panel Assembly Installation

Before installing the control panel assembly, check to see that the

•

engine speed control lever [A] move smoothly in all directions. If any part is worn or damaged, replace the control panel assembly. After installation, adjust the low idle speed and high idle speed to the

•

speciﬁcations (see Low Idle Speed and High idle Speed Adjustment).

Governor Arm Removal

Remove:

•

Control Panel Assembly

Loosen the clamp nut [A] and remove the governor arm [B].

•

Clear the throttle link rod [C] from the governor arm.

•

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FUEL SYSTEM 2-23

Digital Fuel Injection (DFI) System

Governor Arm Installation

Insert the bracket [A] onto the governor shaft [B] thoroughly to the

•

bottom of the woodruff area of the shaft, and tighten the clamp nut

[C].

Torque - Governor Arm Clamp Nut: 8 N1m (0.8 kg

Install the control panel assembly, and connect the bracket with the

•

governor spring [I].

Install the end of the throttle link rod [H] with the link spring [G] around

•

it into the governor arm hole [K], and the other end into the throttle

body assy lever [L] hole.

Be sure the link spring around the throttle link rod is in place and that

•

it pulls the governor arm and throttle lever each other.

Install the governor arm [D] on the bracket [A] with the bolt [F] and

•

washer by turning the bolt counterclockwise so the projection of the

bracket ﬁts into the governor arm hole [E].

Loosen the bolt (turn clockwise) [F], and fully turn the bracket [A]

•

counterclockwise and hold it there.

Turn the top end of the governor arm [D] counterclockwise to

•

fully open the throttle body assy valve and tighten the bolt (turn

counterclockwise) [F].

m, 69 in

lb)

Throttle body Assy

Throttle Body Assy Removal

Remove:

•

Air Cleaner and Related Parts (see Air Cleaner Removal) Radiator (see Radiator Removal) Cooling Fan and Fan Belt (see Cooling Fan and Fan Belt Removal) Fan Mounting Holder

Turn the fuel shut off valve of the OFF position.

•

Loosen the fuel pressure relief screw [A] to relieve the high pressure

•

in the return fuel hose [B], then tighten it.

Disconnect the fuel return fuel hose.

•

Drain the fuel in the hoses into a suitable container.

•

Disconnect the breather hose [C].

•

Unscrew the intake pipe and throttle body assy mounting bolts and

•

nuts [D].

Unhook the throttle link rod [E] at both ends while together pulling off

•

the throttle body assy and fuel pressure regulator.

Throttle Body Assy Installation

Clean the mating surfaces of the throttle body assy and intake pipe,

•

and install new gaskets.

Take care not to bend the throttle link rod during installation.

•

Install the gaskets throttle body assy and intake pipe with mounting

•

bolts and tighten them.

Torque - Throttle Body Assy and Intake Pipe Mounting Bolts: 12 N1m

(1.2 kg

m, 106 in1lb)

Be sure the fuel hoses are clamped securely to prevent leaks.

•

Adjust idle speed.

•

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2-24 FUEL SYSTEM

Digital Fuel Injection (DFI) System

Throttle Body Assy Disassembly

NOTE



Do not attempt to remove the throttle valve and shaft unless they appear to be damaged.

Remove the throttle body assy.

•

Remove the screws [A] and remove the throttle valves [B].

•

Remove the circlip [C] and pull out the throttle shaft [D].

•

Throttle Body Assy Assembly

Before assembling, throughly cleam the throttle body of dirt dust by

•

applying compressed air.

NOTE



Replace the dust seal of the throttle shaft with a new one.

Apply engine oil to the new dust seal insert the throttle shaft.

•

Install the throttle shaft to the throttle body.

•

Apply a non-permanent locking agent to the screws.

•

Install the throttle valves and thighten them.

•

Torque - Throttle valve screws: 0.9 N1m (0.09 kg



After tightening the screws, be sure that the throttle valves is perfectly close in the bore and that the throttle shaft moves freely without any irregularities.

m 7.8 in

lb)

Low Idle Speed Adjustment

Disconnect all possible external loads from the engine.

•

Start the engine and warm it up thoroughly.

•

Always keep your hands clear of the moving parts.

Move the throttle lever on the dash to the idle position.

•

Hold the throttle lever [A] on the carburetor in closed position (turn

•

the governor arm [B] clockwise all the way), and adjust the low idle speed screw [C] until the engine idles at speciﬁed speed.

Idle Speed (Carburetor idle rpm): 1450 rpm

Release the throttle lever and adjust the low idle speed set screw [D]

•

on the control plate to obtain the speciﬁed governed low idle speed.

Low Idle Speed (Governed idle rpm: 1550 rpm

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FUEL SYSTEM 2-25

Digital Fuel Injection (DFI) System

High Idle Speed Adjustment

NOTE



High idle speed adjustment should be made after the idle speed adjustment is performed.

CAUTION

Do not adjust high idle speed with the air cleaner removed.

Start and warm up the engine thoroughly.

•

Always keep your hands clear of the moving parts.

Loosen the lock nut [A], and unscrew the high idle set screw [B] a

•

few turns.

Move the throttle lever on the dash to obtain the speciﬁed high idle

•

speed and leave it there.

High Idle Speed: 3600 rpm

Turn the high idle set screw [B] so that the end of it just touches the

•

speed control lever [C], and tighten the lock nut [A].

Check idle speed, and readjust if necessary.

•

CAUTION

Be sure to make the idle and fast idle speeds respectively correspond to those of the equipment.

Intake Manifold (DFI)

Intake Manifold (DFI) Removal

Turn the ignition switch OFF.

•

Remove:

•

Air Cleaner (see Cleaner Body Removal) Throttle Body Assy (see Throttle Body Assy Removal) Control Panel Assembly

Drain engine coolant (see Coolant Draining).

•

Disconnect:

•

Fuel Injector leads (#1, #2) [A] Water Temperature Sensor Lead [B] Vacuum Sensor Lead [C] Thermo Switch Lead [D]

Unscrew the manifold mounting bolts in numerical sequence, 1/4 turn

•

at a time, until all bolts are loose.

If the mounting bolts removal sequence is not followed, manifold

mating surfaces may be warped.

Remove the manifold [A] and gaskets.

•

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2-26 FUEL SYSTEM

Digital Fuel Injection (DFI) System

Intake Manifold (DFI) Installation

Before assembling the manifold, install the cylinder heads on each

•

cylinder and tighten the head bolts (see Cylinder Head Installation). Place a new gaskets on each mating surface, and install the manifold.

•

Tighten the manifold mounting bolts in sequence 3 N

•

26 in

lb) at a time until the torque on each bolt is 20 N

15 ft

lb).

Torque - Manifold (DFI) Mounting Bolts: 20 N1m ( 2.0 kg

Connect the connectors as shown.

•

m (0.31 kg

m (2.0 kg

m, 15 ft

lb)

[A] #1 Fuel injector (White/Green, White Lead) [B] #2 Fuel Injector (White/Red, White Lead) [C] Air Temperature Sensor (Green, White/Black Lead) [D] Clamp/Tube [E] Vacuum Pressure Sensor (White/Brown Lead) [F] Water Temperature Sensor (Blue, White/Black Lead) [G] Fuel Pressure Regulator [H] Thermo Switch

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FUEL SYSTEM 2-27

Digital Fuel Injection (DFI) System DFI System

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2-28 FUEL SYSTEM

Digital Fuel Injection (DFI) System DFI System Wiring Diagram



Portion surrounded by shows KHI procurement pars.

ECU (Electronic Control Unit)

Vacuum Pressure Sensor

Water Temperature Sensor

Inlet Air Temperature Sensor

#2 Fuel Injector

#1 Fuel Injector

#1 Spark Plug

#1 Ignition Coil

#2. Ignition Coil

10.

#2 Spark Plug

11.

Flywheel

12.

Ignition Switch

13.

Battery (12 V)

14.

Fuel Pump Relay

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NOTE

15.

Main Relay

16.

Diagnosis Lamp

17.

Fuse (10 A)

18.

Seat Switch

19.

Electric Startor

20.

Fuel Pump

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FUEL SYSTEM 2-29

Digital Fuel Injection (DFI) System Terminal Numbers of ECU Connectors

(View from wire side)

#11.

#1 Injector Signal

E1. ECU to Ground E01. Power Source Circuit Ground

FP. Fuel Pump Relay Signal X. Not Used Terminal

E2. Sensor System Circuit Ground S. Seat Switch Signal

WL. Switch Displaying Diagnosis PM1. Vacuum Pressure Sensor Signal

NLG. Engine Speed Signal X. Not Used Terminal

Power Source to Sensor System

VCC.

Power Supply to ECU

+B.

#21.

#2 Injector Signal

Air Temperature Sensor Signal

THA.

Water Temperature Sensor Signal

THW.

Safety Instruction for DFI System Servicing

There are a number of important precautions that must be observed when servicing the electronic fuel injection system. Failure to observe these precautions can result in serious damage. Learn and observe all the rule listed below.

Electrical System

1. Do not disconnect the battery leads or any other electrical connections when the key switch is on, or while the engine is running. This is to prevent damageing the ECU.



Whenever electrical connections are to be disconnected, ﬁrst turn off the key switch, disconnect the lead which connects the fuel injection system harness to the battery positive (+) post and then disconnect the required connection. There are two other leads which are connected to the battery positive post, but these leads can be left connected.

2. Conversely, make sure that all electrical connections are ﬁrmly reconnected before staring the engine.

3. The fuel injection system is designed to be used with a 12 V battery as its power source.

4. Always disconnect the battery positive and negative leads from the terminals, and remove the battery from the equipment for charging. This is to prevent the control unit from being damaged by excessive peak voltage.

5. Avoid spraying water with any great pressure on the electric components, connectors, leads, and wiring harness of the electronic fuel injection system.

6. Keep the electronic fuel injection system wiring harness as for apart as possible from the high tension leads of the ignition system. This is to prevent the control unit from malfunctioning due to external electrical noise.

7. If a transceiver is installed on the equipment, make sure that the operation of the fuel injection system is not inﬂuenced by electric wave radiated from the antenna. Check operation of the system at the engine idles.

NOTE



Locate the antenna as far as possible apart from the control unit. Interference from radio waves can be reduced by grounding the control unit box to the equipment.

Fuel System

NOTE

1. Do not operate the fuel pump dry. This is to prevent the pump from running without lubricant at the friction surfaces.

2. Blow the fuel system components with compressed air before removing the parts.

3. Any hose clamps on the high pressure fuel line must be replaced with new ones once they are loosened.

NOTE



Install the hose clamps in the position, and securlly tighten the clamps. Check the fuel system for leaks.

4. To prevent corrosion and deposits in the fuel system, do not add any antifreeze chemicals.

Air System

1. In order to maintain the correct fuel/air mixture ratio, there should be no air leaks in the system.

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2-30 FUEL SYSTEM

Digital Fuel Injection (DFI) System Electrical Control Unit (ECU)

CAUTION

Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it.

ECU Removal

Remove the bolts [A].

•

Remove ECU [B].

•

If necessary, disconnect the connector [C].

ECU Connector Inspection

Visually inspect the terminals [A] of the ECU connectors.

•

If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the harness connector are cracked, bent, or otherwise damaged. Replace the ECU if the terminals of the ECU connector are cracked, bent or otherwise damaged.

ECU Ground Inspection

Disconnect the ECU connector.

•

Connect the ECU adapter [A] between the connectors [B].

•

Special Tool - ECU Adapter: 57001–1500

NOTE



Terminal number of harness adapter is the same as the ECU connector (see Terminal Number of ECU Adapter).

Connect the handtester to the adapter and Engine ground (or Battery

•

Terminal (-)).

E1 or E01 (BK/W) Terminal E2 (BK/Y) Terminal

[A]: ECU [B]: ECU Adapter [C]: Hand Tester [D]: Engine Gound [E]: Harness

Special Tool - Hand Tester: 57001–1394

If no continuity check the connector or the wire harness (Engine Ground Wire). Repair or replace as necessary.

! !

Engine Ground: 0 Engine Ground: 0

 

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FUEL SYSTEM 2-31

Digital Fuel Injection (DFI) System

ECU Power Source Inspection

Set the tester [A] to the DC25 V range and connect it to the adapter

•

[B].

Special Tool - ECU Adapter: 57001–1500

Hand Tester: 57001–1394

Connections:

Tester Positive (+) Tester Negative (-)

Ignition SW OFF Position:

ECU Power Source Voltage: 0 V

Ignition SW RUN Position:

ECU Power Source Voltage: Battery Voltage (12.5 V or more)

If the tester does not read as speciﬁed, check the following:

Power Source Wiring [A] Fuse (10 A)

Main Relay If the above checks prove in order, then the ECU is damaged and the ECU must be replaced.

+B (W) Terminal

E1 or E01 (BK/W) Terminal

Fuel Pump

Fuel Pump Operation Inspection

NOTE



Be sure the battery is fully charged.

Turn the ignition switch RUN position and make sure that fuel pump

•

operates (make light sounds) for 3 seconds, and then stops. Turn the ignition switch OFF.

•

If the pump does not work as described above, inspect the operating voltage.

Operating Voltage Inspection

NOTE



Be sure the battery is fully charged.

Turn the ignition switch OFF.

•

Connect the hand tester (25 V DC) to the fuel pump connectors.

•

Special Tool - Hand Tester: 57001–1394

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2-32 FUEL SYSTEM

Digital Fuel Injection (DFI) System



Measure the operating voltage with the engine stopped, and with the connector joined. Turn the ignition switch RUN position.

•



The tester needle should indicate battery voltage for 3 seconds, and then 0 V.

Pump Operating Voltage at Pump

Connections to Pump Connectors

Tester (+) Tester (–)

Operating Voltage at Pump Connector

Standard: Battery Voltage (12.5 V or more) for 3 seconds,

If the reading stays on battery voltage, and never shows 0 V. Check the ECU and fuel pump relay. If the voltage is in speciﬁcation, but the pump doesn’t work , replace the pump. If there is still no battery voltage, check the pump relay .

Fuel Flow Rate Inspection



Be sure the battery is fully charged.

Pump (+) Terminal

Engine Ground

and then 0 V.

NOTE

Gasoline is extremely ﬂammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of ﬂame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

Prepare a measuring cylinder.

•

Disconnect the fuel hose from the fuel pump out let pipe [A].

•

Connect the appropriate hose and measuring cylinder [B] as shown.

•

Quickly plug the fuel hose with a plug [C].

•

Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical.

Turn the ignition switch to the RUN position. The fuel pump should

•

operate for 3 seconds, and then stop.



Measure the fuel ﬂow rate so that the appropriate hose ﬁlled with fuel.

Amount of Fuel Flow

Standard: 120 mL or more for 3 seconds

If the fuel ﬂow is much less than the speciﬁed, check the following:

Fuel Pump Fuel Filter Fuel Tank

After inspection, connect the fuel hoses. (see Fuel Tank Installation).

•

Start the engine and check for fuel leakage.

•

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FUEL SYSTEM 2-33

Digital Fuel Injection (DFI) System Fuel Injectors (#1, #2)

CAUTION

Never drop the injector, especially on a hard surface. Such a shock to the injector can damage it.

Fuel Injector Removal

Turn the ignition switch OFF.

•

Remove:

•

Air Cleaner and Related Parts (see Air Cleaner Removal)

Radiator (see Radiator Removal)

Cooling Fan and Fan Belt (see Cooling Fan and Fan Belt Removal)

Throttle Body Assy (see Throttle Body Assy Removal)

Injector Cap [A] Disconnect the injector connector [B].

•

Pull out the fuel injector [C] from the intake manifold.

•

NOTE



Take care not to damage the injector inserts when they are pulled from the throttle body.

Fuel Injector Installation

Replace the seal and O-ring with a new one.

•

Apply engine oil to the seal and O-ring.

•

Install the injector to the intake manifold.

•

Securely place the projections [A] of the injector cap into the holes

•

[B] of the Intake. Connect the injector connector.

•

Power Source Voltage Inspection

Refer:

•

ECU Power Source Inspection in this chapter If the power source voltage is normal, check the injector out put voltage at injector.

Output Voltage Inspection

Measure the output voltage at the injector connector in the same

•

way as power source voltage inspection. Turn the ignition S.W RUN position, but do not start the engine.

Injector Output Voltage at Injector

Connections to injector #1

Tester Positive (+) Tester Negative (–)

#11 (Y/BL) Terminal

E1 or E01 (BK/W) Terminal

Connections to injector #2

Tester Positive (+) Tester Negative (–)

Output Voltage at Injector Connector

Standard: Battery Voltage (12.5 V or more)

Special Tool - ECU Adapter [A]: 57001–1500

Hand Tester [B]: 57001–1394

If the output voltage is normal, check the wiring for continuity. If the wiring is good, perform “Audible Inspection” for conﬁrmation. If the output voltage is out of the standard, perform “Audible Inspection” for conﬁrmation.

#21 (W/R) Terminal

E1 or E01 (BK/W) Terminal

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2-34 FUEL SYSTEM

Digital Fuel Injection (DFI) System

Audible Inspection

Start the engine.

•

Apply the tip of a screwdriver [A] to the injector [C]. Put the grip end

•

onto your ear, and listen whether the injector is clicking or not. A sound scope [B] can also be used.

•

Do the same for the other injector.

•

If all the injectors click at a regular intervals, the injectors are good.



The click interval becomes shorter as the engine speed rises. If either injector doesn’t click, perform the “Injector Signal Test” for injector operation.

Injector Signal Test

Prepare two test light sets with male terminals as shown.

•

Rating of Bulb [A]: 12 V Terminal Width [B]: 1.8 mm Terminal Thickness [C]: 0.8 mm

Do not use larger terminals than speciﬁed above. A larger terminal could damage the injector main harness connector (female), leading to harness repair or replacement. Be sure to connect bulbs in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current.

Remove connectors for injector [A].

•

Connect each test light set [B] to the injector harness connector [C].

•

Turn the ignition switch ON.

•

While cranking the engine with the starter motor, watch the test lights.

•

If the test lights ﬂicker at regular intervals, the injector circuit in the ECU, and the wiring are good. Perform the “Injector Resistance Inspection”.

3 3.4 W

CAUTION



Injector signals can be also conﬁrmed by connecting the hand tester (

10 V AC) instead of the test light set to the injector harness (female) connector. Crank the engine with the starter motor, and check to see if the hand oscillates at regular intervals.

Special Tool - Hand Tester: 57001–1394

If the test light doesn’t ﬂicker (or the test hand does not oscillate), check the wiring and connectors again. If the wiring is good, replace the ECU.

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FUEL SYSTEM 2-35

Digital Fuel Injection (DFI) System

Injector Resistance Inspection

Disconnect the connector from the injector [A] (see Injector Removal).

•

Measure the injector resistance with hand tester [B].

•

Injector Resistance

Connections to Injector

Tester (+) Tester (–) #1: W #2: W

! !

Y/BL Terminal Y/R Terminal

Standard: 12.5

If the reading is out of the range, perform the “Injector Unit Test”. If the reading is normal, perform the “Injector Unit Test” for comﬁrmaion.

Injector Unit Test

Use two wires [A] and the same test light set [B] as in “Injector Signal

•

Test”

Rating of Bulb [C]: 12 V 12 V Battery [D]

Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current.

Connect the test light set to the injector [E] as shown.

•

Open and connect [F] the end of the wire to the battery (–) terminal

•

repeatedly. The injector should click. If the injector does not click, replace the injector. if the injector clicks, check the wiring again. If the wiring is good, replace the ECU.



(3 3.4) W

CAUTION

Fuel Pressure Regulator

Fuel pressure Regulator Removal

Loosen the fuel pressure relief screw [A] to relieve the high pressure

•

in the return fuel hose, then tighten it. Remove:

•

Air Cleaner (see Air Cleaner Body Removal) Vacuum Hose [B] Fuel Return Hose [C] Bolts [D]

Carefully remove the regulator.

•

Fuel Pressure Regulator Installation

Check the vacuum tube, fuel hose and O-ring for brittleness, cracks,

•

diformation or damaged, and replace, if necessary. Apply engine oil to the O-ring.

•

Install:

•

Fuel Pressure Regulator Vacuum Hose and Clamp Fuel Return Hose and Clamp

Tighten the Bolts.

•

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2-36 FUEL SYSTEM

Digital Fuel Injection (DFI) System

Fuel Pressure Regulator Inspection

NOTE



Be sure the battery is fully charged.

Loosen the fuel pressure relief screw to relieve the high pressure in

•

the return fuel hose, Then tighten it. Disconnect the fuel hose ﬁtting from the throttle body assy.

•

Install the prepare pressure gauge [A] between the fuel hose and

•

throttle body assy. Tighten the hose clamp in the correct position.

•

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. Do not try to start the engine with the fuel hoses disconnected.

Start the engine, and set the high idle speed.

•

High Idle Speed: 3600 rpm

Measure the fuel pressure.

•

Fuel Pressure

Standard: 172

182 kPa (1.75 1.85 kg/cm2, 24.9 26.4 psi)

If the fuel pressure is higher than the speciﬁed, check the following:

Fuel Return Hose for sharp bends, kinking, or clogging

Vacuum Hose of the Pressure Regulator for air leaks If they prove good, replace the pressure regulator. If the fuel pressure is much lower than speciﬁed, check the following:

Fuel Line Leakage

Fuel Filter and Fuel Pump If inspection above checks out good, replace the pressure regulator or fuel pump (see ﬂuid ﬂow rate inspection). Remove pressure gauge.

•

Connect the fuel hose to the throttle body assy and clamp it.

•

Self-Diagnosis

Self-Diagnosis Outline

When an abnormality in the ECU system occurs, the Self-Diagnosis

light ﬂash to alert the user, and initiates fail-safe function.

Self-Diagnosis Procedures

Turn on the ignition switch. The Self-Diagnosis light should ﬂash when

•

the switch is turned on. Turn off ignition switch.

•

If the bulb does not ﬂash as described above, check the bulb and wiring of the diagnosis light in the chassis side harness. Turn on the ignition switch again, the Self-Diagnosis light should ﬂash.

•

After about two second, count the number of blinks of the Self-

•

Diagnosis light to read the fault code.

NOTE



Use a fully charged battery when conducting self diagnosis. otherwise, the Self-Diagnosis light will blink very slowly or not at all.

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FUEL SYSTEM 2-37

Digital Fuel Injection (DFI) System

How to Read Fault Codes



Fault codes are shown by a series of long and short blinks of the Self Diagnosis light as shown below.



Read 10th digit and unit digit as the Self Diagnosis light blinks.



When there are a number of problems, all the fault codes can be stored and the display will begin starting from the lowest number fault code in the numerical order. Then after completing all codes, the display is repeated until the ignition switch is turned OFF.



If there is no problem, no code is shown.



For example, if the problems 12 and 22 occur, the fault codes 12 and 22 are shown as follows.

22)

(12

22)

(12

!111111

(repeated)

[A]: 10th digit [B]: Unit digit

Fault

Code

12 13

Footnotes:

1. The ECU may be involved in these problems. If all the parts and circuits check out, check the ECU for ground and power supply. If the ground and power supply are good, replace the ECU.

Self-Diagnoss Light Problems (1)

ON OFF

Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Vacuum pressure sensor malfunction, wiring open or short

Atmospheric pressure measurement error (engine stop, then turn on the ignition switch slowly)

Inlet Air Temperature Sensor (Fault Code 12)

CAUTION

Never drop the sensor, especially on a hard surface. Such a chock to the sensor can damage it.

Removal

Remove the air cleaner upper case and elements.

•

Disconnect the connector [A] from the inlet air temperature sensor.

•

Support the tapered portion with suitable tool and remove the inlet

•

air temperature sensor.

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2-38 FUEL SYSTEM

Digital Fuel Injection (DFI) System

Installation

Push the sensor [A] into the grommet [B] until the ﬂange of sensor

•

[C] touches the grommet, and locks knob [D].

[E]: Air Cleaner Body

Output Voltage Inspection

NOTE



Be sure the battery is fully charged.

Turn the ignition switch OFF.

•

Disconnect the ECU connector.

•

Connect the adapter [A] between the connectors.

•

Special Tool - ECU Adapter: 57001–1500

Set the tester [B] to the DC 10 V range and connect it to the adapter.

•

Special Tool - Hand Tester: 57001–1394 Connections:

Tester Positive (+) Tester Negative (–)

Turn the ignition switch to the RUN position.

•

Output Voltage

Standard: about 2.26



The output voltage changes according to the inlet air temperature.

Turn the ignition switch OFF.

•

If the output voltage is out of the speciﬁed, check the ECU’s ground, and power supply (see ECU section in this chapter). If the ground and power supply are good, replace the ECU. If the output voltage is far out of the speciﬁed, check the wiring. If the wiring is good, check the sensor resistance.

THA (G) Lead

E2 (BK/Y) Lead

2.50 V at inlet air temperature 20C (68F)

NOTE

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FUEL SYSTEM 2-39

Digital Fuel Injection (DFI) System

Sensor Resistance inspection

Remove the inlet air temperature sensor (see this section).

•

Suspend the sensor [A] in a container of machine oil so that the heat-

•

sensitive portion and threaded portion are submerged. Suspend a thermometer [B] with the heat-sensitive portion [C] located

•

in almost the same depth with the sensor.

NOTE



The sensor and thermometer must not touch the container side or bottom.

Place the container over a source of heat and gradually raise the

•

temperature of the oil whilestirring the oil gently foreventemperature. Using a digital meter, measure the internal resistance of the sensor

•

across the terminals at the temperatures shown in the table.

Inlet Air Temperature Sensor Resistance

2.21

0.133

5.47 k

2.69 k

0.163 k

Standard: 5.29

If the measurement is outside the speciﬁed range, replace the sensor. If the measurement is within the speciﬁed range, replace the ECU.

 

at 0 at 20



at 80



C (32



C (68F)



C (176



Water Temperature Sensor (Fault Code 13)

Removal/Installation

CAUTION

Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.

Disconnect the sensor connector [A], and unscrew the water temper-

•

ature sensor [B]. Install new water temp sensor.

•

Silicone Sealant (Kawasaki Bond: 56019–120)

- Threads of Water Temperature Sensor

Torque - Water Temperature Sensor: 20 N

Fill the engine with coolant and bleed the air from the cooling system

•

(see Coolant Filling in the Cooling System chapter).

Output Voltage Inspection

NOTE



Be sure the battery is fully charged.

Measure the output voltage at the water temperature sensor connec-

•

tor the same way as the inlet air temperature sensor output voltage inspection. Note the following.

Connections:

Tester Positive (+) Tester Negative (–)

THW (BL) Lead

E2 (BK/Y) Lead

m (2.0 kg1m, 14 ft1lb)

Output Voltage

Standard: about 2.26

2.50 V at 20C

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2-40 FUEL SYSTEM

Digital Fuel Injection (DFI) System

NOTE



The output voltage changes according to the coolant temperature in the engine.

If the output voltage is out of the speciﬁed range, check the ECU’s ground and power supply (see his chapter). If the ground and power supply are good, replace the ECU. If the output voltage is far out side the speciﬁed range, check the wiring. If the wiring is good, check the water temperature sensor resistance.

Water Temperature Sensor Inspection

Remove the water temperature sensor.

•

Suspend the sensor [A] in a container of coolant so that the

•

temperature-sensing projection and threaded portion are submerged. Suspended an accurate thermometer [B] in the coolant.

•

NOTE



The sensor and thermometer must not touch the container side or bottom.

Place the container over a source of heat and gradually raise the

•

temperature of the coolant while stirring the coolant gently. Using the hand tester, measure the internal resistance of the sensor.

•



The sensor sends electric signals to the ECU (Electronic Control Unit).



Measure the resistance across the terminals and the body (for the gauge) at the temperatures shown in the table below. If the hand tester does not show the speciﬁed values, replace the sensor.

Water Temperature Sensor Resistance

Temperature

20C (68F) 2.21 2.69 1.96 2.94

80C (176

110C (230



0.290 0.354 0.258 0.386

0.133 0.163 0.118 0.178

Resistance (k)

Standard Service Limit

Vacuum Sensor (Fault Code 21)

CAUTION

Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it.

Removal/Installation

Remove the air cleaner.

•

Disconnect the vacuum sensor connector [A].

•

Remove:

•

Vacuum Hose Bolts [B]

Remove the vacuum sensor [C].

•

Make sure the vacuum hose does not get pinched or kinked.

•

Input Voltage Inspection

NOTE



Be sure the battery is fully charged.

Turn the ignition switch OFF.

•

Disconnect the ECU connector.

•

Connect the adapter between the connectors.

•

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FUEL SYSTEM 2-41

Digital Fuel Injection (DFI) System

Special Tool - ECU Adapter: 57001–1400

Set the tester [A] to the DC 10 V range, and connect it to the adapter

•

[B].

Special Tool - Hand Tester: 57001–1394 Connections:

Tester Positive (+) Tester Negative (–)

Turn the ignition switch to the RUN position.

•

Read the voltage of the tester.

•

Input Voltage

Standard: 4.75

If the reading is less than the standard range, check the ECU’s ground, and power supply (see this chapter). If the ground and power supply are good, replace the ECU. If the reading is good, the input voltage is normal, check the output voltage.

Output Voltage Inspection

Measure the output voltage in the same way as the input voltage

•

inspection. Note the following.

Vacuum Sensor Output Voltage

Connections

Tester Positive (+) Tester Negative (–)

VCC (BR/BL) Lead

E2 (BK/Y) Lead

5.25 V DC

PM1 (BR) Lead

E2 (BK/Y) Lead

Output Voltage

Usable Range: 3.26



Depending on the local atmospheric pressure, the output voltage should be changed according to the chart.

[Vout]: Output Voltage

[Popt]: Local Atmospheric Pressure if the output voltage is normal, check the wiring for continuity. If the output voltage is outside the usable range, replace the sensor. Turn the ignition switch OFF.

•

Remove the ECU adapter.

•

4.04 V DC at the standard atmospheric

Puressure (101.32 kPs, 76 cmHg abs.)

NOTE

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COOLING SYSTEM 3-1

Cooling System

Table of Contents

Exploded View...................................................................................................................................................................3-2

Speciﬁcations....................................................................................................................................................................3-4

Cooling System.................................................................................................................................................................3-5

Coolant..............................................................................................................................................................................3-6

Coolant Deterioration.................................................................................................................................................3-6

Coolant level Inspection.............................................................................................................................................3-6

Coolant Draining.........................................................................................................................................................3-6

Coolant Filling.............................................................................................................................................................3-7

Air Bleeding................................................................................................................................................................3-7

Visual Leak Inspection...............................................................................................................................................3-8

Cooling System Pressure Testing..............................................................................................................................3-8

Flushing......................................................................................................................................................................3-9

Water Pump....................................................................................................................................................................3-10

Water Pump Removal..............................................................................................................................................3-10

Water Pump Installation...........................................................................................................................................3-10

Water Pump Disassembly........................................................................................................................................3-11

Internal Parts — Mechanical Seal...........................................................................................................................3-11

Pumps Parts Inspection...........................................................................................................................................3-12

Water Pump Assembly.............................................................................................................................................3-12

Radiator...........................................................................................................................................................................3-13

Radiator Removal.....................................................................................................................................................3-13

Radiator Installation..................................................................................................................................................3-13

Radiator Inspection..................................................................................................................................................3-13

Radiator Cap Inspection...........................................................................................................................................3-14

Radiator Hose Inspection.........................................................................................................................................3-14

Radiator Hose Installation Notes.............................................................................................................................3-15

Cooling Fan, Fan Belt.....................................................................................................................................................3-16

Belt Tension Check...................................................................................................................................................3-16

Belt Replacement ....................................................................................................................................................3-16

Cooling Fan, Fan Belt Removal...............................................................................................................................3-17

Cooling Fan, Fan Belt Installation............................................................................................................................3-18

Cooling Fan, Fan Belt Inspection.............................................................................................................................3-18

Fan Bearing Removal...............................................................................................................................................3-18

Fan Bearing Installation............................................................................................................................................3-18

Thermostat......................................................................................................................................................................3-19

Thermostat Removal and Installation.......................................................................................................................3-19

Thermostat Inspection..............................................................................................................................................3-19

Thermo Switch................................................................................................................................................................3-20

Thermo Switch Removal and Installation.................................................................................................................3-20

Thermo Switch Inspection........................................................................................................................................3-20

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3-2 COOLING SYSTEM

Exploded View

G: Apply grease.

T1: 6 N

m (0.6 kg1m, 52 in1lb) T3: 20 N T5: 1.2 N

m (2.0 kg1m, 15 ft1lb)

m (0.12 kg1m, 11 in1lb)

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COOLING SYSTEM 3-3

Exploded View

1. Thermo Switch

2. Thermostat

3. Drain Plug

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

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S: Follow the speciﬁc tightening sequence.

SS: Apply silicone sealant.

T2: 10 N T3: 20 N T4: 27 N T5: 1.2 N

m (1.0 kg1m, 87 in1lb)

m (2.0 kg1m, 15 ft1lb)

m (2.8 kg1m, 20 ft1lb)

m (0.12 kg1m, 11 in1lb)

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3-4 COOLING SYSTEM

Speciﬁcations

Item

*Coolant:

Type Permanent type of antifreeze for aluminum engine and radiator Color Green Mixed ratio 50% solution of ethylene glycol Freezing point -35 Total amount 2.7 L (2.9 US qt)

Radiator Cap Relief Pressure:

Pressure valve (positive) 78 to 98 kPa (0.80 to 1.00 kg/cm Vacuum valve (negative) 4.90 kPa (0.050 kg/cm

Thermostat:

Valve openning temperature 80.5 to 83.5 Valve full openning lift not less than 8 mm (0.31 in) at 95

Thermo Switch:

Detect Temerature 108 to 114

*A permanent type of antifreeze is not installed in the cooling system when shipped.



C (-31



C (177 to 182



C (226 to 237

, 0.71 psi)



Standard

, 11.3 to 14.2 psi)



C (203



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COOLING SYSTEM 3-5

Cooling System

This engine is equipped with a highly efﬁcient pressurized cooling system using a thermostat to maintain an optimum operating temperature. Coolant bypasses the closed thermostat when cold until operating temperature is attained, causing the engine to warm up more quickly. If the coolant temperature becomes too high, a thermo switch on the engine activates the coolant warning lamp to alert the operator or cooling problem.

[A] Radiator [B] Radiator Cap [C] Cooling Fan [D] Engine Body [E] Thermos Switch [F] Thermostat [G] Jiggle Valve [H] Bypass Tube [I] One Way Valve [J] Drain Plug [K] Water Pump (Impeller)

Prior to disassembly of cooling system parts (radiator, pump, sensor, etc), wait until the coolant cools down, and then drain the coolant.

CAUTION

After assembling and ﬁlling the system with a coolant, purge any air from the system.

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3-6 COOLING SYSTEM

Coolant

Coolant Deterioration

Visually inspect the coolant in the radiator.

•



If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, ﬂush the cooling system.



If the coolant gives off an abnormal smell when changing, check for a cooling system leak. It may be caused by exhaust gas leaking in to the cooling system.

Coolant level Inspection

Put the engine on a level surface.

•

Remove the radiator cap turning it counterclockwise and check the

•

coolant level in the radiator.

Always allow the engine to cool before removing the radiator cap. Then remove the cap slowly and carefully to avoid a possible fast discharge of hot coolant which could cause severe burns.

Coolant level must be maintained a level of the ﬁller neck bottom [A].

•

If the amount of the coolant is insufﬁcient, ﬁll the radiator up to the bottom of the radiator ﬁller neck [A] with the coolant, and install the cap turning it clockwise.

CAUTION

For reﬁlling, add the speciﬁed mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often, there is probably leakage in the cooling system. Check the system for leaks (see Visual Leak Inspection, and Pressure Testing).

Coolant Draining

The coolant should be changed periodically to ensure long engine

life.

CAUTION

Use coolant containing corrosion inhibitors made speciﬁcally for aluminum engines and radiators in accordance with the instructions of the manufactures (see Coolant Filling Section).

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COOLING SYSTEM 3-7

Coolant

To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Since coolant is harmful to the human body, do not use for drinking.

Remove the radiator cap [A] as follows.

•



First turn the cap counterclockwise to the ﬁrst stop and wait there for

a few seconds.



Push down the cap, then turn the cap counterclockwise to the next

stop.



Lift off the cap.

Place a suitable container under the drain plug [B] (black head). Turn

•

the drain plug counterclockwise to drain the coolant in the radiator

and water jacket.

Inspect the old coolant for color and smell (see Coolant Deterioration).

•

Coolant Filling

Install the drain plug. Always replace the gaskets with a new ones, if

•

they are damaged.

Tighten the drain plug to the speciﬁcation (see Exploded Views).

•

Fill the radiator up to bottom of the radiator ﬁller neck [A] with coolant,

•

and install the cap turning it clockwise.

NOTE



Pourin the coolant slowly so that it can expelthe air from the engine and radiator.



To install the radiator cap, push down it and then turn the cap clockwise to the rest of the way.

CAUTION

Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and considerably reduces the efﬁciency of the cooling system.

NOTE



Choose a suitable mixture ratio by referring to the coolant manufacturer’s instructions.

Original Coolant

Type: Permanent type antifreeze for aluminum en-

gine and radiator Color: Green Mixed ratio: 50% solution of ethylene glycol Freezing Point: -35 Total amount: 2.7 L (2.9 US qt)

Air Bleeding

Before putting the engine intooperation, any air trapped in the cooling

system must be removed as follows.

Remove the radiator cap.

•

Fill the radiator up to the radiator ﬁller neck with coolant.

•

Check the cooling system for leaks.

•

Install the radiator cap.

•

Start the engine, warm it up thoroughly, and then stop it.

•

Check the coolant level in the radiator after the engine cools down.

•

If the coolant level is low, add coolant up to the ﬁller neck bottom [A]. Install the cap.

•



C (-31F)

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3-8 COOLING SYSTEM

Coolant

Visual Leak Inspection

Any time the system slowly loses water, inspect forleaks. Small leaks may appear only a rust, corrosion or stain due to evaporation. Watch for these trouble spots.

Checkthe water pump housing drainage outlet passage [A] forcoolant

•

leaks.

If the mechanical seal is damaged, the coolant leaks through the seal

and drain through the passage. Replace the mechanical seal [B].

If there are no apparent leaks, pressure test the system.

Cooling System Pressure Testing

Air pressure leakage tester can help locate external leaks but they cannot depended upon to locate small combustion leaks.

CAUTION

During pressure testing, do not exceed the pressure for which

the system is designed. The maximum pressure is 102.7 kPa

(1.05 kg/cm

, 14.9 psi).

Remove the radiator cap, and install a cooling system pressure tester

•

[A] on the radiator ﬁller neck.

Wetthe cap sealing surfaces with water or coolant to prevent pressure

•

leaks.

Build up pressure in the system carefully until the pressure reaches

•

60 kPa (0.61 kg/cm

Watch the pressure gauge for at least 6 seconds. If the pressure

•

holds steady, the system is all right.

Removethe pressure tester, replenish the coolant, and install the cap.

•

If the pressure drops and no external source is found, check for

internal leaks. Droplets in the engine oil indicate internal leakage.

Check the cylinder head gaskets.

, 8.7 psi).

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COOLING SYSTEM 3-9

Coolant

Flushing

Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspectedor observed, ﬂush the cooling system. If this accumulations is not removed, it will clog up the water passage and considerably reduce the efﬁciency of the cooling system.

Prior to disassembly of cooling system parts (radiator, pump, sensor, etc), wait until the coolant cools down, and then drain the coolant.

CAUTION

After assembling and ﬁlling the system with a coolant, purge any air from the system.

Drain the cooling system.

•

Fill the cooling system with fresh water mixed with a ﬂushing

•

compound.

CAUTION

Avoid the use of a ﬂushing compound which is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacturer of the cleaning product.

Warm up the engine, and run it at normal operating temperature for

•

about ten minutes.

Stop the engine, and drain the cooling system.

•

Fill the system with fresh water.

•

Warm up the engine and drain the system.

•

Repeat the previous two steps once more.

•

Fill the system with a permanent type coolant, and bleed the air from

•

the system.

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3-10 COOLING SYSTEM

Water Pump

Water Pump Removal

Remove:

•

Mufﬂer (see Mufﬂer Assembly Removal)

Loosen the hose clamp [A] and disconnect the water hose [B] at the

•

coolant inlet port of the water pump [C].

Unscrew the water pump mounting bolts in the order shown, and

•

remove the water pump assembly.

NOTE



Note the position of differentlength of bolts so they can be installed in their original positions.

Bolt Dimensions

[A] Bolt M8, L = 80 mm (3.15 in) [B] Bolt M8, L = 45 mm (1.77 in) [C] Bolt M8, L = 30 mm (1.18 in) [D] Bolt M8, L = 60 mm (2.36 in)

Water Pump Installation

Chip the old gasket off the mating surface of the pump-cover and

•

pump housing. Apply sealant bead [A] (wide 1 2 mm) to the mating surface of the

•

pump housing [B] and pump cover [C] as shown in the ﬁgure.

Sealant - Kawasaki Bond (Silicone Sealant): 56019–120

CAUTION

Does not get the sealant into the water line hole on the crankcase or crankcase cover.

Be sure to suitable set the pump gear to be meshed with the cam

•

gear when installing the pump assembly. Do not force the pump into position.

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COOLING SYSTEM 3-11

Water Pump

Install the mounting bolts and tighten them in the order shown.

•

Torque - Water Pump and Cover Mounting Bolts: 20 N1m (2.0 kg

lb)

Note the position of different length of bolts.

•

Water Pump Disassembly

For disassembly, follow the steps (1

10) below (see Illustration).

NOTE



Do not attempt to remove the mechanical seal, oil seal and O-ring unless they are to be replaced.

1. Plastic pump gear [A]

2. Dowel pin [B]

3. Claw washer [C]

4. Extract the impeller subassembly [L] [K] [J] [I] [H] [G] from the pump housing [M]

5. Mechanical seal cartridge [F]

6. Oil seal [D]

7. Dowel Pin [K]

8. Impeller [L]

9. Mating ring [G] and cup-gasket [H]

10. O-ring [J]

[A] Pump Gear [H] Cup Gasket [B] Dowel Pin (1) [I] Pump Shaft [C] Claw Washer [J] O-Ring [D] Oil Seal [K] Dowel Pin (2) [E] Drainage outlet passage [L] Impeller [F] Cartridge [M] Pump Housing [G] Mating Ring

m, 15

Internal Parts — Mechanical Seal

[A] Mating Ring (Floating Seat) [B] Cup Gasket (Cushion Ring) [C] Seal Ring [D] Bellows [E] Spring Retainer [F] Coil Spring [G] Casing [H] Cartridge

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3-12 COOLING SYSTEM

Water Pump

Pumps Parts Inspection

Clean all parts except plastic and rubber parts in a bath of high ﬂash-

•

point solvent and dry them compressed air. Clean non-metal parts with detergent and water, and dry them. Inspect the pump housing for damage. Mating surfaces should be

•

smooth and free of burrs and nicks. Check the other parts for wear or damage, replace the parts if

•

necessary. If the mechanical seal is damaged, the coolant leaks through the seal, and drain through the drainage outlet passage. If the oil seal is damaged, the engine oil drain through the drainage passage. If the mechanical seal parts are damaged, replace the seal as a set. Visually check the impeller.

•

If the surface is corroded, or if the blades are damaged, replace all internal pump parts.

Measure the outside diameter [B] of the impeller shaft [A] with a

•

micrometer at several points. If the shaft end diameter is less than service limit, replace the shaft.

Outside Diameter of Impeller Shaft

Service Limit: 9.935 mm (0.3911 in)

Measure the inside diameter of the water pump shaft bearing on the

•

pump housing at several points. This bearing is not replaceable. Replace the pump housing and shaft as a set if the inside diameter is more than the service limit.

Water Pump Shaft Bearing Inside Diameter

Service Limit: 10.088 mm (0.3972 in)

Water Pump Assembly

When installing the mating ring [A] into the cup gasket [B], moisten

•

outside surface of the mating ring with fresh water and then push the ring into the stop end. Do not damage mating surfaces.



Pack some amount of high temperature grease into the oil seal [C]. Press in the oil seal using a suitable tools so that the oil seal is ﬂush with the shoulder surface.

NOTE



The oil seal must be assembled with spring loaded lip towardinside of the engine.

When installing the impeller [D] sub assembly to the housing [E], coat

•

mating surfacesbetween the mating ring and seal ring [F] with a clean water. To avoid oil seal damage, coat thin ﬁlm of engine oil on the pump

•

shaft [G], and then carefully insert pump shaft into the housing.

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COOLING SYSTEM 3-13

Radiator

Radiator Removal

Always allow the engine to cool before removing the radiator cap. Then remove the cap slowly and carefully to avoid a possible fast discharge of hot coolant which could cause severe burns.

Remove the radiator cap and drain the coolant in the radiator (see

•

Coolant Draining). Loosen the hose clamps [A], and disconnect the radiator hoses [B].

•

Unscrew the radiator mounting bolts [C].

•

Remove the radiator [A] pulling toward you and up.

•

Radiator Installation

Installation is the reverse of removal.

•

Torque - Radiator Mounting Bolts: 6 N1m (0.6 kg

Radiator Inspection

Check the radiator core.

•

If the corrugated ﬁns are deformed, carefully straighten them with the blade of thin screw driver [A]. Inspect the inlet and outlet tubes for cracks, kinks, dents, and

•

fractured seams. Repair or replace the radiator, if necessary. Check for dirt and insects that may be lodged in the radiator. Clean

•

them out by using compressed air or a low-pressure washer.

CAUTION

Using high-pressure water, as from a car wash facility, could damage the radiator ﬁns and impair the radiator’s effectiveness.

If the air passages of the radiator core are blocked more than 30%

•

by unremovableobstructions or irreparablydeformed ﬁns, replace the radiator with a new one. If a radiator leak is detected, by cannot be spotted visually, test it as follows:

1. Install the radiator cap, and plug the overﬂow tube [A] and inlet pipe [B]. Attach an air hose [D] to the outlet connection [C].

2. Pressurize the inside of the radiator with compressed air to about 50 to 70 kPa (7 to 10 psi).

3. Submerge the radiator in water and look for bubbles [E] which indicate the location of the leak.

4. Repair any leaks or replace it with a new one.

m, 52 in

lb)

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3-14 COOLING SYSTEM

Radiator

Check the radiator ﬁller neck for signs of damage.

•

Check the condition of the top [A] and bottom [B] sealing seats in the

•

ﬁller neck. They must be smooth and clean for the radiator cap to function properly.

Radiator Cap Inspection

The radiator cap has two functions:

1. Allow atmospheric pressure to enter the cooling system.

2. Prevents coolant escape at normal operating pressure.

A pressure valve[E] in the cap permits the escape of coolant or steam

when the pressure in the system rises above the relief pressure.

A vacuum valve [D] in the cap opens when needed to prevent a

vacuum in the cooling system.

Check the condition of the valve spring [A], and the top [B] and bottom

•

[C] valve seats of the radiator cap. If any one of them shows visible damage, replace the cap.

Wet the radiator cap [B] seating surfaces with water or coolant to

•

prevent pressure leaks. Install the cap on a cooling system pressure tester [A].

•

Watching the pressure gauge, pump the pressure tester to build up

•

the pressure. The cap must retain the pressure at least 6 seconds. Also the cap must open at the pressure shown in the table.

Radiator Cap Relief Pressure

Pressure Valve: Vacuum Valve: 4.90 kPa (0.050 kg/cm

If the cap cannot hold the speciﬁed pressure, or if it holds too much pressure, replace it with a new one.

Radiator Hose Inspection

In accordance with the Periodic Maintenance Chart, visually inspect

•

the hoses [A] for signs of deterioration. Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or swollen. Replace any damaged hose.

•



Hoses can deteriorated on the inside and still appear to be in good condition on the outside.

78 to 98 kPa (0.80 to 1.00 kg/cm psi)

NOTE

, 0.71 psi)

, 11.3 to 14.2

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COOLING SYSTEM 3-15

Radiator

Radiator Hose Installation Notes

Install the radiator hoses beingcareful to follow bending direction (see

•

Exploded View). Avoid sharp bending, kinking, ﬂatting, or twisting.

NOTE



Locate the hose clamps [A] properly over the connections. A pressurized cooling system will blow a hose that is not installed properly. Tighten the hose clamps securely.

Torque - Radiator Hoses Clamps Bolts: 1.2 N1m (0.12 kg

m, 11 in

lb)

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3-16 COOLING SYSTEM

Cooling Fan, Fan Belt

The only service on the cooling fan is to be srue the fan blades are not deformed, and the blade tips are far enough from the air duct to not strike the duct. The fan belt should be neigher too tight nor too loose.

Belt Tension Check

Remove:

•

Radiator (see Radiator Removal)

Measure the belt tension using a proper belt tension gauges [A].

•

Follow the manufacturer’s instructions for use of the belt tension

gauge. The belt tension is adjusted between 25 kg (55 lb) and 40 kg

(88 lb) in the factory for the manufacturing standard.

If the belt tension is less than speciﬁed limit, adjust or replace the

belt [B].

Belt Tension Service Limit

18 kg (40 lb)

If the belt tension gauge is not available, push [A] the belt with a

•

thumb strongly at the middle between sheaves [B] [C]. The slack [D]

of the belt correspond the measurement of the belt tension gauge are

as follow. Use the table as a guide line.

Belt Tension Measurement Slacks

25 kg (55 lb) 12 mm (0.47 in) 40 kg (88 lb) 9 mm (0.35 in) 18 kg (40 lb) 17 mm (0.67 in)

Belt Replacement

When replacing the fan belt, use only factory recommended belt with

•

the proper length. Tocompensate for the belt length allowance, select

appropriately sized shim(s) [A] from the table to obtain proper level

of the belt tension (25

Fan Belt A B C D E

92180-2013* 1 1 2 1 2 2 No t = 0.6 mm of shim 92180-2014* — — — 1 1 1

t = 1.2 mm

*Part Number A Belt: smaller allowance t = Thickness of shim F Belt: Bigger allowance

40 kg).

NOTE



When tightening the sheave/hub [B] mounting bolts [C], rotate the fan in either direction to avoid pinching the belt [D].

Torque - Sheave/Hud Mounting Bolts: 20 N Drive Belt Speciﬁcation

MITSUBOSHI — 59011-2058

m (2.0 kg

m, 15 ft1lb)

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COOLING SYSTEM 3-17

Cooling Fan, Fan Belt

Cooling Fan, Fan Belt Removal

Remove:

•

Radiator (see Radiator Removal)

Remove the radiator guide.

•



Unscrew the mounting bolts [A] and remove the radiator guide [B].

Remove the radiator brackets [A].

•



Unfold the three clamps [B] that hold the harness, wire and fuel overﬂow pipe connecting to the carburetor.



Disconnect the coupler [C] and fuel overﬂow pipe [D] connecting to the carburetor.



Unscrew the bracket mounting bolts [E] (6 bolts) and remove the radiator brackets.

Hold the fan drive sheave/hub [A] with a suitable spanner [D] to

•

prevent rotating the sheave/hub. Unscrew the sheave/hub mounting bolts [B], and take off the sheave/

•

hub and shim(s) [C]. Remove the fan belt rolling over the fan sheave.

•

NOTE



When removing the fan belt, note the belt so that it may be reinstalled on the sheaves to rotate same direction as original installation.

Unscrew the mounting bolts [A], and take off the cooling fan [C] and

•

fan sheave [B].

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3-18 COOLING SYSTEM

Cooling Fan, Fan Belt

Cooling Fan, Fan Belt Installation

Install the cooling fan as “AISHIN” raised lettering [A] on the fan boss

•

facing toward the radiator. Clean the drive belt by wipping with a clean cloth. Immediately wipe

•

off any spilled oil or grease. Do not use solvent. Install the belt on the sheave to rotate same direction as original

•

installation. When tightening the sheave/hub bolts, rotate the fan in either direction

•

to avoid pinching the belt. Check the belt tension.

•

Cooling Fan, Fan Belt Inspection

Be sure the fan blades are straight. Deformed blades reduce the

•

cooling system efﬁciency and throw the fan out of balance. Check for excessive side wall wear of the sheaves and belt, replace

•

if necessary. The belt and sides of the sheaves should wear evenly. Check to be sure dirt has not lodged and packed in the sheave V-

•

grooves. Check the belt for swells or lumps, replace if necessary.

•

Fan Bearing Removal

Remove:

•

Fan Mounting Bracket [D]

Unscrew the fan shaft nut [A], and remove the shaft [C] and washer

•

[B]. To check the ball bearing [E], rotate the bearing slowly by ﬁnger; if

•

any roughness is noted, the bearing should be replaced.

Do not allow a ﬂame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns.

To remove the ball bearing, heat the bearing housing in a hot 150

•



(320

F) oil.

Use a heat shield gloves to prevent burns.

•

Place the bearing housing on a bench with bearing side up and take

•

off the bearing with a suitable tools.

CAUTION

Do not remove the bearing unless it is necessary. Once it has been removed, it must be replaced.

Fan Bearing Installation

Coat the bearing surfaces with a light ﬁlm of engine oil.

•

Use a bearing driver, press in the fan side bearing ﬂush with the

•

housing [A]. Install opposite side of bearing using a bearing driver until it stops at

•

the stop [spacer [B]] in hole. Install the fan shaft [F], washer [E] and nut [D], then tighten the nut

•

to the speciﬁed torque (see Exploded View).

Torque - Cooling Fan Shaft Nut: 20 N1m (2.0 kg1m, 15 ft1lb)



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COOLING SYSTEM 3-19

Thermostat

Thermostat Removal and Installation

Drain the coolant (see Coolant Draining).

•

Loosen the hose clamps [A], and pull off the three coolant hoses.

•

Unscrew the mounting bolts [B], and removethe thermostat-body [C].

•

Unscrew the bolts [D], and separate the thermostat upper-body [C]

•

from the lower-body [E].

Remove the thermostat [A] from the upper-body [C].

•

[B] Gasket [D] Bolts [E] Lower-Body

Installation is reversal of removal (refer to the illustration).

•



Replace the gasket [B] with a new one.



Tighten the bolts [D] to the speciﬁed torque.

Torque - Thermostat-Body Tightening Bolts: 10 N1m (1.0 kg

lb)

m, 87

Thermostat Inspection

Remove the thermostat, and check the jiggle valve [A] for sticking

•

or binding on the ﬂange [B] due to accumulation of a rust, scale or lime. Clean up the valve to ensure free movement of the valve [C], if necessary.

Inspect the thermostat valve [A] at room temperature.

•

If the valve is open, replace the valve with a new one. To check valve opening temperature, suspend the thermostat and an

•

accurate thermometer [B] in a container ﬁlled with a water. Place the container over a source of heat and gradually raise the

•

temperature of the water while stirring the water gently.



Watch the valve. The valve should begin to open at the temperature speciﬁed.



It should be fully opened to 8 mm (0.31 in) or more at the temperature speciﬁed.

Thermostat Valve Speciﬁcation

Begin Opening 80.5 to 83.5 Full Open 95

The thermostat and thermometer must not touch the container sides. If the thermostat fails any of these check, replace it.



C (203F)



C (177 to 182F)

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3-20 COOLING SYSTEM

Thermo Switch

When coolant temperature rises above 111C (232F), the thermo switch detects this and turns on a warning light on dash. Whenever you start the engine, make sure the warning light is not on in started engine.

If the warning light comes on, stop the engine immediately, and check the cooling system for over heating. Over heating can caused by:

Lack of coolant Loose or slipping fan belt Clogging of cooling system Malfunction water pump or thermostat

Check the coolant level and temperature frequently.

Thermo Switch Removal and Installation

Drain the coolant (see Coolant Draining).

•

Unfold the clamp [C] that hold the switch lead [D].

•

Disconnect the switch lead terminal [B].

•

Unscrew the thermo switch [A] and remove it.

•

When installing the thermo switch [A], apply a non-permanent locking

•

agent to the threads and tighten the switch.

Torque - Thermo Switch: 27 N1m (2.8 kg

m, 20 ft

lb)

Thermo Switch Inspection

Using a ohmmeter, check to see that only the connections in the table

•

have continuity.

If the switch has an open or short, repair it or replaced it with a new

one.

Thermo Switch Connections

• Rising temperature: From Off to On at 108 - 114

• Falling temperature: From On to Off at 101 - 107 ON: Continuity OFF: Inﬁnit

Suspend the switch [B] in a container of coolant [C] so that the

•

temperature sensing projection and threaded portion are submerged. Suspend an accurate thermometer [A] in the coolant.

•



The switch and thermometer must not touch the container sides or bottom.

Place the container over a source of heat [D] and gradually raise the

•

temperature of the coolant while stirring the coolant gently.



C (226 - 237F)



C (214 - 225F)

NOTE

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ENGINE TOP END 4-1

Engine Top End

Table of Contents

Exploded View...................................................................................................................................................................4-2

Speciﬁcations....................................................................................................................................................................4-4

Cylinder Head....................................................................................................................................................................4-5

Compression Measurement.......................................................................................................................................4-5

Cylinder Head Assembly Removal.............................................................................................................................4-5

Cylinder Head Assembly Installation..........................................................................................................................4-6

Push Rod Installation.................................................................................................................................................4-7

Push Rod Inspection..................................................................................................................................................4-7

Valve Mechanism Removal/Installation......................................................................................................................4-8

Cleaning and Inspection.............................................................................................................................................4-9

Valves..............................................................................................................................................................................4-11

Valve Clearance Inspection......................................................................................................................................4-11

Valve Clearance Adjustment....................................................................................................................................4-11

Valve Seat Inspection...............................................................................................................................................4-12

Valve Seat Repair.....................................................................................................................................................4-12

Valve Head Thickness..............................................................................................................................................4-14

Valve Stem Runout...................................................................................................................................................4-15

Valve Stem Diameter................................................................................................................................................4-15

Valve Guide Inside Diameter....................................................................................................................................4-15

Valve Spring Inspection............................................................................................................................................4-15

Cylinder, Piston...............................................................................................................................................................4-16

Piston Removal........................................................................................................................................................4-16

Piston Installation.....................................................................................................................................................4-17

Piston/Cylinder Seizure............................................................................................................................................4-18

Piston Cleaning........................................................................................................................................................4-19

Piston Ring and Ring Groove Wear.........................................................................................................................4-19

Piston Ring End Gap...............................................................................................................................................4-20

Piston Pin, Piston Pin Hole, and Connecting Rod Wear.........................................................................................4-20

Piston Diameter........................................................................................................................................................4-21

Cylinder Inside Diameter..........................................................................................................................................4-21

Cylinder Boring and Honing.....................................................................................................................................4-21

Mufﬂer.............................................................................................................................................................................4-23

Mufﬂer Assembly Removal.......................................................................................................................................4-23

Mufﬂer Assembly Installation....................................................................................................................................4-23

Inspection.................................................................................................................................................................4-23

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4-2 ENGINE TOP END

Exploded View

EO: Apply engine oil.

G: Apply grease. T1: 22 N T2: 21 N T5: 11 N

m (2.2 kg1m, 16 ft1lb)

m (2.1 kg1m, 15 ft1lb)

m (1.1 kg1m, 96 in1lb)

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ENGINE TOP END 4-3

Exploded View

S: Follow the speciﬁc tightening sequence. T3: 27 N T4: 20 N

m (2.8 kg1m, 20 ft1lb)

m (2.0 kg1m, 15 ft1lb)

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4-4 ENGINE TOP END

Speciﬁcations

Item

Cylinder Head:

Cylinder compression (MIN) [1171 kPa (170 psi)] (MIN) Cylinder head warp 0.06 mm (0.002 in.)

Valves:

Valve seating surface width Intake, Exhaust 2.0 mm (0.08 in) Valve head thickness Intake, Exhaust 0.6 mm (0.024 in.) Valve stem runout Intake, Exhaust 0.05 mm (0.002 in.) Valve stem diameter Intake, Exhaust 6.935 mm (0.2730 in.) Valve guide inside diameter Intake, Exhaust 7.080 mm (0.2787 in.) Valve spring free length Intake, Exhaust 31.00 in (1.22 in.) Rocker arm push rod runout Intake, Exhaust 0.50 mm (0.02 in.) Rocker arm collar outside diameter Intake, Exhaust 10.914 mm (0.4297 in) Rocker arm bearing inside diameter Intake, Exhaust 11.052 mm (0.4351 in.)

Cylinder, Piston

Piston ring/groove clearance Top, Second 0.15 mm (0.006 in.) Piston ring thickness Top, Second 1.40 mm (0.055 in.) Piston ring end gap Top, Second 1.0 mm (0.04 in.)

Oil 1.2 mm (0.05 in.) Piston pin outside diameter 18.960 mm (0.7465 in.) Piston pin hole inside diameter 19.080 mm (0.7512 in.) Connecting rod small end inside diameter 19.060 mm (0.7504 in.) Cylinder inside diameter: Standard Cylinder 78.080 mm (3.0740 in.)

0.50 mm Oversize 78.580 mm (3.0937 in.) Piston outside diameter 77.700 mm (3.0590 in.) Cylinder bore out round 0.056 mm (0.0022 in.)

Service Limit

Item Standard

Valve clearance Intake, Exhaust 0.15 mm (0.006 in.) Valve seating surface angle Intake, Exhaust 45 Valve seating surface width Intake, Exhaust 0.5 to 1.1 mm (0.02 to 0.043 in.) Valves guide inside diameter Intake, Exhaust 7.000 to 7.015 mm

Cylinder bore diameter:

Standard cylinder 78.000 to 77.980 mm

0.50 mm Over size 78.500 to 78.480 mm

Special Tools - Piston Ring Pliers: 57001-115

Compression Gauge : 57001-221 Piston Ring Compression Grip: 57001-1095 Piston Ring Compression Belt, Valve Seat Cutter, 45 Valve Seat Cutter, 30 Valve Seat Cutter Holder Bar: 57001–1128 Compression Gauge Adapter M14 x 1.25: 57001–1159 Valve Seat Cutter, 30 Valve Seat Cutter Holder,



- 35.0 : 57001-1116



- 30.0 : 57001-1120



- 33.0 : 57001-1199

67 - 79: 57001–1097

6: 57001–1360



(0.2756 to 0.2762 in.)

(3.0709 to 3.0701 in.)

(3.0905 to 3.0898 in.)

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ENGINE TOP END 4-5

Cylinder Head

Compression Measurement

Before measuring compression, do the following.

•



Be sure the battery is fully charged.



Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running.



Stop the engine. Disconnect the spark plug caps of each cylinder and remove the spark

•

plugs. Attach the compression gauge assembly ﬁrmly into one plug hole.

•

Special Tool - Compression Gauge: 57001–221 [A]

Compression Gauge Adapter: 57001–1159 [B]

Ground the spark plugs to the engine.

•

To avoid ﬁre, do not ground the spark plugs in closed positions to the plug holes. Keep the plugs as far away as possible from the plug holes.

Using the starter motor, turn the engine over with the throttle fully open

•

until the compression gauge stops rising; the compression reading obtainable. Repeat the measurement to the other cylinder.

•

Cylinder Compression (MIN): 1171 kPa (170 psi)

If the compression is higher than the speciﬁed value, the piston rings, cylinder and valves are probably in good condition. If the compression is too high, check the following.

1. Carbon build-up on the piston head and cylinder head - clean off any carbon on the piston head and cylinder head.

2. Cylinder head gasket - use only the proper gasket. The use of a gasket of incorrect thickness will change the compression.

3. Valve guides and piston rings - rapid carbon accumulation in the combustion chamber may be caused worn valve guides and/or worn piston oil rings. This may be indicated by white exhaust smoke.

If cylinder compression is lower than the (MIN), check the following:

1. Gas leakage around the cylinder head - replace the damaged gasket and check the cylinder head warp.

2. Condition of the valve seating.

3. Valve clearance.

4. Piston/cylinder wear, piston seizure.

5. Piston ring, piston ring groove.

Cylinder Head Assembly Removal

Remove:

•

Radiator and it’s Bracket Air Cleaner and Carburetor Mufﬂer Intake Manifold Spark Plug

Unscrew the rocker cover mounting bolts [C], and remove the covers

•

[A], [B] and gaskets.

[A] Rocker Cover (No. 1 Cylinder) [B] Rocker Cover (No. 2 Cylinder) [C] Mounting Bolts (8 bolts)

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4-6 ENGINE TOP END

Cylinder Head

When removing the cylinder head, set the ﬂywheel at top dead center

•

(T.D.C) of power stroke each cylinder.



When setting the ﬂywheel at T.D.C of #1 cylinder, align the ﬂywheel magnet [A] with No.1 ignition coil [B]. If it is not at T.D.C, turn the ﬂywheel clockwise one turn (360



When setting the ﬂywheel at T.D.C of #2 cylinder, turn the ﬂywheelmagnet [A] clockwise from position at T.D.C of #1 Ccylinder to at No.2 ignition coil [C]. If it is not at T.D.C, turn the ﬂywheel clockwise with one turn (360

Loosen the cylinder head bolts 1/4 turn in the sequence shown.

•

If the above procedure is not followed, the cylinder head may be warped during removal.

Repeat the sequence until all bolts are removed and lift off the cylinder

•

head assembly.



Mark the push-rods so they can be installed in their original position during assembly.



CAUTION

NOTE

Cylinder Head Assembly Installation

When installing the cylinder head, set the ﬂywheel at T.D.C of power

•

stroke each cylinder.



When setting the ﬂywheel at T.D.C of #1 cylinder, align the ﬂywheel magnet [A] with No.1 ignition coil [B]. If it is not at T.D.C, turn the ﬂywheel clockwise one turn (360



When setting the ﬂywheel at T.D.C of #2 cylinder, turn the ﬂywheelmagnet [A] clockwise from position at T.D.C of #1 cylinder to at No. 2 ignition coil [C]. If it is not at T.D.C, turn the ﬂywheel clockwise with one turn (360 Clean the mating surfaces of the cylinder heads and cylinder.

•

Install the knock pins on the cylinder.

•

Put a new gaskets [A] and the cylinder head assemblies on each

•

cylinder, then let the cylinder heads with push rods aligned under the rocker arms (see Valve Mechanism Removal/Installation, Push Rod Installation).



As the head gaskets are coated with sealing agents, be careful not to injure the surfaces of them.



NOTE

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ENGINE TOP END 4-7

Cylinder Head

Install the head bolts noting the position of different length bolts.

•

Then tighten the head bolts to the speciﬁcation (see Exploded View).

•



Follow the sequence shown, tighten the head bolts to 15 N kg

m, 11 ft



Tighten the bolts in sequence 3.0 N until torque on each bolt is 27 N

Torque - Cylinder Head Bolts: 27 N1m (2.8 kg

A torque wrench must be used to prevent loose or overtight the head bolts which may result in warping of the cylinder head.

Push Rod Installation

When installing the push rod, set the ﬂywheel at T.D.C of powerstroke

•

each cylinder. (see Cylinder head Assembly Installation) Install the push rods in their original positions on each cylinder.

•



To install the push rod in a correct position on the tappet, insert the push rod so end of the push rod is sliding down along inside wall of the crankcase and position the push rod end on the tappet. Check both intake and exhaust push rods on each cylinder are lowest

•

position on the cam lobes, if not turn the ﬂywheel clockwise one turn (360 Be sure the end of the push rods are correctly seated on the tappets.

•

[A] Push Rods [D] Inside Walls [B] Tappets [E] Sliding Down [C] Lowest Cam Lobes

lb).

m (0.3 kg

m (2.8 kg

CAUTION



m, 27 in

m, 20 ft

lb).

lb)

m (1.5

lb) at a time

Push Rod Inspection

Place the rocker arm push rod in V blocks that are as far apart as

•

possible, and set a dial gauge on the rod at a point halfway between the blocks. Turn the rod to measure the runout. The difference between highest and the lowestdial readings is the amount of runout. If the runout exceeds the service limit, replace the rod.

Rocker Arm Push Rod Runout

Service Limit: 0.5 mm (0.02 in.)

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4-8 ENGINE TOP END

Cylinder Head

Valve Mechanism Removal/Installation

Remove the cylinder head assembly. (see Cylinder Head Assembly

•

Removal)

NOTE



When removing the valve mechanism parts, note their position so that they may be reinstalled in their original position during assembly.

Remove:

•

Nut [A] Bolt [B] Washer [C] Collar [D] Rocker Arm [E]

Remove:

•

Bolts [A] Bracket [B]

Support the valve head in the combustion chamber with a suitable

•

block. To remove the collets [A], push down the valve retainer [B] with

•

thumbs and remove the collets. Remove the spring [C] and valve [D] .

•

Remove the stem seals [A].

•

NOTE



It is not necessary to remove the stem seal unless it is being replaced.



Bottom spring retainer [C] can only be removed with stem seal.



Valve guide [B] is not replaceable, do no remove it.

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ENGINE TOP END 4-9

Cylinder Head

Valve Installation.

•



Apply engine oil to the valve stem to avoid damaging the stem seal.



Check to see that the valve moves smoothly up and down in the guide.



Check to see that the valve seats properly in the valve seat. If it does not, repair the valve seat. Valve installation is the reverse of removal.

•

Install the cylinder head assembly. (see Cylinder Head Assembly

•

Installation) Rocker Arm Installation

•



Set the ﬂywheel at T.D.C of power stroke each cylinder. (see Cylinder Head Assembly Installation)



Install the bracket [A] on the cylinder head with two bolts [B] and tighten them.

Torque - Rocker Arm Bracket Mounting Bolt:

22 N

m (2.2 kg1m, 16 ft



Install the push rods by inserting into “U” notch [C] on the bracket [A]. (see Push Rod Installation)

lb)



Insert the collar [B] into the rocker arm hole [I] so that the groove [C] of the collar face toward upside [D], then set them on the bracket [A].



Insert the washer [E] onto bolt [F], and insert the bolt [F] into the hole at the rightside [G] of the bracket [A] and through the collar installed with rocker arm.



Install the nut [K] onto the bolt [F], and tighten the nut temporarily.



Position the push rod end on to rocker arm dent.

Cleaning and Inspection

Scrape the carbon deposits from the head and exhaust port with a

•

suitable tool [A].



To avoid gouging, use scrapers that are made of a material that will not cause damage. Clean the head in a bath of high ﬂash-point solvent and dry it with

•

compressed air.

Clean the cylinder head in a well-ventilated area, and take care that there are no sparks or ﬂame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low ﬂash-point solvent to clean the cylinder head. A ﬁre or explosion could result.

Laya straightedge [A] across the mating surface of the head at several

•

different points, and measure warp by inserting a thickness gauge [B] between the straightedge and head. If warp exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is badly damaged.

Cylinder Head Warp

Service Limit: 0.06 mm (0.002 in.)

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4-10 ENGINE TOP END

Cylinder Head

Check the cylinder head for cracks or other damage.

•

Cracks not visible to the eye may be detected by coating the

•

suspected area with mixture of 25% kerosene and 75% light engine oil. Wipe the area dry and immediately apply a coating of zinc oxide

•

dissolved in wood alcohol. If a cracks is present, the coating will become discolored at the defective area. If a cracks is present in the cylinder head, replace it.

•

Inspect the mating surface for burrs and nicks.

•

Inspect the cylinder head for accumulation of rust, scale and lime in

•

the water jacket [A]. If this accumulation is observed, ﬂush the cooling system (see Flushing in Cooling System chapter).

Measure the diameter [A] of the rocker arm collar with a micrometer

•

at several points of bearing the rocker arm. If the outside diameter is less than the service limit, replace the rocker arm collar.

Rocker Arm Collar Outside Diameter

Service Limit: 10.914 mm (0.4297 in)

Clean and inspect the rocker arm where it touches the push rod and

•

valve stem. If the contact points [A] are worn or damaged, replace the rocker arm. Measure the inside diameter of the rocker arm bearing [B] at several

•

points using a dial bore gauge or inside micrometer. If the inside diameter is more than the service limit, replace the rocker arm.

Rocker Arm Bearing Inside Diameter

Service Limit: 11.052 mm (0.4351 in)

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ENGINE TOP END 4-11

Valves

Valve Clearance Inspection

NOTE



Valve clearance must be checked when the engine is cold (at room temperature).

Remove the rocker case (see Cylinder Head Removal).

•

Place the piston at top dead center (TDC) of the compression stroke

•

turning the crankshaft clockwise facing the ﬂywheel.

No.1 Cylinder:



Align the ﬂywheel magnet [A] with No. 1 ignition coil [B].



Check the intake and exhaust valves are closed completely, if it is not at T.D.C, turn the ﬂywheel clockwise one turn (360

No.2 Cylinder:



Align the ﬂywheel magnet [A] with No. 2 ignition coil [C]. Follow No.1 Cylinder alignment.

Then check the clearance.

•



Using a thickness gauge [A], measure the valve clearance between the rocker arm and the valve stem end. If the valve clearance is incorrect, adjust it. (see Valve Clearance Adjustment)

Valve Clearance (when cold)

Intake, Exhaust: 0.15 mm (0.006 in)



Valve Clearance Adjustment

Since the valve repairs change the valve clearance, adjust the valve

•

clearance to the speciﬁcation. Assemble the cylinder head and install the cylinder head assembly

•

on the block (see Cylinder Head Installation). Turn the crankshaft proper direction until the piston is at TDC of the

•

compression stroke (described above). Loosen the lock nut [C] and valve clearance adjusting bolts [B].

•

Insert a 0.15 mm (0.006 in.) thickness gauge [A] between the rocker

•

arm and valve stem, and turn the adjusting bolt until the thickness gauge begin to bind between the rocker arm and valve stem end. Use a sweeping motion with the thickness gauge while making this adjustment. Holding the adjusting bolt with a spanner, tighten the locknut to the

•

speciﬁed torque.

Torque - Valve Clearance Adjusting Locknuts: 11 N

lb)

Do not overtighten.

•

m (1.1 kg1m, 96

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4-12 ENGINE TOP END

Valves

Valve Seat Inspection

Remove the valve. (see Valve Mechanism Removal/Installation)

•

Inspect the valve seats for damage.

•

If the seats are warped or distorted by beyond reconditioning, replace the cylinder head. Pitted or worn valve seats can be refaced. Lap the valves to the seats

•

after refacing. Coat the valve seat with machinist’s dye.

•

Push the valve into the guide.

•

Rotate the valve against the seat with a lapping tool.

•

Pull the valve out, and check the seating pattern on the valve head.

•

It must be the correct width [A] and even all the way around.

NOTE



The valve stem and guide must be in good condition or this check will not be valid.

If the valve seating pattern is not correct, repair the seat.

Valve Seating Surface Width (STD)

Inlet 0.8 Exhaust 1.1

1.4 mm (0.03 0.05 in.)

1.6 mm (0.04 0.06 in.)

Valve Seat Repair

Follow the manufacture’s instructions for use of valve seat cutters

•

(special tools).

Special Tools

Intake Valve:

Seat Cutter 45 Outside Cutter 30

Exhaust Valve:

Seat Cutter 45 Outside Cutter 30

Holder and Bar

Holder Bar 57001-1128

If the manufacture’s instructions are not available, use the following procedure.

Seat Cutter Operating Cares:

This valve seat cutter is designed only forvalve seat repair. Therefore

•

the cutter must not be used for other purposes. Do not drop or hit the valve seat cutter, or the diamond particles may

•

fall off. Do not fail to apply engine oil to the valve seat cutter before grinding

•

the seat surface. Also wash off ground particles sticking to the cutter with washing oil.



Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.

7.0 57001-1126



- ø35.0 57001-1116



- ø33.0 57001-1199



- ø30.0 57001-1187



- ø30.0 57001-1120

NOTE

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ENGINE TOP END 4-13

Valves

Setting the valve seat cutter holder [A] in position, operate the cutter

•

[B] with one hand. Do not apply too much force to the diamond portion.

NOTE



Prior to grinding, apply oil to the cutter, and during the operation wash off any ground particles sticking to the cutter with washing oil.

After use wash the cutter with washing oil and apply a thin layer of

•

engine oil before storing.

Marks Stamped on the Cutter:

The marks stamped on the back of the cutter represent the following.

1 Cutter number, selected from 1 to 12



37.5 Outer diameter of cutter [B] KS8B Manufactured lot number

Cutter angle [A]

Operating Procedures:

Clean the seat area carefully.

•

Recondition the valve seats with the valve seat cutters (45

•

lap the valves. Check the seats for good contact all the way around with machinist’s

•

dye. Measure the seat width [A]. If it is more than the STD width, the

•

seating surface should be refaced. If the valve seating pattern is not correct, repair the seat.

Coat the seat with machinist’s dye.

•

Fit a 45cutter [A] to the holder and slide it into the valve guide.

•



Resurface the valve seat with a 45cutter, removing only enough material to produce a smooth and concentric seat.

CAUTION

Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced. Do not turn the cutter counterclockwise or drop it against the seat, or it will be dulled.



,30) and

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4-14 ENGINE TOP END

Valves

Use a 30seat cutter [A] to narrow the seat width to the STD width.

•



Turn the seat cutter one turn at a time while pressing down very lightly. Check the seat width after each turn.

CAUTION



The 30 width frequently to prevent over grinding.



cutter removes material very quickly. Check the seat

NOTE

Keep the seat width as closely as possible to the STD width.

Make a light pass with the 45

•

the edge of the seat. After resurfacing the seat, inspect for even valve seating.

•



Apply a machinist’s dye to the valve face, insert the valve, and snap it closed against the seat several times. The valve surface should show good contact all the way around. Be sure the valve seat is centered on the valve face. The position of the valve in the seat is evident after lapping the valve. If the seat does not make proper contact, lap the valve into seat with a vacuum cap tool [A]. Coat the face of valve sparingly with a ﬁne lapping compound.

•

Use the vacuum cup tool, to grip top of the valve. Rotate the valve in

•

a circular motion to lap the valve to the seat. Lift the valve slightly from the seat every 8 to 10 strokes, continue

•

lapping operation until a uniform ring appears around entire surface of the valve face.

When lapping is completed, wash all parts in solvent to remove

•

lapping compound. Dry the parts thoroughly. Note the position of the lapping mark on the valve face. The lapping

•

mark should appear on or near the center of the valve face. When the engine is assembled, be sure to adjust the valve clear-

•

ances. (see Valve Clearance Adjustment)

Valve Head Thickness

Remove the valve (see Valve Mechanism Removal/Installation).

•

Measure the thickness of the valve head.

•

If the valve head thickness (valve margin) [A] is less than the service limit, replace the valve.

Valve Head Thickness

Service Limit (IN, EX): 0.6 mm (0.024 in)



cutter to remove any possible burrs at

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ENGINE TOP END 4-15

Valves

Valve Stem Runout

Support the valve in V blocks at each end of the stem.

•

Position a dial gauge perpendicular to the stem.

•

Turn the valve and read the variation on the dial gauge.

•

If the stem runout is greater than service limit, replace the valve.

Valve Stem Runout

Service Limit (IN, EX): 0.05 mm (0.002 in.)

Valve Stem Diameter

Measure the diameter of the valve stem [A] in two directions at right

•

angles, at four different positions on the stem. If any single measurement is less than the service limit, replace the valve.

Valve Stem Diameter

Service Limit:

Intake, Exhaust: 6.935 mm (0.2730 in.)

Valve Guide Inside Diameter

Use a small bore gauge or a micrometer to measure the inside

•

diameter [A] of the valve guide a three places down the length of the guide. If the measurement is more than the service limit, replace the cylinder head with a new one.

Valve Guide Inside Diameter

Service Limit:

Intake, Exhaust: 7.080 mm (0.2787 in.)

Valve Spring Inspection

Inspect the valve spring forpitting, cracks, rusting, and burrs. Replace

•

the spring if necessary. Measure the free length [A] of the spring.

•

If the measurement is less than the service limit, replace the spring.

Valve Spring Free Length

Service Limit: 31.00 mm (1.22 in.)

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4-16 ENGINE TOP END

Cylinder, Piston

Piston Removal

Split the crankcase (see Camshaft/Crankshaft chapter).

•

Remove the camshaft (see Camshaft/Crankshaft chapter).

•

Turn the crankshaft to expose the connecting rod cap bolts [A].

•

Remove the bolts and take off the connecting rod caps [B].

•

NOTE



Note the position of the connecting rod caps for reinstalling the caps.

Push the connecting rod end into the cylinder, and pull the piston and

•

connecting rod out of the cylinder.

CAUTION

Note a location of the arrow match mark on the piston head in relation to MADE IN JAPAN on the connecting rod. No.1 cyl. piston is opposite of No.2 cyl. piston. Keep parts together as a set.

[A] No.1 Cyl. Piston [D] MADE IN JAPAN [B] No.2 Cyl. Piston [E] Opposite MADE IN JAPAN [C] Arrow Match marks

Remove one of the piston pin snap rings [A] with needle nose pliers

•

[B].

Remove the piston by pushing the piston pin [A] out the side from

•

which the snap ring was removed.

Remove the top and second rings with piston ring pliers.

•

Special Tool - Piston Ring Pliers: 57001–115

If the special too is not available, carefully spread the ring opening

•

with your thumbs and then push up on the opposite side of the ring [A] to remove it. Remove the 3-piece oil ring with your thumbs in the same manner.

•

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ENGINE TOP END 4-17

Cylinder, Piston

Piston Installation

Install the expander [A] in the piston oil ring groove so that the

•

expander ends [B] touch together, never overlap. Install the upper and lower steel rails. There is no UP or Down to the

•

rails. They can be installed either way.

Install the chrome-plated top ring and second ring with “R” mark facing

•

up. The rings should turn freely in the grooves. Align the piston and rings with the piston ring end gap as shown.

•

[A] Arrow Match Marks [B] Top Ring End Gap, Upper Steel Rail End Gap



[C] 30 [D] Second Ring End Gap, Lower Steel Rail End Gap

Apply engine oil to the piston pins.

•

Assemble the pistons onto the connecting rods as follow:

•

No.1 Cyl. piston, align the arrow match mark on the piston head with

the raised letters (MADE IN JAPAN) on the connecting rod.

No.2 Cyl. piston, align the arrow match mark on the piston head with

opposite MADE IN JAPAN on the connecting rod.

[A] No.1 Cyl. Piston [D] MADE IN JAPAN [B] No.2 Cyl. Piston [E] Opposite MADE IN JAPAN [C] Arrow Match Marks

When installing a piston pin snap ring, compress it only enough to

•

install it and no more. Fit a new piston pin snap ring into the side of the piston so that the

•

ring opening [A] does not coincide with the notch [B] in the edge of the piston pin hole.

CAUTION

Do not reuse the snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

Install the piston and connecting rod so that the arrow match mark

•

[A] on the top of the piston facing the ﬂywheel side [B]. Apply engine oil to the piston skirt and the cylinder bore.

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4-18 ENGINE TOP END

Cylinder, Piston



Using the piston ring compressor grip [A] and the belt [B], insert the piston and connecting rod into the cylinder.



Lightly tap the top of the piston with a plastic mallet [C] to insert the piston and connecting rod into the cylinder.

CAUTION

The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state, so they must be replaced together as a set.

Apply engine oil to the inner surface [A] of the connecting rod big end

•

[B] and caps [C]. Install the connecting rod big end caps on their original position on

•

each connecting rod big ends. Apply a small amount of engine oil to the thread [D] and seating

•

surface [E] of the cap bolts. Tighten the cap bolts.

•

Torque - Connecting Rod Big End Cap Bolts: 21 N1m (2.1 kg

lb)

Install:

•

Camshaft (see Camshaft/Crankshaft chapter) Crankcase Cover (see Camshaft/Crankshaft chapter)

m, 15

Piston/Cylinder Seizure

In case of seizure, remove the piston.

•

Visually inspect the cylinder and piston damage.

•

If there is only light damage, smooth the position with #400 emery cloth. Remove the small aluminum deposits from the cylinder with #400 emery cloth or light honing. If the damage is severe, the both cylinders must be bored oversize and an oversized pistons installed.

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ENGINE TOP END 4-19

Cylinder, Piston

Piston Cleaning

Remove the piston and piston rings (see Piston and Ring Removal).

•

CAUTION

Never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings.

Scrape the carbon off [A] the piston head.

•

Use the scraping tools carefully. Do not gouge the piston head. To

•

avoid gouging, use scrapers that are made of a material that will not cause damage. Clean the piston ring grooves [A] with a broken piston ring or other

•

suitable tools.

CAUTION

Be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement.

Piston Ring and Ring Groove Wear

Clean the piston (see Piston Cleaning).

•

Visually inspect the piston rings and ring grooves.

•

If the piston rings are worn unevenly or damaged, replace them. If the ring grooves are worn unevenly or damaged, replace both the piston and piston rings. Check ring grooves for wear by inserting a new ring in the proper

•

groove at several points around the piston. Measure the clearance between the top and second rings and their

•

grooves using a thickness gauge [A].

If the piston ring/groove clearance is greater than the speciﬁed value, replace the piston.

Piston Ring/Groove Clearance

Service Limit

Top, Second 0.15 mm (0.006 in.)

NOTE



The oil ring is a three piece assembled ring. Difﬁcult to measure the ring groove clearance and thickness, visually inspect only.

Measure the piston ring thickness.

•



Use a micrometer to measure at several points around the rings. If any of the measurement are less than the service limit, replace the entire set of rings.

Piston Ring Thickness

Service Limit

Top, Second 1.40 mm (0.055 in.)

NOTE



When using new rings in a used piston, check for uneven groove wear. The rings should ﬁt perfectly parallel to the groove sides. If not, replace the piston.

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4-20 ENGINE TOP END

Cylinder, Piston

Piston Ring End Gap

Remove the piston rings.

•

Push each ring (one at a time) in the cylinder bore to a point close

•

to the bottom of the cylinder bore.



Use the piston to push it in to be sure it is square. Measure the gap [B] between the ends of the ring [A] with a thickness

•

gauge. If the end gap of any ring is greater than the service limit, replace the entire set of rings.

Piston Ring End Gap

Service Limit Top,Second 1.0 mm (0.04 in.) Oil 1.2 mm (0.05 in.)

Piston Pin, Piston Pin Hole, and Connecting Rod Wear

Remove the piston pin.

•

Measure the diameter of the piston pin with a micrometer at several

•

points. If the outside diameter is less than service limit, replace the piston pin.

Piston Pin Outside Diameter

Service Limit: 18.960 mm (0.7465 in.)

Measure the inside diameter [A] of the piston pin hole at severalpoints

•

on both side. Use a dial bore gauge. If the inside diameter is more than the service limit, replace the piston.

Piston Pin Hole Inside Diameter

Service Limit: 19.080 mm (0.7512 in.)

Measure the inside diameter [A] of the small end of the connecting

•

rod at several points. Use a dial bore gauge. If the inside diameter is more than the service limit, replace the connecting rod.

Connecting Rod Small End Inside Diameter

Service Limit: 19.060 mm (0.7504 in.)

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ENGINE TOP END 4-21

Cylinder, Piston

Piston Diameter

Measure the outside diameter of the piston 11 mm (0.43 in.) up from

•

the bottom of the piston at a right angle to the direction of the piston pin hole. If the measurement is less than the service limit, replace the piston.

Piston Outside Diameter

Service Limit: 77.700 mm (3.0590 in.)

Cylinder Inside Diameter

Clean and measure the cylinder inside diameter.

•



Use a dial bore gauge to measure front-to-back and side-to-side at the points shown below. If any of the cylinder bore measurements is greater than the service limit, the cylinder must be bored to the next oversize and then honed (see Cylinder Boring and Honing).

Cylinder Inside Diameter

Cylinder Inside Diameter:

Standard: 78.000 mm (3.0709 in.) Service Limit: 78.080 mm (3.0740 in.)

0.5 mm Oversize: 78.500 mm (3.0905 in.) Service Limit: 78.580 mm (3.0937 in.)

Cylinder Bore Out-of-Round

Service Limit 0.056 mm (0.0022 in.)

Cylinder Boring and Honing

Always resize to exactly 0.5 mm (0.02 in.) over the standard bore

size.

If this is done accurately, the stock oversize rings and piston will ﬁt

perfectly and proper clearance will be maintained.

Resizing the cylinder bore can be done by reliable repair shop or by

using a drill press and honing tool.

Use the stone recommended by the hone manufactures to produce

correct cylinder wall ﬁnish.

Machine-bore ﬁrst, the bore diameters should be shown in the table.

Fine Boring Bore Diameter

Oversize Bore Diameter

0.50 mm 78.480 to 78.460 mm (3.0898 to 3.0890 in.)

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4-22 ENGINE TOP END

Cylinder, Piston

Change to a honing stone for ﬁnishing, the ﬁnal bore diameter should be as shown in the table. Be sure the correct stone is used and the stone is not worn.

Clean the cylinder at the top and bottom of the cylinder to remove

•

burrs and pieces of the base and head gasket. Anchor the cylinder (block) on the drill press table before honing.

•

Align the center of the cylinder bore to the press center. Set the press

•

to operate from 200 to 250 rpm. Connect the drive shaft to the hone and set the stop on the drill press

•

so the hone can only extend 20 to 25 mm (3/4 to 1.0 in.) above the top or below the bottom of the cylinder liner. Rotate the adjusting nut (knob) on the hone until the stones contact

•

snugly against the cylinder wall at the narrowest point. “Do not Force”. Turn the stone by hand. If you cannot turn it, the stone is too tight.

•

Loosen the hone until it can be turned by hand. Be sure that the cylinder and hone are centered and aligned with the

•

drive shaft and drill spindle. Pour honing oil inside of the cylinder during the honing operation.

•

Start the drill press. Move the hone up and down in the cylinder approximately 20 cycles-per-minute. Check the diameter of thecylinder bore regularly during honing, using

•

an inside micrometer.

Fine Bore Diameter

Oversize Bore Diameter

0.50 mm 78.500 to 78.480 mm (3.0905 to 3.0898 in.)

CAUTION

Stop the drill press before measuring and remove the hone from the cylinder.

NOTE



The ﬁnish should not be smooth, but have a 40 to 60 degree crosshatch pattern.

Hone the cylinder until it is about 0.007 to 0.009 mm (0.0003 to 0.0004

•

in) large to allow for shrinkage when the cylinder cools.

NOTE



Do not use gasoline, kerosene, or commercial solvent to clean the cylinder bore. These ﬂuids only wash all the oil from the cylinder wall. They do not remove the metal particles produced during honing.

Clean the cylinder thoroughly. Use soap warm water and clean rags.

•

Clean the cylinder wall for “white glove” inspection. A clean white rag should not show soil from the cylinder wall. Dry the cylinder and coat with a engine oil.

•

CAUTION

The cylinder must be thoroughly cleaned after honing to eliminate all grit.

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ENGINE TOP END 4-23

Mufﬂer

Mufﬂer Assembly Removal

Unscrew the ﬂange nuts [A], and remove the spring washers and

•

engine hook [B] (Only No.1 Cylinder side). Use a penetrating oil if necessary to break threads loose.

Remove the bolts [A] on the mufﬂer bracket and take off the mufﬂer

•

assembly [B]. Remove the gaskets.

•

Do not use unnecessary force on the exhaust pipes when removing

•

the mufﬂer assembly, or they could become damaged or distored.

Mufﬂer Assembly Installation

Clean the exhaust pipe ﬂanges to the exhaust port gasket surfaces

•

and install a new gaskets each time the mufﬂer installed. Install the gasket.

•

Install the mufﬂer, engine hook, spring washers and nuts.

•

To prevent mis-threading, ﬁngertight the ﬂange nuts ﬁrst. Next tighten

•

the bolts on the mufﬂer bracket. Tighten the nuts and bolts.

•

Torque - Exhaust Pipe Flange Nuts: 20 N1m (2.0 kg

After installation, thoroughly warm up the engine, wait until the engine

•

cools down and retighten the bolts and nuts.

Inspection

Inspect the exhaust pipe or mufﬂer for dents, cracks, rust and holes.

•

If the exhaust pipe or mufﬂer is damaged, it should be replaced for best performance and least noise. Check the mufﬂer for distortion and/or loose internal components.

•

Loss of power could develop if the mufﬂer loose the internal components restricting the exhaust ﬂow. Check for breaks in the seams and check weld at the junction of the

•

exhaust pipes and mufﬂer. Tap the mufﬂer with a plastic hammer to decarbonize.

•

m, 15 ft1lb)

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Kawasaki FD671D, FD711DF, D750D, FD791D Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

Before Servicing

Periodic Maintenance Chart

Torque and Locking Agent

Special Tools

Fuel System

Exploded View

Governor Link Mechanism

Carburetor

Intake Manifold

Fuel Pump

Air Cleaner

Digital Fuel Injection (DFI) System

Cooling System

Exploded View

Cooling System

Coolant

Water Pump

Radiator

Cooling Fan, Fan Belt

Thermostat

Thermo Switch

Engine Top End

Exploded View

Cylinder Head

Valves

Cylinder, Piston