E290 FCSO0U FCAOAM FOA20W FCSAOY Onl : 4-stroke air-cooled gasoline engine WORKSHOP MANUALFOREWORD This manual is designed for use by trained mecha~ nics in a properly equipped shop. 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 equipments are specified, do not use makeshift tools or equipnent, Precision measuresents can only be made if the prop- er instruments are used, and the use of substitute tools may adversely affect safe operation, Whenever you see these WARNING AND CAU- TION symbols, heed their instructions! Always follow safe operation and maintenance prac- tices, WARNING : This safety alert symbol _iden- tifies important safety messages in this wan ual and on the equipnent, When you see this symbol read the message that follows very carefully to ‘avoid fire, personal injury, or loss of 1i CAUTION :This identifies special instructions or procedures to avoid equipment danage or destruc: tion, NOTE © Indicates message or points of particular interest for wore efficient and convenient operation, SAFETY WARNING :Gasoline is extrenely flan 1\ cable and can be explosive andor certain con ditions, Stop the engine, Do not_seoke, Nake sure the area_is well ventilated and Tree fron any source of flane-or sparks; this includes any appliance with tot Light A\ WARNING :¥hen servicing the engine of YS equipnent, always stop the engine and remove the spark plug wire from the spark plug to avoid dental starting, WARNING :Protect your hands with gloves Fa piece of thick cloth fro edges and heat in servicing the produ ‘The term "Replace” and sose abbreviations are used as follows: Replace = Usually seans replace with a new part MIN = Minimua MAK = Maxcimua Assy = Assembly STD = Standard PTO = Poner take off Approx, = Approximately (Approximate) Carb, = Carburetor Con-rod = Connect ing rod cyl, = Cylinder Dia, = Dianeter All rights reserved, No part of this publication ray be reproduced, stored ina retrieval systea, or transmitted in any form or by any means, elec- tronic mechanical photocopying, recording or other- wise, without the prior written permission of Engine Division/awasaki Heavy Industries, Ltd, No liabili- ty 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. All procedures and specif ications sub- ject to change without prior notice or obligation, [lusteations in this publication are intended for reference use only and may not depict actual model component parts, WARNING : Before perforning any disas~ JN senibly operations on the eguiprent with the electric starter, disconect the negative (=) Tead from the battery to avoid the possibility of accidentally cranking the engine while partially disassembled A\ WARNING :Al Y\ when working on the electrical equiprent, Work in a clean, dry environment with dry hands, For max- inun_shock hazard protection, connect the equipnent ‘ound terminal to an earth ground,TABLE OF CONTENTS GENERAL INFORMATION MECHANICAL SYSTEM ++++++e0 ELECTRICAL SYSTEM +++ GENERAL SPECIFICATIONS =~ 4 WIRING DIAGRAM cress 5 C290 ELECTRIC STARTER MODEL <++++++0 5 C400, FC420-FCS40 ELECTRIC STARTER MODEL + 6 PERIODIC MAINTENANCE © 1 TROUBLE SHOOTING 8 ENGINE ~ HARD STARTING. +» 8 ENGINE ~ WALPUNCTIONS AT LOW SPEED oa) ENGINE ~ BRRATICAL RUN +» ENGINE - BXCESSIVE OIL CONSUMPTION ENGINE - LOW POWER +++++s0+e0s0¥e ENGINE ~ EXCESSIVE FUEL CONSUMPTION ++ TORQUE SPECIFICATIONS - CONTROL SYSTEM GOVERNOR LEVER SETTING THROTTLE CABLE INSTALLATION «= FAST OLE SPEED ADJUSTENT ++++++ (CHOKE. ADJUSTMENT « SLOW IDLE SPEED ANJUSTHGNT AIR CLEANER "K" KLBEN SYSTEM + MAINTENANCE +++ seeseeseeeee IG pei CARBURETOR + COMPONENTS «+sesseeeeeeeneesee it REMOVAL muri 18 FLOAT CHAMBER REMOVAL <+++++0ee0e B CLEANING + peers FLOAT ADJUSTHENT + ASSEMBLY AND INSTALLATION + (CARBURETOR TOBNTIFICATION ~ COOLING SYSTEM sree BLADE GAP ADJUSTENT +++s++++seee0eese RECOIL STARTER seen DISASSEMBLY «+ DISASSEMBLY ++ cee REASSEMBLY. -++++e00 ELECTRIC STARTER & CHARGING + TROUBLE SHOOTING SOLENOID AND CIRCUIT CHECK STARTER MOTOR CHECK +++ COMPONENTS. F290 (Bendix Type) + COMPONENTS F400, RC420 (Shift Type) + components FC§MO (Shift. Type) ++e0n BRUSH SERVICE LIMIT = ‘BRUSH SPRING CHECK BRUSH HOLDER CHECK ARMATURE CHECK + ARMATURE SERVICE LIMIT YOKE CHECK +++e+eeee5 PINION CLUTCH CHECK +++++0+ STARTER MOTOR REASSENBLY +» REGULATOR CHECK s++++seseeeee UNREGULATED STATOR OUTPUT (13-154 TYPE) +++0¥+ 35, STATOR OUTPUT (34 TYPE) ++++¥+ eee) IGNITION SYSTEM servesseseeee ‘TYPE OP IONITION SYSTEM SPARK CHECK ++ CONTROL UNIT CHECK IGNITION COIL CHECK «+++ FLYWHEEL REMOVAL «+++e+ee0e FLIMHEEL INSTALLATION ++++++0 IGNITION COIL AIR-GAP ADJUSTHBNT +++ +++ FUEL PUMP -- REWOWAL. AND DISASSEMBLY ~ COMPONENTS «++e0eeeeene cack INSTALLATION e+e+eeeeee CYLINDER HEAD ++ COMPRESSION CHECK + REMOVAL =» MAINTENANCE INSTALLATION VALVE VALVE CLEARANCE ADJUSTHENT ++++++0 AUTOMATIC COMPRESSOW RELEASE (ACR) CHECK VALVE AND RELATED PARTS REMOVAL s++seeeveevevee 43. CHECK AND MAINTENANCE = seeseeseene SERVICE LIMIT +++ se dS VALVE SPRING SERVICE LIMIT + LAPPING =+++ VALVE SEAT RECONDITIONING. «+++ VALVE GUIDE SERFICE LIMIT +» VALVE GUIDE REPLACEMENT +++++0¥e ROCKER ARM SERVICE LIMIT ROCKER SHAFT SERVICE LIMIT PUSH ROD SERVICE LIMITCRANKCASE COVER: REMOVAL SERVICE LIMIT + BUSHING REPLACEMENT ~ FC29Q ++e++eeeeeeeeeeeees 50) COLL SBAL REPLACEMENT +++» INSTALLATION +s+++0 ee 9) see 52 CAMSHAFT REMOVAL =++0+++ VISUAL CHECK ++++++++ SERVICE LIMIT «= INSTALLATION AREAL PLAY ADJUSTHENT « PISTON & CON-ROD - REMOVAL, PISTON AND PISTON RING VISUAL CHECK PISTON CLEANING + PISTON SERVICE LIMIT «+++0+e+seeeesesseeseseoes 58, PISTON PIN SERVICE LIMIT + PISTON RING SERVICE LIMIT PISTON RING INSTALLATION CCON-ROO VISUAL CHECK CON-ROD SERVICE LIMIT « PISTON AND CON-ROD ASSEMBLY PISTON/CON-ROD ASSY INSTALLATION + CRANKSHAFT RENDVAL «+++ VISUAL CHECK +++e+sssessesseesescssesessesesees 63 SERVICE LIMIT s+esssseesessessesesseseeeesesees 6 AXIAL PLAY ADJUSTMENT «+» NSTALLATL OW CRANK PIN RE-GRINDING = BALANCER BALANCE WEIGHT SERVICE LIMIT ~ BALANCE WEIGHT BUSHING INSTALLATION C400, FC420 & FCS4O +++ 70 BALANCE SUPPORT SHART SERVICE LIMIT ++ BALANCE LINK ROD SERVICE LIMIT + LINK ROD BUSHING ASSEMBLY GOVERNOR GOVERNOR GEAR CHECK AND REMOVAL GOVERNOR GEAR INSTALLATION GOVERNOR SHAPT INSTALLATION ++++eeseeeeeeserees 72 LUBRICATING SYSTEM- r ENGINE OIL. OIL SLiNGeR CHECK - F290 OIL WARNING SYSTEM ~ C400, C420 a PC540 FULL PLOW OIL FILTER ~ F400, FC420 & FCSAO ++ DIL PASSAGE CHECK ~ FC4O0, FC420 & PC540 DIL PUMP COMPONENTS - FC4OD, FC420 & PC540 ~ DIL PUMP CHECK ~ FC4O0, FC420 & FCS&O + BREATHER SYSTEM BREATHER REED VAL CYLINDER/CRANKCASE CYLINDER SERVICE LIMIT +++ CYLINDER BORE RESIZING ++ BALL BEARING CHECK «++-+e+eseeeeeeveeeeen BALL BEARING REPLACEMENT ++++s+e+eeeeens OIL SEAL REPLACEMENT «++sssssseeesecseseeseeees BD CCANSHAPT BEARING SERVICE LIMIT ++e+e+severeeees 82GENERAL INFORMATION MECHANTCAL (SYSTEM Be familiar with OPERATOR'S MANUAL before service, Lubrication Supply engine oi as specified even for a short test running to avoid any score in the engine, which may destroy the engine in the field use. Use clean engine oil in the case specified as just “coat oil” in this eanual, Don't use just any oil or grease, Sone oils and greases in particular should be used only in certain applications and way be harmful if used in an ap- plication for which they are not intended, Engine wear is generally at its maxiaur while the engine is varaing up and before all the rubbing surfaces have an adequate Iubricative film, During asseably, oi] or grease (whichever is sore suitable) should be applied to any rubbing surface which has lost its lubricative film, Old grease and dirty oil should be cleaned off, eteriorated grease has lost its lubricative quality and aay contain abrasive foreign particles, Fuel ‘Unleaded gasoline is preferably recommended because of the less deposit in the cosbust ion chanber. Alcohol mixed gasoline is not recommended due to bad influences of alcohol on the engine coaponents in the fuel and combustion systens, High Flash-point Solvent 1 high Flash-point solvent is recomended to reduce fire danger, A comercial solvent commonly available in North America is Stoddard solvent (generic nane), Always follow manufacturer’ s and container’ s direc~ tions regarding the use of any solvent, Dirt Before renoval and disasseably, clean the product, Any dirt entering the product, carburetor, or other parts will work as an abrasive and shorten the life ‘of the product, For the sane reason, before install- ing a new part, clean off any dust or metal fillings, Lig et_and Non-permanent Locking Agent rer’ directions for cleaning and preparing surfaces where these coapounds will be used, Apply sparingly, Excessive anounts aay block engine oil passages and cause serious danage, An example of a non-permanent locking agent commonly available in North America is Loctite Lock’n Seal (ue) Dil Seal, Grease Seal Replace any 011 or grease seals that were renoved, because the renoval generally danages seals, A seal guide is required for certain oil or grease seals during installation to avoid danage to the seal lips, Gasket, O-ring When in doubt as to the condition of a gasket or O-ring, replace it, The nating surfaces around the fasket should be free fron foreign aatter and saooth to avoid leakage, Circlip, Retaining Ring Replace any circlips and retaining rings that were renoved, because the renoval weakens and deforms them, hen installing circlips and retaining rings, take care to compress or expand then only enough to install then,GENERAL INFORMATION Force Connon sense should dictate how much force is neces- sary in assembly and disassembly, If a part seens especially difficult to remove or install, stop and ccheck what may be causing the problem, Whenever tap- ping is necessary, tap lightly using a wooden or plastic-faced aallet, Use an ispact driver for ‘screws (particularly for the renoval of screws held by a locking agent) in order to avoid danaging the heads, Press Hopart, such as a seal, installed using a press or driver should first be coated with oil on its outer or inner surface so that it will go into place smoothly, Ball Bearing Installation When installing @ ball bear ing, the bearing race which is affected by friction should be pushed by @ suitable driver, This prevents severe stress on the balis and races, and prevents races’ and balls fron being dented, Press a ball bearing until it stops at the stop in the hole or on the shaft, Torque The torque values given in this eanual should alvays be adhered to, Bither too little or too auch torque may lead to serious damage, Use a good qual ty, reliable torque wrench, Tightening Sequence Follow the tightening sequence shown in this manual, When installing @ part with several bolts, nuts or screws, they should all be started in their holes and tightened to a snug fit, Then tighten thea evenly, according to the tightening sequence, to the specified torque, This is to avoid distortion of the part and/or leakage, Conversely, when loosen ing the bolts, nuts, or screvs, loosen all of then about a quarter of a turn and then resove thenGENERAL INFORMATION ELECTRECAL SYSTEM No shock ‘The electrical parts should never be sharply struck, with a hamaer, or dropped on a hard surface, Such a shock to the parts may danage thes, Electrical Leads AIT the electrical leads are either single-color or two-color and, with only a few exceptions, must be connected to leads of the sane color, On any of the two-color leads, there is greater anount of prine color and lesser anount of second color, so the two color lead is identified first by the prime color and then the second color. For example, a yellow lead with thin red stripes is referred to as a “yelllow/red” lead; it vould be @ “red/yellov” lead if the colors were reversed to make red the prine color, TWO-COLOR LEAD Lead (cross-sect ion) yellow/red Name of Lead Color Defective Component Never replace a defective electrical component with- out determining what caused the failure, If the failure was brought on by some other item or items, they too must be repaired or replaced, or the new replacement will fail again, Connectors Wake sure all connectors in the circuit are clean and tight, and examine leads for signs of burning, fraying, etc, Poor leads and bad connections will affect electrical systen operation, Coil Resistance Weasure coil and winding resistance when the part ts cold (at roon temperature), Battery Do not disconnect the battery leads or any other electrical connections wien the ignition switch is on, or while the engine is running, unless specifically noted, Do not reverse the battery lead connections, This will buro out the diodes or other parts in the electrical systens, Always check battery condition before blaming other parts of an electrical systen, 4 fully charged battery is a must for perforning accurate electrical system check Starter Never Keep the starter engaged if the starter notor Will not turn over, or the current may burn out the starter aotor windings, KAVASAKT Multimeter KAVASAKT Multimeter” (P/N 39510-98034) is recoa- mended for the electrical systen check because a eter of other type may indicate different value,GENERAL SPECIFICATIONS Bore x Stroke 1TEM Fo290v Fosoov Fo420v_ | FC540V Engine Type Forced Air-cooled, Vertical Shaft, OHV, 4-Stroke Gasol ine Engine | Nuaber of Cylinder 1 : Piston Displacenent 286cc (17, Scub-in,) | 40dcc(24, Soub-in,) | 428cc(25, Scub-in.) | 535ec(32, 6cub-in,) 78 x 60 37x 68 on 09 x 68 mn 89 x 86 an (3.07 x 2.36 in.) | G43 x 2.68 in) | 50 x 268 in) | @.50 x 3.39 in) Direct ion of Rotation = Counterclockvise facing the PTO Shaft Fast Idle Speed _ 3275_~ 3425 rp __f, Note 5, Lov ldle Speed _ 7 1450 _~ 1650 re0 Ack Nechanical Flyweight Type Lubricating Nethod Splash Pressurized it Pan Capacity __[1.11 2.3 0s pty 1.3L @7 0S pb 1.6L G4 05 pt) z | corburetor Float Type Fixed Main Jet Choke Control _ Autonat ic (vith Throttle Control) : | Air Cleaner Seni-cyclone Type with Oval Elesent Ignition ‘Transistorized Flywheel Magneto ee [5 A ith Rectifier = 12. V- 13 A with Regulator Rane Spark Plug _ _Chanpion RNLIYC or NGK BPR5ES REL Suppressor * ___Per Canada and USA Reguirenent 7 Electric Starter ere WV 06 Wy shee Typ ates Cooling Air Inet Rotating Screen with Periphery Blade Protector Fuel Punp «| _ Diaphragn Type Pulse Pump | sovernor Mechanical Flyweight : Balancing _ Reciprocating Balance Weight Recommended Battery |_—__J2 ¥= [Link] _} 2 ¥- 280.cc4 12. - 230 cca 12.v ~ 510 cea Note Specifications are subject to change without not ice, ACR = Autonatic Compression Release, Parts with * are option, Recommended Batteries listed in upper coluan are for regular use and in lower coluan for low tenper- ature application, Fast idle speed may vary depending on each equipment on which engine is used, Refer to the equipment specif ication,WIRING DIAGRAM FO2IOMELEOTRIECY STARTER MODEL 12V-3A 1, Charging coil outputs are shown ‘above each dia~ gran, 2, Portion surrounded by hatching shows KANASAKI procurement parts, 3. Key switch connections are shown below, aye ye yee oF joto RUN o}+o stant 0+0}0 Engine Spark plug Ignition coil Charging coil Controt unit ectifier Fuse (20 A) 12V-13A Battery + Solenoid switchWIRING DIAGRAM FCd00, FORD IN FOS4O ELECTRIC STARTER MODEL i 2) a Charging coil outputs are shown above each eran, Portion surrounded by hatching shows KANASAKI procurenent parts, Key switch connections are shown below, or foto} | RUN loro START o+0 ° + Bagine Spark plug Ignition coil Charging coil Control unit + Rect fier * Connector (3P) = Key switch Fuse (10 4) : Fuse (20 A) : Battery Gil pressure switch Starter Regulator Charge light (12 ¥, 3.4 ™) Oil pressure Light (12 V, 3.4 W 12V-13A (FC400-FC420) 12V-15A (FC540)PERIODIC MAINTENANCE To ensure satisfactory operation over extended period of tine, engine requires nornal maintenance at regular intervals, Chart below shows periodic maintenance, Suitable interval is shova as (O). INTERVAL MAINTENANCE - = | Daily] Gvery | very| Gvery | fvery | Bvery 25 br | 50 hr | 100 br | 200 hr | 300 br Check and add engine oil, Check for loose or lost nuts and screws, Check for fuel and oi! leakage. Check battery electrolyte level, 10 Jo Jo |o jo Check or clean air intake screen, x Clean air cleaner foam elesent, ° ° Tighten nuts and screws, (first) ex Clean air cleaner paper elenent lo Clean fuel | lo jo |__2& Change engine oi1 (without oi! filter) k Change engine oil (with oil filter) lo Jo Clean and regap spark plug, Change oil filter. | I ° 2 Replace air cleaner paper elenent, kk Clean cylinder and cylinder head fins, lo Jo Jo Clean conbustion chamber, { Check and adjust valve clearance, lo jo Clean and tap valve seating surface l 1% Perform these aaintenances after first 5 hours (FC2Q0V) or 10 hours (PC4QOV-FCAZOV-FCS40¥) of use, then at recomended intervals, ek Service more frequently under dusty conditions,TROUBLE SHOOTING ENGENE SHARD STARTING Renove spark plug and |rN0—+| Are sparks produced |-YES —+| Faulty spark plug, | Replace check spark by crank- | | | when spark plug is A ing engine while hav- | YES | replaced? ing the plug grounded | | against engine block, c | instait spare plug to plug hole to avoid | |_| Are sparks produced |-YES —4 Faulty contact of | fuel spitting fron the| | | between high tension plug cap terainal | Correct hole, | |tead and engine No to leat block in state where | | Q\warnine: plug cap is renoved? To avoid electric — | Cs { -_________ Shock, do not hold | a eo etante contro anit. f Replace plug_itse, ' ves lake sure to hold plug | are sparks produced ep. | between high tension | Lat «faulty ignition coil, [- feplace 5 lead and engine | Faulty high tension |- Replace block when control cord, unit is replaced? lncorrect ignition | correct coil air gap. ‘Denagnetized fly- | Replace wheel, Is conpression YES —| Crank engine several |-pNO—+) #No fuel in the tank, | Add sufficien times and then re- Clogged fuel filter, |- Clean xo move spark plug and ‘Plugged air hole in |~ Clean observe electrodes, | tank cap, Are they wet? | Plugged fuel line, | Clean s L_fecesie we ot one tte choke, ‘Clogged air cleaner, |-~ Clean 2 Too high fuel level | Adjust in float bowl, — J storm piston/piston | replace rings, - ‘Stuck piston rings, | Clean or replace ‘Yorn cyl. bore, | fore or replace sTnsufficient cyl, + Retighten ) ~ head tightening, | —+ ecneck for plugged ‘Faulty contact of | Lap fuel passage, valve seat, Check for plugged ‘*Plunged-up valve, | Adjust air passage, ‘Warped cyl, head, Repair or replace Check float level, ‘Broken valve spring, |- Replace Check carb, set- ‘Stuck valve [Clean or grind ting. ‘Burned head gasket, | ReplaceTROUBLE SHOOTING ENGINE SO MALFUNCTIONS “AT: VOWSPEED Renove spark plug and ‘check spark by crank~ ing engine while hav ing the plug grounded | STRONG against engine block, Install spare plug to plug hole to avoid fuel spitting from the hole, Z\wannine: To avoid electric shock, do not hold plug itself, Wake sure to hold plug ao. eS ‘sFaulty plug insulation, ‘*Fouled electrodes, ‘Faulty high tension cord, ‘Incorrect ignition coil air e |— Replace [— Clean [— Replace — Correct S 1 Is unusual snoke enit- } ted out of muffler? open throttle valve by hand, Does revolution drop or does engine stall at a cert position? Is air drawn through |—7—YES carburetor flange? No Overrich fuel in carburetor slow systea Directly and gradually ——¥ES ——+ «Plugging in carburetor interior, + *Loose flange nuts, Damaged gaket, Adjust | Clean |— Tighten [— Replace co! noraal? o—— Is rave clearance |—>—x0 ——+ oConprens in lestage shronh s valve, |— adjust Is alignment of timing ———N0- ear marks correct? ‘Largely deviated valve tin- ing, [— Correct10 TROUBLE SHOOTING 10 ENGINE TST ERRAT ICAL ORUN Problem in fuel systea|——--——+| e Entry of dust or water: into |— Clean (lack of fuel) fuel pipe or fuel filter, ‘Air or vapour lock in fuel ENGENES SEX CESSHVECOTL CONSUMPTION [— Renove Hine, | ‘Plugged air vent of fuel |-— Clean tank cap. | Plugged air/fuel passes in |— Clean carburetor, ‘Too little opening of carb, |— Correct pilot air-screw, Problen in governor —4 incorrect governor linkage [— Correct systen adjustaent, Faulty governor spring, |-— Replace ‘Governor gear assy ealfunc- | — Replace tion, Engine knocks [+ «stale fuel, j— Change ‘Bxcessive carbon deposit in |— Clean engine, sBxcessive engine Toad, | — Adjust ‘Engine overheating, |— See LOW PORER 1s conpression 1s «Plugged ott ring groove, }— clean High oil level, }— Correct ‘Worn valve stews and valve |— Replace guides, Oil leakage along governor |— Replace | shaft, il leakage from oi1 seal, }— Replace Oil leakage from gasket, | — Replace Oil leakage fron drain plug, |— Retighten or replace ‘Faulty breather valve, | Repair or replace Drain-back hole in tappet |— Clean cchanber plugged, Incorrect oi] viscosity, | Change ‘Same as HARD STARTING,ul TROUBLE SHOOTING u ENGENE =e kOW POWER’ Is engine overheated? ‘Excessive engine load, | — Adjust Toad ee ‘Carb, not properly adjusted, | — Adjust i ‘Dirty or clogged air intake [— clean screens, shroud and engine | tins, ‘Carbon deposit in combustion |— Clean chaater. Wrong spark plug. i Replace + - Is lubricating condi- |—-—40—— « Too auch or too little of1 [— correct tion aoraal? in crankcase, Yes ‘Bxcessively contaminated — |— change Tube cating oil, i Is unusual saoke enit-|——yes —— clogged air cleaner, | ctean | ted out of nuffler? ‘Carbon deposit in exhaust. /-— Clean Cc x0 hole and auffier ‘*Cerb, not properly adjusted, — adjust ———___ ‘700 much oi} in crankcase, |— Correct 4 Ts conpression |__yp—['« sane as HARD STARTING sufficient? I. ENGINE (SUIEXCESSTVE? FUEL CONSUMPTION Is conpression 18s ‘Carb, not properly adjusted, |— Adjust sufficient? ‘Clogged air cleaner. L clean - eitigh idling RP. M. J Adiust "0 ‘Tncoaplete opening of choke |— open i valve, {______} esame as HARD STARTING.1 1 TORQUE SPECIFICATIONS LTEM Fo290 Fo420 Fos40 Con-rod bolt 20 Nem (180 Tbf in) Crankcase cover bolt 26 Nem (230 Lbf in) : Valve clearance adjust aut aaa 20 Nem (180 Ibf+in) 2A Nea (220 Voisin) | 52 Wea (38 bff) 52 Nem (38 Ibf-ft) Cylinder head bolt and nut Etywheed out | 86 nem (63 abe-fe) [137 Nem COL abterty | 172 Nem (127 tbt-ft) Blectric starter to block autaien 2 New Cm tot-in) | 16 em (140 Tin) | 16 Nom CLAD Uotin) Electric starter terminal aut | 5 Nem U5 tbf-in) | 9 Nem (80 Ibf-in) 11 Nom (100 thf-in)__| Gil drain extension joint to block Tighten firmly, Be careful not to over torque, to avoid thread danage, Oil drain plug 28 Nom (200 Lbfsin) P10 side crankshaft end bolt (vith plane vasher) | it equipped) Engine nount ing flange bolt (u8) (if equipped) 38 Nem (340 bf in) : 20 Nem (180 Ibf-in) General bolt © 3.5 Nem (30 Tbf-in) 6.0 Nem (50 Tbf-in) 15 Nem (130 1bf-in)3 B CONTROL SYSTEM GOVERNORMUGVERUSET TING Whenever carburetor or governor lever is renoved from engine and then installed again, adjust governor lever position, 1. Install governor lever (A) on governor shaft (6) but do not tighten nut (C) Loosen nut (C) if it is tightened, 2 Turn governor lever (A) clockwise or place throttle lever on dash in “FAST” position to open carb, throttle valve fully, 3. Turn governor shaft (8) clockwise to end of travel, 4. Keeping governor lever position of throttle fully open, tighten aut (C), THROTTUEU CABLE UNSTALLATION 1. Link throttle cable (6) to speed control lever (C) and clanp throttle cable outer housing (F) tenporalily, 2 With throttle lever on dash in “PAST” position, align hole (8) of speed control lever (C) with hole (0) of control plate (E) and insert 6 en (0,24 in.) dia, pin or 6 mm bolt through two holes, 3, Pull out throttle cable outer housing (F) to renove any slack and tighten cable clasp bolt (A) 4. Remove § an pin and set throttle lever on dash in “CHOKE” position, Wake sure cart, choke valve is com Bletely closed, Gee CHOKE ADJUSTHENT)u CONTROL SYSTEM Mu EXSTOUDLE SPEED WOIUSTMENT: NOTE #Air cleaner aust be installed to engine before starting, 1. Start and warm up engine without load, 2 Loosen two control plate bolts (1) A Align hole (8) of speed control lever (C) with hole (0) of control plate (2) and insert 6 ma (0.24 in.) dia pin or § am bolt through two holes, NOTE ‘Wake sure choke valve is fully opened, 4 Adjust fast idle speed for specified rpm (see GENERAL SPECIFICATIONS) by aoving control plate (E). 5, Tighten two bolts (I) securely in a manner to avoid changing specified speed, 6, Stop engine, remove § ae pin, and set throttle lever on dash in * CHOKE” position, Make sure carb, choke valve is closed completely,5 8 CONTROL SYSTEM CHOKE TADSUSTMENT. 1. Align hole (8) of speed control lever (C) with hole (0) of control plate (@) and insert 6 wn (0,24 in.) dia, pin or 6 an bolt through two holes, 2 Turn choke setting screw (K) counterclockwise until it is clear of choke control lever (L) and then turn choke setting screw clockwise until it just contacts choke control lever, Renove 6 aa pin and set throttle lever on dash in “CHOKE” position, Wake sure carb, choke valve is closed completely, SLOWST DEES SPEED TADYUSTMENT: Turn carb, pilot screw (8) in until it just seats and then back out 1-1/2 turns, Start and warm up engine without load, Wore throttle lever on dash to “SLOK” position, Adjust slow idle speed to specified rpm (see GENERAL SPECIFICATIONS) by moving throttle stop screw (A). Adjust pilot screw (@) until engine idles at maxinun ‘speed and then turn pilot screw out additional 1/4 turn, Re-adjust slow idle speed, to specified rp, Pm pep oe16 16 AIR CLEANER “KP OKWEENS SYSTEM Intake air is inducted through rotary screen (A), fan hous- ing (B), and air cleaner (C) to renove grass and rubbish from air, ‘Therefore, condition of air passages affects volume of in- take air and carburetor functions. 1. Assemble related parts neatly to einimize air leakage, 2 Keep clearance between rotary screen and fan housing as shown in COOLING SYSTEM, 3, Do not renove any parts constructing air passages when ‘4 running engine, Keep air passages free from grass and rubbish, MAUNTENANGE: Air cleaner maintenance is one of the most inportant ites to keep engine performing well Instruct users for following cautions, 1, FOAM BLENENT aust be Lightly oiled to perform as intend- ced, Make sure to soak elenent in engine oil and squeeze excessive oil, after washed, 2 PAPER GLEMENT is cleaned by gentle tapping or washing in detergent and water, Do not use pressurized air to paper elenent to avoid breakage, Do not oi] paper element,W 1 CARBURETOR COMPONENTS ‘This carburetor is float type with adjustable pilot screw (idle mixture), fixed aain jet, and float chamber drain seres ret. | vet. | - : Yo | Part Name No. | part ane 2 Collar at Main jet | 3 | serine 2 | Flow 4 | Choke vaive 25 | Float pin cee 5 2 | Gasket \ i 6 | Ring 25 | lost canter | Q 7 | Pilot jet 2% | draia scree | 8 Screw ar Spring. a | Pitot screw % | oor | 10 ] Spring 2 Washer 11 | throttte start a0 | cotter “iz | sea st | spring 1B | Throttle valve “a2 | serew . | screw 33 | ong 15 Main air jet 34 Plate (PC290, FC400, PC420) 16 | Pilot air jet 35 | seal crczan, FeAD0, Fex2n — W Needle valve : 36 collar 18 Clip a7 Carb, body 19 | vain nozzle18 CARBURETOR 8 REMOVAL WARNING : Gasoline is extrenely flaneable, Avoid fires due to saoking of careless practices, Before removing carburetor fron engine, drain fuel in float chanber to suitable container loosening drain screw (A) FLOAT: CHAMBER REMOVAL NOTE :Before removing float chanber, rotate float chan- ber clockwise and counterclockwise for 1/6 turns 2 or 3 tines, pushing float chanber to carb, body to release stick- ing of float chanber and rubber gasket, CLEA NIINGHANDECHECK: CAUTION: 00 not clean jet orifices with hard object, WARNING : follow instructions prepared by clea er eanufacturer when uSing cleaner, 1. Dip carb, components except non-netaric parts such as gasket into carb, cleaner until dirt is renoved and rinse then with solvent, NOTE =Rinse carb, alusinun components in hot water to neutralize corrosive action of cleaner, if so instructed by ‘the manufacturer, 2. Dry components with conpressed air, Wake sure all orifices and passages are free fron dirt or foreign object, CAUTION : 10 not use rags or paper to dry components to avoid plugging orifices by Tint, 3, Check diaphragn for crack, tear, or pin hole, © If defect is found, replace it,CARBURETOR FLOAT ADUUSTMENT! i CAUTION : 0 not strike float pin to remove or install it, to avoid breakage of pin holder, To renove float pin, pull the transforned end with pliers, To install float pin, push float pin transformed end until the other end flushes with pin holder outer surface, NOTE :WHITE FLOAT (ade of polyacetal) does not require check and adjustaent, CAUTION : Do not push dova float or needle valve when checking paral] 1, Check float angle and correct it as folloxs; Place carburetor upside down and check whether float surface (A) is parallel with carb, body (8) when float tang (C) just begins to come in contact with point of needle valve (F), © If not parallel, adjust float surface angle bending tang (©) with needle-nose pliers,CARBURETOR ASSEMBLY AND? ENSTALLAT LON CAUTIONS: 1, Do-not over-tighten small carb, components, Finger ‘tighten pilot screw, 2, Bo -not bend throttle and choke shafts when asseabl ing 3. Apply screw locking agent to screws of throttle valve ‘or choke valve, Do not allow agent to flow into shaft bearing surfaces, 4. Wake sure movenent of throttle and choke valves is swooth, 5, Before carburetor installation, install throttle link age (G) and choke Tinkage (8) on carburetor, 6, Wake sure to fasten fuel Tine at carb, inlet with clamp. CARBURETOR 1DENTEFLCATTON A portion of carb, part number is marked on carb, body, Exaaple: Part Number Stanp 315510 ~ 61006 s510¢ 15001 ~ 2541 12541a a COOLING SYSTEM BEADE GAR ADUUSTMENT L 2 Install fan housing (A) and rotary screen (8) Check gap (C) between contour blades (0) and fan housing and adjust it as near as 1,5 me (0,06 in,) by changing umber of shin (@) used, Install guard (P) or recoil starter (including pulley),RECOIL STARTER 2 DESASSEMBLY CAUTION : Do not wedge rope between reel and case Pull handle out about 250 ax (10 in) Then hold rope in place with locking pliers or knot (A) 2 Pull knot in handle (8) out and untie it, WARNING : Near gloves during disassenbling to avoid injury. 3. While carefully holding reel (C) and case (0), renove locking pliers or untie knot, 4. Unwind spring tension slowly, 5, Remove bolt (G) at center part and then retainer (i), pawls (J), pawl springs (K), and center spring (L) but ‘not including reel (C) WARNING :When renoving reel_(C), be careful that recoil spring under the reel does aot fly loose and causes injury, The spring is under great_pressuré, NOTE : There should be no spring tension on reel when removing reel, If tension is felt, push reel back into place and gently “wiggle” it until reel can be easily removed 6, Rotate reel (C) one-quarter turn clockwise from rest position where no tension can be felt, Then, slovly Lift reel straight up out of case. oOB 2 RECOIL STARTER DISASSEMBLY. WARNING # if recoil spring cassette (W) is sticking with renoved reel (©, be careful that the cassette does not drop. a WARNING :Be careful that recoil spring (W)_does not fly loose from cassette (H)_and causes injury. ‘The spring is under great pressur 7. Slowly Lift recoil spring cassette (N), straight up out of case (0) or reel (C), 8 If recoil spring (N) must be renoved from cassette (N), hold the cassette with opening side dovnward in suit- able container and tap cassette to remove recoil spring, CHECK 1, Dip metal parts in bath of high flash-point solvent, if necessary, CAUTION :Do not clean any non-netalic parts in solvent, They may be damaged by the solvent, 2. Check starter pawis for chips or excessive wear, 3 Check starter rope for excessive wear or fraying, 4, Check springs for break, rust, distortion, or weakened condition, © If danage is found, replace the part, WARNING = Do not throw installed _in cassette, Recoil spring from cassette and cause injury. y Tecoil spring as fly loosemu m4 RECOIL STARTER REAS'SEMBLY WARNING tear gloves during recoil spring 0) installation to avoid injury, The Fecoil spring aust be assembled with great pressure, 1, Lightly grease recoil spring 2 Set recoil soring in spring cassette (N) and install cassette so that hook (P) of spring catches tab (R) on 3, If rope is unwound from reel (C), wind rope in reel counterclockwise facing pavl groove (S) 4, Aligning guide pin (1) on reel with recoil spring hook () on cassette, install reel into case, 5, Install pawl springs (K), pavis (J), center spring and retainer, then tighten bolt, NOTE :Pasl springs (K) and pawis (J) are assenbled into reel as shown, 6, Rotate reel two turns counterclockwise to preload recoil spring, 7. Pull rope out of case through rope hole and install handle,2% ELECTRIC STARTER & CHARGING TROUBLE YSHOOTING 1 terninal, Disconnect spark plug cap, and ground the cap WARNING: test, o not touch, ine and_equipment Engine way be cranked in this any rotating parts of en- during test, 2 Turn engine switch to “START” position and i ccheck condition, CAUTION ®1f starter does not stop by en switch "ORF", disconnect negative () lead froa battery as soon as possible, (STARTER DOES NOT ROTATE) Is click sound fro No Faulty battery, {Charge or replace solenoid (switch)? ‘Faulty leads or connection, | Repair or replace eMelted fuse, }—Replace ‘Faulty engine switch, [Repair or replace ‘Faulty solenoid (switch) }—Replace YES ueeeeeeeeeS I SF - | Weak battery, [Charge or replace | *Faulty leads or connection, }—Repair or replace é + Golenoid to aotor) | eFaulty sotenoid (switch) t—Replace | (lain terminal in solenoid) Faulty starter motor, [Repair or replace (STARTER ROTATES BUT SLOW) a 1 Is battery normal No. ‘Weak battery, [-—Charge or replace and well charged? Ln ves ‘Faulty leads or connect ion, [Repair or replace (Solenoid to motor) ‘Faulty solenoid (switch) t—Replace (ain terminal in solenoid) 5 Faulty starter sotor, [Repair or replace Faulty engine, |—Repair or replace (STARTER ROTATRS BUT CAN NOT CRANK BNGINE) Does pinion mesh NO ——+ Worn pinion or ring gear, j—Replace with ring gear? Incorrect starter alignment, | Correct. YES Faulty clutch, |—Replace a (STARTER DOES NOT STOP IN ENGINE SWITCH “RUN") Can stop starter by No Faulty engine switch, [Repair or replace ‘engine switch "OF"? Faulty solenoid (switch). [Replace ves Faulty pinion or ring gear [Repair or replace Incorrect starter alignment, | Correct ‘Faulty pinion return mechanisa, |—Repair or replace26 ELECTRIC STARTER & CHARGING 2% SOLENOUD AND" OTRCUTT CHECK’ This procedure is for shift type starter, but can be used for Bendix type by replacing word “SOLENOID” to “SOLENOID SHITCH, NOTE =Before this test, make sure battery is fully charged, 1. Disconnect lead (A) between starter motor and solenoid, and keep the lead anay from terminal of solenoid to avoid accidental cranking in test, NOTE :Painted part is not grounded, 2, Disconnect lead (8) between solenoid and engine switch, Set multimeter selector switch to 25V DC position and connect it with lead (8) and grounded part, ‘Turn engine switch to "START" and check voltage, ‘© If voltage is 0 or auch less than battery voltage, check engine switch and/or circuit, ‘© If voltage is sane as battery voltage, go to next step 3. Set multineter selector switch to R x 19 position and check resistance between terminal (C) and grounded part, © If resistance is not nearly 0@, replace solenoid ‘© [f_continuity is observed, go to next step. 4. Connect lead (8) to terminal (©) Set multineter selector switch to Rx 1@ position and Connect it with two terminals on solenoid as shown, Turn engine switch to “START” and check resistance © If resistance is not nearly © oF solenoid does not click, replace solenoid, ‘© If solenoid is normal, go to next step,a a ELECTRIC STARTER & CHARGING STARTER MOTOR GHECK: WARNING : Disconnect negative and then positive () lead to prevent ‘inal 1. Disconnect battery before renoving electric starter from engine to avoid accidental running of starter in handl- ing, 2. Renove electric starter fron engine, WARNING :The test room aust be free from any flammable object, Keep away your body from pi CAUTION :Be careful not to deform electric starter body by holding. 3. Hold electric starter with vice, 4 Connect first jumper cable with positive (+) battery terninal and starter motor terninal (0) on solenoid, 5, Connect second junper cable with negative (-) battery 6, Touch starter body (not painted part) with the other end of second junper cable interaittently (within one second) © If pinion does not turn, repair or replace starter aotor.28 28 ELECTRIC STARTER & CHARGING COMPONENTIS#FO200 (Bendix Type) Ref, Part Name Ref, Part Nane No, No, 1 | Snap! ring 11 | Rear cover 2 | collar 32 | o-ring 3 | Spring 13 | Nasher 4 | Pinion assy 14 | Brush holder assy 5 | Nut 15 | Brush spring 6 | Spring washer 16 | Brush | 7 | tacough vote 11 | Yoke assy 8 | Spring washer 18 | Armature 9 | raster 19 | Nester 10 | O-ring 20 | Front cover COMPONENTS == (Shift Type) FOao0+FCO420 8 | Brush spring Ref, Part Mane | Ref. Part Name Xo, No, 1 | Mut 10 | Yoke assy “a [ AL | Shift lever 3 | solenoid 12 | Araature 4 | port 13 | Washer 5 | Rear cover 1 | Stopper 6 | Insulator 15 | Snap ring 7 | Brush holder 16 | Pinion assy 17 | Front cover 9 | Brusha ELE TRIC STARTER & CHARGING 9 COMPONENTSHFOSHONSHI FE Tyee) et] part tame [et, | Part Nave Ne, 0, 1 | Nut ‘12 | Brush holder assy 2 | Washer 13 | Brush spring 3 | mut 14 [Brash [4 Solenoid assy 15 | Brush 5 | Screw 16 | Yoke assy 6 | Cover IT | shift lever 7 | Stopper 18 | Armature 8 | Spring 19 | Snap ring 9 | Seal = 20 | Pinion stopper 10 | Through bolt 21 | Pinion assy AL | Rear cover aol 22 | Front cover assy30 ELECTRIC STARTER & CHARGING BRUSHYSERVICEEIMUT 1. Check overall length of each brush with vernier calipers, © If length is_tess than WIN, replace brush, BRUSH LENGTH MIN F290 85 an (0,34 in.) Feago-#c420 6.0 an (0,24 in.) Fesao 10.5 a0 (0,41 in.) BRUSHYSPRENG! CHECK 1, Check each brush spring for breakage or distortion, ‘¢ If brush spring does not snap brush fire replace it, 0 place, BRUSH HOLDERMIOHECK check resistance between brush holder (A) and its base @). © If resistance is_ndt infinite ( LL. Set nultineter selector svitch to Bx Ik@ position and F200. B® | replace brush hold- o®. jo31 31 ELECTRIC STARTER & CHARGING ARMATURED CHECK: 1. Check surface of commutator and grooves, © If it has scratch or_is dirty, polish it with very fine F (No, 5000 ~ No, 6000) and clean grooves, 2, Set multimeter selector switch to R x 19 position and check resistance between segnents, © If resistance is not nearly 09, replace arnature, {open circuit) 3, Set aultineter selector switch to Rx 1k® position and check resistance between commutator and armature shaft © If resistance is not infinite (co), replace armature, (short circuit) 4. Check armature windings for shorts, (D) Place armature on grovler (A). @) Hold thin metal strip (e.g, hack saw blade) on top of armature, ) Turn on growler and rotate armature one complete turn If metal strip_vibrates at any position, replace arma ture, (short circuit)32 ELECTRIC STARTER & CHARGING 2 ARMATURE S SERVICES O9M ET 1. Check conmutator outside dianeter at several points with vernier calipers, replace © If dianeter is_less than 27 ma (1.06 in) armature, 2, Check groove depths between conutator segeents, © If depths are less than 0,2 am (0.01 in.), cut insulat- ing material to STD depth with thin file and clean grooves, STD GROOVE DEPTH 0.5 - 0,8 am (0,02 ~ 0,03 in.) A: Segment B : Insulating material C: Depth 3, Support armature in alignment jig at cach ends of shaft as shown, Position dial indicator perpendicular to con rnutator. Rotate araature slovly and check run-out, © If run-out is more than MAK tura down commutator or re~ place araature, COMMUTATOR RUN-OUT MAX c2g0-FC400-FC420 0.4 an (0, 016 in.) F540 0.5 an (0, 019 in,)3 ELECTRIC STARTER & CHARGING 38 MOKE / CHECK 1 Set multineter selector switch to R x 19 position and check resistance between negative terainals (8), (FC400+ Fc420- F540) If resistance is not nearly 02, replace yoke assembly, Set multineter selector switch to R.x 19 position and check resistance hetween negative terminals (8) and yoke case ¢F), (FC4O0> FC420- FCS40) If resistance is not nearly 00, replace yoke assembly, Set aultineter selector switch to Rx 1 position and ccheck resistance between positive terminals (@), (FC400> F420) If resistance is not nearly 08, replace yoke assembly, Set multimeter selector switch to Rx 1kQ position and check resistance between positive terminal (6) and yoke case (F). (FC290+ FC400- F420) If resistance is not infinite (c°), replace armature,4 u PUNTONSCLUTOH CHECK 1, Check pinion to rotate with arrature shaft when turned clockwise (=), 2 Check pinion to rotate freely when turned counterclock- + If pinion does not move normally, replace pinion assem bly, STARTER MOTOR™REASSEMBLY 1. Coat multi purpose grease to following parts, = Sliding surface or pinion and spline shaft Bearings = Dust seal lip = Contact surface of shift lever 2 Do not use removed snap ring again, REGULATOR! CHECK 1, Remove all leads from regulator, Q\+ |S} -|~]}-~1e@ 2 Set aultineter selector switch to R x 1k@ position, 2. 3. Check resistance between terminals as shown on table, e oom [eis |e) B=) AG Key switch @ |a~ 2o0n [Ka~]1K2~| 200K: B: Charging monitor ea me} | SKA | ~e lultineter termina — [axse~ | 2008 1k2.~ | 1402~| 200K ee oe 15kO |~ 1k 5x0. | 5ko |e ~ [ma~ + If resistance is not as specified, replace regulator, m= To | aw «wl. NOTE :Resistance value may vary with individual meters, | ~ |'Sir | = | = | = ° onn~| 1k ~ fsa} akne~ [axn~| CAUTION :)o not use Megger. © [sox | "sks [ses | 2000 | 2068235 35 ELECTRIC STARTER & CHARGING UNREGULATED STATOR (OUTPUT Qa15A TYPE) 1, Disconnect regulator 2 Start and ware up engine, 3. Set aultineter selector switch to 250V AC position, 4 Connect meter with stator lead terminals (6, ) in 3P coupler, Run engine at 3,350 rpm and check voltage, © If voltage is Jess than MIN, replace stator, UNREGULATED STATOR OUTPUT MIN Frog0-Re400-FC420 0 esa ay STATOR OUTPUT (IAS TYPED: Disconnect lead fron rectifier (to engine). Start and warm up engine, Set multineter selector switch to 250V AC posit ion, Connect eter with stator lead (J) and engine body fun engine at 3,350 rpm and check voltage © If voltage is less than Mi replace stator, STATOR OUTPUT MIN c290-FC400-FC420 26 Pesdo ay -36 IGNITION SYSTEM 36 TYPES OFUUONTT ON SYSTEM Transistor controlled ignition systen is used for these engines and this system consists of following coaponents, 1, Ignition coil 2 Control unit 3. Flywheel (with permanent magnet) ‘These components do not mechanically contact and periodic ‘aintenance is not required, yt Primary coil Lat Secondary coil CU: Control unit Ryt Control resistor Rai Control resistor ‘Transistor Transistor Plywhee! Spark plug Engine switch SPARK! CHECK: To check ignition systen, check spark as follows; 1. Renove spark plug and connect plug cap with the renoved spark plug, 2, Install spare plug to plug hole to avoid fuel spitting froa hole, WARNING : To avoid electric shock, hold plug cap,_but not spark plug, 3, Keeping contact with spark plug metal part (not center electrode) and engine block, crank engine, CAUTION : Do not clean spark plug with bead or sand cleaner. © If no or very weak spark is observed, clean spark plug and regap it to 0,7-0.8 an (0,028-.031 in.) and try engine cranking again. © If spark is not improved by cleaning, try checking again with new spark plug, © If spark is not improved yet, check ignition systen,a IGNITION SYSTEM 3a CONTROUTUNETUCHECK 1, Set multineter selector switch to R x 102 position, 2 Check resistance between terminal (A) and case (8) © If resistance is out of specified value, replace control unit, CAUTION : Bo not use Negger, CONTROL UNIT RESISTANCE (a) Meter ® Neter © Ter alk) Case (8) Terminal (A) —— — 60-100 case) 400-600 NOTE !This check may not cover every defect, EGN ETON 1. Check resistance between the points as specified, 2 If resistance is out of specified value, replace ignition coil, IGNITION COIL RESISTANCE COTE CHECK a Primary | Primary terminal (A) 0, 48 - 0,720 coil and Core (C) (R x 10 Range) Secondary Plug lead (B) 10.9 - 16. 3kQ Sour” | _ttowe | a na ane38 38 IGNITION SYSTEM FUYWHEELOREMOVAL WARNING : Renove plug cap fron spark plug to avoid engine starting CAUTION :1o not insert any tool in flywheel fins or ing gear to avoid rotation, The tool will danage Tlywheel, 1, Loosen nut by turning it counterclockwise, Use 1/2” air impact vrench or strap wrench to avoid flywheel rota tion, CAUTION : Keep shoulder of aut flush with end of crankshaft untill taper engagenent is released, 2, Use flywheel puller (A) to renove flywheel, FLYWHEEL UNS TAUEATION! 1. Before installing flywheel, renove grease and oil from taper part of crankshaft and taper hole of flywheel, 2 Make sure key is in place when installing flywheel, 3. Torque nut as specified in TORQUE SPECIFICATIONS, : PENI TVON=COTU AT REGAP ADJUSTMENT If ignition coil is renoved or replaced, adjust AIR-GAP in installing coil, i, Insert 0.3 am (0, 012 in.) feeler gauge or solid sheet (A) between coil Tegs (8) and flywheel rim (C), 2 Pushing coil to flywheel, tighten coil mounting screws firaly,39 9 FUEL PUMP REMOVAL AND YDYSASS EMBLY WARNING :Gasoline is extrenely {1 Avoid fires due to or careless pract WARNING tAvoid spilling of gasoline in removing i and disassenbl ing fuel pup Plug fuel line discon — tcoted from punp intake in, iasediatel, seureeues COMPONENTEN RefNo, Part Name [[Link], | Part dane 1 | screw 7 |atve assy (im 2 | cover 7 [valve assy (out) 3 | Gasket | _ 4 |biephrage 9 [easkee 5 [asker crttery | 10 [ease 6 | Body ; A: Vent hole & screen eaurcomes CHECK 1. Check vent hole and screen for plugging or clogging, ‘© If vent hole and screen are plugged or clogged, resove dirt fron thes, 2 Check diaphragns for crack, tear or hole, © If defect is found, replace it, 3, Check valves for crack, tear or wear, ‘© If defect is found, replace then, CAUTION : Make sure rubber gasket_and rubber dia phragn ace placed as shown in CONPONENTS, eaireoaw ENS TAULAT HON: _ 1. Wake sure to use heat shield washers (A) as shown, on RCAO0-FCA2D and FCSHO, 2. Make sure to fasten fuel and pulse lines at punp with | clamps, =>0 40 CYLINDER HEAD COMPRESS'TONU CHECK 1. Resove spark plug and set compression gauge to plug hole, 2, Crank engine with recoil or electric starter several tines and check highest reading, © If highest reading is less than 483 kPa (71 psi), check engine in accordance with TROUBLE SHDOTING. NOTE :Battery should be fully charged for this test, 5 REMOVAL z 1, Disconnect plug cap from spark plug, 2 Renove rocker cover. NOTE :Always note position of each cyl, head screws so : they are properly re-installed, 3, Renove cyl, head, 4, If push rods are removed, mark push rods so they are placed in their original positions in re-installing eszreoms MAINTENANCE WARNING: If chenical cleaner is used, always follow the manufacturer's safety instructions care: full 1. Renove coating materi stone. stuck on surfaces, with oi CAUTION: 1f deposit on combust ion chanber_is re~ oved, remove valve systen fron cyl,_head, (Gee VALVE AND RELATED PARTS REMOVAL, ) Do not danage valve seat and gasket surface of deposit cleaning, head_in 2. Remove deposit frow cyl, head, 3 Check flatness of head gasket surfase on surface plate with feeler gauge, © If cyl, head is warped_eore than 0.05 ma (0,003 ii replace it,4 CYLINDER HEAD rm UNSTALEATION CAUTION :Gasket is coated with special seal Do not_danage surface of gasket during instalTatior If surface coating is danaged, replace gasket 1 2 CAUTION :1o not tighten one screw completely vhile others are loose, Tt may cause warped cyl, head, 6 Rotate crankshaft until piston cones up at highest position in conpression stroke, Install push rods in their respective position in cylin- der, Place head gasket and cyl, head assy on cyl, block Align push rod ends with recess of rocker arms adjust screws, Put screws and related parts as follows; FC290 + Five (ell) bolts FC4QO = Sequence 1,3 & 4 - bolts Sequence 2 - long nut & spacer F420 + Sequence 1,3 & 4 - bolts Sequence 2 ~ long nut & spacer Sequence 5 - long aut & washer FCSA + Sequence 1,3 & 4 - bolts Sequence 2 & 5 - long nuts, spacers & washers Tighten screws dovn evenly by hand and then torque then in sequence as specified, (See TOROUE SPBCIFICATIONS, )2 VALVE VAUMESCUEARANCE ND IUSTMENT When any part related to valve clearance is changed or nod- ified for defect correction, or after engine has been used for long period, adjust valve clearance, NOTE #00 adjustment yhile engine is cold, 1. Turn crankshaft until piston cones up at highest posi- tion in compression stroke, 2 Check clearance between valve stem and rocker arn with 0.15 106 in.) feeler gauge (A). - for both valves ‘© If clearance is out of specified value, adjust it turn- ing adjuster (G), and then Tock adjuster by nut with torque specified in TORQUE SPECIFICATION, AUTOMATIC: COMPRESS 1 ONOREVEASE (ACR) CHECK AUR is device to release compression during engine start, for easy cranking, 1, Remove rocker cover, 2 Renove spark plug to ease hand cranking, 3. Make sure valve clearance is as specif ied, (See VALVE CLEARANCE ADJUSTMENT, ) 4 Rotate crankshaft slovly in usual direction observing fovenent of exhaust valve (A) and rocker arm (8), ‘* If exhaust valve does not open nore than 0.6 am (O.024in) briefly just after intake valve closes, ACR inechanise on casshaft is faulty, (See CAMSHAFT VISUAL CHECK.) 28 VALVE 4B VALVECANDURECATED (PARTS REMOVAL NOTE :Mark push rods so they are placed in their original positions in re-installing, 1, Renove push rods, 2, Pull out rocker shaft (A) with pliers and resove rocker aras (8), Remove valve rotator cap (C) on exhaust valve sten end, 4 Place screw head of valve spring coapressor (0) on the valve head and slip jaw of compressor between spring (8) and retainer (F), 5. Compress spring and renove retainer (f) and collets (6) = for intake valve ~ with needle nose pliers, 6, Remove conpressor and valve spring, NOTE # Before pulling valve out of guide, remove all burrs from valve stes, and oil to sten to avoid damaging valve stem seal (HW), If sten seal is not danaged, do not re- move seal and bottom spring retainer (I), 7. If stem seal (Q) aust be replaced, remove it with screw iriver. EXHAUST“ VALVE CHECK AND! MAINTENANCE 1. Check valve head for excessive deposit and gas leakage, 2, Renove carbon from valve head with wire brush, 3, Check valve head for warped face (A), dent on face and margine (8) of less than 0.6 an (0.024 in). ‘© If valve head has above defect, replace valve, NOTE ‘Excessive deposit is caused by leaded gasoline, and deposit triggers gas leakage causing valve defects, Therefore unleaded gasoline is recommended, Check valve sten for sticking, gunay deposit, discolora- tion at area covered by valve guide, and excessive corrosion, 5, Renove carbon from valve stem as well as head, If valve stem is worn excessively or does not move ‘smoothly in guide, replace valve, NOTE :Sticking and discoloration are caused by over heating of engine, or gas leakage fron valve face, Therefore such causes must he corrected as well as valve maintenance, Guany deposit is caused by old or stale gasoline, Clean fuel system and use fresh gasoline, Ronove gasoline from fuel systen before long storage.6 VALVE SERVICE T LUMI: 1, Check diameter of valve stem in area covered by valve guide at several points with microneter, ‘+ If diameter is_less than MIN, replace valve, VALVE STEM DIA, MIN Intake 6.930 me (0, 2728 in,) Exhaust 6.915 mm (0, 2722 in,) 2 Check bend of valve stew at center part with V blocks (8) and dial indicator (@), ‘© If bend (dial gauge reading) of valve stem is nore than 0,03 an (0.0012 in,), replace valve, CAUTION :o not try to grind or recondition valve face, If valve face is worn or damaged, replace it. VALVE SPRING SERVIPCE SLAMET 1, Check valve spring for any danage and replace it if necessary, 2 Check free length of valve spring with vernier cali pers, © If length is_tess than WIN, replace spring, FREE LENGTH MIN (Intake & Exhaust) F290 31.0.0 (1.22 in.) C400-FC420-FC540 31.5 am (1.47 in.)46 46 VALVE LAPPING If valve does not contact all way around with seat, lap valve into seat, 1, Coat fine tapping conpound sparingly on valve face, 2 Rotate valve in circular motion with valve lapper (A) NOTE = Lapping aark should appear on or near center of valve face, 3. Check valve every 8 to 10 strokes and continue Tapping until uniform ring appears on valve seat all way around, 4, After lapping, wash parts in solvent to renove compound, Dry parts thoroughly, VALVES SEATSREOOND TT FONENG - Pitted or worn valve seat can be refaced, 1, Reface valve seat with 45° cutter, renoving only enough material to ake saooth and concentric seat, 2 Use 30° cutter to narrow seat to STD width as specified below, A: Seat width STD VALVE SEAT WIDTH (Intake & Exhaust) F290 0.5 - 1.10 mm (0,020 - 0,043 in.) Fe4o0-FC420-FC540 | 1.1 - 1.46 mm (0,043 - 0.057 in.) 3, Make a Light pass with 45° cutter to renove any burr at edge of seat, 4, Coat marker and check contact of valve face and seat, Contact should be at center part of valve face as shown and all way around, 5, Lap valve into seat, (See LAPPING, )a VALVE 7 VAEVEDGUIDEUSERVICE SLIMrT 1, Use valve guide cleaner to clean inside of valve guides, 2 Check inside dianeter of valve guide at several points with inside wicroneter, © If diameter is sore than 7.065 mo (0.2781 in.) valve guide, replace VRUV EN GUE DE SREP UAC EMENT: REMOVAL 1, Place cyl, head on support plate with conbustion cham: ber upward, 2. Resove valve guide with driver (A), xe5 INSTALLATION 1. Place cyl, head on support plate with conbustion chan- ber downward, Install snap ring (8) on valve guide, Coat a filn of oil on outer surface of valve guide, Install valve guide with driver (A) until snap ring (8) Just seats on head, CAUTION :8e careful not to danage head gasket s face while installing valve guide, FINISH 1. Rinish valve guide to 7,00 - 7.015 mm (0, 2756 ~ 0. 2762 in,) - for all valves ~ with valve guide reaner, 2 Lubricate reaner with Kerosene or proper lubricant and ‘turn reaner clockwise, Clean parts thoroughly before assembly, 4 Check valve seating and reface valve seat, if necessary,8 8 VALVE ROCKER YARMYSERVIECE SCUMET 1, Check rocker arm for pitted or worn contact surface with valve stem, © If necessary, replace rocker are, 2, Check inside dianeter of rocker arn at several points with inside wicroneter, © If diameter is more than 13,068 am_(0, 5145 rocker ara, ROCKERS SHARTHSERVECE ML EMIT: 1. Check outside dianeter of rocker shaft at several points with wicroneter, ‘* If dianeter is_tess than 12,936 em (0.5093 in,), re- place rocker shaft, PUSH PROD TSERVECES EM ET: - 1, Check bend of push rod at center part with V blocks (A) and dial indicator (8) If bend (dial gauge reading) is nore than 0. (0.012 in), replace push rod,49 8 CRANKCASE COVER REMOVAL WARNING :Be careful not_to burn yourself by hot 01 ss Drain engine oi to suitable container, Renove rust and burr fron edge of PTO shaft step, Loosen screws, and tap parts near dowel alternately with soft mallet, SERVECEE EMIT: 1. Check inside diameter of PTO bearing (A) at several points with inside micrometer © If dianeter is nore than WAL, replace crankcase cover (FC400+FC420-FC5AO) or bushing (FC290). PTO BEARING INSIDE DIA, MAX F290 30, 125 am (1, 1860 in,) Feago-Fc420 35, 069 am (1, 3807 in, ) F540 38, 056 an (1, 4983 in,) 2. heck inside dianeter of camshaft bearing (8) at several points with inside microneter, © If diameter is nore than MAK, replace crankcase cover, CAMSHAFT BEARING INSIDE DIA, MAX F290 14,054 am (0, 5533 in.) Fe400-FC420-FC540 21,076 wm (0, 8298 in.)50 GRANKCASE COVER BUSHING! REPEWCEMENT = 0 FO290 1. Renove oil seal fro crankcase cover. NOTE £Do not re-use oil seal, 2, Place crankcase cover on bench with oil seal side up, 3. Push out bushing (A) with bushing tool (B). 4, Place crankcase cover on bench with gasket surface side up, 5, Coat a Light film of oil on outside of bushing (A) and entrance of bushing housing (C) 6, Aligning oil grooves (0) and sean (&) as shown, install new bushing (A) into crankcase cover with bushing tool (F) until bushing end goes 1 am (0, 039 in,) below hous~ ing end (6) NOTE =Finishing of bushing inside dia, is not required, ex 5051 CRANKCASE COVER 5 C1) SEAL UREPCACEMENT nm If oi leakage through oi! seal is observed or seal lip is damaged, replace oi! seal, L ie Renove oil seal by tapping it out with screw driver or punch, Placing spring held seal lip (A) inside, push oil seal into housing until seal outside surface becones flush with housing end (0) Before final assembly, pack sone anount of grease for high temperature application into space between seal lip () and dust lip @),52 CRANKCASE COVER INSTALLATION 1, Clean gasket surface and place new gasket on crankcase cover, 2 Pack grease into oil seal, (See OIL SEAL REPLACEMENT, ) 3, Coat a light file of oil on bearings, 4. Wake sure governor weights are closed, NOTE :Make sure to place shia on crankshaft, 5, Wake sure governor gear and oil punp gear are properly aligned to mesh with their respective drive gears when installing crankcase cover, Do not force cover into position, 6, Install crankcase cover and tighten bolts dovn evenly by hand, Tighten bolts in the sequence as shown and to the specif ied torque, (See TORQUE SPECIFICATIONS) Do not tighten one bolt conpletely before the others, It may cause warped crankcase cover, sel FC54053 CAMSHAFT REMOVAL: 1, Place cyl, block upside down on benct, Rotate crankshaft (A) until timing marks (B,C) on crankshaft gear (0) and camshaft gear (8) align, to avoid interference between tappets and carshaft in 3, Renove tappets, and aark then so they can be placed in their original position in re-installing, VUSUALHCHECK: 1, Check cam gear for worn or broken teeth, ‘© If excessively worn or broken teeth are observed, re: place camshaft, 2 Check movenent and danage of ACK aechanisn on camshaft, © If outer surface of tab or arm (A) is not placed above heel (8) when weight (C) is closed, replace ACK echanisa, ‘© If outer surface of tab or arm (A) does not _lover_below cam heel_(B) when weight (C) is pulled toward outside by Finger, replace AUR nechanise, ‘+ If parts of mechanisa are worn, replace ACR wechanisa, 53a CAMSHAFT 5 SERVICECHIMET 1, Check bearing journal dianeter with nicroneter, © If dianeter is_less than MIN, replace casshaft, BEARING JOURNAL DIA. MIN Fo290 Gear side 13,922 am (0, 5481 in, ) Can side 15,921 ao (0, 6268 in, ) FC#00-FC420 Gear side 20,912 am (0, 8233 in, ) Can side 19,912 am (0, 7839 in, ) FOS40 Gear side 20,912 am (0, 8233 in, ) Can side 2, Check cam lobe height with vernier calipers, ‘+ If Tobe height is less than MIN, replace carshaft, LOBE HEIGHT MIN (intake and Exhaust) Feza0 27.08 ea (J, 066 in.) Fed00- FC420 36.75 am (1, 447 in.) Pes40 37,10 wn (1.461 in.) UNS TAGE ATH ON 1, Place cyl, block upside down on bench, 2 Install tappets in their respective positions and push then all the way into guide to avoid interference with camshaft in assenbl ing 3, Rotate crankshaft until piston is at highest position 4. Aligning timing narks (A) and (8), install camshaft into crankcase,55 55 CAMSHAFT AXUA CoP LAY!ADUUSTMENT When any part related to axial play js changed, adjust axial play as follows; 1, Measure distance (A), installing camshaft (C) into crankcase (0) and placing gasket (B) on crankcase, 2 Weasure depth (8) of crankcase cover (F) 43, Select appropriate shim with each chart, 4, Chanfered side of shim should be placed toward can gear, Fo290 Fo540 (ea) PAN Toa) Pa 1.60 | 92025-2162 1.54 | 92025-2177 | ues | samas-ziea 1.575 | 92025-2192 1.70 | 92025-2164 LéL 05-2178 | Las | sam-2165 L615 | s2025-2199 1.80 | 92025-2166 1.68 | 92025-2179 1.85 | 92025-2167 “Ls | 9225-2194 1.90 | se0es-2ans 175 | 92n25-2100 | ~~ 1.95 | sones-2009 | 1.785 | 92025-2195 “se | sana5-2181 1.855 | 92025-2196 1.89 92025-2182 Fo290 9.07 9.02| 9.01 7.10 7.00 7.06 7187.20 7.25 ® F540 (Engine Number: 000001 to 014454) VY T: Thickness of shin P/N: Part Kunber Play after adjustment is 0, 07-0, 19 me (0. 0028-0, 0075 in.) for FC290 and C540, NOTE +FC420 and FC540 with serial nunber higher than 014455 do not require canshaft axial play adjusteent, ‘The canshaft is pressurized to avoid out of adjustment,56 6 PISTON & CON-ROD REMOVAL CAUTION : Renove any carbon or ridge at top of cyl, hore to avoid pi ig breakage i a Rotate crankshaft (A) to expose con-rod bolts (8). Loosen con-rod bolts and remove con-rod cap, Push piston and con-rod out through top of cylinder, Renove piston fron con-rod, 5, Remove piston rings froa piston with ring expander (C),57 5 PISTON & CON-ROD PISTONUAND PISTON RING [VISUAL CHECK Appearance of piston and piston rings shows condition of engine in running, If excessive danage is observed, replace : piston and/or piston rings and renove cause of such : danage, L._ Rings of wrong size or rings having improper end gap Will not fit to shape of cylinder, This causes high oi cconsunption and excessive blowby, ‘© Check ring end gap and arrange end gap as shown in PISTON RING INSTALLATION, 2, Scuffing or scoring of both rings and piston occurs when friction and/or combustion temperature are un- usually high, Check and clean cooling systen - Check and correct quality and level of oil, Check and adjust fuel and conbustion systens, : Engine running at abnormally high teaperature may cause varnish, lacquer, or carbon deposit formed in piston ring grooves making rings stick © Apply sane treatnent as above 2, 4, Vertical scratches across piston rings are due to abrasive in engine, Abrasive aay be airborne, may have heen left in engine during overhaul, or way be loose lead and carbon deposit, Check air cleaner and clean or replace danaged one, Check any air intake through abnormal route, Clean engine inside and change oil, 5, Scratches across oil side rails (A) are due to abrasive aa in engine oil, and other rings will also be worn in this condition causing high oi] consumption, increased deposit in combustion chanber, and ring sticking, © Clean engine inside and change oil,PISTON & CON-ROD PUSTONN CLEANING CAUTION :Do not use caustic cleaning solution or wire brush to clean piston, 1, Remove all deposits from piston, 2 Clean carbon from piston ring grooves with ring groove cleaner, If cleaning tool is not available, use old pis~ ton ring breaking into suitable size, 3, Make sure oil return passages in ring groove are open, PUSTONSSERVINCESEIMET 1. Check clearance between ring groove and ring using new ring and feeler gauge © If clearance is nore than MAX, replace piston, RING GROOVE CLEARANCE MAX Fo290 ‘Top. ring 0,16 mm (0, 0062 in.) Second ring 0.14 om (0, 0055 in.) Dil ring 0,19 wm (0, 0075 in.) FC400-FC420+FC540 Top ring 0.17 am (0, 0067 in) Second ring 0,15 em (0, 0059 in,) Oil ring 0,20 en (0, 0079 in) 2 Check inside dianeter of piston pin hole at several points with inside aicroeter, © If diameter is more than MAX, replace piston, PISTON PIN HOLE DIA. MAX F290 19,031 am (0, 7493 in, ) e400-FCA20-FC540 22,037 an (0, 8676 in, )59 59 PISTON & CON-ROD PUSTONCP INSERVICE LUMET 1. Check outside dianeter of piston pin at several points with microneter, © If piston pin dianeter is less than MIN, replace piston pin, PISTON PIN DIA. MIN F290 18,981 an (0, 7473 in.) c400+FC420-FC540 21.977 am (0, 8652 in.) “en PUSTONSRUNGTSERVICESLIMET 1, Check thickness of piston ring at several points with nicroneter, © If thickness is Jess than MIN, replace piston ring PISTON RING THICKNESS MIN (Top and Second) Fc290-FC400 1.44 an (0,056 in.) Fc420-FC540 1.94 nn (0,076 in.) 2, Check piston ring end gap with feeter gauge, installing each ring squarely in cylinder at approx, 25 ma (1 in.) from top, ‘© If gap is nore than MAK. replace piston ring, PISTON RING END GAP MAX (Top and Second) F290 0.7 wn (0.028 in.) e400-FC420-FC540 0.9m (0,035 in.) NOTE =Replace oil ring together with compression rings, PUSTONURUENG!ENSTALLAT EON 1, Use ring expander, NOTE :Face up “RY sark on top and second rings, 2, Install rings in following sequence; Lover side rail (AI) = Spacer (B) ~ Upper side rail (42) = Second ring (C) ~ Top ring (0), 3, Place end gaps as follows; Heccaat HD, a260 60 PISTON & CON-ROD CONSRODUVISUAL SCHECK Check con-rod especially big end for wearing, scratching, scoring, and/or discolor ing, 1, Abnormal wearing and scratching are caused by foreign particle(s) in oil, Clean engine inside and change oil. Check oil filter and air cleaner and clean or replace daraged one, © If con-rod and/or crankshaft are used again, renove ridges on their surface carefully, 2, Scoring and discoloring are syapton of poor lubricating and/or over heating, + If crankpin surface is danaged by melted con-rod metal, replace con-rod and crankshaft. ‘© Check Iublicating system including oil pump, oil filter, and oil passages and repair or replace damaged part, Check and clean cooling systen, Check quality of oil and saintenance method with user, CAUTION : Check re-used conponents carefully when re asseabl ing engine which had con-rod big end seizure, ever start engine without oi] even for short test rur61 61 PISTON & CON-ROD CON+RODUSERVECESUIMET 1, Check inner dianeter of snall end at several points, with inside sicroaeter, © If inside diameter is sore than WAX, replace con-rod, SMALL END INSIDE DIA. MAX F290) 19, 059 am (0, 7540 in, ) C400+FC420-FC540 22, 059 am (0, 8685 in, ) 2 Asseable con-rod big end aligning pilot grooves (A), and tighten con-rod bolts as specified in TORQUE SPE- CIFICATIONS, 3, Check inner dianeter of big end at several points With inside micrometer © If inside dianeter is more than WAX, replace con-rod, BIG END INSIDE DIA, MAX F230) 35,567 an (1, 4003 in, ) Fe400+FC420-FC540 41, 068 on (1, 6169 PUSTONTAND © CON+ROD ASSEMBLY 1, Aligning sark “47 (A) on piston head with “HADE IN JAPAN” on con-rod, assenble piston over con-rod, 2 Coat a light file of oil on piston pin and insert pin through piston and con-rod, 3, Install retaining rings in each grooves firaly, CAUTION :Do not re-use retaining ring resoved, Re- ‘moval may deform or weaken the ring allowing it to come out during operation causing danage to cly. wall.@ e PISTON & CON-ROD PUSTON/ZCON“ROD?ASSY INSTALLATION 1. Set ring compressor (8) over piston, flushing with piston top, with projection (A) on compressor tovard top of piston, 2. Tighten compressor with wrench (C), then loosen it, slightly, 3, Coat 2 light film of oi! on cyl, bore, 4 Rotate crankshaft with crank pin in lowest position, 5. Aligning aark “A* (k) on piston head tovard flywheel side, install piston/conrod assy into cylinder, 6. Leading big end of con-rod to crank pin, push piston down further, 7. Coat a light film of oil on crank pin, con-rod big end, cap, and con-rod bolts, 8, Aligning pilot groove, install cap to big end and tighten cap bolts (0) as specified in TORQUE SPECI- ICATIORS, 9, Yake sure con-rod moves sidevays lightly on crank pin, CAUTION :Con-rod bolt tightening is one of the most inportant_iteas in asseabling, Alvays use torque wrench,CRANKSHAFT REMOVAL 1, Remove balancer support shaft (A) from crankcase (8). 2 Pull crankshaft and balancer assy (C) out of crank: case (8). 3. Renove crank gear and balancer link rods from crank~ shaft VISUAL PCHECK 1, Check crank pin part and bearing journals for score, wear, of corrosion, 5 © If crank pin part shows any damage, carefully check con-rod big end and repair or replace con-rod and/or crankshaft, (See CON-ROD VISUAL CHECK, ) 2. Check crank gear for worn or broken teeth © If excessively worn or broken teeth are observed, re~ place crank gear,64 CRANKSHAFT 64 SERVICE EMT: 1, Check outside diameter of both main bearing journals at several points with micrometer, © If outside dianeter is less than MIN, replace crank- shaft, JOURNAL OUTSIDE DIA. MIN Fo290 Pro side 29,922 aa (1, 1780 in.) Magneto side 29,940 am (1, 1784 in, ) Fo4o0-FCS20 PTO side 34, 919 am (1. 3747 in.) vagncto side 34, 945 am (1.3757 in.) FCS40 PTO side 37,904 ma (1, 4923 in.) Magneto side 34.945 mm (1, 3757 in.) 2.” Check outside dianeter of crank pin at several points ith micrometer, © If outside diameter is_less than MIN, repair or replace crankshaft, For repair, see RE-GRINDING OF CRANK PIN, CRANKPIN OUTSIDE DIA, MIN F290 35, 428 am (1.3948 in.) Fcd00-Fc420-Fc540 40,928 aa (1, 6113 in,)65 65 CRANKSHAFT 3. Check outside dianeter of balancer link rod journal at several points with micrometer, ‘© If outside diameter is_less than MIX, replace crank- shaft. BALANCER LINK ROD JOURNAL OUTSIDE DIA. MIN 290 16,953 an (1 8483 in.) : eto0-Fc4z0 53,960 ma (2.1240 in.) sto 5.941 aa (2.2811 ia.) 4. Check run out of crankshaft at both bearing journals - with dial indicator (), setting crankshaft £0 aligment [| nis ®) © If total reading of run out is more than 0.05 mm (0. 002 a 7 ut66 6 CRANKSHAFT AXPAL PUNY ADIUSTMENT ’ When any part related to axial play is changed, adjust axial play as follows; 1. Measure distance (A), installing crankshaft (€) into crankcase (0) and placing gasket (B) on crankcase, 2, Weasure depth (8) of crankcase cover (). 3. Select appropriate shim with each chart, Ts Thickness of shim P/N: Part Nusber NOTE : Axial play after adjustment is 0, 09-0, 22 am (0, 0035-0, 0087 in. ). Fo290 1 (aa) Pa 113, | 92025-2168 1.18 | s20a5-2169 92025-2170 92025-2171, 92025-2172 1.38 | 92025-2173 143 | 92025-2174 148 | 90025-2175 1.53 | 92025-2007 © F200 9.10 9.09] 9.08} 9.07 9.06] 9.05 9.04 9.09 9.02 9.01 9.09 735 740745750 7.55 7.60765co e GRANKSHAFT Fo400-FC420 FOs40 ® 0400-F0420 (on PN T (ae) *”N 1180 | 92025-2010 1180 | 92025-2191 i Las | 0es-2211 1.215 | 92025-2188 120 | 9es-2212 1.250 | 92005-2197 1.285 | 92025-2013 1265 | gaoas-2iee | seo | 9205-2214 1.320 | 92025-2198 1.355 | 92005-2215 1.285 | sms-2185 vee 1.390 | 92025-2218 1.390 | 92025-2199 | @ . 1.425 | 92005-2217 Las | oames-oe | 382 i 1.460 | 92025-2018 aon | 920es-2200 | or 1.495 | 92025-2219 485 | soes-21e7 | 305 1.530 | sanes-2zzn 1590 | sana5-2201 249 1.565 | 92025-2221 1.585 | 92025-2188 | 30° 1.600 | 2n25-22z2 1.600 | 920e5-2ane 1.635 | 92005-2209 1.635 | 92025-2188 F670 | sems-2004 1.670 | 92005-2003 1.705 | sns- 2005 1.705 | 92025-2190 : “140 | 9205-2006 1.740 | 92025-2004 “1s | sawes-22006 CRANKSHAFT 68 ENSTALEA TION L. Coat a film of oi! on bearing surfaces of parts as~ senbled 2 Assenble balance weight (A), balancer Link rods (6), collar (0), spacer or governor drive gear for FC290 (0), and crank gear (@) to crankshaft, NOTE =Place following parts in correct direction as shown below ; Balance weight (A)++++: Oil hole (F) to Flywheel side Link rods (8) of FC400+FC420 and FC5{Q++++++eee+e0+2 Side oil grooves to collar (C) and spacer (0) side Conic face to ball bearing side Collar (C) +--+ Governor drive gear of FC290 and spacer of FCHO0+FC420 and FC540 (0): Chanfered face to Tink rod (8) side 3. Tape Key way at taper of crankshaft to avoid cutting of oil seal lips, 4. Pack sone amount of grease for high temperature appli- cation into oil seal 5, Placing crank pin for crankcase bottom, install crank~ shaft and assenbled parts into crankcase, 6, Install balancer support shaft (Il) with o-ring (1) through hole (3) of crankcase,69 6 CRANKSHAFT CRANK PENGRESORTNDING 1, _Re-grind crank pin to specified under size Fo290 A] 29,950 - 30,000 am (1791 - 1.1811 in.) ® B | 34.980 - 34.990 an (1.3772 - 1.3776 in,) c 2.80 ~ 8.20 ma (0,110 ~ 0,126 in.) D 24m (112 in) WE Fo4o0-FC420 A 3,950 - 34.000 mn (1, 3366 - 1.3386 in.) 8 40, 467 ~ 40, 480 mm (1, 5932 - 1.5937 in.) c 3,30 - 3,70 am (0, 130 - 0,146 in.) D 32.5 me (1,28 in.) MAK FC540 A 42, 950 ~ 43,000 om (1, 6909 - 1, 6929 in,) B 40, 467 - 40.480 om (1.5982 - 1.5937 in.) c 3.30 3.70 mm (0, 130 - 0, 146 in.) D 32,5 mm (1.28 in.) MAK NOTE Crank pin must be concentric and parallel within (0.005 an (0, 0002 in.) full indicator reading, and surface must be finished very smooth with super finishing stone, CAUTION: If crank pin is re-ground, under-size con- od must be used to keep specified clearance0 70 BALANCER BXUANCESWETGHT!SERWICES INET! 1, Check bearing inside dianeter at several points with in- side nicroneter, ‘© If inside diameter is gore than 26, 097 replace balance weight. (1.0274 it 2. Wrist pins (A) require no maintenance but if they are severely danaged, replace balance weight, BALANCER’ SUPPORT SHAET SERVICE LIMIT, 1, Check outside dianeter of shaft at several points with nicroneter, © If outside dianeter is_less than 25,927 nm (J, 0208 i replace balancer support shaft,m BALANCER a BALANCER LENK ROD YSERMICE LIMIT 1, Check inside dianeter of small end bearing at several points with inside micrometer, © If inside dianeter is gore than 12.60 ne (0. 4748 in.), replace balancer link rod, 2, Check inside diameter of big end bearing at several points with inside nicroneter, © If inside diameter is gore than NA) replace bushing, BIG END INSIDE DIA, MAX F230) 47.124 am (1, 8552 in.) Fe4o0-FC420 54,121 am (2.1307 in,) Fes4g 58,193 mm (2, 2895 in.) LCENK ROD BUSHENG ASSEMBLY. CAUTION :Place sean (A) of bushing to right angle with lengthwise center (C) 1, Push bushing into Tink rod as shown, NOTE Bushing aust be pushed from opposite side of oil grooves (6) for FC400+FC420 and FC5A0, FC290 does not need such attention because link rod is syanetr ic,7 nm GOVERNOR GOVERNOR GEAR CHECK “AND REMOVAL 1. Check governor gear assy for wear and damage, as in- stalled in crankcase cover, CAUTION =Do not renove governor gear assy fron crank- case cover except to replace, If once renoved, it cannot be re-used, 2. If governor gear assy (A) must be replaced, remove it with proper size screw drivers (8), CAUTION :Do not damage gasket surface by screw drivers, GOVERNOR GEARI INS TACEATNON: 1. Place sleeve (A) into governor gear assy (8), CAUTION: Sleeve can not_be assenbled after governor gear_assy installed in crankcase cover. 2. Place thrust washer (C) on boss of shaft (0) and then install goveraor gear assy (8) with sleeve (A) to shaft untill step (8) fits into groove (F), 3. Check free rotation of governor assy after installation, GOVERNOR SHAR TIANS TAL LATION 1, Install governor shaft (A) into crankcase and set lock- ing pin (B) to governor shaft positioning as shown, NOTE :Be careful for position of locking pin end and projection (C) which is stopper of governor shaft (A)