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

GENERAL INFORMATION

1-16

[Fuel consumption

compression sufficient?

Is

[Oil consumption

is

excessive]

is

excessive]

YES-

r

High fuel float chamber (including overflow) Delay High idling

Incomplete opening of

choke

Excessively backed off car-

burator pilot air screw

Stuck piston Worn cylinder bore

insufficient cyl. head tighteness

Faulty Plunge-up of Wrong

Broken

Stuck

Plugged oil ring groove

High oil Faulty

Worn

guides Oil leakage along governor shaft

Oil leakage from oil Oil leakage from mounting

surface

Oil leakage from drain plug Clogged breather Drain-back hole in tappet -Clean chamber plugged

Incorrect oil viscosity

Worn piston rings

Stuck piston rings Worn cylinder bore

level

is

ignition timing

R.P.M.

valve

seat

valve

timing -Adjust

valve

spring

valve

level

valve

seat

valve

stems and

in carb.

contact

valve

seal

valve

-Adjust

-Clean or replace

-Bore or replace

-Adjust

-Replace

-Clean

-Adjust

-Replace

-Replace gasket

-Retighten

-Clean

-Correct

choke

Replace

valve

or

grind

or

Replace Clean or replace

Bore or replace

Replace

clearance

replace gasket

[Engine runs erratically]

Carb.

not properly adjust-

ed Spark plug fould, pitted,

or

gapped incorrectly Carb. flange leaking ket Carb. body and throttle shaft warn

Restricted

Governor mulfunctioning

gas

[Engine backfires]

head gasket.

valve

[Engine knocks]

Stale

fuel

Excessive carbon deposit in Clean Excessive engine load

Engine overheating Faulty control unit

engine

at

tank vent

gas-

-Clean

-Adjust Tighten

Change

Adjust See low on power

Replace

or adjust

or replace

1-17 GENERAL INFORMATION

TUNE-UP PROCEDURE

A "Tune-Up"

ly

be performed on relatively new engines brought in for minor difficulties. By performing these steps you will either be sure the engine tion properly or will know if and what major repairs should be performed. The steps are PROCEDURE and will normally be performed

as

a

part of the complete overhall.

Remove fuel tank, clean tank and

Check oil

Remove air cleaner, check for proper

servicing.

Remove recoil starter, flywheel housing,

and shrouds.

Inspect rope, recoil starter assembly or

pinion clutch (electric starter). Clean cooling fins and entire engine.

Rock flywheel to check compression.

Remove carb., disassemble and inspect for wear or damage. Wash in solvent, replace parts

Set

Inspect inlet and exhaust flange for damaged gaskets.

Check governor linkage, spring, and speed control lever for damage or wear, also check adjustment.

Remove flywheel, check for both flywheel and PTO shaft sides. Check flywheel key for damage.

Check coil and control unit, inspect wires for breaks damaged insulation.

Be

Check stop switch and lead.

Install flywheel. spark.

Remove cyl. head, check gasket, remove spark plug, and clean carbon, inspect valves

Install cyl. head, torque to the specified torque, the plug if necessary.

Replace oil and fuel, check muffler for

restrictions or damage. Adjust speed control linkage and cable

if used, for correct operation.

Run and adjust idle (mixture), and MAX speed.

(see

the steps below) would normal-

is

func-

also

covered in the OVERHAUL

lines.

level

and drain.

as

necessary and assemble.

initial adjustment.

seal

leakage,

sure lead wires do not touch flywheel.

Set

air gap. Check for

for seating.

set

spark plug gap or replace

all

OVERHAUL PROCEDURE

The following overhaul procedure

help you in systematic and sequential method of repairing obtained when the repair operations are performed in the same sequence every time. The exact procedure will vary according to the engine model being repaired. This table can also be used

For detail information on how to perform each operation refer to the section and page number listed.

a

Kawasaki FB46OV engine. Efficiency

as

an index.

DISASSEMBLY Drain engine oil Air cleaner assy Muffler ass'y Carburetor, heat shield plate and

ket. Intake Carburetor and linkage.

Disassemble carburetor.

Electric starter

Recoil starter Dip stick and blower housing Spin flywheel to check compression

Spark plug-adjust inspect.

Rope starter pulley. Adjust armature air gap. Tappet chamber cover and

pipe

connector Cylinder head and gasket Check valve-to- tappet clearance

and spring.

Flywheel

_-

Breather

Ignition coil and control unit

Starter motor disassembly

Recoil starter disassembly

Governor control base plate and

governor arm

Crankcase cover

Damaged

Damaged governor gear ass'y

Oil

pump and relief Camshaft and gear Tappets

Con-rod and piston

Balance weight support shaft

Crankshaft and balance weight

ass'y

Disassemble crankshaft ass'y

oil

pipe.

I_______-

seal

valve

__

gap,

is

intended to

clean

valve

gas-

and

is

I

GENERAL INFORMATION

1-18

Section

9

10

6

8

I

Section

2

9

DISASSEMBLY

Crankshaft inspect and check Cylinder check bore, main bearings,

valve

guides and

Disassemble connecting rod and piston. Check piston, rings, connecting rod,

piston pin.

Resize

Replace Reface Replace main bearings. Replace oil

Replace governor gear ass'y.

Cylinder head repair

Replace flywheel ring gear. Replace bushing link rod.

cylinder bore to next over

valve

valves

valve

seats.

R

EPAl

R

guide intake, exhaust.

and

seats

and

seals.

size.

lap.

I

Section

9

8

9

5

7

9

5

6

7

2

REASSEMBLY

Assemble crankshaft, link rod and balance weight.

Crankshaft ass'y and balance weight support shaft

Piston, piston pin, rings Connecting rod sub ass'y Tappets, camshaft Governor gear

Crankcase cover

Valves, Adjust

Tappet chamber cover, breather pipe

connector

Breather reed

lgnition coil

Control unit

Charging stator coil

Flywheel and pulley

Adjust air gap Check spark. Cylinder head and gasket

Cylinder head and cylinder cover

Blower housing. Inlet pipe. Governor control base

valve

ass’y

springs, retainers

tappet clearance.

valve

and cover

:

armature to flywheel.

Oil

dip stick

plate.

~-

2-1

IGNITION

Section

IGNITION

A transistor controlled ignition system

FB46OV.

components.

Ignition coil unit Control unit (Igniter) Permanent magnet flywheel Spark plug

The ignition coil unit wheel on the cylinder block. Since the transistor ignition system contains no mechanical parts, no wear occurs and no periodic maintenance

Principle of Operation

SYSTEM

is

used for

This system consists of the following

is

mounted outside the

is

required except for the spark plug.

fly-

2

SPARK CHECK

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

the

plug

as

Keep

possible from the plug hole. To avoid an electric shock do not hold the plug itself. Make sure to hold the plug cap.

is

If there ignition system

good spark between electrodes, the

is

in good condition.

far away

as

:

Primary coil

:

Secondary coil

:

Control Resister

CU

:

Control Unit (Igniter)

:

Control Resister

When voltage

)

flows into Transistor

Transistor

large amplified current to flow, during which the Transistor does not operate because Resister As the flywheel continues to rotate, AC power

(L,

"ON" by high voltage

As soon the base current Transistor Transistor thus the Transistor

turned

is

).

"OFF"

at

point (A)

is

(

)

further generated in the primary coil

Then the Transistor

as

the Transistor

)

changes

because of voltage drop

is

turned "ON" and allows

lowers

at

through Resistor

point

its

flow

valtage

:

Transistor

:

Transistor

F

:

Flywheel

SP

:

Spark plug

SW

:

Stop switch

plus, base current

).

Then the

at

point

C.

)

is

turned

(C).

)

is turned "ON",

(R,

)

to

to )

and to

at

point

)

is

(B).

This sudden current change induces high voltage within the secondary coil

fires the spark plug.

(L,),

which

is

If there

plug and regap to

in.). Replace spark plug if electrodes are worn.

See

"Spark Plug Check and Cleaning" section.

no or very weak spark, clean spark

0.6

to 0.7mm

(0.024

to

0.028

FLYWHEEL REMOVAL

1.

Remove spiral

2.

Disconnect spark plug cap from spark plug.

3.

'Carefully remove the wire out of spiral

CAUTION: Flywheel nut has a left-hand thread.

4.

Place a pry bar against the thick root of the blades to prevent the blades from breaking off.

case.

(Flywheel housing)

case.

6.

Remove flywheel with a flywheel puller

(A).

CAUTION:

deep or

(2)

too

By

using a hammer and bar, strike ring gear

evenly to remove

Do

close.

not cut

it.

flywheel

IGNITION

by

drilling

2-2

too

7.

Remove and inspect flywheel key. Replace the

key if

8.

it

is

bent or sheared.

Inspect crankshaft taper

for

nicks or burrs.

If necessary, finish taper using fine emery

paper.

FLYWHEEL CHECK

CAUTION:

impact weakens magnetic force of

1.

Put flywheel on a wooden surface.

2.

Hold

from flywheel magnet. The metal tool should

be attracted by magnet. If magnetic force

is

weak, replace flywheel.

Do

not

give

impact to magnet,

a

metal tool about 25mm

it.

(1

in.) away

as

drill 5/16 deep (4-6) drill

(3)

Heat a new ring gear

(C),

holes

evenly

to

an extent

that expansion by heating facilitates following

installation.

(4)

With the beveled edge of the gear faced up, quickly install ring gear, quickly followed tapping ring gear evenly to insure good seating.

gear

by

New

ring

gear

2-3

IGNITION

IGNITION COIL CHECK

1.

Remove two mounting screws and remove ignition coil.

2.

Remove the plug cap from high tension cord.

3.

Set KAWASAKI multimeter selector switch

a

specified range and connect leads the chart below,. If meter reading falls within the values shown in the chart, the coil tioning properly.

Spark plug lead Primary terminal

Core

as

shown in

is

func-

at

FB460V-BS. Model

BM1129

Terminal Core

Control Unit Resistance

Terminal

Case

*Resistance value may vary with individual meters.

*Do

(A)

(B)

not use a megger.

ON to ON to

(AS.

Terminal

(A)

BS,

Model)

I

Ignition Coil Resistance

Connection

I

coi

I

Secondary

*Resistance value may vary with individual meters.

CONTROL

Unfasten connectors.

1.

2.

Unscrew mounting screws and remove control unit.

Set

3.

KAWASAKI multimeter selector switch

Rx1

the chart below. If meter reading falls within the values shown in the chart, the unit functioning properly.

FB460V-AS. Model

Primary terminal

UNIT

scale and connect leads

White lead

CHECK

I

Resistance

0.4

(R

x

10

(R

x

to 0.8

1 Range) core to 18 Plug lead

1 Range) core coil

as

at

shown in

is

FLYWHEEL INSTALLATION

Be sure the key

To

tighten flywheel nut, reverse the removal steps.

Torque to spec. listed.

Flywheel Nut Tightening Torque

is

in place when installing flywheel.

83 to 88 N-m

(62

to

65

ft-lbs)

IGNITION COIL AlR-GAP

ADJUSTMENT

(1)

Leave ignition coil mounting screws loose

so

the coil can be moved for air gap adjust-

ment.

(2)

Inserting a 0.3mm thickness gauge (A) coil

legs

on flywheel rim, move the coil to

adjust AIR GAP.

(3) Tighten mounting screws firmly.

(0.012

in.)

at

each area in between

AIR

GAP-

(Ground lead) (Ground lead)

IGNITION

2-4

FLYWHEEL HOUSING INSTALLATION

1.

Install flywheel housing

protector

NOTE: The air gap

(D)

and tighten screws.

(C)

under screen and flywheel housing not

less

than 1 mm

adjust the air gap

Adjust washer (A)

Bracket

2.

Install cylinder head cover and tighten screws.

NOTE:

Flywheel Flywheel housing

Push cylinder head cover firmly against

(0.04

(C).

Rotating screen

flywheel housing to eliminate cooling air leakage.

3.

Install dipstick and air cleaner assembly.

(E),

rotating screen

between contour blades

(E)

should

in.).

Use

(B)

Protector

washers

(D)

(A)

Air gap

(B),

(D)

be

to

Electrodes Spark gap Shell Porcelain Gasket Terminal Seating material Reach

The plug can be cleaned using

a

solvent and

wire brush or other suitable tool.

a

high flash-point

If the spark plug electrodes are burn away or

is

damaged, or if the porcelain

cracked, replace

the plug. Use the following spark plug.

Specified Spark Plug

Spark

plug

NGK

BMR-4A

CHAMPION

RCJ-8

0.6

Gap

to

0.7

0.028

mm

in.)

SPARK PLUG CHECK

AND CLEANING

A

spark plug consists of two electrodes

ed from each other by spark gap

is

electrode plug. The center electrode

connected to shell

is

completely insulated

from the shell.

The high voltage, produced in the secondary coil

is

winding, causes

applied to the center electrode and

a

spark to jump the gap

electrode. This spark ignites the fuel-air-mixture

starts

and

the combustion process in the cylinder.

Gap between electrodes affects the entire

range of engine performance accelerating, power and top speed. Spark plugs must operate within temperature range to give good performance.

(A)

separat-

(B).

The side

(C)

of the spark

(B)

to the side

-

starting, idling,

a

specific

Spark Plug Gap

(1)

Measure the gap with a wire type thickness

is

gauge. If the gap the outer electrode with

incorrect, carefully bend

a

needle nose plier

to obtain the correct gap.

Spark Plug Tightening Torque

28

N-m

(20

ft-lbs)

3-1

AIR CLEANER

Section

AIR

A properly serviced parts of the engine from dust particles in the air.

If the air cleaner instructions are not carefully followed, the dirt and dust which should be collected in the cleaner, will be drawn into the engine and become

is

very detrimental to engine life; dirt in the oil forms an abrasive mixture which wears the moving parts. The air cleaner on every engine brought in for check up or repair should be examined and

ed. An air cleaner element clogged with dirt chokes the air supply to the engine, resulting in an overly rich fuel/air mixture and inefficient combustion. This in turn causes reduced engine power and overheating due to carbon build-up in combustion chamber.

cleaner removed.

air

cleaner protects the internal

a

part of the oil film, which

Do

not run engine with air

CLEANER

servic-

a

3

AIR CLEANER HOUSING INSPECTION

1.

Check air cleaner housing for deformation or other damage. The housing must and permit only filtered air to reach carburetor. Replace the housing if damaged.

2.

Check no foreign material air passage.

AIR CLEANER INSTALLATION

1.

Clean elements, housing, cover and other parts.

2.

Elements and housing must be installed cor-

rectly.

3.

Install O-ring, housing, elements cover, washers

and tighten wing bolts.

is

obstructing the

seal

well

AIR CLEANER SERVICE

A FB460V engine

air

cleaner which has dual elements and an element

housing.

Remove two wing bolts and lift off air cleaner

completely.

CAUTION:

or compressed air.

Foam Element

1.

Visually examine element for turn, puncture and otherwise damaged. Replace element if

necessary.

Wash element in detergent and water and dry throughly.

Immerse in new engine oil and squeeze out

excess.

Paper Element

2.

Clean element by tapping gently to remove dust. If very dirty, wash in detergent and water, and dry throughly. Replace with a new paper element every

Do

is

equipped with a heavy duty

not clean the element with solvent

300

hours.

1.

Wing bolt

2.

Washers

3.

Cover

4.

Element (Foam)

5.

Element (Paper)

6.

Housing

7.

0-Ring

8.

Element housing

CARBURETOR

4-1

CARBURETOR

CARBURETOR OPERATION

1.

In the choke or start position, the choke

is

closed, and the only air entering the engine

enters through opening around the

is

the starting device engine, the air pressure in the carburetor

reduced the air passage fuel

both idle fuel discharge ports and mixes with the air that passes through the throttle This makes a very rich fuel mixture required to

start

2.

At idle a relatively small amount of fuel

required to operate the engine. The throttle almost closed, shutting off the fuel supply

from

orifice,

as

air drawn into the engine. Since

is

drawn from the main nozzle and from

a

Cold engine.

all

except the one idle-fuel discharge

so

that the suction created by the

operated to

blocked by the choke valve,

valve.

start

Section

valve

As

the

is

valve.

is is

4

engine draws fuel only from that orifice.

3.

During intermediate operation, second and

third orifices are uncovered valve opens, and more fuel with the air flowing into the engine.

4.

During high speed operation, the throttle

is

fully opened. Air flows through the car-

at

buretor

The venturi, which decreases the air passage

through carburetor, further accelerates the air

flow. This high speed movement of the

decreases the air pressure, and fuel

into

that opens into venturi, mi ing with the air in

the air passage. As the en 'ne load increases,

is

air

through the air jet located in the air horn.

This allows fuel to be metered freely from the

main nozzle and to be facilitated atomization.

high speed.

the

air stream thro gh the main nozzle

automatically bled into

as

the throttle

is

allowed to mix

the

main nozzle

is

valve

air

drawn

Carburetor

Specifications

Main Jet Pilot Jet Pilot Screw (Turn out) Float Valve

Low Idle Speed

Fast Idle Speed

CARBURETOR REMOVAL

AND DISASSEMBLY

WARNING: Gasoline

Avoid fires due to smoking or careless maintenance practices.

1.

Before removing for repair, check for signs of link rod. air leakage, or mounting gaskets that are loose, deteriorated, or otherwise damaged.

is

dangerous. CAUTION:

2.

3.

4.

F

B460V-AS F B46OV-BS

#

47.5 #47.5

1-1/8

1.5 mm (0.059 in.)

3275 to 3425 rpm 3275

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

Do

not bent

Pull carb. free, and gently twist carb. to free

Remove governor link rod and link spring.

Disassemble carb.

I

the

links or stretch.

(See

illust. below).

1

-1/8

1.5 mm (0.059 1350 to 1450 rpm 1350 to 1450 rpm

to

3425 rpm

in.)

4-2

CARBURETOR

Disassembly Carburetor (See: Illustration)

Parts should remain in cleaner for 1 or

2.

hours. Remove and rinse with solvent. NOTE: Rinse carb. body in hot water to

neutralize corrosive action of cleaner on aluminum.

Dry parts with compressed air.

3.

Be

holes are open. Do not use rags or paper to

dry parts. Lint may plug hole or passages.

CARBURETOR INSPECTION

Inspect carb. body for damage. Flange sealing

1.

surfaces should be smooth and free of burrs and nicks.

Replace gasket if necessary.

2.

Inspect pilot screw and drain screw for wear

3.

at

the seating surface. Inspect for weak springs. Inspect main jet, bleed pipe, main nozzle and

4.

pilot screw for damage.

valve

Inspect inlet needle

5. at

the seating surface.

Inspect clip for damage.

6.

for wear or damage

sure

2

all

Ref.

No.

1

2

5 6 7

9

10

11

12 13 14

15 Gasket

Parts Name

Screw Throttle valve Screw 3

Choke valve 4

Screw Spring Spring

Pilot screw 8 Pilot jet

Drain screw Spring

Spring

Ring

Ref.

No.

16

Float pin

17

Clip

18

Float chamber

19

Choke shaft

20

Throttle shaft

21

Ring

22

Seal

23

Float

24

Main nozzle

25

Main jet

26 27

Washer

Bolt

28

Bleed pipe

29

Spring

30

Parts Name

Needle valve

CARBURETOR CLEANING

CAUTION: Never clean holes or passages with small drill bits or wire.

1.

Place

cleaner or

and plastic parts in cleaner.

carb. body and carb. parts in PT503

its

equivalent. Do not put gaskets

NOTE: Inspect the other parts of carb. for

wear, damage.

CARBURETOR ASSEMBLY

Reassembly

following points:

1.

Install main nozzle, bleed pipe, and main jet by turning clockwise into carb. body. Do not over tighten screws.

2.

Install pilot screw (mixture screw) and spring finger tight.

3.

Install pilot jet screw by turning

into carb. body. Do not over tighten.

4.

Install float and float pin.

CAUTION:

valve

when adjusting float

5. When carburetor

(A)

adjust float surface angle, bend tang

needle-nose pliers.

is

the reverse of removal. Note the

it

Do

not push on float or, inlet needle

level.

is

upside down, float surface

must be parallel to carb. body

clockwise

(B).

(C)

with

To

CARBURETOR 4-3

CARBURETOR ADJUSTMENT

CARBURETOR INSTALLATION

1. Install throttle linkages (A) and choke linkage

(B)

on carburetor.

2.

Install breather connector

(D).

3. Assembly gaskets carburetor

(D).

4. Install carb. ass'y on inlet pipe

(J).

bolts

(G),

(E),

gasket

(C)

on intake pipe

heat shield plate

(H)

and intake pipe

(I)

with through

(F),

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

Adjust Idle Mixture

Air cleaner must be assembled to engine.

1. Turn idle mixture screw

seats,

then back

CAUTION: The pointed end of damage.

2.

Start lever on equipment to "IDLE POSITION".

3. Use screw (A) to obtain 1,350 to 1,450 rpm by turning

the screw against carb. body.

4. Adjust idle mixture screw clockwise (lean) or counterclockwise (rich) to

obtain the peak of idling.

5. Turn idle mixture screw

turn more.

6.

Use a tachometer and readjust throttle stop screw (A) to obtain and satisfy specified 1,350 to 1,450 rpm idling.

7.

Stop engine.

Do

and allow engine to warm. Move throttle

a

tachometer and adjust throttle stop

it

not turn

in or out while holding the end of

is

dangerous.

(B)

in until

out 1-1/8 turns.

the

screw in too far.

valve

seat

is

(B)

it

just

susceptible to

by turning

back out 1/4

5-1

GOVERNOR

Section

5

GOVERNOR

The governor control regulates the engine speed by

changing the governor spring allowing the governor to control the carb. throttle buretor

at

all

times and maintain any desired speed.

A

FB46OV

flyweight type governor. chamber cover.

If the engine

rated speed, the speed will drop if the load increases even slightly. In responce to the decrease, governor weights

amount. Their movement

sleeve

the

(5).

direction of the arrow)

valve

in the opening direction.

As

speed increases,

(8),

and the rod turns the direction. This action/reaction sequence soon creates engine to run while carrying

Dumping the load suddenly will cause increase in speed. But the interaction of the engine-governor-carb. protects the engine from carburetor to free throttle linkage

over-revolution and speed soon

level.

engine

(3)

The arm then moves the link rod

is

equipped with a mechanical

is

carrying a load and running

(2)

contact by corresponding

and governor shaft

(7)

it

is

sensed by the governor

a

state

of equilibrium which allows the

at

nearly the same speed

a

slightly greater load.

(1)

tension, thus

at

is

transmitted through

(4)

to the arm

(6)

(in the

which turns the throttle

valve

in the opposite

as

before

a

rapid

settles

at a constant choke linkage

3.

Remove through-bolts

4.

Remove intake pipe

(GI,

heat shield plate

(J).

(D),

gasket

(F)

(E).

5.

Disconnect breather connector from tappet

6.

Remove link spring

(C).

(A)

and gently twist

Remove linkage.

(H),

and gaskets

(B)

car-

and

Low

speed position

High speed position

REMOVAL (GOVERNOR RELATED)

1.

Remove air cleaner assembly. and remove crankcase cover from crankcase.

2.

Loosen clamp and disconnect fuel line from

carburetor.

GOVERNOR GEAR DISASSEMBLY

1.

Unscrew mounting bolts in the order specified

2.

If necessary, remove governor ass’y

a

proper

size

screw driver.

(A)

with

GOVERNOR GEAR INSPECTION

1.

Inspect governor gear for worn and damage.

as

Replace

ceed.

an unit, if wear and damage

ex-

GOVERNOR

is

Reassembly

following points:

1.

Install governor lever (A) on governor shaft

(B)

and tighten nut

the reverse of removal. Note the

(C)

finger tight.

5-2

GOVERNOR REASSEMBLY

1.

Install thrust washer governor ass'y (A) until inner flange

(B)

of the shaft

CAUTION: The stuffed into the gear to the shaft. governor

2.

ass'y

After installed, governor ass'y should rotate freely on the shaft.

as

sleeve

once removed.

(C)

and stuff into new

(E)

to short stationary shaft

(D)

fitted into groove

shown.

can not

be

installed after

Do

not reuse

2.

The throttle and choke linkages can not installed on the carburetor after the intake pipe was installed.

LINKAGE ADJUSTMENT

1.

Place throttle lever on dash in "FAST" tion. (Equipment side)

2.

Loosen nut

governor shaft

3.

Turn governor shaft travel by inserting needle and tighten nut

(1),

that holds governor arm to

(2).

(2)

clockwise to the end of

(3)

to shaft end hole

(1).

be

posi-

3.

I

nstall governor gear cover.

4.

Place a new gasket on crankcase cover and put

small amount of grease around oil

5.

Lubricate crankshaft bearing in crankcase

cover with engine oil.

6.

Suitably

gear when installing crankcase cover.

set

the gear to be meshed with cam

seal

lips.

NOTE: The throttle lever on "FAST" position when adjusting the governor.

4.

Lower and raise throttle lever after adjustment

to be sure linkage

5.

More throttle lever (on dash) up to "FAST"

position. Speed control lever wide open throttle position [aligned hole and

(D)],

but not enough to move choke link

(4).

If adjustment

clamp bolt (A) and adjust cable.

6.

Retighten clamp bolt (A).

is

not binding.

the

dash must

(C)

should be

is

necessary, loosen cable

be

in

(B)

5-3

GOVERNOR

THROTTLE CABLE INSTALLATION AND ADJUSTMENT

Make sure that the throttle lever and cable on equipment have the speed control linkages with

engine.

1.

Leave

cable clamp bolt (A) loose.

(B)

Align hole

2.

hole (D) of control plate

a

insert bolt) through the two holes. Pull up outer housing

3.

until the inner cable and tighten the cable clamp bolt.

Remove the

4.

Be

completely when throttle lever on equipment

is

form "CHOKE ADJUSTMENT,, described below.

(6

sure that carb. choke

moved to "CHOKE" position. If not, per-

of speed control lever

(E)

mm)

0.24

in. dia. pin (or

(F)

(G)

has almost no slack,

6

mm dia. pin.

valve

moving the lever;

of throttle cable

(H)

(C) a

is

with

6

mm

closed

CHOKE ADJUSTMENT

1.

Align hole (B) of speed control lever hole (D) of control plate

a

6

mm

insert

dia. bolt) through the two holes.

2.

Turn in choke setting screw (K) until just begins to touch the tongue of lever

3.

Remove the 6 mm dia. pin

(0.24

(E)

moving the lever;

in.) dia. pin (or

or

bolt.

(C)

a

its

with

6

mm

end

(L).

MAXIMUM SPEED ADJUSTMENT

Start

engine and allow

1.

Align hole

with hole (D) of control plate

the lever; insert

(or

a

6

mm bolt) through the two holes.

2.

Leave two control-plate-tightening-bolts loose.

3.

Use a tachometer and slide control plate

left

or right to obtain specified

Be

sure that the carb. choke

opened during adjustment.

4.

Tighten two bolts avoid changing the specified speed.

5.

Adjust choke per procedure previously mentioned.

6.

Remove the 6 mm dia. pin or bolt.

7.

Stop engine.

it

warm.

(B)

of speed control lever

a

(6

mm)

0.24

(I)

securely in a manner to

(E)

by moving

in. dia. pin

3,350

valve

is

IDLE SPEED ADJUSTMENT

Before the following procedure, carb. adjustment

must be performed.

(See

CARBURETOR ADJUSTMENT)

Start engine and allow

1.

Move throttle lever on equipment to farest

IDLE position and leave

2.

Turning throttle stop screw (J) in or out to obtain specified idling

3.

Stop engine.

it

warm.

it

there.

1,350

to

1,450

(C)

(I)

(E)

rpm. fully

rpm.

COMPRESSION

6-1

Section

COMPRESSION

COMPRESSION CHECK

Before measuring compression pressure;

Be

Check cyl. head to torque.

charged on electric starter models. Start engine

it

and allow for leaks around cyl. head gasket. Stop engine.

1.

Remove spark plug and screws compression

gauge into the plug hole securely.

2.

Crank engine with recoil or electric starting for several seconds and take highest pressure gauge

reading. Cylinder compression should not be

3.

If compression reading carbon built up in combustion chamber. Carbon deposits in combustion chamber should be removed every

of.

4.

If the compression pressure cified,

Leaking cyl. head gasket. Warped cyl. head. Worn piston rings.

Damaged piston. Worn cyl. bore.

Burned or warped

Improper

Broken

To

practically measured by:

to warm up. During warm up, check

less

than 3 kg/cm²

use, or whenever cyl. head

it

is

usually the result of one or more of:

valves.

valve

clearance.

valve

springs.

a

great extent, compression can also be

sure battery

(43

psi).

is

too high, check for

100

to

is

removed.

is

less

is

fully

200

hours

than spe-

6

torque and maintain positive sealing of the combustion chamber.

1.

Remove cyl. head and

CYLINDER HEAD TIGHTENING

PROCEDURE

CAUTION: Do not use a sealer of any kind on

ket.

1.

Coat head bolts threads with a light film of oil and install the bolts.

2.

Tighten screws down evenly by hand.

3.

Use a torque wrench and tighten head bolts in the sequence torque.

gasket.

as

shown, and to the specified

gas-

*-

Disconnect spark plug cap to prevent engine starting during compression Be careful not to get your fingers caught in flywheel fins during

Spin flywheel counter clockwise (flywheel side) against the compression stroke; indicates satisfactory compression. Slight or no rebound indicates poor compression.

test.

a

sharp rebound

test.

CYLINDER HEAD AND

HEAD GASKET REMOVAL

CAUTION: Always note the position of each

cyl. head screw

bled.

A

FB46OV

in the exhaust

so

they may

has 3-heat-resistant high-tension studs

valve

side area to prevent

be

properly reassem-

loss

of

Cylinder Head Tightening Torque

34

to

39

N-m

(25

to

29

L

CAUTION: Do not turn one screw down completely before the others,

cyl. head.

as

ft-lbs)

it

may cause a warped

6-2

COMPRESSION

CYLINDER HEAD CHECK

AND REPAl

1.

Clean cyl. head.

WARNING: Be

cleaner

2.

3.

Cyl.

I

4.

is

used.

Check cyl. head flatness by placing cyl. head on

a

surface plate more than

Use

a

space between surface plate and cyl. head.

Head Warp (MAX)

If cyl. head

replace

R

alert

thickness gauge

0.4

mm

(0.01

is

warped more than specified,

it.

to fire if combustible

at

six points.

(A)

to measure the

5 in.)

I

J

VALVE SPRING INSPECTION

1.

Inspect springs if necessary.

2.

Measure the free length of springs. If shorter than specified, replace spring.

Intake Exhaust 39.0

TO

ANALYZE VALVE

When leaded gasoline deposits on the exhaust exhaust dicates the Clean the seating face and lap the valve into the

reface the

CAUTION: Be sure to reset valve-to-tappet ance after grinding

valve

Valve Spring Free Length

I

gas

seat.

springs for damage. Replace

43.3

leakage past the

valve

is

not seating properly.

If worn severly, grind the

seat

to correct condition.

valve.

mm

is

(MIN)

(1.705 in.) (1.535 in.)

used,

valve

excessive

are caused by

valve.

valve

lead

This in-

and

clear-

5.

If cyl. head

limit, reface the head surface by rubbing on emery paper (first: placed on

6.

Check cyl. head gasket for burn and trace of

gas

leakage. Replace gasket if necessary.

is

warped

a

surface plate.

less

than the specified

No. 200,

then: No. 400)

VALVE AND SPRING REMOVAL

1.

To remove

pressor over the spring

2.

Compress spring. Remove retainer by a needle

nose plier. Pull out sor and

(A),

valve

(B)

and retainer

valve

valves

using a valve spring com-

put screw head of compressor

head and slip lower jaw between

(C).

valve.

spring.

Remove compres-

Valve stem corrosion

in the engine. Moisture in the fuel-air mixture or combustion engine when the engine down. Valve corrosion can also occur during storage.

Fogging or pouring oil in combustion chamber

before storing helps prevent

Corroded or pitted and may cause sticking

Replace badly corroded or pitted

Poor engine cooling due to dirt or obstructions

is

a

common cause for overheating an engine and the clean cooling fins. Other causes for

valve guides or

clearance, lean fuel-air mixture and incorrect or overheated plug. Use of old or stale gasoline for sticky be seen on the exists, the carburetor may also contain gum deposits and will require

CAUTION: Always use fresh gasoline and drain fuel tank, lines and carburetor before storing equipment.

valves.

gases

Remove flywheel housing and

valve

valves.

is

caused by moisture

can condense inside the

is

stopped and cools

valve

valves

valves.

valves

springs, incorrect

This gummy deposit can

valve.

collect deposits

running hot are worn

is

a

When this condition

a

complete cleaning.

corrosion.

valves.

valve

common cause

VALVE INSPECTION

1.

Remove carbon from

a

stem with sure carbon ed.

power-operated wire brush.

is

removed and not merely burnish-

valve

head, face and

Be

2.

Check fects. sive

valve

Look

faces, heads and stem for defor bent

valve

corrosion causing pits on

stem.

3.

Replace less than (0.6mm)

valves

with a warped head or with

0.02

stem ends should be ground square before checking valve-to-tappet clearance.

stems and exces-

valve

in. margin. Valve

face or

COMPRESSION

6-3

Warped Head Worn

or

Improperly Ground Valve Stems

No

Margin

Valve Stem Bend Check

(1)

Support

valve

in V blocks

stem.

at

each end

of

the

Valve Stem Diameter

If any single measurement replace the

valve.

VALVE GUIDE

(MIN)

Valve Stem Diameter

7.91

2

mm

(0.31

CHECK

is

15

less

in.)

than MIN,

AND REPLACEMENT

1.

Use valve guide cleaner to clean the inside of

valve guides.

2.

Measure inside diameter of inside micrometer

at

several points.

valve

guide with

(2)

Position

a

dial gauge perpendicular to the

stem.

(3)

Turn

valve

and read the variation on dial

gauge.

Valve Stem Bend

If

the stem bend

valve.

(MAX)

0.03 mm (0.001 2 in.)

is

greater than MAX, replace

Valve Stem Diameter Check

(1)

Measure the diameter of

at

directions

right angles,

positions on the stem.

valve

at

stem

(A)

four different

in two

Valve Guide

Intake

Replace MAX.

Reject

Valve Guide Inside Diameter

valve

Size

(MAX)

8.062

mm (0.3174 in.)

8.062

mm (0.3174 in.)

guide if inside diameter exceeds

6-4

COMPRESSION

To

Replace Valve Guide

To

Remove Valve Guide:

(1

)

Use

a

valve

guide remover

(A) to replace

guide.

(2)

Fix

valve

guide remover on cylinder with bolts

and nuts.

(3)

Put a coat of engine oil to the remover bolt threads and screw

at

be seen

(4)

Install thrust washer

valve

it

in until the threads can

guide lower end.

(B)

and nut

hand thread) to the remover bolt.

Draw out

valve

(C)

(left

(4)

Turning the remover bolt, drive new guide into the hole to proper depth.

Valve Guide Depth h

30

mm

(1.18

in.)

Exhaust

30

mm

(1.18 in.)

valve

(5)

Turn out the bolt to remove

it

is

bushing until

completely removed from

valve

the guide.

To

Install Valve Guide:

(1)

Use

a

valve

guide remover to install

(2)

Apply a coat of engine oil to the outer surface of

valve

guide (A).

(3)

Install thrust washer

(B)

and new

valve

(A) to the remover bolt and retain them with

(C)

as

nut

shown.

Draw

in

guide

guide.

guide

(5)

Use stanisol or kelosen lubricant to finish reaming by

(6)

Turn to finish specified reamer (A) clockwise.

(7)

Throughly clean

a

valve

guide reamer.

valve

area before reassembling

engine.

VALVE SEAT RECONDITIONING

1.

Inspect

warped or distorted by beyond recondition-

ing, replace cyl. block.

Pitted or worn

valves

2.

To repair the then

and Check the around with machinist's dye.

valve

seats

to

seats

after refacing.

seats;

30"

to obtain standard

45"

again to finish.

seat

for damage. If

valve

seats

can be refaced. Lap

first use

for good contact

45"

valve

seats

cutter (A)

seat

all

the way

are

width

D

COMPRESSION

6-5

Right

CAUTION: Loosen moved up or down.

Use a center punch to tighten insert

:

Wrong

valve

If

this appears;

seat

can

be

turned

at

three

or

points equally spaced. Otherwise peen over edge around entire insert.

Valve Lapping

(1)

\

lap

If the

seat

valve

does not make proper contact,

into the

seat

with a vacuum cup

tool.

(2)

STD

Valve Seat Width

I

Intake Exhaust

I

Valve

1

.0

to 1.6 mm

1

.0

to 1.6 mm

Seat

Width

(0.039 (0.039

to 0.063

to 0.063 in.)

in.)

Coat face of compound.

(3)

Use vacuum cup tool Rotate

seat.

(4)

Lift

valve

continue lapping operation until an uniform

ring appears around the entire surface of

valve

face.

valve

from

valve

sparingly with a fine lapping

(A),

to grip top of

valve.

in a circular motion to lap to

seat

every 8 to 10s strokes,

:

Valve Sealing Width.

:

Valve

Seat

Angle.

:

Valve Face Angle. In.:

:

Valve Margin. 0.6mm

:

Valve Narrowing Angle. In.: 30°/ Ex.: 30°

3.

Follow

the

valve face

"Valve

seat

contact with the middle point of the center of the

(as

shown).

See

Table.

In.:

45°/ 45°/

Lapping" procedure to keep The lapping mark should appear on or near

Ex.: Ex.:

(0.02

45"

45°

in.) MIN.

(5)

When lapping

is

completed, wash in solvent to remove lapping compound. Dry parts thoroughly.

(6)

Note position of lapping mark on

valve

face.

(7)

Check

valve

clearance after lapping.

all

valve

the parts

face.

6-6

COMPRESSION

TAPPET CLEARANCE CHECK AND REPAIR

4.

Install Reassembly

all

parts related to

is

the reverse

valve

of

removal.

repair.

valve

Since

to-tappet), check the clearances (intake and ex-

haust sides). Make Sure to do this when engine

is

cold.

1.

Insert

cyl. block.

2.

Turn crankshaft until piston position in compression stroke. Then insert

a

thickness gauge

and tappet to check tappet clearance.

repairs change tappet clearance

valves

in their respective positions in

(A)

between

valve

is

(valve-

at

highest

stemsend

CAUTION: After installing check retainers are positioned Correctly.

Use

not

valve

molybdenum dissulfied when installing

in cyl. block.

valves

and springs,

DO

Specified Tappet Clearance (Cold)

Tappet Clearance

3.

If the clearance the end of tappet clearance.

To

Grind Valve Stem End:

Place

valve

in

valve

the stem end over oil stone back and forth.

is

less

than specified, grind

valve

stem to obtain the specified

lapping guide

(A)

and slide

LUBRICATION

7-1

Section

LUBRICATION

Oil

has four purposes.

lubricates.

A pressurized lubrication system used on the

FB460V engine pressure-lubricates the crank pin,

PTO main journal and balancer link. The FB46OV utilizes

pump to pressurize the lubrication system.

is

first drawn through the inlet (2) and into the pump chamber pressure of above speed). The oil

journal (4) into crankshaft and lubricates the

lower link rod

rod journal

is

passed through a metered orifice in the connect-

ing rod and piston and prevent ring sticking. The return oil mists then lubricates the magneto side ball bearing and others.

is

adjusted by a relief

(3

kg/cm² ) 42.6 psi

is

(5),

(7).

A portion

is

sprayed on the piston to cool the

It

cools, cleans,

a

camshaft driven trochoid

a

filtering screen

valve

at

3,000

then pumped to the PTO main

crank pin

of

(6)

and upper link

oil

at

seals

and

Oil

(1)

then

(3).

Oil

(8)

to a value

rpm (Rated

the crank pin

7

I I

Oil

pressure sensor

FULL FLOW OIL FILTER

The FB46OV can accept an optional car-

oil

tridge type full flow extend oil change intervals to

hours. (STD intervals:

filter (A) which can

25

hours)

(Optional)

as

mush

as

50

OIL WARNING SYSTEM

(Electric

Starter Model

Triggered by the sensor (A), a warning light comes on when pressure falls below kg/cm² ) 4.26 psi lubrication problem.

(See

ELECTRICAL

only)

SYSTEM)

(0.3

CAPACIT

Crankcase

IE

S

1.4

(2.96

Pt

US)

7-2

LUBRICATION

OIL RECOMMENDATION

Use

a

high quality detergent engine oil classified

"API

Service

engine oils keep the engine cleaner and delay the formation of gum and vernish deposits. Nothing should be added to the recommended oil.

Recommended

Temperature

I

Viscosity SAE 5W-20 SAE 30

OIL

1.

2.

3.

4.

5.

6. Check oil

LEVEL CHECK

Put engine on a level Remove dipstick; wipe dipstick with a clean rag; insert dipstick into filler tube. Let dipstick cap (A) threads rest on top of

the tube. Do not screw dipstick in.

Remove dipstick to check oil necessary. Install and tighten dipstick.

ing equipment.

SF,

SE/CC,

SAE

I

SE,

or

SD".

Viscosity Grades

Below Above

0°C

(32°F)

surface.

0°C

I

level.

DO

NOT overfill.

level

and add regularly before operat-

Detergent

(32°F)

Add if

I

BREATHER CHECK

It

is

the breather's function to maintain a vacuum

a

reed

valve"

a

reed

crankcase

valve,

valve

in the crankcase. The breather has which limits the direction of air flow caused by the piston movement of up and down. Air can flow out of the crankcase, but the "one way blocks the return flow, thus maintaining a vacuum

in the crankcase. A partial vacuum must be maintained in the crankcase

to prevent oil from being forced out of

at

engine, The FB460V uses the combination of and four expansion chambers

breather. through chambers where the oil and drained back to the crankcase. The breather

is

vented through the air cleaner, to prevent dirt

from entering the crankcase.

the piston rings, oil

Oil

laden air in the crankcase passes

a

maze by the reed

seals

and gaskets.

(1

4)

valve

and expansion

is

separated from the air

Full

level

OIL CHANGE

Change oil after first 5 hours of operation. There-

25

after dirty operating conditions.

1.

2.

3.

4.

.Remove dipstick and refill with new oil up to

5.

hours of operation; more often under

Put engine on a level Remove oil drain plug, and drain oil while

is

engine Install drain plug.

no higher than "Full" mark on dipstick.

(See

Install dipstick.

warm.

OI

L LEVEL CHECK)

surface.

1.

Inspect reed

2.

Inspect reed valve seating surface. They must

not have any nicks or burrs.

3.

Inspect reed

and broken.

4.

Check to be sure vent tube and sealed properly.

valve

for stuck and binding.

valve

for hair crack, distortion

is

not damaged

LUBRICATION

7-3

OIL

1.

2.

I

PUMP INSPECTION

Remove crankcase cover from crankcase. (See

Section Measure camshaft bearing on oil pump cover (A) with an inside micrometer bearing replaceable.

Bearing Inside Diameter

is

9

:

Crankshaft Removal)

cast

with oil pump cover and

t

(MAX)

20.071

mm

(0.7902

(B).

in.)

is

The

not

OIL

1.

2.

3.

4.

Pump Cover Tightening Torque

PUMP INSTALLATION

Install inner and outer rotors together. Install oil screen. Put relief-valve ball on Install oil pump cover with relief and tighten cap screws to specified torque.

valve

seat.

valve

spring

Replace pump cover, if inside diameter ex-

MAX.

ceeds

3.

Remove oil pump cover and inspect oil screen

for broken mesh. Replace

4.

Inspect relief ball have any nicks or burrs.

5.

Measure free length of ball

Free Length of Spring (MIN)

Replace spring if free length

6.

Inspect inner and outer place rotors if wear or damage

NOTE: relief

(3).

Do

not unscrew bolts

valve

cover

These bolts are applied locking bond.

valve

19.5

mm

._______-

(2)

and oil induction guide plate

it,

if necessary.

seating, they must not

valve

spring.

(0.768

in.)

is less

than

oil

pump rotors.

is

excessive.

(1)

which tighten

MIN.

I

Re-

17

to

23

N-m

(12

to

17

___--

After installation, the oil pump should rotate freely in the housing.

5.

Install crankcase cover on block. (See

Section

9

:

Crankcase Cover Installation)

ft-lbs)

8-1

PISTON, PISTON RING, AND CON-ROD

Section

PISTON, PISTON RING, AND

PISTON AND CON-ROD REMOVAL

1.

Remove any carbon cyl. bore; this will help prevent piston rings from breaking.

2.

To

remove piston and con-rod from engine,

rotate crankshaft (A) to expose con-rod bolts

(B)

as

shown.

3.

Remove rod bolts and con-rod cap. Push piston and con-rod out through the top

4.

of cylinder.

or

ridge

at

the top of

To Analyze Piston Ring Wear:

(1)

8

CON-ROD

Rings of the wrong

proper end gap will not conform to the shape of cylinder. This results in high oil consumption and excessive blow-by.

Ring end gaps should be staggered on piston during installation. End gaps in alignment can cause oil consumption and blow-by.

Light scuffing

piston occurs when unusually high friction and combustion temperatures approach the melting point of piston material. Probable

causes of this condition one:

Dirty cooling shroud and cyl. head.

Lack of cylinder lubrication.

Improper combustion. Wrong bearing Too much oil in crankcase causing fluid

friction.

size

or

rings having im-

or

scoring of both rings and

or

piston clearance.

To

Remove Piston From Con-Rod:

(1)

Remove piston pin snap rings with thin nose

pliers and slide out piston pin.

CAUTION: Removal weakens and deforms the rings.

(2)

Remove piston rings one

them over (A) ring lands. Use

(A) to prevent damage to rings and piston.

Do

not reuse snap rings once removed.

at a time, by slipping

a

ring expander

(2)

An engine operating

peratures may cause varnish, lacquer

deposits to form in the piston grooves making

the rings stick.

When this happens, excessive oil consumption

and blow-by will occur. Engine overheating and ring sticking

ly

caused by one

Overloading.

Incorrect ignition timing.

Lean fuel mixture.

Dirty cooling fins.

Incorrect oil.

Low oil supply.

Stale

fuel.

(3)

Vertical scratches across piston rings are due to an abrasive in engine. Abrasives may be airborne, may have been left in engine during

or

overhaul deposits.

When this exists, check for one

Damaged, collapsed air cleaner.

Loose connection air cleaner and carb.

Air leak around carburetor-to-cyl. block ket.

Air leakage around throttle shaft.

Failure to properly clean cyl. bore after

reconditioning engine. Scratches across oil side rails (A) are due to abrasive in engine oil.

may be loose lead and carbon

at

abnormally high tem-

or

more of:

or

improperly installed

or

damaged gasket between

or

more of:

carbon

is

usual-

/-

gas-

In this condition and much use, compression

(B)

rings

Oil

cause increase oil up by pumping action of oil ring. This results in high oil consumption, increased deposit in combustion chamber and stick of rings.

will also be worn.

inner spacer wear

(C)

and distorsion may

ring

PISTON, PISTON RING, AND CON-ROD

4.

Visually inspect rings and grooves for uneven wear or damage. Replace them if uneven wear or damage are excessive.

5.

Measure piston ring groove width. Use vernier caliper piston.

Piston Ring Groove Width (MAX)

at

several points around the

8-2

a

PISTON INSPECTION

No need to proceed with the steps shown if cyl-

is

inder shows wear or scoring piston.

1.

2.

CAUTION: or

3.

CAUTION: Never clean piston head with engine

assembled. Carbon particles will fall between

piston and cylinder, and may cause severe seizure.

to be resigned or visual inspection of piston

-

which require replacing

Remove all deposits from piston. Clean carbon from piston ring grooves with ring groove cleaner.

Do

not use a caustic cleaning solution

a

wire brush to clean piston.

Be

sure oil return passages in ring grooves are

open.

a

Ring

Top

If the width of any of the grooves

than MAX

6.

Inspect piston for scoring or fractures ring lands.

PISTON

I

at

any point, replace piston.

RING

Groove

2.120

rnm

(0.0835

2.095

mm

(0.0825

4.055

rnm

--_-

(0.1596

THICKNESS

INSPECTION

Use

a

micrometer to measure piston ring

at

thickness

several points around rings.

Width

in.) in.)

in.)

is

I

wider

at

Piston Ring Thickness

(MIN)

1.945

1.941

mm mm

(0.0766 (0.0764

in.)

8-3

PISTON, PISTON RING, AND CON-ROD

NOTE:

ness. Replace oil ring together with compression

rings.

PISTON RING END

1.

2.

NOTE:

square.

3.

Difficult to exactly measure oil ring thick-

GAP

Insert each ring in cyl. bore and check end

gap.

Install ring squarely in the bore to a point

1

approx. (25mm) cylinder.

Use piston to push

Check ring end gap with feeler gauge (A).

in. down from the top of

INSPECTION

it

in to

be

sure

it

is

Piston Pin Dia.

1.

Measure inside diameter in piston with an inside micrometer points.

2.

If inside diameter exceeds MAX, replace pis-

ton.

Piston Pin Hole Dia. (MAX)

(MIN)

20.978

mm

(0.8259 in.)

of

piston pin hole

at

I

several

End

Gap

(MAX)

0.7

mm

(0.028 in.)

mm

(0.028 in.)

is

of rings.

greater than MAX,

4.

If the end gap replace the entire

of

any ring

set

0.7

PISTON PIN AND PIN HOLE DIA. INSPECTION

Measure outside diameter

a

with

If piston pin diameter replace piston pin.

micrometer

at

several points.

of

piston pin (A)

is

msaller than MIN,

21.028

To

Analyze Piston Wear:

Detonation can cause an extensive damage to piston, cyl. head, gasket or others. Detonation

cessive

bustion chamber. Commonly called carbon knock, spark knock or timing knock, detonation occurs mixture ignites spontaneously to interrupt the normal ignition.

Following nation:

Lean fuel mixture.

Low octane fuel. Advanced ignition timing. Engine lugging.

Build-up of carbon deposits on piston or cyl. head.

Wrong cyl. head or milling of head increasing

compression ratio.

Poor cooling. Pre-ignition mixture prior to regular ignition spark. Preignition causes internal shock, resulting in pings, vibration, detonation and power

.Severe damage to piston, rings and

results from pre-ignition. Check following for causes

Internal carbon deposits. Incorrect spark plug.

Broken ceramic in spark plug.

Sharp edges on combustion chamber.

Poor cooling.

is

temperature and pressure in the com-

is

mm

(0.8279 in.)

abnormal combustion causing ex-

as

the compressed fuel-air

a

list

of possible cause for deto-

is

the ignition of the fuel-air

of

pre-ignition:

I

loss.

valves

Check con-rod and piston alignment when

a

piston shows

diagonal wear pattern extend-

ing across the skirt of piston. Contact with

the cyl.

on bottom of skirt

at

left (or

wall

right) and ring lands on right (or left).

at

A cylinder bored

an angle to crankshaft can also cause improper ring contact with cylinder. This condition causes:

Rapid piston wear. Uneven piston wear. Excessive oil consumption.

PISTON, PISTON RING, AND CON-ROD

8-4

CON-ROD

1.

Clean and inspect bearing surface on con-rod

INSPECTION

and cap. Replace parts if scored.

2.

Measure inside diameter of the small end of con-rod

at

several points by a telescoping

gauge.

Small End Inside Dia. (MAX)

Big End Inside Dia. (MAX)

37.066

6.

If inside diameter exceeds MAX, replace con-

mm

(1.4593

in.)

rod.

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

be

re-

I

3.

If inside diameter

21.039

mm

(0.8283

is

in.)

greater than specified, replace con-rod.

4.

Place

con-rod cap over con-rod big end to align pilot grooves (A) on the cap and rod. Screw cap bolts and tighten bolts to the specified torque shown.

Rod Cap Tightening Torque

19

to

20

N-m

----_____

5.

Measure the inside diameter of big end

(14

to

--I--

15

ft-lbs)

several points by a telescoping gauge or inside micrometer.

at

To Analyze Con-Rod Wear:

Check con-rod and cap for damage or unusual wear patterns.

Lack of lubrication or improper lubrication

seize

can cause con-rod and cap to

to

shaft.

seize

When rod and cap

to crankshaft, the conrod and piston may both break causing other internal damage. Inspect the block carefully before rebuilding engine.

Con-rod and crankshaft damage can result from:

Engine run low on oil or without oil.

Oil

pump broken or damage.

Oil

hole in con-rod plugged.

Oil

not changed regularly.

Bearing cap installed incorrectly.

crank-

8-5

PISTON, PISTON RING, AND CON-ROD

PISTON AND CON-ROD ASSEMBLY

1.

Aligning match mark with "MADE

install piston over con-rod.

2.

Coat piston pin with a light film of oil. Insert pin through piston and con-rod.

3.

Install retaining rings in each end of piston pin bore. Rings should be seated firmly in retainer grooves in piston.

CAUTION:

Do

not reuse the rings which was removed. Removal weakens, deforms the rings and could fall out

and

"

on the piston head

IN

JAPAN" on the con-rod,

score

the

cyl. wall.

Marking

(R)

facing

UP

30'

to

45'

Top and upper side rail and gap

Position Ring End Gaps

2nd and lower

TOP

(chrom plated)

Second

Oil

(three piece)

side

PISTON RING INSTALLATION

1.

Be

sure oil return holes are clean and carbon

is

removed from

2.

Use

a

ring expander to install rings

rated.

3.

Make sure rings are installed

Install top and second rings with the mark-

4.

ings facing up. "TOP" or "Bottom".) After installation, rings should rotate freely in the grooves.

Space top and second ring end gaps

5.

grees apart.

6.

Space side rail and gaps respectively.

See

all

grooves.

(Oil

I

Ilust.

ring

as

shown.

steel

rails have no

180°

degrees a part

as

180

illust-

de-

PISTON AND CON-ROD ASSY INSTALLATION

TO INSTALL RINGS TO PISTON:

1.

Place the projections (A) on compressor toward the top of piston. Push compressor down until the top of piston. Tighten compressor with

a

2.

3.

ring compressor (B) over piston with

it

is

flush with

wrench

Coat the inside of cyl. bore with

(C),

then loosen slightly.

a

light film of oil. Align arrow mark (A) on piston head towards flywheel end and install con-rod and piston ass'y through the top of cyl. bore. Push pis-

a

ton into cyl. bore with

hammer handle.

4.

Turn crankshaft gently and

in lowest position. Then further insert piston into cylinder while leading big end bearing

surface to place above crankpin. Turn cyl.

block upside down on bench.

5.

Coat the inside of big end bearing surface

a

and cap screws with

6.

Install rod cap

(B)

align and tighten cap screws

specified torque

light film of oil.

(A)

so

assembly pilot groove

as

shown.

place

(C)

crankpin

to the

PISTON, PISTON RING, AND CON-ROD

8-6

Con-Rod Bolt Tightening Torque

r

CAUTION: Tighten rod screws securely. After tightening rod screws, con-rod should move sideway wrench must tight cap screws which may result in breakage and/ or scoring of rod.

19

to 20

N-m

(14

to

15

on

crankpin of shaft. A torque

be

used to prevent loose or over-

ft-lbs)

be

able to

9-1

CRANKSHAFT AND CAMSHAFT

Section

CRANKSHAFT

CRANKSHAFT AND CAMSHAFT REMOVAL

1.

To

remove crankshaft from cyl. block, remove rust or burrs from power take-off shaft end of crankshaft.

2.

Lightly tapping the both ends near dowel

alternately with

case

cover.

3.

Turn cyl. block upside down on a bench.

4.

Rotate crankshaft until timing marks on

crankshaft gear and cam gear align.

5.

Pull out the camshaft, then remove tappets.

NOTE: Align timing marks to prevent damage to tappets when removing camshaft. Mark tappets

so

they can

during assembly.

be

a

soft mallet, remove crank-

installed in their original guides

9

AND

PTO Main Journal Dia. (MIN)

Mag. Side Journal Dia. (MIN)

CAMSHAFT

mm

(1.3746

6.

Remove con-rod and piston.

(See

Section

7.

Rotate crankshaft gently until the crank pin

positioned opposite side of cylinder bore.

8.

Remove balancer guide.

9.

Remove crankshaft.

8)

34.945

If journal diameter

crankshaft.

3.

Measure con-rod big-end journal (A) point with

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

a

36.934

mm

(1.3757 in.)

is

micrometer.

mm

(1.4541 in.)

less

than MIN, replace

at

several

CRANKSHAFT INSPECTION

1. shaft for scored. Inspect crankshaft gear(s) points with for cracked, scored or broken teeth.

place parts if necessary. Link Rod Journal Dia. (MIN)

2.

With a micrometer, measure both main journals at

and

inspect

bearing

surfaces

On

crank-

Re-

several points around journal circumference.

If journal diameter

shaft.

4.

Measure crankshaft link rod journals

a

dial-caliper.

53.951

is

less

mm

(2.12406 in.)

than MIN, replace crank-

at

several

CRANKSHAFT AND CAMSHAFT

9-2

is

less

If journals diameter

than MIN, replace

crankshaft.

TO

5.

CHECK CRANKSHAFT ALIGNMENT:

Place

crankshaft into an alignment jig, rotate

crankshaft slowly, and measure total indicat-

at

ed runout

locations shown.

Dial indicator

\

Turn crankshaft

Run Out

(TIR)

If total run out exceeds MAX, replace crankshaft.

e

Crankshaft damage can result from:

Engine runs with low oil

Oil

dipper broken

Oil

hole in con-rod plugged.

Oil

not changed regularly.

Bearing cap installed incorrectly.

slowly

(MAX)

0.05

mm

(0.002

or

damaged.

in.)

or

without oil.

3. A-Surface must be concentric and parallel to each other within 0.005 mm

(0.0002

in.)

full indicator reading.

NOTE: Finish should

be

very smooth; use a super

finishing stone.

LINK ROD INSPECTION

1.

Clean and inspect bearing surfaces on link rod. If the bearing surface of small end scored or damaged, replace the rod. Scored or damaged big end bearing (bushing) must

a

be replaced with

2.

With a micrometer, measure both inside bearing surfaces

at

new bushing.

several points.

is

UNDER-SIZE CON-ROD

1.

Con-rod journal can accept an under-size con-rod having 36.5 mm (1.437 in.) dia. grinding

size.

2.

The final finishing diameter should be 36.48

to 36.467 mm (1.4362 to 1.4357 in.).

c

I-

Under

D= R=

B=

size

36.480

2.30

to

32.3

mm

is

required before using the under-

R

B

dimentional spec.

to

36.467

2.70 MAX (1.272

mm

(1.4362

(0.09

in.

to

MAX)

0.1

1

to

in.)

1.4357

in.)

Re-

Small End Inside Dia. (MAX)

12.059

mm

(0.4748

in.)

If the inside diameter exceeds MAX, replace

the link rod.

Big End (bushing) Inside Dia. (MAX)

r

If

the inside diameter

54.121

mm

(2.13074

in.)

is

greater than MAX,

replace bushing.

BUSHING REPLACEMENT

1.

Place

link rod on a bench plate (4) with radial

oil-groove side up.

2.

With a bearing driver

(2)

as

shown.

NOTE:

the

Do not forget the direction of seam

shell to reinstall new one.

(1),

drive out bushing

of

9-3

CRANKSHAFT AND CAMSHAFT

3.

1. Bearing driver

2. Big end bushing

3.

Clean the parts in solvent throughly and dry them. Put

4.

Re-install the bushing using an arbor press

or bearing driver.

5.

Press-in the bushing flange surface

a

light coat of oil on a new bushing.

0.5

(3).

Link rod

4. Bench plate

mm

(0.02

in.) below

BALANCER GUIDE -INSPECTION

1.

Clean and inspect bearing surface on the shaft

it

for worn or damage, replace

2.

Measure bearing surface diameter

a

point, using

Support Shaft Dia. (MIN)

I

micrometer.

25.927

mm

(1.0208

if necessary.

at

in.)

several

I

BALANCE WEIGHT INSPECTION

1.

Clean and inspect bearing surface of bushing

it,

for worn or damage. Replace

2.

Wrist pins (A) are press fit on weight strongly, and normally require no mainte-

nance.

3.

With a inside micrometer or telescoping gauge,

measure bearing surface of bushing

if necessary.

(C).

(B)

If shaft diameter

support shaft.

is

less

than MIN, replace

CAMSHAFT INSPECTION

1.

Inspect camshaft for worn or broken teeth.

2.

Measure with a micrometer, camshaft bearing

at

surfaces and camlobes

3.

Replace camshaft if worn

point shown.

or

damaged.

Bushing Inside Dia. (MAX)

26.097

If inside diameter exceeds the MAX replace bushing. Bushing can be replaced

as

that of link rod bushing.

NOTE:

on

Align oil hole on bushing and

weight, when installing service bushing.

mm

(1.02744 in.)

as

the same procedure

oil

passage

CRANKSHAFT AND CAMSHAFT

9-4

Bearing Surface Dia. (MIN)

is

If bearing surface diameter

less

replace camshaft.

Lobe

Height (MIN)

If lobe height

is

less

than MIN for either lobe,

replace camshaft.

CRANKSHAFT AND CAMSHAFT

INSTALLATION

1.

Assemble crankshaft, link rods, collares, gear

as

and balance weight

16 17 18

illustrated below.

I

than MIN,

NOTE: Radial oil-grooves of

toward the outside of

balance

weight to crankshaft with oil hole

the

crankwebs.

link rods must

Install

be

(7)

facing flywheel side.

2.

Cover key way on flywheel end of crankshaft

a

with

tape to prevent

seal

damage when

installing crankshaft.

3.

Put a light film of oil on crankshaft bearing surfaces.

4.

Pack preferably high temperature grease into oil

5.

Put crankpin

seals.

at

bottom dead center of engine.

Install crankshaft carefully.

6.

Align center hole of balance weight and support shaft hole in crankcase.

7.

Install support shaft, O-ring and nuts.

8.

Install con-rod and piston assembly.

(See

Section

9.

Install tappets in their respective guides from

8)

which they were removed.

NOTE: Push tappets

the way in to

valve

guides

all

to prevent damage to tappets when installing

camshaft.

Install governor shaft and snap pin by properly

the

positioning

as

illustrated.

shaft,

pin and projection-stopper

1.

Crankshaft

2.

Crankcase

3.

Oil

seal

4.

Ball bearing

5.

Collar

6.

Balance weight

7.

Oi

hole

8.

O-ring

9.

Nut

10.

Washer

11.

Support shaft

12.

Stud

13.

Bushing

14.

Wrist pin

15.

Link rod

16.

Crank gear

17.

Collar

18.

Bushing

7

8

1.

Case

cover mounting face

2.

Crankcase

3.

Snap pin

4.

Governor shaft

5.

Stopper (projection)

6.

Governor shaft in crankcase

9-5 CRANKSHAFT

AND

CAMSHAFT

Rotate crankshaft until piston top dead center. Install camshaft with timing mark (A) aligned with mark gear.

is

positioned

(B)

on crankshaft

at

CRANKCASE COVER INSTALLATION

Crankcase Cover Tightening Torque

17

to

23

N-m

(12

to

17

ft-lbs)

CRANKSHAFT END PLAY

1.

Measure crankshaft end play with a dial in-

dicator.

2.

Install dial indicator (A) on crankshaft

shown. Move crankshaft in and out. End

0.20

play must be 0.09 to

0.0078 in.).

mm (0.035 to

as

1.

Clean gasket surface and put a new gasket on crankcase cover.

2.

Pack preferably high temperature grease into oil

seal.

3. Lubricate crankshaft bearing in with engine oil.

4. Check governor weights closed.

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

Be

5.

6. Install crankcase cover and tighten cap screws

sure to suitably

meshed with cam gear when installing crank-

case

cover.

down evenly by hand.

a

torque wrench and tighten screws in the

Use

squence shown, and to the specified torque.

Do not turn one screw down completely before the others,

crankcase cover.

as

set

governor gear to be

it

may cause

case

a

cover

warped

CRANKSHAFT END PLAY

ADJUSTMENT

1.

The end play should be 0.09 to to 0.0078 in.) with the 0.5 mm gasket placed in-between crankcase cover and crankcase.

2.

Check end play and adjust if necessary.

3. Measure depth mounting surface to PTO shaft bearing end

shown.

4. Measure depth (b); from crank gear end to

crankcase gasket surface

5. Calculate (a-b), and shim(s) from "Adjusting Shim Table" to

correctly adjust end play.

6. Insert the shim(s) to PTO shaft and install

crankcase cover.

sizes

7. Shim

of 1.74 mm (0.0685 in.) to 1.18 mm (0.0464

in.) in 0.07 mm (0.0027 in.) increments

shown.

(thickness) are provided in the range

(a);

from crankcase cover

as

select

0.2

mm (0.0035

(0.02

shown.

appropriately sized

in.)

as

Gasket Crankshaft

Crankcase

bearing

CRANKSHAFT AND CAMSHAFT

9-6

Crankcase cover

Adjustment

Difference in depth

1.92

(0.0755

-___-_-

1.85

(0.0728

1.78

(0.0700

1.71

(0.0673

1.64

(0.0645

1.57

(0.0618

1.50

(0.0590

1.43

(0.0562

1.36

(0.0535

A-0

to

1.99 mm

to

0.0748

to

1.92 mm

to

0.0755

to

1.85 mm

to

0.0728

to

1.78 mm

to

0.0700

to

1.7 mm

to

0.0673

to

1.64 mm

to

0.0645

to

1.57 mm

to

0.0618

to

1.50 mm

to

0.0590

to

1.43 mm

to

0.0562

Shim

:

in.)

of Shim

92025-2153

92025-2152

92025-2151

92025-2 150

92025-2149

92025-2 148

92025-2 147

92025-2 146

92025-2145

1.74mm

(0.0685

1.67 mm

(0.0657

1.60 mm

(0.0629

1.53mm

(0.0602

1.46 mm

(0.0574

1.39 mm

(0.0547

1.32 mm

(0.0519

1.25 mm

(0.0492

1.18 mm

(0.0464

in.)

in.) in.)

in.)

10-1

CYLINDER BLOCK AND BEARING

CYLINDER BLOCK

CYLINDER BLOCK INSPECTION

AND REPAl

Visually inspect cyl. block, whenever engine disassembled, to ped bolt holes, broken fins, or cyl. wall

Use an inside micrometer, or telescoping gauge and micrometer to determine the bore. Measure parallel with crankshaft and right angles to crankshaft bottom

If cyl. bore

and/or the out of round,

R

see

of

ring travel.

is

if there are any cracks, strip-

is

scored.

size

at

top, center and

more than the wear tolerance

it

must be resized.

Section

is

of cyl.

at

10

AND

Resize

rized repair shop or by using honing tool.

hone manufacturer to produce the correct

cyl.

wall finish.

1.

MACHINE THE

the allowance table below.

0.25

mm

0.50

mm

BEARING

cyl. bore can be done by an autho-

a

drill press and

Use

a

stone recommended by the

BORE

89.23

(3.5130

89.48

(3.5228

89.73

(3.5327

first according to

Bore Dia.

to

89.21

to

mm

3.5122 in.)

89.46

mm

3.5220 in.)

89.71

mm

3.5319 in.)

Cylinder Bore Wear Tolerance (MAX)

0.076

mm

(0.003 in.)

Out of Round Cylinder Bore (MAX)

0.063

mm

Dia.

(0.0025 in.)

88.980

(3.5031 in.)

MIN

mm

(0.010

(0.03

in.)

in.) over

I

Standard Bore

89.000 (3.5039 in.)

TO

RESIZE

Size

MAX

mm

Bore to Next Oversize: Always resize to exactly 0.25mm or 0.50mm (0.02 in.) or 0.75mm standard

If this

size

as

shown in table.

is

done accurately, the stock oversize rings and pistons will fit perfectly and proper clearances will be maintained.

I

2.

TO

FINISH THE BORE:

Select

and use

suitable stone (normally driven by a drill

press)

CAUTION: Allow for

size) of

0.006

to 0.008mm

a

shrinkage (from the final

(0.00024

to

0.00031

in.) which will occur when engine cools down.

Final Bore Size Dia.

0.25

mm

0.75

mm

(1)

Clean cylinder

89.250

(3.51378

89.500

(3.52362

89.750

(3.53346

at

to

89.230

to

89.480

to

89.730

to

mm

3.51299 in.)

mm

3.52283 in.)

mm

3.53268 in.)

top and bottom to remove

burrs and pieces of base and head gasket.

(2) Anchor cyl. block on drill press table before

honing.

(3)

Align center of the cyl. bore to drill press

Set

center.

the press to operate from 200 to

250 rpm.

(4)

Connect drive shaft to hone and drill press mm

so

hone can only extend

(3/4

to 1 in.) from the top or bottom

set

stop on

20

to 25

of cylinder.

(5)

Rotate adjusting nut (knob) on hone with

finger or small screw driver until stones contact

at

snugly against cyl. wall

DO

NOT

FORCE.

(6)

Turn stone by hand. If you cannot turn

hone

is

too tight, Loosen hone until

be

turned by hand.

narrowest point.

it

a

I

it,

can

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

(7)

Coat inside of cylinder with honing oil. Start

60

cyl-

degree

drill press. Move hone up and down in

inder spprox.

(8)

Check diameter of cylinder regularly during

honing, using an inside micrometer.

ing,

and remove hone from cylinder.

CAUTION: Finish should have

cross-hatch pattern.

(9)

Clean cylinder thoroughly. Use soap, warm water and clean rags. Clean cyl. wall for

"white glove" inspection. A clean white rag

should not show soil from the cyl. wall.

(10)

Dry cylinder and coat with engine oil.

20

cycles-per-minute.

Stop drill press before measur-

a

40

to

Do

not use solvent or gasoline.

a

CYLINDER BLOCK AND BEARING

Bearing driver Ball bearing Crankcase cover

BALL BEARING INSPECTION

1.

Clean bearing in high flash point solvent throughly and dry

2.

Spin bearing by hand and check for play.

Replace bearing if

smoothly spin, or has excessive play.

it.

it

is

noisy, or does not

10-2

be

CAUTION: Cylinder must after honing to eliminate

thoroughly cleaned

all

grit.

BALL BEARING REMOVING

Ball

bearings are press-fit into crankcase and

case

cover.

1.

Remove oil not be reused once removed.

2.

Place

UP.

3.

Using

as

shown.

seals

on crankcase.

crankcase on a bench with oil

a

bearing driver, drive out bearings

Oil

seal

should

side

AXIAL

RADIAL

PLAIN BEARING INSPECTION

The camshaft bearings and PTO journal bearing

are

cast

with the cyl. block and covers.

Cylinder block and covers should be replaced

if scored or worn.

1.

Measure camshaft bearing on block with an

inside micrometer or telescoping gauge.

10-3

CYLINDER BLOCK AND BEARING

Camshaft Bearing Inside Dia.

16.068

mm

Replace cyl. block, if inside diameter exceeds

MAX.

2.

Measure PTO and camshaft bearings on covers with an inside micrometer or telescoping gauge.

PTO

Bearing Inside Dia.

(MAX)

(0.6326 in.)

(MAX)

0.5mm

(0.02 in.)

mm

(1.3804 in.)

Camshaft Bearing Inside Dia.

I

Replace crankcase cover or oil pump cover, if inside diameter exceeds MAX.

20.071

mm

(MAX)

(0.7902 in.)

I

BALL BEARING INSTALLATION

1.

Clean cylinder/crankcase and the cover in high flash point solvent throughly and dry.

2.

Put a light coat of oil on bearing surface.

3.

Press-fit ball bearing into cyIinder/crankcase

and the cover with an arbor or bearing driver.

OIL SEAL REPLACEMENT (PTO SIDE)

1.

Remove old oil

with

a

screw-driver or punch from the inside.

2.

Pack preferably high temperature grease into

a

new oil

3.

Press-in oil lip toward inside of engine. (Dust outside.)

4.

For flywheel side, press-in oil

with housing.

5.

For PTO side, press-in oil below outside end most face of PTO bearing.

seal.

seals

by tapping them out

seal

with sharp edge of oil

seal

0.5

to

mm

seal

be flush

(0.02

in.)

lip

ELECTRIC STARTER AND CHARGE

11-1

Section

ELECTRIC STARTER

STARTER MOTOR CIRCUIT

The starter motor circuit includes the engine switch, starter solenoid, battery and starter motor.

is

When the engine switch

(See

position of current flows through the switch and the

solenoid. This current magnetizes the solenoid core, which then pull the plunger to solenoid contacts complete er motor, and the starter armature rotates. At the same time plunger pull the shift lever end. The pinion linkaged to the other end of the lever

on

slides with flywheel ring gear. As engine fires and speed up, starter armature pinion to disengage. The key switch

"I"

to system. Starter motors used on and shift lever type.

CAUTION: Because of never hold engine switch in START position starter motor will not turn over, or current may burn out starter motor windings.

(ON) position, cutting off the cranking

Wiring Diagram),

the armature shaft, engaging the pinion

turned to (START)

a

small amount

it,

closing

a

circuit for the

is

overrun, causing

is

returned

FB46OV

a

large amount of current,

are a Bendix type

start-

if

11

AND

STARTER

MOTOR

STARTER SYSTEM CHECK

If a starting problem occurs, check engine thoroughly to be sure engine problem.

plug and rotate crankshaft by hand, to be sure

it

rotates freely. Any belt, clutch or other load of this nature will affect cranking performance. The Trouble Shooting you in diagnosing problems.

It

CHARGE

STARTER

SOLENOID

is

not the cause of the

is

a

good practice to remove spark

(1-1

7)

table should aid

IGNITION SWITCH

Wiring Diagram

Bendix-Type

(FB460V-AS

ENGINE

Model)

Shift

Lever-Type

(FB46OV-BS

Model)

AV

20

11-2 ELECTRIC STARTER AND CHARGE

STARTER MOTOR CHECK

A performance

in the following manner.

Needed for the

A tachometer capable of reading 20,000 rpm. A 12V 32Ah (or more) battery. An ammeter capable of reading 200 amperes.

test

of starter motor can be made

test

are:

A shorted, open, or grounded armature or field coil. A defective

starter

motor switch.

STARTER SOLENOID TEST

WARNING:

and corrosive. clothing. Handle

ed, flush immediately with

Battery electrolyte

It

is

injurious

it

carefully.

to

If

electrolyte

a

solution of one part

is

eyes,

poisonous

skin and

is

baking soda to four parts water.

1. Connect starter motor, battery and ammeter

as

shown in illust.

(Wiring

diagram

for

performance

A

test)

I

Starter motor should not be loaded. The

test

should be quickly conducted,

is

rating

2.

Insert tachometer in the end of starter motor and

30 seconds.

activate

starter motor. A starter motor

as

in good condition will be within the follow-

ing spec.

spill-

the

Use the same procedure for starter relay the Bendix

1.

Disconnect lead (A) to starter motor

Measure the continuity of solenoid when

2.

starter

and shift lever starter.

as

activated.

3.

Set

a

multimeter selector switch to

position and connect leads across the large

terminals.

test

for

shown.

Bendix Type

(FB460V-AS

Model)

Terminal voltage Starter motor rpm

Current draw (A)

Shift Lever Type

(FB46OV-BS

7,000

Model)

rpm (MIN)

60

A (MAX)

Terminal voltage Starter motor rpm Current draw (A)

6,000

rpm (MIN)

50

A (MAX)

If not, check for the following and correct

if necessary:

A binding or seizing condition in the starter

motor bearings.

'Starter motor brushes sticking in brush hold-

ers. A dirty or worn armature commutator brushes.

12

v

11.5 V

or

Turn engine switch to START and read the

4.

meter. If solenoid does not click or if the meter reads

more than continuity, solenoid

Replace

If solenoid makes

it.

a

single clicking sound,

is

the meter read continuity, and pinion

moves outward (shift lever solenoid only), solenoid and the rest of the starter circuit

are

good.

faulty.

gear

ELECTRIC STARTER AND CHARGE

11-3

If solenoid clicks once but the meter does

not read continuity, solenoid

it.

place

If solenoid does not click

at

is

faulty.

all,

proceed with

following.

5.

Disconnect lead

position and connect leads

(BW)

and

set

multimeter to

as

shown.

If the meter does not read close to continuity, solenoid

faulty. Replace

it.

is

If the meter reads close to continuity, solenoid may be good. Check the voltage to sole-

noid from engine switch.

Set

multimeter selector switch to 25VDC

it

as

position and connect

shown.

Re-

STARTER MOTOR DISASSEMBLY

(Bendix

Type)

2

6.

Turn engine switch to START and read the

meter. If the meter reads battery voltage, the cir-

is

cuit,

good. the previous If the meter reads much

voltage or no voltage

or engine switch

Test engine switch.

7.

Inspect the wiring shown carefully for damaged

8.

or broken wires and replace

If

solenoid would not click in

tests,

it

is

faulty. Replace

less

than battery

at

all, either the wiring

is

faulty.

as

required.

it.

Parts

1

Pinion stopper set

2

Pinion ass'y

Front cover

3

4

Front cover metal

5

Thrust washers Armature

6 7

Brush holder ass'y

8

Brush

(-)

Name

No.

Parts Name

For disassembly, follow the steps below.

1.

Pinion stopper

2.

Pinion ass'y

3.

Through bolts

4.

Rear

cover

5.

Brush holder ass'y

6.

Brush

7.

Yoke ass'y

8.

Armature

9.

Thrust washers (5)

10.

(10)

Front cover

set

(1

)

(2)

(14)

and screws

(

1

)

(7)

and brush springs

(16)

(11)

(1

(9)

5)

11-4

(Shift

ELECTRIC

Lever

Type)

STARTER

AND

CHARGE

Ref, No.

1

2 3 4

5

6

7

8

9

Parts Name

Front cover Washer Stopper Snap ring

ass'y

Clutch Shift lever Armature

Brush holder Brush

Ref

No.

10 11 12 13 14 15 16 17

Parts Name

Brush spring

Insulator

Rear cover Bolt Solenoid Nut Nut Yoke ass'y

For disassembly, follow the steps below.

1. Nut (16)

2.

Nuts and solenoid (14), (15)

3. Long bolts (13)

4.

Rear cover

5. Insulator

6.

Brush holder and spring

7.

Yoke ass'y

8.

Shift lever

9.

Armature

10.

Washer

11. Stoppers and snap ring

12.

Clutch ass'y (5)

(1

1)

(9),

(6)

(7)

(2)

2)

(17)

(8),

(3),

(4)

(10)

Measure commutator outside diameter several points around diameter circumference,

a

using

Commutator Outside Dia.

Bendix Type

If outside diameter

vanier caliper.

lever Type

I_--

(MIN)

32

27

is

less

mm mm

(1.26 (1.10

than

in.) in.)

(MIN),

armature.

Measure depth of grooves between commutator segments.

Commutator Groove Depth

Shift lever Type

(MIN)

0.2

mm mm

(0.01 (0.01

in.) in

)

at

replace

STARTER MOTOR INSPECTION

1.

Armature Inspection

Inspect surface of commutator. If

it

has a scratch or piece of very fine emery paper (No.5000 to No.6000).

is

dirty, polish

it

with

a

2.

Segment

3.

Good

4.

0.2

mm

(0.08

5.

Insulating Material

in.) limit

If grooves are shallower than (MIN), under cut insulating material to standard depth using thin file.

Standard Groove Depth

Bendix Type

Shift lever Type

If

grooves are only dirty, clean them carefully.

Support armature in

as

shaft pendicular to commutator. Turn armature slowly and read run-out on dial indicator.

0.5

to

0.8

mm

(0.02

to

0.03

0.5

to

0.6mm

shown. Position dial indicator per-

tail

(0.02

stock

to

0.023

at

each, end of

in.) in.)

a

ELECTRIC STARTER AND CHARGE

Commutator-to-Shaft Resistance

r

If

resistance

shorted. Test armature windings for shorts.

Place

armature on a growler.

a

Hold

on top of armature.

is

less

than infinite, armature

thin metal strip

(e.g.,

(52)

hack

saw

11-5

is

blade)

Commutator Run-Out

Bendix Type

Shift lever Type

If run-out commutator or replace starter motor.

Set

multimeter selector switch to R x tion and check resistance between each ment and

Armature Winding Resistance

is

all

(MAX)

0.3

mm

0.4

mm

greater than (MAX), turn down

the others.

(0.012

(0.016

in.) in.)

posi-

seg-

I

Turn on growler and rotate armature .one complete turn.

If metal strip vibrates, windings are internally shorted to each other and starter motor must be replaced.

2.

Brush Length Check Measure overall length of each brush.

Very

Low

If resistance ture winding has an open circuit. Replace starter motor.

Set

multimeter selector switch to position and measure resistance between commutator and armature shaft.

is

too high or even infinite, arma-

R

x

11-6

ELECTRIC STARTER AND CHARGE

Brush Length

Shift

lever Type

If brushes are shorter than (MIN), replace shorted to ground. Replace yoke assembly.

them.

3.

Brush Spring Check position and measure resistance between field

Inspect brush spring for damage. Replace coils‘ terminals (A).

springs if necessary.

If brush spring are able to snap the brushes firmly into serviceable. If they cannot, replace them.

Field Coil Check

4.

Bendix-Type Starter Motor

4-

1

Set tion and measure resistance between field coils’ terminals

(M

IN) Terminal-to-Ground Resistance

6

mm

(0.24

in.)

place,

multimeter selector switch to R x

they may be considered

(A).

posi-

If resistance

4-2

Shift lever-Type Starter Motor

Set

multimeter selector switch to R x

is

less

than infinite. field coil

is

Terminal-to-Terminal Resistance

Very

Low

If resistance

(no continuity), replace yoke assembly.

Set

multimeter selector switch to R x position and measure resistance between yoke (A) and one terminal of each coil

is

greater than indicated above

(52

(B).

1

Terminal-to-Terminal Resistance

Very

Low

If there

If resistance

(no continuity). Replace yoke assembly.

Set

position and measure resistance between yoke

(A)

is

continuity field coil

is

greater than indicated above

multimeter selector switch to R x

and one terminal of each coil

is

still

(B).

good.

Terminal-to-Yoke Resistance

I

If resistance

continuity), replace yoke ass‘y.

Set

multimeter selector switch to R x position and measure resistance between positibe brush (A) and starter motor yoke

Very

Low

is

greater than indicated above (no

I

1

(B).

ELECTRIC STARTER AND CHARGE

11-7

Positive Brush-to-Yoke Resistance

is

less

If resistance

is

horted to ground. Replace entire positive

brush ass’y

(C).

than infinite, positive brush

BRUSH HOLDER CHECK

(Bendix-Type only)

Set

multimeter selector switch to R x

position and measure resistance between

its

base

brush holder (A) and

Positive Brush Holder-to-Ground Resistance

(B).

1

)

If any irregularity

should be replaced.

is

noted, pinion clutch

STARTER MOTOR REASSEMBLY

Reassembly Note the following points.

Apply multi-purpose

Sliding surface of pinion and shaft’s spline.

Dust Metal holding shaft

Do not reuse retaining ring on shaft, which

was removed.

Removal weaken and deform the retaining ring.

Charging System A charging system produces the current required

to maintain the battery in good

The charging system consist of

magnet, charging coil (stater) and regulator.

The charging coil output current

(changed from AC to DC) and

constant voltage for battery charging.

Rated speed of AC generator

at

lower speeds available output will be re-

duced relatively.

seal

is

the reverse order of disassembly.

glease

lip.

to:

at

front and rear cover.

state

of charge.

a

flywheel

is

maintained

is

3,350 rpm, and

rectified

If resistance

holder.

is

less

than infinite, replace brush

PINION CLUTCH INSPECTION

Rotate pinion manually. While rotating pinion in direction of normal operation, smoothly reverse the direction of

it

rotation to confirm that

locks.

CHARGING SYSTEM CHECK

Be

sure to perform more basic checks first such

1.

Battery defective or not charged.

2.

Eroded or

3.

Cracked insulation or brocken wires.

4.

Wire grounding out the system.

5.

Defective switch.

Condition Found (Battery Run Down) Check battery polarity. Negative

battery should be grounded to engine or frame (equipment), positive regurator charge lead.

loose

terminals or connections.

(+)

side of battery to

(See

I

Ilustration)

(-)

as;

side of

11-8

ELECTRIC STARTER

If the wiring

damaged.

AC generator

CHG

AND

CHARGE

is

reversed, regulator will be

3.4w

monitor

Stater Unregulated Out Put (MIN)

34.5

volts

3,350 rpm

If voltage

is

less

than specified, replace stater.

Regulator Resistance Measurement

all

Remove

Set

multimeter selector switch to R x

the wires from regulator.

position. Connect tester leads to regulator connecter terminals using the table below. The resistance value should be specified.

OHM Meter Readings Connected Between

1

d

Key

SW.

Out Put Test

Start engine and allow

ly.

Set

multimeter selector switch to the 25V DC

position. (Use KAWASAKI multimeter)

Connect meter positive

(+)

positive

terminal, and negative

lead to battery negative

at

Run engine shoule show the system

rated

a

minimum of

is

defective and the components

of the system should be checked.

Test Stater Out Put

Start engine and allow

ly.

Disconnect coupler from charging circuit.

Connect voltmeter leads to stater lead ter-

minals on coupler.

Run engine

at

rated

voltage should be

it

to warm up complete-

(+)

(-)

terminal.

RPM

(3,350 rpm), meter

it

to warm up complete-

RPM

(3,350 rpm). Output

as

specified below.

Stater

lead to battery

(-)

12

amps. If not,

meter

CHG

(by

KAWASAKI

monitor

TESTER)

If resistance

is

not

as

specified, replace the

regulator.

NOTE: Resistance value may vary with individual meters.

TROUBLESHOOTING

ELECTRIC STARTER AND CHARGE

11-9

t

Does crankshaft rotate? Does starter rotate?

Yes

and ring gear satisfac- or replace pinion and/

I

Yes

Check

clutch for damage, and run? replace if necessary.

I

pinion‘s ent starter. Does motor

Inspection

terminals

Is

operating sound pro-

duced out of starter’s

Item

for

->-

Faulty

/Make connection

terminal of independ-

and

No

Remedy

Correct connection or

Check and repair wiring to solenoid switch.

Wiring connection

Repair or replace sole-

noid switch.

Check return spring for permanent defor-

mation and check pinion for dragging. Correct meshing of pinion and ring gear

or ring gear.

Replace motor (field coil or armature).

(rotation

Is

rotation normal?

Check ignition system

Faulty

Check battery charge Charge or replace the

is

slow) and also check battery

terminals for disconnec- Correct connection or tion and corrosion, corrosion

Yes

engine

starter new one?

Inspect interior of engine.

oil

is

satisfac- Change engine oil.

is

replaced with

t

No

Faulty solenoid switch

terminals.

Faulty

If abnormal (Immedi-

ately disconnect cable

from of the battery.)

‘Motor fails to stop even

Repair or replace start- when key switch

turned to OFF position.

I

at

battery

is

12-1 RECOIL STARTER

Section

RECOIL

RECOIL STARTER DISASSEMBLY

1. Pull handle out about 10 to 12 inches or until

is

notch (A) in pulley rope in place with knot

near rope hole. Hold

(B).

12

STARTER

6.

Remove bolt (A) and ratched cover

7.

Remove pawls (A) and spring

(B).

2. Pry knot out of handle and untie handle off rope.

3.

While carefully holding rotating parts with one

hand, untie knot

4.

Pull rope in through rope hole (A) in housing

and hold

5.

Allow spring tension slowly to unwind recoil

mechanism.

CAUTION:

the

reel and

it

Do

the

(B)

with the other.

in notch

not

housing. Be careful that spring does not

(B)

in reel

let

the rope wedge between

(C).

it.

Pull

8.

Remove reel.

loose

fly Turn reel one-quarter turn counterclockwise past

the

Now, slowly lift reel straight up out of housing.

NOTE:

reel

reel may be easily removed.

9.

and injure you.

rest position where no tension can be

There should

when removing reel. If tension

back

into place and gently "wiggle"

If necessary, remove spring.

It

is

under great pressure.

be

no spring tension on

is

felt,

it

felt.

push until

RECOIL STARTER REASSEMBLY

Assembly

Note the following points.

is

reverse of disassembly.

RECOIL STARTER

12-2

If spring was removed,

as

shown. If

starter will not operate properly.

//\WARNING: Spring must pressure during installation. Wear gloves to avoid injury.

1.

Lightly

glease

it

spring

it

must be installed Pawls (A) must be installed

is

not installed correctly,

be

put under

(A).

great

as

proper starter operation.

Install coil spring (A), ratched cover

tighten bolt

(C).

shown for

(B)

and

If rope was unwound from reel,

(as

wound clockwise

starter operation.

Set

reel into place

case

catch on tabs

(B)

shown) for correct

so

that slots (A) on spring

on reel.

it

must be

Rotate reel three turns counterclockwise to preload the spring. Pull rope in through rope hole in housing and install handle.

RECOIL STARTER INSPECTION

Disassemble recoil starter.

Immerse only metal parts in flash-point solvent.

Do

CAUTION:

in solvent

as

Use compressed air to dry cleaned components.

not clean any non-metalic parts

they may

be

damaged.

a

bath of high

Check starter pawls for chips or excessive wear.

Check starter rope for excessive wear or fraying.

Check condition of recoil spring and ratched cover spring.

Inspect springs for breaks, rust, distortion,

or weakened condition.

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

Specifications and Main Features

Frequently Asked Questions

User Manual