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KG390 Engine Service Manual

The Coast Distribution System,
Ver. 2, October 1, 2007

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Summary of Contents for KG390

Page 1: ...KG390 Engine Service Manual The Coast Distribution System Ver 2 October 1 2007...

Page 2: ...odels currently sold outside North America Contact Kipor for the applicable service information Careful observance of the instructions contained in this manual will result in safe and quality service...

Page 3: ...e 8 3 3 3 Cylinder Cover 8 3 3 4 External Diameter of Valve Stem 9 3 3 5 Inside Diameter of Valve Bore 9 3 3 6 Clearance between Valve Base and Valve Conduit Pipe 9 3 3 7 Valve Clearance Adjustment 10...

Page 4: ...ion system Transistorized electric ignition Ignition timing 28 B T D C Spark plug F7RTC Carburetor Float type Horizontal butterfly valve type Air cleaner Dry Replaceable Element Governor Electronic co...

Page 5: ...and that you are wearing appropriate clothing and safety equipment When performing maintenance or repairs be especially careful of the following Read the instructions before you begin and be sure you...

Page 6: ...Hold the connector body to disconnect the connector Do not disconnect by pulling the wire harness To disconnect the locking connector be sure to unlock first and then disconnect Check the connector te...

Page 7: ...winding with electrical insulating tape When using an electrical tester like a volt ohm meter or clamp on meter read the manufacturer s operating instructions carefully before operating the tester Be...

Page 8: ...ge end I D 36 015 36 025 36 09 Crankshaft Main Journal O D 35 960 35 975 35 90 IN 0 10 0 02 Valve clearance EX 0 15 0 02 IN 6 570 6 585 6 50 Stem O D EX 6 550 6 570 6 50 Guide I D IN EX 6 600 6 622 6...

Page 9: ...5 3 0 Crankcase side cover bolt M8 30 20 23 2 0 2 3 Rotor nut M18 1 5 120 130 12 0 13 0 Rocker arm shaft bolt M8 16 20 23 2 0 2 3 Adjusting nut of rocker arm shaft M6 0 75 10 12 1 0 1 2 M5 bolt nut 6...

Page 10: ...3 CYLINDER COVER AND CYLINDER HEAD ASSEMBLY 3 1 Cylinder Head Removal 3 2 Cylinder Head Disassembly and Reassembly 7...

Page 11: ...of valve base Standard mm Service limit mm 0 8 1 2 2 0 3 3 3 Cylinder cover Remove all accumulated carbon from the combustion surfaces Check for cracks in the spark plug hole valve base and valve cond...

Page 12: ...70 6 585 6 50 exhaust 6 55 6 57 6 50 3 3 5 Inner diameter of valve bore Standard mm Service limit mm intake exhaust 6 600 6 622 6 68 3 3 6 Clearance between valve bore and valve conduct pipe Standard...

Page 13: ...der cover and cylinder cover gasket Spark plug Cylinder cover Cylinder cover gasket 2 Rotate the engine in a clockwise position until the piston is at top dead center and the intake and exhaust valves...

Page 14: ...stment is necessary proceed as follows A secure the rocker arm adjustment screw and loosens the nut B adjust the screw until the desired valve clearance is attained C tighten the nut D recheck the cle...

Page 15: ...4 CRANKSHAFT COVER PISTON AND CONNECTING ROD CRANKSHAFT AND CAMSHAFT 4 1 Crankshaft Cover 4 2 Crankshaft camshaft and piston M8 20 22N m 12...

Page 16: ...camshaft gear and timing gear during installation 4 4 Bearing clearance Clean and dry the shaft rotate the shaft manually and check the free gap replace the shaft if any noise or movement Free gap Fre...

Page 17: ...4 5 Piston Ring and Connecting Rod 14 Manufacture mark...

Page 18: ...first and second rings check that the piston rings can rotate freely when installed align the piston ring gaps at a 120 degree angle 1st ring chrome plate 2nd ring su ace phosph Oil d rf oresced ring...

Page 19: ...ron of piston Standard mm Service limit mm 87 96 87 98 87 85 10m m 4 7 3 Clearance between piston and cylinder Standard mm Service limit mm 0 045 0 065 0 120 Side clearance of piston Standard mm Servi...

Page 20: ...ix the piston ring in the cylinder using the top part of piston and measure the terminal clearance of piston Standard mm Service limit mm 0 20 0 35 1 0 4 7 5 Piston ring height Standard mm Service lim...

Page 21: ...4 7 6 External diameter of piston pin Standard mm Service limit mm 19 994 20 000 19 950 4 7 7 Internal diameter of piston pin bore Standard mm Service limit mm 20 002 20 008 20 050 18...

Page 22: ...vice limit mm 0 002 0 014 0 080 4 8 Connecting Rod Inspection 4 8 1 Internal diameter of connecting rod small end Standard mm Service limit mm 20 007 20 020 20 090 4 8 2 Internal diameter of the conne...

Page 23: ...aft Inspection 4 9 1 External diameter of main journal Standard mm Service limit mm 35 960 35 975 35 900 4 9 2 Clearance of connecting rod big end and crank journal Standard mm Service limit mm 1 05 1...

Page 24: ...rque 14 16 Nm Do not rotate the crankshaft when tightening 3 Remove the connecting rod and measure the thickness of plastic line gauge 4 If clearance exceeds the service limit replace the connecting r...

Page 25: ...t Inspection 4 10 1 Height of camshaft Standard mm Service limit mm Air intake 32 60 32 80 32 25 Air outlet 32 09 32 29 31 75 4 10 2 External diameter of camshaft Standard mm Service limit mm 15 95 15...

Page 26: ...4 10 3 Inner diameter of camshaft bearing Standard mm Service limit mm 16 000 16 018 16 050 23...

Page 27: ...5 ELECTRIC STARTER 24...

Page 28: ...n remove the washer from shaft Thrust washer Meshing gear assembly with clutch 5 2 Inspection 5 2 1 Electromagnetic switch with attraction coil Check that there is continuity between the switch body a...

Page 29: ...hot coil 5 2 2 Brush length Measure the brush length repair or replace the brush if the wear exceeds maintenance limit Standard value Service limit 15mm 10mm 5 2 3 Mica depth If mica depth is less th...

Page 30: ...e commutator and shaft Replace the armature if there is any continuity 5 2 6 Meshing gear assembly with clutch Meshing gear inspection Check for any wearing or damage of the driving gear teeth Replace...

Page 31: ...ny resistance is noted check for distortion or dirt on the sliding surface Clean or replace as necessary Check the insulation of brush shelf per the diagram below There should be no continuity 5 2 8 E...

Page 32: ...Inspection of excitation coil ground Check the continuity between the brush and starter cover Any continuity means the coil has failed 29...

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