Toro 55-7800, 30106, 30112, 30115, 30165 Service Manual

KAWASAKI FB460V ENGINE MANUAL

Table of Contents – Page 1 of 3

FOREWORD

SECTION 1 - GENERAL INFORMATION BEFORE SERVICING PERFORMANCE CURVES DIMENSIONAL SPECIFICATIONS PERIODIC MAINTENANCE 4-STROKE ENGINE THEORY CONSTRUCTION (INTERNAL COMPONENT) FUEL SYSTEM AND OPERATION ELECTRICAL SYSTEM PRELIMINARY ENGINE CHECKS TROUBLE SHOOTING TUNE-UP PROCEDURE OVERHAUL PROCEDURE

SECTION 2 - I GNITION IGNITION SYSTEM SPARK CHECK FLYWHEEL REMOVAL FLYWHEEL CHECK IGNITION COIL CHECK CONTROL UNIT CHECK FLYWHEEL INSTALLATION IGNITION COIL AIR-GAP ADJUSTMENT FLYWHEEL HOUSING INSTALLATION SPARK PLUG CHECK AND CLEANING

SECTION 3 - AIR CLEANER

AIR CLEANER SERVICE AIR CLEANER HOUSING INSPECTION AIR CLEANER INSTALLATION

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

SECTION 5 - GOVERNOR

REMOVAL (GOVERNOR RELATED) GOVERNOR GEAR DISASSEMBLY

KAWASAKI FB460V ENGINE MANUAL

Table of Contents – Page 2 of 3

SECTION 5 - GOVERNOR - continued GOVERNOR GEAR INSPECTION GOVERNOR REASSEMBLY REASSEMBLY (GOVERNOR RELATED) LINKAGE ADJUSTMENT THROTTLE CABLE INSTALLATION AND ADJUSTMENT CHOKE ADJUSTMENT MAXIMUM SPEED ADJUSTMENT IDLE SPEED ADJUSTMENT

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

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

SECTION 8 - PISTON, PISTON RING, AND CON-ROD PISTON AND CON-ROD REMOVAL PISTON INSPECTION PISTON RING THICKNESS INSPECTION PISTON RING END GAP INSPECTION PISTON PIN AND PIN HOLE DIA. INSPECT IO N CON-ROD INSPECTION PISTON AND CON-ROD ASSEMBLY PISTON RING INSTALLATION PISTON AND CON-ROD ASSY INSTALLATION

KAWASAKI FB460V ENGINE MANUAL

Table of Contents – Page 3 of 3

SECTION 9--CRANKSHAFT AND CAMSHAFT CRANKSHAFT AND CAMSHAFT REMOVAL CRANKSHAFT INSPECTION UNDER-SIZE CON-ROD LINK ROD INSPECTION BUSHING REPLACEMENT BALANCE WEIGHT INSPECTION BALANCER GUIDE INSPECTION CAMSHAFT INSPECTION CRANKSHAFT AND CAMSHAFT INSTALLATION CRANKCASE COVER INST ALL AT IO N CRANKSHAFT END PLAY CRANKSHAFT END PLAY ADJUSTMENT

SECTION 10--CYLINDER BLOCK AND BEARING CYLINDER BLOCK INSPECTION AND REPAIR BALL BEARING REMOVING BALL BEARING INSPECTION PLAIN BEARING INSPECTION BALL BEARING INSTALLATION OIL SEAL REPLACEMENT (PT O SIDE)

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

SECTION 12 - RECOIL STARTER RECOIL STARTER DISASSEMBL Y RECOIL STARTER REASSEMBL Y RECOIL STARTER INSPECTIO N

4-stroke

air-cooled

gasoline engine

FOREWORD

This manual nics in

In order to perform the work efficiently and to

avoid costly mistakes, read the text, thorough-

ly

familiarize yourself with the procedures before

starting work, and then do the work carefully

a

clean area. Whenever special tools or equip-

in ment are specified, do not use makeshift tools

equipment. 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

symbols, heed their instructions!

Always follow safe operating and maintenance

practices.

special instructions or procedures which, correctly followed, could result

injury, or

CAUTION:

or procedures which,

could result in equipment damage or destruction.

NOTE:

ular interest for more efficient and convenient

operation.

is

designed for use by trained mecha-

a

properly equipped shop.

see

these

WARNING

WARNING:

loss

This identifies special instructions

Indicates message or points

of

This warning

life.

if

not strictly observed,

and

symbol

in

fire,

or

CAUTION

identifies

if

not

personal

of

partic-

The term "Replace" and some abbreviations are used

as

follows:

-

Replace

MIN MAX

Ass'y

STD

I

Ilust.

Spec.

PTO Approx. Carb.

Con-rod

Cyl.

All rights reserved. may be reproduced, stored in or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Engine Division/Kawasaki Heavy Industries,

Ltd. curacies or omissions in this publication, although every possible care has been taken to make complete and accurate and specifications subject to change without prior notice or obligation. 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

=

I

llustration

=

Specification(s)

=

Power take off

=

Approximately (Approximate)

=

Carburetor

=

Connecting rod

=

Cylinder

No

part

of

this publication

a

retrieval system,

No

liability can be accepted for any inac-

as

possible. All procedures

it

as

TABLE

OF

CONTENTS

/-

Section

GENERAL INFORMATION

Before Servicing Specifications. Performance Curves Dimensional Specifications Periodic Maintenance 4-Stroke Engine Theory Construction (Internal Component)

Fuel System and Operation

Electrical System Preliminary Engine Checks Trouble Shooting Tune-up Procedure Overhaul Procedure

Ignition System

Spark Check

Flywheel Removal

Flywheel Check

Ignition Coil Check

Control Unit Check

Flywheel Installation Ignition Coil Air-gap Adjustment Flywheel Housing Installation

Spark Plug Check and Cleaning

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

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

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

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

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

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

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

Section

IGNITION

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

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

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

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

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

1

.....

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

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

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

2

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

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

...........

1-1 1-3 1-4

.........

........

..........

1-5 1-7 1-7 1-8 1-9 1-10 1-11 1-13 1-17 1-17

2-1

2.1

2.2 2-3

2-3 2-3 2-3 2-4

2.4

Section

GOVERNOR

Removal (Governor Related) Governor Gear Disassembly Governor Gear Inspection Governor Reassembly

Reassembly (Governor Related)

Linkage Adjustment Throttle Cable Installation and

Adjustment Choke Adjustment

Maximum Speed Adjustment

Idle Speed Adjustment

Compression Check

Cylinder Head and Head Gasket Removal

Cylinder Head Tightening Procedure

Cylinder Head Check and Repair

Valve and Spring Removal

Valve Spring Inspection

To Analyze Valve Valve Inspection Valve Guide Check and Replacement Valve

Seat

Tappet Clearance Check and Repair

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

Reconditioning

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

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

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

Section

COMPRESSION

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

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

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

5

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

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

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

...........

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

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

6

..........

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

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

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

5-1 5-1 5-2 5-2 5-2

5-2 5-3

5-3 5-3 5-3

6-1

...

6-1

.......

........

6-1 6-2 6-2 6-2 6-2

6-2 6-3 6-4 6-6

Section

AlR-CLEANER

Air cleaner Service Air cleaner Housing Inspection Air cleaner Installation

Carburetor Operation Carburetor Removal and Disassembly Carburetor Cleaning Carburetor Inspection

Carburetor Assembly Carburetor Installation Carburetor Adjustment

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

Section

CARBURETOR

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

3

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

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

4

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

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

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

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

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

3.1

4.1

......

4.1 4-2

4.2

4.2 4-3 4-3

LUBRICATION

Lubrication

Oil Warning System

Full Flow Oil Filter Capacities Oil Recommendation Oil Level Check Oil Change

Breather Check Oil Pump Inspection Oil Pump Installation

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

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

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

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

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

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

Section

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

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

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

7

7-1 7-1 7-1 7-1 7-2

7-2 7-2 7-2 7-3

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

7-3

Section

PISTON. PISTON RING. AND CON-ROD

8

Section

RECOIL STARTER

12

Piston and Con-rod Removal Piston Inspection Piston Ring Thickness Inspection Piston Ring End Gap Inspection Piston Con-rod Inspection Piston and Con-rod Assembly Piston Ring Installation Piston and Con-rod Assembly Installation

Crankshaft and Camshaft Removal Crankshaft Inspection Under

Link Bushing Replacement Balance Weight Inspection Balancer Guide Inspection

Camshaft Inspection

Crankshaft and Camshaft Installation Crankcase Cover Installation Crankshaft End Play Crankshaft End Play Adjustment

and Pin Hole Dia . Inspection

CRANKSHAFT AND CAMSHAFT

Size

Con-rod

Rod

Inspection

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

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

Section

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

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

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

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

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

..........

...........

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

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

9

.........

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

.......

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

..........

8-1

8.2 8-2 8-3

.....

8-3

8-4

8-5

...

8-5

9-1 9-1

9-2 9-2 9-2 9-3

9-3 9-3 9-4 9-5 9-5 9-5

Recoil Recoil Starter Reassembly Recoil

Starter Starter

Disassembly Inspection

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

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

12-1

12-1 12-2

Section

CYLINDER BLOCK AND BEARING

Cylinder Block Inspection and Repair Ball Bearing Removing Ball Bearing Inspection Plain Bearing Inspection Ball Bearing Installation Oil

Seal

Replacement

Section

ELECTRIC STARTER AND CHARGE

Starter Motor Circuit Starter System Check Starter Starter Solenoid Test Starter Motor Diassembly Starter Motor Inspection Brush Holder Check Pinion Clutch Inspection Starter Motor Reassembly Charging System Check Trouble Shooting

Motor Check

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

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

10

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

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

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

11

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

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

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

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

......

10-1

10-2

10-3

11-1

11-2

11-3

11-4 11-7 11-7 11-7 11-7 11-9

1-1

GENERAL INFORMATION

Section

GENERAL

BEFORE

Before starting to service a engine carefully read the applicable section to eliminate unnecessary work. However, tations;

is

required for successful work. Especially note

the following:

Mechanical

Adjustments Adjustments shall be made in accordance with the Periodic Maintenance Chart or whenever troubleshooting or presence of symptoms indi-

cate

that adjustments may be required.

Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your

hands with gloves or

lifting the engine or turning

Dirt

Before removal and disassembly, clean the engine.

dirt

Any

parts, will work

of the engine. For the same reason, before install-

a

new part, clean off

ing

Tightening Sequence

Where there

this

Service must be tightened in the order and method indicated. When installing or screws, they should and tightened to evenly, according to the tightening sequence, to the specified torque. This of the part and/or causing Conversely, when loosening the bolts, nuts, or screws, loosen turn and then remove them.

Torque The torque values given in this should always be adhered to. Either too or too much torque may lead to serious damage.

Use

a

good quality, reliable torque wrench.

SERVICING

a

detailed account has limi-

a

certain amount of basic knowledge

Systems:

a

piece of thick cloth when

it

over.

entering the engine, carburetor, or other

as

an abrasive and shorten the life

any

dust or metal fillings.

is

a

tightening sequence indicated in

Manual, 'the bolts, nuts, or screws

a

part with several bolts, nuts,

all

be started in their holes

a

shug fit. Then tighten them

is

to avoid distortion

gas

or oil leakage.

all

of them about

a

quarter of

Service

INFORMATION

Manual

little

a

1

Force

Common sense should dictate how much force

is

necessary in assembly and disassembly. part seems especially difficult to remove or install, stop and examine what may be causing the pro-

is

blem. Whenever tapping using impact driver for screws (particularly for the removal of screws held by to avoid damaging the heads.

greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended.

a

wooden or plastic-faced mallet.

Lubricant

Don't use just any oil or grease. Some oils and

Battery Ground

Before performing any disassembly operations

on the equipment, remove the ground

from the battery to prevent the possibility of

accidentally turning the engine over while partially

disassembled.

Lubrication

Engine wear the engine surfaces have an adequate lubricative film. During assembly, oil or grease (whichever should be applied to any rubbing surfave which has lost oil should be cleaned off. Deteriorated grease has lost abrasive foreign particles.

Press A part installed using

seal,

should first be coated with oil on

inner circumference smoothly.

Oil

Seal, Grease

Replace any oil or grease with new ones, seals. A seal grease to the

seal,

perature grease, to the lips to reduce rubber-tometal friction.

Gasket,

When in doubt

O-ring, replace

surfaces around the gasket should be free of for-

eign matter and perfectly smooth to avoid oil or

compression leaks.

seals

seal

apply

O-ring

is

generally

is

warming up and before

its

lubricative film. Old grease and dirty

its

lubricative quality and may contain

so

Seal

as

removal generally damages

guide

during installation to avoid damage

lips. Before

a

little

is

lubricant, preferably high tem-

as

to the condition of a gasket or

it.

with a new one. The mating

necessary, tap lightly

a

lacking agent) in order

at

its

maximum while

all

the rubbing

is

more suitable)

a

press or driver, such

its

that

it

will go into place

seals

that were removed

required for certain oil or

a

shaft passes through

If

Use

(-)

lead

as

outer or

an

a

GENERAL INFORMATION

1-2

Liquid

Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will used. Apply sparingly. Excessive amounts may

block engine oil passages and cause serious damage. An example of

commonly, available in North America

Lock'n

Ball Bearing Installation When installing which

a

balls and races, and prevents races and balls from

being dented. Press at

Circlip, Retaining Ring

Renew any circlips and retaining rings that were

removed, When installing circlips and retaining rings, take care to compress or expand them only enough

to install them.

High Flash-point Solvent

A high flash-point solvent

reduce fire danger. A commercial solvent com-

monly available in North America

solvent (generic name). Always follow manufac-

turer and container directions regarding the use of

any solvent.

Molybdenum Disulfide

This manual makes reference to molybdenum

disulfide grease in the assembly of certain engine

and chassis parts. Always check manufacturer

recommendations before using such special lubricants.

Engine Rotation

When turning the crankshaft by hand, always turn

it

clockwise, viewed from the front (flywheel end) of the engine. This will ensure proper adjustments.

Gasket

and Non-permanent Locking Agent

be

a

non-permanent locking agent

is

Loctite

Seal

(Blue).

a

ball bearing, the bearing race

is

affected by friction should be pushed by

suitable driver. This prevents severe stress on the

a

ball bearing until

the stop in the hole or on the shaft.

as

removal weakens and deforms them.

is

recommended to

)

Grease

in the direction of normal rotation; which

it

is

Stoddard

stops

is

The electrical parts should never be struck

as

sharply, on a hard surface. Such can damage them.

Do

not disconnect the battery leads or any other electrical connections when the ignition switch

ning, unless specifically noted. Never keep the starter engaged

motor will not turn over, or the current may burn out the starter motor windings.

Never replace

without 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 will fail.

Make sure clean and tight, and examine wires for signs of burning, fraying, connections will affect electrical system ope-

ration.

Measure coil and winding resistance when the

is

part All the electrical leads are either single-color

or two-color and, with only

must When soldering or unsoldering connections,

do not use

watts capacity. Use

60/40

wiring.

with a hammer, or allowed to

a

shock to the parts

is

on, or while the engine

if

the starter

a

defective electrical component

all

connectors in the circuit are

etc.

Poor wires and bad

cold

(at

room temperature).

a

few exceptions,

be

connected to leads of the same color.

a

soldering iron of more than

16

gauge

resin core solder when reconnecting

(0.062

is

fall

run-

40

in.)

Electrical

Always minimize shock hazards when working on electrical equipment. Work in dry environment with dry hands. For max-

imum shock hazard protection, connect the

equipment ground terminal to an earth ground.

Do

This will burn out the diodes in the electrical parts.

Always check battery condition before condemning other parts of an electrical system. A fully charged battery

ing accurate electrical system

Systems:

not reverse the battery lead connections.

is

a

must for conduct-

tests.

a

clean,

1-3

GENERAL INFORMATION

SPECI

FlCATlONS

ENGINE MODEL

ENGINE TYPE NUMBER OF CYLINDER PISTON DISPLACEMENT

BORE x STROKE COMPRESSION RATIO

MAX. OUTPUT

MAX. TORQUE

MIN. SPECIFIC FUEL CONSUMPTION RATIO

DIRECTION OF ROTATION

FAST IDLE SPEED SETTING

SLOW IDLE SPEED SETTING

LUBRICATION

BALANCING THROTTLE CONTROL CHOKE CONTROL

STARTER

CARBURETOR

IGNITION

CHARGING COIL

RFI GOVERNOR OIL FILL AND DIP STICK OIL DRAIN COOLING AIR INLET COOLING SHROUDS AIR CLEANER

FB460V Forced Air Cooled, Vertical Shaft, 4-Stroke Gasoline Engine

1 460 cc (28.1 cu.in.) 89 mm x 74 mm (3.50 in. x 2.91 in.)

6.4

:

1

12.5/3,600 r.p.m. (with JX156-K112-01 muffler)

2.78 kg-m/2,300 r.p.m. (20.1 ft-lbs/2,300 r.p.m.)

315 gr/hp-hr (0.694 Ibs/hp-hr)

Counter-Clockwise Facing the PTO Shaft

3,350 r.p.m.

1,400 r.p.m.

Pressurised Lubrication

Reciprocating Weight

Remote Cable Automatic Electric Starter or Recoil Starter

Float Type Fixed Main Jet Transistorized-Fly-Wheel Magneto (Point

12V-13A with Regulator (Electric Starter Model

per Canada and U.S.A. Requirement

Mechanical Governor

Extended Above Engine

with Extention

Rotating Screen with Periphery Blade Protector Noise Suppresive Layered Sheet Semi Cyclone Type with Dual Element

Pipe

Less)

LUBRICANT

FUEL

DIMENSION (H x

NET WEIGHT

OPTIONAL PARTS

Specifications and dimensions are subject to change without notice.

W x L)

API Service Classification At temperatures below 0°C (32°F) At temperatures above 0°C (32°F)

Regular Grade Leaded or Unleaded Gasoline

(Electric Starter Model) (Recoil Starter Model)

307 mm x 381 mm x 419.5 mm 356 mm x 365 mm x 511 mm (12.08 in. x 15.00 in. x 16.51 in.) (14.01 in. x 14.37 in. x 20.12 in.

36 kg (79.36

Oil Warning System, Full Flow Oil Filter

Ibs)

:

SD, SE, SE/CC, SF Class

:

SAE 5W-20

:

SAE 30

36 kg (79.36

Ibs)

PERFORMANCE CURVES

GENERAL

INFORMATION

1-4

FB46OV

WOT

PERFORMANCE

(SAE

J607a)

TORQUE

kgm

2.6

2.4

ft-

18

Ibs

gr/hp.hr Ibs/hp.hr

300

2000

ENGINE

SPEED

3000

r.p.m.

3600

4000

The horsepower ratings shown herein are established in accordance with Society of Automotive Engineers Code J607a.

sea

Power curves are corrected to standard conditions of

F)

temperature of 15.6°C (60"

and are developed from laboratory

level barometer and

test

engines equipped with standard air cleaner and muffler. The "Maximum

B.H.P."

Production engines will develop not

curve represents performance

less

than 95% of the "Maximum

of

laboratory

test

engines.

B.H.P."

when tested after run-in to reduce friction and after cleanout of combustion chamber, with

valves,

carburetor and ignition system adjusted to laboratory standards. Engine power will decrease for each 5.6°C (10°F) above standard temperature of 15.6°C

3.5%

for each 305m

(1,000

ft.)

above

(60°F).

sea

level

and 1%

1-5

GENERAL INFORMATION

DIMENSIONAL SPECIFICATIONS

(Recoil Starter Model)

276 143.5

I

GENERAL INFORMATION

1-6

(Electric

Starter

Model)

1-7

GENERAL INFORMATION

PERIODIC MAINTENANCE

Engine Serial Number

is

The engine serial number

located on the front of the cylinder-head cover above the spark

plug.

Periodic Maintenance

Chart

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

regular intervals.

The chart below shows periodic inspection and maintenance required and suitable interval designated with

Electric start models only.

5

Perform these operations after the first Clean the air cleaner element more often when operating under dusty conditions.

hours of use, then

at

the recommended interval.

Fuel Use regular grade leaded or unleaded.

CAUTION: Gasohol

Don't use additives, such

oil

Don't mix

with gasoline. Always use a clean container.

is

not recommended.

as

carburetor cleaners, de-icers, or moisture-removing liquids in the gasoline.

Engine Oil Use API classification

at

temperatures below

SF,

SE/CC,

0°C

(32°F). Don't put additives in the oil.

SE

or SD. Use SAE

30

at

temperatures above 0°C (32°F) and SAE 5W-20

4-STROKE ENGINE THEORY

KAWASAKI

and tractors. There are four strokes to one complete power cycle.

Intake Stroke:

1.

Compression Stroke:

2.

Power Stroke:

3.

Exhaust Stroke:

4.

FG

Series engines are of the same basic "4-stroke cycle design"

The piston goes down, creating

gas

draws

through open intake The piston comes up with both the

gas

into the space left between the top of the piston and cyl-

inder head. At this point the magneto sends high tension current to the spark plug, firing or exploding the compressed the piston down.

valve

Exhaust out

all

of the burnt gases, thus completing the power cycle.

opens and the upward stroke of the piston forces

as

used in automobiles, trucks

a

vacuum in the cylinder which

valve

into the space above piston.

valves

closed, highly compressing

gas

and driving

CONSTRUCTION (INTERNAL COMPONENT)

GENERAL INFORMATION

1-8

1. Cylinder head

2. Gasket

3. Ignition coil

4.

Ring gear

5.

Rotating screen

6.

Flywheel nut

7.

Flywheel with blades

8.

Charging stater coil

9. Ball bearing

10. Balance weight

1 1. Support shaft

12. Wrist pin

13. Link rod

14. Adjust shim

15. Oil seal

16. Crankshaft

17.

Crankgear

18. Connecting rod

19. Piston

20.

Piston pin

21. Snap ring

22. Piston rings

\

14

11

A. Intake valve

B.

Exhaust valve

12 C. Valve guide

D.

Valve rotater

E.

Valve spring

F.

13

Spring retainer

G.

Tappet

H.

Oil pump

I.

Governor assembly

J.

Camshaft

K.

Breather valve

The intake and exhaust

a

with

bushing. The cylinder block and bushings can be reamed out to install service guide bushings and standard

valve

A

guide wear exceeds the service-limit.

satellite

exhaust valve with a rotator

valve

guide are fitted

size

valves,

valve

when

is

used to prolong the life of the exhaust valve.

is

The function of the breather

to create vaccum in the crankcase which prevents oil from being forced out of the engine through

piston rings, oil in the crankcase passes through

seals,

or gaskets. Oil laden air

a

maze created by the reed valve and expansion chambers where the oil

is

separated from the air and

drained back to the crankcase. The air passes

a

through

hose out to the aircleaner.

a

Internal components

for

FB460V

engine consist of the piston, connecting rod, camshaft, crankshaft, reciprocating balancer, tappets, oil pump and governor.

Pressurized oil directly lubricates the PTO

journal, crankpin, and link rod journals.

is

A balance weight with link rods and reciprocating balance

mounted on crankshaft

is

accomplished in the exact line of the piston motion.

all

The flyweight governor governs

speed

ranges.

0.25

mm,

0.5

Oversize pistons and rings

0.75

mm

(0.01

in.,

0.02

in.,

0.03

in.) are avail-

mm,

able.

is

Camshaft The camshaft which

raise

gear-driven by the crankshaft.

lobs

operate against the tappets,

and lower valves.

1-9

GENERAL INFORMATION

FUEL SYSTEM

AND

OPERATION

n

8.

1. Atomospheric pressure

2. Air cleaner

3.

Paper element

4. Foam element

5.

Intake pipe

6.

Choke valve

7.

Main nozzle

Needle valve

9.

Tongue

10. Main

11. Bolt

12. Gasket

13. Float bowl

14. Float

Fuel enters the carburetor bowl through the

needle

valve

contolled

by

the float. The downward movement of the piston on the intake stroke creates negative pressure in the cylinder. Atomospheric pressure forces out side air through the air cleaner and venturi into the engine.

Heigh speed air in the venturi creates negative

pressure.

jet

15. Throttle valve

16. Venturi

17. Intake valve

18. Lower pressure

19. Piston

20. Starter motor

21. Control plate

bowl

Atomospheric pressure in the

forces

fuel up the main nozzle into the venturi, where

the fuel mixes with air moving through the

valve

venturi. The choke

controls the amount

of air entering the venturi during starting

operation.

valve

The throttle

controls the fuel-air mixture

entering the engine.

n

ELECTRICAL SYSTEM

GENERAL INFORMATION

1-10

The electrical system for FB460V consists of an ignition system, electric starting system, charging

system and monitor system (optional).

a

The ignition system includes

flywheel, ignition coil, control unit, spark plug and engine stop switch (recoil starter model only).

a

The starter system includes

key switch,

Wiring Diagram

FB46OV-AS. Model (Bendix Starter Motor)

ENGINE

solenoid and starting motor. The charging system consists of

a

flywheel

stator and regulator to convert AC current to

DC

current. The stator out put

3,350

rpm.

is

12

amps

The monitor system consists of an oil pressure sensor (oil switch), oil pressure warning lamp and charge lamp.

FB46OV-BS. Model (Shiftlever Starter Motor)

ENGINE

Spark plug

I

Control unit

at

Key

switch

FB460V. (Recoil-Starter Model)

OFF

RUN

START

Specifications

Ignition System

Control unit

I

resistance

~-

ignition NGK BMR4A or CHAMPION RCJ-8

0.6

to

0.7

mm

See

CONTROL

UNIT

CHECK

1-1 1

GENERAL INFORMATION

Electric Starter System (Bendix-type)

I

ITEM

Battery rating

current

Starter-rating Brush length 12 mm (0.47 in.) (MINI Commutator

groove depth

Commutator

diameter Commutator

Run-out Current draw

12 V/35 A.H. or more

of

One tenth

12 V

-

0.2 mm 32 mm (1.26 in.) (MINI

0.3 mm (0.012 12 V, 7000 rpm (MINI 60A (MAX)

battery capacity Max charging

0.8

KW

(0.008

in.) (MINI

in.)

(MAX)

Electric Starter System (Shiftlever-type)

Battery rating Max charging

current

Starter-rating Brush length

Commutator 0.2 rnm groove depth

Commutator 27 mm (1.10 in.) (MAX) diameter

Commutator 0.4 mm (0.016 in.) (MAX) run-out

Current draw 11.5 V, 6000 rpm (MINI

test

12 A.H. One-tenth

12 V

6

/

35 A.H. or more

of

-

0.75

mm (0.24 in.) (MIN)

(0.008

I

50A (MAX)

battery capacity

KW

in.) (MIN)

PRELIMINARY

1

A complete diagnosis of engine malfunctions appears in this section.

However, the majority of engine problems

normally due to ignition or fuel system diffi-

I

culties.

1.

If engine will not start with gasoline in the tank, remove spark plug and check spark by cranking engine while having the plug touched against engine block.

WARNING:

plug in close positions to

as

plug

To

avoid an electric shock, do not hold the plug

itself. Make sure to hold the plug

If there

I

1-1.

the ignition system

I

far away

ENGINE

To

avoid fire, do not hold spark

the

as

possible from the plug hole.

CHECKS

plug hole. Keep the

cap.

is

good spark between electrodes,

is

in good condition.

is

Charging System

I

ITEM

Stator output

No-load voltage Regulator-type

Regulator resistance

Monitor System

I

Approx. 12 amps-0 rpm

/

34.5 V 12V system, constant voltage,

regulator See Regulator Inspection

3350 rpm (MIN)

I

1-2.

If there

plug and regap to

0.028 in.). Replace the plug if

is

no or a very weak spark, clean the

0.6

to 0.7mm (0.024 to

it's

electrodes

are of worn.

1-3.

If there

is

still

no spark refer to "IGNITION"

section.

A

2.

If engine

still

fails to start, check the fuel

system for the tank to carburetor to be sure

gas

is

getting to carburetor. Check carb. adjustments and be sure choke and throttle controls are working properly.

Refer to Section 4 for carb. information.

Check for

3.

a

plugged air cleaner. Clean or re-

place if necessary.

still

If engine

4.

will not start, or starts but

does not run properly, perform the compres-

test

sion

that follows, and refer to "Diagnose

Malfunction" in this Section.

5.

Test compression when engine loses power or

runs erratically and fuel and ignition

adjustments do not correct the problem.

systems

GENERAL INFORMATION

1-12

CAUTION:

engine from starting during compression

6.

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

7.

If

of one or more of following:

8. Use sion by:

8-1. Remove spark plug and screw compression

gauge into the plug hole securely.

Disconnect spark plug cap

compression

Leaking cyl. head gasket.

Warped cyl. head.

Worn piston rings.

Worn cyl. bore.

Damaged piston. Burned or warped Improper

Broken

a

compression gauge and

valve

is

low,

clearance.

springs.

valves.

it

is

usually the result

to

test

prevent

compres-

test.

8-2. Crank engine with electric or recoil starter

and take highest pressure gauge reading.

8-3. Cylinder compression should not be

(55

380 KPa

8-4.

If

compression reading

for carbon built up in combustion chamber.

psi).

is

too high, check

less

than

1-13

GENERAL INFORMATION

TROUBLE

SHOOTING

points. This chart describes typical troubleshooting

If engine malfunctions, check if the way the en- procedures.

is

used

is

gine even if engine

correct. If engine malfunctions

is

used correctly, systematically magneto or engine unless

Do

not unnecessarily disassemble carburetor,

carry out troubleshooting starting with simple the cause of malfunctioning.

[Engine hard to start]

Remove spark plug and

check spark by crank-

I

ing engine while having the plug touched again-

st

engine block.

WARNING:

Keep the plug

as

away the plug hole.

To

shock, do not hold the plug ,Make sure to hold the

plug cap.

possible

avoid an electric

itself.

as

from

far

between high tension lead and engine block in the

state

where plug

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

is

it

has been found to be

Check carb.

Make starting attempts

number of times and then remove spark plug and observe

[odes.

Are they wet?

fuel line. Check for plugged

air passage.

Check float

level.

elec-

NO-

Y

ES-,

gap

Demagnetized fly- Replace

wheel

into fuel pipe or filter tank cap

Plugged fuel line Clean

turn the crankshaft

without loading

in float bowl

Worn piston/piston

t

rings Stuck piston rings Clean or replace

Worn cyl. bore Bore or replace tightening

seat

Plunge-up by

Warped cyl. head

Broken Stuck

valve

spring Replace

Replace

Adjust

valve

Clean or grind

Replace

clearance

GENERAL

INFORMATION

1-14

[Engine

Is

normal?

Is

normal?

loss

power]

the ignition spark NO-

lubricating condition NO-

Adjust

level

Excessive engine load. Adjust load

screens, shrouding and engine fins.

chamber.

Wrong spark plug. Replace Faulty spark plug. Replace

Faulty control unit. Replace Faulty ignition coil Replace Faulty high tension cord. Adjust gap Armature air gap incorrect. Replace Demagnetized flywheel. Correct

in crankcase. bricating oil.

or add

Is

unusual smoke emit- YES

ted out of muffler?

Is

compression suffici-

ent?

[Engine runs erratically]

Plugged air cleaner. Clean

@Carbon deposit in

hole and muffler.

not properly

Too

much oil in crankcase. Adjust

-I_--

Hard.

fuel pipe or fuel filter.

level

Problem in the governor system

I

justment.

Faulty governor spring. Replace

tioning.

1-15

GENERAL INFORMATION

[Engine malfunctions

Is

revolution fluctuation of relatively large period produced when

a

[Engine malfunctions

Remove spark plug and check spark by cranking engine while having the plug touched against engine block.

WARNING:

Keep the plug

as

possible from the plug

hole.

To

avoid an electric shock,

do not hold the plug

self.

Make sure

plug cap.

load

as

to

at

is

appli-

at

far away

hold the

high

low

it-

speed]

fuel filter or fuel pipe

speed]

Faulty plug insulation Replace Fouled electrodes Clean Faulty control unit Replace Faulty ignition coil Replace Faulty high tension cord Replace Incorrect armature air gap Correct

J

t

Is

unusual smoke emitted

out

of

muffler?

Directly and gradually open Disassemble and clean

valve

stall

by hand. Does

at

a

certain

throttle

the revolution drop or does

engine

position?

Is

air sucked through car- Retighten

buretor flange? Damaged gasket Replace

t

Are

valve

mal values?

clearances of nor- Adjust

t

Is

alignment of timing gear

marks correct?

NO

YES

Overrich fuel in

Wrong

valve

timing

Largely deviated

i

ng

slow

system Turn off pilot air

a

minor extent

valve

tim-

timing gear marks

jet

valve

clearances

alignment of

by