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Honda WX15T, Manual

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Honda WX15T Manual Download Page 84

11-9

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CRANKCASE

CAMSHAFT 
DISASSEMBLY/ASSEMBLY

CRANKSHAFT/CAMSHAFT 
ASSEMBLY(TIMING ALIGNMENT)

Install the camshaft [1] assy. by aligning the alignment
mark [2] on the camshaft assy. with the timing mark [3]
on the crankshaft [4].

VALVE LIFTER (2)

CYLINDER BARREL

VALVE LIFTER COLLAR

CAMSHAFT

ASSEMBLY:
Be careful not to drop 
the camshaft.

CAMSHAFT ROLLER (5 x 29.8 mm) 

 (

Gear teeth, journal, cam

profile, and decomper shaft

)

 (

Journal and slipper surface

)

VALVE LIFTER ROLLER

 (

Whole surface

)

[1]

[4]

[2]

[3]

Summary of Contents for WX15T

Page 1: ...ing appropriate 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 too...

Page 2: ...ad SPECIFICATIONS 1 SERVICE INFORMATION 2 MAINTENANCE 3 TROUBLESHOOTING 4 FUEL SYSTEM 5 CONTROL SYSTEM 6 IGNITION SYSTEM 7 STARTING SYSTEM 8 PUMP 9 ENGINE REMOVAL INSTALLATION 10 CRANKCASE 11 CYLINDER...

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

Page 4: ...hole Use only metric 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...

Page 5: ...R Digital Auto Voltage 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 Fo...

Page 6: ...1 1 1 dummytext 1 SPECIFICATIONS SERIAL NUMBER LOCATION 1 2 SPECIFICATIONS 2 3 PERFORMANCE CURVES 2 4 TOOLS 2 5 DIMENSIONAL DRAWINGS 2 6...

Page 7: ...me serial number 2 is located on the frame Refer to these numbers when ordering parts and when making technical inquiries SPECIFICATIONS DIMENSIONS AND WEIGHTS 2 1 Model WX15T Description code WAHT Ty...

Page 8: ...ooling system Forced air Starting system Recoil starter Stopping system Ignition primary circuit ground Carburetor Float type Air cleaner Semi dry type Breather system Reed valve type Fuel used Unlead...

Page 9: ...mmyhead dummyhead SPECIFICATIONS PERFORMANCE CURVES TOTAL HEAD LIFT 10 20 30 m 100 200 40 300 20 40 60 80 100 120 feet DISCHARGE CAPACITY TOTAL HEAD LIFT Liters min 20 40 60 US gal min 20 40 60 Imp ga...

Page 10: ...1 5 dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS 275 10 8 375 14 8 355 14 0 Unit mm in...

Page 11: ...MEMO dummyhead dummyhead...

Page 12: ...2 1 2 dummytext 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 3 LUBRICATION SEAL POINTS 2 4 TOOLS 2 5 HARNESS AND TUBE ROUTING 2 6...

Page 13: ...21 Big end oil clearance 0 02 0 04 0 001 0 002 0 100 0 0039 Crankshaft Crankpin O D 14 971 14 980 0 5894 0 5898 14 940 0 5882 Cylinder barrel Journal I D Cam Lifter 5 005 5 023 0 1970 0 1978 5 050 0 1...

Page 14: ...0 6 4 4 Cylinder head cover bolt M5 0 8 CT 1 5 9 0 6 4 4 Engine oil drain plug bolt M8 1 25 10 8 1 1 8 Flywheel nut M10 1 25 21 1 2 15 16 Apply engine oil to the threads and seating surface Fuel tank...

Page 15: ...e surface Piston pin outer surface Cylinder inner surface Connecting rod big and small end bearing Crankshaft pin Taper degreasing Engine oil Crankshaft gear teeth Taper degreasing Connecting rod bolt...

Page 16: ...d dummyhead SERVICE INFORMATION TOOLS Float level gauge 07401 0010000 Attachment 24 26 mm 07746 0010700 Driver 07749 0010000 Attachment 28 30 mm 07946 1870100 Oil seal driver attachment 27 5 x 44 mm 0...

Page 17: ...MATION HARNESS AND TUBE ROUTING 20 To engine stop switch To oil level switch To ignition coil To oil alert unit OIL ALERT UNIT ENGINE STOP SWITCH STOP SWITCH WIRE IGNITION COIL STOP SWITCH WIRE FAN CO...

Page 18: ...2 7 dummyhead dummyhead SERVICE INFORMATION FUEL TUBE TUBE CLAMP A type...

Page 19: ...MEMO dummyhead dummyhead...

Page 20: ...K PLUG CHECK ADJUSTMENT REPLACEMENT 3 6 SPARK ARRESTER CLEANING Optional part 3 7 IDLE SPEED CHECK ADJUSTMENT 3 7 VALVE CLEARANCE CHECK ADJUSTMENT 3 8 COMBUSTION CHAMBER CLEANING 3 9 FUEL TANK AND FIL...

Page 21: ...3 2 dummyhead dummyhead MAINTENANCE MAINTENANCE TOOL Vacuum tester 07APJ YB3A100 25 30 1 0 8 BA R 10 0 x Kp a H g 0 6 0 4 0 2 0 20 1 5...

Page 22: ...hever comes first Refer to page Each use First month or 10 hrs Every 3 months or 25 hrs Every 6 months or 50 hrs Every year or 100 hrs Every two years or 300 hrs Engine oil Check Level 3 4 Change 2 3...

Page 23: ...er 3 and drain the oil into a suitable container Please dispose of used oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycli...

Page 24: ...or holes or tears and replace if damaged Clean the element if they are to be reused Installation is in the reverse order of removal ELEMENT CLEANING Clean the filter 1 in warm soapy water rinse and al...

Page 25: ...MOVAL Disconnect the spark plug cap 1 and remove the spark plug 2 Clean around the spark plug base with compressed air before removing the spark plug and be sure that no debris is allowed to enter int...

Page 26: ...orrectly page 6 3 Remove the impeller Running the engine with the impeller installed will damage the pump Install the casing with the impeller removed to protect the rotating area Use a tachometer wit...

Page 27: ...alignment mark turn the recoil starter pulley one turn and align the marks Insert a feeler gauge 1 between the valve rocker arm 2 and the valve and measure the valve clearance If adjustment is necess...

Page 28: ...e against the combustion chamber FUEL TANK AND FILTER CLEANING FUEL TUBE CHECK Drain the fuel in a suitable container and disconnect the fuel tank tube 1 Remove the fuel filter 2 Remove any foreign ma...

Page 29: ...e the volute case 1 Check the impeller 1 and volute 2 for damage or excessive wear and replace if necessary IMPELLER CLEARANCE CHECK Remove the volute case 1 page 9 4 Measure the depth 2 of the volute...

Page 30: ...ract the height of the impeller 1 from the depth of the volute case 2 to obtain the impeller clearance 3 If the clearance is not within specification adjust the clearance by adding or removing adjuste...

Page 31: ...rease by approximately 1 in Hg per 1000 ft increase in elevation Shut off the engine and confirm the vacuum gauge reading remains steady This verifies the intake flapper is sealing Test Results If the...

Page 32: ...4 1 4 dummytext 4 TROUBLESHOOTING BEFORE TROUBLESHOOTING 4 2 ENGINE TROUBLESHOOTING 4 2 WATER PUMP TROUBLESHOOTING 4 6...

Page 33: ...and volute case and check the pump condition Cannot be cranked Abnormal Cranks Inspect the recoil starter page 8 3 Disassemble the cylinder barrel and replace the faulty part s page 11 3 Replace the f...

Page 34: ...free length page 12 4 Piston ring side clearance page 11 11 Piston ring width page 11 11 Piston ring end gap page 11 12 Piston skirt O D page 11 10 Cylinder sleeve I D page 11 10 Disassemble the carb...

Page 35: ...he decompressor Check around the air intake joint and carburetor replace the insulator and or gasket if necessary Disassemble and clean the carburetor page 5 6 Inspect the spark plug and adjust the sp...

Page 36: ...l Normal No continuity Replace the engine stop switch page 7 5 Check the engine stop switch page 7 8 Check the wire harness connecting the oil level switch and ignition coil for open or short circuit...

Page 37: ...e Air leak Throttle not in FAST position Move pump closer to water source Suction hose damaged Inlet valve damaged Replace Fill pump housing with water Won t prime Replace page 9 6 Replace page 9 3 Ch...

Page 38: ...age 3 10 Lift head too high Reduce discharge head Pump RPM too low Move throttle to fast Adjust throttle page 3 7 or governor page 6 3 Suction discharge hoses too long Correct Suction head too great M...

Page 39: ...MEMO dummyhead dummyhead...

Page 40: ...FUEL SYSTEM TOOL 5 2 FUEL TANK REMOVAL INSTALLATION 5 3 AIR CLEANER REMOVAL INSTALLATION 5 4 CARBURETOR REMOVAL INSTALLATION 5 5 CARBURETOR DISASSEMBLY ASSEMBLY 5 6 CARBURETOR INSPECTION 5 7 PILOT SCR...

Page 41: ...5 2 dummyhead dummyhead FUEL SYSTEM FUEL SYSTEM TOOL Float level gauge 07401 0010000...

Page 42: ...t sparks and flame away Handle fuel only outdoors Wipe up spills immediately FUEL TANK FUEL TANK TUBE INSTALLATION Check for deterioration hardening cracks and gasoline leakage Replace if necessary FU...

Page 43: ...FUEL SYSTEM AIR CLEANER REMOVAL INSTALLATION Remove the fuel tank and fuel tank tube page 5 3 AIR CLEANER SEAL AIR FILTER AIR CLEANER GASKET AIR CLEANER COVER AIR CLEANER CASE BOLT 5 x 75 mm 2 4 4 N...

Page 44: ...Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately INSULATOR GASK...

Page 45: ...MAIN JET PILOT SCREW FLOAT VALVE CARBURETOR BODY FUEL COCK LEVER FUEL VALVE GASKET VALVE LEVER SPRING LEVER SETTING PLATE O RING ADJUSTMENT page 3 7 FLOAT FLOAT PIN SET SCREW SET SCREW GASKET DRAIN SC...

Page 46: ...ce the carburetor in the position shown and push in the float with a finger Measure the distance float height between the float top and carburetor body when the leg of the float just starts to push th...

Page 47: ...move 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...

Page 48: ...6 1 6 dummytext 6 CONTROL SYSTEM CONTROL BASE GOVERNOR ARM REMOVAL INSTALLATION 6 2 GOVERNOR ADJUSTMENT 6 3...

Page 49: ...SPACER GOVERNOR ROD CONTROL LEVER SPRING CONTROL LEVER CONTROL BASE THROTTLE RETURN SPRING INSTALLATION Hook the ends through the big holes in the governor arm and throttle Install the spring with the...

Page 50: ...ide and open the carburetor throttle valve 4 fully Holding the carburetor throttle valve fully opened turn the governor arm shaft 5 clockwise fully and tighten the governor arm nut to the specified to...

Page 51: ...MEMO dummyhead dummyhead...

Page 52: ...7 3 ENGINE STOP SWITCH OIL ALERT UNIT REMOVAL INSTALLATION 7 5 ENGINE STOP SWITCH REMOVAL INSTALLATION 7 5 OIL LEVEL SWITCH REMOVAL INSTALLATION 7 6 OIL LEVEL SWITCH INSPECTION 7 6 IGNITION COIL AIR...

Page 53: ...l Black Y Yellow Bu Blue G Green R Red W White Br Brown O Orange Lb Light blue Lg Light green P Pink Gr Gray Replace the engine stop switch page 7 5 Check for continuity between the engine wire harnes...

Page 54: ...With oil level switch and oil alert unit NUT 10 mm HIGH TENSION WIRE RECOIL STARTER PULLEY INSTALLATION Check for tears and damage causing current leakage before connection 21 1 N m 2 15 kgf m 15 5lb...

Page 55: ...the flywheel Do not hit the flywheel with a hammer INSTALLATION Clean the tapered part of dirt oil grease and other foreign material before installation Be sure that there is no washer or other foreig...

Page 56: ...tab 1 of the engine stop switch 2 and remove the engine stop switch Install the engine stop switch to the stop switch bracket aligning its groove with the boss of the stop switch bracket Bend the tab...

Page 57: ...ground terminal green lead 2 The oil level switch is normal if there is no continuity with the switch set upside down There must be continuity between the leads with the switch in its normal position...

Page 58: ...the following before conducting the spark test Oil level Faulty spark plug Loose spark plug cap Water in the spark plug cap ignition coil secondary voltage leaking Loose ignition coil connector Disco...

Page 59: ...the tester to the terminal inside the spark plug cap and another lead to the iron core and measure the secondary resistance of the ignition coil ENGINE STOP SWITCH INSPECTION Attach the tester leads t...

Page 60: ...a following range of recommended tester TH 5H KOWA R x 100 range SP 15D SANWA k range Read the tester manufacturer s operation instructions carefully before operating the tester Follow the instruction...

Page 61: ...MEMO dummyhead dummyhead...

Page 62: ...8 1 8 dummytext 8 STARTING SYSTEM RECOIL STARTER FAN COVER REMOVAL INSTALLATION 8 2 RECOIL STARTER DISASSEMBLY ASSEMBLY 8 3...

Page 63: ...8 2 dummyhead dummyhead STARTING SYSTEM STARTING SYSTEM RECOIL STARTER FAN COVER REMOVAL INSTALLATION RECOIL STARTER NUT 5 mm 3 FAN COVER COLLAR 3 FAN COVER...

Page 64: ...es and eye protection during this procedure and take care not to allow the spring to come out SWING ARM COLLAR RECOIL STARTER REEL RECOIL STARTER SPRING RECOIL STARTER CASE SWING ARM RECOIL STARTER RO...

Page 65: ...own Wind the starter rope around the recoil starter reel 3 in the direction of arrow Install the starter reel on the starter case so that the spring inner hook 1 is hooked to the case tab 2 The recoil...

Page 66: ...case and pull it outwards 1 Pass the starter rope through the starter knob and tie the rope so that it can be untied easily 2 by pulling it as shown Set the friction spring to the starter reel install...

Page 67: ...MEMO dummyhead dummyhead...

Page 68: ...1 9 dummytext 9 PUMP TOOLS 9 2 INLET PIPE OUTLET PIPE REMOVAL INSTALLATION 9 3 CASING VOLUTE CASE REMOVAL INSTALLATION 9 4 IMPELLER CASING COVER REMOVAL INSTALLATION 9 5 MECHANICAL SEAL REPLACEMENT 9...

Page 69: ...9 2 dummyhead dummyhead PUMP PUMP TOOLS Driver handle 07749 0010000 Bearing driver attachment 28 x 30 mm 07946 1870100 Oil seal driver attachment 27 5 x 44 mm 07948 9540000...

Page 70: ...or breakage excessive wear or damage Align the tab 1 on the inlet valve with the groove 2 of the inlet pipe FILLER CAP OUTLET PACKING ALIGN INLET PIPE BOLT 6 x 25 mm 3 O RING BOLT 6 x 20 mm 4 OUTLET P...

Page 71: ...MOVAL INSTALLATION VOLUTE CASE O RING BOLT 8 x 28 mm 4 O RING 174 x 3 5 mm O RING 41 5 x 5 7 mm INSTALLATION Check the mating surface for damage and nicks INSPECTION Inspect the inside for excessive w...

Page 72: ...t to damage the magnet 3 part Remove the impeller INSTALLATION Hold the flywheel 1 with a commercially available strap wrench 2 being careful not to damage the magnet part 3 Tighten the impeller to th...

Page 73: ...ed and is not tilted in the casing cover Install a new rubber ring 1 over a new ceramic ring 2 Be careful not to damage the sliding surface of the ceramic ring Apply soapy water around the rubber ring...

Page 74: ...10 1 10 dummytext 10 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL INSTALLATION 10 2...

Page 75: ...L INSTALLATION ENGINE REMOVAL INSTALLATION INSTALLATION Check for cracking deformation or other damage before installation Install by aligning with the hole in the frame HANDLE FRAME BED BOLT 6 x 14 m...

Page 76: ...COVER REMOVAL INSTALLATION 11 3 PISTON DISASSEMBLY ASSEMBLY 11 6 GOVERNOR DISASSEMBLY ASSEMBLY 11 7 CAMSHAFT DISASSEMBLY ASSEMBLY 11 9 CRANKCASE COVER CYLINDER BARREL PISTON CONNECTING ROD CRANKSHAFT...

Page 77: ...11 2 dummyhead dummyhead CRANKCASE CRANKCASE TOOLS Attachment 24 x 26 mm 07746 0010700 Driver 07749 0010000...

Page 78: ...OLT GASKET OIL FILLER CAP CONNECTING ROD BOLT 2 CONNECTING ROD CAP Gear teeth CRANKSHAFT Threads and seating surface GOVERNOR ARM SHAFT DOWEL PIN 6 x 15 mm 2 CYLINDER BARREL Piston pin hole and outer...

Page 79: ...0 08 0 10 in of liquid gasket ThreeBond 1206 1216E 1207B Hondabond 4 Hondabond HT or equivalent 2 to the crankcase cover mating surface of the cylinder barrel Install the crankcase cover on the cylin...

Page 80: ...iston assembly in the cylinder so that the mark 1 on the piston head is toward the intake valve side The crankshaft must be at the top dead center of the compression stroke Take care not to break the...

Page 81: ...end gap of the clip 1 with the cutout 2 in the piston bore MAKER MARK 1 TOP RING PISTON RINGS ASSEMBLY Install with the maker mark facing upward as shown Do not interchange the top ring and the secon...

Page 82: ...NOR HOLDER CLIP 7 3 N m 0 75 kgf m 5 4 lbf ft BOLT 5 x 23 mm 6 DOWEL PIN 6 x 10 mm 2 ASSEMBLY Insert firmly into the shaft groove ASSEMBLY Before installing check for wear and damage of the gear Check...

Page 83: ...Hondabond 4 Hondabond HT or equivalent 2 as an even bead 1 5 2 0 mm 0 08 0 10 in centered between the edges of the mating surface and bolt holes in the cylinder barrel Assemble within 3 minutes after...

Page 84: ...igning the alignment mark 2 on the camshaft assy with the timing mark 3 on the crankshaft 4 VALVE LIFTER 2 CYLINDER BARREL VALVE LIFTER COLLAR CAMSHAFT ASSEMBLY Be careful not to drop the camshaft CAM...

Page 85: ...e cylinder Inspect the cylinder sleeve I D page 11 10 PISTON TO CYLINDER CLEARANCE Subtract the piston skirt O D from the cylinder sleeve I D to obtain the piston to cylinder clearance If the calculat...

Page 86: ...ring groove of the piston using a feeler gauge If any of the measurements is more than the service limit inspect the piston ring width page 11 11 If the piston ring width is normal replace the piston...

Page 87: ...t is more than the service limit replace the connecting rod and recheck the clearance If the clearance is still more than the service limit with a new connecting rod replace the crankshaft page 11 3 C...

Page 88: ...ing surface Place a piece of plastigauge on the crankpin install the connecting rod upper and the connecting rod lower and tighten the connecting rod bolts 1 to the specified torque Be careful not to...

Page 89: ...urement is more than the service limit replace the camshaft page 11 9 DECOMPRESSOR Move the decompressor arm with your finger Make sure the decompressor weight 1 operates smoothly Check that the decom...

Page 90: ...ment is more than the service limit replace the crankcase side cover page 11 7 CYLINDER BARREL JOURNAL I D Measure and record the camshaft 1 valve lifter roller 2 journal I D If the measurement is mor...

Page 91: ...own CRANKCASE SIDE COVER Wipe the replacement oil seal clean and wipe any oil from the corresponding surface of the crankcase side cover Place a clean shop towel or equivalent material under the crank...

Page 92: ...12 1 12 dummytext 12 CYLINDER HEAD CYLINDER HEAD COVER VALVE REMOVAL INSTALLATION 12 2 CYLINDER COMPRESSION CHECK 12 3 CYLINDER HEAD VALVE INSPECTION 12 4...

Page 93: ...2 VALVE SPRING RETAINER 2 INSTALLATION page 12 3 When removing the cylinder head cover pry off slowly at each corner of the head cover Do not remove the cylinder head cover with force Replace the cyl...

Page 94: ...minutes after applying the liquid gasket Loosely tighten each bolt then tighten to the specified torque in the numbered sequence Wait for approximately 20 minutes after assembly before filling oil and...

Page 95: ...O D from the corresponding guide I D to obtain the stem to guide clearance If the calculated clearance is more than the service limit replace the valve and cylinder barrel as a set VALVE SPRING FREE...

Page 96: ...service limit page 11 3 ROCKER ARM I D Measure and record each rocker arm I D Replace the rocker arm if the measurement exceeds the service limit page 12 2 ROCKER ARM SHAFT O D Measure and record roc...

Page 97: ...MEMO dummyhead dummyhead...

Page 98: ...13 1 13 dummytext 13 MUFFLER MUFFLER REMOVAL INSTALLATION 13 2...

Page 99: ...proceeding COLLAR 3 AIR GUIDE MUFFLER MUFFLER PROTECTOR INSTALLATION After removing any carbon deposits from the muffler install using a plastic hammer Do not tap on the muffler seal flange 1 or damag...

Page 100: ...5 3 G GOVERNOR ADJUSTMENT 6 3 GOVERNOR DISASSEMBLY ASSEMBLY 11 7 H HARNESS AND TUBE ROUTING 2 6 I IDLE SPEED CHECK ADJUSTMENT 3 7 IGNITION COIL AIR GAP CHECK ADJUSTMENT 7 7 IGNITION COIL INSPECTION 7...

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