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(6) Warning Buzzer and Lamp (LED),
and Control of Engine Revolution
Speed .......................................... 4-24
1) Location of Warning Buzzer and
Lamp (LED) .................................... 4-24
2) Waring Notification, Abnormality and
Action to be taken ........................... 4-24
5. Ignition System .............................. 4-25
(1) Configuration of Ignition System ... 4-25
(2) Ignition Control ........................... 4-26
1) Ignition Timing Control ..................... 4-26
2) Ignition and Combustion Order ............ 4-26
3) Ignition Timing ................................. 4-26
4) Operations ....................................... 4-26
(3) Fuel Feed System ........................ 4-27
6. Components of Fuel Feed System ... 4-28
1) Fuel Pump
[Low Pressure Mechanical Pump] ......... 4-28
2) Vapor Separator .............................. 4-28
3) Fuel Regulator ................................. 4-29
4) Fuel Cooler .................................... 4-29
7. Outline of Fuel Injection System ... 4-30
1) Air Intake System .............................. 4-30
8. Inspection Items .............................. 4-31
1) Inspection of Fuel Supply System ......... 4-31
2) Inspection of Filter ........................... 4-31
3) Inspection of Fuel Pump ..................... 4-33
4) Inspection of Fuel Connector ............... 4-33
5) Measurement of Fuel Pressure ............ 4-34
6) Draining Fuel ................................. 4-35
7) Disassembly of Vapor Separator ......... 4-36
8) Inspection of Vapor Separator ............ 4-37
9) Reassembly of Vapor Separator ......... 4-37
10) Inspection of ISC (Idle Speed Control) ... 4-38
11) Inspection of Idle Speed ..................... 4-38
5. Power Unit
1. Special Tools .................................... 5-2
2. Parts Layout .................................... 5-3
Engine ................................................ 5-3
Magneto ............................................. 5-4
Intake Manifold .................................... 5-6
Fuel System ....................................... 5-8
Electrical Parts .................................... 5-12
Pulley & Timing Belt .............................. 5-16
Cylinder Head & Oil Pump ..................... 5-18
Cylinder & Crankcase ........................... 5-22
Piston & Crankshaft .............................. 5-24
Top Cowl ............................................. 5-26
Recoil Starter ....................................... 5-28
3. Inspection Items .............................. 5-30
1) Inspection of Compression Pressure ... 5-30
2) Inspection of Oil Pressure .................. 5-30
3) Inspection of Valve Clearance ............ 5-31
4) Removal of Power Unit ..................... 5-31
5) Removal of Oil Strainer ..................... 5-34
6) Inspection of Oil Strainer .................. 5-34
7) Removal of Flywheel ........................ 5-35
8) Installation of Flywheel ..................... 5-37
9) Removal of Timing Belt and Pulley ...... 5-39
10) Inspection of Timing Belt ..................... 5-40
11) Installation of Pulley and Timing Belt ...... 5-41
vi
12) Removal of Air Intake System &
Fuel System .................................... 5-43
13) Removal of Electrical System Parts ...... 5-46
14) Removal of Cylinder Head Assy ......... 5-49
15) Disassembly of Cylinder Head Assy ...... 5-50
16) Inspection of Valve Spring .................. 5-51
17) Inspection of Valve ........................... 5-52
18) Inspection of Valve Guide .................. 5-52
19) Inspection of Valve Seat ..................... 5-53
20) Correction of Valve Seat ..................... 5-54
21) Inspection of Rocker Arm and
Rocker Arm Shaft .............................. 5-56
22) Inspection of Camshaft ..................... 5-57
23) Inspection of Cylinder Head ............... 5-58
24) Inspection of Oil Pump ..................... 5-59
25) Installation of Valve ........................... 5-60
26) Installation of Camshaft ..................... 5-61
27) Installation of Rocker Arm Shaft ......... 5-61
28) Installation of Oil Pump ..................... 5-62
29) Installation of Cylinder Head Assy ......... 5-63
30) Disassembly of Cylinder Block ............ 5-65
31) Inspection of Cylinder Block ............... 5-66
32) Inspection of Piston Outer Diameter ...... 5-67
33) Inspection of Cylinder Inner Diameter ...... 5-67
34) Inspection of Piston Clearance ............ 5-68
35) Inspection of Piston Ring Side Clearance ... 5-68
36) Inspection of Piston Rings .................. 5-68
37) Inspection of Piston Pins .................. 5-69
38) Inspection of Connecting Rod Small End
Inner Diameter ................................. 5-69
39) Inspection of Connecting Rod Big End
Side Clearance ................................. 5-69
40) Inspection of Crankshaft ..................... 5-70
41) Inspection of Crank Pin Oil Clearance ...... 5-71
42) Inspection of Crankshaft Main Journal
Oil Clearance ................................. 5-72
43) Inner Diameter of Cylinder/Crankcase
Bearing Holder (Inner Diameter Codes) ... 5-73
44) Thickness of Metal Bearing
(Color of Inner Diameter Code) ............ 5-73
45) Installation of Piston and Connecting Rod ... 5-74
46) Assembly of Cylinder Block ............... 5-76
47) Installation of Electrical System Parts ......... 5-78
48) Installation of Air Intake System &
Fuel System .................................... 5-81
49) Installation of Oil Strainer .................. 5-84
50) Installing the Power Unit ..................... 5-84
51) Removal of Recoil Starter .................. 5-88
52) Disassembly of Recoil Starter ............ 5-88
53) Inspection of Recoil Starter ............... 5-89
54) Installation of Recoil Starter ............... 5-90
6. Lower Unit
1. Special Tools .................................... 6-2
2. Parts Layout .................................... 6-4
Gear Case (Drive Shaft) ........................ 6-4
Gear Case (Propeller Shaft) ..................... 6-8
3. Inspection Items .............................. 6-10
1) Draining Gear Oil .............................. 6-10
2) Removal of Propeller ........................ 6-10
3) Removal of Lower Unit ..................... 6-11
4) Removal of Water Pump and Cam Rod ... 6-12
5) Inspection of Water Pump .................. 6-13
4st 25/30 2022
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