Saton S-650G Repair Manual

*

{-^

SATOH

TRACTOR

f

L

s-65()G

REnAIR

MANML

SATOH AGRICUTTURAL

MACHINE

7

Publication

No.

03

MFG.

CO*LTD,

CO}ITENTS

ENGiINE

SYSTEM

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PUBLICATI0il

JIo.03-A

MoDEL

s.65()(G

REPAIR

MANUAL

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I

CONTENTS

THE ENGINE

.

GENERAL

1.

Cylinder

Head

2. Cylinder

Block

3.

Pistons and

Crankshaft

4.

Valve

Mechanism

5.

lntake

and

Exhaust

Mechanism

6. Governor

7.

Cooling

System

8. Lubricating

Mechanism

9.

Elestrical

SYstem

ETUGINE

Disassembling

Order

1-1

.

Removing

the

Engine

.

1-2.

Disasembling

the

Engine

Checking

Maintenance

and Limit

of

Adiustment

2-1

.

Cylinder

Head .

.

2-2.

Piston

and Cylinder

Block

2-3. Connecting

Rod

24.

Crankslraft

and

Main

Bearing

Metal

2-5.

Camshaft

.

2-6.

Timing

Chain Sprocket

and

Chain

Adiuster

AssemblingOrder ..

..

3-1

. Assembling

the

Engine

3-2.

Mounting

the

Engine

Spgcifications

.. ..........

LUBRICATIOT{SYSTEM

....

1.

Lubrication System

-

General

2. Disassembling

the

Oil

Pump

.

2-1

.

Removing

the

Oil

Pump

2-2.

Disasembling the

Oil

Pump

3. Checking,

Maintenance

and Limit

of Adiustment

3-1

. Checking

and

Adjusting

the

Oil

Pump

3-2. Oil

Filter

Replacement

3-3.

Checking

and

Adjusting the Oil

Pump

Driven Gear

Shaft

34.

Adjusting

the

End

Play

of

Oil

Pump

Driven Gear Shaft

4

tT'I?"ruili,ff':

:

1.

2.

3.

4.

3

3 3

7 15 15 18

21

23 25 26

27

27 38

38

39

40 40 40 40

40

41 41

42 42

5, Specif

ications

51.

Oil

Pump

Specifications

5-2.

Oil

F

ilter Specif

ications

SYSTEM

....

Cooling

System

-

General

- .

Disasembling

Order

.

2-1

.

Removing the

Water

PumP

2-2.

Disassembling

the

Water

PumP

Checking

Maintenance

?nd

Limit of

Adiustment

31 .

lnspection of

Water

PumP

.

3l2. Checking

the

Thermostat

AssemblingtheWaterPumP

....

..

Mounting

thg

Water

Pump .

. .

. . . .

. .

.

lrstalling

the

Thermostat

. . . . . . .

. .

.

Specifications

..

7-1

.

WaterPump

r.

.

. . .

. . . .

. . .

.

7-2.

ThgrmosEt..

,o....o.

.42 .42 .42

.43

j

COOLING

1.

2.

3.

*4.

5.

6.

7.

FUEL

SYSTEM

Fuel

System

-

.Generct

AirCleaner o o

. .

.

2-1

.

Rennving

the

Air

Cleaner

Element

2-2. Checking

the

Air

Cleaner

. . . .

2-3.

Air

Cleaner Specifications

.

Fugl

Pump...,.....

31

"

Removing

the

Fuel

Pump

. .

3-2. Disasembling

the

Fuel Pump

.

3-3. Checking the

Fuel

Pump

34.

Assembling

the

Fuel

Pump

.

35.

lnsUlling

the

Fuel

Pump

36.

Fuel

Pump

Specifications

.

. .

.

4.

Fugl Filtgr

. . .

. . . ...

. , . . .

.

5. Carburetor

..

51

.

C"onstruction

.

5-2.

Disassembling the

Carburetor

$3.

Checking,

Maintenance

and

Limit of

5.4.

Assembling

the

Carburetor

.

t5.

MountingtheCarburetor

.... .

$6. Specif

ications

.

1.

2.

43 43 43 43

4

M

4 4

45 45 45

45

47

47 47

47

47 47

47

48

48 48 49 49

49

50 50

50

54

55

I_

gOiustment

6. Governor

6-1.

Governor System

-

General

6-2.

Governor

-

Operation

and

Construction

6-3.

Purpose

of Governor

Adjustments

&4.

Maintenance

6-5.

lnterlock

Adjustment between

C;rburetor

Spark

Plug

.55

55

.56 .58 .58 .58

.59

59 59 59 59 59 59

60

61 61 61

6l

63

.63 .63

.63

.63 .63

.64

.il

.64

.u

.64

.u

.64 .65

.65

.65 .65

and

Governor

IGTTIITION

SYSTEM

1.

Spark

Plug

1

-1

.

lnspection and

Adjustment

of

1-2.

Spark

Plug

Specifiiitions

Distributor

2-1 .

Removing

the

Distributor

2-2. Disasembling the

Distributor

2-3.

Checking,

Maintenanc€ and

Limit

of

Adjustment

24. Asembling

the

Distributor

2-5.

Mounting

the

Distributor

2-6.

lgnition Timing

lnspection and

Adiustment

2-7 . Distributor

Specifications

TOURBLESHOOTI]UG

1.

The Ergine

Lacks

Power .

.

1

-1

.

Fuel

C.omprssion

is

lnsuff

icient

1-2. lgnition

Timing

is

lncorrect

1-3. Fuel

Lsrel

is

Low

14.

Carburetor

Dravw

lnsufficient

Amount

of

Air

1-5. Engine

Overheats

.

2.

Fuel

Canzumption

is

Excessive

2-1 .

Engine

Oil

Leaks

2-2.

Oil

Comes

Up

into the

Combustion

Chamber

2-3. Oil

Comes

Down

from

Valve

System

Engine is

Hard

to Surt

3-1.

Engine

has

Starting

Difficulty

:

.

3-2.

lgnition System

is Defective

3-3.

Engine

34. Carburetor

Engine

is

Noisy

4-1

.

Piston

+2. Crankshaft +3.

ConnectingRod

.... ....

U.

tMiscellaneous

3.

4.

I

l

6.

5.

F

iring

lrregularities

S1.

lgnition

System

*2.

Air-fuel Mixture

$3.

Valves

.

u. cylinderHead

.. ....

lncorrest

ldle

Speed

Adiustment

.

Gl .

Carburgtor

. . .

.

. . . .

G2.

AirEnteringFuel

Line

....

6-3.Va1vgs...........o....

il.

Cylindgr

Head . .

.

. . . .

.

. . .

.

Engine

Runs

not

Smoothly

(when

acceleratedl

.

. . .

7-1

. Carburgtor

. o

. . . . . . . . . . . . . . . .

7-2.

lgnitionSystgm

..

......

...

7

3" Ergine, . .

. . . . .

. . . . . .

.

. .

. . .

.

65 65 65 65 66 66 66 66 66 66 66 66 66 66

7.

THE

ENGINE

-

GENERAL

TllE

ENGINE-GENERAL

This

PB

engine is a

high

performance,

water-cooled,

4-cylinder,

in-line

gasoline

engine,

employing

the overhead

valve

and

high

cam

shaft system.

The

cylinder

bore

and the

piston

stroke

measure

2'6772

in'

(68

mm) and

2'6772

in'

(68

mm)'

respectively. ln

this sense, the

cylinder

is

o{ a

square type,

having a total

displacement

of

60.2 cu.

in'

(987

cc)

and a

compr.ession

ratio

of

8.6 to l.

The maximum output

is

25

PS

at

2,800

r.p.m. and

the

maximum torque

46'9

lt-lbl2,2$O

r.p.m.

(6.5

kg-m/2,2OO r.p.m.). The description

of

the

engine is as

follows:

t

1.

Cylinder

Head

Being

made

of

a

light

alloy, the

cylinder

head

is light

in

weight,

provid

ing excellent

rad iation

eff

iciency.

The

domeshaped combustion

chamber

is shrinkage-

fitted

with

ductile cast iron

valve seats.

The

intake

and the

exhaust

valves

are

arranged

opposite

to

each

other the

cylinder head;

that

is,

the

cros-flow

design

is

employed

for

better combustion

eff

iciency.

2. Cylinder

Block

The

cylinder

block

is

precisioncast

from a

light

alloy

meEl

by

means

of

pressure

die

casting.

To

support

the

crankshaft,

f

ive

bearings

of

the deep

skirt

type

are

employed.

The

cylinder

liners

are

made

of

special

cast iron

and

replaceable.

They

are directly

cooled

by

water

and sealed

with

two

"4"

rings.

3.

Pistons

and

Crankshaft

The

pistons

are

of a

conical ellipse type

manufacturd

by

LO-EX.

The

crankslraft

is made

of

ductile

cast

iron

supsior in

durability

and wear-resistance,

and

supported

by

five main

bearings.

The

main

bearings

are

made

of an aluminum alloyed

with

tin,

which

is

also excellent in

durability

and

wear-resistance.

4.

UalYe

Meclnnism

The

high

cam

shaft design

is employed,

along

with

five

special

iron

bearings,

for increased rigidity.

This

permits

high

speed

relolutions.

The

cam

shaft

is

driven

by a

Renold-made

chain,

wtrose tension

is

adjustable

by

means

of

the

chain.

adjuster

and

vibration

dampr. To

reduce the

cfrain

noise, the

contacting

surfaces of

the

chain

is

finished with

heat-proof

and

wear-proof

rubber.

5.

lntake

and

Exhaust

Mechanism

The

exhaust

manifold

is made

of cast

iron,

and

the

intake

manifold

made of

a

light

alloy

metal.

Both

manifolds ?re

of

independent

branch

Wpe.

The hot

spot

is heated

by

warmed

"cooling

water".

ln

the

intake system,

a Stronberg

type

carburetor,

having a

downdraft

double-venturi

is used.

6.

GoYernor

The

Governor

is

of

f

ly weight

type

and controlled

by

means of

all

speed

governor

system.

-1

8.

Lubricating

Mechanism

Total

pressure

lubrication is carried

out by

a

trochoid

gpar

oil

-pump,

which is

driven

by

the

cam shaft drive

gear.

A

cartridge

type oil

f ilter

is

employed.

9.

Electrical

System

Electrical

component

is

of

12-volt

capacity.

The

alternator

is

l

Samp.

capacity, and the starter of

1.O-kW.

As

the

battery,

the

N40L

Wpe

is used,

and

the distributor

is

provided

with

a

vacuum

and

centrif

ugal

type

automatical

advancer.

7. Cooling

System

Cooling

system

is

the type

of

forcedcirculation,

and

the

pressure

in the

radiator

is 9.954 lbs/sq.

in.

by

which

the

high

efficiency

of

heat

radiation is secur-

ed.

Their

qystem

is

incorporated

with

the

Wax

type

thermostat

and

the

water

pump

is

of the

centrifugal

type.

The miterial

of

cooling

fan

is the synthetic

resin,

consisting

of

4

wings,

ENGINE

1.

Disassembling

0rder

Note:

Notes

on

Engine Dirssembly

Both

engine and

transmission

are very

heavy

in weight. ln

addition,

they

must

be

kept in

a

horizontal

position

while

being disassembled,

and therefore,

engine

disassembly operations

should

be

performed

on solid

f loors.

To keep

the

tractor in a

horizontal

position,

place

a

wooden wedge between the

front extension and

the

axle beam.

Be sure

that

necessary wrenche, such as

a special

tool

(No.

N033S

SOCKET

WRENCH SET), special

tool

(No.

BT-100 DOUBLE

OFFSET

BOX

WRENCH SET),

and

(No.

BT-9 OPEN-END

WRENCH

SET),

and other

special tools

including a

chain

block are all available on

hand.

Put

a rnark

on

each engine

component

part

such as a

piston.

piston

ring,

valve, valrre spring,

metal,

tappet,

push

rod. etc. in order of the

cylinders,

so that

you

will not

corifuse

dbout

parts.

Take

special

care not

to datnage

the

removed

parts,

and

put

them

in order.

l-1

.

Remoying

the Engine

1.

Bemove

the negative

(-)

corde

from

the

battery.

2.

Remove

the

wires from

the alternator

(A)

,

starting

motor

(B)

and

hed

light

(cl.

c

o

o o

b

\

Fig. I

Remove

the

bonnet.

Disconnect

the

wires

from

the oil

pressure

switch

(A)

and

the

water heat

gauge

(B)

.

Fig.

2

5.

Removing

the

radiator

Throughly

drain

off the cooling water from

the

radiator

and

cylinder

block. Loose

the water hose

clip

(A)

and

pull

out

the

water

hose from

the

radiator.

Remove

the

radiator

mounting

bolts

(B)

,

(C),

and

fitting

nut for

radiator

support

(D),

and

remove

the

radiator.

3.

4.

Fig.

3

ENGINE

6.

Removing

the

tractor

meter

cable,

throttle

wire

and

choke

wire

Remove

the

governor

cover

{A),

and

disconnect

the

tractor meter

cable

(B)

,

throttle

wire

(C)

and

choke

wire

(D)

.

Remove

the

governor

cover.

*l

Fig.

4

7 .

Removing

the

fuel

pipe

Remove

the

fuel

pipe

(Al

.

To

prevent

entering

the

fuel

tank, cover

it

with

a

cloth

"

Fig.

6

9.

Figr'

7 end

I

10.

Removing

the hydraulic

oil

pipe

a.

Remove

the

hydraulic

oil

pipe

clamp

(A).

Removing

the

silencer

pipe

Remove

the

nut

(A)

mountlng

both

exhaust

manifold

and silencer

pipe,

and

remove

the

silenc-

er

mounting nut

(B).

Then

remove

the

silencer

pipe.

dust

from

clean

dry

Fis.

5

8.

Removing

the

drag

link

Pu

ll

out

the split

p

in

from

the

ball

socket

connecting

the

Pitman

arm

and

drag

link,

and

remove

the slotted

nut

(A).

Remove

the

ball

socket

by

using

the

special

tool

(No.

TRH-12

TIE

ROD

END

REMOVEBI

Fig. 9

EN GINE

Fig.

l0

c.

Remove

the banjo bolt

(Cl"

Fig.

I I

d. Loosen

the strainer

body

(D),

and

take it

out.

Fig.

t 2

e.

b.

Remove

the magnet

plug

(B),

and

drain

off the

hydraulic

oil case.

When reusing

the oil,

put

it

in a

clean

container

while

taking

care

not

to

allow dust

to

enter

the

oil.

Remove

the

pump

flange

mounting

bolt

(E)

from

both

inlet

and outlet

sides. Cover the

ends

of the

pipe

so that

no

dust

will enter

the

pipe.

Removing

the

hydraulic

pump

and

pump

bracket.

Remove

the

four

bolts setting

the

pump

joint

(A),

and

remove

the

pump

joint.

Remove

the

four nuts

(B)

from

the

pump

(C).

Remove

the

two

screw

(M8

x

25l,

and

three bolts

(MB

x 45)

from

the

pump

bracket,

and

remove

the bracket

(D).

Note:

As alignment

of

the center

line

betureen

crankshaft

and the

hydraulic

oil

pump

had

been

correctly

fixed

at

0.001

181

in.

(0.03

mm)

during

factory

assembly, do

not

attempt

to

remove

the

pump

unless otherwise

it is definitely

necsary

to

work

out

its

remowt.

Removing

the

flange

coupling

and

CG-type

rubber

coupling

Remove

the

three

bolts

which

fasten

the

CG-type

rubber

coupling

to

the

crak

pulley,

and

remove

the

flange

coupling

and

CG-type rubber

coupling.

Fig.

l3

11.

Fig.

14

12.

EN

G INE

13.

Remove

the

engine

mounting

rubber

mounting

nut

(A)

on

both

right

and

left sides,

and

remove the

engine support

mounting bolt

(B).

Fig. 15

14.

Removing the

alternator

and

V-belt

a.

Remove

the

bolt

as shown

in

Fig.

16,

and

remo\€

the alternator

strap

tB)

from

the

alternator

(A)-

b.

Remove

the

alternator

mounting

nut and bolt,

and

remove

the

alternator

and

V-belt

(C)

from

the

alternator

bracket.

i,,'

{e

Fig.

16

15.

lnstall the chain

block

on

the engine

hanger

(A)

on

the

manifold on

both exhaust

and

inuke

sides.

Do

not

hoist

the

engine, but

pull

the

wire so that

it

becomes

slightly tight.

Place

a

garage

jack

under

the clutch

housing.

Do

not

iack

up the tractor,

Just

raise

the

jack

so

that

it is

just

tightly

locked under

the

tractor.

Remove

the'bolts

(A)

,

four

each on both

right

and

left sides,

and

the

four

bolts

(B)

,

also

four

each

on

both sides,

which

mounting

the

chasisand

clutch

housing.

Remove

the three

screws

(C)

from

the

re*,r

plate,

and

pull

the

re:,r

plate

downuard.

Pull

out

the

clrasis

and

front

axle

toward the

front.

Removing

the

engine mounting

and

alternator

bracket

Remove

the

mounting

nut,

and

remove

the

engine

mounting

(A)

from

the

alternator

bracket.

l

Fig. l7

16"

17.

Fig. t

8

18.

19.

a.

EN

GI

NE

Fis.

l9

b.

Remove

the

three

mounting

nuts, and

remove

the

alternator

bracket

(B)

from

the

cylinder

block-

Fis. fr

20.

Remove

the

starter

starter.

mounting

nut,

and

remove

the

Remove

the

four

nuts

(A)

and

nuts

(B)

(one

each

on both

right

and

left

sides)

,

which

mounting

the

engine

and

clutch

housing.

Next,

adjust

the

chain

block

suspending

the

engine

so that

the

stud bolt

will not be

under

excessive

load.

Then

pull

the

engine toward

the

front.

Fig.

22

1-2.

Dlsasembling

the

Engine

1. lnstall

the

engine on

the

special

tool

(No.

@90010

ENGINE

STAND)

by

mears of

one

bolt

and

three

nuts then

renpving

the

clutch

unit.

Fig.

23

21

.

Fis.

2l

_l

EN

GIN

E

2.

Draining

the

engine lubricants

Remove

the drain

plug

and

drain

off the engine

lubricants.

Fig.

24

3-

Remove

the

clutch, flywheel

and

crank

pulley

a.

As

shown

in

Fig.

25,

remove

6

pcs.

of scrarus

and

remove

the

clutch"

Make

sure

that

the

removal

order

for

screws

should

be diagonally

done.

Fig.

25

b. As

shown

in

Fig.

26, raise

up

the

lock

washer

of

its

bent

portion.

c.

As

shown

in

Fig.

26, install

the

special

tool

(No.

0490100

RtNG

GEAR

BRAKE)

so

that

the crank-

shaft

and

f lywheel

cannot

be

rotated.

d. Remove

6

pcs.

of the

rock

bolts

and

remove

the

flywheel

(A)

from

the

crankshaft.

Fig.

fi

e. Rernove

lock

bolt from

the

crank

pulley

(A)

at

the

front

of the

engine.

Fig"

27

f

.

Remove

the

special

tool

(No.

0490100

R

tNG

GEAR

BRAKE).

4. Removing

the

air

cleaner

a.

Loosen

two hose

bands,

and

remove

the hot

air

hose

(A)

from

the

air

cleaner

and

the

carburetor.

Fig.

28

b,

Loosen

two wing

nuts,

and

raise

the

clamp

(B).

Remove

the air

cleaner

bands

(c)

and

remove

the

air cleaner"

'*t

J

EN G INE

R

emoving

the

d

istributor

Pull

the

high

tension

wire

out of

each

spark

plug,

Pull

out

the vacuum

advance

hose

(A)

connected

to

the

distributor,

as

shown in

Fig.

30.

Unscraru

the nuts

(B),

and

pull

upward

the

distributor,

as

shown in Fig.

31.

Fig.

3l

Removing

the

V-belt

and

idler

assembly

Screw

in

the

adjusting

bolt

(A)

to make

the

V-belt

tight,

and

loosen

the

governor

pulley

lock

nub,

as

shown

in

Fig.

32.

Loosen

the adlusting

bolt

and

move

the

idler

pulley

(B

)

in the

direction

of

the

arrow

shown

in

F

is

33.

Then

pull

down the

governor

operating

lever

(C)

to the carburetor

side, and

remove

the

V-belt

(D)

from

each

pulley.

Unscrew

two

nuts

and

bolts, and

remove

the

idler

assembly

(E)

from

the

governor

bracket

and

the

timing

chain

cover.

Fb.

33

7.

Removing

the

governor

and

governor

bracket

a.

Remove

the

lock nut which

has

been already

loosened

according

to 6-a

above,

and

slip

the

governor pulley

(A)

off

the

governor

shaft. Then

remove

the

key

(B)

on

the

governor

shaft.

b

c.

Fig.

29

Fig.

fi

6.

a.

5.

ct.

b.

c.

';.

Fis.

32

Fig.

34

I

10

EN

GINE

b.

Remove

the

governor

operating

lever

and

remove

the

rod

assembly.

c.

Remove

the

nuts

and

bolts shornrn

in

Fig.

35.

d. Unscrew

three

nuts

shown in

Fig.

36,

and

remove

the

governor.

Remove

the

governor

bracket

and

remove

the engine

bracket

from

the cylinder

block.

Fig.35

e.

Unscrew

three

bolts and nuts

(

D), then,

the

gpvernor

(A),

the

go\emor

bnacket

(B)

and

the

engine

bracket ,(C)

which

have

already

.bem

removed

aaording

to 74

above, can

be separated.

Fig. 37

8.

Removing

the

cooling fan and

cooling

fan

oom-

plete

a. Unscrew

four

bolts, and

remove

the cboting

fan

(A)

,

fan

spacer,

pump

pulley

(B)

from

the

cooling

fan

complete.

b.

Unscrew

three

nuts,

and

remove

the cooling

fan

complete

(C)

and

alternator

strap from

the

rylin-

der

head.

c.

Take

out the thermosEt

from

the thermostat

casing.

'Removing

the

water

pump

Pull

the

inake rnanifold

water

hose

(A)

out

of

the

water

pump

by loosening

the clip.

Unscrew

four nuts,

and

remove

the alternator stay

(C)

and

water

pump

(B)

from

the cylinder head.

Fig.

fi

Fig.

39

:Fig.

s6

b.

Fig.

4l

EN

GIN

E

11

R

emoving

the

oil

f

ilter

Pull

out

the oil

level

gauge.

Remove

the oil

f

ilter

from the

cylinder

block

by

using an

special

tool

(No.

0490130 OIL

FILTER

WRENCH}

(A).

Fig.

42

I 1. Removing

the

fuel

filter

a. Unscrew the carburetor

connecting bolt,

remove

the

f

uel

hose

(Al

connected

to

carbu

retor.

b. Unscrew

two

nuts,

and

remove

the

fuel

pump

from

the cylinder block.

Then remove

the

and

the

(B)

in-

su

lator.

c.

Remove

the

oil

pressure

switeh

(C)

and

the

breather

pipe

(D).

Fis.

43

12.

R

emoving

the

carburetor

Unscrew

two

nuts, and

remove

the carburetor

(A).

Remove

the

insulator

(B)

from

the

intake

manif

old.

Fig.

44

13.

Removing

the

intake

manifold

Unscrew

eight

nuts

and

remove the

engine

hanger

(A).

Then

remove

the

intake

manifold

(B)

from

the

cyl

inder

head,

together

with the

governor

cover

stay

and the

a

ir cleaner

stay

mounted

thereon.

Fig. 45

14"

Rernoving

the exhaust manifold

Unscrew

eight nuts, remove

the

engine

hanger

(A)

,

and

then

remove

the

exhaust

manifold

(B)

from

the

cylinder

head.

10.

a.

b.

Fig.

46

-l

12

EN

GI

NE

-trlE

Fig.47

15.

Removing

the

rocker

arm cover

Unscrew

two

bolts

and

remove

the

rocker

arm

cover

from

the

cYlinder

head-

16.

Removing the

cylinder

hed

assembly

a. Unscrew ten

cylinder

head

nuts.

b.

Pull

upward

rocker

arm

asembly

(A).

c.

Pull

upward

eight

push

rods

(B).

d.

Remove

the

cylinder

head

assembly

(C)

from the

cylinder block.

e.

Remove the

cylinder

had

gasket.

Fis.

48

17.

Pull

eight

tappet

followers

from

the

cylinder

head

by using

a

proper

tool

such as

a magnet.

>'*.g-

ap

18. Removing

the

oil

pump

drive

gear

shaft.

a. Unscrew

two

nutS

and

remove the

oil

pump

drive

gear

cover

(A).

b.

Unscrew

three

nuts and

remove the

blind

cover

(B).

c.

Lift

off

the oil

pump

drive

gear

shaft

(D)

together

with the

shim

(E)

and

the

thrust

washer

(C)"

Fig.

fi

19. Turn

the

engine upside

down and

noW

the

oil

pan

is

upward.

20.

Removing

the oil

pan.

Undo twenty-two

nuts securing

the oil

pan

(B)

and

lift off the oil

pan

from

the

rylinder

block.

21

.

Unfasten

the

lock

bolts

and

remove the crank*raft

Pullqr

(A)

from

the crankshaft.

Fig.

5l

?E

,#€

Fi,.

49

EN

GI

]'IE

13

22.

Removing

the

timing

chain

cover

Undo

nine

nuts

and

remove the

timing chain

cover

(A)

Fig.

52

23.

Removing

the

chain

adjuster

assembly.

a. Undo

two nuts and

remove

the

chain

adjuster

assembly

(A).

b.

Remove

the oil baffle

plate

(B)

from

the

crank-

shaft.

c.

Remove

the

key

(C)

from

the

crankshaft.

d. Undo two nuts

and

remove

the

vibration damper

assembly

(D),

Fis.

53

24.

Removing the timing chain.

a"

Undo two

nuts securing the camshaft

(A)

b.

Remove

the

camshaft

& camsprocket

wheel

and

the timing

sprocket

wheel

together

with

the

timing

chain

(B)

from

the crankshaft

and

the

rylinder

block as

shown

in

Fig.

54.

{-t

Fig. 54

25.

Removing the

front

Plate.

Undo

two

nuts and

r'emove

the

front

plate

from

the

cylinder

block.

Fig.

55

n.

Removing

the oil

pump.

a. Loosen the

conn€tion nuts

and detach the oil

pipe

(A)

from

the

cylinder

block.

b.

Unscrew two

nuts

and

remove

the oil

strainer

(B)

from

the

oil

pump

(C).

c.

Unscrew

four

nuts

and lift up the oil

pump.

)

>-,

'\\

4,

{rir*

\

*

''

rl-.

l>*

Il

1r Il

ll

t

f=1

Di'r-

Fig.

56

>\-{

14

EN

GI

NE

27.

Removing

the

connecting

rod

cap

Loosen

eight

connecting

rod

lock

bolts

and

re-

move four

connecting

rod

caps

(A)

together

with

the

connecting

rod

bearing

metal

and

the

lock

bolts.

Note:

The

connecting rod

caps are marked

with

rylinder

numbers

(1,2,3

and 4),

respectively.

Fig.

57

28.

Removing

the

main

bearing

cap

a.

Straighten

the

bent

edges

of the lock washer

and

ten

nuts

securing

the

main

bearing

caps.

Fis.

58

b.

Remove

five

main

bering caps

together

with

the

main

bearing

metal.

n.

Removing

the

carnkshaft

Fig'

6o

a.

Remove

the

crankshaft from

the

cylinder

block

32.

Fig.

59

b.

Remove

five main

bearing

metals

from

the

cylin-

der block.

30"

Lift

up

four

piston

&

connecting

rod

assemblies

from

the

rylinder

block.

31.

Disassembling

the

piston

&

connecting

rod

as-

sembly.

Remove

three

pbton

rings

and

the

expander.

Remove

the

clips

at both ends of the

piston

pin.

Heat

the

piston

with

the

piston

heater

250

^'r'

300"F

1120

^,

150oC) and

pull

out

the

piston

(

by

means

of

the special

tool

(No.

e190070

PISTON

INSTLLER)

(A)

and

detach

the

piston

from

the connsting

rod.

Disassembling

the

cylinder

head

asembly.

Disasemble

each

valve mechanism

in

the

following

procedure.

Press

the

valve

by

means

of the

special

tool

(No.

0490030

VALVE

SPR

ING

Ll

FTER

)

(A)

and

remove the

taper

sleeves

(B).

a.

b. c.

ct.

ENGINE

15

Fig.

6l

b.

Remove the

valve

spring

lifter

and

dismantle

the

valve

springs,the

spring

Seat

upper

and

lower,

and

va I

ves.

Cylinder

Head

Bend

Limit

Grinding

Limit

0.006 in. (0.15

mm)

0.008

in.

(0.20

mm)

Fig. 63

3.

Valve

seat

Check

the

valve

seat

for

wear

and

damage,

and if it

is

defective,

correct it

with

a special

tool

(No.

0490140 VALVE

SEAT

currERl

{A}

.

Besides,

if

the sinking

of

the

valve

sear is more

than 0.0s9

in.

(1.5

mm) replace

the cylinder head

with

a new

one.

2.

Checking

Maintenance

and

Limit

0f

Adiustment

2-1

.

Gylinder

Head

Wash

the cylinder

head

if

there

is

much

fur in

the

v\nter

passage

of the cylinder

head.

check

the oil

apertures

for

blockage.

:

Bend

of the

cylinder

head

bottom

To

check

the

cylinder

head

bottom

for

bend,

measure

the

points

(1)

'\'

(6)

of

the cylinder

head

bottom

shown

in

Fig.

63

using a

thicknes

gauge

and a

surface

gauge.

lf

the measured wlue

is

beyond the

limit, correct

it with

a

surface

grinder.

o o o

Notes:

Before

inspecting

the engine.

Clear each

component

of

dust, carbon,

fur, etc.

and

wash it in solvent.

Check

the

cylinder hed and

cylinder

block

for

leakages

and damage.

Blow dust and

so on off

the oil aperture

of

each component

by

means of an air

gun

to

ensure

that

there

is no

blockage.

Put

the

valves. bearing

metals.

bearing

caps,

etc.

to

be

joined

in

good

order and

see

that

they

do

not

get

mixed.

1.

2.

I

16

EN

GI NE

Fb.il

Fig.

65

4.

Valve

face

Check

the

valve

face

for wear

and

darnage,

and

if is

defective, correct it with a valve

face

grinder.

Besides,

if

the

valve

head is

less

than

0.039

in.

(1

mm) thick,

replace it with

a

n€nru

one as

shown

Fig.

66.

Note:

After

grinding

the

valve

sheet

and

rralve

face, insen

and

adjust the

valve

spring sheet lower

into

the spring

bottom

to

obtain the

standard

measurement

(A)

1.596

in.

{40.5

mm},

The

valve

spring

seat lower is

0.020

in.

(0.5

mm)

thick

as shown

Fig.

67.

Fig.

ffi

Fig.

67

5.

Valve

stem

diameter

Check the

diameter

of

the

ralve

stem

with

a

micrometer.

lf the valve stem

is

worn

more

than

the

limit

compared

with

the standard

diameter,

replrce

the

valve with

a

new

one.

Standard

Valve

Stem Diameter

Wear

Limit

lN

valve

0.27s6-l

3:33??

'n

(7.0ri3:31!'*r

0.O02 in. (0.O5

mm)

EX valve

0.27b6

l3:333!

i"

(7.ooi3:3f!n.'"r

0.O02 in.

{0.05

mm}

Seat

Cutter

Pilot

43

cutter

(for

lN

side sheet)

45"

cutter

(for

EX

side

sheet)

15o

cutter

(for

lN

side

port)

15"

cutter

(for

EX

side

port)

TS

cutter'(for

lN

side

face)

TS

cutter

(for

EX

side

face)

Valve

-

S€t

1.74

{0.O684

in)

1.4

(0.0551

in)

'

3?4

(1.2599

inl

24

(0.9449

inl

24.W

(0.9649

in)

26.W

(1,O433

inl

'

35o

(1.378O

in)

2W

(1.1023

inl

28.W

(1.1220

inl

310

11.2212

inl

Valve Head

Standard

Thickness

lN

side

0.059

in.

(1.5

mm)

EX

side

O.G59

in"

(1.5

mm)

ENGINE

17

Fig. 68

Fig.

Z0

6.

Clearance

between

the

valve stem

and

valve

guide

check

the

clearance

between

the

valve

stem

(A)

and

valve

guide

(B).

lf

the clearance

exceds

the

limit,

replace

the

valve

and

valve

guide.

Standard

Stem

and

Guide

Clearance

Limit

lN

side

0.001

-

0.003

in.

{0.020

-

O.O3b

mm}

O.O08

in.

lO.2

mml

EX

side

0.002

-

0.003

in.

(0.040

-

0.085

mm)

0.0O8 in.

lO.2

mm)

The valve

guide

at

lN

side is

different

from

that

as

EX

side

as

shown in

Fig.

71 .

EX side

lN

side

ln

case

the valve

seal

fitted

to

the

lN

and

EX

valve

guides

is

defective,

replace

it

with

a

new

one

using

a

special

tool

(No.

0490000

VALVE

SEAL

PUSHER).

Valve

spring

check

the

valve

spring

for

free

length,

spring

pressure,

and

squareness

in

the

procedure

outlined

below,

and

if

it

is

defective,

replace

it

with

a new

one.

Measure

sguareness

of

the

valve

spring

with

a level

block

and

a square.

Replace

the

spring

if

out

of

squareness

is

0.118

in.

(3

mm)

per

3,g37

in.

(100

mm).

Fig.

7l

b.

8.

a.

Valve

Guide

F.,,

Fig. 69

7. Valve

guide

replacement

a.

Remove

the

valve

guide

from

the

rylinder

head

and n€i\ru

one with

a

special

tool

(No.

0490050

VALVE

GUIDE INSTALLER)

(A)

as

shown

in

F

is.

70.

18

ENGINE

Valve

Spring

SPecif

ications

rree

rensth

l;3?3r'*,,.,.,r

set

length

1 .378

in.

(35.00

mm)

spnng

pressure

46,3

tb

(21.ookg)

Fig.

72

b. Measure

the

free

lengrth

of the

valve

spring.

Replace

the spring

if it decreases

more

than

3o/o

ol

the standard d

i

mension.

Fis.

73

c.

Measure

the spring

tester.

Replace

the

under set condition

sundard

dimension.

pressure

with

a

valve spring

spring

if

the spring

pressure

reduces more

than

15o/o of

the

Fig.

74

Note:

Before

measuring

the

free

length

and

pres-

sure

of

the

valve

spring,

press

the

valve

Spring

several

times

to

be

fitted.

9.

Rocker

arm

shaft

checking

a.

Measure the

clearance

between

the

rocker

arm

shaft and

rocker

arm,

and

if the

measured

value

exceeds

the

limit,

replace the

rocker

arm

or

rocker

arm shaft.

Standard

Limit

Clearance

between

the straft and

arm

0.001

-

O.0O3

in.

(0.032

-

0.068

mml

O.OO4

in.

{0.1

mm}

Fig.

75

b.

lf there

is

a

rernarkable

bend

in

the

rocker

arm

shaft, corect

it

to

less than

0.0004 in.

(0.001

mm)

by

means

of

.a press.

2-2.

Plston

and Gylinder

Block

1.

Piston

checking

a.

Check

the

piston

for

crank and

damage.

lf

it is

defective,

replace

it.

b.

Measure

the

(A)

thrust diameter

just

below the sil

ring

and

(B)

thrust skirt diameter.

Standard

diarneters of

(A)

and

(B)

are as

follows:

(A)

2.6756

t

0.0004

in.

(67.96

t

0.01

mm)

(B)

2.6779

t

0.0004

in.

(68.02

t

0.01

mm)

EN

GINE

19

Fig.76

2.

F

itting

the

piston

and

piston

Measure the allowance

between

the

piston

pin.

lf the

rneazured

value

is

replace

the

piston

and

Piston

Pin-

Standard

allowance betrrueen

I

0.0002

-

0.OO09

in.

the

piston

and

piston pin

I

{0.004

-

0.023 mm}

Fig.

77

Note: When

fitting and removing

the

piston

ard

piston pin,

heat

the

piston

to

250

-

300"F

(12A

-

150"C).

3.

Clearance

between

the

piston

ring

and ring

groove

Measure

the clearance

between the

piston

ring and

ring

groove

with

a special tool

(No.

N026

STAN-

DARD

FEELER

GAUGE).

lf

the

measured

wlue

exceeds

the

clearance

limit,

replace

the

piston

ring.

Parts

Standard

clearance

Clearance

limit

Top

R

ing

0.001

-

0.003 in.

(0.035

-

0.070 mm)

0.006 in. (0.15

mm)

Second

B

ing

0.001

-

0.003 in.

(0.030

-

0.064

mm)

0.0O6 in.

(0.15

mm)

Oil

R

ing

0.001

-

0.002 in.

{0.030

-

0.062 mm)

0.0O6 in.

(0.15

mm)

Fig.

78

4.

Piston

ring

end

gap

Meazure

the

piston

ring end

gap

with a special

tool

(No.

N026 STANDARD

FEELER GAUGE)

(A)

thickness

gauge.

lf

the

measured

value exceeds

the

standard

end

gap

remarkably,

replace

the

piston

ring.

Parts Standard

end

gap

Top

Fl

ing

Second

R

ing

Oil

R

ing

0.008

-

0.016

in.

(0.20

-

0.40

mm)

Fig.

79

5.

Cylinder

block

a.

check

each

water

passage

and

oil

apefture

of

the

cylinder

block,

and

if

much

fur

is

found,

wash

it

altay

in

solvent.

b. The

cylinder

is

a

wet

type.

check

the inside

of

the

cylinder

for

scratching,

and

if

it

is

defective,

reprace

the

cylinder

liner.

c.

Check

the inside

of the

cylinder

liner

for

wear

at

six

points

shown

in

Fig.

81 .

piston

and

too

small,

I

2A

ENGINE

6. Cylinder

liner

replacing

When

removing

and

fitting the

cylinder

liner

from

and

to the

cylinder

block, use

a special

tool

(No.

O49OO9O

CYLINDER

LINER

PULLER)

(A)

.

Fig.

82

shows

pulling

the

cylinder

liner out

from

the

cylinder block.

J

t

t:

t

t'.

Fig.

80

lf

the

measured

value

is

0.006

in.

(0.15

mml

more

than the standard

value

below,

replace

the

cylinder

liner.

Cylinder

mark

Standard

value

Wear limit

A

2.6z72oi

3:3ffi3

,n.

{68

613.3;;

mm}

0.0O6 in.

(O.15

mml

No

Mark

z.6ztzr

l3:3ffi!

'".

(68

613.313

mml O.OO6 in.

c

2.67720

I3:3ffi

,',.

(68

613:ffi3

mml

0.006

in.

{0,15

mm}

Fig.

8l

Fitting

tre

cylinder

liner

and top

deck

When fitting

the cylinder

llner

and top deck,

fit

them

togefier

bearing same

marks in

order to

keep

fre amount

of

protrusion

uniform

(marks

are

classified

into

t\ o,

A

and

no mark,

?s

shown

in

Table 1). Marks

are on the

rylinder

liner

f

ront

and

rear

and

on the

top

of the

top

deck.

Fig.

83

shovra

mea$tring

the cylinder

liner

protru-

sion.

Fig.

82

7.

Fig.

&l

Mark

Top Deck

Cylinder Liner

Protrusion

A

o.34on':3'*t2

in.

(B.sf

3'os

mm)

034ili3:ffi?3'n

(B.s

l3:313

mm)

0.OOO4

-0.0024

in.

(0.01Q

a'

0.060

mm)

No Mark

0.34fr

I3"00.,

zin.

{8.5

I3.0,

mm}

0.346s

l3:ffi13,n.

(B.s

l3:ffi3

mm)

0.0006

-0.O028

in"

(0.O1$

a,

O.O7O

mml

Cylinder

Liner

Protrusion

EN

GINE

21

Mark

Cylinder

Liner

Standard

Value

Piston

Standard

Value

Clearance

A

A A'qA

+

0.0008

.

z'ot tt

+

o.o0o5

In'

(68613:31!mm)

2

67s6

1

3.3331

,"

(67.e6ri3:33!mm)

03017

n

0.0022

in.

(A.O42

-0.056

mm)

No

Mark

z.677zi

3:ffi31

,n.

(68

e

l3:3J3

mm)

2.67561

3.*01

in.

(67.e6

o]

3.00,

mm)

0.0017

-

0.0O22

in.

(0.046

-0.055

mm)

c

z.aTzzl

3'o*2

in.

(68

01

3'o*

mml

2.67s6:3.3331

'n.

(o7.e6

r:

3:3ff;

*'r

0.0017

-

0.0022

in.

(0.043

-0.056

mm)

8.

Standard

clearance

between

the

cylinder

and

piston

The

standard clearance

between

the cylinder

and

piston

is

0.001

^.,

0.007

in.

(0.030

-

0.069

mm).

Clearance

between

the

tappet

and

guide

Check the clearance

between

the

tappet

and

guide,

and if

the

clearance

exceeds

the

limit,

replace

the

tappet.

Push

rod

Measure

the

push

rod

bend

with

a special tool

(No.

N026 STANDARD

FEELER

GAUGE) and

if

the

measured

value

exceeds the

accuracy

remarkably,

correct

or

replace

it

as

shown

in

Fig.

85.

less than

0.004

in.

Push

Rod

Bend

Accuracy

I it.*'i'nrn

0.1

mm)

Fig.

85

2-3.

Connecting

Rod

1.

Connecting

rod

and

piston

check

the

clearance

between

the

connecting

rod

small

end

bush

and

piston

pin.

lf

the

clearance

exceeds

the limit,

replace

the

piston

and

small

end

buslr.

The

cylinders and

pistons

(A,

no

mark,

and

C)

and

are

f

itted

together.

are

classified

into

three

those

with

same

marks

o

r/r

Fig.

84

10.

Tappet and Guide

Standard clearance

Clearance

limit

0.0008

-

0.O029 in.

(0.020

-

O.O74

mm)

0.0O4 in.

(0.10

mm)

Fig.

86

_l

22 EN

GINE

Small

end bush

and

piston ptn

Standard

clearance

Clearance

limit

0.0004

-

0.O012

in,

{0.010

-

0.030

mm)

0.006 in.

(0.15

mm)

Connecting

rod small end

bush

replacing

When

pulling

and

press-fitting

the

samll

end

bush,

use a

bushing

tool

and

a

Press.

4" Connecting

rod deflection

Check

the

connecting

rod deflection

with

a

con-

rod

a ligner,

and

if the

measLl

red

value

is not

satisfactory

,

correct

the

con

necting

rod

with a

press

or

replace

it.

Connecting

rod

def lection

less

than

0.002

in.

per

3.94

in.

(less

than

0.04

mm

per

1OO

mm)

Distance

between

the large

end

and

srnall

end

4.84

t

0.O02

in.

n23

t

O,O5

mm)

-I

2.

FA.

W

Fig.

87

Note:

When

press-fitting

tre

small end

bush

to

the

connecting

rod,

align

the

oil aperture of the

small

end

bush

with

that of the

connecting rod.

3.

Connecting

rod large end

play

Measure

the connecting

rod

large end

play

with

a

special

tool

(

No. N026

STANDARD

F

EE

LER

GAUGE),

and

it is

good

if the

measured value is

in

the

range

of

0.004

^,

0,008 in.

{0.1

10

-

A.214

mm).

Note: On

the

side of

the

connecting

rod

cap

it,

inscribed

one

of

the

weight

marks

(8,

C,

D,

E,

F,

G and

H).

5.

Connecting

rod

bearing

metal

Check the

connecting rod

bearing

metal

for

scrape

and darnage,

and

if it

is defective,

replace it.

Note:

Connecting rod

bearing metals

are available

in

three

kinds

of

the

undersize

metal,

0.01

in.,

0.02

in.

and

0.03 in.

(0.25

mm,

0.50

mm

and

0"75

.

mm).

I

Samll

end bush

lnternal diameter

(after

pressfitted)

External

diameter

a.7s74r

i

3:3ffi?

'n

t2o

ol

3:313

mm)

o.eoss

ol$:ffi#,".

e3

o:3:333

mm)

Fig.

88

EN

GINE

23

6.

oil

clearance

benrueen

the

connecting rod

bearing

metal

and

crank

check

the

oil clearance

between

the

connecting

rod

bearing metal

and

crank

with

a

prastigauge

in

the

following

procedure.

a.

Clear

the

bearing

rnetal

and

crank

of dust,

oil,

etc.

b.

Place

the

plastigauge

on

the crank

pin.

c.

Fit

the bearing

cap

to

the

connecting

rod and

secure

it

to

the

crank

with

cap

bolts at the

specified

torque

of 25.3

-

28.9

ft-lb

(3.5

-

4.A

m-kg)'

d.

Loosen

the

cap

bolts

and

remove

the connecting

rod

and

place

the

plastigauge

as shwon

in

Fig.

g1.

Standard

Oil

Clearance

0.001

-

0.003

in.

lA.A27

-

0.O73 mml

24.

Crankshaft

and Main

Bearing

Meul

1 . Check

the crankshaft

for

crack and

it

is

defective,

replace

it.

Check

trre crankshaft oil

passage

shown in

Fig.

92.

damage,

and

if

in

dotted

line

Fig.

92

2. Crankshaft r,\,iarp

To

check

\

fiarp,

mount

the crankshaft

on the

center holding

device

and

m€sure

the \n€rp

with

special

tool

(No.

107M

DIAL INDICATOR,

No.

YM-l

MAGNETIC

BASE

FOR

DIAL lN-

DICATOR).

lf

the measured

value

exceeds

the

limit,

correct

it

with

a

press.

Fig.

9l

when

the

clearance

is rather

excessive

compared

with.the

standard

oil

clearance,

grind

the crank

to

an

u

ndersize

and

use

the

undersize

bearing

metal

to obtain

the standard

oil

clearanqe.

Accuracy

Limit

Crankshaft

warp

less

than

0.OOO8

in.

(less

than

0.O2 mml

0.001

in.

(O.O3

mml

Fig.

93

24

EN

GINE

3.

Crank

and main

journal

Measure

the diameter

of the

crank

and

main

journal

with

a special tool

(No.

75MB OUTSIDE

MICROMETOR

CALIPER}.

ln

case

wear

is more

than

0.002

in.

(0.05

mm),

correct the

crankshaft

by

grinding

to the

undersize

of

0.01,

A.OZ

or

0.03 in.

(0.25,0.50

or

0.75

mm)

with

a

crankshaft

grinder.

4" Main

bearing metal

The main

bearing

metal

is

of

interchangeable

type,

and

fit

them together in

the

proedure

shown

in

Fis.

95.

Check

the

rnain

bering metal for

flaking

or any

damage,

and if it is

defective,

replace,it.

-5.

Oil clearance

betvveen

the

rnain

bearing

metal and

main

ioumal

Measure the

standard

oil

cleararrce

between

the

rnain

bearing

metal

and

main

journal

with

a

plastigauge.

The

measuring

and correcting

pr&

CedureS

are

aS

in

"Oil

Clerance

between

connect-

ing

rod

bearing

metal and

crank

pin".

Standard

oil

clearance

0.0007

-

O.O029

in.

(0.01$

a,0.073

mml

Main

bearing

cap torque

43

-47

ft-lb

(6.0

-

6.5

t-kgl

Undersize

metal

0.01

in.,0.02 in.,0.03

in.

(0.25

mm, O.5O

mm, 0.75

mm)

-I

Fig.94

Standard

diameter

Wear

limit

Grinding

limit

Crank

1.7717

o:

3:331?

,n.

(4so-3:333mm)

0.O02

in.

(0.05

mml

0.O3 in.

(0.75

mml

Main

journal

z2crr.o:3:Sl?,^.

(s6o:

3:#3

mml

0.002 in"

10.05

mml

0.03

in.

(0.75

mm)

Fig.96

EN

GINE

25

6.

Crankshaft end

play

Measu

re

tha

cran

kshaf

t

end

play

with

a

special

tool

(No

N026 STANDARD

FEELER

GAUGE).

lf

the

measured value

exceeds

the

limit,

replace

th e th

rust washer inserted

into the

main

bearing

cap

rear with an oversize

washer

in

order

to

obtain

the standard

end

play.

Standard

value

Limit

Crankslraft end

play

0.004-0.001

1in.

(0.1

1Q

'v

A.274

mm)

0.01

2

in.

t0.3

mm)

Oversize

I

O.Ot

in.,

0.02

in.,

0.03

in.,

thrust

washer

I

t0.25

mm,

0.50

mm

,4.7

5

rnm)

Camshaft

iournal

and

cam

height

Measure

the

diameter

of

the

camshaft

journal

with

a special

tool

(No.

75MB

OUTSIDE

MICRO-

METE R

CALIPER)

,

and

if the

measured

value

!s

more than

0.002 in.

(0.05

mm) smaller

than

the

standard diameter,

replace

the

journal.

2.

a.

b.

Measure

the

cam

height

with

replace

the

camshaft

if wear

is

(0.2

mm).

a

micrometer, and

more

than

0.008 in.

Fig.

97

2-5.

Camshaft

1

.

Check the

camshaft

pump

drive

gear

(A)

cam

and

journal

for

replace it.

distributor

drive

gear

and

oil

for

damagp and wear,

and the

damage. lf

one

is

defecti\re,

,-

,

t

I

i

t

a

,

v

Cam-

slraft

Journal

No.

Standard diameter

Wear

limit

1

1.88e8

:

3:33?l

'".

t4B:3:333

mm)

0.002

in.

(0.O5

mm)

2

1.8111-

3:3313'".

(46:

3:3??

mm)

3

1.7717:3:33i3'"

(45:

3:3??

mm)

4

1.7323:

3:3313

'n.

144_3:3??

mm)

5

1.6s2e

:

3:33??

,n

(43

:3:333

mm)

Cam height

(lN

and

EX)

Standard

height Wear

limit

1.4352

in.

(36.454

mm)

0.008 in. (0.2

rnm)

Fig.

98

Fig.

99

26 EN G INE

3. Camshaft

warp

Measure the

camshaft

warp

with a

specia

I

tool

(No.

107M

DIAL

INDICATOR,

No-

YM-1

MAGNETIC BASE

FOR

DIAL

INDICATOR).

If

the measured

value

exbeeds

the

limit,

correct

it

with

a

press.

Accuracy

{standard

}

Limit

Camshaft

run-out

less

than 0.0OO4

in.

(less

than 0.01

mm)

0,001

in,

(0.03

mm)

5.

Camshaft

end

PlaY

Measure

the

camshaft

end

play

with

a

special

tool

(NO.

NO26

STANDARD

FEELER

GAUGE}.

RC-

place

the

thrust

plate

if

the

measured

value

exceeds

the

limit.

Camshaf

t

end

play

Standard

value

Limit

0.0008

-0.0071

in.

(0.02

a,,

Q.18

mm)

O.OOB

in.

(0.2

mm)

I I

I

j

Fig.

100

4"

Fig.

,0,

Clearance

Measure the clearance

betnveen

the

camshaft

journal

and

rylinder

block

iournal

bearing.

Re

place

the

camshaft

and

cylinder block

if

the

measured value

is

0.006

in.

(0.1

5

mm)

more

than

the sta

ndard clearance.

2-6.

Timing

Ghain Sprocket

and Chain

Adiuster

Timing

chain

and

sprocket

wheel

Check

the

timing

chain

and

sprocket'wheel

for

wear and

damage,

and

if it

is

defective,

replace it.

Timing

chain

tension

To

check

the

timing

chain

tension,

remove the

timing

chain

cover,

and

it

is

good

if

(A)

dimension

of

the

chain

adjuster

is within

0.5

in.

(12

mm).

lf

it exceeds

0.5

in.

112

mm),

replace the

timing

chain

and

sprocket

wheel.

1.

2.

Journal

No.

Standard clearance

Clearance

limit

Camshaft

and

iournal

bearing

1,

5,

O.OOOB

-

0,0018

in.

(0.020

-

0.061

mm)

O.OO6 in.

(0.15

mm)

2,3,4,

0.001Q,v0.0027

in.

(0.025

-

O.O66

mm)

Fig.

102

I

ENGINE

27

J.

a.

Chain

adjuster

and

vibration

dar,tper

Check the

chain

adjuster

spring

(A)

for corrosion,

and the

sl ip

per

head

(

C)

f

or

wear.

I

f

one

is

defective,

replace

the assembly.

The vibration

damper

(B)

is

f

inished

with heat-

proof,

oil-proof

and

wear-proof

synthetic

rubber.

l

\

ffi.,

@nnecting

rod

as shown

in

Fig.

104.

Fit

a

clip

to

theclip

groove

at

the other

end

of the

piston

as shown

in

Fig.

104.

Fitting

the

pbton

ring

to the

piston

Fit

each

piston

ring

as

shown

in

Fig. 105 following

the

procedure

outlined

below:

Fit

the

expander

to

the

lornest

groove

on the

piston

and

ring

(A).

Fit

the second

ring

(B)

and

top

ring

(C).

Note:

Be

sure

to

fit

each

piston

ring

with

the

mark

R

(D)

upvr@rds. Besides,

do

not expand

rings

more

than

n*essitry

to

install.

(A

b

3. Assembling

0rder

Fig.

103

c.

o

Notes:

On the engine

asembling.

Check the clearances between

the engine

main

parts,

oil

clearance, and

play,

bending,

etc.,

referring

to

Chap.

4

"Engine

Checking and

Maintenance".

Be sure to

apply

engine

oil to the

engine

rwolving and sliding

parts.

Usually

replace

the

packings,

gaskets,

lock

washers, etc. with

nevv

ones.

Secure

the bolts,

nuts. etc.

of

the

engine

main

parts

at the specified

torque by

means of

a

torque

wrench.

After insulling

the

engine rwolving

parts,

start the engirn to

ensure that

it runs smoothly

without a

strange

sound.

knocking, unreasonable

vibration, etc.

3-l

. Asembling

the

Engine

1. lnstalling

the

piston

and

connecting

rod

a.

Fit

a clip

to the clip

groove

at

one

end

of

the

piston.

b.

Heat

the

piston

with

the

piston

heater 2W

A,

300"F

(120

^,

150"F)

and

insert

the

piston pin

quickly

into

the

contact

point

with

the

clip

by

means

of the special tool

(No.

0490070

PISTCN

INSTALLER)

(A}.

Note: When

f

itting

the

piston pin

to

the

connect-

ing

rod,

the

mark

F

(B)

on the

piston

must

be

positioned

in relation

to the

oil

jet

hole

{C}

of

the

2.

a.

b.

lo

-

lo30'

.g.g

oo o0

li

T

.5

.S

-el

00 oo

rl

Fig."

104

Fig.

I

05

rso

N

28 ENGINE

3.

lnstalling

the

valve

mechanism

to

the

cylinder

head

Follow

the

procedure

outlined below

to

install

the

valve mechanism

to

the cylinder

head:

Fit

the valve,

spring

seat

lower,

y?

lve

spring,

and

spring

seat u

pper

to

the cylinder

head, and

compress the

spring valve,

using

the

special

tool

(No.0490030

VALVE

SPRING

LIFTEn),

lnsert

the

taper

sleeves

(A)

and

ease

the

compres-

sion

to

the

valve

spring

slowly,

and

remove

the

wlve spring

lifter.

rection

of

P

I

i

a.

b.

-r

Fig. t 06

Fig.

lO8

b.

Using

a special

tool

(No.

0490080

PISTON

lN-

SERTING GUIDE)

(B),

insull the

piston

and

connecting

rod

large

end with

"F"

mark on

the

piston

toward the

front

of

the engine,

tapping

the

head

of

the

piston

with a

plastic

hammer.

Note: Prevent

the

gap

of

the

piston

ring

from

facing

the

thrust side and the

piston pin

side.

Fig.

109

6.

Turn

the

engine

upside

down and now the

crankshaft

is

upward.

7 .

lnstalling

the

crankshaft

a.

Fit

the

main

bearing metals

to the cylinder

block

and the

main

bearing cap.

Note: Fit

the

main

bearing

metals

with

the same

rnark

at the

disasembly.

b.

Fit

$e

block thrust

washer

to both ends

of the

o/linder

block

rear

{B)

with

the oil

groove

{A}

outside.

Note:

The

taper sleews

at

the

lN

side

are

differenti

from

those at the

EX

side,

and

the

taper

sleeve

fitting

is as shown in

Fig"

107.

K

EX.

Fig.

107

4.

Fit

the c',/linder block

to

the

special

tool

(No.

04g0O10

ENG

INE

STAND)

with

the cylinder

head

upwards"

lN.

5.

a.

lnsulling

the

piston

and connecting

rod large

end

Place

each

piston

ring at about

l20o

apart

and

alternate

the

gap

of the

oil

ring

and

that

of

the

expander

(A).

ENGINE

29

Thrust

washer

Fig. lll

c.

lnstall

the crankshaft

on the

main

bearing

metals.

Note:

Be careful not

to drop

the

thrust

washer.

d. Appfy

graphite

grease

to the lip

of the

oil seal

(A)

and

f

it

to

the

rear

of

the

crankshaft.

e.

lnsert

the side

seals

(B)

into

the

grooves

at both

sides

of

the

No.

5

main

bearing

cap.

Then

f

it

the

thrust

washers

(C)

to

the cap

(Fig.

112)

and

install

the

cap

to the

cylinder

block

and

crankshaft.

Note:

Apply

the special

tool

(No

TL-05 THREE

BOND

No.

5) to the side

seal and

fit

it with

the

wider

lip

of

the

side seal

toward the

flank

of

the

engi ne.

Fig. I l3

8.

A d.

Fig. I l4

9.

a.

Torque

for

tightening

25.3

-

28.9

ft'lb

Fit

the

main

bearing

caps and

tighten

them to

the

specified

torque of

43

-

47

tt-lb

(6.0

^''

6.5

m-kg)

with

ten

nuts.

Note: F

it the

ma

in

bearing

caps

in

accordance

with

the

marks

showing the

arrangement

order

(A,

B,

A

and

D

from

the

front

of the

engine)

.

Bend the

lock washer around the

nut.

F

itting

the

piston

and

connecting

rod

to the

crankshaft

Fit

the

piston

and

connecting

rod

large end,

and

the

connecting

rod

caps

to the

crankshaft.

Note:

When fitting

them, be

sure

to

match

the

mark

of

the

cap with

that

of the large end.

Tighten

ech

connecting rod

cap

to the specified

torque

of 25.3

-

28.9

ft-lb

(3.5

-

4.0 m-kg)

with

eight

cap

bolts.

f.

g.

Fig.

I

lO

{A}

e&?

5t

oE

Block side

peceK

Sto€

Cap

side

-.-

t

*-#

lnstalling

the

oil

pump

and

oil

strainer

lnsert

the

oil

pump

from

above

the cylinder

block

and secure

it

with four

nutS.

Then,

f

it

the

oir

pipe

to

the

cylinder

block

and

oil

pump.

'!

b.

Fig.

1J

2

30

ENGINE

12. lnstalling

the

timing chain

and sprocket

wheel

a. Set the

f

irst

cylinder

at top

dead

center.

b.

Fit

the

camshaft &

camsprocket

wheel

and

the

timing

sprocket

wheel

to

the

timing

chain.

Note:

Match

the

mark

of

the timing

chain

with

that of each sprocket

wheel

as shown

in

Fig.

118.

There

are

eleven

lanes

between

both

match

marks.

c. \Mren

installing the

sprocket wheel

and

timing

chain

to the cylinder

block

and crankshaft,,be

&reful

not to

go

wrong

the

meshing

of them.

t

Fig.

I

l5

b.

Secure

the oil

strainer

to

the

nuts.

Note:

lnsert

the

"Oo'

ring

(A)

as shown

in

Fig.

1 16-

oil

pump

with

two

into

the

oil

strainer

Fig.

I

16

10.

Turn

the

engine

upside down

so

that

the cylinder

head

is

upward.

1 1.

Fitting

the

front

plate

Secure

the

front

plate

together

with

the

packings

to the

cylinder

block

with

tup

nuts.

\

-t

t'

---**-

a.-,__,

-..-

Turn

the

camsprocket

wheel

to

match

the

kqf

grooves

of the

cmnkshaft

and

the

timing

sprocket

wheel,

and

f

it

the key

(A).

secure

the

camshaft

&

camsprocket

wheel

to

the

cylinder

block

with

two

nuts

(B).

Fit

the

oit

baffle

plate

(Cl.

Secure

the vibration

damper

(D)

to

the

front

plate

with

hnto

bolts.

Fig.

I

18

d.

e.

f.

g.

Fig.

1t7

Fig. I

19

ENGINE

31

13.

Chain

adjuster

assembly

a.

Straighten

the bent

edges

of

the

lock

washer

(B)

and

remove

the

plug

(A)

from

the body

(C).

lnsert

the spring

(E

)

and

inner

cylinder

(D)

into

the slipper

head

(F),

and

fit a hexagonal wrench

(G)

to the

inner

cylinder and

rotate

the

wrench

clockwise

until

the inner cylinder

enters the

slipper head

completely

lnsert

the slipper

head into

the body.

b.

c.

h

Trll

(Fl

Fig..l2

b.

c.

Secure

the

crankslraft

pulley

tq the crankshaft

temporarily

with

lock bolts

as shown

in

Fig. 123.

Rotate

the

crankslraft

and

ensure

that

it

runs

smoothly, and then

tighten

the timing

chain cover

holding

nuts

securely.

Turn

the

engine

upside

down so that

the oil

pan

is

in

front.

Then,

cut

off

the unnecesry

parts

(A)

of the

timing chain cover and the

packin5

with a

knife.

16.

Fig. ln

14. lnstalling

the

chain adjuster

assembly

a.

Sectrre

the chain

adjuster

asembly

to the

cylinder

block

with

two

bolr.

b.

Rotate

the

inner

cylinder in

the direction

of the

arrow

shown

in

Fig.

66

with

the hexagonal

wrench

and

loosen

the

slipper head.

c.

Secure

the lock

raasher

and

tl':e

plug

(A)

to the

body and

bend

the

lock

washer

around

fte

plug.

Fig.

123

17.

lnsulling

the

oil'pan

a. Apply

a thin

coat

of the

special

tool

(No.

TL{57

THREE

BOND No.

5)

to

the

parts

on the cylinder

block where

the No.

5

main

bearing

cap

and the

timing

chain

cover

are

f

itted.

b. secure

the

oil

pan

together

with

the

packings

to

the cylinder

block with

twenty-two

nuts.

Fig.

|

?l

15.

a.

lnstalling the timing chain

cover

and

the dynamo

drive

pulley

Apply

a bit of

graphite

grease

to

the

oil

seal

(A)

and

secure the

timing

chain cover

together

with

the

packings

to the cylinder block temporarily

with nine nuts.

32

EN

GINE

i

--.*l

Fig"

124

18.

lnstalling

the oil

pump

driven

gear

assembly

a.

lnsert

the

oil

pump

driven

gear

asembly

(B)

,

shim

(C)

and thrust washer

(A)

into

the cylinder block

as

shown in Fig.

125,and

fit

them

to

the oil

pump

drive

shaft and

fre camshaft

drive

gear.

Tighten

the

oil

pump

drive

g€r

cover

(D)

to 6.6

ft-lb

(0.9

m-kg).

Note:

Be sure

to

fit

the

c'O"

ring

to the drive

gpd

oover.

Fig.

126

19"

lnsert

eight

tappet floors

into

the cylinder

block.

Fig.

127

n.

lnstalling

the

cylinder

head

assembly

a.

Place

the

cylinder

head

gasket

on

the

cylinder

block

and

install

the

cylinder

head

assembly.

Note:

Apply

the

special

tool

(No.

TL-0br

THR

EE

BOND

No.

5)

to

both

sides

of

the

cylinder

hed

gasket.

Fig.

125

b.

Check the end

play

of the

oil

pump

driven

gpar

assembly,

and if

the

measured

value

is

in

the range

of 0.002

^.,0.004

in.

(0.05,-"

0.1 mm),

it

is

good.

lf

it

is

not

satisfactory,

check

the shim

and/or

thrust

washer.

Note: For

the

kind

of

the shim

and

the

thrust

washer

,

refer

to

Para.

"Checking

and

Adjusting

the

Oil

Pump

Driven

Gear Shaft"

on

page

41.

Secure

the blind

cover

together with

the

packings

to

the

cylinder

block with

three nuts.

c.

Fig. ,28

ENGINE 33

lnsert

eight

push

rods

into

the tappet

f

lower

with

the

longer

ones

into

the

EX

side,

Rocker

arm

and shaft assembly

Assemble

the

rocker

arm,

rocker

arm shaft,

rocker

arm supporter,

lock

bolts,

and

washers

as shown

in

F

ig.

129.

Fig.

129

d.

lnstall

the rocker

arm

assembly

on the

rylinder

head

asembly.

Note:

Check

the adjusting

screws

of the

push

rod

and rocker

arm.

e.

Place

ten cylinder

head

holding

nuts

and

adjust

the

Ex

rocker

arm

suppofter

so

that the

center

of the

wlve

stem is 0.04

in.

(1

mm)

shifted

from

that

of

the

rocker

arm as shown

in

Fig.

130

0.O4

inl

Fis.

130

Fig.

l3l

Note:

F

ig.

1

30

shona

the

E

X

valve

rotation

mechanism,

and

the center

of the

valve

stem

is

0.04

in.

(t

mm)

shifted

from

that

of

the arm.

There

is

a clearance

of O.O2

in.

(0.5

mm

).

while

the

valve

is

working,

the Ex valve

rotates

slowly.

This

helps

clearing

a!^Ey

foreign

matters

between

the

valve

seat

and the valve

face,

and

prevents

excesive

abrasion

of

the

valve

face

and

valve

seat

and lengthen

the

valve

durability.

21 .

lnsulling

the exhaust

manifold

secure

the exhaust

manifold

together

with

the

gnskets

to

the

rylinder

head

with

eight nuts

and

the engine

hanger.

Tighten

the manifold

to the

specified

torque

of

7 .2

n

14.5

ft-lb

(

1

.0

-

2.O

*-kg).

b.

't

.

Tighten

th

e

cy linder

head

ft-lb

(6.5

,+,

7.0

m-kg)

in

131

.

holding nuts

to

47

-

51

the

order

shown in

Fig.

*-

*'

t

Lrril--

\,i +-

2_

Fig.

132

22.

lnstalling

the

intake

manifold

secure

the

intake

manifold

together

with

the

packings

and

the

engine

hanger

to

the

rylinder

head

with

six nuts.

Tighten

the inuke

maniford

to

the

specif

ied

torgue

of

1

1.5

-

2O.l ft-lb

(1.0

-

2.g

m-kg).

! l-

34

EN

G INE

I nstalling

the carburetor

Fit

the

packings

and the

insulator

(A)

to the

intake

manifold, and

then

secure the

carburetor

to

the

intake

manifold

with two

nuts.

25.

lnstalling the

oil filter.

a.

lnsert

the oil

pressure

switch

(A)

.

b.

Apply engine oil

to

the

oil

seal of

the

oil

filter

and

secure

it to

the

cylinder block.

Fig.

136

T

Fig. 133

23.

Fig.

134

24.

a.

b.

lnstalling

the f

uel

pump

Fit

the

packings

and the insulator

(A).

"

Secure

the

fuel

pump

to the cylinder

block with

two

nuts.

c. connect

the

fuel

hose

to

the

carburetor

and

the

fuel

pump

outlet.

Fig.

l

g8

Align

the

marks

on the distributor

drive

gear

and

housing

as shown

in

Fig.

138.

lnstall

the distributor

in

the timing

chain

cover.

Note:

When

meshed

with

the

drive

gear

on

the

camshaft, the mark

on the distributor

drive

gear

moves

by

49o

counterclockwise

due

to the

gear

twist. Connect

the

vacuum

advance

hose

to the

carbu-

retor

and

the distributor.

Fig. 137

b.

c"

Fig.

1.35

d.

ENGINE

35

\

.l

Fig. I

g)

27

.

lnstalling

the water

pump

a. Connect

the

water

hose

to

the

intake

manifold and

the water

pump.

b. Secure

the

water

pump

(A)

together

with the

packings

to the

cylinder

head

with

two

nuts.

c.

Secure

the altemator

stay

(B)

to

the

water

pump

with

two

nuts.

Fig.

141

d.

Fit

the spacer

(A)

,

fan

pulley

(B),

fan

spacer

(C)

,

and

cooling

fan

(D)

to the

pulley

boss

of

the

cooling

fan

complete

in

that

order

as

shown

in

F

ig.

142

with

four

holding

bolts.

f'

t

g-'

28.

lnstalling

the cooling

fan

complete

a.

I

nsert

the

therrnostat

(A

)

into the

casi

ng.

F

it

the

pack

ings.

b

'

F

it

the

alternator

strap

(

B)

to the

complete.

c. Secure

the

cooling

fan

complete

to

head

with three

nuts.

Fig.

142

n.

lnstalling

the

governor

and

governor

bracket

a. Secure

the

governor

to

the

governor

bracket with

three

nuts.

b.

Secure

the

governor

together

with

the spacer

(A)

in

Fig.

143

to the

timing chain

cover with

bolts

gnd

nuts.

thermosut

cooling

fan

the

cylinder

Fig.'l#)

36 ENGINE

Secure

the

engine

bracket

at

the

lower

part

to

the

cylinder

block

with

three

nuts.

Connect

the

rod

asembly

(B)

with

the

carburetor

throttle

valve

closed

and

the

governor

operating

lever

{A)

at the

top.

Fig.r4

30.

lnstalling

and

adjusting

the

idler assembly,

governor

pulley

and

V-bett

a.

Secure

the

idler

assembly

to

the

timing

chain cover

and

cover

bracket

with

turo

nuts

and

one bolt.

Fit

the

V-belt

(C)

to

the

idle

pulley, governor

pulley,

and

pump

pulley.

Tighten

the

adjusting

bolt

(D)

to

adjust

the

tension of the

V-belt

so

that the

governor

lock nut

(E)

may

be tightened to the

specified

torque

of

36.2

ft-lb

(5

kg-m).

Floute

the adjusting

bolt as

shown

in

Fig. 147

so

that the

V-belt f

lexes 0.55

-

0.78 in.

(

14

'>

n

mm)

tin

case

of tension of

sorne

22.05

lb

(10

fg))

by depressing with fingers midvray

between the

pulleys.

lf

the

belt

is

a

new

one, adjust the

f

lexion

of the

belt to

0.55

-

0.67

in.

(

14

-

17 mm).

Secure

the

governor

cover

to the

governor

stay

and

governor

bracket with

three bolts.

Va

lve

clearance

adjustment

Adjust

the lN

and EX valve

clearances

to 0.01 in.

(0.25

mm),

setting

each

piston

at

the

top dead

center"

c.

d.

T

Fig.

l6

c.

d.

Fig. 147

31.

e.

f.

Fig.

145

b.

Fit

the ks/

(A)

to

the

governor

shaft

and

governor pulley

(B),

and secure

them

temporarily

with

lock nuts.

EN GINE

37

Fig.

148

32. lnstalling

the

cylinder

head cover

Secure

the cylinder

head

cover together

with

the

packings

to the

cylinder

head

with tv\o

bolts.

3El. lnstalling

the

air cleaner

Fit

the air

cleaner

to the

air

cleaner stay

with

the

air cleaner

band and two

wing

nuts. Connect the

hot

air hose

to the air

cleaner

and

the

carburetor.

I

nstal I

ing the

f

lywheel

Fit

the

flywheel

to the crankshaft

rear

with lock

washers

and

six lock bolts.

One

of the

six

lock bolts is

a

reamer

bolt

and

fit

it

to the

holes

(A)

and

(B)

as shown

in

Fig.

149.

Bulb

clearance

Both

lN

and

EX are

0.01

in.

C,0/

o

/

ilL

,l

AaO

|

--

D

.t

,,

^-

\.rF

Hold

the

crankshaft by

means

of

special

tool

(No.

M90100

RING

GEAR BRAKE) and

tighten

six

lock

bolts

to

60

-

65

ft-lb

(8.3

-

9.0

m-kg)

and

bend

the lock

washers

around the

bolts.

\,

.-,

tfi

c.

For

clutch assembly

mounting, see

"Clutch

System"

of

Repair Manual.

d.

Tighten

the

lock

bolts

of the

engine

front

crank-

shaft

pulley

to the

specified

torgue

of

58

^'

72

ft-lb

(8

^,

10

m-kg).

e. Remove special tool

(No.

0490100

RING

GEAR

BRAKE}.

Fig.

l5l

35.

Dismount

the engine

from

the

engine

stand.

36.

lnstalling

the

alternator

bracket

and

alternator.

a.

Secure

the alternator

brdcket

(A)

to the

cylinder

block

with

three nuts.

b.

Fit

the

alternator

to

the alternator

bracket

and'

alternator

stay

(C)

,

and

secure

it

temporarily

with

bolts

and nuts.

c. Raise

the alternator

and

connect

it

with

the

alternator

strap

(B)

and

bolts.

Fig.

g.

a.

-'

i:

Fig.

149

b.

38 EtuGttuE

j

Fig.

,Q

37.

V-belt

fitting and

adjusting

a.

Fit

the

V-belt

(A)

to

the cooling

fan

pulley,

alternator

pulley,

and

crankshaft

pulley.

b.

Adjust

the alternator

so

that the

V-belt

flexes O.47

A'

0.63 in.

n2

'v

16 mm)

(in

cise of

tension

of

sorne 22.05

lb

(10

fg))

at the

center of the belt.

Fasten

the alternator

holding

bolt

(B)

securely.

lf

the V-belt is nary,

adjust the

flexion

of

the

belt

to

0.40

-

0.51

in.

(10

-

13 mm).

4. Specifications

FA. tE'

x2.

1.

Mounting

the

Engine

can

be rnounted

by

meatrs of the

reverse

order

for engine

removal.

(see

1-1 Removing the

Engine)

Type

Number

of cylinders

Cylinder arrangement

Piston

displacement

Bore

and stroke

Rated

r.p.m.

Maximum

r.p.m.

Roted

power

Maximum

power

Masimum

torque

Compression

ratio

Compression

pressure

lgnition

order

Valve

position

Weight Valve

clearane lntake

Exhaust

P.B.

4

ln

series

60.2

in2

(987

cc)

2.6772 x 2.6772

in

(68

x

68

mm)

2,800

r.p.[Tl.

3,150 r.p.m.

23

P512,800

r.p.m.

25

PS/2,800 r.p.m.

46.9 ft-lblZ,z}O

r.p.m.

(6.5

kg-m/2z0o r.p.m.)

8.6:1

145

lb/inz

(10.2

kg/cmz

)

1,3,4,2

Overhead ralve

system

258 lbs

(1

17

kg)

=---

0.01O in.

(0.25

mnfl.

Sl)l0in:={025 mm}=

I

LU

BRICATION

SYSTEM

39

LUBRI

CATION

SYSTEM

1.

Lubrication

System-General

A

total

pressure-feed

lubrication system

is employed

with

the oil

pump

of a trochoid

coryvheel

type

and

oil

f ilter of a

cartridge type.

Lubricant

circulates as shown

in

Fig. 1.

After filtered

through

the oil

pan

strainer,

it is

drawn

into the

oil

pump.

ln

theoil

pump,

the

pressure

of lubricant

is

maintained

at

a constant

level of 53.9

lb/inz

(3.8

kg/cmz

)

by

means of

the oil

pump

pressure

control

mechanism'

The

oil returns

to the oil

pan

after

lubricating

every

necessary

part

of

the

engine

as

indicated by

the arrow.

Rocker

arm

shaft

Oil

pump

Oil

strainer

Fig. ,54

4A

LUBRICATION

SYSTEM

2"

Disassembling

the

[Iil Pump

2-1

.

Removing

the

Oil

Pump

1.

Before

disassembling

the

oil

pump

,

refer

to

"1-2,

Disassembling

the

Engine".

2-2.

Bisasemhling

the Oil

Pump

1. Remove

the'two nuts,

and

remove

the

oil

strainer

from

the

pump

cover.

Remove

the

pump

cover

(B),

outer rotor

{C)

and

pump

drive

shaft

assembly

(D)

from

the

pump

body

(A).

Remove

the

split

(H).

Pull

out the spring seat

(E),

pressure

control spring

(F)

and

pressure

@ntrol

plunger

(G)

from

the

pump

body.

Note:

Take

c;rre

of

that

the

spring seat

and

pressure

control

spring

will

not

spring

out

wtren

the

split

is remored.

(D)-

2.

3.

-,

Fig.

155

{A}

o

C

3. Checking, Maintenance

and

Limit

0f

Adjustment

3-l .

Checking and Adiusting

the Oil

Pump

Wash

and clean the

parts

removed

from

the oil

pump.

lnspect

the

parts

for

cranking,

heavy

damage

and

breakage. If

any

of these

parts

is found

faulty,

replace

it.

J. Clearance

between

the oil

pump

body and outer

rotor:

Measure

the

clearance

benrueen the

oil

pump

body

and

outer rotor

with

a

special

tool

(No.

N026

STANDARD

FEELER

GAUGE).

Replace

both if

'

t're

measurement

exceeds

0.0118

in.

(0.30

mm).

STD

clearance

between

|

0.00$

'^"

0.01

1 in.

pump

booy

and

outer

rotor

|

(0.20

-

0.27

mm)

Fig.

156

2.

Clearance between the

oil

pump

cover and outer

rotor:

Measure

the clearance between the

oil

pump

cover

and outer

rotor with

a

straight

scale

and a

special tool

(No.

N026

STANDARD

F

EE LE

R

GAUGE).

Replace

both

parts

if

the

measurernent

exceeds

the

maximum

limit.

Clear.

between

oil

pump

cover

and

outer rotor

STD

clearance

Max.

allow

clear

0.001g

,v

0.0039

in.

(0.04

a,Q.1O

mml

0.OO59

in.

(0.15

mm)

Fig. 157

3.

Oil

pump

cover

Check

the oil

pump

cover

bottom

(contacting

surface

with

oil

pump

body,

inner

rotor

and

outer

rotor)

.

lf

stepped

wear

is

found,

replace

the

cover. lf

the wear

is

slight, smooth

it

out.

LUBRICATION

SYSTEM

41

Fig. 158

4.

Fig.

159

5.

Pressure

control

sPring

Check

the

pressure

control

spring

for

lf

it

fails

to

meet

the

specifications

table

below,

rePlace

it.

Clearance

between

the

oil

pump

drive

shaft

as'

sembly

and

pump

body/pump

cover

bearing

Measure

the clearance

between

the

oil

pump

drive

shaft

assembly

(1

)

and

the

pump

body

l2l

and

pump

cover

(3)

bearings

(A)

and

(B)

.

lf

the

measurement exceeds

the

specif

ied

maximum

limit,

replace the

parts.

Fig.

160

3-2.

Oil

Filter

Replacement

1.

Replace the oil

f

ilter

(cartridge

type)

after

300

hours

of

operation

(First

replacement:

after

30

hours of

operation).

Replacement

must

be

made

as

an

asemblY.

2.

Oil

filter

-

removal

and

installation

a.

Use

the

special

tool

(No.

0490130

OIL

FILTER

WRENCH)

(A)

as

shown

in

Fig.

161 to

remove the

oil

filter.

b.

Apply

engine oil to

the oil

filter

gnsket,

and bolt

it

to

the

cylinder block

with a

specified

tightening

torque

'7

.2

-

10.8

ftob

(1

.0

-

1 .5

m-kg).

Note: After the

insullation,

make

sure

that

no

oil

leks.

Fig.

l6l

3-3.

Checking

and Adiusting the

Oil

Pump

Driven Gear

Shaft

1.

Remove

the

blind cover

(A)

.

2.

Check the oil

pump

driven

gear

shaft

(B)

for

damage and

breakap of

teeth.

any

defects

given

in

the

Clear.

between drive shaft ass'y and

pump

body

cover bearings

STD clearance

Max.

allow

clear

0.0003

-

0.0018

in.

(0.007

-

O.O47

mm)

0.0O39

in.

(0.1

mm)

Pressure

control

spring

specif

ications

Free

length

2.16U

in.

(55

mm)

Length

-

when

installed.

1.6929 in.

(43

mml

Load

-

when

installed

5.91

lbs.

t2.68

kg)

-t

42

LUBRICATION SYSTEM

4.

Assembling

0rder

+1

.

Assembling

the

Oil

PumP

Follow

the

disassembling

procedures

in

reverse.

4-2.

Mounting

the

Oil

PumP

Oil

pump

can be

mounted by

means

of the

reverse

order

for

assembling

the

engine.

(See

3-1

Assembl-

ing the

Engine

of

Chapter

Engine)

Note:

The

following-listed

engine

oils

are

com-

mendable.

Fig. 162

3.

Fig.

163

34.

Measure

the

oil

pump

driven

gpar

shaft's

end

play

by

use

of

a special

tool

(No.

N026

STANDARD

FEELER

GAUGE}.

0.002

-

0.O04 in.

Driven

gear

shaft's

end

play

I iffi|trre.l

mml

Adjusting

the

End

Play

of Oil

Pump

Driyen Gear

Shaft

lf

the

measurement of the

end

play

is not within

the

range

of 0.002

^'

0.004

in.

(0.05

^,

0.1

mm),

remove

the

drive

gear

cc'!,er

(C)

,

and

pull

out the

thrust

washer

(D)

and driven

gear

shaft.

Adjust

the

end

play

by using

thrust

washers

as

specified

below:

(F

igs.

162

and

1

63)

Oil

Filer

Specifications

Type:

Canridge

filter

Pressure

for

aditsting

1 1

.4

*

17 .1 lb/inz

the relief wlve

(0-8

'-'

|

-2

kglcrnz

)

5-2.

5. Specifications

5-1.

Oil

Pump Specificatiom

Type: Drive system:

Rated

oil delivery:

Regulated

oil

pressure:

Trochoid

gear

Total

pressure

feed

25.36

US

pints/2,O@

rpm

(12

A2,OOO

rpm)

53.9

lb/inz

(3.8

kg/cmz

)

at

3,000

rpm

Part No.

Part Name

Thickness

01

40050

Thrust washer

0.07910.0079

in.

12.ffi.2mm)

01 40060

Thrust

washer

0.10@.0079

in.

(2.5t0.2

mm)

01

40070 Thrust

washer

0.0O4

in.

(0.1

mm)

01 40090

Thrust

wa*ter

0.07110.0079

in.

(1.8t0.2

mm)

I

43

I

b

CO

O

LING

SYSTEM

1.

Cooling

Sfstem-General

The forcedcirculation

cooling

system

is

imployed

with a centrifugal

water

pump,

four'blade

cooling

fan, and

wax'type

thermometer.

when

the temperature

of

the

cooling

water

is low,

it circulates

in the

direction

of thearrowwith

a dotted

line

in

Fig'

l

O4.

When

the temperature

is

high,

the

cooling

raater

flows

in the direction

of

the arrow

with a

solid line.

Cooling

fan

complete

Cmling

tan

,a<

{

165

3.

Take

out the

floating seat

and

cu$rion

rubber

from

the

water

pump

impeller.

COOLING

SYSTEM

{

Radiator

Water

pump

Fig.

l&t

L

Disassembling

Order

2-1.

Removing

the

Water

Pump

1. For

the

removal

of

the

water

pump,

refer to

"1'2-

Disassembling

the

Engine of Chapter.

Engine"-

2-2. Disasembling

the

Water

Pump

1.

Loosen

the

scr€nil

and bolt,

and

remo\re tte

end

plat

(B).

2.

Pull out

the

water

pump

impeller

(A)

by

using

the

.,

speial

tool

(No.

04901

10

WATER

PUMP

IMPE

LLER

PU

LL}.

J

COOLING

SYSTEM

4.

5.

6.

7.

8.

Pull

out the

water

pump

pulley

boss

(G)

by

using

a

press.

Remove

the

dust

seal

plate

(F).

lf

the

water seal,

ball

bearing,

etc.

are

found

defective,

perform

the

following

disassembling

proced

ures.

Pull

out

the

snap

ring

(H)

by using

the

snap

ring

pliers.

Bemove

the ball

bearing

and

water

pump

fraft

from

the water

pump

body

(D)

by

using

a

pliers.

Disassemble

tlre

ball bearing

and

water

pump

shaft

into

three

parts:

pump

straft

(El,

ball

bearing

(K)

and

spacer

(J).

For

this

operation,

use a

prs.

9.

Pull

out the

water

seal

(C)

from

the

water

pump

body.

Whenever the

water

pump

is

disassembled,

the

water seal

should be

replaced

with

a

new

one.

Checking

th

e

Thermostat

Check

the

thermostat

spring

(A)

for

cranks

and

breakage"

lf

found faulty,

replace

it.

lf

the

thermostat

valve

is

found

open,

rephe

it.

Put

the thermostat

into

water,

and

slowly

raise the

water

temperature.

Check

for

temperature

at

which

the thermostat

valw

opens.

lf found faulty,

replace it.

3'2.

Fig.

167

2.

3.

1.

Fig. 166

3.

Checking

Maintenance

and

Limit

0f

Adiustment

3-l

.

lnspection

of

Water

Pump

1.

Check

the

disasembled

parts

for

the

following-

listed

defects.

lf

any of

them is

found faulty,

replace

it.

a. Cracks

and

damage of

the

water

pump

body.

b. Cracks and damage

of the

water

pump

impeller.

c.

Play

and

noise of the ball

bearing.

"

d.

Damage

of

the

water

seal.

Valve

opening

temperature

177

*

1

83oF

(80,5

^,83.5oC)

Valve

lift

0.315

in.

or

more

at

203oF

(8

mm

or

more

at 95oC)

4. Assemhling

the

lTater

Pump

1,

2.

a.

b.

c.

d.

Follow

the disassembling

procedures

in reverse

order.

Notes

on water

pump

rsslrUling

Be sure

that the

two

ball bearings

are

placed

with

the unsealed side facing

toward

the spacer.

Feed

Albania

Grease Nos.

2 and 3

so

that

one-third

of

the space between

the

dust seal

plate

and the

ball bearing

is f illed

with

the

grease.

Slightly

apply

grease

to the contacting

surfaces

between

the

floating

seat

and

water

seal.

After

assembling

the

water

pump,

rnake

sure

that

the ball bearing

turns smoothly without

excessive

play

and noise.

COOLING

SYSTEM

45

-

5.

Mounting

the

Water

PumP

7. Specifications

1. Follow

the

removal

procedures

of

the

water

pump

7-1

. Water

Pump

-

in

reverse order.

For

details,

refer

to

"3-1.

Assembling the

Engine

of

Chapter.

Engine.

Type: Centrifugal

Notes:

Water

PumP Pulley

ratio:

1

:

0.8

r

1) Replace

all

packings

with

new

ones.

Water

seal:

Mechanical

seal

2',

Adjust

the

V-belt

so

that

it will

have an up

and down

movement of

0.55

-

0.79

in.

(14

-

20 mm).

When the

belt

is

nevv, the

7'2- Thermctat

L

slackness

*rould

be 0.43

-

0.55

in.

(11

-

14

mm).

TYPe:

Wax

tYPe

'

3) Make

sure that the

quantity

of

cooling

water

Valve diameter:

1 .'102 in.

(28

mm)

-

is 18.5

gal

(71).

Valve

opening

temperature:

180

t

2"F

(82

r

1.5"C)

Valve lift:

0.315

in.

(8

mm)

l

b

6.

lnstlling

fte

Thermosbt

Follow

the

removal

procedures

of

the thermostat.

Always

replace

the

packings.

MEMO

FU

E

L SYSTEM

47

1.

Fuel

System-General

The

carburetor

is

Nihon

Kikaki-made. Stronberg

type, 210028-061, double-venturi, single carburetor.

The

fuel

pump

is

of

mechanical

type

(PU56U),

made

by

Nihon Kikaki,

and

the

pump

rocker

arms are

operated

by

cams attached to the cam shaft.

The

gasoline

filter

is

of

cartridge

type,

which

provides

easy access to seryie,

while

the air

cleaner is of oil

bath type.

'lF

Fig.

t

68

2-2.

Ghecking

the

Air

Cleaner

1

.

check

the air

cleaner

element

(A)

for

dirt

ac-

cumulation

and

clogging.

lf

necessary,

wash

and

clean

it.

Check

the

oil

pan

assembly for

diny

oil.

lf

the

oil

is

found

dirty,

replace

it.

Check whether

the

oil

level

in

the

air cleaner

oil

pan

assembly

is

between

the upper

and

lower

level

I

ines. lf

necessa

ry

,

refill

with

oil

.

An

incorrect

oil

level will

reduce

engine

performance,

and there-

FUEL

SYSTEM

Figl

t 6e

4.

2-3.

Air

Gleaner

Specificatiom

Type:

Rated

air

flow

rate

(max.):

Cleaning

efficiency:

(lnitial

stage

-

full

tife)

fore,

the

oil

level

must

be

maintained

as specified.

The

engine

oil

should

be

used

tor retilling.

Cleaning

the

air

cleaner

element

Both

air cleaner

element

and

oil

pan

assembly

should

be

cleaned with

cleaning

solvent.

Time

lntervals

of

Element

Cleaning

Cleaning After

first

50

hours

Every

100 hours

2. Air

Cleaner

2-1.

Removing

the Air

Cleaner

Element

1.

Remove

the

clamp

(A)

from

the

air

cleaner

asembly,

and remove

the

oil

pan

assembly

(B).

2.

Remove

the wing

nut

(C)

fastening

the

air cleaner

and cap

assembly

(D),

and

remove

the cap

assembly

by

pulling

it

uprnard.

3.

Remove

the

two

wing nuts,

and

remove

the aitr

cleaner

assembly.

E

A

c-t

Oil-bath

type

4,731

.2

gal/min

(1,250

[/min)

95o/o

2.

3.

Fuel

Pump

$1 .

1.

Removing

the Fuel

Pump

Remove

the

clip,

and

disconnect

the

fuel

hoses

(A)

from

the

fuel

pump

(B)

at

the

both

inlet

and

intake

sides.

ffi FUEL

SYSTEM

Fig.

l7O

3-2.

1.

2. Renrove

the two

nuts, and

remo\€ the

fuel

pump.

3.

Remove the diaphragm

(D)

and

diaphragm

spring

(E)

from the

body.

Fig.

173

4.

As

shown

in

Fig.

174,

pull

out

the

pin,

and

remo\€

the

rocker

arm

(G)

and

rocker

arm spring

(F)

from

the body.

(Fig.

173

and

174l'

Fig. ,74

3-3.

Checking

$e

Fuel Pump

1.

Checking the fuel

pump

a.

Check

the

valve

spring for

breakage

and

fatigue.

lf

the spring is

found

faulty,

replace

it.

lf

the

valve

is

found

open,

.

even

though

slightly,

it

should

be

replaced.

b. Check

the diaphragm for

breakqe,

damage

and

aging. lf

it is found

faulty,

replace

it.

c.

check the

diaphragm

spring

for

breakage

and

fatigue.

lf found

faulty,

replace

it.

d.

Check

the

rock

arm

bearings

for

excessive

pray.

(Fis.

171)

$4.

Asembling

the Fuel

Pump

follow

the

disassembling

procedures

in

r€verse

order.

Disassembling

the

Fuel

hrmp

Rernow

the

f

ive

set

scre$/s,

and

separate

the

housing

(A)

from

the body

(B).

Fig"

l7l

2.

Remove

the

two screws, and

remove

the

valve

(C)

from

the

hotsing

Fig.

In

FU

EL

SYSTEM

49

Model:

Disharge:

Fully-closed

discharge pressure:

Suction head:

4.

Fuel

Filter

3-5.

lnstalling

the

Fuel

Pump

Follow

the

removal

procedures

in

reverse

order.

After installation,

make sure

that

no

fuel leaks.

3-6.

Fuel Pump Specifications

found

faulty,

replace

it as

a

unit

assembly.

When

replacing

the

f

uel

f

ilter,

make

sure

that

it

is

installed

correctly

in

direction

and

no

fuel

leaks.

O

our

Fig.

175

3.

Time

intervals

of

fuel

filter

replacement

Fuel

filter

should

be

replaced

every

300

hours

of

operation.

Mechanical

A32

pint/min

at

low speed

(150

cclmin

at

low speedl

lN

Q

1.5

pint/min

with

full-open

(700

cclmin

with

fullopen)

1

.42

^'

2.13

lbs

linz

(0.

t

^,

| .5

kg/cmz

)

19.7 in.

(500

mm)

1.

The fuel

f

ilter

is

of the

cartridge

type.

2.

The

fuel filter is

not

required to be

clerred.

lf it is

50

FUEL

SYSTEM

5, Carburetor

$1. Construction

Air

Bent

Pipe

lvlain

Air

Bleed

Chalk

Valve

ttlhin

Nozzte

\

Pump

Arm

Link

pump

Rod

SPring

Damper

Spring

Piston

Shaft

Piston

Leather

Pump

Piston

lnlet

Check

Valve

Outlet

Check Valve

Pump

Nozzle

Large

Venturi

Small

Venturi

Throttle

Valve

Fis.

176

Main

jet

circuit

The

construstion

of the

main

carburetor

system

is

as shown

in

fig.

176. The fuel flowing

out of

the

f

loat chamber

is

meered

by

the

main

jet

and

mixed

with

the

air

f lowing from

the.

main air

bleed

emulsion

hole, then

jetted

into

the

air

stream at

the

narrowest

zone

of

the

venturi.

The

main

carburetor

incorporates a double-venturi,

wherein

the

large

venturi

has

the

small

venturi

skirt

at

its

narrowest

portion.

The

speed

of the air

flow

is

extremely

high

at

the

narrowest

portion

of

the

small

venturi,

and

accordingly,

the

quick

atomiza-

tion of

fuel

can

be asured.

Fuel

consurnption

is

also

economized

Slow

speed

circuit

The

fuel

pasing

through

the

main

iet

is

metered

Slow

Port

ldle

Port

by the

slow

iet,

and

mixed

with

the

air

flowing

from

the

No. 1

air bleed

iet

located

near

the

slow

jet

end.

This.atomizes

the air-fuel

mixture, which

is

further

metered

by the

slow

economizer.

The

metered

air-fuel

mixture is

mixed

with

the

air

stream

from

the

No.

2 slow air bleed

jet

positioned

on the

top end

of

the

vertical

slow

passage,

and

further

atomized, then

flowing

to the

slow

port.

The

slow

port

has

a

goundshaped

hole

and

positioned

on the

side wall

of the

main

bore

near

the throttle

valve. The

fuel

is

jetted

through this

slow

port

when

the

engine runs

with low load.

While

the

engine runs

idle,

the

fuel

is supplied

through

the

idle

port

located

on the

intake

pipe

side of the

slow

port.

ln

general,

the

air-fuel

mixing ratio for

engine

idling

varies

depending

on

the

engine,

and there-

Second Slow Air Bleed

Ja

First

Slow

Air

Bleed

Jet

I

Pump Connecting

Rod

It

Slow

Economizer

ldle

Adiusting

Scrwv

--Strainer

Float

Valve

Sea

\*inJet

Float

Valve

F

loat

Float

.--/

/

Float Room

1.

2"

FU

EL

SYSTEM

51

fore,

the

id le speed

ad

just

screw

is

provided

to

regulate

the

ratio.

The

optimum

opening

of

the

idle

speed

adjust

screw

is the

position

where

the

adjust screw

is

backed

off

1-1

12

turns

from

the

fullyclosed

position.

The

slow

jet

has

a

very small

hole

measuring

0.017

in.

(0.42

mm)

in

diameter,

and

therefore,

it

is

easily

clogged

with

f

ine

dust.

The

slow

jet

is

designed

to

be

removed

with

a

screw

driver,

providing

great

convenience

to

service-

4.

3.

Float

circuit

The f loat

system

consists

of

the

f

loat

valve

and

the

float,

and

its

purpose

is

to

maintain constant

the

level

of

fuel

in

the

float chamber.

The

fuel

which

is

fed from

an

mechanical

fuel

pump

at

a

pressure

of

1

.42

A,

2.13

lb/inz

(0.t

-

0.15

kg/cmz

)

is

filtered

by

the

strainer

located

at

the

carburetor

inlet,

and

flows into

the

float

chamber

through

the

clearance between

the

float

ralve and

the

valve

seat.

As

the f uel

level

rises,

the

float also

rises,

and the

f

loat

valve

moves

upward

accord

ingly.

ln this

way,

the

float valve is

finally

forced tightly

against

the

rnalve

sat, thus stopping

the

fuel flow

to

the

float

chamber.

Then, if the

fuel level

drops,

the

float

moves

down

and

releases

the

float valve

so

that

the

fuel

inlet is

opened.

ln

this

manner,

in

actual operation,

the

f

uel

is

maintained

at

a

practically

constant

level.

The

float

level of this

carburetor is

0.616

t

0.039

in.

(15.5

mm

t

1)

above the

body

top.

Therefore, the

carburetor

can

be

tilted

14o

at

maximum

so that

it

provides

smooth

engine

start

and

idling on

a slope.

Fig.

177

The

float chamber

vent is

provided

immediately

before

the

choke

valve; that

is,

it

employs

the

inner

vent

system.

This

prevents

the air-fuel

mixture

from

becoming

rich

due to

the clogging

of

the

paper

filter

element.

The f

loat

is

made

of

oil-resistant

foamed

rubber.

"

Unlike

a conventional

type

f

loat,

it is not

hollow-

ed.

Therefore,

there

will

be

no

troubles

resulting

from

faulty

soldering.

Faulty

soldering

allows

f uel

to

enter

the

inside

of

the

float, letting

it sub-

merge.

Further,

float and

needle

valve

are

in-

corporated

in

the

float chamber

to

ensure

that

the

f loat

level

can

be

constantly

ma

inta

ined at

a

ceftain

position.

Overflowing

caused

by

the

ex-

cessive

vibration

can

be

protected

by

means of the

hole

on

the

f

loat.

Acceleration'pump

c

ircu

it

The

acceleration-pump

circuit

includes

a

vacuum

piston

linked

to

a

throttle

valve,

and

consists

of a

pump

piston,

inlet

check

valve,

outlet

check

valve

and

pump

nozzle.

The

.1.mp

piston

is separated

into

two

sections,

which

is

connected

by

a

fitted

in

holes

in

the

piston

shaft,

and

is

provided

with a damper

spring.

Accordingly,

when

the

pump

piston

comes

to

contact

the

cylinder

bottom,

the

pump

rod is

pushed

by

the

pump

arm.

Then the

damper

spring

contracts,

and as

a

result, the

pump

arm

and

throttle

rnlve operate

so

that

the

valve

becomes

fully

opened.

When the

throttle

valve

quickly

opens

from

the

fully-closed

position,

the

pump

piston

is

pushed

downward

by

means

of

the

pump

arm,

connecting

rod,

and

pump

arm

link

connected

to

the throttle

valve

rod.

The

fuel

under

the

piston

causes

the

inlet

check

valve

to

close,

thereby

stopping

the

reverse flow

of

fuel

to

the

t

loat

chamber.

As a result, the outlet

check-valve opens

and

the

fuel is

sprayed

into

the

air stream

through the

pump

jet.

The acceleration

fuel is

sprayed to

the

narrowest

area of the

large

venturi, where the

air

flow

speed

is

highest,

and

accordingly,

the

atomization of

f

uel

is

made

easy

When

the throttle

valve

closes

from

the

fully-

opened

position,

the

piston

moves

up and

the

pressure

under

the

piston

becomes

negative.

This

rnakes the

inlet

check valve

(in

the

float

chamber)

open,

and

the

.fuel

in

the

float

chamber

is

drawn

out.

Then,

the outlet

check valve

closes

and

prevents

the

reverse flor

of

air

from

the

pump

jet.

ln

this

way,

the acceleration

pump

correctly

operates.

A

spring

is

inserted

between the

pump

rod

and the

upper

body, and

prevents

the excesive

play

of the

pump

rod

link and

pump

arm. lt

also

prevents

Two holes

are

provided

on the side

opposit

to

the

pump

piston,

and

the

fuel

spray amount

can be

chagned by

inserting

the

connecting

rod

into

the

inner

hole

or

the

outer

hole.

ln

general,

the acceleration

spray amount

of

f

uel

varies

according

to the

operating

conditions

of the

engine

as

well

as

to

the conditions

of

climate.

.9;

oF

sltr

Se

dg

6.669

in.

(17

mm)

1.OO4

in.

(25.5

mml

FUEL

SYSTEM

Normally,

the

amount

of

fuel

spray

is less

in

summer

than

in

winter.

With

the

connecting

rod

in

the

outer

hole, the

pump

spray

rate

is

0.000528

pt

(0.3

cc)

per

stroke

throughout

the

v@r,

but

when the

rate

has

decreased

due to

the

wear of

the

pump

leather

and

other defects,

the

inner

hole should

Oe

used

for

optimum

spray

q

uantity.

As

mentioned

earlier,

this

carlruretor's

pump

nozzle

also serves

as

auxiliary

fuel

sr/stem.

When

the engine

runs

at

high

speed

or

with

high

load,

a

large amount

of

air

is

required and

the

neptive

pressure

affmting

the

pump

nozzle

raises

the

outlet ctreck

valve

weight.

The fuel is

drawn

out

through the

purnp

nozzle

and

mixed

with

air.

The

pump

weight

overcomes

the

negative

pressure

until

the

amount of

air

drawn

in reaches

a

certain

level,

and causes

the

chgck

valve to

close.

Thus

stops

its

rrrork

as auxiliary

fuel system.

5.

Surting

system

The

starting

system

of

this

carburetor

includes the

choke

valve

linked

with

the choke button

on

the

dash board

and

the

fast idle

system

coupled

with

the

choke valve.

When

the

choke

button

is

pulled,

the

choke

lever,

which

is

linked

by

a

cable, is also

pulled,

thereby

closing

the

choke

valve.

The

choke

valve

is

attached

to

the

choke

valve

shaft

with

two screws,

which

is

positioned

eccentrically

in

relation to

the

a

ir

horn.

The

choke

valve shaft

is

coupled

with the

choke

lever by

means of

the choke

valve

spring.

The

choke

lever

is

fitted

with a

link.

When

the

choke

lever

is

pulled,

the

link

makes the throttle

lenrer open

so

that

the

opening

is suitable

for

starting.

Then,

if

the

starter

is

turned,

a

rich

mixture

is obtained,

and

ea$/ starting

is

assured.

When

the

engine

is

started,

the

vacuum

in

the

inlet

pipe

increases

and

the

choke valve, being

affected

by

negative

pressure,

overcones

the

spring ten-

sion.

ln this

stage,

the

choke valve

opens

properly

so

that

the

over

choke

is

prwented

and

the

engine

continues

sunning.

As

the

engine

is

rmarmed up,

the

choke button

is

depressed

to

open

the

choke

valve

properly.

After

the

engine

is

fully

vrarmed

up, the

choke

rralve

fully

opens

and the

thronle

valve

opens

to

a

specified

idl

ing opening.

The use of

the

choke

valve in

the

position

closer to

the

closed

position

will

result

in

greater

fuel

consumption.

when

you

stop

your

tractor

wh ile

travelling,

depress

the

choke

button

as

far

as

the

engine

will

not

stall.

*2.

0isasembling

the hrburgtor

Notes:

On

carburetordisasernbling

Place

the

rerpve

parts

ordsly

so that

you

will

not

confuse about

ttrem

when

performing

reasembly.

Clean

all

ttre

remowd

parB

with

gsoline.

Bloru

evry;mall hole in

parts

with compressed

air

to

remove

dust

O

Never

clean

jets

and

small

holes.

R emoving the carburetor

Loose the

hose

band,

and

remove

the

hot

air

hose

(A)

.

Remove

the

connecting

bolt

(B)

,

and

rernove the

fuel

hose.

Pull

out the

vacuum

advance

hose

(C),

and

remove

the

rod assembly

(D)"

Remove the two

nrounting

nuts

(El,

and

remove

the carburetor

from

the

inuke

manifold.

o o

1.

cl ,

b.

c.

d.

Fig.

178

FUEL

SYSTEM

53

Removing

the link mechanism

Remove

the

throttle

return

spring

(A).

Remove

the

split

pin,

and

remove

the

choke

connecting

rod

(B)

from

the

throttle

lever.

Remove

the split

,

a

nd

remove

the

pump

connecting rod from

the

pump

lever

(C).

Fig.

179

3.

Removing

the air horn

a.

Remove

the

pump

return

spring.

b.

Remove

the

five

screws,

and

remove

the

air

horn

from

the body,

together

with

the

float

and

needle

valve"

Fig.

180

4.

Removing

the

f loat valve

and

f

loat

a.

Pull

out

the

f

loat

f

rom

the

air

horn,

and

remove

the

f

loat.

(night

in

Fig.

181

)

b.

Remove

the

valve

spring

and

needle

valve.

(Left

in

Fig

181

)

Fig. l8l

5.

Removing

the accelerating

pump

Pull

out

the

aaelerating

pump

piston

assembly

i

from

the

body.

Fig.

,82

6.

Removing

the air

bleeds

and

iets

Remove

the

slow

air

bleed, slow

jet,

rrrain

air

bleed,

injet

chek

valve

and

power

jet

from

the

body,

as

shown

in

Fig.

183.

2.

a.

b

c.

#

T

(Al

Slow air

bled

(B)

Slow

iet

(C)

Main

air bleed

Fig.

183

(D)

I

nlet

chtrk vatrre

(E)

Power

jet

il

FUEL

SYSTEM

To

remove

a

nd

insta ll

the

po\

/er

jet,

use the

special

tool

(No.

0490120

POWEH

VALVE LOCK

DR

I VE

R).

7.

Removing

the

body

Remove

two

mounting

screws,

and

remove

the

body

from

the

throttle

chamber.

tu

8.

Removing

the main

jet

Renrove

the

plug

(A

from

the

body, and

remove

the

main

jet

(Bl

as

strown in

Fig.

185.

Check the

throttle

shaft

bearing

for

wear

and

throttle

valve

for

smooth

operat

ion.

I

f

any

of

these

is

found

faulty,

reBlace

it.

Checking

and

repairing

the

bodY

Check

the body

for

cracks

and

deformation

of

contacting

surface

with the

air

horn and

throttle

chamber.

lf it

found

faulty,

replace

it.

Check

the

main

iet,

slow

air

bleed,

slow

jet

and

power

jet

for

clogging. Check

the air

passages

and

fuel

psages

for

clogging.

lf

necessary, clean

or

replace.

Checking

the repairing

the link

mechanism

Check

the

levers, arms,

and connecting

rods for

deformation,

bend

and

wear.

lf

any

of

these

is

found faulty"

replace it.

Adjusting the throttle opening

linked with starting

The

choke

valve

is

linked with the throttle

valve

(A)

,

and therefore,

when

the

choke button

is

f

ully

pulled,

the

choke

valve is

fully

closed

and

the

throttle

valve

opening

will

be

suiuble

for

starting

opening

is

139

-

17o

.

When

the

choke valve

is fully

opened, the clear-

ance

(A)

of

the

throttle

\€lve

on

the

primary

side

should

be

0.039

in.

(0.91

mm). lf

not,

adjust it

mrrectly

by bending

the

choke

connecting rod

*

(B).

Fig.

186

6.

Adiusting

the f

loat

level

a.

Remove

the

air horn

from

the

carburetor,

and

raise

the

f

loat

(A)

.

b. slowly

lower

the

float

(A)

and

stop

it

when

the

float

seat

(C)

contacts

the needle

valve

stem

(B).

Meazure

the

c,

and

if

the

measurement

is

0.16 in.

(4.0

mm),

the

float

level

is

correct. lf

not,

adjust

it

by

bending

the f loat

seat .

I

3.

a.

b.

4.

5.

Fig.

:a-

Fig.

185

53.

Checking,

Mainunance

and

Limit of

Adjustment

Checking

the air horn

Check

the

air

horn for

cracks

and deformation of

contacting . surface

with

the

body. check

the

choke

valve

shaft

bmring

for

wear.

Check the

choke

valve for

smooth

operation.

Check the

f

loat

for

damage

and

deformation.

Check the

needle

valve

for

contacting surfaces

between the

valve

and

seat.

lf

any

of these

is

found

faulty, replace

it.

Checking

the throttle

chamber

Check

the

throttle

chamber

for

cracks and

da

formation

of

its contacting

zurface with

the body.

1.

2.

A'0.035 in.

10.91

mm|

FUEL

SYSTEM

55

Fig. 187

7.

ldle

speed

adiustments

For

idle

sped adjustments,

be

used.

Adjustments are

throttle

adjust screw

(A)

and

54.

Asembling

the

Garburetor

For

the d

isassembly

procedures

in

reverse order.

Note:

O

Replace

the

packing

with

a

new

one.

O

After

assembling,

make

sure that

the

throttle

valve and

choke

valve

operate

smoothly.

5-5.

Mounting

the Garburetor

Follow the

removal

procedures

in reverse

order.

$6.

Specificatiom

Model

21AO28 - 061

Construction

Stronberg

type

Draft direction

Downward

draft

Outlet diameter

1.O24

in.

(28

mn$)

Venturi

0.732

x 0.256

in0

(18.6

x 7

mmOl

Ma

n

let

#77

Ma

n air bleed

#50

Slow

iet

#11

Slow

air

bleed

Pr

124

Pz

17O

Power

jet

#45

Pump

injector 0.0236

in@

(0.6

mmO)

Needle

valve

0.059

inO

(1.5

mmo)

Float

level 0.61m.mg in.

(15.5t1

mm)

Throttle valve

10o,

0.059 in.

(1

.5

mm)

tn ict

a

tachometer

should

made

by

using

the

idle adjust

screw

(B).

Fig. 188

a.

b.

c.

d.

Fully

turn

in

the

idle

adjust

acrew, and

back

it

off

3

turns.

Then

screw in

the

throttle

adjust screw 2

or

3.

turns,

and start the

engine

Sloly

back out

the

throttle

adjust

screw,

and

the

engine speed will slow down.

Stop turning

the

screw

just

before

the

engine

begins

to

run roughly.

Then

slowly

turn

in

the

idle

adjust screw.

When

the

engine

begins to

run

smoothly

at

maximum

speed,

stop

turning

the screw.

Slow down the

engine speed

by turning out

the

throttle

adjust screw.

,

Repeat

this

operation

so

that

the

engine

will

smoothly

run

at 700

-

800

rpm.

Note:

Do

not

turn

in

the

idle

adjust screw

too

hard,

otherwise, the

screw end will

be damaged.

6.

GoYernor

Sl .

Governor

System

-

Genenl

The

KSP

gpvernor,

made

by

Koshida

Shoko

K.K.,

is

of

the

mechanical

type. lt

is

used, being

interlocked

with

the

Stronberg

type

carburetor

Q1W28l061)

for

the

PB

engine.

The

governor

is

operated

by

f

ly-weight

centrifugal

force,

and

its

adjustment

can be

done

accurately

according

to the

engine

specif ications.

E

ngin

e S

pec

if ications

:

Specified

engine

speed

2,800

r.p.m.

(25

PS)

Static

speed variation

12o/o

or less

Momentary

no-load

variation

17o/o

or les

Note:

The

governor

has

been

adjusted

most

suiubly for

engine

operating

conditions,

and

therefore,

you

should

make

no

attempt

to

disas-

se.--r$lq it,

except

for

oiling

it

or

for

repairing

Criticril-defects.

56 FUEL

SYSTEM

6-2.

Governor

-

0peration

and

Construction

1.

Operation

The

governor

detects

the difference

between

the

actual

engine

speed

and the specif

ied

engine speed,

and

contro

ls

the carburetor's

throttle

valve

to

adjust

the

engine

speed

to the

specif

ied value.

As

the engine

sped changes,

variation

occurs

in

fly-weight

centrifugal

force,

and

according to

the

variation,

the

governor

spring

length varies.

As

a

resu

lt,

th

is

variation

changes the

throttle

valve

opening

by means

of

the

link mechanism,

thereby

changing

the engine

speed.

GOVERNOR

TEVER

(5T

}

2. Construction

(

Refer

to

F

igs.

1

89,

1

90 and

1

91

).

The

governor

shaft

(5)

,

which

is locked to

the

governor

pulley

(6),

is

provided

with

two balance

weights

(9).

The

balanceweights

are

constantly in

contact

with

the thrust bearing

collar

(13)

,

to

which

the

thi'ust

bearing

(31)

is

f

itted.

The

thrust

bearing

is

designed to

move

back and

forth

on the

governor

shaft

(5).

One end

of the thrust

bering

(31)

is

in

contact

with

the

fork

lever

(381

attached

to

the

fork shaft, and

variation in

centrifugal

force

is transmitted

to

the

fork

lever

shaft

(5).

ADJUSTING

LEVER

I42I

STOPPER

BOLT

I22I

GOVERNOR

SPRING

(45}

-]

O'J

o\

\O\

\o

SPR|NG

BI)LT

l44l

Fifi.

189

Side

Weu-

FUEL

SYSTEM

57

NUT

(20}

FORK

LEVER

SHAFT

(37}

GEAR

CASE

(62}

FoR@

GOVERNOR

SHAFT

(5}

GOVERNOR

PULLEY

(6}

BALANCE

WEIGHT

(9}

/

I

Fig.

,g)

*ctionl

View

THRUST BEARTNG

COLLARjfII\

For

Tractor

Mgter

Fig:

I9l &aiornl

Vievvs A

and

B

58

FUE

L

SYSTEM

3.

Construction

of control

mechanism

64.

Maintenance

The

governor

spring

(45)

is

hooked

on

the

spring

bolt

(zl4)

which

is attached

to the

fork shaft

(5)

To keep the

governor

in best

condition,

proper

and on

one

of the adjusting

lever

'42)

.

Variation

oiling is

required,

and

no other

service

is neces-

in

centrifugal

force

affects

the spring bolt

(44),

sary. Oiling

should

be

made as

folloras:

and

thereby the

length of the

governor

spring

(45)

a.

Use the

same

oil

as

for

the

engine.

I

is changed.

b.

Replace

the oil after

50

hours of operation,

and

thereafter,

replace

it every

100

hours.

4. Construction

of link

mechanism

c.

Oil

quantity

should be

0.01

gal

(40

cc).

ThegovemorlEyer(51

)

isboltedtotheforkstraft

Feedtheoil sothattheoil

level isatthelower

(37),

and

the

lever

has

the

ball

joint

(interlocked

level

line

marked on thepuge.

(Thequantitywill

with the carburetor)

on

its

end.

be about

0.01

gal.

(40

cc))'

According to

variation

in output

at the

detector,

the

governor

lever

(51)

moves up

and down,

and

controls the throttle

valve

opening

by

means

of

5-5.

Intedock

Adiustment

between

Carburetor

and

the

link

rod.

thereby

regulating

the

engine

speed. Governor

The

interlock

adjustment

is rbguired only

when

6.3.

Purpose

of

Govemor

Adjustner8

the

gowrnor

is found to

be

faulty because of

instable

engine

speed,

fluctuations

in specified

Note: The

adjustment

procedures

as

described

in

engine sped

and increases

in speed

variation.

athis

section is

applicable

only

when the

governor

a. Turn

in the

throttle adjusting

screw

to bring

the

itself is

required

to be

adjusted.

Accordingly,

throttle

valve opaning

to zero.

when

the

governor

is

ncessary to be adjusted

in

b.

Fully

pull

out the

adjusting

lever, and loosen

the

relation to the carburetor,

refer

to

"5. Adjusting

govemor

lerrer

not so that the t'rrottle

valve

lnterlocking

betwen

C,arburetor

and Governor"

opening

will be betwen

7Oo

and

75".

which will be discused

laler.

c.

Return

the

adiusting lever to

its

original

position,

It should be noted that the

go\rernor

ha been

and adiust

the

fork

lever

stopper so that

the

';

properly

adjusted

before the tractor

is shipped

throttle

adiusting

valve will

return

to the

zero

out from th€ factory.

ln

Fig.

189, the double

position.

circle

I

@

shows sealing by

pinch,

and

the

d. By using the throttle

adjusting

screw

and

the idle

circle

(O

indicates the

position

painted.

Avoid to

adjusting screrru,

perform

idle

speed adjustmeng.

make an attempt to

adjust unnecessarily.

O

ldle

adlusting screw . . . Adjust so that the

\racuum

gauge

reading will be at maximum.

1.

Adiustingenginespeedasspecified

O

Throttle

adjusting

screw .. .

Use a tacho-

Adjustmena can

be

made

by cfranging

the tension

meter.

of the

governor

spring

(45).

The

spring

tension

e.

Adjust

the

adjusting lever

position

by using

the

can be

changed byvaryingthelength.of

thespring

stopper bolt so

that

the

engine

speed

will

be at

by turning

in

or out

the stopper

bolt

(22)

attadled

3,150t50 r.p.m.

with

no

load and

with f ull

.

to the

adjusting

lever

1421.

To incresetheengine

throttle.

speed,

the spring

length should

be

made

longer,

Note:

Disasembling of the

whole

governor

while to decrease

the sp€ed,

it should

be

storten-

should

be done by

its manufacturer,

and therefore,

ed.

the disassembling

procedures

are not described

herein.

2.

Adjusting

speed

variation

Speed

variation adjustments

can be

done

by

changing

the

lengith

of

the

spring bolt

(44).

when

'

the

projected

part

of

the spring bolt

is

longa,

speed

variation

becornes

greater,

while the

part

is

shorter, speed

variation

is smaller.

lf

the

spring

bolt

is adjusted,

the

specif

ied engine speed

is also

changed,

and

therefore,

readjustment

is

required

FUEL

SYSTEM

58-1

6-6.

Governor

-

Troubles

and

Remedies

1.

The

troubles

of

the

governor

can

be classified

into

the following

four types:

a.

Hunting

-

periodic

variation

of

engine speed.

b.

Variation

of

specif

ied

engine

speed.

c.

lncrease

of

fluctuation

coeff

icient.

d.

lnoperative

governor.

2. Causes

of

troubles

and

remedies

a.

Hunting

-

periodic

variation

of

engine

speed

b.

Variation

of specified

engine

speed

Cause

Remedy

I

ncorrectly

adjusted

governor

spring.

Readjust.

c. lncrease

of

fluctuation coefficient

d.

lnoperative

governor

6-7.

Govern0r

Disasembling

Procedures

1. Remove

the

governor

from

the engine

a.

Remove

the ball

joint

at the

end

of

the

governor.

b.

Remove

the

nut

at

the

front

of the

pulley,

and

remove

the

pulley.

c.

Remove'the bracket

mounting

bolts, and

remove

the

governor

assembly.

2.

Disassembling

the

governor

assembly

a.

Remove

the

gear

case stud

nut,

and

remove the

gear

case

k

id.

b.

Pull

out

the

drive

gear

roll

pin,

and

remove the

drive

gear.

c.

Remove

the

counter-sunk

screw

at

the

f

ront

of

the

governor

case.

d.

Hold

the

governor

case

flange

with

your

hand,

and

lightly strike

the

governor

shaft

projecting

to the

governor

case

rear side

with a

hammer.

The

gover-

nor shaft

kid and

bearing

case

kid

can

be

removed.

Disassembling

the

governor

shaft

kid

Pu

ll out

the

thrust

collar.

The

bearing

case

kid

can be

re-

moved

in such

a

man-

ner as

shown

in the

photo.

Do

not

attempt

to

further disassemble

the

removed sections.

Necessary

check

can

be

made

without

per-

forming

further

dis-

assembling.

4.

Disassembling

the

governor

shaft kid

a.

Remove

the bayonet

set-screw

on

the

rear

of

the

weight

holder.

The

governor

shaft

kid can

be dis-

assembled into

the weight set

pins,

weights,

and

weight

pins,

in

that

order.

b.

Remove

the taper

pin,

and

the

weight

holder

can

be

removed

with ease.

5. Disassembling the

bearing case kid

a.

Remove

the

snap ring,

and

disassemble

the bearing

case kid

in

order

of

the

oil

seal

and

bearing.

3.

a.

Cause

Remedy

Fatigued

gwernor

spring.

lncreased

friction

on

link

mechanism.

Excessive

wear

on

link

joints.

Replace.

Clean

and

oil.

Replace.

Cause

Remedy

Lack

of

lubrication.

lncreased

friction of

moving

parts.

oil.

Disassemble

and

check.

Cause

Remedy

Damage

and seizure

of

inner

parts.

Disassemble

and

cfieck.

58-2

FUEL

SYSTEM

d.

6.

Disassembling

the

governor

case

kid

a.

Pull

out

the

lever

joint

cotter

located on

the

bottom

end

of

the

adjust

lever.

b.

Remove the adjust

lever

snap

ring.

The

governor

case

kid

can be

disassembled

into

the

adjust

lever,

governor

spring,

spring

bolt,

and

lever

rod,

in

that

order.

c.

Remove the spring

bolt

holder

taper

pin,

and

the

bolt

holder can be

pulled

out

with

ease.

Loosen the

governor

lwer

f

itting

bolt,

and

remove

the

govemor

lever.

Remove

the

fork

lever

fit-

ting

ten

in

the

case.

Lightly strike

trre

fork

*raft

projecting

into the

case

(on

the

bolt

holder

sidel

witlr

a

hammer, and

trte

fork lwer

can be

removed.

One

half

of the

lwer

is attached

with fie

oil

seal and

bearing.

7. Disassembling

the

gear

case

a.

Remove

the

sleeve,

and

the

driven

gear can be

removed.

6-8.

Parts

-

lnspection

a.

When

the

governor

shaft

kid

is removed

from the

governor

case,

inspection

should

be

started

b.

lf

any

parts

are

found

damaged

,

scratched

or

excessively

worn,

they

should

be

replaced.

c.

The tolerance

of

main

parts

is

as

follows:

(lf

any

parts

are

found

in

excess of

tolerance,

they

should

be

repaired or

replaced.)

T.

Name

of

Part Measuring

Point

Specif

ied

Dimensions

Tolerance

Fork

shaft

Wear

on bearing

contacting

surface

as74loz4o-o'00019685

'--o.ooo5bl

18

In'

(0.520i3?lmm)

-0.0007874

in.

(-0"02

mm)

Bend of shaft

0

0.0007874

in.

(0.02

mm)

Fork

lever

Outside diameter

0.3149fu

t0.0019685

in.

(8o

10.05

mm)

-0.003947

in.

(-0.1

mm)

Weight

set

Outside diameter

a236zzol:3ffi3:313

in

, A

-0.009

'

t@

o.01,

mml

-0.0007874

in.

(-0.02

mm)

Bend

0.0003937

in.

(0.01

mm)

0.001 181

1

in.

(0.03

mm)

Weight

Outside diameter

0.3149fu

10.0019685

in.

(Bo

t0.0b

mm)

-0.003937

in.

(-0.1

mm)

Thrust

collar

Wear

inside

diameter

0.433070

(1

16

+0.00106299.

0

ln'

+0.0017

_0

'mm)

+0"001

181 1

in.

(+0.03

mm)

FU

EL

SYSTEM

58.3

Name

of

Part

Measuring

Point

Specif

ied

Dimensions

Tolerance

Balance

weight

in.

Wear

on bush

inside diameter

A.23622o

(60

+0.00047244

0

ln'

+0.012

0

mm)

+0.001

1811

in.

(+0.03

mm)

Governor

spring

F ree

length

2.48031

10.019685

in.

(6310.5

mm)

+0.019685 in.

(+0.5

mm)

Spring

constant

5o/o

23.039

lb/in.

5o/o

(

''-

)

'2.0

kg/mm

-5%

-50/

lnitial

tension

1 5.435

lbrl .103

(7.010.5

t

g)

-1

.103

lb

(-0.5

kg)

Governor

shaft

Wear on thrust

collar

contacting

surface

o4330r,1:3ffi33i33in

(1

1p

-3:319

mm)

-0.001

181

1

in.

(-0.03

mm)

Wear

on

bearing

contacting

surface

o3e37o':33ffJ3ff;

(1oo

-3:?3

mm)

-0.0007874

in.

(-0.02

mm)

Bend of

shaft

0 0

0.0007874

in.

(0.02

mm)

6-9. Asembling

Procedures

1.

For

assembly,

the disassembly

procedures

should

be

followed in reverse

order.

2.

Assembling notes

a.

Thoroughly wash

all

disassembled

parts

with

light

oil.

b.

Be

sure

to

replace all

gaskets

and oil seals

with

new

ones. Otherwise

oil

leakage

may

result.

It

is

also

advisable

to

replace

bearings

as

a

rule.

c.

When

press-f

itting

the bearing

case k

id into the

governor

shaft,

grease

the

oil seal

inner surface

and

bearing

side surface.

d.

When

installing thrust collars, apply

a

small

quan-

tity of

mobile

oil

to contacting

surfaces.

e.

Feed

a

plenty

of

f iber

grease

into

the

gear

case.

f.

Tighten the

pulley

with a

torque

of

36.25

ft-lb

(5

kg-m).

g.

When

replacing

the balance

weights,

make

sure

that

new weights are

the

same

in

mass

as old

ones.

h.

Make sure

that

the

governor

lever

is

at an angle

of

4o

to

the

horizontal

line.

i.

Set

the spring

bolt so

that the distance

from

the

center

of

the spring

bolt

holder

to that

of

the

spring

hole

i5

0.1024

in.

(28

mm).

j.

Make

sure

that

the

runout

of

the

pulley

V

groove

is

0.0098

in.

(0.25

mm)

or

less

measured

from

the

governor

case

mounting

surface, after

assembling

is

completed.

6-10.

Adiusting

the Governor

1.

lnstalling the

governor

assembly

a.

When

installing the

governor

on

the engine,

be

sure

that

the

V-belt

is

flexes

0.55

-

0.78

in.

(14

-

20

mm)

(in

case

of

tension

of

some22.05

lb

(10

kg))

by

depressing

with

fingers

midway between

the

pulleys.

l{ the

belt

is

a

new

one, adjust

the

f lexion

of

the belt to

0.55

-

0.67

in.

(14

-

17 mm)"

58.4 FUEL

SYSTEM

2.

Adjusting the specif

ied engine speed

6-1

1.

Lubrication

a.

Adjustment can be done by turning

the adjust

lever

stopper

bolt and

by changing

the

governor

lt

is requested

to supply

lubricant

(Engine

Oil)

spring tension. lncreasing the

length

of

the

spring

in

the

volume of

approx.

0.0

1

gal.

(0.04

lit.)

installed

causes

the

engine

speed to increase,

and

The standard

oil

level should

be

read

on

the top

shortening causes the speed to

dbcr""r". position

of

the oil

level

gauge

when

it is

fully

b.

Adjusting

speed

fluctuation

coefficient

inserted.

Adjustment

can be done by

changing the distance

from

the

center

of

the spring bolt

holder to

that

of the spring hole. When

the distance is

longer,

the coefficient

is

larger.

and

vice versa.

3.

Correcting

periodic

speed

variation

a. lf

hunting

(to

slight

degree)

is found,

it

should

be

adjusted

by

the

damper

spring attached

to

the

lever

rod

end"

b. lf

hunting

is

phenomenal

,

governor

adjustment

is

incorrect.

Readjustment

should

be

made by

ad-

justing

the

specific speed and

fluctuation

coeffi-

cient,

alternately.

IGNITION

SYSTEM

59

IGNITION

SYSTEM

1. Spark

Plug

1-1

.

lnspection

and

Adjustment

of

Sprk

Plug

1.

Clean

the

plug's

electrode

with

a

plug

cleaner

tester.

Fig. 192

2.

Check

the spark

plug

for

the

following and

if it is

faulty,

replace it.

a.

Whether

the

insulator

is

damaged.

b.

Whether

the electrode

is worn.

c.

Whether

the

Easket

is

darnagd.

3.

Measure

the

plug

gap

with

a

plug

gap gauge.

Any necessary

adjustment

;an be

made

by

bending

the

plug's

outer

electrode.

Sparking

plug

clearance

|

0.031 in."(0.8

mm)

1-2.

Spark

Plug

Specifications

TYPe:

Plug

gap:

2.

Distributor

B6E

(NG

K)

W2OEP

(DENSO)

0"031

in.

(0.8

mm)

2-1

.

RemoYing

the

Distributor

1

.

Remove the

primary

coil

from

the

distributor.

2.

Remove

the

high tension

mde

from

each

spark

plug.

3.

Remove

the

vacuum advance

hose

f rom

the

vacuum

control asembly.

4.

Unscrew

the

distributor

securing

nuts and

lift

up

the distributor.

2-2. Disasembling

the

Distributor

Disassemble

the

distributor

is

in

the

procedure

out-lined

below.

Remore

the

distributor

cap

(A)

and

pull

off

the

rotor

(B).

Remove

two

vacuum

control asembly securing

screw

bolts,

and clips

securing

the

link

to the

breaker

base asembly, and then

the vacuum

@ntrol

asembly

(C).

Loosen

the

nyt

(D)

at the

primary

coil terminal.

Remove

the breaker

asembly and two

breaker

arm support

securing

screw

bolts,

and lift up

the

breaker base

(E)

and breaker arm support

(F).

Remove

the condenser

(H)

from

the housing

asembly

(G).

Pull

off the

holding

the drive

gear

(J)

and

shaft

asembly

(l),

and

remove

the

drive

gear

and shaft

assembly

(K)

frorn

the

housing

assembly.

Pull

off the cam

(L)

from

the

shaft assembly.

1.

2.

3.

4.

tr

\.r.

6.

*

Fig.

193

7.

60

IGNITION

SYSTEM

J

Fig.

l%

8.

Pull

off the

clip connwting the

shaft

asembly

to

the

governor

weight, and remove

the

governor

weight

(M)

and

governor

spring

(N).

Contact

arm spring

tension

Measure

trre

contact

arn

spring

tension

with a

spring

tension

tester,

and

if

the

measured

value is

not satisfactory,

replace

it.

1.1

-

1.4

lb

Contact

arm

spring

tension

I

f

dgb

^,

OSO

gl

See whether

the

drive

gear

teeth are

cranked,

damaged

or broken,

and if

it is faulty,

replace

it.

I nspecting

dovral angle

Measure

the dowel

angle

with

a

disributor

tester.

lf

the

measured

value

is not in

the

following

range,

it

is

assumed

due

to

inconect

point

gap,

uorn

cam,

worn

contact

arm heel,

deflected

contact

arm,

etc.

See what

is

the

trouble,

and if it is

faulry, correct

or

replace it.

5.

2-3

Checking,

Maintenance rnd Limit

of Adius0nsnt

Check ing th

e

d istri

butor

Distributor cap

Check

the

distrbutor

cap

for

crack,

split or

damage,

and

if

it is

faulty, replace

it.

lf the

high

tension terminal

is corroded,

scrape it

off.

Rotor

Check the

rotor

for

crack

or

darnage,

and

check

whether

the tip

of the terminal

is

burnt.

lf

it is

faulty, replace

it.

Contact

point

Check

the contact

point

for wear,

burnt

pan

or

sticking.

lf

it

is

only slightly

damaged,

grind

it

with

an oil stone,

while

if

swerely

damaged,

replace

it.

Condenser Meazure

tre condenser

caprcity

with

a

condenser

tester,

and

if it is faulty,

replace

it.

Condenser

capacity

|

0.2O

-O.24pF

1.

2.

A

J.

6.

7.

4.

IGNITION

SYSTEM

61

Dowel

angle

I

S6

-

610

t96

8.

Adjusting

the

point

gap

a. Set

the

contact arm

heel to

the

high

part

of

the

cam

so

that

the

clearance

between

points

becomes

widest.

b.

lnsert

a special tool

(No.

N026

STANDARD

FEELER

GAUGE)

into

the

point

gap

and

measure

the

point

gpp.

To

adjust

the

point

gap,

loosen

two

scrqnts

and

adjust

the

point

gap

and

retighten

the screws.

Point

gpp

|

0.019

'v

0.020 in.

lO.4

-

0.5 mml

Fig.

197

24.

Asemhling

the

Distributor

Follow

the

reverse

procedure

of

"Disassembling"

2-5.

Mounting

the dbtributor

Follow

the

re\/erse

procedure

of

"Removing".

Note: After

installing

the distributor,

adjust

igni-

.,

tion timing

with

a

timing

light.

2-6. lgnition

Timing

lnspection

and

Adiustment

To inspect

and

adjust

the

ignition timing,

use

No.

1

cylinder

together

with

the

timing

light and

tachometer.

Connect

the

timing

light

secondary

coil

to

No.

1

spark

plug,

and

each

primary

coil

to the

battery

terminals

(+)

and

(-).

Connect

the

techometer.

Start

the

engine

to

reach

the ordinary

idling

revolution of

700

-

800

rpm.

See the timing

mark

with the

timing

light.

It is

good

if

the

T

(timing)

mark

notch shown

in

Fig.

198

is aligned to

the

indicator

end.

To

adjust

the

ignition

timing,

loosen the distribu-

tor

lock

nut

and

move

the distributor

properly.

Retighten

the

lock nut

and

agnin

inspect

the

ignition timing

with

the timing

light.

Fig.

198

2-7 . Dlstributor

Specifications

1.

2.

3.

Fig.

4.

5.

6.

Type: Point

gap:

TVD-4MR

0.016

-

0.020

in.

(0.45

*

0.05 mm)

Point

pressure:

1.1

^,

1.4

lb.

(500

-

650

g)

Condenser

capacity

.

O.ZhrF

t10%

lgnition

clearance:

90"

+

15o

Dowel

angle:

58.5"

t

3"

(distributor

axle)

lgnition

order:

1-34-2

..-4.'54,rU-{

v

,7

i7,',TA

c-

Jrl-'

|

(

o

MEMO

TROU

BLESHO OTIN

G

63

TROUBLESHOOTING

Symptom

&

Possible

Cause

1.

The Engine Lacks

Power

1-1. Fuel

Compresion

is

lnsufficient.

1

2

3

4

5

6

7

Valve

clearance

improper.

Valve

seat

leaky.

Valve

stem

stuck.

Valve

spring

weaken

or

broken.

Cylinder

head

gasket

leaky.

Piston

ring

stuck

or broken,

Piston

ring

or

cylinder

worn.

Adjust

the

clearance.

Smooth

contacting

surface

with

valve.

Replace

guide

and

valve.

Replace valve

spring.

Replace

gnsket.

Replace

ring.

D isassemble

engi

ne

and.

correct.

1-2.

lgnilion

Timing is lnconect

1

|

lgnition

timing incorrect.

(Early

or

late)

|

Adiust ignition timing.

2

|

Spark

plug

faulV.

I

Clean and correct

or replace spark

plug.

3

I

Distributor

points

faulty.

I

Correct

or

replace

points.

1-3.

Fuel

Level

is

Low

1

|

Carbilretor clogpd. Disassemble

and

clean carburetor.

Clean

pipe.

Check

joints

and

retighten.

Correct

or

replace

pump.

Replace

fuel filter.

2

|

Fuel

pipe

clogged.

3

|

Fuel

system oDntains

air.

4

|

Fuel

pump

in

poor

condition.

5

|

Fuel

filter

clogged.

14.

Carburetor

Drayrn lnsufficient

Amount

of

Air

cleaner clogged.

Clean air cleaner.

l

-5.

Engine

Overheats

1

|

Cooling

water insufficient. Add water

2

I

V-belt loose

or

slipery.

Adjust

or

replace

belt.

3

I

V-belt worn

or broken.

3

I

V-belt worn

or broken.

I

Replace V-b€lt.

q

I

Thermostat inoperative.

I

nepuce

thermostat.

5

|

Water

pump

inoperative.

5

I

Water

pump

inoperative.

I

Disasemble

and correct

pump.

0

|

Radiator

clogged or

leaky.

I

Ctean and correct

or

replace

radiator.

7

|

lgnition

timing

incorrect.

Adjust

timing.

2.

Fuel Consumption

is

Excessive

2-1

.

Engine

Oil Leaks

1

2

3 4

5 6

Oil

pan

drain

plug

loose.

Oil

pan

set

bolts

loose.

Oil

pan packing

faulty.

Oil seals

faulty.

Cylinder

head

gasket

broken.

Oil

filter

set bolts

loose.

Retighten

plug.

Retighten

bolts.

Replace

packing.

Replace

oil

seals.

Replace

gasket.

Retighten

f

ilter

set

bolts.

TROUBLESHOOTING

J

Symptom

&

Possible

Cause

-"n-*

7

I

Rocker arm

cover

packing

faultY.

Tim

ing

chain

cover

pack

ing

f

au

lty.

R

eplace

pack

ing.

Replace

packing.

1

I

Piston

ring damaged.

Replace

piston

ring.

Adjust

end

gap.

Replace

ring.

Replace

piston

or

cylinder

liner.

2

|

Piston

ring

end

gap

incorrect.

3

|

Piston

ring

worn

or

stuck.

4

|

Piston

and

cylinder

worn.

2-2.

Oil Comes

Up

into the

Combustion

Chamber

2-3.

Oil

Comes

Down

from

Valve System

1

I

Valve

seat

worn.

Replace

valve

seat.

Replace

valve and

valve

guide.

2

I

Valve

stem

and

valve

guide

worn.

3.

Engine

b Hard

to

Shrt

3-1.

Engine

has Surting

Difficulty

Replace

oil

with specified

brand.

Charge

battery.

Replace

battery.

Clean

and

tighten

terminals.

Replace cables.

Disassemble

starter and

correct

or

replace.

Adjust clearance between

cam

and

snritch,

or

replace sruitch.

Engine

oil

too

thick" Battery discharged. Battery capacity low. Battery

terminal

connection

faulty.

Starter

faulty.

Safety

sritch

faulty.

1

2 3

4

5

6

3-2. lgnition

System is DefectiYe

r

I

Distributor

points

faulty

I

Correct

or

replace

points.

2

|

Point

gap

incorrect.

I

Adjust

point

gap.

3

I

Spark

plug

gap

incorrect.

3

I

Spark

plug

gap

incorrect.

I

Adjust

spark

plug

gap.

4

|

Spark

plug

cord loose or

faulty.

I

Tighten cord connection

or

replace.

5

I

lgnition

coil

faulty.

I

Replace

coil.

6

|

Primary

winding

connection

faulty.

I

Check

and

retighten

connection.

-7

|

Condenser

faulty.

I

Replace

condenser.

3-3.

Engine

34.

Carburetor

Valve

seized

up.

Piston,

piston

ring

or

cylinder

worn.

Cylinder

head

gasket

broken.

Correct

valve

or

replace.

Disassemble

and correct.

Replace

gasket.

1

|

Choke

valve

faulty.

Correct

or

replace

choke

mechanism"

Adjust.

Disassemble

and clean.

Retighten

bolts.

2

i

ldle

speed

circuit

faulty.

3

|

Carburetor

clogged

or too dirty.

4

I

Carburetor

mounting bolts loose.

TROU

BLESHO

OTIN

G

65

Symptom

&

Possible

Cause

Remedy

4. Engine

is

iloisy

+1

.

Piston

I

Piston-to-cylinder

clearance

excessive due to

worn

I

Replace

piston

and

cylinder

liner.

cylinder.

Z

I

Piston-to-piston

clearance excesively

large.

I

Replace

piston

and

piston

pin.

3

|

Piston

ring

broken.

I

Replace

piston

ring.

4

|

Piston

seized

up.

I

Replace

piston.

+2.

Crankslraft

t

I

Oil

clearance excesively

large

due

to

worn

main

I

Replace

bearing

metal.

bearing

metal.

2

|

Crank*raft

journal

worn.

I

Machine

crankshaft or

replace.

3

|

Main

bearing

metal

damaged.

I

Replace bearing meul and

check lubrication

system.

&3.

Connesting

Bod

M.

Miscellaneous

Replace

bearing

metal.

Correct

or

replace

rod.

Machine

crank

or

replace.

Replace

bearing

metal

and

check

lubrication

system.

Oil clearance

excessively

large

due

to

worn

con-

necting

rod

bearing

metal.

Connecting rod

bent.

Crank

worn.

Connecting rod

bearing

metal

damaged.

1

I

Valve

clearance incorrect.

Adj

ust clearance

correctly.

2

I

Crankshaft

thrust

washer

worn. Replace

washer.

3

I

Engine

oil

level

low.

Add

engine

oil or disassemble

and

correct engine.

5-1. lgnition

System

5-2. Air-fuel

Mixture

lgnition

system wiring

connection loose.

Spark

plug

faulty.

lgn ition

tim

ing

incorrect.

5.

Firing

lnegularities

Check connection

and

correct.

Clean

spark

plug

or correct,

or

replace.

Adjust

timing.

Clean

and

adjust

carburetor.

Clean

and

adiust carburetor.

Clean

or

replace fuel

pipe.

1

I

Valve

clearance

incorrect.

1

|

Valve

clearance

incorrect.

I

Adjust

valve

clearance.

Z

I

Valve stuck.

I

Oisasemule valve,

and correct

or replace.

3

|

Valve

spring

weak.

I

Replace

spring.

Air-fuel

misture

too

lean.

C,arburetor

clogged.

(or

dirty)

Fuel

pipe

clogged

or dirty.

5-3. Valves

TROUBLESH

OOTITUG

-t

Symptom

&

Possible

Cause

Remedy

4

Valve

tim

ing incorrect.

Adjust

valve timing.

Carbon

build-up

in

combustion

chamber.

Cylinder

head

gnsket

leaky.

6. lnconect

ldle

Speed Adiustment

54. Cylinder

Head

Remove carbon.

Replace

gasket.

6-1.

Carburetor

Readjust

idle

speed.

ldle

speed

adjustment

incorrect.

6-2.

Air En&ring

Fuel

Line

1

I

Air

enters carburetor

fuel

line.

Retighten carburetor

mounting

bolts.

Replace

gasket.

2

|

lntake manifold

gnsket

faulty.

6-3. Valves

1

|

Valrae

clearance incorrect.

I

Adjust rralve clearance.

2

|

Valvetovalve

seat contact

not

perfect.

I

Smooth

out

valve.

3

|

Vatve

stem-tGvalve

guide

clearance

excessively

I

Replace valve

and

rralve guide.

large.

6-4.

Cylinder

Hmd

1

I

Cylinder

head

gasket

leaky.

Replace

gasket.

7

"

Engine Runs

not

Smooilrly

(when

accelrated)

7

-1.

Carburetor

C.arburetor

accelsation

pump

circuit

clogged.

Spark

plug

faulry.

H

igh-tension

wire

faulty.

Distributor

point

gap

adiustment

incorrect.

lgnition

coil

faulty.

7-3.

Engine

1

|

Valve

seized up or

adjusted

incorrectly.

I

Readjust

or replace.

2

|

Compression insufficient.

2

|

Compression insufficient.

I

Disassemble engine

and

adjust.

3

|

Cylinder

head

gpsket

leaky.

I

Replace

gasket.

D

isassemble

carburetor and correct.

Disassemble

carburetor and correct.

7-2. lgnition

System

Clean spark

plug

or

replace.

Replace

wire.

Adiust

point

gap

or

replace

points.

Replace

ignition

coil.

SATOH

TRACTOR

I

\

al

MoDEL

s,65OG

REPAIR

MANUAL

CTUTCH

SYSTEM

PUBLICATI0t{

Jlo.03-B

I

t

-

CONTENTS

CLUTCH

SYSTEM

1 .

General

2. C,onstruction

3. Disassembling

Order

3-1

.

Disasembling

Order Using

"

A"

Method

3-2.

Clutch

Asembly Disassembling

Order

3-3.

Disassembling

Order

Using

"8"

Method

34. Clutch

Pedal

Mechanism

Disasembling

4. Assembling

{Adiusting}

Order

4-1

.

Clutch

Pedal

Mechanism

Assembling

+2. Clutch Assembly

Assembling and

Fitting

+3.

Overall

Assembling

lrspection,

Maintenance

and Limit

of Modification

Troubleshooting

G1.

Clutch Slips

. .

6-2.

Clutch Drag

6-3.

Shudder

when Starting

il.

Clutch Overheat

Specif

ications

5.

6.

1

2 2 2 2

4

5

tr

5

7

B

I I I I

10

107.

CLUTCH

SYSTEM

1.

General

The

clutch

for

the

S-650G

is

of

a dry

single

plate

lever

type.

Each

component

of

the

clutch

is

made

not

to

degensate or

be damaged

due

to the

sliding

abrasion

of

the

clutch

disc

in case

of

connection,

moreover,

to

bear a

shock in case of disconnection

or

a

sudden

load in case

of

change

in

transmission

torque.

The

operation of the

clutch

is

smooth

and

secure

and

provision

is made

for

keeping

it

from

being

worn

or

damaged

due to

repeated use.

This

clutch has

the

following special

systems

in

order

to transmit securely

a

great

torque.

2. Construction

When

the

clutch

pdal

(A)

is depressed

forwards,

the

shaft

(B)

is caused

to

rotate,

the

fork

secured to

the

shaft

with

cotter

pins

slides

in

the

arrow direction to

push

the thrust

bearing

carrier

(D),

forcing

the

thrust

bearing

(E)

into

contact

with

the

release

lever

(F),

the

CLUTC}I

SYSTEM

Six

pressure

springs

are

used,

enabling a

high

pressure

to

be

applied

to

the

clutch disc

to

transmit

the torque

completely

and

evenly.

For

the

material of

the

clutch

facing,

a

wire-

reinforced

woven

fabric whose

constant

of

friction and

shape

are

hardly changed

even

at a

high temperature.

Besides,

on

the

facing there

are

radial

grooves

0.03

in.

(0.8

mm)

in depth

and

0.07

in.

(1.8

mm) in

width, thus

preventing

the temperature

rise

of

the

facing,

incrasing

its durability

and

making it ea$/

for

the

clutch

to

be

releaed.

release

lever

is

pushed,

the

Bressure

plate

is

sh

ifted

toward the

transmission

by

the

pressure

of

the

pressure

spring

(G),

the

clutch

disc

is

disengaged, the

drive

from

the

engine is cut

off.

(a)

(b)

t ll

k

A

B

c

D

E F

G H

I

J

clutch

pedal

shaft

fork

thrust bearing

carrier

thrust bearing

release lsrer

pres$rre

spring

pressure

plate

clutch

disc

f

lywheel

Fig.

I

Cltttch

Meclnnkm

-t

CLUTCH SYSTEM

3,

Disassembling

0rder

To

dismount

the clutch

assemb

ly

f rom

the

"tractor,

there

are two

methods

for it, which

to take

depend-

ing

on

the

facilities

of

its repair

shop.

A

Method:

Dismounting

method

when

the

repair

shop

has

heavy repair

tools

such as

a

chain block.

B

Method:

Dismounting

method

when

the

repair

shop

has light

repair tools.

C"aution:

ln

dismounting

the

clutch asembly,

it

should

be done

on

a broad,

f

irm and

flat

ground

as

the

transmission

is

detached

at

its connection

with

the engine

assembly

and

each component

is

very

heavy.

3-l

. Disasembling

0rder Using

"

A"

Method

1.

ln A MethoC,

the

front

wheel

axle

and the

engine

are

removed

before

removing

the

clutch assembly

(see

REPAIR

MANUAL,

ENGINE,

1.

Disasembl-

ing

Order,

1-1. Removal

the

Engine

(No.

1

^'

21l,

"

2. Support

the

removed

engine

with

a special tool

(0490010

ENGINE

STAND) or

in

other

ways.

3. lnsert

a special

tool

(1

102T01

CLUTCH

DISC

PILOT)

into the clutch

asembly

center

and

put

an

alignment

mark

both on

the

f

lywheel

and

the

clutch asembly

(to

avoid an

improper fitting in

the case

of

reassembly).

4.

Unscrew

four

clutch asembly

set

bolts and

t\o

reamer

bolts,

and

remove

the clutch

asembly

together

with the disc

from

the

flywheel.

3-2. Glutch

Asemhly

Disasembling 0rder

1

.

Attaoh the

clutch

cover

asembly to the special

tool

(11O2TO4

CLUTCH

RELEASE LEVER

DIS-

ASSE MB

LY

TOO

L)

(see

Fis.

2l

.

2. D iscription of

F

iS. 2

The

clutch

cover

asembly

taken

from

the

f

ly-

wheel

is

as shwon

in

dotted

lines

(

1

)

,

howevs,

under this condition

a

force which

pushes

up the

clutch

co\€r acts on

the

lever nut

(F)

and

it is

impossible to

loosen the

lever

nut

properly.

So, tighten

the bolt

(A)

of

the special

tool

(1

102T04)

to

lower the

clutch cover

assembly

down

to

a solid

lines

Ql

.

Then

the

release

lever

(E)

is set

free

and

the lever

nut can

be

easily taken

.,,

out

after

r€moving

the

cotter

pin.

Fig. 2

Dissembling

by use

of a

Drsassembling

Tool

3.

Tighten

the bolt

to

set the

asembly

to the

position

Ql

and

remove

the cotter

of

the

lever

nut

(F)

and

unscrew three

lever

nuts

(F)

and

remove the

release

lever

(E)

from

the

lever

bolt

(J).

Slowly

loosen

the bolt

(A)

to

remove it

from

the

base

(D),

and

remove

the

clutch

cover.

Remove

six

pressure

springs and

lift

up

the

pressure

plate

f

rom

the

base

(D).

3-3.

Dlsasembling

0rder Using

"8"

Method

ln

B

Method,

the

front

wheel

axle, the

engine

and

the

frame

are

deuched

from

the clutch

housing

and

the

engine

f itted

place.

Follow the

proced

ure,

referring

to

R E

PA

I R

MANUAL,

ENG

lN

E,

1

. Disassembling

Order,

1

-

1

.

Engine

removal

INo.

1

^.,

10)

"

Set

the

iack iust

below the

clutch

housing

and

put

a

piece

of

wood between the

jack

and the

clutch

housing

(to

avoid a

slip).

Jack

up the

clutch

housing

to

keep the

tractor

rear

half

horizonta

I when

the

f ront wheel and the

engine are

detached,

but

the tractor

must not

be

lifted.

-

Condition

before

tightening bolts

Condition

ready

for

disassembling

A

bolt

B

washer

C clutch

cover

claw

D

base

E

release

lever

F

lenrer

nut

G

release

washer

H

clu tch cover

I

pressure plate

J lever bcllt

t

1.

2.

3.

CLUTCH

SYSTEM

Fig. 3

Front View

Deached

4.

Drive

in

a

wedge

(A)

as

shown

in Fig.

4

to

keep

the

tractor

secure.

The

wedge

must

be

a

f

irm

piece

of

lucod

of about

6 in.

(about

150

mm),

and

see to

it

that

thewedge

will

not be

removed during

operation.

Fig.

4

Wedge

(A)

5.

To

hold

the

engine oil

pan

to

the

gnrage

jack,

use a

special tool

(1102T03

OIL

PAN RECEIVER

FOR

CLUTCH

REMOVAL)

as

shown

in

Fig.

5.

When

using

the

garage

jack,

the

tractor

must

not

be

lifted

u

p.

6.

Unscrew

six

nuts

(M

1

0)

securing

the

engine and

the

cl utch

assemb

lY .

As

both

nuts

inside

the

chasis

(see

Fig. 6)

are

very

hard

to

be

unscrewed,

use

a

special

tool

(BT-100

DOUBLE

OFFSET

BOX

WRENCH

SET).

Fig.

6

Positions of

Nuts

lnside

Chassis

7.

Take

out

the

starter

motor

wiring,

and

loosen

t\40

starter

motor

securing

bolts,

and

remove

the

starter

motor

from

the

engine

cylinder

block.

8.

Loosen

eight

bolts

(Ml6

x

40)

at both

sides

of the

chasis.

Fig.

7

Remotnl

of

hrt

of

Chasis

9.

Unscrew

four

bolts

(M16

x

40)

(C)

shown in

Fig.

8.

Unscrew

three

re;,r

plate

securing screws

(M6

x 12)

(A)

and

pull

down the

rear

plate.

A

Garage

jack

B

1

102T03

C Chassis

Fig.

5

Oil

Pan Holding

Oil

pan

Front

wheel

axle

D

E

CLUTCH SYSTEM

A

Position

of rear

plate

B Chassis C

Bottom

position

Fig.

8 lnsalling

Bolts

of

Chassis

10.

Now

the clutch

housing

and the

engine body

are

removed,

however,

if

the

chassis

is not

completely

pulled

off the

clutch

housing,

loosen the

nuts

(A)

at both

sides shown

in

Fig.

9.

rig.

9 Nut

(A)

Position

Set up

the

garage

iack

a

little

to

keep the

tractor

horizontal,

slide

the

jack

forwards

and

the tractor

is

divided

into trnp as shown

in

Fig.

3.

Note:

The engine

body

for

the

5-650

is

made

of

alminum.

lf

you

treat

the

tractor

roughly

when

sliding

the

jack,

the

stud bolts

in

the

engine

body

may

be

twisted,

and at

last

the

engine

may be

damaged,

therefore,

be

very

careful.

12. Support

the

removed

tractor

rear half

with a

rigid

rack

instead of

the

iack.

13.

To

remo\€

and disassemble

the

clutch

asembly

fitted

to

the

flywheel

wh ich has

been

removed

together

with the

front wheel axle and

the

engine,

refer to

3:1

.

Disassembling

Order Using

A

Method

3. and

3-2. Clutch

Asembly

Disassembling

Order.

34.

Clutch

Pedal Mechanism

Disasemhling

1.

Remove

the spring

with

pliers

and

then

remove

thrust

bearing

carrier

with

the

thrust

bearing

from

the

support

snout as shown

in

Fig.

10.

lf

the

thrust bearing

is again

used,

do

not

wash

it.

Fig.

l0 Removal of

Thrust Bearing hrrier

2"

Remove

the circlip

(A)

,

the

liner

(B)

,

the

clutch

pedal

(C),

the

spring

clutch

shifter

metal

(D),

and

the

"O"

ring

(E)

from

the

shaft

(G)

with

a

special

tool

(S-O

SNAP

RING PLIEnS).

Then

drive

out the

key

(see

Fig.

11).

11.

A

Circlip

B

Liner

C

Clutch

pedal

D

Metal

E

"o"

ring

F

Key

G

Shaf

t

Fig.

ll

Pedal

Mshanism

H

I

J

K

L

M

Taper

Fork

pin Roller Nut Cotter

Fork

FK

CLUTCH

SYSTEM

\

"{-

'&',

/'

'*.L

3.

Pull

out

the

shaft,

referring to

Fig. 12.

To

remove

the

fork

from

the

shaft,

pull

out

two

taper

pins

(H)

shown

in Fig.

11

with

a

special

tool

(

17OOTO3

SPR ING

P

IN INSTALL

AND-OUT

TOOL),

pull

out

the cotter

(L)

,

unscrew the

nut

(K),

and

remove

the

roller

(J)

and

the

fork

(t).

Fig. l2

Removal

of Shaft

+2.

Clutch

Asembly Asembling

and

Fitting

C DE

F

Flywheel

Clutch L:over PrssJre

plate

Lever

nut

Lever bolt

Release washer

Return

spring

4.

Assembling

(Adiusting)

Order

+1 . Glutch

Pedal

Mechanbm

Asembling

1.

Follow

the

reverse

procedure

of

"Clutch

Pedal

Mechanism Disassembling",

seeing

Fig.

1 1. ln

this

case

use

nerru taper

pins

(H).

2. Clean

the

fork

(l)

and

shaft

(G)

sliding

parts

and apply

grease

to them.

lf the

snout

and

thrust

bearing

carrier

sliding

parts

are

considerably

worn, correct

or

replace

it.

7

o

t

A

B

c

D

E F

G

H

R

ivet

I

Release lever

J

Clutch

disc

K Spring

cap

L

Pressure

spring

M

Lever

seat

Fig.

l3

Clutch

assembly

CLUTCH

SYSTEM

a.

b.

2.

1

. Before

assemb

I

ing the

clutch

assembly, check

the

fo

llowing.

Put

the

pressure

spring

(L)

to a

pressure

test,

and

ensure

that

the

spring

meets

the

following

require-

ments.

Spring

pressure

(length

when

checking)

146.67

lb.

(67.5

tg

)

Length

when

checking

the spring

1.58

in.

(40.6

mm)

c.

No f

low

on the

pressure

plate

To

reasemble

the

clutch

assembly,

follow the

reverse

procedure

of

3-2.

Clutch

Assembly

Dis-

assembling

Order

with

use of

a special

tool

(1102T04

CLUTCH

RELEASE

LEVER

DISAS-

SEMB

LING

TOO

L)

,

however, as

for

the

cotter

for

the

lever nut

(D)

,

put

in

the

cotter

after

setting

the

height

of

the

release

lever

(l

).

Note:

A washer

rnery

be

needed

to

the

pressure

spring

after

grinding

the

pressure

plate.

ln

every

case,

adjust

the total

pressure

upon the

three

release levers

to

be

825.99

lb.

(375

kg).

See

whether

oil

is

attached

to the clutch disc

(D).

When

using

the

removed clutch d

isc,

if

the

measurement

A

shown

in

Fig.

14

becomes

over

0.078

in.

P.2

mm), replace

it.

The measurement

A

of

a

nqr/

clutch disc

is 0.039

-

0.043

in.

(

1

.0

^.'

1.2

mm).

A

Engine

Front and

Back

Dir*tion

of

Di*

When

fitting

the

clutch

assembly

assembled

in

the

flywheel,

put

the assembly

in

the

right

place

recorded in

the item

(3)

of

3-1 . Disassembl

ing

Order Using

A

Method, especially

fit

two

reamer

bolts

to their

right

place

anci tighten them dia-

gonally

at the

torque of

13.0 f

t-lb.

(1

.B kg-m).

After f itting

the

clutch

assembly

measure

the

height

of

the

release lever

with a

special

tool

(

1

O2TA2

CLUTCH

RELEASE HEIGHT

GAUG E). ln

this

case be sure to turn

up and

down

the

release

lever

several

times.

The

adjustment,of

the

release

lever

can

be

made

with

the

lever nut

(D)

shown

in

F

ig.

13,

and

finally

made

after

putting

in

the

cotter

pin.

Fig.

16

Release

Lever

and

Gauge

Fig. l5

5.

J.

6.

B

A

0.078

in.

{0.2

mm}

B Clutch

disc

Fig.

14

Clutch

Disc

C Rivet D

Cushion

plate

4.

See

whether

oil

is

attached

to the

flywheel.

lnsert

a

special tool

(1102T01

CLUTCH

DISC

PILOT)

together

with

the

clutch disc

into the

ball

bearing

in the center

of the

f

lywheel.

ln

this

case

set the

clutch

disc as shown

in

Fig. 15.

*l

Fig. 17

U*

of

Gauge

:

ll

CLUTCH

SYSTEM

4-3.

0verall Asembling

After

the

clutch

asembly

is

f

itted

to

the

engine

and

the clutch

pedal

mechanism to the

clutch

housing,

fit

the engine

and the housing,following

the

reverse

procedu

re

of

the

section

3.

Disas-

sembling

Order

Using

A

Method

or B

Method.

Then

adjust the clutch

pdal

play.

This

adjustment

is

important

when setting

the

clearance

between

the

clutch

release lever

and

the

thrust bearing.

Loosen the

nut

(A)

shown

in Fig.

18,

and

fully

tighten

the adjusting

screw

(B).

Pushing

the clutch

pedal

(D)

f

ully

to the

f

loor,

return

the

pedal

till

the

adjusting

screw

(B)

gets

in

contact with

the

shoulder

(C)

,

rotate the

pedal

by

one

turn

in

the

arrow

direction,

and

lock

it with

the

nut

(A).

Th

is

ad

justment

serves

to

control the

clutch

pressure

spring

just

before

the total

pressure,

and

the operating

length

of

the

release lever is 0.39

in.

(10

mm).

A

Nut

C Shoulder

B

Adjusting screw

D

Clutch

pedal

Adjusting

Clutch Pedat

As

the

grease

n

ipple

is

f

itted

under

the thrust

bearing

carrier,

remove

the

adjusting cover

below

the

clutch

housing

and

apply

grease.

Then

push

the

clutch

pedal

several

times

and

check

the clutch

pedal

for normal

operation

or

any strange

sound.

1.

2.

?

{

Fig.

t

8

2

\)'

8

CLUTCH

SYSTEM

5.

lnspection,

Maintenance

and

Limit

of

Modification

lnspection

Ma

intenance

Limit of

Modif

ication

1 Faulty

operation

of

thrust

bearing

carrier spring

lf

trouble

lies

in

bearing

carrier,

see

item

4-1

at

4.

If carrier

does

not

return due

to spring

load,

replace.

2

Wear

in clutch

disc

lf

measurement

A in

Fig. 14

becomes

over

0.078

in.

(0.2

mm),

replace.

3

Hardened

clutch

d

isc

Grind.

4

Oil on clutch disc

R

eplace.

5

Roll

of

clutch

disc

Rotate and

check

at

d

isc

tip.

lf

over

0.03

in.

(t

mm),

replace.

6

F

law

on

clutch

pressure

plate

Grind.

Up to

0.007 in.

rc.z

mm).

ln

this case

adjust

the

shim

so that

the

pressu

re

spr

i ng

tota

I

pressu

re

may

be

825.99

lb.

(375

kg).

This

pressure

also

applies

in

the

case

of

grinding

the

fly-

wheel.

7 Length

and

pressure

when

check

ing

pressure

spring

Adjust shim

for

adjusting

pressure.

Length when checking

1.583

in.

(40.6

mm).

lf

pressure

is within

146.67 lb.

(67.5

kg)

,

replace.

B

Height

of

release

lever

Adjust lever

nut.

1.81

in.

(46

mm)

from

flywheel.

Height

allowance

of

three

levers 0.01

in.

(0.4

mm)

I

Release

lever

operating

length

lf

over

0.39

in.

(10

mm),

trace trouble.

10 Release

bearing

Note:

This

can not

be

washed.

Rotate

it with

a

hand

and

if

any strange

sound and

irregular

rotation

are

found,

replace.

11

Clutch

pedal play

Determine

the

play,

using

release lever.

Make

sure that

it

is

within

1.57 in.

(40

mrn).

I

GLUTCH

SYSTEM

9

6.

Troubleshooting

6-1.

Clutch Slips

Caution:

lf

the

clutch slips, the engine

power

deteriorates

and the

fuel consumption

increases.

6-2.

Clutch Drags

6-3. Shudder

when

Starting

Trouble

Remedy

No

clutch

pedal play. Adjust

lever

nut

of

release

lever.

Oil on clutch disc.

Replace.

Wear

in

clutch

disc.

Replace.

lrregular

height

of

release lever.

Readjust within

allowable

limit

0.01

in.

(0.4

mm).

lncorrect

release

lever

return.

As lever seat which supports lever

is

worn and the

lever

drags,

correct it.

Weak

pressure

spring

lf length is

less

than

1.583

in.

(40.6

mm) in

the

case

of

1

46.67

lb.

(67.5

kg), replace.

lf

total

pressure

is less

than

825.99

lb.

(375

kg),

replace.

Trouble

Remedy

Release

lever

height

exceedingly

shorter than

the

specif

ied.

Readjust

it

to

1.81

in.

(46

mm).

lf it

is

due to worn

disc,

replace

disc.

Disc

considerably vibrates.

Replace

if it

exceed

ingly

vibrates,

or

if vibration

exceeds

allowable limit

0.03 in.

(1

mm).

Rust

due to

oil shortage

in

disc

spline

groove.

Scrape

away

the

rust

and

apply

grease

thinly.

Trouble

Remedy

Hardened

disc surface.

Grind

it

with

sandpaper

or

replace.

Exceed ing d isc shudder.

Rep lace.

Release lever

height

not uniform.

Adjust.

Rust in disc spline

groove.

Correct

and apply

grease.

Loosened

or damaged

tension spring.

Replace.

1O CLUTCH

SYSTEM

J

64.

Clutch 0verheat

Trouble

Remedy

Burnt

release

bearing.

Replace.

No

clearance

between

release

lever and

release

beari

ng.

Adjust

release

lever

height.

7.

Specificatisns

I

Type

Clutch disc

material

Disc dimensions

(outer

diameter

x

inner

diameter

x depth)

Static

transrn

ission

torque

Release

bering

Operation

Pressure

spring

pressure

(when

checking)

Pressure

spring

length

(when

checking)

Pressure

spring total

pressure

Number

of

pressure

springs

Pressure

spring

collar

Release

lever

maximum

operating

length

Release lever

height

Reamer

bolt

reamer

diameter

and number

Dry

single

plate

lever

Wpe

Wire-reinforced

woven fabric

7 .26 x 5.00

x

0.3

in.

(184.2

x

127 x

7.5

mm)

100.9

ft-lb.

(1

5.0

kg-m)

Non-l

ubrication

system

Foot

operating

146.67

lb"

1.583

in.

826.50

lb.

0.39

in.

1.81

in.

0.35

in.

sYstem

67.5

kg)

40.6

mm)

375

kg)

(10

mm)

(46

mm)

t9

mml,2

6

Light

blue JAPAN

paint

n7

SATOH

TRACTOR

MoDEL

s.65(o(G

REPAIR MANUAL

\

4.

STEERING

LINI(AGE

SYSTEM

PUBLICATI0N

ilo.03-C

CO}ITENTS

STEERING

LINKAGE

SYSTEM

1.

2.

3.

4.

5.

6.

7.

8.

General

Front

Axle

and Steering

Assembly

Explanation

of Construction

Disassembling

Order

. .

3-1. Disassembling

the

Entire

Front

Axle

3-2.

Disasembling

King

and

Front

Hub

Assembling

(Adiustingl

Order

4-1

.

Assembling Related

Parts

for

King

and

Front

Hub

4-2.

Assembling

of

Entire

Front Axle

Disassembling

Order

.

5-1

.

Disassembling Order

of

Steering

Assembling

(Adiusting)

Order

.

6-1

.

Assembling

(Adjusting)

Order

of

Steering

Method of

lnsp*tion,

Adjustment, and

Limit

of

Repair

Troubleshooting

......

.. ..

8-1.

Front

Whel

Shimmy

. .

8-2.

Hard

Steering

.

8-3.

Pull

to

One

Side

.

. .

.

84.

Excessive

Play

on

Handle

.

Specifications

....

..

9.

1

2

3

4 4 4

5 5

7

10

11 11 11

11

STEERING

LINKAGE

SYSTEM

STEERING

LINKAGE

SYSTEM

l.

General

Front Axle

and

Steering

Asembly

Utilizing

the

center

pivot

movement

system,

the

front

axle moves

up

and

down

8

degrees

with

the

center

as

its

p

ivot. Simple construction of

the

front

wheel

axle

allovla

for

ease

in

installing the

knuckles;

furthermore,

the

central

portion

of

the

front

axle

is

raised

basing

on the

Lumoan construction

system.

The

worm

sector

type

steering

box

is

installed

in the

steering

assembly.

Steering

method

conforms

to

Ackerrnan

Steering Gear System.

2.

Explanation

of

Construction

o

I

Tie

rod

J

Steering

lever

K

Beam

ex

tension

(

L.H

l

L

Center

beam

M

Center

N

Beam

exrension

{R.Hl

O

Fronr

hub

(R)

P

Fronr

hub

{

L

}

,According

to Diagram

Fig. 1,

turning

the

steering

wheel

(A)

turns

the steering

mast

(B)

which

transmits

the

motion to the

pitman

arm attached

to

the

Pitman

Worm Wheel

(C),

which in

turn transmits

the

motion

to

the

steering

lever

(J)

on

the

right

and to the

steering

lever

(F)

on

the left

by

vray

of

the

drag

ring

(E)

and tie

rod

(l)

which

allows driving

in

the desired

direction

when the

movement is

transmitted to

the

hub

linked

to the steering

lever

(F)

and

(J).

A

B

c

D

E

F

G

H

Steering

yvheel

Steering

mast

Worm

wheel

Pitman

arm

Drag

ring

Steering

lever

(R

H)

Ball

socket-ass'y

"c"

Ball

socket

ass'y

"H"

Fig. I

Stering Linkage

STEERIN

G

LIN

KAG

E

SYSTEM

3.

Disassembling

0rder

3-l

. Disasembling

the

Entire

Front

Axle

1.

As shown

by

Diagram

Fig. 2,

place

wedges

on

the

upper

surface

of

the

center

beam

and

between

the

chasis

f rom

both

the

right and

left

side

to

prevent

rnovement

of

bodY

of

vehicle.

Fig.

2

Wadge

Loosen

all

eight

screws

from

the

front

hubs

(R.

L.),

slip

ggrage

iack

underneath,

iack

front-end

up

and

take

front

wheels off

Then,

place

rigid

rack

beneath

frame

on

both

sides

and

release

jack

slowly.

Pull

cotter

out

f

rom

ball

socket

asembly

which

links

steering

lever

and

drag

ring, unloosen

nut and

unloosn

ball

socket

using

special

tool

(TR

H-12

TIE-ROD

END

R

EMOVE

R.}

Draw

downward

to

pull

cotter

(A)

out,

8S

shown

in

Diagram

Fig.

3.

Place

(prage

jack

in

the

middle

beneath

center

beam

and

iack

up

so

top

of

jack

touches

the

front

axle

lightly.

A

B

Chassis

C

Center

beam

D

Center

E

Center

bush

F

Nipple

G

0.01-

O.03

in.

(0.4

-

1 mm)

FRONT

0.23 in.

(6

mm)

2.

3.

4.

A

t

I

0.39

(

10.4

1

tn.

mm)

E

I

v

D

Fig.

3 &nts

STEERING

LINKAGE

SYSTEM

5.

At

the

forward

section

of

the

center

pin,

there

is

a

groove

where

an

special

tool

(BT-9

OPEN

END

WRENCH

SET

19 x

211

can

be

inserted,

as

shown

in

Diagram

Fig. 4. By

manipulating

the

wrench,

right

to

left,

unloosen

center

by

pulling

forward.

Caution:

When center

does

not

dislodge,

tap

lightly

from

the

rur.

However, in

doing

this,

be

careful

not

to

raise

iack

too

high

or

let

iack

down too

lovu

but,

have it

iust

right

or

the

may not

dislodge

and

the

center

bush

may be

scratched.

As

the

center

is

withdrawr'l,

the

entire

front

axle will

rest on

jack.

Release

iack

slowly,

simultaneously,

pulling

foruard.

This

will cause

front

axle to

dislodge

from

chassis.

3-2.

Disasemhling

King

and

Front

Hub

1.

Either let

front

axle

rest

on

rigid

rack

or

have

large-size

vise

hold

on

to

entire

front

axle.

2.

Loosen

nut

from

bolt

(M16

x

65),

securing

beam

extension

from

center beam

and

unloosen

bolt

as

well

as

beam

extension

(

R

. L. ) .

Caution:

Because

disasembling

of

parts

from

both

right

and

left

beam

extension

is the

same,

except

for

the

steering

lever, disasembling

instruc-

tion

for

beam

extension

located

on the

other

side

is omitted.

3.

With a

large-size

vise,

hold

beam

extension.

Take

hub

cap

(A)

off

,

as

shown

by

Diagram

Fig.

5,

take

slotted

nut

(B)

off

and

pull

the

entire

front

hub

(D)

off

from

the

king

(l).

Since

the top

section of the

king

is

connected

to

the

steering

lever,

release

and

unloosen

bolt

(M12x7O)

(U),

placewedge

in

opening

of

steering

lever

to

widen

opening,

and

pull

steering

lever

upwardl then,

pull

key

(P)

out.

Caution:

When ke/ withdrawn,

king

will

fall

downward on

its

own

weight

thus,

be

careful.

Place

hand

beneath

king

and

pull

downward.

King

will not

dislodge

with ease

when

not

properly

lubricated

after

lengthy

use.

Tap head

of

king

with

plastic

hammer

to dislodge.

A

Hub

cap

B Slotted

nut

C

Washer

D

Front

hub

E

Screw

F

Taper

roller

bearing

(outer)

G

Oil seal

H . Taper

roller bearing

(inner)

I

King

J

Thrust bearing

K Center

bush

L

King

bush

M

Beam

extension

N

"O"

ring

(Upper)

tLower)

O

Steering

lwer

(R.H)

P

Key

O

"o"

ring bush

R

Oil

sel

plate

S

Grease

T

Heel

U Bolt

6.

4.

5.

Fig.

4

Center

(21

mml

Fig.

5

King

and

Front Hub

STEERING

LINKAGE

SYSTEM

6.

Wash

all

parts

in

cleaning

solvent.

lnspect

all

parts

closely

for

galling,

nicks, etc.

4.

Assembling

(Adjusting)

0rder

Though

asembling

is

done

in reverse

order

of

disasembling,carefully

check

and

adjust

the

following

points

while asembling.

Furthermore,

refer

to Fig.

5 when

assembling.

+1

. Asembling

for King Pin and

Front

Hub

1

.

After

the

inner

laces of taper

roller

bearing

(inner

and

outer)

located within the

front

hub

had been

washed

in

cleansing

solvent, air

dry

and

thorough-

ly rub

special

wheel

grease

to

them.

2.

Place

taper

roller

bearing

(in)

in

hub

toward

king

pin,

insen

oil

seal

plate,

and

insert

oil

seal by

apply ing

pressure

with

special tool

(2050T01

,

FRONT

HUB

OIL SEAL

PRESSURE

TOOL}.

Then

grease

(S)

ponion

of

hub.

3.

R

id

k

ing

of dust

and

appf

y

grease

lightly.

Replace

with ngt/

"O"

ring

to

"O"

ring

bush

(O)

and

assemble

from

upper section

of

king

and

inseft

oiled thrust bearing.

Clamp

heel

(Tl

ponion

of

king

with

vise.

4.

Bearing.

Assembled front

hub

with

oil seal

insert-

ed in

king

folloued

by taper

roller

bearing

(outer) (F),

washer

(C),

and bearing

tightened

with

slotted

nut

(B).

After

slotted

nut

tightened,

nut

turned

counterclockwise

1/1

6

turn

and

a naru

cotter

insefted

tightly

and

secured.

Then,

gasket

placed

prior

to

replacing

hub

ctrp.

5.

Relationship

between

king

and beam

extension

(M).

When

tolerance

between

king

and

king

bush

(L)

and

center

bush

(

K)

exceeds

0.011

in.

(0.3

mm),

bush

or

the

king

need

be

changed; thus,

check

these

parts

closely.

King

standard

measurement:

1.18

oin.

(30

6mm)

Bush

standard

measurement:

1

.1

8

o

in.

(30

6mm)

When measurement

for

both

king

and bush

meet

the

standard

requirement,

appfy

grease

light-

ly

to

k ing

,

place

"O"

ring

bush; then

insert

thrust

bearing.

6.

Using

special

tool

(2050TO2,

BEAM

EXTENSION

BUSH DRIVER), drive

king

bush

(L)

and

center

bush

(K)

into

beam extension

(M).

There is

a

groove

inside

the

bush of

king

bush

(L).

Place

nqry

"O"

ring

(N)

(up)

in

it.

7.

Assemble set

of

king

pins

put

together

previously

from

beneath

beam

extension

(M)

and

drive

in

key

(P),

carefully,

not

to

let the

king

drop

on

its

s1*1r

weight. lnsen steering

lever

(R.L.),

link

with

link

bolt

(U)

and

set

lock

nut into

place

with

special tool

(

1

860 QL,

TOR

QU

E WR E

NC

H

)

at

43,3

ft-lb

(6

kg-m).

8.

Atrer

assembling

completed,

inseft

grease

through

grease

nip so

grease

a

pears

from

the

rear section

of

king

pin.

Then, check

whether

or

not

king

revolves

smoothly

right

to

left.

+2.

Assembling

of Entire

Front

Axle

Refer to Fig.

3

at

time of assembling.

Standard

diametric

measurement for

center

(D)

is 1.18

Oin.

(30

omm).

There

is

no

over-size

or under'

size;

thus,

when tolerance for both

and

bush

(E)

exceeds

0.011

in.

(0.3

mm), replace

thern.

1

.

Apply

grease

lightly

to

contact

point

of

center

pin.

2.

Drive

center

p

in

bush

(E

)

into center

beam

(C)

with

special tool

(2050T03,

CENTER

BUSH

DR

IVER)

and

apply

grease.

3.

Raise

entire center

beam

with

jack

and

align

chassis

with

section

to be brought

together

and

lightly

drive in center

from

the

front.

Ulti-

rnately,

to

set

the

position

of the

center

pin, place

wrench on

wrench

catch,

as

shown

in

Fig.

4.

Align

hole

so

can be

inserted,

drive

(A)

from

beneath,

insert

thrust

washer, insert

and

secure

cotter

pin.

4.

Verify

(G)

in

Fig.

3, with

special tool

(No.

26,

FEELER

GAUGE),

in

other'words,

opening

b*

tween

chassis

(B)

and

center

bush

(E).

Shsuld

be

0.01

^,0.03

in.

(0.4

^,

1

mm).

Apply

grease

through

grease

nipple

and

be sure

grease

exudes

from

space

(G).

5.

First,

insert

prwiously

assembled

beam

extension

(

L.

H.

)

to

both

extremes

of center

beam,

insert

bolt

(Nnt6

x

65),

pass

spring

washer

through it

and

secure

with nut

(N16).

Then,

set

front wheel

in

place

and secure with front

hub

screw.

Further,

lock

the

lock

nut from

backside.

Lower

and

pull

jack

forward"

STEERING

LINKAGE

SYSTEM

5.

Should

be

0.01

-

0.03

in.

(0.4

^,

1

mm). Apply

grease

th

ro

ugh

grease

n ip

p

le

a

nd

be

su

re

grease

exudes

from

space

(G).

First,

insert

previously

assembled

beam

extension

(

L.

H.

)

to both

extremes

of

center

beam,

insert

bolt

(M16

x

65),

p€tss

spring

washer

through

it

and

secure

with nut

(N16).

Then,

set

front

wheel in

place

and

secure

with

front

hub screw.

Further,

lock

the

lock nut

from

backside. Lower

and

pull

jack

forward.

Asemble

ball

socket

asembly

linking

steering

lever

and

drag

lug,

secure

with lock

nut, and

insert

and

bend

cutter

pin.

5.

Disassembling

0rder

$l

. Disasembling

0rder

of Steering

ln

order to

d

isasemble the

entire

steering, the

following should

be

adhered

to.

Refer

to Fig. 6,

7.

1.

Remove

steering

wheel

cap

(A)

,

pull

out

cotter

pin,

unbolt

slotted

nut

(C)

,

atuch

special tool

(T.608,

UNIVERSAL

STEERING

WHEEL

PULLER) to

steering

whel and

remove

wheel

(B)

,

remove

kerr

(E),

and

remove end cap

(F).

6.

H

I

J

K

L

A

B

c

D

E

F

Steering

wheel cap

Steering

wheel

Slotted

nut

Washer

Key End

cap

Circlip

Washer

(1

)

Circlip

Rubber

cushion

Washer

(1

)

Washer

(2)

G H

I

J

K

L

Fig.

6

-I

STEERING

LINKAGE

SYSTEM

5.

2.

3.

Open bonnet, d

isengge

battery

cord

(black-

yellow)

to

prevent

short-circuit.

Drain

f

uel

from

f

uel tank.

After

completely

draining

fuel,

disengage

fuel

line and

remove

fuel

tan

k.

Caution:

Becuase

of

inflarnability

of

fuel,

precau-

tion

is

necessary

while

at the

same time,

measures

must

be

taken

to

prevent

foreign maters

from

entering

f

uel

line.

Frorn

behind

the

instrument

panel,

disengage

tractor

cable

and throttle

wire,

and

all electrical

wirings

such as

starter

sruitch,

light

switch

(red/

blue,

red,

red/white)

,

regulator

connector,

tractor

meter

lamp socket,

and

thermometer

connectiOns.

M Key

N

Steering

worm

gpar

O

Screw

P

Taper

roller bearing

-

-O

Flange

packing

R

Shim

S

Steering

box

T Taper

roller bering

U

Worm wheel

V Pitman

W Grooue

X

Column

gtpport

Remove

steering

box

cover

assembly

screw

(six

screws

to box

M8

and

four screws

to

instrument

panel

MB).

Couple

of bands

on

top

side

of

cover

used

to

secure

fuel

tank but

need

not

be

removed.

Remove

lever

holding steering column support

located above

instrument

panel

and

rernove entire

instrument

panel.

Remove

the

four

screv\6,

M

10,

securing

entire

steering

box

to

clutch housing

and

raise

steering

box.

For

this

purpose,

hno

dovels emplaced to

secure

position;

thus, entire box

*rould

be

remov-

ed straight upward.

After

draining

oil

from

steering

box,

place

steering

box

horizontally

in vise.

6.

7.

4.

8.

Fig.

7

St*ring

Box

STEERING

LITUKAGE

SYSTEM

f+8

WitZ8ox

Referring

to

Fig.

8, remove three

pieces

of

screws

(F)

and

remove bearing

housing

(B).

Remove

four

pieces

of

screws

(J)

and

pull

out

bearing

housing

(A).

Pitman

(B)

and

pitman

arm

(P)

need'not

be

dismantled

at

this

time.

However,

if

oil

seal

(N)

must

be

changed,

replace

seal

by

removing

pitman

arm.

Remove

worm

wheel

(H)

upward.

Referring

to

Fig.

6

and

7, remove

four

pieces

of

screws

(O)

and

pull

upward

to

disengge

entire

column

support

(X).

To

disassemble

steering

mast

(L)

from

column

support

(X),

remove

circlip

(on

side of

mast)

(G)

using

special

tool

(S-0

SNAP-

RING

PLIER),

remove

washer

(H),

removecirclip

(on

side

of

column

support)

{l)

with

special

tool

(H-1,

SNAPRING

PLIER), remove

(H)

(L)

washer

(1)

(2t,

remove

by

pulling

upward

on

rubber

cushion

(J)

and

remove

washer

(K)

{1}

and

(L}

l2l

to allow

removal

of

steering

mast

to

the

rear

of

column

supporter.

Then,

because

steering

mast

and

steering

worm

bear

(N

)

are attached

rather

securely,

tap

steering

worm

gear

(N)

with

either

wood

or

plastic

hammer

to

separate.

lnner

lace of

taper

roller bearing

(P.T.)

in

steering

worm

gear

assembly

should

be

pulled

out

by using

A

Bearing

housing

B

Pitman

C

Taper

roller

bearing

D Liner

E

Gasket

F

Ssew

G

Steering

box

H Worm

wheel

I

Gasket

J

Screw

K

Bearing

housing

L

Mark

position

M

Ball

bearing

N

Oil

seal

O

Key

P

Pitman

arm

O

Washer

R Nut

the

inner

bearing

puller.

Attach

special tool

(2100T04,

STEERING

TAPER

ROLLER

BEARING

OUTER

I-ACE

PULLER)

to

groove

of outer

lace

(w)

to

remove

outer

lace

of

bper

roller

bearing

(T).

9.

10.

6-l .

1.

6.

Assembling

(Adiusting)

Order

Asembling

(Adlustingl

0rder

of Steering

Caution:

Arrange

in

order disesembled

pars

washed in cleaning solvent so

they can

be asembl-

ed

at ease.

However,

do

not

rnash

rubber

cu*rion

in

cleaning

solvent.

Refer

to

Fig. 6

and

7 in

regard

to

steering mast.

First,

apply

pressure

to

insert

taper

rolling

bearing

(P.T.)

into

steering

worm

gear

(N)

by using special

tool

(21OOTO1

,

STEERING WORM

GEAR

T.

R.

B.

INSERTER

PLATE). Tap

taper

roller

bearing

(T)

outer

lace

into

steering

g€r

box

with

special

tool

(21OOTO3,

STEERING

GEAR

BOX

T. R.

B.

TAPPING TOOL). Then,

mount

g€ar

box

on

vise

11.

I

STEERING LINKAGE

SYSTEM

in

horizontal

position.

Tap

key

(M

)

into

steering

worm

gear

to connect

steering

mast

(L),

lnsert

column

support

(X)

from

top

section

of

th

is

u

nif

ied steering

mast

and

place

washer

(K)

in

proper

position,

press

rubber

cushion

(J)

in,

insert

washer

(H)

and

insert serclip

(G

)

by

using

specia

I

tool

(S'0

SNAPR

ING

PLIE

R). By use

of

special

tool

(H-1,

SNAPRING

PLIER),

attach sercl

ip

(l)

on the

side

of

column

support

(X)

.

Thereafter,

replace and

cap

(F

).

So

that

end

cap

(F)

does

not

fall

off

,

place

key

(E)

into

mast

and

to

pre\€nt

key

(E)

from falling off

,

secure key with

cellotape.

Steering

mast,

\

rorm

gear,

column

support,

etc,

completely

asembled.

lnstall flange

packing

(O)

to

steering

mast

(do

not apply

three

bond

to

packing

at this

time) and

asemble

with

steering

gear.

Securely

tighten

with screw

(O);

then,

apply

faru

drops of oil

to taper

roller

bearing

to

loosen

it.

When

assembling

is completed,

check

to

see

if

taper

roller

bearing

thrust

play

is

0.003

-

0.005

in.

(0.1

^,

0.15

mm).

lf necessary,

inseft

shim

(R)

between taper

roller

bearing

(P)

and

column

support

(x)

.

When thrust

direction

play

is

set,

remove

scra^,

(O)

bv

tapping

at

86.7

'-,

123

ft-lb.

(1/

-

17

kgml

and

secure

tightly.

Secure

with

special

tool

(1800

QL

TOROUE

WRENCH}.

Scranv

Taper

roller

bearing

Front

pack

ing

Shirn Steering

gear

box

Column

support

Referring

to

Fig.

8,

press

ball

bearing

(M)

into

bearing

housing

(K)

from

inside

and

insert

oil

seal

with

special

tool

(2100T03,

olL

SEAL

PRESS

TOOL).

lnsert

pitman

(B)

with

press

into bearing

housing

(K).

lnsert

key

(O)

into

pitman

(B),

set

washer

(O)

and

spring

waslrer

in

place

and

tighten

nut

{R)

slightly.

Attach

gasket

(l)

to asembled

bearing

housing

(K)

and

insert

in

steering

box

(G)

while

inserting

pitman

wheel

(H)

into

front

end of

pitman.

ponch

position

(L)

on

pitman

spline

and

pon

4

location

on

pitman

whel

brought

together

as

shown

in

Fig.

10.

When the

ponch

is

brought

into

position,

secure

with

screw

(J)

at

torque

86.7

-

123 ft'lb.

n2

^'

17 kg-m).

Pitman

wheel

(H)

is

secured

to

pitman

(B) (1)

seaion.

6.

2

7.

8.

3.

9.

4.

5.

X

o

s

R

P

R

S

X

o

P

O

Fis.

9

STEERING

LINKAGE

SYSTEM

Pitman Wheel

Ponch

Mark

Fig.

l0

Press

ball bearing

(C)

into

bearing

housing

(A)

and

attach

gnsket

{E},

asemble

in

steering box

so ball

bearing

(C)

and

pitman

coincides.

Then secure

with

screw

(F).

Measure

space between

pitman

wheel

and

pitman

at

(2)

with special

tool

(No.

26,

STANDARD

FEELER

GAUGE).

Space

should

be

0

,-,0.011

in.

(0

-

0.4

mm).

lf

necessary, adiust

by

placing

liner

(D)

in

space.

lf

measurement

correct,

once

again,

disassemble

bearing

housing

(A),

rub

three bond

to

gasket

and

put

together. Cover

screw

(J)

with

tape

seal

(oil

Pitman

Ponch

Mark

sealing

tape)

and

secure

at torque

13

ft-lb.

(15

kgrm).

After

assembling

completed,

assemble

entire box

to

clutch

housing,

and

after

filling

0.704

pt

(0.40

P)

of oil,

replace instrument

panel,

electrical

wiring,

etc. , accord

ing

to

reverse

order

of

reas-

sembling.

Finally,

test and

adjust,

according to

Wheel Align-

ment

Data.

I

,1,

Pitman

Key

(O)

10.

12.

13.

11.

Saton S-650G Repair Manual

Specifications and Main Features

Frequently Asked Questions

User Manual