Table of Contents
Advertisement
(Engine Serial Number) .................. 1-2
2. Work Safety .................................... 1-2
1) Fire Prevention ................................. 1-2
2) Ventilation ....................................... 1-2
3) Protection ....................................... 1-2
4) Genuine Parts ................................. 1-2
5) Tools ............................................. 1-3
6) Recommendations on Service ............ 1-3
Assembling Components ..................... 1-4
3. Tools and Instruments ..................... 1-5
1) Test Propeller .................................... 1-5
2) Instruments ....................................... 1-5
3) Special Tools .................................... 1-6
4. Pre-delivery Inspection .................. 1-8
1) Steering Handle ................................. 1-8
2) Gear Shift ....................................... 1-8
3) Engine Oil ....................................... 1-8
4) Gear Oil .......................................... 1-8
5) Fuel Tank Line ................................. 1-9
6) Rigging .......................................... 1-9
7) Inspection of Tilt Stopper ..................... 1-9
8) Inspection of Stop Switch ..................... 1-10
9) Cooling Water Check Port .................. 1-10
10) Idle Operation.................................... 1-10
11) Propeller Selection ........................... 1-11
12) Inspection of Forward and Reverse Shifts ......... 1-11
5. Break-in Operation ........................... 1-12
6. Test Run .......................................... 1-12
7. Checks After Test Run ..................... 1-13
1. Outline Dimensions ........................ 2-2
1) Engine Dimensions ........................... 2-2
2) Clamp Dimensions ........................... 2-4
Diagram .......................................... 2-5
Specifications ................................. 2-6
5. Maintenance Data ........................... 2-10
6. Tightening Torque Specifications ... 2-14
7. Sealant and Lubricant ..................... 2-15
1. Special Tools .................................... 3-2
2. Inspection Schedule ........................ 3-3
3. Inspection Items .............................. 3-4
1) Inspection of Top Cowl ........................ 3-4
2) Fuel System .................................... 3-4
3) Inspection of Fuel Tank ........................ 3-5
4) Inspection of Fuel Filter ..................... 3-5
5) Replacement of Engine Oil .................. 3-6
6) Inspection of Gear Oil Quantity ............ 3-7
7) Inspection of Water Pump .................. 3-7
8) Replacement of Gear Oil ..................... 3-9
9) Inspection of Gear Case (for leakage) ...... 3-10
10) Inspection of Spark Plug ..................... 3-11
11) Inspection of Compression Pressure ...... 3-12
Valve Clearance ................................. 3-13
13) Throttle Cable.................................... 3-15
14) Inspection of Idle Engine Speed ............ 3-17
15) Inspection of Ignition Timing ............... 3-17
4st 4/5/6 2020
16) Inspection of Anode ........................... 3-18
17) Replacement of Anode ........................ 3-18
18) Inspection of Propeller ........................ 3-19
19) Inspection of Thermostat ..................... 3-19
20) Inspection of Cooling Water Passage ...... 3-20
21) Flushing with Water ........................... 3-21
22) Greasing Points ................................. 3-22
1. Special Tools .................................... 4-2
2. Parts Layout .................................... 4-3
Fuel Tank ............................................. 4-3
Carburetor • Fuel Pump........................... 4-4
Integral Fuel Tank ................................. 4-6
3. Carburetor Inner Passages ............ 4-8
1) Idling Passage ................................. 4-8
2) Off-Idle Passage .............................. 4-9
3) High Speed Passage ........................ 4-10
4) Choking Passage .............................. 4-11
4. Inspection Items .............................. 4-12
2) Draining Fuel .................................... 4-12
Fuel Tank Cap ................................. 4-13
4) Inspection of Fuel Cock ..................... 4-13
5) Inspection of Fuel Filter ..................... 4-13
6) Removing Carburetor ........................ 4-15
7) Disassembling Carburetor .................. 4-16
8) Inspection and clean of Carburetor ...... 4-17
9) Inspection of Fuel Connector ............... 4-18
10) Assembling of Carburetor .................. 4-18
11) Adjustment of Float Height .................. 4-19
12) Installing Carburetor ........................... 4-19
13) Removing Fuel Pump ........................ 4-20
Fuel Pump ....................................... 4-20
15) Assembly of Fuel Pump ..................... 4-21
1. Special Tools .................................... 5-2
2. Parts Layout .................................... 5-3
Engine ................................................ 5-3
Magneto ............................................. 5-4
Cylinder & Oil Pan ................................. 5-6
Cylinder Head & Valve & Camshaft ............ 5-10
Piston & Crankshaft .............................. 5-12
Recoil Starter ....................................... 5-13
Top Cowl ............................................. 5-14
3. Inspection Items .............................. 5-15
1) Inspection of Compression Pressure ...... 5-15
2) Inspection of Valve Clearance ............... 5-16
3) Removing Power Unit ........................ 5-18
Crank Case Head .............................. 5-19
5) Inspection of Crank Case Head ............ 5-20
6) Assembly of Crank Case Head ............ 5-20
7) Installation of Crank Case Head ............ 5-21
8) Disassembly of Power Unit .................. 5-21
9) Removal of Rocker Arm ..................... 5-24
10) Removing Cylinder Head ..................... 5-25
11) Inspection of Rocker Arm and Pivot ...... 5-25
12) Inspection of Push Rod Plate ............... 5-26
13) Inspection of Push Rod ..................... 5-26
Oil Pump .......................................... 5-26
v
Advertisement
Table of Contents
