ENGINE MAIN PARTS

1. Cylinder Heads and Valve Mechanism

1.1 Disassembly

3
1

10
8
9

2 5
14
7 15
16

6
12
11

13

19
20

18
17

Disassembly sequence
1 Rocker cover 8 Rocker shaft bracket 15 Upper valve retainer
2 Adjusting screw 9 Rocker shaft spring 16 Valve spring
3 Bolt (short) 10 Rocker shaft 17 Valve (inlet)
4 Bolt (long) 11 Valve pushrod 18 Valve (exhaust)
5 Valve cap 12 Cylinder head bolt 19 Valve stem seal
6 Snap ring 13 Cylinder head 20 Cylinder head gaske
7 Rocker arm 14 Valve cotters

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(1) Removing rocker shaft assembly

(a) Loosen the adjusting screw one turn.
(b) Loosen the bolts, long and short, that hold the
rocker shaft bracket to the cylinder head. Be sure
to loosen the short bolt first. Remove the rocker
shaft assembly from the cylinder head.

CAUTION
If the long bolt is loosened first, the rocker shaft
bracket might suffer damage.
Removing rocker shaft assembly

(2) Disassembling rocker shaft assembly

Arrange the disassembled rockers in the order removed, so
you can install them in that order at reassembly. This will
ensure the same rockershaft clearance as before.

Disassembling rocker shaft assembly

(3) Removing cylinder head

Remove the cylinder head bolts. Lift the head off the
crankcase.

NOTE
If any parts of the cylinder head are faulty, check the
cylinder head bolts for torque with a torque wrench
before removing them.

Removing cylinder head

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(4) Removing valves and valve springs

Valve spring pusher
Use valve spring pusher (30691–04500) to compress the
valve spring squarely, then remove the valve cotters.

NOTE
If the existing valves are to be reused, put a mark on
each valve for its location.

Removing valves and valve springs

(5) Removing valve stem seals

Remove the stem seals with a pliers, as shown in the
illustration.

NOTE
Do not reuse the stem seals.

Removing valve stem seals

(6) Cleaning cylinder head

Clean the machined surface of the cylinder head that makes
contact with the gasket.

NOTE
Remove the gasket with a scraper, then clean the
machined surface with an oilstone and engine oil.

Cleaning cylinder head

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(7) Measuring piston protrusion

(a) Determine the top dead center of the piston with a
dial indicator.
(b) Install a dial indicator on the crankcase with its
point on the top of the piston. Set the indicator to
read 0 (zero).
(c) Check the piston protrusion at three points on the
top of the piston, as shown in the illustration, and
average the three measurements to determine the
protrusion. Subtract the projection from the
compressed thickness of the gasket to determine Measuring piston protrusion
the clearance between the piston top and the
cylinder head.
If the piston protrusion is not correct, check the
various parts for clearance.

Unit: mm (in.)
Item Assembly Standard
0.13 to 0.60
Piston protrusion
(0.0051 to 0.0236)
Compressed thickness of 1.27 to 1.35
gasket (0.0500 to 0.0531)

CAUTION
Incorrect piston protrusion affects engine
performance and causes valve interference with
piston.

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 ENGINE MAIN PARTS

1.2 Inspection

Replace.

Check surface that makes contact

with valve cap for wear. Check oil
hole for clogging. Check bushing
for wear.

Check threads for stripping.

Check surface that makes contact Check for pitted or fracture
with valve push rod for wear. coils. Test force and length.

Check for wear. Check

oil hole for clogging.

Check end faces for wear.

Check for bend.

Replace.

Check for wear.

Check for cracks, or carbon

or scale deposits.
Replace.

Check for uneven wear.

Check face for pitting or ridging

(exhaust valve). Check stem for
scratches or scuff marks.

Inspection points

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ENGINE MAIN PARTS

Cylinder head
Using a heavy accurate straight edge and a feeler gage,
check for warpage in three positions lengthwise, two
crosswise and two widthwise, as shown in the illustration.
If warpage exceeds the repair limit, reface the head with a
surface grinder.

Unit: mm (in.)
Assembly Repair
Item
Standard Limit
Checking cylinder head for warpage
Warpage of bottom 0.05 (0.0020)
0.20 (0.0079)
face or less

Rocker arms and rocker shafts

(1) Measuring rocker arm bushing and rocker shaft
Measure the inside diameter of the rocker arm (bushing
bore) and the diameter of the rocker shaft, as shown in the
illustration, to check the clearance between the rocker arm
and shaft. If the clearance is not correct, within the repair Measuring
directions
limit, replace the rocker arm. If it exceeds the repair limit,
replace both rocker arm and bushing.
Measuring
points
Unit: mm (in.)
Measuring rocker arm bushing and rocker shaft
Nominal Assembly Repair
Item
Value Standard Limit
Inside diameter of
19 19.010 to 19.030
rocker arm —
(0.75) (0.7484 to 0.7492)
bushing
Diameter of 19 18.980 to 19.000
—
rocker shaft (0.75) (0.7472 to 0.7480)
Clearance
0.010 to 0.050 0.070
between rocker —
(0.0004 to 0.0020) (0.0028)
bushing and shaft

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(2) Measuring valve spring perpendicularity and free

length
Measure the free length and perpendicularity of each valve
spring. If the free length or perpendicularity exceeds the Perpendicularity
service limit, replace the spring.

Free
Assembly Service length
Item
Standard Limit
Free length 48.85 mm 47.60 mm
(1.92 in.) (1.87 in.)
Perpendicularity 1.5° or less — Measuring valve spring perpendicularity and
Set force 177 to 196 N 147 N free length
(Set length: 43 mm (18 to 20 kgf) (15 kgf)
(1.69 in.)) [40 to 44 lbf] [33 lbf]

Valve pushrods
Using V-blocks and a dial indicator, check for runout, as
shown in the illustration. If runout exceeds the assembly
standard, replace the pushrod.

Unit: mm (in.)
Item Assembly Standard
Pushrod deflection 0.3 (0.012) or less

NOTE Measuring valve pushrod runout

Assembly standards refer to dial gage readings.

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ENGINE MAIN PARTS

Valves, valve guides and valve seats

(1) Measureing valve stem
Measure the diameter of the valve stem, as shown in the Measuring
illustration. If the service limit is exceeded, replace the directions
valve.

Unit: mm (in.)
Nominal Assembly Service
Item Measuring
Value Standard Limit
points
Inlet 8 7.940 to 7.955 7.900
Valve
valves (0.315) (0.3126 to 0.3132) (0.3110)
stem
diameter Exhaust 8 7.920 to 7.940 7.850 Measuring valve stem
valves (0.315) (0.3118 to 0.3126) (0.3091)

(2) Checking clearance between valve stem and guide

The valve guide wears more rapidly at its both ends than at Measuring
directions
any other parts. Measure the inside diameter of the valve
guide at its ends, as shown in the illustration, to check the Inside micrometer
caliper
clearance. If the clearance exceeds the service limit,
replace the guide or valve whichever is badly worn.

Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
Measuring
Clearance Inlet 0.065 to 0.095 points
—
between valves (0.0026 to 0.0037) 0.200
valve Measuring valve guide
Exhaust 0.080 to 0.115 (0.0079)
stem and
valves — (0.0032 to 0.0045)
guide
Height to top of 15.5 15.1 to 15.6
—
valve guide (0.61) (0.5945 to 0.6142)

NOTE
Before measuring the valve guides, clean the guides,
removing lacquer or other deposits by running wire
brush through them.

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 ENGINE MAIN PARTS

(3) Replacing valve guides

(a) To remove the valve guide for replacement, use Valve guide remover
valve guide remover (32A91-00300).
(b) To install a replacement valve guide, use valve
guide installer (32A91-00100) and a press.
Valve guide
CAUTION
The height to top of valve guide is specified; be
sure to use the valve guide installer to insure
the correct height. Replaceing valve guide

(c) Insert a new valve into the guide just installed to Press
check how the valve slides in the guide. Valve guide
installer
(d) After replacing the valve guides, check the valve

(0.61 in.)
15.5 mm
contact with the seats.

Valve guide

Installing valve guide

(4) Inspecting valve face

Coat the valve face lightly with red lead. Use the valve
lapper to inspect the valve contacts with its seat. If the
contact is not uniform, or if the valve is defective or if the Valve lapper
service limit is exceeded, repair or replace the valve and
valve seat. Red lead

Inspecting valve face

NOTE
(1) Check the valve contact after checking or
replacing the valve guides.
(2) Do not rotate the valve when holding it against the
seat for checking the contact.
(3) After refacing or replacing the valve or valve seat,
lap the valve in the seat. (See (8) Lapping valves.)
Good Bad

Valve contact pattern

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ENGINE MAIN PARTS

Unit: mm (in.)
Nominal Assembly Service Valve seat
Item width
Value Standard Limit
Angle 30°
Valve 1.18 1.04 to 1.32 1.6 Valve seat
Width angle
seat (0.05) (0.0409 to 0.0520) (0.0630)
Valve 0.8 0.7 to 0.9 1.3 Valve margin
sinkage (0.03) (0.0276 to 0.0354) (0.0512) Valve sinkage
After
refacing Valve contact with valve seat
Valve margin 1.70 (0.07)
1.20
(0.0472)

(5) Replacing valve seat

(a) Weld a stud to the valve seat. Insert a shaft
through the valve guide from the upper side of the Weld
cylinder head to put its end on the stud, as shown Bar
in the illustration. Then, drive the seat off from the Valve seat
cylinder head.
NOTE
When welding the stud to the valve seat, avoid contact
Stud
of any spatter with the machined surface of the
cylinder head. Replacing valve seat

(b) Before inserting a new valve seat, measure the

bores in the cylinder head for the valve seats to
(0.346 ± 0.004)

(0.346 ± 0.004)
(0.11 ± 0.004)

(0.11 ± 0.004)
make sure they are correct in dimension.
8.8 ± 0.1

2.8 ± 0.1

2.8 ± 0.1

(c) Chill the valve seat in liquid nitrogen (about - 8.8 ± 0.1

170°C (-274°F)) for more than 4 minutes with the

cylinder head kept at normal temperature, or heat
the cylinder head to 80 to 100°C (176 to 212°F) 41 +0.02
0 33 +0.02
0

with the valve seat chilled in ether or alcohol 45° (1.61 +0.0008
0 ) (1.30 +0.0008
0 ) 45°

containing dry ice. Inlet valve Exhaust valve

seat bore seat bore Unit: mm (in.)

Valve seat bore dimensions

(d) Use the caulking tool to install the valve seat.

Caulking tool
Tools needed
Tool Name Part Number
Caulking tool (for inlet valve
30691–02700
seat)
Caulking tool (for exhaust valve
30691–02800
seat)

Installing valve seat

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 ENGINE MAIN PARTS

(6) Refacing valve face

If the valve face is badly worn, reface it with a valve
refacer.

NOTE
(1) Set a valve refacer at an angle of 30°.
(2) Grind the valve as little as possible. If the margin
seems to exceed the repair limit as a result of
grinding, replace the valve.
Refacing valve face

(7) Refacing valve seat

Use the Valve seat cutter or valve seat grinder to reface the
valve seat. After refacing, grind the seat lightly using #400
grade sandpaper inserted between the cutter and valve seat.

NOTE
(1) Cut or grind the valve seat only as needed for
refacing.
(2) Replace the valve seat if the seat width is more
than the repair limit as a result of wear or cutting. Refacing vale seat

(8) Lapping valve in valve seat

Be sure to lap the valve in the valve seat after the seat has
been replaced.
(a) Coat the valve face lightly with a lapping
compound.
Compound
NOTE
(1) Do not permit the compound to come in contact
with the valve stem.
(2) Use a compound of 120 to 150 mesh for initial
lapping and the compound finer than 200 mesh for Lapping valve in valve seat
finish lapping.
(3) Mixing the compound with a small amount of
engine oil will facilitate coating.

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ENGINE MAIN PARTS

(b) Use the Valve lapper to lap the valve in the seat.
To lap, raise the valve off the seat, then rotate the
valve only a partial turn and strike it against the
seat.
(c) Wash off the compound with diesel fuel.
(d) Coat the valve face with engine oil, and again lap
the valve.
(e) Check the valve face for contact.

Combustion jets

• Replacing
Replace the combustion jets when they are cracked or
Round bar
otherwise faulty. (6 mm (0.24 in.) diameter)
(a) To remove the combustion jet, tap the jet off the
cylinder head with a 6 mm (0.24 in.) diameter
round bar inserted through the glow plug hole, as
shown in the illustration. Combustion
jet

Removing combustion jet

(b) To install a replacement jet, position the jet so that
the orifice is toward the center of the cylinder and
Combustion
drive it into position with a plastic hammer. jet 15°

Orifice

Center of
cylinder

Installing combustion jet

1.3 Reassembly
(1) Installing valve stem seal Stem seal
installer
(a) Apply engine oil to the valve stem and put the
valve in the valve guide.
(b) Put a new stem seal on the valve guide.
(c) Using stem seal installer (32A91–00200), install Stem seal
the stem seal to the valve guide, making use of the Valve guide
valve stem as a guide. Valve

Installing valve stem seal

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 ENGINE MAIN PARTS

(2) Installing valve and valve spring

Valve spring pusher
(a) Put the valve spring and retainer on the valve
guide. Using valve spring pusher (30691–04500),
compress the valve spring and install the valve
cotters to the valve.

CAUTION
Compressing the valve spring excessively will
cause the retainer to make contact and damage
the stem seal.
Installing valve and valve spring

(b) Tap the top of the valve with a soft faced hammer
several times to make sure the valve spring and
valve cotters are properly installed.

Testing valve cotter installation

(3) Installing cylinder head gasket

(a) Make sure the machined surface of the crankcase
and the top of the pistons are clean.
(b) Put a new gasket on the crankcase with “UP” mark
side up. Make sure the locating dowels enter their
holes in the gasket.

CAUTION
Do not use any sealant.

Installing cylinder head gasket

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(4) Installing cylinder head

Put the cylinder head on the crankcase. Make sure the
locating dowels enter their holes in the cylinder head. Dowel pin

Dowel pin

Installing cylinder head

(5) Tightening cylinder head bolt
Tighten the cylinder head bolts to the specified torque in
the sequence shown. 12 4 5 13
Front 16 1 9 17
8
118 ± 5 N·m
Tightening torque (12.0 ± 0.5 kgf·m) 15 7 2 10 18
[87 ± 4 lbf·ft] 11 3 6 14

Cylinder head bolt tightening sequence

(6) Assembling rocker arms and rocker shaft

When installing the rocker arms to the rocker shaft,
position the arms with their assembly marks pointing
forward. After installing the arms, make sure they move
smoothly.
(7) Installing valve pushrod
(a) Insert the pushrod into position through the
pushrod hole in the cylinder head. Assembly mark
(b) Make sure the ball end of each pushrod rests
securely on the curved surface (R section) of the Assembling rocker arms and rocker shaft
tappet.
(8) Installation of rocker shaft assembly
(a) Install valve caps.
(b) When installing rocker shaft brackets, tighten the
long bolts first, then tighten the short bolts
(reversal of removal sequence).

15 ± 2 N·m
Long bolts (1.5 ± 0.2 kgf·m)
Tightening [11 ± 1 bf·ft]
torque 12 ± 1 N·m
Short bolts (1.2 ± 0.1 kgf·m)
Installing rocker shaft assembly
[9 ± 1 lbf·ft]

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 ENGINE MAIN PARTS

1.4 Valve Clearance Adjustment

(1) Find the top dead center on the compression stroke for
No.1 piston as outlined below:
(a) Using the turning handle (30691–21800), turn the
nut on the crankshaft pulley in the engine’s
forward rotating direction (clockwise when viewed
0
from the front of the engine).
(b) Stop turning when the stamped “0” line on the

40
periphery of the crankshaft pulley aligns with the
pointer on the turning gear case.
Finding top dead center on compression
stroke for No. 1 piston – 1

(c) Try to move up and down the inlet and exhaust

valve rocker arms of the No.1 cylinder to make
sure they are not being pushed up by the pushrods.
The No.1 piston is at the top dead center on the
compression stroke when the rocker arms are not
being pushed up by the pushrods. If the rocker
arms are being pushed up, turn the crankshaft one
turn.

Finding top dead center on compression

stroke for No. 1 piston – 2

(2) Insert a 0.25 mm (0.0098 in.) feeler gage into between

the rocker arm and valve cap. Adjusting screw
Lock nut
(0.0098 in.)
0.25 mm

Unit: mm (in.)
Item Assembly Standard
Inlet
Valve clearance valves
0.25 (0.0098)
(cold setting) Exhaust
valves

(3) Loosen the lock nut for the adjusting screw and turn Adjusting valve clearance
the adjusting screw in either direction until the feeler
gage is slightly gripped between the rocker arm and
valve cap.

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ENGINE MAIN PARTS

(4) After adjusting, tighten the lock nut and recheck the
clearance.
(5) Adjust the valve clearance on the remaining cylinders
by turning the crankshaft 180° at a time, in the firing
order.

Sequence (cylinder No.) Turning angle

1–3–4–2 180°

CAUTION
After adjusting the valve clearance on all
cylinders, turn the crankshaft two or three turns
and recheck the clearance.

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 ENGINE MAIN PARTS

2. Flywheel

2.1 Disassembly

5
4

2
3

Disassembly sequence
1 Flywheel 4 Rear plate
2 Oil seal case, O-ring 5 Gasket
3 Oil seal

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ENGINE MAIN PARTS

(1) Removing flywheel

(a) Have someone hold the crankshaft pulley with a
wrench to prevent the flywheel from turning during
removal.
(b) Remove one of the bolts that hold the flywheel.

CAUTION
During removal, signal each other to avoid
personal injury.

(c) Screw safety bar (M12 × 1.25 mm (0.47 × 0.049 Removing flywheel
in.)) in the bolt hole and remove the remaining
bolts.
(d) Remove the flywheel from the crankshaft by
pulling it straight.

CAUTION
When removing the flywheel, wear heavy gloves
to protect your hands.

(2) Removing oil seal case

Remove the bolts holding the oil seal case, then remove the
oil seal in one piece with the case.

CAUTION
When removing the oil seal, take care that its
surface is not damaged.

Removing oil case

(3) Removing rear plate

Remove the bolts holding the rear plate, then remove the
rear plate.

Removing rear plate

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 ENGINE MAIN PARTS

2.2 Inspection

Replace.

Check friction surface for cracking,

scoring, or other defects that affect
serviceability.Examine ring gear for
worn or defective teeth.

Replace.

Replace.

Inspection Points

Flywheel and ring gear

(1) Flatness of flywheel
Put the flywheel on the surface plate. Set a dial indicator at
one side of the friction surface and move it over to the
opposite side of the surface, as shown in the illustration. If
the friction surface is not flat over the repair limit, regrind
it.

Unit: mm (in.)
Assembly Repair
Item Checking flywheel
Standard Limit
0.10 (0.0039)
Flatness of flywheel 0.50 (0.0197)
or less

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ENGINE MAIN PARTS

(2) Replacing ring gear

Check the ring gear and replace it by the following
procedure if it has missing teeth or shows evidence of
abnormal abrasion on the tooth surface.

Removal
(a) Heat the ring gear evenly with an acetylene torch.
(b) Tap the ring gear all the way around with a bar and a
hammer to remove it from the flywheel.

Installation
Heat a replacement ring gear up to 150°C (302°F) with a Removing ring gear
piston heater and install it to the flywheel with the
unchamfered side of the gear teeth foremost.

2.3 Reassembly
Gasket
(1) Installing rear plate
Rear plate
Aligning holes to the dowel pins on the crankcase, install
the rear plate and gasket together to the crankcase.
(2) Installing oil seal
(a) Apply engine oil to the periphery of the oil seal.
(b) Fit the oil seal in the oil seal case.
(c) Fit O-ring to the oil seal case, then install the oil
seal case to the rear plate. Be sure that O mark on
the oil seal case is atop. Installing rear plate
(d) Apply engine oil to the oil seal lip.
(e) Tighten seven bolts firmly to secure the oil seal
case in place.
O-ring

Oil seal case

Installing oil seal

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 ENGINE MAIN PARTS

(3) Installing flywheel

(a) Install the flywheel in place by using the dowel
pins on the crankshaft for alignment.
(b) Install the washers and bolts, and tighten the bolts
to the specified torque.

83 ± 5 N·m
Tightening torque (8.5 ± 0.5 kgf·m)
[61 ± 4 lbf·ft]

Installing flywheel

(4) Measurement of flywheel runout

Measure the amount of runout of the installed flywheel. If
the measured value exceeds the standard value, check the
bolts for tightening condition and the mounting face for
foreign particles.

Unit: mm (in.)
Assembly Repair
Item
Standard Limit
0.10 (0.0039)
Flywheel runout 0.50 (0.0197)
or less Measurement of flywheel runout

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3. Timing Gears, Camshaft and Oil Pan

3.1 Disassembly

10

11

5
4

3
9

Disassembly sequence
1 Crankshaft pulley 7 Idler gear
2 Cover 8 Oil pan
3 Timing gear case 9 Oil pump
4 Pump drive gear 10 Camshaft
5 PTO idler gear 11 Front end plate
6 Baffle plate

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 ENGINE MAIN PARTS

(1) Removing crankshaft pulley

(a) Install two bolts (M12 × 1.25 mm (0.47 × 0.049
in.)) to the rear end of the crankshaft and put a bar
between the bolts to hold the crankshaft, as shown
in the illustration.
(b) Remove the pulley from the crankshaft.

Bolts
CAUTION M12 × 1.25 mm
(0.47 × 0.049 in.)
Make sure the bar will not come off when
removing the pulley. Removing crankshaft pulley

(2) Removing timing gear case

Remove the timing gear case with the oil pump drive gear
and idler gear from the crankcase. Pull the case straight off
the locating dowels.

CAUTION
The front plate is bolted inside the gear case.
Do not attempt to remove the plate with the
case by tapping.
Removing timing gear case

(3) Measuring timing gear backlash

Measure the backlash between the gears and make a record
of the measurements to be referred to at the time of
assembly. If the backlash exceeds the service limit, replace
the gears.
Unit: mm (in.)

Assembly Service
Item
Standard Limit
Backlash between
0.02 to 0.16
crankshaft gear and
(0.0007 to 0.0002)
idler gear
Measuring timimng gear backlash
Backlash between
0.014 to 0.19
idler gear and
(0.0005 to 0.0074)
camshaft gear
Backlash between
0.03 to 0.17 0.25
injection pump drive
(0.0011 to 0.0066) (0.0098)
gear and idler gear
Backlash between
0.007 to 0.209
crankshaft gear and
(0.0002 to 0.0082)
PTO idler gear
Backlash between
0.029 to 0.189
PTO idler gear and
(0.0011 to 0.0074)
pump drive gear

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(4) Measuring idler gear end play

Measure the end play with feeler gages or a dial gage. If
the end play exceeds the repair limit, replace the thrust
plate.

Unit: mm (in.)
Assembly Service Thrust plate
Item
Standard Limit
0.05 to 0.20 0.35
End play of idler gear
(0.0020 to 0.0079) (0.0138) Measuring idler gear end play

(5) Removing pump drive gear and PTO idler gear

Remove pump drive gear and PTO idler gear.

(6) Removing idler gear

Unscrew the bolt and washer and remove the idler gear.

Removing idler gear

(7) Measuring camshaft end play
Use a dial gage to measure the end play of the camshaft to
which the camshaft gear is installed. If the end play
exceeds the service limit, replace the thrust plate.

Unit: mm (in.)
Assembly Service
Item
Standard Limit
0.10 to 0.25 0.30
End play of camshaft
(0.0039 to 0.0098) (0.0118)

Measuring camshaft end play

(8) Turning crankcase upside down
(a) Turn the crankcase upside down.

CAUTION
To prevent damage to the oil pan, do not place
the engine on the floor with the oil pan facing
down. Oil pan

Turning crankcase uside down

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 ENGINE MAIN PARTS

(9) Removing oil pan and gasket

(a) Unscrew the bolts that hold the oil pan to the
crankcase. Remove the oil pan.
(b) Remove the gasket.

Removing oil pan and gasket

(10) Removing oil pump

Unscrew the set bolt and remove the oil pump from the
crankcase.

Oil pump set bolt

Removing oil pump

(11) Removing camshaft

(a) Position the camshaft gear so that its lightening
holes are on the top and bottom sides. Unscrew the
bolts that hold the thrust plate with socket
(34491–00300).
(b) Pull the camshaft from the crankcase.

CAUTION
Socket
Do not cause damage to the lobes or bushing
journals when removing the camshaft.
Removing camshaft

(12) Removing front plate

Unscrew the bolts that hold the front plate to the crankcase.
Remove the plate (with the injection pump) from the
crankcase.

Removing fromt plate

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3.2 Inspection

Replace.

Check for wear or damage.

Check teeth for wear, nicks burrs or

chips. Check keyway for damage.
Check bushing for wear.

Check for cracks or

defective dowel holes. Replace.

Check oil hole

for clogging.

Check for
wear.

Replace.

Replace.

Replace.
Check V-belt groove
and oil seal running
surface for wear.

Inspection points

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Crankshaft pulley
(1) Checking V-belt groove for wear
Wrap a new belt around the pulley, pressing it in the groove
as far as it goes, and see if the top surface of the belt is
above the top of the pulley. 1.6 mm (0.063 in.)

If the top surface of the belt (or the belts for the pulleys
having two or more grooves) is uniformly above the top of
the pulley all the way around, it is not necessary to replace
the pulley.
Wear limit of V-belt groove of pulley
If the top surface of the belt sinks into the groove more
than 1.6 mm (0.063 in.), replace the pulley.
(2) Inspecting oil seal contact surface
Check the oil seal contact surface of the pulley for
excessive wear by the oil seal. Replace it if necessary.

Idler gear
(1) Checking clearance between idler gear and shaft
Measure the inside diameter of the idler gear (bushing) and
the diameter of the shaft, as shown in the illustration, to
Measuring
check the clearance. If the clearance exceeds the service points
limit, replace the gear or shaft whichever is badly worn.

Measuring
Unit: mm (in.) directions
Assembly Service
Item
Standard Limit
Clearance between idler 0.009 to 0.050 0.100 Measuring idler gear and shaft
gear bushing and shaft (0.0003 to 0.0019) (0.0039)

(2) Replacing idler gear bushing

(a) To replace the bushing, use idler gear bushing
installer (30691–51900).
Idler gear bushing
(b) When installing a replacement bushing, press it installer
into position until its end is flush with the end of
the gear boss.
(c) After installing the bushing, finish its inside
+ 0.025 + 0.0098
diameter to 40 (1.57) H7 0 ( 0 ) 0.8 Ra.

Replacing idler gear bushing

3-27
ENGINE MAIN PARTS

(3) Replacing idler gear shaft

Idler gear shaft puller
To remove the shaft for replacement, use idler gear shaft
puller (MH061077).

NOTE
When installing a replacement shaft to the crankcase,
make sure the oil hole in the shaft points upward.

Replacing idler gear shaft

Camshaft
Measuring
(1) Checking lobe lift D1 points

To fine the lobe lift, use the procedure that follows: D2

(a) Measure lobe height (A).
Measuring
(b) Measure base circle (B). directions
(c) Subtract base circle (B) from lobe height (A). The
difference is lobe lift (C).
If the lobe lift is less than the service limit, replace
the camshaft.
Measuring cam lift
Unit: mm (in.)
Nominal Assembly Service
Item C
Value Standard Limit
A= C= C=
+ 0.1
Inlet 46.916 − 0.3 6.684 6.184
A
valve (1.84709) (0.2631) (0.2435)
Lobe (lobe height)
lift A= C= C=
+ 0.1
Exhaust 45.944 − 0.3 7.344 6.844
valve (1.80882) (0.2891) (0.2694)
B
(lobe height)

(2) Checking clearance between camshaft journal and bore

in crankcase (or bushing)
Measuring
Measure the diameter of the camshaft journal and the inside points
diameter of the bore in the crankcase (or bushing) for
camshaft, as shown in the illustration, to check the
clearance. If the clearance exceeds the service limit,
Measuring
replace the camshaft. directions

Measuring camshaft journal

3-28
 ENGINE MAIN PARTS

Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
No. 1
54 53.94 to 53.96 53.90
Diameter of and
(2.13) (2.1236 to 2.1244) (2.1220)
camshaft No. 2
journal 53 52.94 to 52.96 52.90
No. 3
(2.09) (2.0843 to 2.0850) (2.0827)
Clearance
between camshaft
journal and bore 0.07 to 0.11 0.15
—
in crankcase (or (0.0028 to 0.0043) (0.0059) Measuring bore in crankcase (buhing) for
bushing) for camshaft
camshaft
No. 1
Inside 54 54.030 to 54.050
and —
diameter (2.13) (2.1272 to 2.1280)
No. 2
of bore for
camshaft 53 53.030 to 53.050
No. 3 —
(2.09) (2.0878 to 2.0886)

(3) Measuring camshaft deflection

If the deflection exceeds the repair limit, straighten the
camshaft with a press, or replace it with a new one.

CAUTION
Set up a dial gage on the camshaft, then turn
the camshaft. Take one half (1/2) of the gage
indication as the deflection.

Unit: mm (in.) Measuring camshaft deflection

Assembly Repair
Item
Standard Limit
0.02 (0.0008) 0.05
Camshaft deflection
or less (0.0020)

3-29
ENGINE MAIN PARTS

(4) Removing camshaft gear

To remove the camshaft gear, use a hydraulic press. Thrust plate

NOTE
Do not remove the camshaft, thrust plate or gear
unless it requires replacement.

Removing camshaft gear

(5) Installing camshaft gear and thrust plate

(a) Install the key and thrust plate to the camshaft.
(b) Heat the gear up to a temperature of 250°C
(482°F).
(c) Drive the gear onto the camshaft.

NOTE
Thrust plate
Install the thrust plate before installing the gear to the
Camshaft gear
camshaft.

Installing camshaft gear and thrust plate

3.3 Reassembly
(1) Installing front end plate
(a) Put the front end plate and gasket on the front face
of the crankcase. Make sure the locating dowels
enter their holes in the plate and gasket.
(b) Tighten two bolts to the specified torque.

12 ± 1 N·m
Tightening torque (1.2 ± 1 kgf·m)
[97 ± 1 lbf·ft]

Installing front end plate

(2) Installing camshaft
(a) Apply engine oil to the journals and lobes of the
camshaft.

Apply engine oil.

Applying engine oil to camshaft

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 ENGINE MAIN PARTS

(b) Install the camshaft (with gear) in the crankcase.

NOTE
Do not cause damage to the journals and lobes.

(c) Tighten the thrust plate bolts to the specified

torque with a torque wrench and socket
(34491–00300).
Socket

12 ± 1 N·m
Tightening torque (1.2 ± 1 kgf·m)
[97 ± 1 lbf·ft] Installing camshaft

(d) Make sure the camshaft rotates smoothly. Move

the camshaft back and forth in the axial direction
to make sure it has correct end play.

(3) Installing oil pump

(a) Install the oil pump in position in the crankcase.
Make sure the oil pump gear is meshing with the
oil pump drive gear of the camshaft.
(b) Install the oil pump set bolt with gasket and tighten
it to the specified torque.
Gasket
34 ± 4 N·m Oil pump
Tightening torque (3.5 ± 0.4 kgf·m) set bolt
[25 ± 3 lbf·ft]
Installing oil pump

(4) Installing oil pan

(a) Apply THREE BOND 1207C or 1211, or
equivalent, to the seats formed of the crankcase for
the No.1 and No.5 main bearing caps just enough
to be forced out of the seats when the oil pan
gasket is installed.
(b) Install the oil pan gasket to the bottom of the
crankcase by fitting it into the grooves in the main
bearing caps and into the seats to which THREE Apply THREE BOND.
BOND was applied in Step (a), as shown in the
illustration.
Installing oil pan
(c) Tighten the oil pan bolts to the specified torque.

7.8 ± 1 N·m
Tightening torque (0.8 ± 0.1 kgf·m)
[5.8 ± 1 lbf·ft]

3-31
ENGINE MAIN PARTS

(5) Turn the crankcase upside down for the steps that
follow.

CAUTION
To prevent damage to the oil pan, do not place
the engine on the floor with the oil pan facing
down.

Turning crankcase upside down

(6) Installing idler gear

(a) Apply engine oil to the idler gear shaft.
(b) Install the idler gear with its marks in alignment
Apply engeine oil.
with the marks on the injection pump drive gear,
camshaft gear and crankshaft gear, as shown in the
illustration.

Thrust plate

Installing idler gear

(c) Put the thrust plate on the idler gear and tighten
Pump drive gear Injection pump
the bolt with washer to the specified torque. drive gear
PTO idler gear
(d) Move the idler gear back and forth in the axial
direction to make sure it has correct end play.

3 3
22
2

1
11

Camshaft gear
Idler gear
Crankshaft gear

Marks on timimng gears

(7) Installing pump drive gear and PTO idler gear

Install the pump drive gear and PTO idler gear together
with bearings.

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 ENGINE MAIN PARTS

(8) Checking timing gear backlash

After installing the timing gears, check them for backlash,
as shown in the illustration.
Unit. mm (in.)
Assembly Service
Item
Standard Limit
Backlash between
0.02 to 0.16
crankshaft gear and
(0.0007 to 0.0062)
idler gear
Backlash between
0.014 to 0.19
idler gear and Checking timing gear backlash
(0.0005 to 0.0074)
camshaft gear
Backlash between
0.03 to 0.17 0.25
injection pump drive
(0.0011 to 0.0066) (0.0098)
gear and idler gear
Backlash between
0.007 to 0.209
crankshaft and PTO
(0.0002 to 0.0082)
idler gear
Backlash between
0.029 to 0.189
PTO idler gear and
(0.0011 to 0.0074)
pump drive gear

(9) Installing oil seal

Using an installer, install a new oil seal to the timing gear Installer
case until it is flush with the end face of the case, as shown
in the illustration. The lip of the seal must be toward the
inside of the gear case.

Installing oil seal

(10) Installing timing gear case

(a) Install the oil pump drive gear and idler gear to the
timing gear case. Install the cover in position.
(b) Install the baffle plate to the crankshaft.
(c) Install the timing gear case and gasket to the front
face of the crankcase. Make sure the locating
dowels enter their holes in the case and gasket.
(d) Install long bolts and tighten to the specified
torque.

12 ± 1 N·m Installing timing gear case

Tightening torque (1.2 ± 0.1 kgf·m)
[9 ± 1 lbf·ft]

3-33
ENGINE MAIN PARTS

(11) Installing crankshaft pulley

(a) Apply engine oil to the oil seal running surface of
the pulley.
(b) Push the pulley on to the crankshaft in alignment
Washer
with the keys.
(c) Install two lock bolts (M12 × 1.25 mm (0.47 ×
0.049 in.)) to the rear end of the crankshaft and Apply engine oil.
insert a bar between the bolts to hold the
crankshaft.
Installing crankshaft pulley
(d) Tighten the nut with washer to the specified torque.

392 ± 10 N·m
Tightening torque (40 ± 1 kgf·m)
[289 ± 7 lbf·ft]

CAUTION
To ensure safety, make sure the bar and bolt
used to prevent the crankshaft from turning
have sufficient strength.

Crankshaft rotation stopper

3-34
 ENGINE MAIN PARTS

4. Pistons, Connecting Rods, Crankshaft and Crankcase

4.1 Disassembly

12
13
14
16
11

10
9

2
15
1

6
5

Disassembly sequence
1 Connecting rod cap 6 Main bearing (upper half) 11 Piston
2 Connecting rod bearing 7 Connecting rod 12 No.1 ring
(lower half) 8 Connecting rod bearing 13 No.2 ring
3 Main bearing cap (upper half) 14 Oil ring
4 Main bearing (lower half) 9 Snap ring 15 Tappet
5 Crankshaft 10 Piston pin 16 Crankcase

NOTE
When replacing the crankcase, carefully remove the parts (such as the relief valve, etc.) from the crankcase to
reuse them at the time of reassembly.

3-35
ENGINE MAIN PARTS

(1) Laying crankcase on its side

Carefully lay the crankcase on its side.

Laying crankcase on its side

(2) Checking thrust clearance of connecting rod big-end

(a) Check the clearance between the connecting rod
big-end and the crankpin with a feeler gage, as
shown in the illustration.
(b) If the thrust clearance exceeds the service limit,
replace the connecting rod.

Unit: mm (in.)
Assembly Service
Item
Standard Limit Checking thrust clearance of connecting rod
Thrust clearance of big-end
0.15 to 0.35 0.50
connecting rod big-end
(0.0059 to 0.0138) (0.0197)
(End play)

(3) Maximum permissible difference between average

weight of all connecting rod assemblies in one engine
When replacing the connecting rods, select new connecting
rods having the same weight rank marks so that the
difference between average weight of all connecting rod
assemblies in one engine does not exceeds the maximum
permissible limit.
A

Matching
marks
Maximum permissible difference between
10 g Weight rank mark
average weight of all connecting rod
(0.35 oz)
assemblies in one engine
Weight rank mark on connecting rod

3-36
 ENGINE MAIN PARTS

(4) Removing connecting rod caps

(a) Put a mark on each cap so it can be installed in the
same position from which it was removed.
(b) Remove the caps and the lower halves of the
connecting rod bearings.
(c) Put a mark on each connecting rod bearing (lower
half) so it can be installed in the same position
from which it was removed.

Removing connecting rod caps

NOTE
Be careful not to cause damage to the bearings.
Arrange the removed bearings in a proper order so that
they can be reinstalled in their original positions
during reassembly.

(5) Removing carbon from cylinders

Use a cloth or sandpaper to remove all carbon deposits
from the upper areas of the cylinder liner. If any carbon
deposits are present, this will make it difficult to pull a
piston upward.

Removing carbon from cylinders

(6) Removing piston and connecting rod

(a) Turn the crankshaft to bring the piston to the top
dead center.
(b) Push the piston and connecting rod away from the
crankshaft with the handle of a hammer until the
piston rings are above the cylinder. Then remove
the piston and connecting rod from the crankcase.

Removing piston and connecting rod

3-37
ENGINE MAIN PARTS

(7) Removing piston rings Piston ring pliers

Remove the piston rings with piston ring pliers
(31391–12900).

Removing piston rings

(8) Removing piston pins

(a) Using ring pliers, remove the snap rings.
Snap ring pliers
(b) Remove the piston pin to separate the piston from
the connecting rod.
(c) If it is difficult to pull out the pin, heat the piston
with a piston heater or in hot water to expand the
pin bore.

Removing snap ring

(9) Turning crankcase upside down

Turn the crankcase upside down with the oil pan side up.

Turning crankcase upside down

(10) Measuring end play of crankshaft

(a) With a dial indicator at the end of the crankshaft,
check the end play, as shown in the illustration.
(b) If the end play exceeds the service limit, replace
the thrust bearing.

Unit: mm (in.)
Assembly Service
Item
Standard Limit
0.100 to 0.204 0.30
End play of crankshaft Measuring end play of crankshaft
(0.0039 to 0.0080) (0.0118)

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 ENGINE MAIN PARTS

(11) Removing main bearing caps

Remove the main bearing caps with lower halves of the
main bearings.

NOTE
Be careful not to cause damage to the main bearings.
Put a mark on each bearing cap so it can be installed in
the same position from which it was removed.

Removing main bearing caps

(12) Removing crankshaft

Carefully remove the crankshaft.

NOTE
Be careful not to cause damage to the main journals
and crankpins. Put a mark on each bearing.

Removing crankshaft

(13) Orderly arrangement of bearings

If bearings scatter during disassembly, they cannot be
reinstalled in their original positions. Be sure to arrange
the removed bearings in a proper order so that they can be
reinstalled in their original positions.

3-39
ENGINE MAIN PARTS

4.2 Inspection

Check fo scale deposits,

Check for wear or damage. corrosion or other defects.
Check for wear, score
marks, cracks or
carbon deposits. Check for fatigue.

Check for
Check for wear. stripped
threads.

Check for wear or

clogged hole.

Check for cracks or

clogged oil hole.

Check serrated portions

for wear or cracks.

Check for wear.

Check for cracks, clogged

oil hole or other defects.

Check for nicks, chipping or

abnormal tooth contact.
Check for cracks.

Check for stripped

threads.

Typical failures for which main bearing

are to be checked are scratches due to
dirt embedded into bearing material,
loss of overlay due to lack of oil, craters
or pockets due to fatigue failure, failure
due to poor seating, radius ride, etc.

Inspection points

3-40
 ENGINE MAIN PARTS

Pistons, piston rings and piston pins Direction transverse

to piston pin
(1) Measuring piston diameter

(0.6 in.)
14 mm
(a) Using a micrometer, measure the diameter of each
piston perpendicular to the piston pin (at the
position shown). If the diameter exceeds the
service limit, replace the piston. If any pistons
have to be replaced, select new pistons so the
weight difference in an engine is within assembly
standards.

Unit: mm (in.)
Measuring piston diameter
Nominal Assembly Service
Item
Value Standard Limit
Front of engine
Standard 87.970 87.955 to 87.985 87.770
Piston diameter

(3.4634) (3.4628 to 3.4640) (3.4555)

Weight
0.25 (0.0098) 88.220 88.205 to 88.235 88.020 “Front” mark identification
oversize (3.4732) (3.4726 to 3.4738) (3.4654)
Size
0.50 (0.0197) 88.470 88.455 to 88.485 88.270 identification
oversize (3.4831) (3.4825 to 3.4837) (3.4752)
Weight difference in one 5 g (0.2 oz)
—
engine or less

(b) The weight of the piston is stamped on the top of

Identification on top of piston
the piston.

(2) Checking piston and piston ring

No.1 ring
(a) Check the clearance between the groove and the
piston ring with a feeler gage, as shown in the
illustration. If the clearance exceeds the service No. 2 ring
limit, replace the piston ring.

Unit: mm (in.)
Service
Item Assembly Standard
Limit
No. 1 0.060 to 0.100 0.200
ring (0.0024 to 0.0039) (0.0079) Checking between groove and piston ring
Clearance
between No. 2 0.045 to 0.080
groove and ring (0.0018 to 0.0032) 0.150
piston ring (0.0059)
Oil 0.025 to 0.065
ring (0.0010 to 0.0026)

(b) Install a new piston rings and recheck the

clearance. If the clearance still exceeds the service
limit, replace the piston.

3-41
ENGINE MAIN PARTS

(3) Checking clearance between ends of piston ring

Install the piston ring in a new cylinder or a gage and
measure the clearance between the ends of the ring with a
feeler gage. If the clearance exceeds the service limit,
replace all piston rings.

Inside diameters of gages

Standard gage:
+ 0.035 + 0.0014
88 0 mm (3.46 0 in.)
0.25 mm (0.0098 in.) oversize gage: Checking clearance between ends of piston ring
+ 0.035 + 0.0014
88.25 0 mm (3.4744 0 in.)
0.50 mm (0.0197 in.) oversize gage:
+ 0.035 + 0.0014
88.50 0 mm (3.4843 0 in.)

NOTE
Use a piston to place the piston ring in the liner by
pushing it squarely.

Unit: mm (in.)
Service
Item Assembly Standard
Limit
No. 1,
0.25 to 0.40
Clearance No. 2
(0.0098 to 0.0157) 1.50
between end ring
of piston ring Oil (0.0591)
0.30 to 0.50
ring (0.0118 to 0.0197)

(4) Checking clearance between piston pin and bore

Measure the inside diameter of the pin bore of the piston
and the diameter of the pin, as shown in the illustration, to
check the clearance. If the clearance exceeds the service
limit, replace the parts.

Measuring points Measuring directions

Unit : mm (in.)

Nominal Assembly Service

Item
Value Standard Limit
Diameter of 28 27.994 to 28.000
— Measuring piston pin and bore
piston pin (1.10) (1.1021 to 1.1024)
Clearance
0.000 to 0.016 0.050
between piston —
(0.0000 to 0.0006) (0.0020)
pin and bore

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 ENGINE MAIN PARTS

(5) Checking clearance between connecting rod bushing

and piston pin Measuring
directions
Measure the inside diameter of the connecting rod bushing
bore and the diameter of the piston pin, as shown in the
illustration, to check the clearance. If the clearance
exceeds the service limit, replace the parts.
Measuring
points
Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
Inside diameter 28 28.020 to 28.045 Measuring connecting rod bushing
of bushing (1.10) (1.1031 to 1.1041)
Clearance
0.020 to 0.051 0.080
between bushing —
(0.0008 to 0.0020) (0.0032)
and piston pin

(6) Replacing connecting rod bushing

(a) Use a connecting rod bushing puller to replace the Weight mark side
connecting rod bushings.
(b) When installing a new bushing, align the oil holes
in the bushing and connecting rod. Position the Oil hole
ends of the bushing at the location shown in the
illustration.
(c) After installing the bushing, insert the piston pin
into position and make sure it rotates smoothly.
Ends of bushing

Installing connectng rod bushing

Connecting rods
C < 0.05 ( 0.0020 )
(1) Measure “C” and “L”. If the measurement at C is L 100 3.94
larger than 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) C 0.05 ( 0.0020 )
<
C L 100 3.94
of L, straighten the rod with a press.
L
L
Piston pin C L
Unit: mm (in.)
Assembly Repair Twist
Item
Standard Limit
Bend
0.05/100 Unit: mm (in.)
Connecting rod bend 0.15/100
(0.0020/3.94)
and twist (0.0059/3.94) Inspecting connecting rod
or less

3-43
ENGINE MAIN PARTS

(2) A connecting rod aligner is generally used for checking

the connecting rod for twist and bend.

NOTE
To check the connecting rod for bend, install the cap to
the rod and tighten the cap nuts to the specified torque.

54 ± 5 N·m
Tightening torque (5.5 ± 0.5 kgf·m)
[40 ± 4 lbf·ft]
Checking connecting rod with a connecting
rod aligner

(3) When the measurement is taken with the piston

installed to the connecting rod, place the piston upside D
down on a surface plate, insert a round bar having the
C
same diameter as the crank pin, and measure the height
of the round bar using a dial gage.

A B

Checking connecting rod with a dial indicator

Crankshaft
54 ± 5 N·m
(1) Checking oil clearance of connecting rod bearing Measuring Measuring (5.5 ± 0.5 kgf·m)
directions points [4.0 ± 4 lbf·ft]
(a) Install the upper and lower halves of the bearing
and the cap to the connecting rod, and tighten the
cap nuts to the specified torque. Measure the
inside diameter of the bearing, as shown in the
illustration.

54 ± 5 N·m
Tightening torque (5.5 ± 0.5 kgf·m)
[40 ± 4 lbf·ft]
Measuring connecting rod bearing

3-44
 ENGINE MAIN PARTS

(b) Measure the diameter of the crankpin of the

crankshaft, as shown in the illustration, and
subtract the diameter of the crankpin from the
inside diameter of the bearing (Step (a)). The
difference is the oil clearance of the connecting rod Measuring Measuring
bearing. directions points

Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
Diameter of Measuring crankpin
58 57.950 to 57.970
crankpin —
(2.28) (2.2814 to 2.2823)
(standard)
0.030 to 0.095 0.20
Oil clearance —
(0.0012 to 0.0037) (0.0079)

(c) If the oil clearance exceeds the repair limit, replace

the bearing and recheck the oil clearance.
(d) If the oil clearance still exceeds the repair limit,
use 0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.) or
0.75 mm (0.0295 in.) undersize bearings. When
using undersize bearings, refinish the crankpins to
any of the undersizes listed below.

Unit: mm (in.)
Finishing dimension
0.25 - 0.030 - 0.0012
57.75 - 0.050 (2.2736 - 0.0019 )
(0.0098)
Undersize of 0.50 - 0.030 - 0.0012
57.50 - 0.050 (2.2638 - 0.0019 )
crankpin (0.0197)
0.75 - 0.030 - 0.0012
57.25 - 0.050 (2.2539 - 0.0019 )
(0.0295)

NOTE
(1) Grind all crankpins to the same undersize.
(2) Finish the fillet radius to 3 mm (0.12 in.)

R 3 mm
(0.12 in.)

Fillet radius

3-45
ENGINE MAIN PARTS

(2) Checking oil clearance of main bearing Measuring Measuring

(a) Install the upper and lower halves of the bearing directions points
and the cap to the crankcase, and tighten the cap
nuts to the specified torque. Measure the inside
diameter of the bearing, as shown in the
illustration.

83 ± 5 N·m
Tightening torque (8.5 ± 0.5 kgf·m)
[61 ± 4 lbf·ft]

Measuring main bearing

(b) Measure the diameter of the journal of the

crankshaft, as shown in the illustration, and
subtract the diameter of the journal from the inside
diameter of the bearing (Step (a)). The difference
is the oil clearance of the main bearing. Measuring Measuring
directions points

Unit: mm (in.)
Nominal Assembly Service
Item
Value Standard Limit
Diameter journal 65 64.965 to 64.985
—
(standard) (2.56) (2.5577 to 2.5585)
Measuring journal
0.035 to 0.095 0.200
Oil clearance —
(0.0014 to 0.0037) (0.0079)

(c) If the oil clearance exceeds the repair limit, replace

the bearing and recheck the oil clearance.
(d) If the oil clearance still exceeds the repair limit,
use 0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.) or
0.75 mm (0.0295 in.) undersize bearings. When
using undersize bearings, refinish the journals to
any of the undersizes listed below.

Unit: mm (in.)
Finishing dimension
0.25 - 0.015 - 0.0006
64.75 - 0.035 (2.5492 - 0.0014 )
(0.0098)
Undersize of 0.50 - 0.015 - 0.0006
64.50 - 0.035 (2.5394 - 0.0014 )
journal (0.0197)
0.75 - 0.015 - 0.0006
64.25 - 0.035 (2.5295 - 0.0014 )
(0.0295)

3-46
 ENGINE MAIN PARTS

NOTE
R 3 mm [0.12 in.] R 3 mm [0.12 in.]
(1) Grind all journals to the same undersize.
(2) Finish the fillet radius to 3 mm (0.12 in.).

Fillet ratius

(3) Checking oil seal running surface

Check the oil seal sleeve running surface of the crankshaft
rear-end. If the sleeve is badly worn by the oil seal, replace Frywheel housing

the oil seal sleeve. Oil seal

Oil seal running
surface
Oil seal sleeve

Checking oil seal running surface

(a) Removing oil seal sleeve

Hold a flat cold chisel at right angles to the sleeve
and cut the sleeve at three places to loosen it, as
shown in the illustration. If it is impossible to
remove the sleeve in this method, hold the chisel in
the axial direction and lightly tap the sleeve to
loosen it.

CAUTION
Be extra careful not to cause damage to the
crankshaft when removing the sleeve. Removing oil seal sleeve

(b) Installing oil seal sleeve

Apply oil to the inside of an oil seal sleeve and, Sleeve
using crankshaft sleeve installer set installer
(30691–13010), install the sleeve in position, as
shown in the illustration. Guide
(30691–13100)

CAUTION
Be extra careful not to cause damage to the
sleeve when installing it. Installer
(30691–13200)

Installing oil seal sleeve

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ENGINE MAIN PARTS

When the oil seal sleeve is worn after the engine

has been operated, replace both oil seal and oil seal
sleeve.
Frywheel housing

Oil seal
Oil seal running
surface
Oil seal sleeve

Checking oil seal running surface

(4) Checking crankshaft deflection

Support the crankshaft on its front and rear journals in V-
blocks. With the dial indicator set at 0.00 mm (0.0000 in.)
at the center journal, turn the camshaft full one revolution
and read the indicator, as shown in the illustration. If
deflection is out of the assembly standard but does not
exceed the repair limit, repair the crankshaft by grinding.
If deflection exceeds the repair limit, repair the crankshaft
by cold working. Replace the crankshaft if runout exceeds
the repair limit excessively. Checking crankshaft deflection

Unit: mm (in.)
Assembly Repair
Item
Standard Limit
0.02 (0.0008) 0.05
Crankshaft deflection
or less (0.0020)

(5) Removing crankshaft gear

Remove the crankshaft gear with a gear puller, as
shown in the illustration.

NOTE
Do not remove the gear unless it requires replacement.

Removing crankshaft gear

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 ENGINE MAIN PARTS

(6) Installing crankshaft gear

(a) Heat the gear in an oven to a temperature of 100°C
to 150°C (212°F to 302°F).
(b) Install the key to the crankshaft. Fry key into keyway

(c) Install the gear by fitting the key into the keyway
in the gear.

Installing crankshaft gear

Crankcase
Measuring
(1) Checking crankcase bore directions

(a) Measure the entire bore with a cylinder bore gage

having a dial indicator. Take measurements at A, B AB C
and C positions in the bore on axes 90° apart, as
shown in the illustration, to check the diameter,
out-of-round and taper. If the bores exceeds the
service limit for diameter, out-of-round and taper,
increase them for oversize pistons. Measuring
points

Unit: mm (in.) Checking crankcase bore

Pistons available Bore Diameter
Size Service
Size Assembly Standard
Code Limit
+ 0.035 + 0.0014
Standard STD 88 0 (3.46 0 )
0.25 (0.0098) + 0.035 + 0.0014
25 88.25 0 (3.4744 0 ) +0.2
oversize
(+0.008)
0.50 (0.0197) + 0.035 + 0.0014
50 88.50 0 (3.4842 0 )
oversize
Out-of-round and
0.015 (0.0006) or less —
taper of bores

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ENGINE MAIN PARTS

(b) Boring of cylinders

1) There are two piston oversizes (0.25 mm (0.0098
in.) and 0.50 mm (0.0197 in.) over standard size)
as listed above. Determine the piston size to be
used based on the largest bore diameter of the
cylinders.
2) Measure the outside diameter of the piston to be
Perpendicular
used. to piston pin

[0.55 in.]
14 mm
3) Based on the measurement of the piston outside
diameter, calculate the finishing dimension to be
achieved by boring.
A: Measured piston outside diameter
(selected oversized piston) mm
B: Clearance between piston and cylinder
(standard value) 0.03 mm (0.0012 in.)
C: Honing allowance 0.04 mm (0.0016 in.) or less
Measuring piston diameter
Finishing dimension = A + B - C
4) Bore the cylinders to the calculated dimension.

CAUTION
Bore the cylinders in the order of the cylinder
numbers to prevent distortion due to the heat
generated by the boring operation.

5) Hone the cylinders to the final dimension (piston

outside diameter + cylinder clearance).

(2) Checking crankcase top face

Check the top face for warpage, using an accurate straight
edge and a feeler gage, in three positions lengthwise, two
crosswise and two widthwise, as shown in the illustration.
If warpage exceeds the repair limit, grind the crankcase.

Unit: mm (in.)
Assembly Repair
Item
Standard Limit
Warpage of crankcase 0.05 (0.0020)
0.20 (0.0079)
top face or less Checking crankcase top face

NOTE
The maximum limit of stock to be removed from the
crankcase and cylinder head for grinding is 0.2 mm
(0.0079 in.) in all.

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 ENGINE MAIN PARTS

Tappets
(1) Checking for wear
Check the cam contact face of each tappet for wear.
Replace badly worn tappets if any.

Good Bad Bad

Cam contact face of tappet

(2) Checking clearance between tappet and bore

Measuring directions Measuring directions
Measure the diameter of the tappet and the inside diameter
of the bore in the crankcase for the tappet, as shown in the
illustration, to check the clearance. If the clearance
exceeds the service limit, replace the tappets.

Unit: mm (in.)
Nominal Assembly Service
Item Measuring
Value Standard Limit
points
Inside diameter 14 14.000 to 14.018 14.100
of bore for tappet (0.55) (0.5512 to 0.5519) (0.5551) Checking clearance between tappet and bore
Clearance
0.016 to 0.052 0.080
between tappet —
(0.0006 to 0.0021) (0.0032)
and bore

NOTE
If the bores are worn beyond the service limit, replace
the crankcase.

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ENGINE MAIN PARTS

4.3 Reassembly
Apply engine oil.
(1) Installing tappet
(a) Apply engine oil to the tappets and install them in
the bores in the crankcase.
(b) Make sure the tappets rotate smoothly.

Installing tappet

(2) Installing main bearings

(a) Install the lower halves of the main bearings in the No.5 bearing Apply engine oil
main bearing caps. Install the upper halves of the (with flange)
main bearings in the crankcase.
Tab and
notch
NOTE
(1) Make sure the upper and lower halves of the main
bearings are installed so the bearing tabs fit into
the notch in the crankcase and main bearing caps.
(2) Only the upper halves of the main bearings to be
Installing main bearings
installed in the crankcases has an oil groove.

(b) Install the upper and lower halves of the main

bearing having flanges in the crankcase and main
bearing cap for No.5 journal of the crankshaft.
(c) Lightly coat the inside surface of the shells with
engine oil.

(3) Installing crankshaft

(a) Wash the crankshaft with cleaning solvent and
blow dry with compressed air. Make sure all oil
holes in the crankshaft are clean. Check the oil
holes for condition.
(b) Hold the crankshaft in a horizontal position by
using a hoist, and carefully put it in the crankcase.
(c) Lightly coat the journals with engine oil.

Installing crankshaft

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 ENGINE MAIN PARTS

(4) Installing main bearing caps

“Front” mark
Install the main bearing caps in position so the “front”
Front
mark (arrow) on the cap is toward the front of the engine of
and the number on the cap is the same as the number on the engine
crankcase on the left side of each main bearing cap. 5
1 2 3 4

NOTE Flush
The end faces of No.1 and No.5 bearing caps must be
flush with the end faces of the crankcase. Cap number

Installing main bearing caps

(5) Tightening main bearing cap bolts

Tighten the main bearing cap bolts evenly to the specified
torque.

83 ± 5 N·m
Tightening torque (8.5 ± 0.5 kgf·m)
[61 ± 4 lbf·ft]

Tightening main bearing cap bolts

(6) Checking crankshaft for rotation

Make sure the crankshaft rotates smoothly.

Checking crankshaft for rotation

(7) Measuring crankshaft end play
(a) Check the crankshaft end play with a dial indicator,
as shown in the illustration.
Unit: mm (in.)
Assembly Repair
Item
Standard Limit
0.100 to 0.204 0.30
End play of crankshaft
(0.0039 to 0.0080) (0.0118)

(b) If the end play is less than the assembly standard, Measuring crankshaft end play
retighten the main bearing cap bolts.
(c) If it exceeds the service limit, replace the flanged
bearings.

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ENGINE MAIN PARTS

(8) Reassembling piston and connecting rod

A
(a) Put the connecting rod in position in the piston
with the matching mark of the rod on the same side Weight identification
as the weight identification on the top of the piston.
(b) Apply engine oil to the piston pin and install it in
Matching
position. mark

View A

Reassembling piston (1)

(c) Install the snap rings in the grooves in the piston
with a pliers. Make sure the snap rings fit in the
grooves properly. Pliers

NOTE
The snap ring ends must be toward the bottom of the
piston.

Reassembling piston (2)

(9) Installing piston rings

Using piston ring pliers (31391–12900), install the Mark pointing
upwards
compression (No.1 and No.2) rings and oil ring on the
R
piston with the mark “R” toward the top of the piston. No.1 ring
No.1 No.2

No.2 ring

Oil ring

Piston and piston rings

NOTE
Spring joint
The oil ring must be installed on the piston with the
ring end gap 180° from the coil spring joint.

180°

Ring end gap

Oil ring end gap and spring joint

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 ENGINE MAIN PARTS

(10) Laying crankcase on its side

Lay the crankcase on its side.

Laying crankcase on its side

(11) Apply engine oil to bores

Clean the bores with a clean rag and apply engine oil to the
bores.

Apply engine oil.

Apply engine oil to bores

(12) Installing connecting rod bearing

(a) Install the connecting rod cap bolts in the big-end Tab and notch
of the connecting rod so the flats of their heads fit
on the connecting rod properly.
(b) Install the tipper half of the connecting rod bearing
in the big-end of the connecting rod. Make sure
Apply engine oil.
the tab on the back of the bearing is in the notch of
the connecting rod.

Installing connecting rod bearing

(13) Installing piston assembly

Camshaft side Thrust direction
(a) Apply engine oil to the piston rings.
(b) Make sure the piston ring end gaps are arranged on End gap of
No.1 ring
the piston, as shown in the illustration.

Piston pin

End gap of End gap of

No.2 ring oil ring
Anti-thrust direction
Combustion chamber side

Installing piston assembly (1)

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ENGINE MAIN PARTS

(c) Turn the crankshaft to bring the No.1 (or No. 4)

crankpin to the top center.
(d) Put piston installer (30691–58100) on the top of
the crankcase in alignment with the bore center.
Hold the installer in position by one hand.
(e) Put the piston assembly in the crankcase through
the installer. Make sure the “front” mark on the
top of the piston is toward the front of the engine. “Front” mark
Piston installer

Installing piston assembly (2)

NOTE “Front” mark

Make sure the big-end of the connecting rod fits on the
crankpin properly.

(f) Lightly tap the top of the piston with the handle of
a hammer to put the big-end of the connecting rod
on the crankpin.

CAUTION Front of engine

Be careful not to cause damage to the crankpin Installing piston assembly (3)
when putting the connecting rod on the
crankpin.

(14) Installing connecting rod cap

(a) Install the lower half of the connecting rod bearing
in the connecting rod cap. Make sure the tab on the
back of the bearing is in the notch of the
connecting rod cap. Apply engine oil to the inside
of the bearing.
(b) Install the connecting rod cap (with the bearing) to
the connecting rod (over the crankpin) with the
matching mark of the cap on the same side as the Apply engine oil.
mark of the rod.
Installing connecting rod cap (1)

(c) Tighten the connecting rod cap nuts finger tight.

NOTE
Steps (a) through (c) are for the installation of the
piston assemblies in the No.1 and No.4 cylinders.
Turn the crankshaft 180° and install the piston
assemblies in the No.2 and No.3 cylinders. Matching marks

Installing connecting rod cap (2)

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 ENGINE MAIN PARTS

(d) Tighten the connecting rod cap nuts evenly to the

specified torque with a torque wrench.

54 ± 5 N·m
Tightening torque (5.5 ± 0.5 kgf·m)
[40 ± 4 lbf·ft]

(e) Check the thrust clearance of the connecting rod

big-end. If the thrust clearance is less than the
assembly standard, retighten the cap nuts.

(15) Raising crankcase

Raise up the crankcase with the oil pan side up.

Raising crankcase

(16) Checking crankshaft rotation

Make sure the crankshaft rotates smoothly.

Checking crankshaft rotation

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