Honda WT30XK4 Manual Download Page 22

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3-1

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3. MAINTENANCE

MAINTENANCE SCHEDULE························3-2

ENGINE OIL LEVEL CHECK/CHANGE ·······3-3

AIR CLEANER
CHECK/CLEANING/REPLACEMENT ··········3-5

SEDIMENT CUP CLEANING ························3-6

SPARK PLUG
CHECK/ADJUSTMENT/REPLACEMENT ····3-7

SPARK ARRESTER CLEANING
(OPTIONAL PART) ·······································3-8

IDLE SPEED CHECK/ADJUSTMENT ··········3-9

VALVE CLEARANCE
CHECK/ADJUSTMENT ································ 3-9

COMBUSTION CHAMBER CLEANING ····· 3-11

FUEL TANK AND FILTER CLEANING ······ 3-11

FUEL TUBE CHECK ··································· 3-12

IMPELLER CHECK ····································· 3-12

IMPELLER CLEARANCE CHECK ············· 3-13

PUMP INLET VALVE CHECK ···················· 3-13

61YG1000.book 1 ページ２０１２年２月２０日　月曜日　午後２時４３分

Summary of Contents for WT30XK4

Page 1: ...opriate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the r...

Page 2: ...TION 2 MAINTENANCE 3 TROUBLESHOOTING 4 COVER 5 FUEL SYSTEM 6 GOVERNOR SYSTEM 7 IGNITION SYSTEM 8 STARTING SYSTEM 9 PUMP 10 ENGINE REMOVAL INSTALLATION 11 CYLINDER HEAD VALVES 12 CRANKCASE 13 MUFFLER 1...

Page 3: ...or possible to warn you about all the hazards associated with servicing these products You must use your own good judgement Honda Motor Co Ltd SERVICE PUBLICATION OFFICE Date of Issue February 2012 Y...

Page 4: ...ic tools when servicing this unit Metric bolts nuts and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the unit SYMBOLS The symbols used...

Page 5: ...tage Regulator EBT Engine Block Temperature ECT Engine Coolant Temperature ECM Engine Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground H...

Page 6: ...1 1 1 dummytext 1 SPECIFICATIONS SERIAL NUMBER LOCATION 1 2 SPECIFICATIONS 1 2 PERFORMANCE CURVES 1 4 DIMENSIONAL DRAWINGS 1 5 61YG1000 book 1...

Page 7: ...and when making technical inquiries SPECIFICATIONS DIMENSIONS AND WEIGHTS FRAME SERIAL NUMBER ENGINE SERIAL NUMBER Model WT30XK4 WT40XK3 Description code WAWJ WAYJ Type AC C Overall length 660 mm 26 0...

Page 8: ...m Ignition exciter coil circuit open Carburetor Horizontal type butterfly valve Air cleaner Dual type Governor Mechanical centrifugal Breather system Reed valve type Fuel tank capacity 5 3 liters 1 40...

Page 9: ...meters feet 30 5 100 24 4 80 18 3 60 12 2 40 6 1 20 0 0 50 189 100 378 150 568 200 757 250 946 300 1136 350 1324 400 1514 meters feet 30 5 100 24 4 80 18 3 60 12 2 40 6 1 20 0 0 75 284 150 568 225 85...

Page 10: ...SPECIFICATIONS 1 5 DIMENSIONAL DRAWINGS Unit mm in 660 26 0 WT30XK4 735 28 9 WT40XK3 515 20 3 WT30XK4 565 22 2 WT40XK3 495 19 5 WT30XK4 535 21 1 WT40XK3 61YG1000 book 5...

Page 11: ...MEMO 61YG1000 book 6...

Page 12: ...2 1 2 dummytext 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 4 LUBRICATION SEAL POINTS 2 5 TOOLS 2 6 HARNESS AND TUBE ROUTING 2 9 61YG1000 book 1...

Page 13: ...0 711 Big end side clearance 0 1 0 4 0 004 0 016 1 0 0 04 Big end I D 33 025 33 039 1 3002 1 3007 33 07 1 302 Big end oil clearance 0 040 0 064 0 0016 0 0025 0 12 0 005 Crankshaft Crank pin O D 32 975...

Page 14: ...rance 0 1 0 4 0 004 0 016 1 0 0 04 Big end I D 36 025 36 039 1 4183 1 4189 36 07 1 420 Big end oil clearance 0 040 0 064 0 0016 0 0025 0 12 0 005 Crankshaft Crank pin O D 35 975 35 985 1 4163 1 4167 3...

Page 15: ...x 1 06 0 45 0 046 0 33 Recoil starter center screw M5 x 0 8 Special bolt 3 9 0 4 35 Sediment cup M24 x 1 0 3 9 0 4 35 Item Tread Dia mm Torque values N m kgf m lbf ft Front cover bolt setting bolt 12...

Page 16: ...haft journal Flywheel nut threads and seating surface Cylinder head bolt threads and seating surface Balancer shaft bearing and gear WT40XK3 GX390T2 Oil seal lips Multi purpose grease O ring Recoil st...

Page 17: ...01 0010000 Remover weight 07936 371020A Attachment 32 x 35 mm 07746 0010100 Attachment 52 x 55 mm 07746 0010400 Attachment 72 x 75 mm 07746 0010600 Driver 40 mm I D 07746 0030100 Attachment 30 mm I D...

Page 18: ...emover head 15 07936 KC10200 Valve guide driver 6 0 11 5 mm 07942 6570100 Attachment 45 x 50 mm 07946 6920100 Attachment 62 x 64 mm 07947 6340400 Valve guide reamer 6 612 mm 07984 ZE2000D Puller colla...

Page 19: ...7 30 AM until 7 00 PM CT Monday through Friday Tool name Tool number Application Digital multimeter FLU88 Electrical testing Valve seat cutter 30 x 45 degree NWYCU128 Valve seat reconditioning Valve s...

Page 20: ...e stop switch To ignition coil To oil level switch YELLOW YELLOW RED BLACK BLACK RED INSIDE HARNESS CLIP ENGINE STOP SWITCH CORD ENGINE WIRE HARNESS OIL LEVEL SWITCH OIL LEVEL SWITCH CORD ENGINE STOP...

Page 21: ...S CYLINDER BARREL RIB HIGH TENSION CORD CARBURETOR INSULATOR IGNITION COIL CONTROL BASE GOVERNOR ARM CONTROL BASE HIGH TENSION CORD BREATHER TUBE TUBE CLAMP 2 FUEL TUBE 2 4 mm 0 1 0 2 in 2 4 mm 0 1 0...

Page 22: ...ANING 3 6 SPARK PLUG CHECK ADJUSTMENT REPLACEMENT 3 7 SPARK ARRESTER CLEANING OPTIONAL PART 3 8 IDLE SPEED CHECK ADJUSTMENT 3 9 VALVE CLEARANCE CHECK ADJUSTMENT 3 9 COMBUSTION CHAMBER CLEANING 3 11 FU...

Page 23: ...o page Each use After use First month or 20 hrs Every 3 months or 50 hrs Every 6 months or 100 hrs Every year or 300 hrs Engine oil Check Level 3 3 Change 3 4 Air cleaner Check 3 5 Clean 1 3 5 Replace...

Page 24: ...oil level shown on the oil level gauge If the oil level is low fill with recommended oil to the upper level 4 of the oil filler neck SAE 10W 30 is recommended for general use Other viscosities shown...

Page 25: ...led container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or pour it down a drain Install a new drain plug washer and tighten t...

Page 26: ...over 2 Remove the wing nut 3 and air filter assembly 4 5 Separate the inner filter Paper 4 from the outer filter Foam 5 Carefully check both filters for holes or tears and replace if damaged Clean the...

Page 27: ...O ring 3 Remove the cup filter 4 while releasing the tabs 5 Clean the sediment cup and the cup filter with non flammable solvent and allow them to dry thoroughly Install the cup filter in the directio...

Page 28: ...er gauge If the measurement is out of the specification adjust by bending the side electrode Install a new spark plug finger tight to seat the washer and then tighten it to the specified torque A loos...

Page 29: ...ONAL PART Remove the 5 x 8 mm tapping screws 1 R muffler protector 2 and L muffler protector 3 WT30XK4 Remove the 4 x 6 mm tapping screw 4 and spark arrester 5 WT40XK3 Remove the 5 x 8 mm tapping scre...

Page 30: ...are installed correctly page 7 4 Use a tachometer with graduations of 50 min 1 rpm or smaller that will accurately indicate 50 min 1 rpm change Fill the pump housing with water before starting Start...

Page 31: ...lve clearance If adjustment is necessary proceed as follows Hold the rocker arm pivot bolt 1 and loosen the rocker arm pivot lock nut 2 Turn the rocker arm pivot to obtain the specified clearance Hold...

Page 32: ...and allow them to dry thoroughly Check the screen of the fuel tank joint for clogs or damage replace if necessary Install a new O ring to the fuel tank joint and install them to the fuel tank Tighten...

Page 33: ...emove the front cover 1 page 10 3 Check the impeller 2 for damage or contamination and replace if necessary Gasoline is highly flammable and explosive You can be burned or seriously injured when handl...

Page 34: ...t adjust clearance by adding or removing adjuster shims page 10 4 PUMP INLET VALVE CHECK Remove the bolts 1 and inlet 2 Check the pump inlet valve 3 for damage or contamination and replace if necessar...

Page 35: ...MEMO 61YG1000 book 14...

Page 36: ...4 1 4 dummytext 4 TROUBLESHOOTING BEFORE TROUBLESHOOTING 4 2 ENGINE TROUBLESHOOTING 4 2 WATER PUMP TROUBLESHOOTING 4 6 61YG1000 book 1...

Page 37: ...check the pump for any foreign material that is preventing the pump from turning Cannot be rotated Abnormal Rotates Inspect the recoil starter page 9 6 Disassemble the cylinder barrel and replace the...

Page 38: ...nder and rings for wear If the test reveals leakage out the intake port inspect the intake valve for proper sealing If the test reveals leakage out the exhaust port inspect the exhaust valve for prope...

Page 39: ...carburetor and refill with fresh fuel Normal operation Advise customer to only use fresh fuel RPM stabilizes Remove and clean carburetor Replace intake gaskets when reinstalling Inform the customer of...

Page 40: ...il if abnormalities are found and recheck Abnormal Normal Continuity No continuity Replace the engine stop switch page 5 2 Check the engine stop switch page 8 9 Check the wire harness connecting the o...

Page 41: ...inlet valve damaged Cracked pump housing Leaking drain or fill plugs Low vacuum Vacuum normal Perform vacuum test page 10 7 Check customer s system and usage Air leak in suction hose and or fitting Su...

Page 42: ...5 1 5 dummytext 5 COVER FAN COVER REMOVAL INSTALLATION 5 2 61YG1000 book 1...

Page 43: ...op switch connector When installing refer to the HARNESS ROUTING page 2 9 ENGINE STOP SWITCH TUBE CLIP BOLT 6 x 12 mm 5 REMOVAL The fan cover can be removed with the recoil starter assembly installed...

Page 44: ...3 AIR CLEANER REMOVAL INSTALLATION 6 5 CARBURETOR REMOVAL INSTALLATION 6 6 CARBURETOR DISASSEMBLY ASSEMBLY 6 7 CARBURETOR BODY CLEANING 6 8 CARBURETOR INSPECTION 6 8 PILOT SCREW REPLACEMENT 6 9 CHOKE...

Page 45: ...FUEL SYSTEM 6 2 FUEL SYSTEM TOOLS Float level gauge 07401 0010000 Jet cleaner set 07JPZ 001010B 61YG1000 book 2...

Page 46: ...INT TUBE CLAMP FUEL TUBE 24 N m 2 4 kgf m 18 lbf ft FUEL FILLER CAP PACKING INSTALLATION Before installing check for deterioration or cracks FUEL TANK 2 N m 0 2 kgf m 18 lbf in INSTALLATION Before ins...

Page 47: ...er cap Before installing check the air vent hole of the fuel filler cap for clogs If necessary clean it using low pressure compressed air Install the fuel filter holder into the fuel filler neck and a...

Page 48: ...clean the inside of the air cleaner elbow Viewed from air cleaner side INSTALLATION Before installing check for damage Note the installation direction AIR CLEANER ELEMENT PAPER WING NUT BREATHER TUBE...

Page 49: ...ALLATION Before installing clean the carburetor bowl vent passage thoroughly with compressed air Install the carburetor insulator with the vent groove facing toward the carburetor After installing cla...

Page 50: ...FLOAT PIN ASSEMBLY Before installing clean thoroughly with a jet cleaning tool carburetor cleaner and low pressure compressed air Lightly lubricate the O ring to ensure easy installation into the carb...

Page 51: ...ressed air Pilot screw hole 1 Pilot jet hole 2 Pilot air jet 3 Main air jet 4 Transition ports 5 Pilot outlet 6 Main nozzle holder 7 External vent port 8 Internal vent port 9 CARBURETOR INSPECTION FLO...

Page 52: ...the broken pilot screw Place the spring on the replacement pilot screw and install it on the carburetor Turn the pilot screw in until it is lightly seated and then turn the screw out the required num...

Page 53: ...4 of the choke valve plate Operate the choke lever 5 and check for proper choke plate operation CYLINDER STUD BOLT REPLACEMENT Thread two nuts onto the stud bolt and tighten them together and then us...

Page 54: ...7 1 7 dummytext 7 GOVERNOR SYSTEM GOVERNOR ARM CONTROL BASE REMOVAL INSTALLATION 7 2 CONTROL BASE DISASSEMBLY ASSEMBLY 7 3 MAXIMUM SPEED ADJUSTMENT 7 4 61YG1000 book 1...

Page 55: ...ne to a point where the groove 2 of the throttle arm lines up with the governor rod 3 and then lift the governor rod out of the hole of the throttle arm and unhook the throttle return spring 4 GOVERNO...

Page 56: ...ote the installation direction CONTROL LEVER WASHER ASSEMBLY Install the control lever washer by aligning the cutout of the control lever washer with the tab of the control base CONTROL LEVER SPACER C...

Page 57: ...rm moved to open the throttle valve Tighten the 6 mm nut securely Install the fuel tank page 6 3 Start the engine and allow it to warm up to normal operating temperature Make sure the pump is full of...

Page 58: ...N SYSTEM TROUBLESHOOTING 8 3 COOLING FAN FLYWHEEL REMOVAL INSTALLATION 8 4 IGNITION COIL REMOVAL INSTALLATION 8 6 SPARK TEST 8 7 SPARK PLUG CAP INSPECTION 8 7 IGNITION COIL INSPECTION 8 8 OIL LEVEL SW...

Page 59: ...IGNITION SYSTEM 8 2 IGNITION SYSTEM TOOL Puller collar set 07APC ZY1A100 61YG1000 book 2...

Page 60: ...NGINE STOP SWITCH Replace the engine stop switch page 5 2 Check the harness connecting the ignition coil and the engine stop switch for open or short circuit and for proper connection No continuity No...

Page 61: ...ap wrench and use the special tool to remove the flywheel Do not hit the flywheel with a hammer REMOVAL Hold the flywheel with a commercially available strap wrench and remove the 16 mm nut Take care...

Page 62: ...ng fan 1 to the flywheel 2 by aligning the three projections of the cooling fan with the holes of the flywheel Attach the starter pulley 3 by aligning the hole of the pulley with the projection at the...

Page 63: ...page 5 2 ENGINE WIRE HARNESS INSTALLATION Clamp the engine wire harness to the ribs of the cylinder barrel as shown ENGINE WIRE HARNESS Viewed from above RIB IGNITION COIL BOLT 6 x 28 mm 2 INSTALLATI...

Page 64: ...ndary voltage Loose ignition coil connector Disconnect the spark plug cap from the spark plug Connect a known good spark plug to the spark plug cap and ground the spark plug to the cylinder head Crank...

Page 65: ...ise the correct resistance value cannot be obtained Use an analog tester that is equivalent to or higher than the performance specified internal resistance 20 k V DC 9 k V AC Read the tester manufactu...

Page 66: ...ere should be continuity Check continuity between the switch terminals while filling the engine oil The ohmmeter reading should go from continuity to no continuity as the oil is filled If the correct...

Page 67: ...MEMO 61YG1000 book 10...

Page 68: ...9 1 9 dummytext 9 STARTING SYSTEM RECOIL STARTER REMOVAL INSTALLATION 9 2 RECOIL STARTER DISASSEMBLY ASSEMBLY 9 3 RECOIL STARTER INSPECTION 9 6 61YG1000 book 1...

Page 69: ...STARTING SYSTEM 9 2 STARTING SYSTEM RECOIL STARTER REMOVAL INSTALLATION BOLT 6 x 10 mm RECOIL STARTER 61YG1000 book 2...

Page 70: ...protection During disassembly assembly take care not to allow the return spring to come out CENTER SCREW SPRING RETAINER FRICTION SPRING RATCHET 2 RATCHET SPRING 2 RECOIL STARTER PULLEY RECOIL STARTER...

Page 71: ...e starter return spring 2 to the groove 3 of the recoil starter pulley 4 and then install the starter return spring by winding it Apply grease to the cutout 1 of the recoil starter case 2 Set the reco...

Page 72: ...or equivalent to the threads of the center screw 3 Hold the spring retainer and tighten the center screw to the specified torque Turn the recoil starter pulley 1 more than 2 turns counterclockwise to...

Page 73: ...er page 9 2 Pull the starter grip several times to inspect that the ratchets 1 are operated properly the ratchet ends come out from the spring retainer 2 STARTER PULLEY Remove the recoil starter page...

Page 74: ...dummytext 10 PUMP TOOL 10 2 FRONT COVER REMOVAL INSTALLATION 10 3 CASING REMOVAL INSTALLATION 10 4 FRONT COVER DISASSEMBLY ASSEMBLY 10 5 CASING DISASSEMBLY ASSEMBLY 10 6 PUMP VACUUM TEST 10 7 61YG1000...

Page 75: ...PUMP 10 2 PUMP TOOL Vacuum gauge 07APJ YB3A100 61YG1000 book 2...

Page 76: ...ally available FRONT COVER FRONT COVER PACKING HOSE COUPLING HOSE CLAMP RING HOSE BAND 2 STRAINER HOSE COUPLING PACKING CHECK Replace if necessary CHECK Replace if necessary FRONT COVER KNOB 4 43 N m...

Page 77: ...by giving it a shock using a wooden stick 2 and hammer as shown taking care not to damage the impeller INSTALLATION Tighten the impeller by hand The impeller will further self tighten when the pump is...

Page 78: ...25 mm PLUG 25 mm VOLUTE CASE BOLT WT30XK4 6 x 16 mm 3 WT40XK3 6 x 20 mm 3 WASHER 6 mm 3 O RING CHECK Replace if necessary WEAR PLATE WASHER 8 mm 3 BOLT 8 x 35 mm 3 13 N m 1 3 kgf m 10 lbf ft WT40XK3 1...

Page 79: ...tallation BOTTOM RUBBER WT30XK4 2 FRONT COVER KNOB 4 FRONT COVER BOLT 4 FRONT COVER WASHER 4 PLUG 25 mm O RING 25 mm CHECK Replace if necessary BOLT 10 x 30 mm 4 BOLT WT30XK4 12 x 45 mm 2 WT40XK3 12 x...

Page 80: ...engine and confirm the vacuum gauge reading remains steady This verifies the intake flapper is sealing RESULTS 1 If the vacuum gauge won t remain steady after shutting off the engine disassemble and...

Page 81: ...MEMO 61YG1000 book 8...

Page 82: ...11 1 11 dummytext 11 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL INSTALLATION 11 2 61YG1000 book 1...

Page 83: ...TALLATION Remove the casing page 10 4 NUT 10 mm 2 BOTTOM RUBBER 2 FRAME NUT 8 mm 2 BOLT WT30XK4 10 x 35 mm 2 WT40XK3 10 x 40 mm 2 INSTALLATION Check for cracking deformation or other damage before ins...

Page 84: ...ALVES TOOLS 12 2 CYLINDER HEAD REMOVAL INSTALLATION 12 3 CYLINDER HEAD DISASSEMBLY ASSEMBLY 12 4 CYLINDER HEAD VALVES INSPECTION 12 5 VALVE GUIDE REPLACEMENT 12 8 VALVE GUIDE REAMING 12 9 VALVE SEAT R...

Page 85: ...CYLINDER HEAD VALVES 12 2 CYLINDER HEAD VALVES TOOLS Valve guide driver 6 0 11 5 mm 07942 6570100 Valve guide reamer 6 612 mm 07984 ZE2000D 61YG1000 book 2...

Page 86: ...HEAD COVER HEAD COVER PACKING BOLT 10 x 80 mm 4 Threads and seating surface HEAD COVER BOLT INSTALLATION Before installing the cylinder head remove any carbon deposits from the combustion chamber and...

Page 87: ...E SPARK PLUG CYLINDER HEAD INTAKE VALVE GUIDE BOLT 6 x 12 mm SHROUD VALVE SPRING 2 PUSH ROD 2 PUSH ROD GUIDE PLATE VALVE STEM SEAL ASSEMBLY Before installing the push rods check the ends of the push r...

Page 88: ...the cylinder head page 12 4 VALVE SEAT WIDTH Remove the carbon deposits from the combustion chamber Inspect each valve for face irregularities If necessary replace the valve page 12 4 Apply a light co...

Page 89: ...ile removing it from the valve guide Measure and record each valve guide I D If the measured valve guide I D is more than the service limit replace the valve guide page 12 8 VALVE FACE Inspect each va...

Page 90: ...d clearance is more than the service limit replace the following Valves page 12 4 Valve guide page 12 8 VALVE SPRING FREE LENGTH Measure the valve spring free length If the measured length is less tha...

Page 91: ...REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour Use a hot plate or oven to heat the cylinder head evenly to 150 C 300 F Do not use a torch to...

Page 92: ...temperature Ream the valve guide VALVE GUIDE REAMING For best results be sure the cylinder head is at room temperature before reaming valve guides Coat the reamer and valve guide with cutting oil Rota...

Page 93: ...the valve and snap it closed against its seat several times Be sure the valve does not rotate on the seat The transferred marking compound will show any area of the seat that is not concentric Measur...

Page 94: ...ves into their seats using a commercially available valve lapper and lapping compound After lapping wash all residual compound off the cylinder head and valve Do not push the valve against the seat wi...

Page 95: ...MEMO 61YG1000 book 12...

Page 96: ...OR DISASSEMBLY ASSEMBLY 13 7 PISTON DISASSEMBLY ASSEMBLY 13 8 CRANKCASE COVER CYLINDER BARREL PISTON CONNECTING ROD CRANKSHAFT CAMSHAFT INSPECTION 13 9 CRANKSHAFT BALANCER WEIGHT BEARING OIL SEAL REPL...

Page 97: ...t 52 x 55 mm 07746 0010400 Attachment 72 x 75 mm 07746 0010600 Driver 40 mm I D 07746 0030100 Attachment 30 mm I D 07746 0030300 Attachment 35 mm I D 07746 0030400 Pilot 15 mm 07746 0040300 Pilot 30 m...

Page 98: ...CRANKCASE 13 3 Bearing remover shaft 15 07936 KC10100 Bearing remover head 15 07936 KC10200 Attachment 45 x 50 mm 07946 6920100 Attachment 62 x 64 mm 07947 6340400 61YG1000 book 3...

Page 99: ...sing page 10 4 Position the engine at TDC of the compression stroke before removing the cover page 3 9 DOWEL PIN 8 x 12 mm 2 CASE COVER PACKING CRANKCASE COVER OIL FILLER CAP OIL FILLER CAP PACKING 2...

Page 100: ...ing rod lower with the oil dipper toward the camshaft INSTALLATION Before installing the crankshaft check the oil seal of the cylinder barrel for damage or hardening Be careful not to damage the oil s...

Page 101: ...o the cylinder barrel by aligning the punch marks 2 of the balancer weight and the crankshaft 3 marked on the balancer drive gear 4 CAMSHAFT INSTALLATION Install the camshaft 1 to the cylinder barrel...

Page 102: ...eight to install the governor slider After installing the governor slider check to be sure it moves smoothly GOVERNOR WEIGHT HOLDER GROOVE GOVERNOR WEIGHT PIN WT30XK4 2 WT40XK3 3 GOVERNOR WEIGHT WT30X...

Page 103: ...ring and second ring are not interchanged Install the top ring and second ring on the piston with the maker mark side facing up Check that the piston rings rotate smoothly after installing them Space...

Page 104: ...th this inspection page 13 15 CYLINDER SLEEVE I D Measure and record the cylinder I D at three levels in both the X axis perpendicular to crankshaft and the Y axis parallel to crankshaft Take the maxi...

Page 105: ...rance is still more than the service limit with the new piston replace the cylinder barrel page 13 5 PISTON PIN BORE I D Measure and record the piston pin bore I D of the piston If the measurement is...

Page 106: ...piston page 13 8 PISTON RING SIDE CLEARANCE Measure the clearance between each piston ring and ring groove of the piston using a feeler gauge If any of the measurements is more than the service limit...

Page 107: ...e clearance between the connecting rod big end and crankshaft using a feeler gauge If the measurement is more than the service limit replace the connecting rod page 13 8 and recheck the clearance If t...

Page 108: ...he crank pin O D of the crankshaft If the measurement is less than the service limit replace the crankshaft page 13 5 WT30XK4 STANDARD 18 005 18 020 mm 0 7089 0 7094 in SERVICE LIMIT 18 07 mm 0 711 in...

Page 109: ...If the clearance is more than the service limit inspect the connecting rod big end I D and the crank pin O D page 13 13 If necessary replace the part that is not within the service limit and reinspec...

Page 110: ...ves smoothly If the decompressor weight does not move correctly replace the camshaft page 13 5 WT30XK4 STANDARD IN 31 895 32 195 mm 1 2557 1 2675 in EX 31 616 31 916 mm 1 2447 1 2565 in SERVICE LIMIT...

Page 111: ...bearing with your finger and check for play Replace the radial ball bearing if it is noisy or has excessive play CRANKSHAFT BALANCER WEIGHT BEARING OIL SEAL REPLACEMENT CRANKCASE COVER SIDE LOCATION B...

Page 112: ...of a new oil seal 1 Drive the oil seal in the position as shown using the special tools WT30XK4 6206 TOOLS Attachment 62 x 64 mm 2 07947 6340400 Pilot 30 mm 3 07746 0040700 Driver 4 07749 0010000 WT4...

Page 113: ...ew bearing 5 Drive the radial ball bearing until it is fully seated on the end using the special tools TOOLS Bearing remover head 15 mm 2 07936 KC10200 Bearing remover shaft 15 mm 3 07936 KC10100 Remo...

Page 114: ...out the radial ball bearing 2 using a commercially available bearing puller 3 Drive the new radial ball bearing 4 until it is fully seated on the end using the special tools and hydraulic press WT30X...

Page 115: ...al 1 Drive the oil seal in the position as shown using the special tools CRANKSHAFT OIL SEAL WT30XK4 30 x 46 x 8 mm WT40XK3 35 x 52 x 8 mm BALANCER WEIGHT BEARING 6202 WT40XK3 only GOVERNOR ARM SHAFT...

Page 116: ...NLY Remove the oil seal from the cylinder barrel Apply grease to the lip of a new oil seal 1 Drive the oil seal in the position as shown using the special tools TOOLS Bearing remover head 15 mm 2 0793...

Page 117: ...MEMO 61YG1000 book 22...

Page 118: ...14 1 14 dummytext 14 MUFFLER MUFFLER REMOVAL INSTALLATION 14 2 EXHAUST PIPE STUD BOLT REPLACEMENT 14 3 61YG1000 book 1...

Page 119: ...proceeding WT40XK3 only 24 N m 2 4 kgf m 18 lbf ft 24 N m 2 4 kgf m 18 lbf ft MUFFLER GASKET R MUFFLER PROTECTOR L MUFFLER PROTECTOR SCREW 5 x 8 mm 6 NUT 8 mm 3 NUT 8 mm 2 EXHAUST PIPE SCREW 5 x 8 mm...

Page 120: ...EMENT Thread two nuts onto the exhaust pipe stud bolt 1 and tighten them together then use a wrench to turn the stud bolt out Install new stud bolts SPECIFIED LENGTH STUD BOLT 8 x 48 32 mm 1 26 in SHO...

Page 121: ...MEMO 61YG1000 book 4...

Page 122: ...15 1 15 dummytext 15 WIRING DIAGRAM WIRING DIAGRAM 15 2 61YG1000 book 1...

Page 123: ...D OIL_ALT EXT EXT R Bl R Bl Y Y IGNITION COIL SPARK PLUG OIL LEVEL SWITCH ENGINE STOP SWITCH Bl Black Y Yellow Bu Blue G Green R Red W White Br Brown O Orange Lb Light blue Lg Light green P Pink Gr Gr...

Page 124: ...STALLATION 5 2 FRONT COVER DISASSEMBLY ASSEMBLY 10 5 FRONT COVER REMOVAL INSTALLATION 10 3 FUEL TANK AND FILTER CLEANING 3 11 FUEL TANK REMOVAL INSTALLATION 6 3 FUEL TUBE CHECK 3 12 G GOVERNOR ARM CON...

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