Toro 73545, 73546, 73547, 73580 Service Manual

KAWASAKI FD620D 4-STROKE LIQUID COOLED ENGINE SERVICE MANUAL

Table of Contents – Page 1 of 2

GENERAL INFORMATION

BEFORE SERVICING MODEL IDENTIFICATION GENERAL SPECIFICATIONS PERIODIC MAINTENANCE CHART EXCEPT U.S. PERIODIC MAINTENANCE CHART FOR U.S. TORQUE AND LOCKING AGENT

FUEL SYSTEM

EXPLODED VIEW SPECIFICATIONS GOVERNOR LINK MECHANISM CARBURETOR INTAKE MANIFOLD FUEL PUMP AIR CLEANER

COOLING SYSTEM

EXPLODED VIEW SPECIFICATIONS COOLING SYSTEM COOLANT DISASSEMBLY AND ASSEMBLY PRECAUTIONS WATER PUMP RADIATOR COOLING FAN, FAN BELT THERMOSTAT THERMO SWITCH

ENGINE TOP END

EXPLODED VIEW SPECIFICATIONS SPECIAL TOOLS CYLINDER HEAD VALVES CYLINDER, PISTON MUFFLER

LUBRICATION SYSTEM

EXPLODED VIEW ENGINE OIL FLOW CHART SPECIFICATIONS ENGINE OIL AND OIL FILTER PRESSURIZED LUBRICATION SYSTEM OIL PUMP AND RELIEF VALVE OIL SCREEN FILTER

KAWASAKI FD620D 4-STROKE LIQUID COOLED ENGINE SERVICE MANUAL

Table of Contents – Page 2 of 2

CAMSHAFT / CRANKSHAFT

EXPLODED VIEW SPECIFICATIONS CRANKCASE BREATHER CAMSHAFT TAPPET CRANKSHAFT, CONNECTING ROD

ELECTRICAL SYSTEM

EXPLODED VIEW SPECIFICATIONS SPECIAL TOOLS WIRING DIAGRAM WIRE HARNESS PRECAUTIONS CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER SYSTEM

TROUBLESHOOTING

ENGINE TROUBLESHOOTING GUIDE STARTER MOTOR TROUBLESHOOTING GUIDE

4-stroke liquid-cooled v-twin gasoline engine

Service Manual

O-l

Kawasaki

FD62QD

4-stroke liquid cooled v-twin gasoline engine

Service Manual

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

Ltd., Japan. .’

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care

has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to

make such changes to products manufactured previously.

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

0 Kawasaki Heavy Industries. Ltd. 1996

Second Edition(l) : Jan. 20,1996(T)

o-2

This warning may apply to any of the following components or any assembly containing one or

more of these components:-

Brake Shoes or Pads Clutch Friction Material Gaskets

Insulators

Emthing rbmto~

dust is dm~rous

instructionr

A ampere(s)

ABDC

ATDC

BBDC

BDC

BTDC

‘C

DCF

after bottom dead center alternating current

after top

dead center before bottom dead center bottom dead center before top dead center

degree(s) Celsius

direct current farad(s)

‘F degree(s) Fahrenheit ,

ft 9 gram(s)

foot, feet

hour(s) liter(s)

SAFETY INSTRUCTIONS

Operate if possible out of doors or in a well

ventilated place.

Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped.

lf possible, dampen before cutting or drilling.

@Dampen dust and place it in properly closed

receptacle and dispose of it safely.

LIST OF ABBRE(/IATIONS

lb m min

N Pa PS psi

rpm

TDC TIR

pound(s) meter(s) minute(s) newton(s) Pascal(s)

horsepower

pound(s) per square inch

revolution

revolution(s) per minute

top dead center

total indicator reading volt(s)

watt(s)

ohm(s)

Read OWNER’S MANUAL before operating.

Foreword

o-3

This manual is designed primarily for use by

trained mechanics in a properly equipped shop.

However, it contains enough detail and basic

information to make it useful to the owner who

desires to perform his own basic maintenance and

repair,work. A basic knowledge of mechanics, the proper use of toofs, and workshop procedures must be understood in order to carry out maintenance and

‘repair satisfactorily.

insufficient experience or has doubts as to his ability

to do the work, all adjustments, maintenance, and

repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to

avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment.

Precision measurements can only be made if the

proper instruments are used, and the use of substitute tools may adversely affect safe operation.

To get the longest life out of your engine:

Follow the Periodic Maintenance Chart in the

Service Manual.

Be alert for problems and non-scheduled mainte-

nance.

Use proper tools and genuine Kawasaki engine parts. Genuine parts provided as spare parts are

listed in the Parts Catalog.

FOIIOW the procedures in this manual carefully. Don’t take shortcuts.

*Remember to keep complete records of mainte-

nance and repair with dates and any new parts

installed.

Whenever the owner has

How to Use this Manual

In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular

system from adjustment through disassembly and

inspection is located in a single chapter.

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

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

If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug.

Next, use the Quick Reference Guide to locate the electric System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

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

This warning symbol identifies special

instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

ACAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in damage to

or destruction of equipment.

This manual contains four more symbols (in

addition to WARNING and CAUTION) which will

help you distinguish different types of information.

NOTE

o This note symbol indicates points of partic-

ular interest for more efficient and convenient operation.

Indicates a procedural step or work to be done.

olndicates a procedural sub-step or how to do the

work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or

NOTE.

*Indicates a conditional step or what action to take

based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of

the system components follows the Table of

Contents.

instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

In these illustrations you will find the

Quick Reference Guide

1 General Information I 1 1 Fuel System ( Cooling System 1 Engine Top End

Lubrication System ( 5

( Camshaft / Crankshaft 1 Electric System I Trouble Shooting

I 2 I 3

This quick reference guide will assist you in

locating a desired topic or procedure.

0 Bend the pages back to match the black tab

of the desired chapter number with the black tab on the edge at each table of contents page.

Refer to the sectional table of contents for

the exact pages to locate the specific topic

required.

GENERAL INFORMATION l-l

General Information

Table of Contents

Before Servicing .........................................................................................................

Model Identification ....................................................................................................

General Specifications Periodic Maintenance Chart except U.S Periodic Maintenance Chart for

Torque and Locking Agent.. ......................................................................................

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

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

U.S. ......................................................................... .1-B

. ................................................... l-6

.I -2

l-5

1-7

.l -9

1-2 GENERAL INFORMATION

Before Servicing

Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work.

Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever

necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required

for successful work.

Especially note the following:

(1) Dirt

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

:) Battery Ground

Remove the ground (-) lead from the battery before performing any disassembly operations on the equipment. This prevents:

(a) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts.

(3) Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly, in a staggered sequence. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely, when loosening the bolts, nuts, or screws, first

loosen all of them by about a quarter of a turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated.

(4) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may

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

(5) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws

(particularly for the removal of screws held by a locking agent) in order to avoid damaging the heads.

(6) Edges

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

with gloves or a piece of thick cloth when lifting the engine or turning it over.

(7) High-Flash Point Solvent

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

(8) Gasket, O-Ring

Do not reuse a gasket or O-ring once it has been in service.

should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.

(9) Liquid Gasket, Non-Permanent Locking Agent

Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be

used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An

example of a non-permanent locking agent commonly available in North America is Loctite Lock’n Seal

(Blue).

(10) Press

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

(11) Ball Bearing

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

For the same reason, before installing a new

The mating surfaces around the gasket

.-~

GENERAL INFORMATION 1-3

(12) Oil Seal, Grease Seal

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

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

(13) Seal Guide

A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips.

Before a shaft passes through a seal, apply a little oil, preferably high temperature grease on the lips to

reduce rubber to metal friction.

(14) Circlip, Retaining Ring

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

(15) Cotter Pin

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

(16) Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable)

should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should

be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.

Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain

applications and may be harmful if used in an application for which they are not intended. This manual

makes reference to molybdenum disulfide grease (MO& ) in the assembly of certain engine parts. Always

check manufacturer recommendations before using such special lubricants.

(17) Electrical Wires

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

it would be a “red/yellow” wire if the colors were reversed to make red the main color.

Wire (cross-section)

Red

Wire Strands

Yellow

Red

(18) Replacement Parts

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

(19) Inspection

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

Abrasion Crack

Bent Dent Scratch

Color change Deterioration Seizure

(20) Specifications

Specification teams are defined as follows:

“Standards”: show dimensions or performances which brand-new parts or systems have.

“Service Limits” Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

Name of Wire Color

Yellow/Red

Hardening Warp

Wear

l-4 GENERAL INFORMATION

KAWASAKI Multimeter:

KAWASAKI Multimeter (P/N 3951 OO-9803A) is recommended for the electrical system check because a

meter of other type may indicate different value.

Model Identification

GENERAL INFORMATION 1-5

Cylinder Number Designation:

No.1 Cyl. is the right-hand cylinder viewed from the flywheel. No.2 Cyl. is the left-hand cylinder viewed from the flywheel.

1-6 GENERAL INFORMATION

General Specifications

Items

Type of engine

Bore x Stroke Piston displacement Max. output

Direction of rotation Low idle speed except U.S. Low idle speed for U.S.

High idle speed except U.S. High idle speed for U.S. Ignition system RFI

Starting system

Charging system Carburetor Fuet pump

Air cleaner Governor

Lubrication system

“Oil filter

‘Oil pressure switch

Cooling system

Radiator

Dimensions (H x W x L) Dry weight 41.5 kg (91.5 lb)

Liquid-cooled, Horizontal shaft, OHV, 4-stroke, 9O”V-twin, Gasoline engine. 76 mm x 68 mm (2.99 in x 2.66 in) 617 mL (37.7 cu. in)

14.9 kW/3 600 rpm (20 HP/3 600 rpm)[SAE J1349]

Counterclockwise facing PTO shaft end

1550 -?r 100 (rpm)

1450 (rpm) to 1650 (rpm) 3600 + 75(rpm)

3600 (rpm)

Battery, Full transister, Fixed timing

Per Canada and U.S.A. requirements Shift type electric starter 12 V - 20 amps with regulator

Down draft type, Fixed main jet Electra magnetic pump (in-line type) Dual stage element

All speed mechanical fly weights

Pressure feed by positive displacement pump Cartridge type full flow filter ON-OFF switch Pressurized forced circulation type

3-rows with louverless corrugated fin 624 mm x 448 mm x 556 mm

(24.6 in x 17.6 in x 21.9 in)

FD620D

‘Specifications are subject to change without notice.

GENERAL INFORMATION l-7

Periodic Maintenance Chart except U.S.

To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and maintenance items\ and suitable intervals. The bullet mark (0) designates that the corresponding item should be performed at that interval.

Some adjustments require the use of special tools or other equipment. An electronic tachometer will facilitate

setting idle and running speeds.

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

INTERVAL

MAINTENANCE

Check and add engine oil, coolant and fuel Check for loose or lost nuts and screws Check for fuel, oil and coolant leakage Check battery electrolyte level Check or clean air intake screen Clean air cleaner foam element (1) Clean air cleaner paper element (I )

Change engine oil Tighten nuts and screws Clean and regap spark plug

Change oil filter

Change air cleaner paper element (1)

Change spark plugs

Clean combustion chamber*

Inspect radiator and hoses*

Check fan belt conditions and tension*

Change coolant* Valve maintenance*

Check and lap valve seating surface*

Dally

I I I

I I I I I I

First Every Every Every Every Every Every

20 hr. 25 hr. 50 hr. 100 hr. 200hr. 3OOhr 400 hr.

a 0 0

I 0 I I 0 I

( 0 1

0 0

l l l

I.1 I

( 0 )

(1) Service more frequently under dusty conditions.

These items must be performed with the proper tools. See your authorized Kawasaki engine dealer for service, unless you have the proper equipment and mechanical proficiency.

1-8 GENERAL INFORMATION

Periodic Maintenance Chart

To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals. The bullet mark (0) designates that the corresponding item should be performed at that interval.

Some adjustments require the use of special tools or other equipment. An electronic tachometer will facilitate

setting idle and running speeds.

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

MAINTENANCE

for

U.S.

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

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

necessary by operating condition. * : Service more frequently.under dusty conditions. K : Have an authorized Kawasaki engine dealer perform those services.

0 0

GENERAL INFORMATION l-9

Torque and Locking Agent

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

locking agent or liquid gasket.

Letters used in the “Remarks” column mean*

L : Apply a non-permanent locking agent to the threads. M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. 0 : Apply an oil to the threads, seated surface, or washer.

S : Tighten the fasteners following the specified sequence.

Fastener

N-m

Torque Remarks

kg-m ft-lb

Fuel System:

Carburetor Mounting Nuts

Governor Arm Nut

Fuel Shut-Off Solenoid Valve

17.0

7.8

9.8

1.7

0.8

12.0

69 in-lb

1 .o 7.0

Cooling System:

Radiator Mounting Bolts Cooling Fan Shaft Nut Water Pump Cover Bolts Therm0 Switch

17.0

20.0

7.8

27.0

1.7 12.0

2.0 14.5

0.8 69 in-lb

2.8 20.0

Engine Top End:

Cylinder Head Bolts and Nuts Valve Clearance Adjust Nuts Spark Piugs

21 .o

8.8

25.0

2.1 15.0

0.9 78 in-lb

2.5 18.0

Lubrication System:

Oil Drain Plug Oil Pressure Switch

23.0

15.0

2.3

16.5

1.5 11 .o L

Camshaft/Crankshaft:

Case Cover to Block Bolts

Con-Rod Cap Bolts

21 .o 21 .o

2.1

15.0 S

2.1 15.0 0

Electrical System:

Flywheel Nut

Starter Motor “B” Terminal

110.0

9.8

11 .o 80.0

1 .o 7.0

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All

of the values are for use with dry solvent-cleaned

threads.

Bark Toraue for General Fasteners

hreads

dia.

(mm)

4 1.2-2.2 5 3.4-4.9 6 5.9-7.8 8 14-19

N-m

Torque

Fuel System

Table of Contents

FUEL SYSTEM 2-l

Exploded View Specifications.. Governor Link Mechanism

Control Panel Assembly/Removal Control Panel Assembly Installation Notes Governor Am, Removal Governor Arm Installation Governor Assembly Removal

Governor Assembly Installation Notes Governor Assembly Inspection Governor Shaft Removal Governor Shaft Installation Notes

Carburetor

Fuel and Air Flow

Fuel Shut Off Solenoid Valve ..............................................................................................

Idle Mixture Screw (Pilot Screw) and Idle Speed Adjustment Fast Idle Speed Adjustment.. High Altitude Operation Main Jet Replacement.. Fuel System Cleanliness Carburetor Removal Installation Notes

Disassembly Assembly Notes ............................................................................................

Cleaning

Inspection.. Fuel Shut-Off Solenoid Valve Test

Intake Manifold..

Removal. ..............................................................................................................................

Installation Notes inspection

Fuel Pump..

Fuel Pump Test ..................................................................................................................

Air Cleaner.. .......................................................................................................................... ...2-17

Element Removal.. ............................................................................................................. .2-l 7

Element Installation Notes.. Element Cleaning and Inspection Cleaner Body and Bracket Removal

Cleaner Body and Bracket Installation Notes

Housing (Case and Body) Inspection

.......................................................................................................................... 2-2

.......................................................................................................................... 2-4

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

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

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

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

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

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

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

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

.................................................................................................................................. 2-8

.......................................... 0 ......................................................................

............................................................................................... 2-9

..................................................................................................... 2-10

Inspection

........................................................................................................... 2-l 1

............................................................................................................... 2-l 1

............................................................................................................................. 2-12

......................................................................................................................... 2-l 3

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

..................................................................................................................... 2-l 5

............................................................................................................... 2-l 5

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

.......................................................................................................................... ...2-16

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

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

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

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

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

.................................................................................. 2-l 1

................................................................................ ..2-18

.................................................................... 2-18

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

2-5 2-5

.2-5

2-5 2-5 2-6

2-6

2-6 .2-6 .2-7

2-8 2-8 2-9

2-l 2

2-14 2-l 5

..2-15

2-16

2-17 2-17

2-18

2-2 FUEL SYSTEM

Exploded View

Tl: 2.00 N-m (0.20kg-m,17.0 in-lb)

(Stopper Screw)

T2: 1.16 N-m (0.13 kg-m, 10.3 in-lb)

(Drain Screw)

T3: 0.66 N-m (0.90 kg-m, 7.6 in-lb)

(Throttle Valve Screws)

T4: 9.80 N-m (1 .OO kg-m, 87.0 In-lb)

(Solenoid Valve)

T5: 1.00 N-m (0.10 kg-m, 8.9 in-lb)

(Main Jet)

T6: 2.94 N-m (0.30 Kg-m, 26.0 In-lb)

(Air Hone Mounting Screws)

T7: 1.00 N-m (0.10 kg-m, 8.9 in-lb)

(Pilot Ah Jet)

T8: 0.88 N-m (0.90 kg-m, 7.8 in-lb)

(Choke Valve Screw)

l8: 1.00 N-m (0.10 kg-m, 8.9 in-lb)

(Main Air Jet)

TlO: 17.00 N-m (1.7 kg-m, 12.0 Mb)

(Carb. Mounting Nuts)

FUEL SYSTEM 2-3

Tl: 7.6 N-m (0.8 kg-m, 89 in-lb)

0: Apply engine oil

2-4 FUEL SYSTEM Specifications

Item

Carburetor Specifications:

Make/type Main bore diameter

Venturi diameter

Main jet (MJ) Pilot jet (PJ) Main air jet (MAJ) Pilot air jet (PAJ) Pilot Screw turns out (PS) (Idle mixture screw turns out) Float level

Idle Speed except U.S.

Low idle speed High idle speed

Idle Speed for U.S.

Low idle speed High idle speed

Air Cleaner:

Type

Pre-cleaner

Two-stage cleaner

Standard

TEIKEI/FD22K-1 A 26 mm (1.02 in) 22 mm (0.87 in) #112

#58

#1.8 #0.9 1 314

Float parallel to carburetor body

1550 _+ 100 (rpm)

3600 a 75(rpm)

1450 (rpm) to 1650 (rpm)

3600 (rpm)

Dual stage filtration system Foam element Paper element

Fuel:

Fuel requirement except U.S. Fuel requirement

Fuel Pump:

Type

Rated voltage Delivery (MIN)

Shut-off delivery pressure

Governor:

Type

for U.S.

Leaded or unleaded automotive grade gasoline

Unleaded regular grade gasoline

Electra-magnetic Pump (in-line type) 12VDC 400 mL (0.4 qt)/(MIN) at free flow

19.6 to 26.5 kPa (2.8 to 3.8 psi)

Flyweight all speed governor

Governor Link Mechanism Control Panel Assembly/Removal

0 Remove:

Air Cleaner (see Air Cleaner)

Muffler (see Muffler Assembly Removal)

Carburetor(see Carburetor Removal)

OUnscrew the M6 mounting screws (A) and take off the control panel

assembly (B) while unhooking the governor spring (C) end loop at the middle of the governor arm(D).

NOTE

0 Note the position of the different length of the screws. The longer

screw has a collar (E) between control panel and the crankcase.

Control Panel Assembly Installation Notes

Before installing the control panel assembly, check to see that the choke lever and engine speed control lever move smoothly all the ways.

*If any part is worn or damaged, replace the control panel assembly.

After installation, adjust the low and fast idle speeds to the specifications (see Idle Speed and Fast Idle Speed adjustment).

A. Choke Lever C. Choke Spring

B. Engine Speed Control Lever D. Governor Spring

FUEL SYSTEM 2-5

Governor Arm Removal

0 Remove:

Control Panel Assembly

Loosen the clamp nut, and take off the governor arm.

A. Clamp Nut B. Governor Arm

Governor Arm Installation

install the governor arm onto the governor shaft temporarily.

install the control panel assembly, and connect the governor arm with the governor spring.

0 Install the carburetor except for the air cleaner bracket.

Be sure the link spring around the throttle link rod is inplace and that it pulls the governor arm and throttle lever each other.

Loosen the clamp nut on the governor arm enough to move the governor shaft.

Turn Top end of the governor arm counterclockwise to fully open the carburetor throttle valve and hold it there.

@Turn the governor shaft counterclockwise by inserting a needle into

shaft end hole. Fully turn the shaft to end of its travel and tighten the clamp nut to the specification (see Exploded View).

Be sure the governor shaft extend from the governor arm is approximately 7mm (0.3in).

1. Link Spring 6. Governor Shaft

2. Throttle Link Rod 7. Clamp Nut

3. Throttle Lever 6. Small Hole

4. Governor Arm 9. Governor Sleeve

5. Carburetor (Controll panel is removed for clarity)

2-6 FUEL SYSTEM

Governor Assembly Removal

@Split the crankcase (see Crankcase Splitting in the Camshaft/Crank-

shaft chapter).

@Remove the governor assembly (A) with the sleeve (B) by prying the

gear with’ two proper size screw drivers.

OTo avoid damaging the parting surface of the casecover, use a

suitable soft mats (C) as shown.

ACAUTION

Do not remove the governor assembly unless it is necessary. Once

It has been removed, it must be replaced.

oRemove the thrust washer.

Governor Assembly Installation Notes

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

NOTE ,

0 The sleeve and the governor assembly cannot be installed separately.

Push the set onto the shaft until inner flange snaps into the groove securely.

1. Sleeve

2. Governor Assembly

3. Inner Flange

4. Thrust Washer

5. Groove

6. Shaft

@Spin the governor assembly by hand and check that the flyweights

operate freely and the center sleeve moves outward.

Governor Assembly Inspection

OVisually check the assembly for wear and damage.

*If any part is worm or damaged, replace the assembly.

Governor Shaft Removal

0 Remove:

Camshaft (see Camshaft Tappet Removal in the camshaft/Crankshaft

chapter). 0 Unscrew the governor arm clamp nut, and remove the governor arm. ofurn the governor shaft clockwise l/4 turn to remove governor shaft.

NOTE

O/t is not necessary to remove the governor shaft unless it is being

replaced.

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

damaged.

The oil seal must be assembled, with seal lip towards inside of the

engine.

Press in the oil seal 1 .Omm (0.04 in) below the crankcase surface.

1. Governor Shaft

2. Oil Seal 5. Crankcase

3. Shaft Arm

4. Projections

Governor Shaft Installation Notes

install the governor shaft (A) by properly positioning shaft arm between projections (B) as shown (see above PHOTO).

NOTE

olnstall the governor shaft before installing the camshaft to the ‘>

crankcase.

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

FUEL SYSTEM 2-7

2-8 FUEL SYSTEM

Carburetor

Fuel and Air Flow

The main system of the carburetor consists of the main jet, main

nozzle, and the main air passage (main air jet). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel flows through the main jet and into the main nozzle, where it is joined by air

from the main air passage (main air jet). The resulting mixture flows out the end of the main nozzle into the carburetor bore, where it is atomized by the high speed air flow, and carried into the engine.

The pilot system includes the pilot jet, pilot screw (Idle mixture screw), pilot air jet, pilot outlet, and the bypass outlet. The pilot system meters the fuel/air mixture while the engine is idling and running under a light lead. Under these conditions there is very little air flow through the carburetor bore; so little that it is not enough to draw fuel through the

main system of the carburetor and atomize it. Instead, the fuel is drawn

through the pilot system, since the nearly closed throttle valve causes

high speed air flow past the pilot outlet and bypass holes(even at low

engine speed).

Fuel flow in the pilot system is metered by the pilot jet. Air for better atomization is admitted via the pilot air jet in the mouth of the carburetor. The fuel/air mixture passes into the bore of the carburetor downstream

of the throttle valve through the bypass holes and pilot outlet. While the throttle valve is almost closed, it covers the small bypass holes opening into the bore from the pilot system. As the throttle valve begins to open, it uncovers the bypass holes, allowing more fuel/air mixture to flow. The extra flow is needed because the engine starts to run faster as the throttle is opened. The pilot screw controls the amount of fuel/air mixture allowed through the pilot outlet, but dose not meter the bypass holes. A moderate amount of air comes in around the throttle valve at an idle, so adjusting the pilot screw changes the fuel/air ratio. Turning the pilot screw (Idle mixture screw) out (Counterclockwise) enrichens the mixture; turning it in (clockwise) leans the mixture.

1. Main Jet 8. Bypass Holes

2. Main Air Jet 9. Pilot Outlet

3. Emarsion Tube 10. Pilot Screw

4. Float (Idle Mixture Screw)

5. Ball Plugs 11. Throttle Valve

6. Pilot Jet

7. Pilot Air Jet 13. Plate Plug

12. Main Nozzle

Main Fuel Flow

----

Pilot Fuel Flow

Fuel Shut Off Solenoid Valve

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

The valve opens automatically when the switch key is turned to the

“Run” position.

1. Solenoid Valve

2. Main Jet

Idle Mixture Screw (Pilot Screw) and Idle Speed AcQustment

ACAlJTtON

Do not attempt to adjust idle mixture screw with air cleaner removed

Stop the engine.

@Turn the idle mixture screw (A) all the way in until it seats lightly.

ACAlJTfON

Do not turn tfte idle mixture screw in too far or the carburetor body will be damaged and require replacement

@Back the idle mixture screw out the specified number of turns (1 3/4).

This setting is approximately correct. To make fine adjustment, follow the steps below.

Disconnect all possible external loads from the engine.

Start the engine and warm it up thoroughly.

FUEL SYSTEM 2-9

Always keep your hands clear of the moving

@Move the throttle lever on dash in the idle position, and hold the

throttle lever on the carburetor in closed position (turn the governor

arm clockwise all the way) and adjust the idle speed screw (A) until the engine idles at specified speed.

Keep on throttle lever on the carburetor in the closed position, and search for the point at which the engine speed gets the highest by slowly turning the idle mixture screw in or out and then turn the idle

mixture screw back out additional l/4 turn.

0 Make adjustment by turning the idle speed screw so that the engine

may be kept at specified idle speed while keeping the on the carburetor in the closed position.

idle Mixture Screw Turns Out

1 3/4 (nearly about) idle Speed except U.S. 1550 + 100 (rpm)

idle Speed for U.S. 1450 to 1650 (rpm)

parts

throttle lever

NOTE

OA remote throttle control cable nlust be made the idle

respectively

1. Throttle Cable

2. Choke Cable

3. Idle Position

4. Throttle Lever (Carb.)

correspond to that of the equipment.

5. Governor Arm

6. Idle Speed Screw

7. Idle Mixture Screw

speed

Fast Idle Speed Ac#ustment

NOTE

OFast idle speed adjustment should be made after the idle speed

adjustment is performed.

ACAUllON

Do not adjust fast idle speed with the air cleaner removed

Start and warm up the engine thoroughly.

2-10 FUEL SYSTEM

Always keep your hands clear of the moving parts.

Move the throttle lever on dash in the fast idle position and leave it

there.

@Loosen two M6 control panel mounting bolts enough to move the

control panel assembly.

Carefully move the control panel assembly left or right to obtain the specified fast idle speed.

*Tighten the M6 Mounting bolts.

Fast Speed

3600 f 75 rpm

Check the idle speed, and readjust the idle speed if necessary.

ACAlJTlON

Be sure to make the idle and fast idle speeds respectively

correspond to those of the equipment.

A. Control Panel C. Fast Idle

B. M6 Mounting Bolts (Air cleaner is removed for clarity)

D. Open Choke

High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installihg a smaller diameter main-jet in the carburetor and readjusting the pilot screw (idle mixture screw) to meet good idling and idle speed is the specified rpm.

NOTE

0 The main jet high altitude kits are available if the equipment is to be

used in the high altitudes. ends of the main jets.

High Altitude Main Jet

Altitude 0 y 1000 m (o-3000 ft) 1000 - 2000 m (3000 -6000 ft) #llO 2000 m (6000 ft) and higher #lOS

The main jet numbers are stamped on

Main Jet No.

#112 (STD)

Main Jet Replacement

Place the engine (equipment) on a level surface.

Close the fuel shut off valve in the equipment.

Drain the fuel in the carburetor completely by unscrewing the drain

screw (C) at the bottom of the float chamber.

ORemove the carburetor (see Carburetor Removal).

Unscrew the solenoid valve (A), and take off the valve and gasket.

@Using a proper blade screw driver, carefully replace the main jet (B)

with a new one for altitude expected.

@Tighten the main jet to the specification (see Carburetor Disassembly

Assembly Notes).

install the gasket and solenoid valve.

f uef System Cleanliness inspection

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

Place a suitable drain hose (B) under the drain screw (A) on the

carburetor.

Run the lower end of the hose into a container.

Turn out the drain screw a few turns to drain the carburetor and check to see if water or dirt has accumulated in the carburetor.

Tighten the drain screw.

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

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

FUEL SYSTEM 2-11

Carburetor Removal

0 Remove:

Air Cleaner and Related Parts (see Air Cleaner). @Turn the fuel shut off valve to the OFF position. 0 Drain the carburetor. 0 Disconnect the fuel tube at the fuel inlet joint (A) of the carburetor. 0 Disconnect the solenoid valve lead terminal.

Unscrew the carburetor mounting nuts.

Unhook the throttle link spring (B) at the governor arm (C) top end

with a long nose plier.

Unhook the throttle and choke link rods (D.E) at the top ends of their

arms while lifting off the carburetor.

Installation Notes

Clean the mating surfaces of the carburetor and intake manifold and

fit a new gasket.

Take care not to bend the throttle and choke link rods during installation. Make sure the link spring around the throttle link rod is inplace

and that it pulls the governor arm and carburetor throttle lever toward

each other.

Adjust:

Carburetor Idle Mixture screw

Idle Speed

2-12 FUEL SYSTEM

Disassembly Assembly Notes

@Refer to the illustration shown for disassembly and assembly. @There are a number of the plate or boll plugs in the carburetor. None

of these should be removed.

@Turn in the idle mixture screw and count the number of turns until it

seats fully but not tightly, and then remove the screw. This is to set the screw to its original position when assembling.

Turn the idle mixture screw all the way in until it seats lightly, and then

back it out the same number of turns counted during disassembly.

install the throttle valve on the shaft as the numerical mark on the valve

facing out side.

Note the metering hole in the choke valve, install the choke valve on the shaft so that the metering hole towards fuel inlet joint of the carburetor.

Drive in the float pin so that the pin extends the same distance on both side of the float hinge bracket.

The fuel inlet valve seat is pressed into the carburetor body and is not

replaceable.

When assembling the carburetor parts which are attached to the carburetor with the recommended tightening torque of a bolts and screws. (see Exploded View)

1. Choke Shaft 19. Spring

2. Seal 20. Screws

3. Collar

4. Collar 22. Solenoid Valve

5. Air Hone 23. Gasket

6. Emarsion Tube

7. Float 25. Carb. Body

8. Gasket 26. Carb. Mounting Nuts

9. Pilot Jet 27. Float Pin

10. Screw 28. Float Valve

11. Stopper 29. Screws

12. Throttle Shaft 30. Pilot Air Jet

13. Seal 31. O-ring

14. Spring

15. Idle Speed Screw 33. Choke Valve

16. Spring 34. Main Air Jet

17. Pilot Screw

18. Drain Screw

21. Throttle Valve

24. Main Jet

32. Screw

Cleaning

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

ACAUTION

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

0 Disassemble the carburetor.

immerse all the carburetor metal parts in a carburetor cleaning solution and clean them.

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

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

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

All holes must be open.

Assemble the carburetor.

Inspection

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

*Inspect the carburetor body for damage. Flange sealing surfaces

should be smooth and free of burrs and nicks. Replace the gasket if necessary.

Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly.

*If the valves do not more smoothly, replace the carburetor body and/or

throttle shaft and choke shaft assembly.

Check that the gasket on the carburetor body.

*if the gasket is not in good condition, replace it.

Check the other parts of the carburetor for wear or damage. Replace the part if necessary.

Clean and check the float level as follows.

FUEL SYSTEM 2-13

ACAUTlON

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

With the float (3) assembly installed onto the air hone (I), hold the air hone upside down at an eye level. Gently support the float with a finger and bring it down slowly so that the float arm tab (4) just touches the float valve needle (5). The float lower surface should be parallel with the carburetor body to the air’hone mating surfaces (2).

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

adjustment.

@Inspect the inlet needle valve for excessive wear or damage. The tip

should be smooth, without any grooves, scratches, or tears. The rod at the other end of the needle should move smoothly when push in and released.

*If either the needle or the seat is worn or damaged, replace the float

assembly and carburetor body as a set.

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