Toro 20044, 20046, 22170, 22171, 22172 Service Manual

KAWASAKI FC150V ENGINE MANUAL

Table of Contents – Page 1 of 3

GENERAL INFORMATION

MECHANICAL SYSTEM
ELECTRICAL SYSTEM

GENERAL SPECIFICATIONS

WIRING DIAGRAM

ELECTRIC STARTER MODEL

PERIODIC MAINTENANCE

TROUBLE SHOOTING

ENGINE - HARD STARTING
ENGINE - MALFUNCTIONS AT LOW SPEED
ENGINE - ERRATICAL RUN
ENGINE - EXCESSIVE OIL CONSUMPTION
ENGINE - LOW POWER
ENGINE - EXCESSIVE FUEL CONSUMPTION
ENGINE - MALFUNCTIONS OF STOPPING

TORQUE SPECIFICATIONS

CONTROL SYSTEM

GOVERNOR LEVER SETTING
THROTTLE CABLE INSTALLATION
FAST IDLE SPEED ADJUSTMENT
CHOKE ADJUSTMENT
SLOW IDLE SPEED ADJUSTMENT

AIR CLEANER

"K" KLEEN SYSTEM
MAINTENANCE

CARBURETOR

COMPONENTS
REMOVAL
FLOAT CHAMBER REMOVAL
CLEANING
FLOAT ADJUSTMENT
ASSEMBLY AND INSTALLATION
CARBURETOR IDENTIFICATION

COOLING SYSTEM

ENGINE COVER REMOVAL
ENGINE COVER DISASSEMBLY
ENGINE COVER ASSEMBLY AND INSTALLATION

RECOIL STARTER

DISASSEMBLY
CHECK
REASSEMBLY

KAWASAKI FC150V ENGINE MANUAL

Table of Contents – Page 2 of 3

ELECTRIC STARTER & CHARGING

TROUBLE SHOOTING
STARTER MOTOR CHECK
COMPONENTS
RING GEAR CHECK
STARTER MOTOR REASSEMBLY
STATOR OUTPUT

IGNITION SYSTEM

TYPE OF IGNITION SYSTEM
SPARK CHECK
CONTROL UNIT CHECK
IGNITION COIL CHECK
FLYWHEEL REMOVAL

FLYWHEEL INSTALLATION

IGNITION COIL AIR-GAP ADJUSTMENT
INTERMEDIATE CONNECTOR INSTALLATION
THROTTLE-LEVER-LINKED ENGINE SWITCH
BAND-BRAKE-LINKED ENGINE SWITCH

CYLINDER HEAD

COMPRESSION CHECK
REMOVAL
MAINTENANCE
INSTALLATION

VALVE

VALVE CLEARANCE ADJUSTMENT
AUTOMATIC COMPRESSION RELEASE (ACR) CHECK
VALVE AND RELATED PARTS REMOVAL
ROCKER ARM STUD INSTALLATION
CHECK AND MAINTENANCE
SERVICE LIMIT
VALVE SPRING SERVICE LIMIT
LAPPING
VALVE SEAT RECONDITIONING
VALVE GUIDE SERVICE LIMIT
ROCKER ARM SERVICE LIMIT
PUSH ROD SERVICE LIMIT

CRANKCASE COVER

REMOVAL
SERVICE LIMIT
OIL SEAL REPLACEMENT
INSTALLATION

KAWASAKI FC150V ENGINE MANUAL

Table of Contents – Page 3 of 3

CAMSHAFT

REMOVAL
VISUAL CHECK
SERVICE LIMIT
INSTALLATION

PISTON & CON-ROD

REMOVAL
PISTON AND PISTON RING VISUAL CHECK
PISTON CLEANING
PISTON SERVICE LIMIT
PISTON PIN SERVICE LIMIT
PISTON RING SERVICE LIMIT
PISTON RING INSTALLATION
CON-ROD VISUAL CHECK
CON-ROD SERVICE LIMIT
PISTON AND CON-ROD ASSEMBLY
PISTON/CON-ROD ASSY INSTALLATION

CRANKSHAFT

VISUAL CHECK
SERVICE LIMIT
INSTALLATION
CRANK PIN RE-GRINDING

GOVERNOR

GOVERNOR GEAR CHECK AND REMOVAL
GOVERNOR GEAR INSTALLATION
GOVERNOR SHAFT INSTALLATION

LUBRICATING SYSTEM

ENGINE OIL
OIL SLINGER CHECK
BREATHER SYSTEM
BREATHER REED VALVE CHECK

CYLINDER/CRANKCASE

CYLINDER SERVICE LIMIT
CYLINDER BORE RE-SIZING
BALL BEARING CHECK
BALL BEARING REPLACEMENT
OIL SEAL REPLACEMENT
CAMSHAFT BEARING SERVICE LIMIT

BAND BRAKE

BAND BRAKE MECHANISM
BRAKE SHOE REPLACEMENT
BRAKE CABLE ADJUSTMENT

4=stroke

air-cooled

gasoline

engine

WORKSHOP

MANUAL

FOREWORD

This manual
nics in a properly equipped

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

Whenever you see these

T

I

0

Always follow safe operation and maintenance prac­t ices.

A

ual and on the equipment. When you see this symbol,
read the message that follows very carefully to
avoid fire, personal injury,

C

A

UT

or

procedures to avoid equipment damage

t ion.

N

0

T E :

interest for more efficient

is

designed for

N

symbols, heed their instructions!

W

A

R N I N

tifies important safety messages in this man-

I 0 N

Indicates message

G

:

:

This

identifies special instructions

use by trained mecha­shop.

or

equipments are

or

equipment.

W

A

R N I N

This safety alert symbol iden-

or

or

and convenient operat ion.

G

AND

C

A

U

loss

of life.

or

destruc-

points of particular

The term "Replace" and some abbreviations are used
as follows:

Replace

MIN
MAX

Assy

STD

PTO
Approx.
Carb.
Con-rod
Cyl.
Dia.

All

may be reproduced, stored in a retrieval system,

or

tronic mechanical photocopying, recording
wise. without the prior written permission of Engine
Division/Kawasaki Heavy Industries, Ltd.

ty can be accepted for any inaccuracies

in this publication, although every possible care
has been taken to make it as complete and accurate
as possible.
ject to change without prior notice
Illustrations in this publication are intended for
reference use only and may not depict actual model
component parts.

=

Usually means replace with a new part

=

Minimum

=

Maximum

=

Assembly

=

Standard

=

Power take off

=

Approximately (Approximate)

=

Carburetor

=

Connecting rod

=

Cylinder

=

Diameter

rights reserved.

transmitted in any form

All

procedures and specifications sub-

NO

part of this publication

or

by any means, elec-

or

other-

No

liabili-

or

omissions

or

obligation.

EOOFCOIW9

SAFETY

WA

R

W

A

R N I N

mable and can be explosive under certain con- sembly operations on the equipment with the

A

ditions. Stop the engine. Do not smoke. Make sure electric starter, disconnect the negative
the area
of flame
a pilot light.

the spark plug wire from the spark
accidental starting.

A

in servicing the product.

is

or

W A R

equipment, always stop the engine and remove

WARN I NG

or

a piece of thick cloth from edges and heat

G

:

Gasoline

is

extremely flam-

__--

well ventilated and free from any source lead from the battery to avoid the possibility of
sparks; this includes any appliance with accidentally cranking the engine while partially

disassembled.

N I N G

When servicing the engine

or

A

plug

to avoid

:

Protect your hands with gloves

in a clean. dry environment with dry hands. For max­imum shock hazard protection, connect the equipment

ground terminal to an earth ground.

N I N G

W

A

R N I N G

when working on the electrical equipment. Work

:

Before performing any disas-

:

Always minimize shock hazards

EO1FC1W1

TABLE

OF

CONTENTS

PI STON
PI STON
PI STON
PI STON

1

STON

P
PI STON

GOVERNOR

GOVERNOR GEAR CHECK AND REMOVAL
GOVERNOR GEAR INSTALLATION
GOVERNOR SHAFT INSTALLATION

60
60

60
60

1

1

GENERAL

Be famil iar with OPERATOR’

Lubrication
Supply engine oil as specified even for a short
test running to avoid any score
which may destroy the engine in the field use.
Use clean engine oil in the case specified as just
“coat oil” in this manual.
Don’ t use just any
greases
applications and may be harmful if used in an ap­plication for which they are not intended.
Engine wear
engine
surfaces have an adequate lubricative film. During
assembly, oil or grease (whichever
should be applied to any rubbing surface which has

lost its lubricative film. Old grease and dirty oil

should be cleaned off. Deteriorated grease has lost

its

foreign particles.

Fuel
Unleaded gasoline
of the less deposit in the combustion chamber.
Alcohol mixed gasoline
bad influences

in the fuel and combustion systems.

in

particular should be used only

is

is

warming up and before all the rubbing

lubricative quality and may contain abrasive

oil

generally at

is

of

alcohol on the engine components

S

MANUAL before service.

in

the engine,

or grease. Some

its

maximum while.the

preferably recommended because

is

not recommended due to

oils

and

in

certain

is

more suitable)

I

NFORMAT

Dirt
Before removal and disassembly, clean the product.
Any dirt entering the product, carburetor, or other
parts will work as an abrasive and shorten the life
of the product. For the same reason, before install-

ing

a

Liquid Gasket and Non-permanent Locking Agent
Follow manufacturer’s directions for cleaning and
preparing surfaces where these compounds wi
used. Apply sparingly. Excessive amounts may block
engine oil passages and cause serious damage. An
example of a non-permanent locking agent commonly
available in

(Blue).

Oil Seal, Grease Seal
Replace any oil or grease seals that were removed,
because the removal generally damages seals.
A seal guide
seals during installation
seal lips.

Gasket, 0-r
When
O-ring, replace
gasket should be free from foreign matter and smooth
to avoid leakage.

I

ON

new part,

in

doubt as to the condition of a gasket or

’

clean off any dust

North

America

is

required for certain oil or grease

ing

it.

The mating surfaces around the

or

metal fillings.

11

be

is

Loctite Lock’n Seal

to

avoid damage to the

High Flash-point Solvent

A

high flash-point solvent

fire danger.

in

North America
Always follow manufacturer’s and container’s direc­tions regarding the use of any solvent.

A

commercial solvent commonly available

is

Stoddard solvent (generic name).

is

recommended to reduce

Circl ip, Retaini,ng Ring
Replace any circlips and retaining rings that were

removed, because the removal weakens and deforms
them. When installing circlips and retaining rings,
take care to compress or expand them only enough to

install them.

2

2

GENERAL

Force
Common sense should dictate how much force

sary in assembly and disassembly.
especially difficult to remove
check what may be causing the problem. Whenever tap­ping

is

necessary, tap lightly using a wooden or
plastic-faced mallet. Use an impact driver for
screws (particularly for the removal of screws held
by a locking agent) in order to avoid damaging the
heads.

Press

A

part, such as a seal, installed using a press or

driver should first be coated with oil on

.or inner surface

smoothly.

Ball Bearing Installation
When installing a ball bearing, the bearing race
which

is

affected by friction should be pushed by a

suitable driver. This prevents severe stress on the

balls and races, and prevents races and balls from

being dented. Press a ball bearing until it stops

at the stop

so

that

it

in

the hole or on the shaft.

If

or

install, stop and

will go into place

is

neces-

a part seems

its

outer

I

NFORMAT

Torque
The torque values given
always be adhered to. Either too little or too much

torque may lead to serious damage. Use a good quali­ty, reliable torque wrench.

Tightening Sequence
follow
When installing a part with several bolts, nuts or
screws, they should all be started in their holes
and tightened to
evenly, according to the tightening sequence, to

the specified torque.
of the part and/or leakage. Conversely, when loosen-

ing the bolts, nuts,

about a quarter of a turn and then remove them.

I

ON

the

tightening sequence shown

a

snug fit. Then tighten them

in

this manual should

in

this manual.

This

is

to avoid distortion

or

screws, loosen all of them

EOSPCOIW7

3

3

GENERAL

No

Shock
The electrical parts should never be sharply struck,
with a hammer, or dropped on a hard surface. Such
a shock to the parts may damage them.

Electrical Leads

All

the electrical leads are either single-color or
two-color and,
connected to leads of the same color. On any of the
two-color leads, there
color and lesser amount of second color,

color lead
and then the second color. For example, a yellow
lead with thin red stripes
“yellow/red” lead;

if the colors were reversed to make red the prime

color.

TWO-COLOR

(cross-sect ion)

with

only a few exceptions,

is

greater amount of prime

is

identified first by the prime color

is

referred to as a

it

would be a “red/yellow” lead

LEAD

must

so

the two-

red

Lead

red’

I

NFORMAT

Defective Component
Never replace
out determining what caused the failure. If the
failure was brought on by some other item or items,
they too must be repaired or replaced, or the new
replacement

be

Connectors

~-

Make sure all connectors in the circuit are clean

and tight, and examine leads for signs of burning,
fraying, etc. Poor leads and bad connections will
affect electrical system operation.

Coil Resistance
Measure coil add winding resistance when the part

is

cold (at room temperature).

Battery

~-

Do

not disconnect the battery leads or any other

electrical connections when the ignition switch

is

on, or while the engine

specifically noted.

Do

not reverse the battery lead connections.

will burn out the diodes or other parts

electrical systems.
Always check battery condition before blaming other
parts of an electrical system.
battery

system check.

Starter
Never keep the starter engaged if the starter motor

will not

starter motor windings.

I

ON

a

will

is

a must for performing accurate electrical

turn

over, or the current may burn out the

defective electrical component with-

fail again.

is

running, unless

This

in

the

A

fully charged

Name of

Lead Color

ye

1

1

ow/red

KAWASAKI
KAWASAKI

mended for the electrical system check because a
meter of other type may indicate different value.

Multimeter­Multimeter

(P/N

395100-9803A)

is

recom-

4

4

Number of Cylinder

Oil

Pan Capacity

GENERAL SPEC

I F I

CAT

I

ONS

~__=.-

Automatic (with Throttle Control)

FC15OV

1

3200

rpm cf. Note

Mechanical Flyweight Type

0.55

L

(1.16

US

Pt)

1.

3

g.

37

us

qt.

4

Note

:

one Type with Dual Element

ransistorized Flywheel Magneto

V

0.5

A

with Diode

Per Canada and USA Requirement

12

V

0.2

kW

Bendix Type

Mechanical Flyweight

Band Brake on Flywheel

1.

Specifications are subject to change without notice.

2.

ACR = Automatic Compression Release.

3.

Parts with * are option.

is

4.

Fast idle speed may vary depending on each equipment on which eng

specification.

ine

used. Refer to the equ

ipment

5

5

1.

Portion surrounded

procurement parts.

A:

Engine

B:

Spark plug

C: Ignition coil

D:

Charging coil

E:

Control unit

P:

Connector

G:

Stop switch

H:

Key switch

I:

Battery

J:

Discharge chute interlock switch

K:

Control lever

1:

Starter

Lead Color

by

(3P)

WIRING DIAGRAM

hatching shows

KAWASAKI

1

E.

1:

Red

2:

Black

3:

Yellow

E06PC09W2

6

PER

I

OD

I

C

MA

I

NTENANCE

To ensure satisfactory operation over extended period of time, engine requires normal maintenance at regular

intervals.

Chart below shows periodic maintenance. Suitable interval

MAINTENANCE

is

shown as

Daily

(0).

Every

25

I

NTERVAL

Every

hr

50

Every

100

hr

Every

300

6

Check and add engine oi
Check for loose
Check for fuel and oil leakage.
Check battery electrolyte level.
Check and clean air intake screen.

Clean engine switch and control panel on engine.

**

Clean air cleaner foam element.

Tighten nuts and screws.

Clean fuel filter.

*

Change engine oil.
Check band brake system on engine.
Check and adjust band brake cable.

**

Clean air cleaner paper element.
Clean and regap spark plug.
Clean combustion chamber.
Check and adjust valve clearance.

or

1.

lost nuts and screws

(first)

Clean and lap valve seating surface.

**

Replace air cleaner paper element.

**

Clean cylinder and cylinder head fins of dust and

Ir Perform these maintenances after first

**

Service more frequently under dusty conditions.

5

hours of use, then at recommended intervals.

7

7

I

Remove spark plug and
check spark by crank-

ing engine while hav­ing the plug grounded

against engine block.

Install spare plug to
plug hole to avoid
fuel spitting
ha le.

Make sure to hold plug

from

YES

the

Are sparks produced
when spark plug

lead and engine
block
plug cap

Are sparks produced
between high tension
lead and engine
block when control

unit

TROUBLE

in

state where

is

removed?

is

replaced?

SHOOTING

is

elty

I

spark plug. Replace

plug cap terminal Correct

Faulty high tension Rep1 ace

Incorrect ignition Correct

Is

compression

sufficient?

Check carburetor.

Demagnetized fly- Rep ace

Rep lace

I.---

Crank engine several
times and then re­move spark plug and
observe electrodes.
Are they wet?

’

YES

*No

fuel in the tank.
*Clogged fuel filter. Clean
.Plugged air hole in Clean

tank cap.

*Plugged fuel line. Clean

Excessive use of

Clogged air cleaner.

*Too

high fuel level

in float bowl.

Open choke

Clean

Adjust

~_-

Worn piston/piston

ings.

*Stuck piston rings.

Worn cyl. bore.

Insufficient cyl.
head tightening.

I-

*Check for plugged

fuel passage.

.Check

for

plugged
air passage,
Check float level.
Check carb. set-

t

ing.

*Faulty contact of Lap

valve seat.
Plunged-up valve.

Warped cyl. head.

Broken valve spring. Replace
Stuck valve. Clean
Burned head gasket.

Replace
Clean

or

replace

Bore

or

replace

Retighten

Adjust

Repair

Replace

or

replace

or

grind

EOOPCOIW4

8

8

I

Remove spark plug and
check spark by crank-

ing engine while hav­ing the plug grounded

against engine block.

Install spare plug to
plug hole to avoid
fuel spitting from the

hole.

To avoid electric

shock, do not hold

plug itself.

Make sure to hold plug

cap.

STRONG Incorrect ignition coil air Correct

TROUBLE

Faulty plug insulation.
Fouled electrodes.

*Faulty high tension cord. Rep

SHOOT,I

NG

1

ace

Is

unusual smoke emit-

ted out of muffler?

Directly and gradually
open throttle valve by
hand. Does revolution
drop or does engine
stall at a certain
position?

Is

air drawn through

carburetor flange?

Is

valve clearance Compression leakage through

NO

YES

NO

*

Overrich fuel
slow system.

I

*Plugging in carburetor

interior.

Loose flange nuts. Tighten
Damaged gaket. Replace

in

carburetor Adjust

Clean

Is

alignment

of

timing

EOBPCOZW4

9

9

Problem
system

in

governor

TROUBLE

.Entry of dust

fuel pipe

.Air

1

ine.

*Plugged air vent of fuel Clean

tank cap.

*Plugged air/fuel passes in Clean

carburetor.

.Too

pilot air-screw.

Incorrect governor linkage Correct
adjustment.
Faulty governor spring. Rep 1 ace
Governor gear assy malfunc- Replace

t

ion.

SHOOT

or

or

vapour lock in fuel Remove

little opening of carb. Correct

I

NG

or

fuel filter.

Engine knocks

NO

Stale fuel.
Excessive carbon deposit
engine.

Excessive engine load.

Engine overheating. See LOW

.Plugged oil ring groove. C 1 ean
.High

oil

level. Correct

.Worn valve stems and valve Replace

guides.

.Oil

leakage along governor Rep1 ace

shaft.

.Oil leakage from oil seal.

*Oil

leakage from gasket.

.Oil leakage from drain plug. Retighten

Faulty breather valve. Repair

.Drain-back hole

chamber plugged.
Incorrect oil viscosity. Change

in

in

tappet

Change
Clean

Adjust

POWER

1

ace

Rep
Replace

or

Clean

or

replace

replace

Same as

HARD

STARTING.

I

EOIFCOBV?

10

10

Is

unusual

ted out of

TROUBLE

~Carb. not properly adjusted. Adjust
*Dirty or clogged air intake Clean

screens, shroud and engine
fins.
Carbon deposit
chamber.

*Wrong spark plug. Rep

NO--

I

*Too much or too little oil Correct

in crankcase.

Excessively contaminated Change

lubricating oil.

Clogged air cleaner. Clean
Carbon deposit

hole and muffler.
Carb. not properly adjusted. Adjust

SHOOT

I

NG

in

combust ion Clean

I

io

exhaust Clean

Adjust load

1

ace

Correct

Same as

sufficient?

sufficient?

Is

compress ion *Carb. not properly adjusted. Adjust

Clogged air cleaner. Clean

High id1 ing
Incomplete opening
valve.

HARD

STARTING.

R.

P.M.

___-

of

choke Open

Adjust

EOBFCO4W3

11

11

TROUBLE

(BAND BRAKE MODEL)

Engine does not stop

3

within
when being braked.

I

Does engine stop -+Faulty band brake.
within
when being braked?

seconds

10

seconds

I

*Faulty band brake.
.Faulty switch lead.

Faulty switch terminal.
Dirty switch terminal. Clean

Faulty switch lead. Replace

*Faulty switch terminal.

Dirty switch terminal. Clean

SHOOT

I

NG

Rep

1

ace

1

ace

Rep
Repair or replace

Rep

1

ace

Repair or replace

E08PC07W2

12

12

I

Governor arm nut

TORQUE

SPEC

I

F

I

CAT

I

ONS

12

N-m

7

N.m

7

N-m

23

N-m

45

N-m

6

N-m

7

N-m

3.5

N-m

7

N-m

7

N-m

7

N.m.(60 lbf-in

7

N-m

7

N-m

FC150

(105

lbf-in

(60

lbf-in

(60

lbf-in)

(205

lbf-in)

(33

lbf -ft)

(50

lbf-in)

(60

lbf-in)

(30

lbf-in)

(60

lbf-in)

(60

lbf-in)

(60

lbf-in)

(60

lbf-in)

__.___..___

3.5

N.m

(30

9.5

N-m

(85

3

N-m

(26

20-22

N-m

Side drain plug

21

(with plane washer)

Engine mounting flange bolt

BBC mounting bolt (M8)
General bolt

(M10)

38

28

18

3.5

15

j,

All bolts and screws especially for plastic part tightening

**

***

When new crankcase cover
first, then tighten it to specified torque to get good sealing face.

Do

not over-tighten it. Crankcase cover may be damaged.

BBC = Blade Brake Clutch

is

used, tighten plug to minimum specified torque and loosen it a little at

(180-190

N-m

(185

N-m

(340

N-m(250 lbf-in
N-m

(160

N-m

(30

6

N-m

(50

N-m

(130

Do

lbf-in
lbf .in)
lbf-in

lbf-in)

lbf-in)

lbf-in)

lbf-in

lbf-in)
Ibf-in)

lbf-in

not tighten completely at a time.

E09FCOZW4

13

13

Whenever carburetor

or

governor lever

CONTROL

is

removed from engine

SYSTEM

and then installed again. adjust governor lever position.

Install governor lever

on governor shaft

(B)

but do

(A)

not tighten nut (C).

(C)

Loosen nut
Turn governor lever
throttle lever on dash in

if it is tightened.

(A)

counterclockwise

"FAST*

position to open carb.

or

place

throttle valve fully.
Turn governor shaft

(B)

counterclockwise to end

of

travel.
Keeping governor lever position of throttle fully open,
tighten nut

(C).

Link throttle cable

clamp throttle cable outer housing

(G)

to speed control lever

(F)

temporalily.

(C)

and

With throttle lever on dash in "FAST" position, align

hole

(B)

of

speed control lever

control plate

or

6

mm bolt through two holes.

Pull

out throttle cable outer housing

(E)

and insert 6 mm

any slack and tighten cable clamp bolt

(C)

with hole

(0.24

in.) dia. pin

(F)

to remove

(A).

(D)

of

Remove 6 mm pin and set throttle lever on dash in

is

"CHOKE* position. Make sure carb. choke valve

~~

corn-

pletely closed. (See CHOKE ADJUSTMENT)

E

I6FCO6W2

E

16FCO?W2

14

14

CONTROL

NOT

E

:

Air cleaner must be installed to engine before

starting.

1.

Start and warm up engine without load.

2.

Loosen two control plate bolts

3.

Align hole
of control plate (E) and insert 6 mm
pin or

NOT

E

4.

Adjust fast idle speed for specified rpm (see GENERAL
SPECIFICATIONS) by moving control plate (E).

5.

Tighten two bolts
changing specified speed.

6.

Remove 6 mm pin, stop engine, and set throttle lever on
dash in "CHOKE" position.
Make sure carb. choke valve

(B)

of

speed control lever (C) with hole

6

mm bolt through two holes.

:

Make sure choke valve

(I)

securely in a manner to avoid

(I).

(0.24

in.) dia.

is

fully opened.

is

closed completely.

SYSTEM

(I))

!

1.

Align hole

of control plate

or

6

2.

Turn choke setting screw

is

clear of choke control lever
setting screw clockwise until it just contacts choke
control lever.

3.

Remove 6 mm pin and set throttle lever on dash
posit ion.
Make sure carb. choke valve

(B)

of

speed control lever (C) with hole

(E)

and insert

mm bolt through two holes.

6

mm

(0.24

in.) dia. pin

(K)

counterclockwise until it

(1)

and then turn choke

is

closed completely.

(D)

in

"CHOKE"

E16PCOSWZ

15

15

CONTROL

1.

Turn carb. pilot screw

then back out

2.

Start and warm up engine without load.

3.

Move throttle lever on dash to "SLOW" position.

4.

Adjust slow idle speed to specified rpm (see GENERAL
SPECIFICATIONS) by moving throttle stop screw (A).

5.

Adjust pilot screw

speed and then turn pilot screw out additional

6.

Re-adjust slow idle speed to specified rpm.

1

turn.

(B)

in until it just seats and

(B)

until engine idles at maximum

SYSTEM

1/4

turn.

E

I6FC

I

OW2

16

16

AIR

1.

Assemble related parts neatly to minimize air leakage.

2.

Do

not remove any parts constructing air passages when

running engine.

3.

Keep air passages free from grass and rubbish.

CLEANER

Air cleaner maintenance
to keep engine performing well.

Instruct users for following cautions.

1.

FOAM

ELEMENT

ed. Make sure to soak element
excessive oil, after washed.

2.

PAPER

ELEMENT

detergent and water.

Do

not use pressurized air to paper element to avoid

breakage.

Do

not oil paper element.

must be lightly oiled to perform as intend-

is

one of the most important items

in

engine oil and squeeze

is

cleaned by gentle tapping

or

washing in

E22FC03W2

E22FCO4W2

17

17

CARBURETOR

This carburetor

(idle mixture) and fixed main jet.

NOT

E

:

conf igulation.

is

float type with adjustable pilot screw

Refer to each parts catalog for detailed parts

10

E24FC08WS

18

W A R

N I

N

G

:

Gasoline

Avoid fires due to smoking or careless practices.

1.

Shut fuel valve.

2.

Drain fuel from float chamber.

3.

Disconnect fuel line
fuel line opening immediately

into suitable container.

4.

Disconnect breather tube

5.

Disconnect adaptor

6.

Remove bolts

c

A

UT

0

N

:

Do not lose collars in intake pipe bolt

holes.

(D)

(E).

is

extremely flammable.

(C)

from carburetor. Plug the

or

drain fuel

(A)

from intake pipe

from intake pipe

CARBURETOR

in

the line

(B).

(B).

18

Unhook throttle rod

7.

(GI.

lever

Unhook choke rod

8.

lever

(J).

(E)

and rod spring

(H)

and choke rod spring

(F)

from throttle

(I)

from choke

E24FCOSW3

19

19

CARBURETOR

N 0 T E :

ber clockwise and counterclockwise for

Before removing float chamber, rotate float cham-

1/6

turns 2 or

3

times, pushing float chamber to carb. body to release stick-

ing

of

float chamber and rubber gasket.

C

A

UT

I

0

N

:

Remove main jet before removing main nozzle.

Main iet will interfere with main nozzle

C

A

UT

I

0

N

:

Do not clean jet orif ices and float valve

seat with hard object.

W

A

R

N I N

G

:

Follow instructions prepared by clean-

er manufacturer when using cleaner.

1.

Dip

carb. components except non-metaric parts such as

is

gasket into carb. cleaner until dirt

removed and

rinse them with solvent.

E24FCIOWI

NOT

E

:

Rinse carb. aluminum components

neutralize corrosive action of cleaner, if

in

hot water to

so

instructed by

the manufacturer.

2.

Dry components with compressed air.
Make sure all orifices and passages are free from dirt
or foreign object.

C

A

U

T I 0 N

:

Do

not use rags or paper to dry components

to avoid plugging orif ices by lint.

E24FCI

1W3

20

C A UT

install

I

0 N :

Do

not strike float pin

it,

to avoid breakage of pin holder

(A)

to remove or

(B).

To

remove

float pin, pull the transformed end (C) with pliers.

To

install float pin, push float pin transformed end until

both coming off pin ends are at same length.

NOT

E

:

Float

(D)

does not require check and adjustment.

I I

CAUT I

1.

ONS:

Do

not over-tighten small carb. components. Finger:

tighten pilot screw.

2.

Do

not bend throttle and choke shafts when assembling.

3.

Apply screw locking agent to screws of throttle valve

Do

or choke valve.

not allow agent to flow into shaft

bearing surf aces.

4.

Make sure movement of throttle and choke valves

is

smooth.

EZIFCIZWI

1.

Install adaptor (G) to intake pipe

2.

Fit holes

(W)

in gasket

(X)

on projections

pipe flange.

3.

Put collars

4.

Arrange gasket

(Y)

in place.

(A).

insulator

shown.

Gasket
Gasket

(A)

:

Cylinder side

(E):

Carburetor side

(B).

(F),

and gasket

(V)

of intake

(E)

as

21

21

CARBURETOR

Hook throttle rod

5.

and choke rod spring

6.

Set related parts through the bolts
sequence

7.

Install the related parts on cylinder flange and

tighten bolts to specified torque.

(See TORQUE SPECIFICATIONS.)

:

Intake pipe

Gasket for intake pipe

Carburetor
Gasket with round hole
Insulator
Gasket with square hole

(HI,

rod spring

(M)

to carburetor

(I).

choke rod

levers.

in

following

(L),

8.

Connect adaptor (G) to air cleaner joint (P).

C A UT

adaptor
joint (P) firmly.

9.

10.

I 0 N

:

Confirm both connecting parts of

(G)

fit in with intake pipe

Connect breather tube
Connect fuel line to carburetor and fasten the line
with clamp.

(J)

(B)

and cleaner

to intake pipe

(B).

22

22

CARBURETOR

315510 6100C 5510C

15001 2541 12541

EZIPAOTWI

23

23

COOL

W

A R N

I

N

G

:

Gasoline

Avoid fires due to smoking

Engine cover
fuel valve, and fuel tank cover,

1.

Shut fuel valve
carburetor inlet.

2.

Open fuel valve and drain fuel into suitable container,

3.

Remove recoil starter.

CAUT I ON:

4.

Remove oil filler cap

5.

Disconnect fuel line

is

removed together with fuel tank, tank cap,

(A)

and disconnect fuel line

Do not lose washers

is

extremely flammable.

or

careless practices,

(C)

(E).

(F)

from fuel valve (A).

and collars (D).

I

NG

(B)

from

SYSTEM

W A R

N I N G :

avold engine starting.

6.

Loosen flywheel nut (G) by turning
Use air impact wrench to avoid flywheel retation.

7.

Remove flywheel nut (G). washer

(I).

8.

Slightly lifting up engine cover, disconnect intake

pipe adoptor

9.

Remove engine cover assy.

10.

Remove oil filler

Remove plug cap from spark plug to

it

counterclockwise.

(H),

and starting pulley

(J)

from air cleaner outlet

(1).

(K).

E26FCOZW4

24

1. Remove fuel tank cap (D).

2. Pull fuel valve knob (B)

COOLING SYSTEM

off from valve shaft (E)

: : :
: : : : :

.::,

24

N 0 T E : Knob (B) is install

ed on valve shaft (E) w i

fit.

3.

Disconnect fuel line

(F)

fiom fuel tank (C).

4. Remove fuel strainer (I) from fuel tank (C).

5.

Remove fuel tank cover (G).

t

h snap

l

J

I

/;;\A---

w

I

1

C AUT I ON : Do not lose collars

6.

Remove fuel valve (A).

C

A UT

I 0 N : Do not disassemble fuel valve (A).

(If).

t

E2SFC03W3

,

COOLING SYSTEM

Assembly and installation are reverse of disassembly and
removal.

1.

2.

3.

4.

5.

6.

7.

Note following points.

Apply locking agent on thread

when

replace stud for
engine cover mounting.
Align notch (A) of oil filler with projection

(B)

filler port.
Make sure O-ring (C) is in place.
Coat a light film of oil on O-ring and install oil
filler.
Tighten screws in crisscross sequence and evenly
specified torque.
Do not tighten screw completely at a time.
Holding pulley, torque flywheel

nut

as specified
TORQUE SPECIFICATIONS.
Connect air cleaner outlet

(0)

and intake pipe adaptor

(E) firmly.

of

to

in

25

:‘:’
:::::
.::::
,jjjj

: :

EZSFCO4W2

26 26

RECO

C

A

UT

I 0 N

:

Do

not wedge rope between reel and case.

1.

Pull

handle

Then hold rope in place with locking pliers or knot

2.

Pull

knot in handle

W

A R N I N

avoid injury.

3.

While carefully holding reel

locking pliers or untie knot.

4.

Unwind spring tension slowly.

NOT

E

:

1

through 4 are not necessary except when rope and/or
handle are changed. Instead of the steps, unwind spring
tension keeping rope in notch

out

about

250

mm

(10

in).

(B)

out and untie

G

:

Wear gloves during disassembling to

(C)

and case

As

for recoil starter with extended rope, steps

(E)

of reel.

I L STARTER

(A).

it.

(D),

remove

5.

Remove screw

6.

Remove retainer

7.

Before removing pawl
pawl, then remove pawl and spring

i

(F)

and washer

(H)

with circlip

(J),

(G).

(I)

carefully.

make sure position of the

(K).

27

27

W

A R N I

RECO

N

G

:

When removing reel (C), be careful

I L 'STARTER

that recoil spring under the reel does not fly loose

and causes injury. The spring

NOT

E

:

There should be no spring tension on reel when

removing reel. If tension

is

under great pressure.

is

felt, push reel back into

place and gently "wiggle" it until reel can be easily

removed.

8.

Rotate reel

(C)

one-quarter turn clockwise from rest

position where no tension can be felt. Then, slowly

lift reel straight up out of case.

W A R

N I N

G

:

Be careful that recoil spring

(M)

does not fly loose from reel (C) and causes injury.

The

9.

If

is

under great pressure:

recoil spring

(M)

must be removed from reel (C), hold
the reel with spring side downward in suitable container
and tap reel to remove recoil spring.

1.

Dip

metal parts in bath of high flash-point solvent, if

necessary.

C

A

UT

I

0

N

:

Do not clean any non-metalic parts

in

solvent. They may be damaged by the solvent.

2.

Check starter pawl for chips

3.

Check starter rope for excessive wear

4.

Check springs for break, rust, distortion,

i

t

ion.

cond

If

damage

WAR

is

found, replace the part.

N 1 N

G

:

Do not throw away recoil spring as

or

excessive wear.

or

fraying.

or

weakened

installed in reel. Recoil spring may fly loose from

reel and cause injury.

E27FAO2W2

28

28

RECO

W

A R N I

!

installation to avoid injury. The recoil spring must

be assembled with great pressure.

1.

Coat grease for high temperature application on recoil
spring

2.

Set recoil spring

(C)

catches

3.

Wind recoil spring

4.

Make sure that gap between spring hook
of reel boss

If not, make the gap by bending spring end with long
nose pl ier.

N

G':

Wear gloves during recoil spring

_._-

(A)

and sliding surfaces.

(A)

in reel

hook

(D)

in

reel.

(A)

into reel

(F)

is

2 4 mm

(B)

so

(B)

(0.08

that spring end

counterclockwise.

0.16

I

L

(E)

and outside

in.).

STARTER

(M)

If rope

5.

3.5

(G)

is

unwound from reel

turns

counterclockwise facing pawl groove

(B),

wind rope

in

(H).

reel

29

29

RECO

7.

Install spring

groove.

8.

Install retainer

NOT

E

:

Apply locking agent on screw

C

A U T I 0

tightening may disturb movement

9.

Tighten screw

SPECIFICATIONS.)

N

(J)

and pawl

(M),

(K)

into the respective

covering pawl with

"R*

(N).

:

Do

not over tighten screw

of

pawl.

(N)

to specified torque. (See TORQUE

(N).

Over

I

L

STARTER

side groove.

11.

Pull

rope out of case and install handle.

12.

Check movement

13.

Pull

rope out to the end.
out to the end
preloading
clockwise, keeping rope
then check the condition again.

of

pawl, pulling and returning rope.

If

rope can not be pulled

or

can not be rewound when released,

is

too much. Rotate reel

(G)

in

notch

(B)

1

turn

(0)

of reel, and

30

30

ELECTRIC

1.

Disconnect spark plug cap, and ground the cap
terminal. test. Do not touch any rotating parts

2.

Turn key switch to "ON" position and check

condition.

(STARTER DOES NOT ROTATE)

I--

Does pinion rotate?

""-I

(STARTER

ROTATES

BUT

SLOW)

STARTER

I--

@Weak or faulty battery.
@Faulty leads or connection.
*Faulty key switch.

0

Faulty starter motor.

k

W

and equipment during test.

C

A

UT

"OFF", disconnect negative lead from battery as

soon as possible.

CHARGl

A R N I N G :

NG

Engine may be cranked in this

-_-

I

0 N :

If

starter does not stop by key switch

Charge
Repair or replace
Repair or replace
Repair or replace

or

replace

of

engine

and well charged?

(STARTER ROTATES

(STARTER DOES NOT STOP

BUT

CAN

IN

NOT

CRANK

NO

KEY

SWITCH "OFF")

NO

ENGINE)

harge or replace

@Faulty leads or connection.

0

Faulty starter motor.

0

Faulty engine.

*Worn pinion or ring gear.

0

Incorrect starter alignment. Correct

0

Faulty key switch.

+Repair or replace

Repair or replace
Repair or replace
Repair or replace

Repair or replace
Correct
Repair or replace

31

31

ELECTRIC STARTER

WA

R N I

N

G

:

Disconnect negative

(+)

then positive

1.

Disconnect battery before removing electric starter from

lead to prevent spark at terminal.'-'

(-)

lead first and

&

CHARGl NG

engine to avoid accidental running of starter in handl-

i

ng.

2.

Remove electric starter from engine.

W A

R N I

N

G

:

The test room must be free from any

flammable object. Keep away your body from pinion.

CA

UT

I

O

N

:

Be careful not to deform electric starter

I-

body by holding.

Hold electric starter with vice.

Connect cable
Connect jumper cable

(A)

with positive

(B)

with negative

(+)

battery terminal.

(-)

battery

terminal.

Touch starter body with the other end of jumper cable

(B)

intermittently (within one second).

or

If pinion does not turn, repair

replace starter motor.

E28FC22W2

1

C

A

U

T

I

0

N

:

Because of difficulty

further disassembling

is

not

recommended.

in

reassembling,

8

5

E28FC23W2

32

32

ELECTRIC STARTER

1.

Coat multi purpose grease on reduction gears.

2.

Do

not miss putting

shim

on shaft

in

cover assy.

&

CHARGl NG

E28FC15WI

1.

Disconnect connector

2.

Start and warm up engine.

3.

Set multimeter selector switch to

4.

Connect tester positive prove with stator term

and negative prove with crankcase.

5.

Run

engine at

If voltage

3,000

is

less than

(A).

2!jV

DC

rpm and check voltage.

8V,

replace stator.

ion.

posit

inal

(B)

E28FC24WI

E28FC25WI

I

GN

I T I

ON

SYSTEM

33

Transistor controlled ignition system

engines and this system consists of following components.

1.

Ignition coil

2.

Control

3.

Flywheel (with permanent magnet)

These components do not mechanically contact and periodic
maintenance

I,:

CU: Control unit

R,
R2:

unit

is

not required.

Primary coil

Secondary coil

:

Control resistor

Control resistor

is

used for these

TR,

:

Transistor

TR2:

Transistor

F

:

Flywheel

SP

:

Spark plug

SW

:

Engine switch

To check ignition system, check spark as follows;

1.

Remove spark plug and connect plug cap with the removed
spark plug.

2.

Install spare plug
from hole.

W

A R N I N G :

cap, but not spark plug.

3.

Keeping contact with spark plug metal part (not center
electrode) and engine block, crank engine.

C

A

UT

I

0

N

:

Do

cleaner.

e

If

no

or

very weak spark

and regap

try engine cranking again.

If spark
with new spark plug.

it

is

not improved by cleaning, try checking again

to

plug hole to avoid fuel spitting

To

avoid electric shock, hold plug

not clean spark plug with bead

is

observed, clean spark plug

to

0.7

0.8

mm

(0.028

0.031

or

in.

sand

and

E30FCOIW2

If

spark

is

not improved yet, check ignition system.

E30FCOBW2

34

I

GN

1.

Set multimeter selector switch to

2.

Check resistance between terminal

R

x

(A)

and case

IT

I

ON

SYSTEM

position.

(B).

34

If resistance

unit.

C A U T I 0 N

I

.CONTROL UN IT RES I STANCE

Case

N 0 T

E

:

This check may not cover every defect.

is

out of specified value, replace control

:

Do

not use Megger.

Terminal

(B)

(A)

Case

(B)

E30FCOSW2

r

1.

Check resistance between the points as specified.

2.

If resistance
ignition coil.

IGNITION COIL RESISTANCE

Primary

coil

Secondary

1

coi

is

out

of

specified value, replace

Connect ion

Primary terminal

and Core (C)

Plug lead
and Core (C)

(A)

(B)

Resistance

0.67

(R

x

6.0

(R

x

Range)

Range)

EBOFC

I

OW2

35

35

IGNITION

1.

Remove starting pulley and engine cover assy. (See
GINE COVER REMOVAL.

2.

Avoiding flow-out of engine oil, place engine on bench

so

that flywheel faces sideward.

3.

Put soft metal piece on shaft end to avoid demage and
strike metal piece sharply until flywheel comes loose.

1.

Before installing flywheel, remove grease and oil from

taper part of crankshaft and taper hole of flywheel.

2.

Make sure key

3.

Torque

nut

as specified

(See ENGINE COVER ASSEMBLY AND INSTALLATION.

)

is

in

place when installing flywheel.

in

TORQUE SPECIFICATIONS.

SYSTEM

EN-

ESOFCIIWI

If ignition coil
installing coil.

1.

Insert

(A) between coil legs (B) and flywheel ‘rim

2.

Pushing coil to flywheel, tighten coil mounting screws

firmly.

Intermediate connector installation
Be careful of terminal direction.

A:

Nut

B:

Control

C: Stop switch terminal

D:

Nut

E: Washer

0.3

is

removed or replaced, adjust AIR-GAP in

mm

(0.012

in.)

feeler gauge or solid sheet

(c).

is

as shown.

F:

Insulator

unit

terminal G: Control plate

H:

Insulator

I:

Bolt

E30FCIZWI

E30FC I3Wl

36

I

GN

I T I

ON

SYSTEM

36

Engine switch linked with throttle lever
trol pannel of engine and operated as follows:

1.

When control lever

idle, or choke, control lever

(B).

tang

2.

When control lever

tion, the lever contacts with engine switch tang
grounds ignition circuit.

C

AUT

I

0

N

:

Check and clean engine switch tang area to

keep good contact.

3.

Engine switch installation

Control lever
Switch tang
Nut
Washer
Control plate

Insulator

G:

Insulator

H:

Bolt

(A)

(A)

is

positioned at slow idle, fast

is

is

pulled beyond slow idle posi-

is

as shown,

is

equipped on con-

far from engine switch

(B)

and

ESOFC

l5W2

is

Engine switch linked with band brake
case side and operated as follows:

1.

When brake control lever on equipment
position, control cable

(B)

shoe
tang

2.

When brake control lever on equipment
position, control cable
shoe
tang

C

A

UT

keep good contact.

NOT

throttle-lever-linked engine switch.

from flywheel and to release engine switch

(F)

from lever

(B)

to contact flywheel and to make engine switch

(F)

contact with lever

I 0 N

:

Check and clean engine switch tang area to

E

:Switch configulation

(A).

(D)

pulls lever

(D)

releases lever

(A).

is

equipped on crank-

is

moved to start

(A)

to release

is

moved to stop

(A)

to force

the same as that of

E30FC16W2

31

CYL

I

NDER HEAD

1.

Remove spark plug and set compression gauge to plug hole.

2.

Crank engine with recoil or electric starter several
times and check highest reading.

is

less

than

343

kPa

(50

If highest reading

in

check engine

NOT

E

:

Battery should be fully charged for this test.

1.

Disconnect plug cap from spark plug.

2.

Remove rocker cover.

3.

Remove cyl. head.

4.

If push rods are removed, mark push rods

placed in their original positions in re-installing.

accordance with TROUBLE SHOOTING.

psi),

so

they are

37

E32FCOSWI

W

A

R

N

I N

G

:

If chemical cleaner
follow the manufacturer's safety instructions care­fully.

1.

Remove coating material stuck
stone.

C

A

UT

I

0

N

:

If deposit on combustion chamber

moved, remove valve system from cyl, head.

(See

VALVE

AND

RELATED

Do not damage valve seat and gasket surface of cyl. head in
deposit cleaning.

Remove deposit from cyl. head.

2.

Check flatness of head gasket surfase on surface plate

3.

with feeler gauge.

If cyl. head

replace it.

PARTS

is

warped more than

on

REMOVAL.)

is

used, always

surfaces, with oil

is

re-

0.07

mm

(0.003

in.),

E32FC06WI

38

CVL

I

NDER

C

AUT

I

0 N :

Gasket

Do

not damage surface of gasket during installation.

If surface coating

1.

Rotate crankshaft until piston comes up at highest
position in compression stroke.

2.

Install push rods in their respective position

der.

3.

Place head gasket and cyl. head assy on cyl. block.

4.

Make sure both spherical ends of push rods are
on rocker arms and tappets.

is

coated with special sealant.

is

damaged, replace gasket.

in

in

HEAD

cylin-

place

38

CAUT I

others are loose.

5.

0

N

:

Do

not tighten one screw completely while

It

may cause warped cy]. head.

Tighten screws down evenly by hand and then torque them

in

sequence as specified.

(See TORQUE SPECIFICATIONS.

E32FCOSW2

39

39

VALVE

When any part related to valve clearance

ified for defect correction,

or

after engine has been used

is

changed or mod-

for long period, adjust valve clearance.

NOT

E

:

Do

adjustment while engine

1.

Turn

crankshaft

in

tion

2.

Check clearance between valve stem and rocker arm with

compression stroke.

feeler gauge

If clearance

until

(A).

is

out

piston comes

of

value specified below, adjust

is

cold.

up

at highest posi-

clearance as follows:

(1)

Make sure both spherical ends of

push

rod are

in

place

on rocker arm and tappet.

(2)

Loosen lock nut
out until valve clearance becomes
then tighten lock

(B)

and turn rocker arm pivot (C)

0.3

mm

(0.01

nut

to specified torque. (See TORQUE

in

or

in.), and

SPECIFICATIONS.

(3)

Turn lock
comes

C

A

UT

enlarge valve clearance If necessary to do

0.12

I

0

nut

(B)

clockwise

mm

N

:

Do

(0.005

in.). for both valves

not turn lock nut

until

valve clearance be-

(B)

counterclockwise to

so.

follow

E33FC

I4W3

40

VALVE

is

ACR
for

1.

2.

3.

4.

device to release compression during engine start,

easy cranking.

Remove rocker cover.
Remove spark plug to ease hand cranking.
Make sure valve clearance

(See VALVE CLEARANCE ADJUSTMENT.
Rotate crankshaft slowly in usual direction observing
movement of exhaust valve

is

as specified.

(A)

and rocker arm

(B).

40

If exhaust valve does not open more than

(0.02

in.)

briefly

mechanism on camshaft

(See CAMSHAFT VISUAL CHECK.

just

after intake valve closes.

is

faulty.

0.50

mm

ACR

E33FC15WZ

41

NOT

E

:

Mark push rods

original positions in re-installing.

1.

Remove push rods.

2.

Unscrew lock nuts
rocker arms (C).

3.

Place screw head of valve spring compressor
valve head and
and retainer

4.

Compress spring and remove retainer
pliers.

5.

Remove compressor and valve spring.

(F).

so

they are placed in their

(A)

and pivots

SI

ip jaw of compressor between spring

(B),

and then remove

(F)

with needle nose

VALVE

(D)

on the

(E)

41

NOT

E

:

Before pulling valve out of guide

burrs

from valve stem, and oil to stem to avoid damaging

valve guide.

When re-installing

ing agent on thread and tighten to specified torque. (See

TORQUE

SPECIFICATIONS.

or

replacing rocker arm stud, apply lock-

)

(G),

remove all

E33FC16W3

42

1.

Check valve head for excessive deposit and gas leakage.

2.

Remove carbon from valve head with wi-re brush.

3.

Check valve head for warped face
margine

If valve head has above defect, replace valve,

N

0

T

and deposit triggers gas leakage causing valve defects.
Therefore unleaded gasoline

4.

Check valve stem for sticking, gummy deposit, discolora­tion at area covered by valve guide, and excessive
corrosion.

5.

Remove carbon from valve stem as well as head.

If valve stem

smoothly in guide, replace valve.

(B)

of less than

E

:

Excessive deposit

is

worn excessively or does not move

0.5

is

is

(A)

dent on face and

mm

(0.020

caused by leaded gasoline,

recommended.

in.).

42

N 0 T

E

:

Sticking and discolorat ion are caused by over
heating of engine, or gas leakage from valve face. Therefore
such causes must be corrected as well as valve maintenance.
Gummy deposit
system and use fresh gasoline. Remove gasoline from fuel

system before long storage.

6.

Check valve stem for worn stem end.

7.

Grind worn stem end (C,D) squarely to stem shaft with
valve lapping guide

If length from stem end to groove

(0.15

is

caused by old or stale gasoline. Clean fuel

(E)

and oil stone

in.) after grinding, replace valve.

(F).

is

less than

3.8

mm

I

\

E33FC

I7W4

43

1.

Check diameter
guide at several points with micrometer.

If

diameter

of

valve stem in area covered

is

less than

MIN.

replace valve.

VALVE

by

valve

43

VALVE STEM DIA.

2.

Check bend of valve stem at center part with

(A)

and dial indicator

If bend (dial gauge reading) of valve stem

0.03

mm

C

AUT

face.

(0.0012

I

0

N

If

valve face

in.

:

Do

not try to grind or recondition valve

is

worn or damaged, replace

MIN

(B).

replace valve.

V

blocks

is

more than

it.

E33FC

I8W2

1.

Check valve spring for any damage and replace it if

necessary.

2.

Check free length of valve spring with vernier cali­pers.

If length

spring.

is

less than

for

both springs

31.5

mm

(1.240

in.), replace

E33FC

I9WI

44

VALVE

If valve does not contact all way around with seat, lap
valve into seat.

1.

Coat fine lapping compound sparingly on valve face.

2.

Rotate valve in circular motion with valve lapper (A).

N 0 T

E

:

Lapping mark should appear on or near center of

va

1

ve face.

3.

Check valve every
until uniform ring appears on valve seat all way around.

4.

After lapping, wash parts
Dry parts thoroughly.

8

to

10

strokes and continue lapping

in

solvent to remove compound.

44

Reface valve seat with

1.

enough material to make smooth and concentric seat.
Use

30°

2.

(0.021

A

Make a

3.

at edge of seat.
Coat marker and check contact of valve face and seat.

4.

Contact should be at center part of valve face as shown
and all way around.
Lap valve into seat. (See LAPPING.)

5.

cutter to narrow seat width to

0.046

in.

:

Seat width

light

pass with

1.

45’

cutter, removing only

0.53

45’

cutter to remove any burr

1.16

E33FC2OW2

mm

E33FC2lW2

45

1.

Use valve guide cleaner to clean

2.

Check inside diameter of valve gu

i

nside of valve guides.

11

de at several points

with inside micrometer.

45

VALVE

If diameter

VALVE

Intake

Exhaust

is

more than

GUIDE

MAX,

rep

ace cyl. head.

INSIDE

5.550

5.560

mm

mm

D

(0.2185
(0.2189

I

A.

MAX

in.

in.

E33FC22W2

(A

with push rod),

(B

th valve stem), and (C

wi

with pivot).

If necessary, replace rocker

1.

Check bend of push rod at center part with

(A)

and dial indicator

If bend (dial gauge reading)

(0.024

in.),

replace push rod.

(B).

arm.

is

more than

V

blocks

0.6

mm

E33FC23WI

E33FC24WI

46

CRANKCASE COVER

W

A R N

I

N

G

:

Be careful not to burn yourself by

oil.

1.

Drain engine

2.

Remove rust and burr from edge

3.

Loosen screws, and tap parts near dowel alternately with

soft mallet.

1.

Check inside diameter
points with inside micrometer.

oil

to suitable container.

of

PTO

of

PTO

bearing

shaft step.

(A)

at several

46

E34PCOIWI

If diameter

is

more than

25.100

mm

(0.9882

place crankcase cover.

2.

Check inside di-ameter

of

camshaft bearing

several points with inside micrometer.

If

diameter

is

more than

14.070

mm

(0.5539

place crankcase cover.

.in.), re-

(B)

at

in.), re-

E34FCO6W2

47

47

CRANKCASE

0

1

':L

SEAL

If

oil leakage through oil seal

damaged, replace oil seal.

1.

Remove oil seal by tapping
punch.

2.

Placing spring held seal lip

into

housing

with

housing end (C).

3.

Before final assembly, pack some amount of grease for

high

temperature application into space between seal

(A:)

and dust 1 ip

REPLACEMENT

is

observed or seal lip

it

out with screw driver or

(A)

inside, push oil seal

until

seal outside surface becomes flush

(B).

COVER

is

1

ip

Clean gasket surface and place new gasket on crankcase.

1.

Pack grease into oil seal. (See

2.

Coat a light film

3.

Make sure governor weights are closed.

4.

Make sure governor gear

5.

with

cam gear when installing crankcase cover.

of

oil on bearings.

is

OIL

SEAL

REPLACEMENT.)

properly aligned to mesh

Do

not

force cover into position.

Install crankcase cover and tighten bolts down evenly

6.

by hand. Tighten bolts

in

the sequence as shown and

to

the specified torque. (See TORQUE SPECIFICATIONS.)

Do

not tighten one bolt completely before the others.

It

may cause warped crankcase cover.

is

When new crankcase cover

7.

drain plug

(A)

must be performed carefully. (See NOTE

used, tightening of side

in TORQUE SPECIFICATIONS.)

E34FC04W2

E34FCO7W2

48

CAMSHAFT

1.

Place cyl. block upside down on bench.

2.

Rotate crankshaft
crankshaft gear
avoid interference between tappets and camshaft
removal.

3.

Remove tappets, and mark them

in

their original position

Check cam gear for worn or broken teeth.

If excessively worn or broken teeth are observed, re-

place camshaft.

(A)

until timing marks

(D)

and camshaft gear

so

they can be placed

in

re-installing.

(B,

C) on

(E)

align, to

in

48

E35FC06WI

Check movement and damage of ACR mechanism on camshaft.

(A)

is

If outer surface of tab

heel

(B)

when weight (C)

mechanism.

If

outer surface of tab

(B)

heel
finger, replace ACR mechanism.

If parts of mechanism are worn, replace ACR mechanism.

when weight (C)

not placed above cam

is

closed, replace ACR

(A)

does not lower below cam

is

pulled toward outside by

E35PCO'IWZ

49

CAMSHAFT

2.

Check cam lobe height with vernier calipers,

49

If lobe height

replace camshaft.

1.

Place cyl. block upside down

2.

Install tappets in their respective positions and push
them all the way into guide to avoid interference with
camshaft in assembling.

3.

Rotate crankshaft

4.

Aligning timing marks

into crankcase.

is

less

until

than

22.80

on

piston

(A)

and

mm

(0.898

bench.

is

at highest position.

(B),

install camshaft

in.).

E35FC08W2

E35FCOSWI

50

PI

STON

C

A

UT

I 0

N

:

Remove any carbon or ridge at top of cyl.

bore to avoid piston ring breakage in. removing.

4t

CON-ROD

50

Rotate crankshaft

1.

Loosen con-rod bolts and remove con-rod cap.

2.

Push piston and con-rod out through top of cylinder.

3.

Remove piston from con-rod.

4.

Remove piston rings from piston with ring expander

5.

(A)

to expose con-rod bolts

(B).

(C).

E36FCIZW2

51

PI

STON

Appearance of piston and piston rings shows condition of
engine
piston and/or piston rings and remove cause of such
damage.

in

running. If excessive damage

is

observed, replace

&

51

CON-ROD

Rings of wrong size

1.

will

I

2.

e

3.

e

4.

e

not fit
consumption and excessive blowby.
Check ring end gap and arrange end gap as shown in
PISTON RING INSTALLATION.

Scuffing
when friction and/or combustion temperature are un­usually high.
Check and clean cooling system.
Check and correct quality and level of oil.
Check and adjust fuel and combustion systems.

Engine running at abnormally high temperature may cause
varnish, lacquer,
grooves making rings stick.
Apply same treatment as above

Vertical scratches across piston rings are due to
abrasive
been left in engine during overhaul, or may be loose

lead and carbon deposit.
Check air cleaner and clean
Check any air intake through abnormal route.

Clean engine inside and change oil.

to

or

scoring of both rings and piston occurs

in

engine. Abrasive may be airborne, may have

or

rings having improper end gap

shape of cylinder.

or

carbon deposit formed

This

causes high oil

2.

or

replace damaged one.

in

piston ring

(A)

Scratches across oil side rails

5.

in

engine oil, and other rings will also be worn

this

condition causing high oil consumption, increased

in

deposit

e

Clean engine inside and change oil.

combustion chamber, and ring sticking.

are due to abrasive

in

52

PI

STON

C

A

UT

I 0 N

:

Do

not use caustic cleaning solution

brush to clean piston.

1.

Remove all deposits from piston.

2.

Clean carbon from piston ring grooves with ring groove

is

cleaner. If cleaning tool
ton ring breaking into suitable size.

3.

Make sure oil return passages in ring groove are open.

not available. use old pis-

&

CON-ROD

or

wire

52

1.

Check clearance between ring groove and ring using
new ring and feeler gauge.

If clearance

piston. for top and second rings

2.

Check inside diameter of piston pin hole at several
points with inside micrometer.

If diameter
replace piston.

is

more than

is

more than

0.10

15.050

mm

(0.004

mm

(0.5925

in.), replace

in.),.

E36FC 13W

I

E36FC

E36FC

I4W2

I

SW

I

53

PI

STON & CON-ROD

1.

Check thickness of piston ring at several points with

micrometer.

If

thickness

piston ring. for top and second rings

2.

Check piston ring end gap with feeler gauge, insta

each ring squarely in cylinder at approx.
from top.

is

less than

1.40

am

(0.0551

in.), replace

.11

ing

25

mm

(1

in.)

53

If gap

PISTON

1.

Use ring expander.

N 0 T

2.

lnstall rings in following sequence;
Lower side rail

(A21

Place end gaps as follows

3.

1

11

is

more-than

RING

Top Second

E

:

Face up

Second ring (C)

:

C.

A1

:

D,

A2

MAX,

replace piston ring.

END

“N”

mark on top and second rings.

(Al)

GAP

1.0

mm

1.5

mm

Spacer

(B)

Top ring

MAX

(0.04

(0.06

Upper side rail

(D).

.

in.

in.

E36PC

I6W2

E36FCl7WI

54

PI

STON

Check con-rod especially big end for wearing, scratching,

scoring, and/or discoloring.

Abnormal wearing and scratching are caused by foreign
particle(s) in oil.
Clean engine inside and change oil.
Check air cleaner. and clean

If con-rod and/or crankshaft are used again, remove

ridges on their surface carefully.

or

replace damaged one.

&

CON-ROD

54

Scoring and discoloring are symptom of
and/or over heating.

is

If crankpin surface
replace con-rod and crankshaft.
Check and clean cooling system.
Check quality of oil and maintenance method with.user.

C

A

UT

I 0 N

:

Check re-used components carefully when re­assembling engine which had con-rod big end seizure.
Never start engine without oil even for short test

damaged by melted con-rod metal,

poor

lubricating

Assemble con-rod big end aligning pilot grooves

(A),

Check inner diameter of big end at several points
with inside micrometer.

1.

Aligning mark

JAPAN"

2.

Coat a light film of oil on piston pin and insert pin

on con-rod, assemble piston over con-rod.

"A"

(A)

on piston head

with

"MADE

IN

through piston and con-rod.

3.

Install retaining rings

C

A

UT

I 0 N

:

Do not re-use retaining ring removed. Re-

moval may deform or

weaken

during operation causing damage

in

each grooves firmly.

the

ring'

allowing

to

cly. wall.

it

to come out

E36FC

I9W2

56

1.

Set ring compressor
piston top, with projection
of piston.

2.

Tighten compressor with wrench
slightly.

3.

Coat a light film of oil on cyl. bore.

4.

Rotate crankshaft

5.

Aligning mark
side, instal

6.

Leading big end of con-rod to crank pin, push piston
down further.

7.

Coat a light film of oil
cap, and con-rod bolts.

1

(B)

over piston, flushing

(A)

on compressor toward top

(C),

then loosen

with

crank pin

(A)

on piston head toward flywheel

piston/conrod assy into cyl inder.

on

in

lowest pos

crank pin, con-rod big end,

with

it

it

ion.

56

ligning pilot groove. install cap to big end and

a.

A

ighten cap bolts

t

F

I

CAT

IONS.

9.

Make sure con-rod moves sideways lightly on crank pin.

C

AUT

I 0 N

:

important items

(D)

as specified

Con-rod bolt tightening

in

assembling. Always use torque wrench.

in

TORQUE

is

SPECI-

one of the most

E36FCZIW3

57

CRANKSHAFT

Check crank pin part and bearing journals for score,
wear, or corrosion.

If crank pin part shows any damage, carefully check
con-rod big end and repair or replace con-rod and/or
crankshaft. (See CON-ROD

Check crank gear for worn or broken teeth.

If excessively worn or broken teeth are observed, re-

place crank gear.

VISUAL

CHECK.

)

57

E37FCOZW2

58

58

CRANKSHAFT

Check outside diameter of crank pin

2.

points with micrometer.

If outside diameter
replace crankshaft.

3.

Check run out of crankshaft at both bearing journals
with dial indicator

jig

(B).

If total reading of run out

(0.008

in.), replace crankshaft.

is

less

than

(A),

setting crankshaft to alignment

is

(A)

at several

27.920

more than

mm

(1.0992

0.20

in.),

mm

1.

Install key

2.

Install crank gear

3.

Make sure end

surf ace (C)

4.

Coat a film of oil on bearing surfaces of crankshaft.

5.

Tape key way at taper of crankshaft to avoid cutting of

oil seal

6.

Pack some amount of grease for high temperature appli­cation into oil seal.

(A)

of

lips.

as shown.

(B)

as timing mark facing outside.

key

is

not projecting from crank gear

E37FCO7W3

-59

1.

Re-grind crank pin to

0.5

mm under size.

59

CRANKSHAFT

NOT E :

0.005

mm

22.950 23.00

27.467 27.480

1.5

-24.00

Crank pin must be concentric and parallel within

(0.0002

in.) full indicator reading, and surface

1.8

mm

24.10

mm

(0.9035 0.9055

mm

(1.0814 1.0819

(0.059 0.071

mm

(0.945 0.949

in.

in.

in.

in.)

)

must be finished very smooth with super finishing stone.

C

A

UT I 0

N

:

If crank pin

is

re-ground, under-size con-

rod must be used to keep specified clearance.

E37FCOSW2

60

1.

Check governor gear assy for wear and damage, as in-

stalled in crankcase cover.

C

A

UT

I

0

N

:

Do

not remove governor gear assy from crank-

If

case cover exceot to reolace~
re-used.

2.

If governor gear assy

(A)

with proper size screw drivers

C

A

U T

I

0

N

:

Do

not damage gasket surface by screw

drivers.

once removed.

must be replaced, remove

(B).

GOVERNOR

it

cannot be

it

60

1.

Place sleeve

C

A

UT I

0

(A)

into governor gear assy

N

:

Sleeve can not be assembled after governor

(B).

gear assy installed in crankcase cover.

2.

Place thrust washer (C) on boss of shaft

(B)

install governor gear assy

until1 step

3.

Check free rotation of governor assy after installation.

1.

Install governor shaft

ing pin

NOT

E

:

projection (C) which

(E)

fits into groove

(A)

(B)

to governor shaft positioning as shown.

Be careful for position of locking pin end and

is

stopper of governor shaft

with sleeve

(F).

into crankcase and set lock-

(D)

and then

(A)

to shaft

(A).

E39FC04W2

E39FCOZWI

E39PCOSYI

61

61

LUBR

NOT

E

:

Detergent engine oil delays formation of gum and

Do

varnish.

2.

Select oil viscosity depending on expected environmental
temperature as shown.

not add any additives to detergent oil.

I

CAT

I

NG

SYSTEM

-20°c

-4°F

-10°c

14°F

0°c

32°F

IO°c

5O°F

20°c

68°F

30°c

86’°F

E4OPCOIWI

40°C

104°F

If slinger

Function of breather

ing oil being forced
Reed valve controls direction of air flow caused by piston

movement

reed valve but not from outside to inside.

Oil laden air in crankcase passes through first reed valve

(A) and expands in valve chamber, where some portion

is

separated from air and returns to crankcase through hole

(B)

.

The

air passes through second reed valve
breather chamber (D), where remained oil
air and drain to valve chamber through hole
Then air passes through maze in breather chamber (D) and
vented to intake pipe through tube

is

damaged, replace

is

to keep vacuum

out

of engine.

so

that air flow from inside to outside can pass

it.

in

crankcase avoid-

of

oil

(C)

and expands

is

separated from

in

(E).

is

(G).

E4OFCIOWI

E4OFC11W2

62

62

1.

Check valve and valve seat

or

wear.

2.

Install reed valve
tool

(C),

and check gap between reed valve

surface (C) with feeler gauge.

is

If gap

or

replace valve.

more than

(A)

and back plate

0.2

mm

LUBR

for

any damage such as crack

(0.008

in.). turn over valve

I

CAT

I

NG

(B)

on inspection

(A)

and tool

SYSTEM

EIOFC12WI

63

CYL

I

1.

Visually check cyl. block for scored bore, broken fin,

or

other damages.

63

__-

If unrepairable damage

2.

Check inside diameter at
directions of parallel and right angle to crankshaft,
with inside micrometer.

If

inside diameter and/or out of round are more than

resize cyl. bore

CYL.

CYL.

BORE INSIDE DIA.

BORE OUT

is

observed, replace cy]. block.

10

mm

(0.4

or

replace cyl. block.

OF

ROUND

in.) from top in

MAX,

MAX

MAX

E41FC06W2

Oversize piston and piston rings

(0.01

in.),

0.50

mm

(0.02

in.), and

available. Select suitable size depending on condi

cyl.

bore

to

be re-sized.

1.

Bore cylinder finely to size as shown on right

i

before hon

S.

B.S. : Boring Size

ng.

:

Over Size

for

standard plus

0.75

mm

(0.03

0.25

mm

in.) are

tion

of

table

64

CYL I NDER/CRANKCASE

2.

Hone cylinder to final size as shown on right table
following procedure shown below.

C

A

UT I

0

N

:

Consider shrinkage of cyl. bore for

0.008

mm

(0.0002-0.0003

in.) after cooling down from honing

heat.

F.S.

:

Final Size

N 0 T

E

:

Use honing stone recommended by hone manufacturer.

(1)

A1ign

centers of cyl. bore and drill press carefully

and-set cyl. block on drill press table.

(2)

Install hone to drive shaft and set stopper of dril

press

so

that hone can only extend

20-25

mm

from top to bottom of cyl. bore.

(3)

Adjust honing stone to contact snugly against cyl.
narrowest point.

DO

NOT

FORCE.

(4)

Rotate hone by hand. If it cannot be rotated, adjust
hone until it can be rotated by hand.

(5)

Set dri11 press rpm to

(6)

Coat honing

oil

on cyl. bore.

200 250.

0.006-

(3/4-1

11

in.

)

wall at

0.25

0.50

0.75

mm

mm

mm

F.

S.

65.230 65.250

mm

(2.5681 2.5689

65.480 65.500

mm

(2.5779 2.5787

65.730 65.750

mm

(2.5878 2.5886

64

in.

in.

in.

C

A

UT I

0

N

:

Do not use solvent or gasoline.

(7)

Drive drill press and move hone up and down in cyl. bore
about

20

cycles/minute.

W

A R N I N

G

:

Stop drill press when checking

or

mea-

suring cyl. bore.

(8)

Measure inside diameter in suitable periods with inside
micrometer, and check finishing pattern which should be

40

to

60

degrees crosshatch.

(9)

Clean cyl. block thoroughly with soap and warm water for
“white glove inspection”.

C

AUT

I

0

N

:Thoroughly wash honing grit from cylinder.

Grit

is

extremely abrasive to engine components.

(10)

Dry cyl. block and coat engine

oil

to cyl. bore.

E4lFC07W6

65

CYL

I

NDER/CRANKCASE

C

AUT

I

ON

:Do

not remove ball bearing from housing

except replacing.

1.

Clean ball bearing with high flash point solvent.

2.

Pour engine

3.

Rotate bearing inner race slowly by hand.

oil

to bearing.

65

If any roughness

re-cleaning, replace ball bearing.

is

felt and

it

can not be removed by

r-

1.

Remove oil seal preceding ball bearing replacement.

Do

not re-use removed oil seal.

2.

Push out ball bearing with bearing driver.

3.

Clean bearing housing

dry

and

4.

Coat a light film of

5.

Push new ball bearing into housing to end.

If

oil leakage through oil seal

damaged, replace oil seal.

1.

Remove oil seal by tapping
punch.

2.

Placing spring held seal lip

into housing until seal outside surface becomes flush

with housing end (C).

3.

Before final assembly, pack some amount of grease for
high temperature application into space between seal lip

(A)

it.

and dust 1 ip

(B).

with

high flash point solvent

oil

on bearing.

is

observed

it

out

(A)

inside, push oil seal

or

seal lip

with

screw driver

is

or

E4IFC03WI

EIIFCO4WI

66

66

If

inside diameter

llace cy1 inder/crankcase.

rep

is

more than

CY

14.070

mm

NDER/CRANKCASE

(0.5539

in.

),

E4IFCOIWI

67

67

BAND BRAKE

In the brake system, shoe

flywheel
on equipment
engine switch tang

(C)

to stop engine quickly when brake control lever

is

moved to stop position. At the same time,

(F)

(B)

operated by lever

contacts with lever

ignition circuit.

The operations are as follows:

1.

Starting

When brake control lever on equipment

position, control cable

shoe

(B)

from flywheel (C) and to release engine switch

tang

(F)

from lever

C

A

UT

I

0

N

:

Do

not try to start engine when band brake

is

ON.

Starter and band brake

(A).

(D)

pulls

will

lever (A) to release

be damaged.

(A)

brakes

(A)

to ground

is

moved to start

I

2.

Stopping

When brake control lever

position, control cable
shoe

(B)

to contact flywheel

(F)

switch tang

C

A

UT

I

0

N

contact lever

:

Check and clean engine switch tang area to

on

equipment

(D)

releases lever

(C)

and to make engine

(A).

is

moved to stop

(A)

to force

keep good contact.

3

Make sure that band brake always stop engine within
onds when band brake

is

ON.

If not, check brake shoe and/or

sec-

related parts for wear and damage. Replace parts if neces­sary.

68

BAND BRAKE

1.

Do

not remove brake shoe

replacing the shoe.

2.

If stud

(G)

is

removed to replace shoe

ing agent on the thread when reinstalling the stud.

3.

Shoe

(B)

does not requ

Operate brake control lever on equipment and check brake
cable for any slack. If necessary, adjust brake cable con-

nect ion.

1.

Release brake control lever on equipment.

2.

Loosen outer cable clamp bolt

to

remove any slack.

3.

Then tighten clamp bolt

(B)

from stud

(G)

(B),

ire adjustment

(A).

in installation.

(A)

and pull outer cable

except when

apply lock-

68

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I

E43FCO3WI

t