CONTENTS
1. Specifications........................................................................................................................................1
2. Service...................................................................................................................................................2
2.1 The Importance of Proper Service.......................................................................................................2
2.2 Safety Precautions...............................................................................................................................2
2.3 Service Rules.......................................................................................................................................3
2.4 Electrical Precautions..........................................................................................................................3
2.5 Serial Number and Bar Code Location................................................................................................4
2.6 Maintenance Standards.......................................................................................................................5
2.7 Fastening Torques...............................................................................................................................6
3. Cylinder Cover and Cylinder Head Assembly........................................................................................7
3.1 Cylinder Head Removal.......................................................................................................................7
3.2 Cylinder Head Disassembly and Assembly.........................................................................................7
3.3 Inspection ...........................................................................................................................................8
3.3.1 Free Length of Valve Spring.............................................................................................................8
3.3.2 Width of Valve Base..........................................................................................................................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
4. Crankshaft Cover, Piston and Connecting Rod, Crankshaft and Camshaft.........................................12
4.1 Crankshaft Cover...............................................................................................................................12
4.2 Crankshaft, Camshaft and Piston......................................................................................................12
4.3 Alignment of Timing Marks.................................................................................................................13
4.4 Bearing Clearance.............................................................................................................................13
4.5 Piston and Connecting Rod...............................................................................................................14
4.6 Piston Ring Assembly........................................................................................................................15
4.7 Piston Inspection...............................................................................................................................15
4.8 Connection Rod Inspection................................................................................................................19
4.9 Crankshaft Inspection........................................................................................................................19
4.10 Camshaft Inspection........................................................................................................................20
5. Electric Starter......................................................................................................................................24
5.1 Disassembly and Reassembly...........................................................................................................25
5.2 Inspection..........................................................................................................................................26
Summary of Contents for KG390
Page 1: ...KG390 Engine Service Manual The Coast Distribution System Ver 2 October 1 2007...
Page 17: ...4 5 Piston Ring and Connecting Rod 14 Manufacture mark...
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...
