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Yamaha EH63 Service Manual Download Page 39

PERIODIC MAINTENANCE

2-13

1

2

3

4

5

6

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8

9

10

P

E

RIODIC

 CH
ECKS AND ADJUSTMENTS

Adjustment steps:

a. Loosen the locknut “1” and insert the thickness

gauge between the rocker arm and the valve
stem end.

b. Return or tighten the adjuster “2” and set the

valve clearance to the correct value. Move the
thickness gauge up and down to check for the
proper resistance.

c. Tighten the locknut “1”.

6.

Install:

• Cylinder head cover gasket
• Cylinder head cover
• Engine hanger

• Breather hose
• Spark plug

• Spark plug cap

2

1

Thickness gauge:

90890-03268

Feeler gauge set:

YU-26900-9

Adjuster

Valve clearance

Clockwise

Clearance decreases

Counterclockwise

Clearance increases

Valve adjuster locknut:

8 N·m (0.8 kgf·m, 5.9 lb·ft)

Cylinder head cover bolt:

8 N·m (0.8 kgf·m, 5.9 lb·ft)

Spark plug:

13 N·m (1.3 kgf·m, 9.6 lb·ft)

T

R

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New

T

R

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T

R

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Summary of Contents for EH63

Page 1: ...SERVICE MANUAL EH63 EH64 EH65 EH72 7D5 28197 E0 2019 03 1 7D5 28197 E0_cover indd 1 2 2019 03 12 10 04 33 ...

Page 2: ...7D5 28197 E0_cover indd 3 4 2019 03 12 10 04 33 ...

Page 3: ... MANUAL 2019 by Yamaha Motor Powered Products Co Ltd 1st Edition February 2019 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Powered Products Co Ltd is expressly prohibited ...

Page 4: ...ons and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol...

Page 5: ...ANKSHAFT 3 46 PISTONS AND CRANKSHAFT Order Job Parts to remove Q ty Remarks Removing the pistons and crankshaft Remove the parts in the order listed 2 p a c d o r g n i t c e n n o C 1 1 t f a h s k n a r C 2 1 m i h s t f a h s k n a r C 3 2 d o r g n i t c e n n o C 4 4 p i l c r i c n i p n o t s i P 5 2 n i p n o t s i P 6 2 n o t s i P 7 g n i r p o T 2 g n i r n o t s i P 8 g n i r d n 2 2 g...

Page 6: ...ot relevant to every machine SYMBOL DEFINITION SYMBOL DEFINITION Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data Replace the part with a new one Lithium soap base grease Molybdenum disulfide grease Engine oil Apply locking agent LOCTITE T R New LS M E LT ...

Page 7: ...GENERAL INFORMATION PERIODIC CHECKS AND ADJUSTMENTS ENGINE FUEL ELECTRICAL TROUBLESHOOTING SPECIFICATIONS 1 2 3 4 5 6 7 8 9 10 INDEX ...

Page 8: ... EH72A EH72B EH72K 2 8 AIR FILTER ELEMENT 2 8 MUFFLER 2 10 BREATHER HOSE 2 11 CYLINDER HEAD DECARBONIZATION 2 11 ADJUSTING THE VALVE CLEARANCE 2 12 ENGINE SPEED EH63K EH64A EH64K EH65A EH65B 2 14 ENGINE SPEED EH72A EH72B EH72K 2 16 FITTINGS AND FASTENERS 2 18 ENGINE ENGINE INSPECTION 3 1 MEASURING THE COMPRESSION PRESSURE 3 1 AIR FILTER 3 3 EH63K EH64A EH64K EH65A EH65B 3 3 EH72A EH72B EH72K 3 4 M...

Page 9: ... COVER 3 44 CAMSHAFT 3 45 PISTONS AND CRANKSHAFT 3 46 CRANKCASE 3 47 CHECKING THE RELIEF VALVE 3 48 ASSEMBLING THE RELIEF VALVE 3 48 CHECKING THE OIL PUMP STRAINER 3 48 ASSEMBLING THE OIL PUMP STRAINER 3 48 REMOVING THE FLYWEIGHT SHAFT ASSEMBLY AND GOVERNOR FORK 3 48 DISASSEMBLING THE FLYWEIGHT SHAFT ASSEMBLY 3 49 CHECKING THE FLYWEIGHT SHAFT ASSEMBLY 3 49 ASSEMBLING THE FLYWEIGHT SHAFT ASSEMBLY 3...

Page 10: ...IGNITION SPARK GAP 5 6 CHECKING THE AIR GAP 5 7 CHECKING THE IGNITION COIL TCI UNIT PRIMARY RESISTANCE 5 7 CHECKING THE IGNITION COIL TCI UNIT SECONDARY RESISTANCE 5 7 CHECKING THE ENGINE SWITCH EQUIPPED MODELS ONLY 5 8 CHECKING THE STARTER MOTOR OPERATION 5 8 CHECKING THE WIRE HARNESS 5 9 ELECTRIC STARTING SYSTEM 5 10 REMOVING THE STARTER MOTOR 5 10 CHARGING SYSTEM 5 11 CHECKING THE STATOR COIL A...

Page 11: ...FOLD EH64K FOR KOR EH65A EH65B 7 25 CARBURETOR AND INTAKE MANIFOLD EH72A EH72B EH72K 7 26 TCI UNIT EH63K 7 27 TCI UNIT EH64A 7 28 TCI UNIT EH64K EXCEPT FOR KOR 7 29 TCI UNIT EH64K FOR KOR 7 30 TCI UNIT EH65A 7 31 TCI UNIT EH65B 7 32 TCI UNIT EH72A 7 33 TCI UNIT EH72B FOR SEA EH72K FOR CHN 7 34 TCI UNIT EH72K EXCEPT FOR CHN 7 35 RECTIFIER REGULATOR AND STARTER MOTOR EH63K 7 36 RECTIFIER REGULATOR A...

Page 12: ...MEMO ...

Page 13: ...UMBER The serial number is printed on the label affixed to the position 1 of the multi purpose engine as shown in the illustration TIP The first four digits identify the model and the remaining digits indicate the production number Designs and specifications are subject to change without notice 1 ...

Page 14: ...ERAL INFORMATION DIMENSIONS DIMENSION CHART FOR P T O mm in 35 1 38 19 0 75 28 1 1 63 2 48 80 3 15 M10 1 25 12 0 47 10 5 0 41 30 1 18 35 1 38 3 0 12 63 2 48 80 3 15 M10 1 25 21 0 83 28 58 1 13 7 16 20UNF 2B 99 3 3 91 38 1 5 47 1 85 85 5 3 37 ...

Page 15: ...EH72B C EH64A EH65A EH72A D EH64A EH65A EH72A E EH63K EH64K EH72K F EH63K EH64K EH72K 28 58 1 13 13 5 0 53 12 0 47 3 0 12 7 16 20UNF 2B 99 3 3 91 40 1 57 49 1 93 85 5 3 37 35 1 38 22 1 0 87 19 2 0 76 16 0 63 24 0 94 5 16 24UNF 2B 35 1 38 5 16 24UNF 2B 10 0 39 8 5 0 33 18 0 71 3 0 12 26 1 02 19 2 0 76 22 1 0 87 ...

Page 16: ...DIMENSIONS 1 4 1 2 3 4 5 6 7 8 9 10 GENERAL INFORMATION TOP MOUNTING BASE mm in mm in 57 1 2 25 26 1 02 90 5 3 56 195 7 68 16 0 63 102 4 02 61 4 2 42 4 2 0 17 105 1 4 14 63 4 2 5 16 0 63 4 R 5 3 4 1 0 6 ...

Page 17: ...DIMENSIONS 1 5 1 2 3 4 5 6 7 8 9 10 GENERAL INFORMATION LEFT SIDE FRONT mm in mm in 133 3 5 25 190 6 7 5 5 0 2 99 9 39 3 417 3 16 43 25 0 98 317 4 12 5 477 18 78 253 5 9 98 475 18 7 ...

Page 18: ...ORMATION REAR 1 UNC Unified coarse thread Unit in mm in 144 5 67 288 1 11 34 116 4 57 153 9 6 06 7 16 14 UNC 3 8 16 UNC 26 1 02 26 1 02 30 30 5 45 5 45 65 0 2 2 56 0 01 52 0 15 2 05 0 01 M8 1 25 M8 1 25 127 0 2 165 1 0 2 196 8 0 2 52 0 15 2 05 0 01 ...

Page 19: ...g the engine always keep the engine and yourself away from fire NOTES ON SERVICE Correct tools Be sure to use the correct special tool for the job to guard against damage Oil grease and seals Be sure to use genuine Yamaha oils grease and sealers or the equivalents Expendable parts Always replace the gaskets O rings cotter pins and cir clips with new parts when servicing engine ...

Page 20: ...sassembly Contact surfaces of moving parts should be oiled when reassembled Make sure that the parts move smoothly after each sec tion of the machine is assembled ALL REPLACEMENT PARTS We recommend the use of genuine Yamaha parts for all replacements Use oil and or grease recommended by Yamaha for assembly and adjustment GASKETS OIL SEALS AND O RINGS 1 All gaskets seals and O rings should be repla...

Page 21: ...ium base grease to the seal lip s Oil the bearings liberally when installing BASIC SERVICE INFORMATION ELECTRICAL SYSTEM Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V 1 2 Do not use compressed air to spin the bearings dry This causes damage to the bearing surfaces NOTICE a Never insert the tester probes into the coupler...

Page 22: ...ir blower Rust stains Connect and disconnect several times When disconnecting a coupler release the coupler lock hold both sections of the coupler securely and then disconnect the coupler There are many types of coupler locks therefore be sure to check the type of coupler lock before discon necting the coupler NOTICE When disconnecting a connector do not pull the leads Hold both sections of the co...

Page 23: ... the terminal is flattened bend it up After disassembling and assembling a coupler pull on the leads to make sure that they are installed securely 4 Connect Lead Coupler Connector TIP When connecting a coupler or connector push both sec tions of the coupler or connector together until they are connected securely Make sure all connections are tight 1 ...

Page 24: ...r and coupler of the TCI unit CDI unit when replacing the TCI unit CDI unit As a quick remedy use a contact revitalizer available at most part stores Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 For waterproof couplers never insert the tester leads directly into the coupler When performing any checks using a waterproof coupler use the specified test har nes...

Page 25: ...eter YU A1927 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 Digital tachometer 90890 06760 YU 39951 B Compression gauge 90890 03081 Engine compression tes ter YU 33223 Compression gauge extension 73mm 90890 04082 YM 04082 Sheave holder 90890 01701 Primary clutch holder YS 01880 A Flywheel puller 90890 01362 Heavy duty puller YU 33270 B Valve spring compressor 90890 01253 Cylinder gauge C...

Page 26: ...SPECIAL TOOLS AND TESTERS 1 14 1 2 3 4 5 6 7 8 9 10 GENERAL INFORMATION MEMO ...

Page 27: ...enance services related to emissions control These controls not only function to ensure air filter but are also vital to proper engine operation and maximum performance PERIODIC MAINTENANCE LUBRICATION INTERVALS Maintenance Items Every 8 hours Daily Every 50 hours Every 200 hours Every 500 hours Every 1000 hours Clean engine and check bolts and nuts Daily Check for leakage from hoses and fitting D...

Page 28: ...o gar den soil or into open streams Your local zoning or environmental regulations will give you more detailed instructions on proper disposal 2 More frequent oil changing oil filter replacement and air cleaner service on replacement may be necessary depending on operating conditions This would include dusty environment high ambi ent temperature heavy engine loading Check and adjust valve clear an...

Page 29: ...e or thickness gauge Out of specification Adjust If necessary clean the spark plug with a spark plug cleaner Check and adjust the areas around the cylinder head after the engine has cooled down completely WARNING Before removing the spark plug use compressed air to clean the cylinder head cover to prevent dirt from falling into the engine NOTICE 1 2 a Spark plug type BPR5ES NGK Except for EH64A BP...

Page 30: ...amaged temporally tighten the spark plug to position a before tightening it to the specified torque b FUEL LEAKAGE 1 Check Gasoline leakage Check the fuel pump fuel hose and carburetor FUEL FILTER a b Spark plug 13 N m 1 3 kgf m 9 6 lb ft T R Replace the fuel hose every two years NOTICE Do not smoke and keep away from open flames sparks or any other source of fire when handling or in the vicinity ...

Page 31: ... dirt clogging Replace ENGINE OIL LEAKAGE 1 Place the multi purpose engine on a level surface 2 Check the areas outside of the engine for oil leakage Oil leakage Replace the gasket oil seal or O ring ENGINE OIL LEVEL 1 Remove Oil filler cap 1 Oil level gauge 2 Be sure to replace the fuel filter without cleaning it NOTICE 1 2 ...

Page 32: ... as before and remove it f Check that the engine oil is between the lower limit a and the upper limit b of the oil level gauge Add oil if necessary 3 Install Oil level gauge Oil filler cap REPLACING THE ENGINE OIL 1 Warm up the engine for several minutes and then stop the engine 2 Remove Oil drain bolt 1 Oil drain bolt gasket 2 TIP This engine is equipped with two oil drain bolts Use whichever sid...

Page 33: ...ilter and tighten with an oil filter wrench commercially available product 5 Install Oil drain bolt gasket 2 Oil drain bolt 1 2 1 1 2 Oil filter wrench 65 mm 2 55 in A EH63K EH64A EH64K EH65A EH65B B EH72A EH72B EH72K Check that the O ring 3 is correctly installed in the groove portion of the oil filter Oil filter 12 N m 1 2 kgf m 8 9 lb ft NOTICE T R 1 2 1 2 Oil drain bolt 21 N m 2 1 kgf m 15 lb ...

Page 34: ...heck Oil cooler Damage Replace Dirt clog Clean AIR FILTER ELEMENT 0 10 30 50 70 90 110130 F 20 10 0 10 20 30 40 50 C SAE 10W 40 SAE 10W 30 Recommended oil brand YAMALUBE Available oil grade API SE type or higher JASO MA or MB Available viscosity index 10W 30 or 10W 40 Engine oil quantity 1 55 L 1 64 US qt 1 36 Imp qt Be sure not to run the engine without air filter element Otherwise this can resul...

Page 35: ... the element and squeeze out the excess oil 4 Check Inner element Damage Replace Clogged Either tap lightly or blow air from the inside of the element to blow the dust off 3 4 2 1 Do not wash the element with gasoline or with acidic alkalic or organic solvents Do not wring out the element This could cause it to tear WARNING NOTICE Do not wash the inner element with white kerosene gasoline or oil o...

Page 36: ...ark arrester 1 3 Remove Muffler Refer to MUFFLER on page 3 5 4 Decarbonize Muffler Tap on the muffler in the area shown in the illustra tion to loosen carbon buildup and then shake it out from the end of the muffler The engine and muffler will be very hot after the engine has been run Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during check...

Page 37: ...oor connection Connect CYLINDER HEAD DECARBONIZATION The following procedure applies to all of the cylinder heads 1 Remove Cylinder head assembly Refer to CYLINDER HEAD COVERS CYLINDER HEADS on page 3 26 2 Eliminate Carbon deposits Refer to CHECKING THE CYLINDER HEADS on page 3 32 3 Install Cylinder head assembly Refer to INSTALLING THE CYLINDER HEAD ASSEMBLIES on page 3 33 When cleaning with a wi...

Page 38: ...eel is lined up with the 1 mark 2 of cylinder head 1 For the cylinder head 2 side as well rotate the crank shaft until the I mark of the flywheel and the 2 mark of cylinder head 2 match 4 Measure Valve clearance Between the rocker arm and valve stem end Out of specification Adjust TIP Valve clearance must be measured when the engine has cooled down enough to be touched 5 Adjust Valve clearance 2 5...

Page 39: ...ess gauge up and down to check for the proper resistance c Tighten the locknut 1 6 Install Cylinder head cover gasket Cylinder head cover Engine hanger Breather hose Spark plug Spark plug cap 2 1 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 Adjuster Valve clearance Clockwise Clearance decreases Counterclockwise Clearance increases Valve adjuster locknut 8 N m 0 8 kgf m 5 9 lb ft Cylinde...

Page 40: ...3 Attach Digital tachometer 1 4 Measure High engine speed with no load Out of specification Adjust Measurement steps a Move the throttle lever 1 to the high engine speed position a b Check that the high engine speed is the specified valued 5 Measure Low engine speed with no load Out of specification Adjust 1 1 Digital tachometer 90890 06760 YU 39951 B High engine speed 3200 3400 r min 1 a Low engi...

Page 41: ... lever 1 in the direction a or b until the high engine speed reaches the specified value with no load on the engine c Hold the throttle lever at the position where the high engine speed reached the specified value then turn the screw 2 until it comes in contact with the throttle lever and serves as a stopper 7 Adjust Low engine speed Adjustment steps a Start the engine b Check that the governor ar...

Page 42: ... e Tighten the locknut 4 ENGINE SPEED EH72A EH72B EH72K 1 Warm up the engine for several minutes 2 Remove Air filter cover 1 Refer to AIR FILTER on page 3 3 3 Attach Digital tachometer 1 4 Measure High engine speed with no load Out of specification Adjust 3 a b Direction a Low engine speed is increased Direction b Low engine speed is decreased 5 4 c d Low engine speed 1500 1700 r min Direction c L...

Page 43: ...6 Adjust High engine speed Adjustment steps a Start the engine b Set the engine speed to the specified value with the throttle lever Move the throttle lever 1 in the direction a or b until the high engine speed reaches the specified value with no load on the engine c Hold the throttle lever at the position where the high engine speed reached the specified value then turn the screw 2 until it comes...

Page 44: ...he spring 2 c Move the carburetor s throttle stop screw 3 in the direction a or b until the low engine speed reaches 1900 2100 r min with no load on the engine FITTINGS AND FASTENERS 1 Check All fittings and fasteners Loose Tighten Rough movement Replace the defective part s Damage pitting Replace 1 2 3 a b Direction a Low engine speed is increased Direction b Low engine speed is decreased ...

Page 45: ... extension 73mm 2 4 Measure Compression pressure Crank the engine until the needle stop rising on the compression gauge Out of specification Refer to the testing steps Before removing the spark plug use compressed air to clean the cylinder head cover to prevent dirt from falling into the engine NOTICE 1 2 Compression gauge 90890 03081 Engine compression tester YU 33223 Compression gauge extension ...

Page 46: ...m specification a Check the cylinder head valve surfaces and pis ton crown for carbon deposits Carbon deposits Eliminate 5 Install Spark plug Spark plug cap Reading Diagnosis Higher than without oil Worn cylinder piston and piston ring s Same as without oil Defective piston piston ring s valve s and cylinder head gasket Improper valve timing and valve clearance Spark plug 13 N m 1 3 kgf m 9 6 lb f...

Page 47: ...4A EH64K EH65A EH65B Order Job Parts to remove Q ty Remarks Removing the air filter Remove the parts in the order listed 1 Air filter cover nut 1 2 Air filter cover 1 3 Air filter element 1 4 Air filter plate 1 5 Breather hose 1 1 2 3 5 4 8 N m 0 8 kgf m 5 9 lb ft ...

Page 48: ...72B EH72K Order Job Parts to remove Q ty Remarks Removing the air filter Remove the parts in the order listed 1 Air filter cover nut 1 2 Air filter cover 1 3 Air filter element 1 4 Air filter plate 1 5 Breather hose 1 1 2 3 5 4 8 N m 0 8 kgf m 5 9 lb ft ...

Page 49: ... EH63K EH72B EH72K Order Job Parts to remove Q ty Remarks Removing the muffler Remove the parts in the order listed 1 Muffler 1 2 Gasket 2 3 Muffler bracket 1 1 3 2 2 2 2 8 N m 0 8 kgf m 5 9 lb ft 18 N m 1 8 kgf m 13 lb ft 18 N m 1 8 kgf m 13 lb ft ...

Page 50: ...NE EH64K Order Job Parts to remove Q ty Remarks Removing the muffler Remove the parts in the order listed 1 Muffler 1 2 Gasket 2 3 Muffler bracket 1 1 3 2 2 2 2 8 N m 0 8 kgf m 5 9 lb ft 18 N m 1 8 kgf m 13 lb ft 18 N m 1 8 kgf m 13 lb ft ...

Page 51: ...NE EH65B Order Job Parts to remove Q ty Remarks Removing the muffler Remove the parts in the order listed 1 Muffler 1 2 Gasket 2 3 Muffler bracket 1 1 3 2 2 2 2 8 N m 0 8 kgf m 5 9 lb ft 18 N m 1 8 kgf m 13 lb ft 18 N m 1 8 kgf m 13 lb ft ...

Page 52: ...arts to remove Q ty Remarks Removing the muffler Remove the parts in the order listed 1 Muffler cover 1 2 Muffler 1 3 Gasket 2 4 Muffler bracket 1 1 2 4 2 2 3 3 8 N m 0 8 kgf m 5 9 lb ft 18 N m 1 8 kgf m 13 lb ft 18 N m 1 8 kgf m 13 lb ft 8 N m 0 8 kgf m 5 9 lb ft ...

Page 53: ...lt 3 TIP Temporarily tighten muffler nut 1 muffler nut 2 and muf fler bolt 3 2 Tighten Muffler nut 1 Muffler nut 2 Muffler bolt 3 TIP Tighten the nuts and bolt to the specified torque in order of muffler nut 1 muffler nut 2 and muffler bolt 3 3 1 2 New Muffler nut 18 N m 1 8 kgf m 13 lb ft Muffler bolt 8 N m 0 8 kgf m 5 9 lb ft T R T R ...

Page 54: ...ING THE ENGINE OIL on page 2 6 1 Oil filter 1 2 Oil pressure switch 1 3 Oil cooler 1 EH72A EH72B EH72K 4 Oil hose 1 1 EH72A EH72B EH72K 5 Oil hose 2 1 EH72A EH72B EH72K 6 Bracket 1 EH72A EH72B EH72K 7 Adapter 1 EH72A EH72B EH72K 8 O ring 1 EH72A EH72B EH72K Except EH72A EH72B EH72K 8 N m 0 8 kgf m 5 9 lb ft 1 2 1 1 2 5 4 3 6 8 N m 0 8 kgf m 5 9 lb ft 7 8 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5...

Page 55: ...itch CHECKING THE OIL COOLER EH72A EH72B EH72K 1 Check Oil cooler 1 Oil hose 1 2 Oil hose 2 3 Adapter 4 Damage Replace Dirt clog Clean INSTALLING THE OIL COOLER EH72A EH72B EH72K 1 Clean Mating surface of adapter and crankcase Wipe off with a rag to which solvent has been applied 2 Install O ring 1 Adapter 2 1 2 3 4 1 2 Adapter bolt 8 N m 0 8 kgf m 5 9 lb ft New T R ...

Page 56: ...5 6 7 8 9 10 ENGINE 3 Install Bracket Oil cooler Oil hose 2 Oil hose 1 Oil filter Oil pressure switch Bracket bolt 8 N m 0 8 kgf m 5 9 lb ft Oil cooler bolt 8 N m 0 8 kgf m 5 9 lb ft Oil pressure switch 8 N m 0 8 kgf m 5 9 lb ft T R T R T R ...

Page 57: ...3 4 5 6 7 8 9 10 ENGINE RECTIFIER REGULATOR Order Job Parts to remove Q ty Remarks Removing the rectifier regulator Remove the parts in the order listed 1 Rectifier regulator 1 2 Connector 1 Disconnect 1 2 7 N m 0 7 kgf m 5 2 lb ft ...

Page 58: ...moving the case and fan Remove the parts in the order listed Air filter Refer to AIR FILTER on page 3 3 1 Fan case 1 2 Fan 1 4 5 N m 0 45 kgf m 3 3 lb ft 4 5 N m 0 45 kgf m 3 3 lb ft 4 5 N m 0 45 kgf m 3 3 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 2 4 5 N m 0 45 kgf m 3 3 lb ft ...

Page 59: ... 2 3 4 5 6 7 8 9 10 ENGINE REMOVING THE CASE AND FAN 1 Remove Air filter Refer to AIR FILTER on page 3 3 2 Remove Fan case 1 Fan 2 CHECKING THE CASE AND FAN 1 Check Fan case 1 Fan 2 Damage Replace Dirt clog Clean 2 1 2 1 ...

Page 60: ...LING THE CASE AND FAN 1 Install Fan 1 Fan bolt 2 Install Fan case 2 Fan case bolt side Fan case bolt front 1 2 Fan bolt 4 5 N m 0 45 kgf m 3 3 lb ft Fan case bolt side 2 5 N m 0 25 kgf m 1 8 lb ft Fan case bolt front 4 5 N m 0 45 kgf m 3 3 lb ft T R T R ...

Page 61: ...s Removing the cylinder covers Remove the parts in the order listed Muffler Refer to MUFFLER on page 3 5 Air filter Refer to AIR FILTER on page 3 3 Fan case Refer to CASE AND FAN on page 3 14 1 Cylinder cover 1 1 2 Rectifier regulator 1 3 Cylinder cover 2 1 1 2 3 13 N m 1 3 kgf m 9 6 lb ft 7 N m 0 7 kgf m 5 2 lb ft 8 N m 0 8 kgf m 5 9 lb ft ...

Page 62: ... cylinder cover Remove the parts in the order listed Muffler Refer to MUFFLER on page 3 5 Air filter Refer to AIR FILTER on page 3 3 Fan case Refer to CASE AND FAN on page 3 14 Fuel pump Refer to FUEL PUMP on page 4 1 1 Cylinder cover 3 1 8 N m 0 8 kgf m 5 9 lb ft 13 N m 1 3 kgf m 9 6 lb ft 8 N m 0 8 kgf m 5 9 lb ft 1 ...

Page 63: ... the parts in the order listed Muffler Refer to MUFFLER on page 3 5 Air filter Refer to AIR FILTER on page 3 3 Fan case Refer to CASE AND FAN on page 3 14 1 TCI unit 1 lead connector 1 Disconnect 2 TCI unit 2 lead connector 1 Disconnect 3 TCI unit 1 1 4 TCI unit 2 1 5 Spark plug 2 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 1 3 5 5 13 N m 1 3 kgf m 9 6 lb ft 13 N m 1 3 kgf m 9 6 lb ft 2 4 ...

Page 64: ...isted Air filter Refer to AIR FILTER on page 3 3 Fan case and fan Refer to CASE AND FAN on page 3 14 Rectifier regulator Refer to RECTIFIER REGULATOR on page 3 13 Cylinder cover Refer to CYLINDER COVERS on page 3 17 TCI unit Refer to TCI UNITS on page 3 19 1 Flywheel 1 2 Stator coil assembly 1 3 Woodruff key 1 3 4 N m 0 34 kgf m 2 5 lb ft 3 4 N m 0 34 kgf m 2 5 lb ft 110 N m 11 kgf m 81 lb ft 1 2 ...

Page 65: ...age 3 13 4 Remove Cylinder covers Refer to CYLINDER COVERS on page 3 17 5 Remove TCI units 1 6 Remove Flywheel nut 1 Washer 2 TIP Attach the sheave holder 3 to hold the flywheel 7 Remove Flywheel 1 Woodruff key TIP Remove the flywheel 1 using the flywheel puller 2 Fully tighten the tool holding bolts making sure the tool body is parallel with the flywheel If necessary one bolt may be backed out sl...

Page 66: ...Y 1 Install Stator coil assembly Stator coil assembly bolt TIP Install the lead a of the stator coil assembly so that it is at about the 2 o clock position as shown in the illustration 2 Install Flywheel 3 Install Washer 1 Flywheel nut 2 TIP Attach the sheave holder 3 to hold the flywheel Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 2 1 a Stator coil assembly bolt 3 4 N m 0 34 kgf m 2 ...

Page 67: ...GULATOR on page 3 13 7 Install Fan case and fan Refer to INSTALLING THE CASE AND FAN on page 3 16 8 Install Air filter Refer to AIR FILTER on page 3 3 9 Install Muffler Refer to INSTALLING THE MUFFLER on page 3 9 INSTALLING THE TCI UNITS The following procedure applies to all of the TCI units 1 Install TCI unit TCI unit bolt Sheave holder 90890 01701 Primary clutch holder YS 01880 A TCI unit bolt ...

Page 68: ...3 Adjust TCI unit air gap Adjustment steps a Loosen the TCI unit bolts 1 b Adjust the TCI unit air gap c Tighten the TCI unit bolts 1 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 TCI unit air gap 0 3 0 5 mm 0 011 0 019 in 1 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 TCI unit bolt 8 N m 0 8 kgf m 5 9 lb ft T R ...

Page 69: ...CH AND OIL WARNING LIGHT EQUIPPED MODELS ONLY Order Job Parts to remove Q ty Remarks Removing the engine switch and oil warning light Remove the parts in the order listed 1 Key 1 2 Nut 1 3 Washer 1 4 Engine switch cover 1 5 Engine switch 1 6 Nut 1 7 Spring washer 1 8 Oil warning light 1 1 2 3 4 5 6 7 8 ...

Page 70: ...ND FAN on page 3 14 Rectifier regulator Refer to RECTIFIER REGULATOR on page 3 13 Fuel pump Refer to FUEL PUMP on page 4 1 Cylinder cover Refer to CYLINDER COVERS on page 3 17 TCI unit Refer to TCI UNITS on page 3 19 Carburetor Refer to CARBURETOR ASSEMBLY on page 4 4 Intake manifold Refer to INTAKE MANIFOLD on page 4 14 Starter motor assembly Refer to REMOVING THE STARTER MOTOR on page 5 10 8 N m...

Page 71: ...ylinder head cover 1 4 Gasket 1 5 Locknut 2 6 Adjuster 2 7 Rocker arm 2 8 Push rod 1 Intake side 9 Push rod 1 Exhaust side 10 Pivot bolt 2 11 Push rod guide 1 1 2 3 4 5 6 7 8 9 10 11 8 N m 0 8 kgf m 5 9 lb ft 45 N m 4 5 kgf m 33 lb ft 25 N m 2 5 kgf m 18 lb ft 3 9 N m 0 39 kgf m 2 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 18 N m 1 8 kgf m 13 lb ft 1st 2nd ...

Page 72: ... Breather cover 1 13 Gasket 1 14 Breather assembly 1 15 Gasket 1 16 Cylinder head assembly 1 1 17 Gasket 1 18 Dowel pin 2 12 13 14 15 16 17 18 18 8 N m 0 8 kgf m 5 9 lb ft 45 N m 4 5 kgf m 33 lb ft 25 N m 2 5 kgf m 18 lb ft 3 9 N m 0 39 kgf m 2 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 18 N m 1 8 kgf m 13 lb ft 1st 2nd ...

Page 73: ... regulator Refer to RECTIFIER REGULATOR on page 3 13 Fuel pump Refer to FUEL PUMP on page 4 1 Cylinder cover Refer to CYLINDER COVERS on page 3 17 TCI unit Refer to TCI UNITS on page 3 19 Carburetor Refer to CARBURETOR ASSEMBLY on page 4 4 Intake manifold Refer to INTAKE MANIFOLD on page 4 14 Starter motor assembly Refer to REMOVING THE STARTER MOTOR on page 5 10 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 ...

Page 74: ... 2 5 Adjuster 2 6 Rocker arm 2 7 Push rod 1 Intake side 8 Push rod 1 Exhaust side 9 Pivot bolt 2 10 Push rod guide 1 11 Bracket 1 EH64A EH64K EH65A EH65B only 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 45 N m 4 5 kgf m 33 lb ft 25 N m 2 5 kgf m 18 lb ft 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 18 N m 1 8 kgf m 13 lb ft 1 2 3 4 5 6 8 7 9 10 11 1st 2nd ...

Page 75: ... 12 Carburetor breather hose 1 From carburetor 13 Cylinder head assembly 2 1 14 Gasket 1 15 Dowel pin 2 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 45 N m 4 5 kgf m 33 lb ft 25 N m 2 5 kgf m 18 lb ft 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 18 N m 1 8 kgf m 13 lb ft 12 13 14 15 15 1st 2nd ...

Page 76: ...ING THE VALVE CLEARANCE on page 2 12 CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylinder heads 1 Check Cylinder head combustion chamber Check the combustion chamber for carbon depos its Carbon deposits Eliminate TIP Be sure not to damage the contact surface of the cylinder 2 Check Cylinder head Cracks damage around the hole of spark plug Replace 3 Measure Cylinder he...

Page 77: ...the bolts to the specified torque in two steps and in order from 1 4 2 Install Cylinder head assembly 2 Cylinder head bolt 1 4 TIP Tighten the bolts to the specified torque in two steps and in order from 1 4 Warpage limit 0 1 mm 0 0039 in 4 1 4 2 3 Cylinder head bolt 1st 25 N m 2 5 kgf m 18 lb ft 2nd 45 N m 4 5 kgf m 33 lb ft T R 4 1 4 2 3 Cylinder head bolt 1st 25 N m 2 5 kgf m 18 lb ft 2nd 45 N ...

Page 78: ...valves Remove the parts in the order listed Cylinder head assembly Refer to CYLINDER HEAD COVERS CYL INDER HEADS on page 3 26 1 Valve cotter 4 2 Valve spring retainer 2 3 Valve spring 2 4 Valve spring seat 1 Exhaust side only 5 Exhaust valve 1 6 Valve stem seal 1 Intake side only 7 Intake valve 1 1 1 2 2 3 3 7 5 4 6 ...

Page 79: ...es Remove the parts in the order listed Cylinder head assembly Refer to CYLINDER HEAD COVERS CYL INDER HEADS on page 3 26 1 Valve cotter 4 2 Valve spring retainer 2 3 Valve spring 2 4 Valve spring seat 1 Exhaust side only 5 Exhaust valve 1 6 Valve stem seal 1 Intake side only 7 Intake valve 1 1 1 2 2 3 3 5 7 6 4 ...

Page 80: ... the parts below from the exhaust side Valve cotter 1 Valve spring retainer 2 Valve spring 3 Valve spring seat 4 Exhaust valve 5 Remove the parts using the valve spring compres sor 6 CHECKING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valve and valve springs 1 Measure Valve stem length a Valve head diameter b 1 2 3 4 5 6 Do not compress the valve spring more than ne...

Page 81: ...417 in Valve stem length Exhaust 80 3 mm 3 1614 in Valve head diameter Intake 34 99 35 01 mm 1 3775 1 3783 in Valve head diameter Exhaust 30 9 31 1 mm 1 2165 1 2244 in a Valve stem diameter Intake 5 970 5 985 mm 0 2350 0 2356 in Valve stem diameter Exhaust 5 970 5 985 mm 0 2350 0 2356 in Limit Intake 5 940 mm 0 2338 in Limit Exhaust 5 940 mm 0 2338 in Valve stem runout limit 0 01 mm 0 0004 in a Va...

Page 82: ...the valve face a 3 Insert the valve into the valve guide and use a valve lapper to contact the valve face with the valve seat TIP Do not rotate the valve while the valve face is contacting the valve seat 4 Measure Valve face contact width a Make sure that the contact width along the entire valve face is within specifications Out of specification rough eccentric wear Replace a a a Valve face contac...

Page 83: ...y fine lapping compound on the valve face and lap the valve as described in step 1 3 Once the contacting surface of the valve face is pol ished and becomes shiny apply mechanic s blue lay out fluid to make sure that there are traces of even contact in the center of the valve face TIP After every lapping procedure clean off the compound from the valve face and valve seat a Valve seat contact width ...

Page 84: ...ide Exhaust valve 1 Valve spring seat 2 Valve spring 3 Valve spring retainer 4 Valve cotter 5 Install the parts using the valve spring compressor 6 TIP When installing the valve stem seal do so in such a way that the outer spring a does not come off 5 4 3 2 1 6 Valve spring compressor 90890 01253 5 4 3 2 1 6 Valve spring compressor 90890 01253 Do not compress the valve spring more than neces sary ...

Page 85: ...emove the parts in the order listed Cylinder head assembly Refer to CYLINDER HEAD COVERS CYL INDER HEADS on page 3 26 Crankshaft Refer to PISTONS CAMSHAFT CRANK CASE AND CRANKSHAFT on page 3 44 1 Oil pump cover 1 2 O ring 1 3 Inner rotor 1 4 Outer rotor 1 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 4 3 2 1 ...

Page 86: ...Out of specification Replace 3 Check Oil pump operation Rough movement Replace ASSEMBLING THE OIL PUMP 1 Install Crankshaft Refer to PISTONS CAMSHAFT CRANKCASE AND CRANKSHAFT on page 3 44 TIP Install the oil pump related parts after installing the crank shaft If the oil pump related parts are installed first the crankshaft cannot be installed properly 1 4 3 2 1 2 b a Inner rotor to outer rotor tip...

Page 87: ...ter rotor 3 Install O ring 1 Outer rotor 2 Inner rotor 3 Oil pump cover 4 Oil pump cover bolt TIP The oil pump cover should be installed with the arrow mark a facing upward Recommended lubricant Engine oil a 4 3 2 1 Oil pump cover bolt 8 N m 0 8 kgf m 5 9 lb ft New T R ...

Page 88: ...ks Removing the crankcase cover Remove the parts in the order listed Cylinder head assembly Refer to CYLINDER HEAD COVERS CYL INDER HEADS on page 3 26 1 Spring washer 1 2 Washer 1 3 Woodruff key 1 4 Crankcase cover 1 5 Gasket 1 6 Flyweight shaft assembly 1 7 Washer 1 8 Thrust bearing 1 9 Washer 1 9 8 6 3 1 2 4 5 10 7 25 N m 2 5 kgf m 18 lb ft 13 N m 1 3 kgf m 9 6 lb ft ...

Page 89: ...CAMSHAFT CRANKCASE AND CRANKSHAFT 3 45 1 2 3 4 5 6 7 8 9 10 ENGINE CAMSHAFT Order Job Parts to remove Q ty Remarks Removing the camshaft Remove the parts in the order listed 1 Camshaft 1 2 Valve lifter 4 2 2 1 ...

Page 90: ...stons and crankshaft Remove the parts in the order listed 1 Connecting rod cap 2 2 Crankshaft 1 3 Crankshaft shim 1 4 Connecting rod 2 5 Piston pin circlip 4 6 Piston pin 2 7 Piston 2 8 Piston ring 2 Top ring 9 Piston ring 2 2nd ring 10 Piston ring 2 Oil ring 1 2 3 4 5 6 7 8 9 10 5 5 7 10 9 8 5 6 1 25 N m 2 5 kgf m 18 lb ft 25 N m 2 5 kgf m 18 lb ft 4 ...

Page 91: ...ty Remarks Removing the crankcase Remove the parts in the order listed 1 Oil drain bolt 2 2 Gasket 2 3 Oil pump strainer 1 4 Clip 1 5 Washer 1 6 Washer 1 7 Governor fork 1 8 Relief valve 1 1 3 7 2 2 1 4 5 8 20 N m 2 0 kgf m 15 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 6 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft ...

Page 92: ...heck Oil pump strainer Cracks damage Replace ASSEMBLING THE OIL PUMP STRAINER 1 Install Oil pump strainer Oil pump strainer bolt REMOVING THE FLYWEIGHT SHAFT ASSEMBLY AND GOVERNOR FORK 1 Remove Crankcase cover Governor assembly 2 Remove Clip 1 Governor fork 2 Washer 3 Relief valve operating pressure 373 kPa 3 73 kgf cm 54 09 psi Relief valve 20 N m 2 0 kgf m 15 lb ft T R Oil pump strainer bolt 3 8...

Page 93: ...assembly by tapping the weight shaft from outside of the crankcase cover DISASSEMBLING THE FLYWEIGHT SHAFT ASSEMBLY 1 Remove Flyweight shafts 1 Weights 2 Collar 3 Weight shaft 4 CHECKING THE FLYWEIGHT SHAFT ASSEMBLY 1 Check Flyweight shaft assembly move smoothly Rough movement Replace 2 Check Weights Flyweight shafts Collar Weight shaft Wear damage Replace 1 2 3 4 1 2 2 3 1 4 ...

Page 94: ...hafts 4 INSTALLING THE FLYWEIGHT SHAFT ASSEMBLY AND GOVERNOR FORK 1 Install Washer 1 Thrust bearing 2 Washer 3 Flyweight shaft assembly 4 2 Install Washer 1 Governor fork 2 Clip 3 3 Install Governor assembly Crankcase cover Refer to INSTALLING THE CRANKCASE COVER on page 3 54 4 Adjust Governor Refer to ADJUSTING THE GOVERNOR on page 4 13 4 3 3 2 4 1 New 4 3 2 1 3 2 1 1 ...

Page 95: ... Since there are two types of camshafts refer to the illus tration and check the camshaft gear mark Remove the camshaft 1 when the camshaft gear mark a and the crankshaft gear mark b are aligned as shown 2 Remove Intake valve lifters 1 Exhaust valve lifters 2 CHECKING THE CAMSHAFT 1 Check Camshaft Cracks damage wear Replace 1 a b 1 a b 1 1 2 2 Mark so as not to confuse the valve lifters when insta...

Page 96: ... 35 46 mm 1 3881 1 3960 in EH63K EH64A EH64K EH65A EH65B 35 56 35 76 mm 1 3999 1 4078 in EH72A EH72B EH72K Limit 35 16 mm 1 3842 in EH63K EH64A EH64K EH65A EH65B 35 46 mm 1 3960 in EH72A EH72B EH72K Lobe height a Exhaust 35 26 35 46 mm 1 3881 1 3960 in EH63K EH64A EH64K EH65A EH65B 35 88 36 08 mm 1 4125 1 4204 in EH72A EH72B EH72K Limit 35 16 mm 1 3842 in EH63K EH64A EH64K EH65A EH65B 35 78 mm 1 4...

Page 97: ...1 Check Crankcase cover Damage Replace Bearing Noise wear rotational failure Replace 1 1 2 2 1 a b 1 a b Since there are two types of camshafts refer to the illustration and check the camshaft gear mark Be sure to align the camshaft 1 gear mark a with the crankshaft gear mark b After installing the intake and exhaust valves rotate the crankshaft clockwise and check that there is no contact with th...

Page 98: ...n and piston rings as a set 2 Measure Cylinder warpage TIP Measure the warpage on the contact surface of the cylin der head at six points using a straight edge and thickness gauge Out of specification Replace the crankcase assembly 3 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cylinder bore gauge 10 1 2 3 4 5 6 7 8 9 10 Crankcase cover bolt 25 N m 2 5 kgf m 18 lb ft...

Page 99: ...tom edge EH72A EH72B EH72K d If out of specification replace the piston and pis ton rings as a set e Calculate the piston to cylinder clearance with the following formula Bore 80 000 80 019 mm 3 1496 3 1503 in EH63K EH64A EH64K EH65A EH65B 84 000 84 022 mm 3 3070 3 3079 in EH72A EH72B EH72K Warpage limit 0 1 mm 0 0039 in C maximum of D1 D2 D3 D4 D5 D6 P a Piston diameter 79 960 79 980 mm 3 1480 3 ...

Page 100: ...ration grooves Replace the piston pin and then check the lubrication system 2 Measure Piston pin hole inside diameter a Out of specification Replace 3 Measure Piston pin diameter a Out of specification Replace Piston to cylinder clearance 0 012 0 051 mm 0 0004 0 0020 in EH63K EH64A EH64K EH65A EH65B 0 0 042 mm 0 0 0016 in EH72A EH72B EH72K Limit 0 15 mm 0 0059 in a Piston pin hole inside diameter ...

Page 101: ...sure Piston ring side clearance Out of specification Replace the piston and pis ton rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and pis ton rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end ...

Page 102: ...HECKING THE CONNECTING RODS OIL CLEARANCE TIP Measure the oil clearance if replacing the crankshaft or connecting rod Top ring End gap installed 0 20 0 40 mm 0 0079 0 0157 in Limit 1 50 mm 0 0590 in 2nd ring End gap installed 0 20 0 40 mm 0 0079 0 0157 in Limit 1 50 mm 0 0590 in Oil ring End gap installed 0 20 0 70 mm 0 0079 0 0276 in Limit 1 50 mm 0 0590 in 1 a Crank pin outside diameter 38 956 3...

Page 103: ...ollowing procedure applies to all of the pistons and piston rings 1 Install Top ring 1 2nd ring 2 Oil ring 3 TIP Be sure to install the EH63K EH64A EH64K EH65A EH65B 2nd ring so that the R mark a faces toward the piston head Be sure to install the EH72A EH72B EH72K 2nd ring so that the N mark b faces toward the piston head Make sure that the piston rings move smoothly 2 Apply the engine oil to the...

Page 104: ...or the piston to be installed on cylinder 1 install so that the number 1 b on the connecting rod faces the crankcase cover side and for the piston to be installed on cylinder 2 install so that the number 2 c on the connecting rod faces the crankcase cover side INSTALLING THE CRANKSHAFT 1 Make sure that the end gap of each piston ring is positioned correctly as shown in the illustration 2 Install P...

Page 105: ... cyl inder 2 install so that the number 2 b on the connect ing rod faces the crankcase cover side 5 Install Crankshaft 1 6 Install Connecting rod cap 1 1 Connecting rod cap bolts 1 2 TIP Make sure that the mark a on the connecting rod is aligned with the mark b on the connecting rod cap Tighten the connecting rod cap bolts alternately two to three times 1 a 1 1 2 b 1 1 2 b 1 2 2 a Connecting rod c...

Page 106: ... Pre adjustment clearance X Calculation and adjustment procedure a Measure dimensions 1 and 2 b Measure the value of the A part of the crank case cover 1 c Measure the value of the B part of the crank shaft sprocket 3 and the crankcase 4 d Calculate the pre adjustment clearance X Pre adjustment clearance X value of A value when gasket 5 is tightened 0 48 mm value of the B dimension 1 dimension 2 e...

Page 107: ... of the depth gauge dimension 2 on the b side Place a horizontal bar or a base on the crankcase and install a depth gauge as shown in the illustration 2 Select and install the parts below Adjustment shim TIP Adjust so that the clearance value after adjustment is 0 2 mm or less List of adjustment shim thicknesses 6 7 8 a b Part number Shim thickness 7D3 11561 00 0 8 0 04 7D3 11561 10 1 0 0 04 7D3 1...

Page 108: ...PISTONS CAMSHAFT CRANKCASE AND CRANKSHAFT 3 64 1 2 3 4 5 6 7 8 9 10 ENGINE MEMO ...

Page 109: ... Order Job Parts to remove Q ty Remarks Removing the fuel pump Remove the parts in the order listed 1 Fuel filter 1 2 Fuel hose 1 3 Fuel pump 1 4 Fuel pump bracket 1 5 Pulsar hose 1 6 Fuel hose carburetor side 1 1 2 3 4 5 6 5 N m 0 5 kgf m 3 7 lb ft 8 N m 0 8 kgf m 5 9 lb ft ...

Page 110: ...ob Parts to remove Q ty Remarks Removing the fuel pump Remove the parts in the order listed 1 Fuel filter 1 2 Fuel hose 1 3 Fuel pump 1 4 Fuel pump bracket 1 5 Pulsar hose 1 6 Fuel hose carburetor side 1 1 2 3 4 5 6 5 N m 0 5 kgf m 3 7 lb ft 8 N m 0 8 kgf m 5 9 lb ft ...

Page 111: ...uum pump vacuum pres sure pump gauge set 1 to the pulsar hose 2 b Place the container near the lower side of the fuel hose carburetor side 3 c Operate the manual vacuum pump vacuum pressure pump gauge set 1 and check if gaso line flows out from the fuel hose carburetor side 3 d If the gasoline does not flow out replace the fuel pump 2 3 4 1 2 1 3 Vacuum pressure pump gauge set 90890 06945 Pressure...

Page 112: ...er to MUFFLER on page 3 5 Air filter Refer to AIR FILTER on page 3 3 Fan case Refer to CASE AND FAN on page 3 14 1 Spring 1 2 Choke lever 1 3 Choke lever rod spring 1 1 4 Throttle lever assembly 1 5 Spring 1 6 Governor arm 1 7 Link rod spring 1 1 8 Carburetor assembly 1 The illustration is for EH72B 9 Gasket 1 10 N m 1 0 kgf m 7 4 lb ft 18 N m 1 8 kgf m 13 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 2 3 ...

Page 113: ...emove Q ty Remarks Disassembling the carburetor Disassemble the parts in the order listed 1 Drain screw spring 1 1 2 Throttle stop screw spring 1 1 3 Float pin screw 1 4 Float pin 1 5 Float valve 1 6 Float 1 7 Slow jet 1 8 Main jet 1 9 Gasket 2 10 Solenoid valve 2 11 Lead assembly 1 8 9 10 7 1 2 11 3 4 5 6 9 10 ...

Page 114: ...CARBURETOR ASSEMBLY 4 6 1 2 3 4 5 6 7 8 9 10 FUEL Order Job Parts to remove Q ty Remarks 12 Gasket 1 13 Screw 4 14 O ring 1 14 13 12 ...

Page 115: ...arts to remove Q ty Remarks Disassembling the carburetor Disassemble the parts in the order listed 1 Drain screw spring 1 1 2 Throttle stop screw spring 1 1 3 Float pin screw 1 4 Float pin 1 5 Float valve 1 6 Float 1 7 Slow jet 1 8 Main jet 1 9 Gasket 2 10 Solenoid valve 1 11 Plug 1 8 9 10 7 1 2 3 4 5 6 9 11 ...

Page 116: ...CARBURETOR ASSEMBLY 4 8 1 2 3 4 5 6 7 8 9 10 FUEL Order Job Parts to remove Q ty Remarks 12 Gasket 1 13 Screw 4 14 O ring 1 14 13 12 ...

Page 117: ...FLER on page 3 5 Air filter Refer to AIR FILTER on page 3 3 Fan case Refer to CASE AND FAN on page 3 14 1 Spring 1 2 Spring 1 3 Choke lever rod 1 4 Throttle lever assembly 1 5 Link rod spring 1 1 6 Governor arm 1 7 Gasket 1 8 Joint 1 9 Gasket 1 10 Carburetor assembly 1 11 Gasket 1 8 N m 0 8 kgf m 5 9 lb ft 8 N m 0 8 kgf m 5 9 lb ft 7 9 8 5 3 6 1 4 10 4 0 N m 0 40 kgf m 3 0 lb ft 11 2 10 N m 1 0 kg...

Page 118: ...rts in the order listed 1 Drain screw spring 1 1 2 Float chamber 1 3 Screw 2 4 Solenoid valve 1 5 Gasket 1 6 Float pin 1 7 Float valve 1 8 Spacer 1 9 Float 1 10 Gasket 1 11 O ring 1 12 Main jet 1 Right side 13 Main jet 1 Left side 14 Gasket 1 15 Gasket 1 16 Throttle stop screw spring 1 1 9 5 1 10 12 13 14 8 3 6 7 11 4 15 16 2 0 N m 0 20 kgf m 1 5 lb ft 3 9 N m 0 39 kgf m 2 9 lb ft 2 ...

Page 119: ...Joint EH72A EH72B EH72K 3 CHECKING THE CARBURETOR 1 Check Carburetor assembly Cracks damage Replace 2 Check Throttle valve operation Does not move smoothly Replace Engine speed The engine speed cannot be adjusted with ENGINE SPEED EH63K EH64A EH64K EH65A EH65B on page 2 14 or ENGINE SPEED EH72A EH72B EH72K on page 2 16 Replace 2 1 1 1 2 3 1 A EH63K EH64A EH64K EH65A EH65B B EH72A EH72B EH72K ...

Page 120: ...rottle lever assembly Governor arm Spring 1 TIP Install the long side a of the spring to the throttle lever assembly the short side b to the hole d position of the governor arm Install the link rod spring in the hole c position of the governor arm 2 1 1 1 2 3 1 A EH63K EH64A EH64K EH65A EH65B B EH72A EH72B EH72K Carburetor assembly bolt EH63K EH64A EH64K EH65A EH65B 18 N m 1 8 kgf m 13 lb ft Carbu...

Page 121: ...djustment steps a Loosen the governor arm bolt 1 b Turn the governor arm 2 counterclockwise until it stops so that the throttle lever is fully open c Turn the governor fork 3 counterclockwise until it stops d Tighten the governor arm bolt 1 1 2 3 Governor arm bolt 10 N m 1 0 kgf m 7 4 lb ft T R ...

Page 122: ...5 Air filter Refer to AIR FILTER on page 3 3 Fan case and fan Refer to CASE AND FAN on page 3 14 Rectifier regulator Refer to RECTIFIER REGULATOR on page 3 13 Fuel pump Refer to FUEL PUMP on page 4 1 Cylinder cover Refer to CYLINDER COVERS on page 3 17 TCI unit Refer to TCI UNITS on page 3 19 Carburetor Refer to CARBURETOR ASSEMBLY on page 4 4 1 Intake manifold 1 2 Gasket 2 1 2 2 18 N m 1 8 kgf m ...

Page 123: ...n page 3 3 Fan case and fan Refer to CASE AND FAN on page 3 14 Rectifier regulator Refer to RECTIFIER REGULATOR on page 3 13 Fuel pump Refer to FUEL PUMP on page 4 1 Cylinder cover Refer to CYLINDER COVERS on page 3 17 TCI unit Refer to TCI UNITS on page 3 19 Carburetor Refer to CARBURETOR ASSEMBLY on page 4 4 1 Intake manifold 1 2 Gasket 2 3 Bracket 1 18 N m 1 8 kgf m 13 lb ft 8 N m 0 8 kgf m 5 9...

Page 124: ...manifold 1 Gasket 2 CHECKING THE INTAKE MANIFOLD 1 Check Intake manifold Cracks damage Replace INSTALLING THE INTAKE MANIFOLD 1 Install Gasket 1 Intake manifold 2 1 2 2 1 2 2 A EH63K EH64A EH64K EH65A EH65B B EH72A EH72B EH72K 2 1 1 2 1 1 A EH63K EH64A EH64K EH65A EH65B B EH72A EH72B EH72K New ...

Page 125: ...INTAKE MANIFOLD 4 17 1 2 3 4 5 6 7 8 9 10 FUEL 2 Install Intake manifold nut 4 4 A EH63K EH64A EH64K EH65A EH65B B EH72A EH72B EH72K Intake manifold nut 18 N m 1 8 kgf m 13 lb ft T R ...

Page 126: ...5 1 1 2 3 4 5 6 7 8 9 10 ELECTRICAL ELECTRICAL CIRCUIT DIAGRAM G M B L S OFF RUN START B B R R W Y Y Gy B W Y R W B G 1 2 3 4 5 6 7 e 8 8 9 0 q w ...

Page 127: ... 2 Oil pressure switch 8 Spark plug 3 Oil warning light option 9 TCI unit 1 4 Engine switch option 10 Rectifier regulator 5 Battery 12 V option 11 Stator coil assembly 6 Tachometer hour meter option 12 TCI unit 2 13 Starter relay B Black W White G Green Gy Gray R Red B W Black White Y Yellow ...

Page 128: ...ELECTRICAL COMPONENTS 5 3 1 2 3 4 5 6 7 8 9 10 ELECTRICAL ELECTRICAL COMPONENTS 3 1 1 6 5 2 4 ...

Page 129: ...ELECTRICAL COMPONENTS 5 4 1 2 3 4 5 6 7 8 9 10 ELECTRICAL 1 TCI unit 2 Stator coil assembly 3 Oil pressure switch 4 Engine switch equipped models only 5 Rectifier regulator 6 Starter motor ...

Page 130: ...back and forth between the switch positions a few times Measurement example of the electric components CHECKING THE OIL PRESSURE SWITCH 1 Drain Engine oil 2 Disconnect Oil pressure switch lead Ω O L Never insert the tester probes into the coupler termi nal slots Always insert the probes from the opposite end of the coupler taking care not to loosen or dam age the leads Digital circuit tester CD732...

Page 131: ... page 2 3 3 Check Ignition spark gap Out of specification Perform the ignition system troubleshooting starting with step 6 Refer to ENGINE DOES NOT START on page 6 1 TIP If the ignition spark gap is within the specification the igni tion system circuit is operating normally a Disconnect the spark plug cap 1 from the spark plug b Connect the ignition checker 2 as shown c Connect the ignition checke...

Page 132: ...y coil resistance Out of specification Replace a Remove the ignition coil TCI unit b Connect the digital circuit tester to the pri mary terminal c Measure the primary coil resistance CHECKING THE IGNITION COIL TCI UNIT SECONDARY RESISTANCE 1 Check Secondary coil resistance Out of specification Replace TCI unit air gap 0 3 0 5 mm 0 011 0 019 in Primary coil resistance 0 5 1 2 Digital circuit tester...

Page 133: ...ester to the engine switch connectors as shown c Check the engine switch continuity CHECKING THE STARTER MOTOR OPERATION 1 Remove Starter motor 2 Check Starter motor operation 1 2 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Positive tester probe High tension cord 1 Negative tester probe Wire 2 2 1 OFF RUN START LOW OIL a b Digital circuit tester CD732 9089...

Page 134: ... motor operation c Connect the jumper lead 1 to the side of the battery and the starter relay terminal as shown in the illustration and ground the side of the bat tery to the main body of the starter motor d Check the starter motor operation CHECKING THE WIRE HARNESS 1 Check Connector terminal Dirt corrosion or poor connection Clean or replace the connector 1 The wire to be used as the jumper lead...

Page 135: ...ING THE STARTER MOTOR Order Job Parts to remove Q ty Remarks Removing the starter motor Remove the parts in the order listed Rectifier regulator Refer to RECTIFIER REGULATOR on page 3 13 Cylinder cover Refer to CYLINDER COVERS on page 3 17 1 Starter motor assembly 1 18 N m 1 8 kgf m 13 lb ft 1 ...

Page 136: ...tion Replace a Connect the digital circuit tester to the stator coil assembly b Measure the stator coil assembly resistance CHECKING THE RECTIFIER REGULATOR 1 Remove Rectifier regulator Refer to RECTIFIER REGULATOR on page 3 13 Stator coil assembly resistance 0 2 20 at 20 C 68 F Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 Positive tester probe Connector te...

Page 137: ...ut of specification Replace TIP Measure the resistance value between terminals a d Refer to the table for the resistance value between termi nals d b c a a b c d a b c d A Negative terminal B Positive terminal Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 ...

Page 138: ...CHARGING SYSTEM 5 13 1 2 3 4 5 6 7 8 9 10 ELECTRICAL MEMO ...

Page 139: ...SISTANCE on page 5 7 Replace the ignition coil 7 Check the carburetor for clogged passages or fuel overflow Clean 8 Check the compression pressure Refer to MEASURING THE COMPRESSION PRES SURE on page 3 1 Too high Decarbonize the combustion chamber if there is carbon deposits Too low Next checking steps 9 Measure the valve clearance Refer to ADJUSTING THE VALVE CLEARANCE on page 2 12 Adjust the val...

Page 140: ...ircuit is OK No Checking steps Possible remedy 1 Check the fuel level Add the fuel if it is insufficient 2 Check if the fuel hoses are clogged Clean 3 Check if there is air suction from the carburetor joint gas ket or throttle shaft Tighten the carburetor nuts securely Replace the carburetor joint or gasket with a new one 4 Check the compression pressure Refer to MEASURING THE COMPRESSION PRES SUR...

Page 141: ...CE on page 2 12 Adjust the valve clearance 5 Check the valve face and valve seat for wear Refer to VALVES on page 3 34 Resurface or replace the valve face and valve seat 6 Check if the marks on the crankshaft and camshaft are aligned Refer to INSTALLING THE VALVE LIFTERS AND CAM SHAFT on page 3 53 Correct 7 Check if there is seizure wear or damage on the piston piston ring or cylinder Refer to PIS...

Page 142: ... the valve clearance Refer to ADJUSTING THE VALVE CLEARANCE on page 2 12 Adjust the valve clearance 8 Check the valve face and valve seat for wear Refer to VALVES on page 3 34 Resurface or replace the valve face and valve seat 9 Check if there is seizure wear or damage on the piston piston ring or cylinder Refer to PISTONS CAMSHAFT CRANKCASE AND CRANKSHAFT on page 3 44 Rebore or replace No Checkin...

Page 143: ...the governor link operate smoothly Adjust or replace 2 Check that the governor spring is stretched Replace 3 Check the governor adjustment Refer to ADJUSTING THE GOVERNOR on page 4 13 Adjust 4 Check the governor weight and governor bushing function Refer to CHECKING THE FLYWEIGHT SHAFT ASSEM BLY on page 3 49 Adjust or replace ...

Page 144: ...GOVERNOR OPERATION 6 6 1 2 3 4 5 6 7 8 9 10 TROUBLESHOOTING MEMO ...

Page 145: ...H65B EH65A 46 kg 101 41 lb EH72A EH72B EH72K Engine Engine type Air cooled 4 cycle V type 2 cylinder OHV gasoline engine Cylinder arrangement 2 Displacement 0 653 L 653 cm EH63K EH64K EH64A EH65B EH65A 0 720 L 720 cm EH72A EH72B EH72K Bore Stroke 80 0 65 0 mm 3 1496 2 5590 in EH63K EH64K EH64A EH65B EH65A 84 0 65 0 mm 3 3070 2 5590 in EH72A EH72B EH72K Compression ratio 8 3 Standard compression pr...

Page 146: ...Governor type Centrifugal weight system Electrical Ignition system TCI Ignition timing 3600 r min BTDC 26 5 2 3600 r min Spark plug type BPR5ES NGK Except for EH64A BPR4EY NGK EH64A Spark plug gap 0 7 0 8 mm 0 028 0 031 in Except for EH64A 0 6 0 7 mm 0 024 0 028 in EH64A Solenoid valve resistance 34 2 41 8 at 20 C 68 F The power rating of the engine indicated in the SPECIFICATIONS is the net power...

Page 147: ...0 0 mm 0 3937 in EH72A EH72B EH72K Piston pin hole inside diameter 21 002 21 011 mm 0 8268 0 8272 in Limit 21 041 mm 0 8283 in Piston pin Piston pin diameter 20 989 21 002 mm 0 8263 0 8268 in Limit 20 969 mm 0 8255 in Piston ring Top ring Type Barrel Dimensions 1 5 3 4 mm 0 0590 0 1338 in EH63K EH64K EH64A EH65B EH65A 1 5 3 6 mm 0 0590 0 1417 in EH72A EH72B EH72K End gap installed 0 20 0 40 mm 0 0...

Page 148: ...utside diameter 38 956 38 970 mm 1 5336 1 5342 in Limit 38 900 mm 1 5314 in Connecting rod Small end diameter 21 010 21 023 mm 0 8271 0 8276 in Big end diameter 39 000 39 010 mm 1 5354 1 5358 in Camshaft Camshaft lobe dimensions Lobe height Intake 35 26 35 46 mm 1 3881 1 3960 in EH63K EH64K EH64A EH65B EH65A 35 56 35 76 mm 1 3999 1 4078 in EH72A EH72B EH72K Limit 35 16 mm 1 3842 in EH63K EH64K EH6...

Page 149: ...2 0 mm 0 0787 in Valve seat contact width Intake 0 7 1 0 mm 0 0275 0 0393 in Valve seat contact width Exhaust 0 7 1 0 mm 0 0275 0 0393 in Limit Intake 2 0 mm 0 0787 in Limit Exhaust 2 0 mm 0 0787 in Valve stem runout limit 0 01 mm 0 0004 in Valve guide Valve guide inside diameter Intake 6 035 6 053 mm 0 2375 0 2383 in Valve guide inside diameter Exhaust 6 035 6 053 mm 0 2375 0 2383 in Stem to guid...

Page 150: ...11 EH65A 7B3 1410101 EH72A EH72B EH72K Bore size ø27 EH63K EH64K EH64A EH65B EH65A ø28 EH72A EH72B EH72K Main jet 132 EH63K EH64K EH64A EH65B EH65A 132 L 133 R EH72A EH72B EH72K Main nozzle ø2 8 EH63K EH64K EH64A EH65B EH65A ø3 0 EH72A EH72B EH72K Float height 12 mm 0 472 in EH63K EH64K EH64A EH65B EH65A 3 5 mm 0 14 in EH72A EH72B EH72K Governor arm Tension spring attach hole posi tion 2 Engine sp...

Page 151: ...oil Primary coil resistance 0 5 Secondary coil resistance 8 16 k TCI unit air gap 0 3 0 5 mm 0 011 0 019 in Minimum ignition spark gap 6 0 mm 0 2362 in Charging system Stator coil assembly resistance 0 2 20 at 20 C 68 F Rectifier regulator Regulator type Single phase full wave rectification Voltage 13 8 14 3 V Oil pressure switch Resistance when engine is stopped 0 ...

Page 152: ...gf m 5 2 lb ft Flywheel nut M18 1 5 110 N m 11 kgf m 81 lb ft Governor arm bolt M6 1 0 10 N m 1 0 kgf m 7 4 lb ft Throttle lever assembly bolt M6 1 0 8 N m 0 8 kgf m 5 9 lb ft Accelerator lever nut EH63K EH64A EH64K EH65A EH65B M6 1 0 8 N m 0 8 kgf m 5 9 lb ft Free accelerator lever nut EH72A EH72B EH72K M6 1 0 7 N m 0 7 kgf m 5 2 lb ft Choke lever bolt EH63K EH64A EH64K EH65A EH65B M6 1 0 4 0 N m...

Page 153: ...lb ft Throttle valve screw EH63K EH64A EH64K EH65A EH65B 0 7 N m 0 07 kgf m 0 52 lb ft Throttle valve screw EH72A EH72B EH72K 0 9 N m 0 09 kgf m 0 66 lb ft Choke valve screw EH72A EH72B EH72K 0 9 N m 0 09 kgf m 0 66 lb ft Float chamber screw EH72A EH72B EH72K 3 9 N m 0 39 kgf m 2 9 lb ft Carburetor drain screw EH63K EH64A EH64K EH65A EH65B 2 0 N m 0 20 kgf m 1 5 lb ft Carburetor drain screw EH72A ...

Page 154: ... assemblies are included in the applicable sections of this book To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specifications call for clean dry threads Components should be at room temperature Thread size Tightening torque N m kgf m lb ft M4 2 0 0 20 1 5 M5 3 0 0 30 2 2 M6 7 0 7 5 2 M7 10 1 0 7 4 M8 1...

Page 155: ...l lip Governor fork oil seal lip Bearing Connecting rod big end Crank pin Crankshaft journal Connecting rod cap bolt Piston pin Piston Crankshaft gear teeth Valve stem Valve push rod end Camshaft lobe Camshaft gear teeth Camshaft journal Governor collar internal surface Governor fork meet surface Governor weight moving point LS E E E E E E E E E E E E E E E E ...

Page 156: ...TIONS WIRE ROUTING DIAGRAM FUEL PUMP AND FUEL HOSE EH63K 1 Oil pressure switch 3 Fuel hose 2 Spark plug cap 4 Fuel pump A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 157: ... SPECIFICATIONS FUEL PUMP AND FUEL HOSE EH64A 1 Oil pressure switch 3 Fuel hose 2 Spark plug cap 4 Fuel pump A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 158: ...ICATIONS FUEL PUMP AND FUEL HOSE EH64K EXCEPT FOR KOR 1 Oil pressure switch 3 Fuel hose 2 Spark plug cap 4 Fuel pump A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 159: ...CIFICATIONS FUEL PUMP AND FUEL HOSE EH64K FOR KOR 1 Oil pressure switch 3 Fuel hose 2 Spark plug cap 4 Fuel pump A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 160: ... Oil pressure switch 5 Spark plug cap 2 Wire harness assembly 6 Fuel hose 3 Relay 7 Fuel pump 4 Clamp A Clamp all wire leads after winding 1 5 or more turns B Point the spark plug cap in the direction shown in the illustration C Install the grommet all the way to the back of the fan case groove ...

Page 161: ... SPECIFICATIONS FUEL PUMP AND FUEL HOSE EH65B 1 Oil pressure switch 3 Fuel hose 2 Spark plug cap 4 Fuel pump A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 162: ...FUEL PUMP AND FUEL HOSE EH72A 1 Oil pressure switch 4 Spark plug cap 2 Wire harness assembly 5 Fuel hose 3 Relay 6 Fuel pump A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 163: ...IONS FUEL PUMP AND FUEL HOSE EH72B FOR SEA EH72K FOR CHN 1 Oil pressure switch 3 Fuel hose 2 Spark plug cap 4 Fuel pump A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 164: ...ICATIONS FUEL PUMP AND FUEL HOSE EH72K EXCEPT FOR CHN 1 Oil pressure switch 3 Fuel hose 2 Spark plug cap 4 Fuel pump A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 165: ...IRE ROUTING DIAGRAM 7 21 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS AIR FILTER CARBURETOR AND FUEL HOSE EH63K EH64A EH64K EXCEPT FOR KOR 1 Carburetor 3 Clamp 2 Air filter element A Insert the hose until it hits ...

Page 166: ...WIRE ROUTING DIAGRAM 7 22 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS AIR FILTER CARBURETOR AND FUEL HOSE EH64K FOR KOR EH65A EH65B 1 Carburetor 3 Clamp 2 Air filter element A Insert the hose until it hits ...

Page 167: ...WIRE ROUTING DIAGRAM 7 23 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS AIR FILTER CARBURETOR AND FUEL HOSE EH72A EH72B EH72K 1 Carburetor 3 Clamp 2 Air filter element A Insert the hose until it hits ...

Page 168: ...OR KOR 1 Fuel pump 4 Breather hose 2 Fuel hose 5 Carburetor breather hose 3 Carburetor 6 Intake manifold A Insert the breather hose to the base B Insert the carburetor breather hose to the base of the carburetor pipe C Tighten together with the bracket D Install the clamp at the position shown in the illustration ...

Page 169: ... EH65B 1 Fuel pump 4 Breather hose 2 Fuel hose 5 Carburetor breather hose 3 Carburetor 6 Intake manifold A Insert the breather hose to the base B Insert the carburetor breather hose to the base of the carburetor pipe C Tighten together with the bracket D Install the clamp at the position shown in the illustration ...

Page 170: ...FOLD EH72A EH72B EH72K 1 Fuel pump 4 Intake manifold 2 Fuel hose 5 Carburetor breather hose 3 Breather hose 6 Clamp A Insert the carburetor breather hose to the base of the carburetor pipe B Insert the breather hose to the base C Install the clamp at the position shown in the illustration ...

Page 171: ...For the terminal install the spark plug cap after caulking to the high tension cord B Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in C There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie D Route over the TCI unit mount ...

Page 172: ...For the terminal install the spark plug cap after caulking to the high tension cord B Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in C There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie D Route over the TCI unit mount ...

Page 173: ...nit 2 A Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in B For the terminal install the spark plug cap after caulking to the high tension cord C There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie D Route over the TCI unit mount ...

Page 174: ...2 A For the terminal install the spark plug cap after caulking to the high tension cord B Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in C There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie D Route over the TCI unit mount ...

Page 175: ...l the spark plug cap after caulking to the high tension cord B Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in C Connect the carburetor terminal to red lead D There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie E Route over the TCI unit mount ...

Page 176: ...For the terminal install the spark plug cap after caulking to the high tension cord B Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in C There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie D Route over the TCI unit mount ...

Page 177: ... cap after caulking to the high tension cord B Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in C Red wire connection of wire lead 1 terminal does not bind only in this place D There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie E Route over the TCI unit...

Page 178: ...I unit 2 A For the terminal install the spark plug cap after caulking to the high tension cord B Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in C There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie D Route over the TCI unit mount ...

Page 179: ...nit 2 A For the terminal install the spark plug cap after caulking to the high tension cord B Position the lock portion on the lower side of the intake manifold Cut the extra portion plastic locking tie so that projection is 0 mm 0 in C There should be no looseness or tightness of the lead Adjustment before and after the plastic locking tie D Route over the TCI unit mount ...

Page 180: ...1 Spark plug cap 5 Clamp 2 2 Rectifier regulator 6 TCI unit 1 3 Starter motor 7 Clamp 1 4 Flywheel A Point the spark plug cap in the direction shown in the illustration B Install this part to the inside of the engine body than the clamp 1 C Install the grommet all the way to the back of the fan case groove ...

Page 181: ...2 Rectifier regulator 5 Flywheel 3 Connector lead Red 6 TCI unit 1 A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove C Connect wire lead terminal to yellow lead D Connect wire lead terminal to red lead E Connect wire lead 1 terminal to black white lead ...

Page 182: ...IER REGULATOR AND STARTER MOTOR EH64K EXCEPT FOR KOR 1 Spark plug cap 4 Flywheel 2 Rectifier regulator 5 TCI unit 1 3 Starter motor A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 183: ...64K FOR KOR 1 Spark plug cap 4 Flywheel 2 Rectifier regulator 5 Clamp 3 Starter motor 6 TCI unit 1 A Point the spark plug cap in the direction shown in the illustration B Bundle 1 5 or more volumes other than the wire of the carburetor C Install the grommet all the way to the back of the fan case groove ...

Page 184: ...R EH65A 1 Spark plug cap 4 Flywheel 2 Rectifier regulator 5 Clamp 3 Starter motor 6 TCI unit 1 A Point the spark plug cap in the direction shown in the illustration B Bundle 1 5 or more volumes other than the wire of the carburetor C Install the grommet all the way to the back of the fan case groove ...

Page 185: ... RECTIFIER REGULATOR AND STARTER MOTOR EH65B 1 Spark plug cap 4 Flywheel 2 Rectifier regulator 5 TCI unit 1 3 Starter motor A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 186: ...R EH72A 1 Spark plug cap 4 Flywheel 2 Rectifier regulator 5 Clamp 3 Starter motor 6 TCI unit 1 A Point the spark plug cap in the direction shown in the illustration B Bundle 1 5 or more volumes other than the wire of the carburetor C Install the grommet all the way to the back of the fan case groove ...

Page 187: ...REGULATOR AND STARTER MOTOR EH72B FOR SEA EH72K FOR CHN 1 Spark plug cap 4 Flywheel 2 Rectifier regulator 5 TCI unit 1 3 Starter motor A Point the spark plug cap in the direction shown in the illustration B Install the grommet all the way to the back of the fan case groove ...

Page 188: ...EXCEPT FOR CHN 1 Spark plug cap 4 Flywheel 2 Rectifier regulator 5 Clamp 3 Starter motor 6 TCI unit 1 A Point the spark plug cap in the direction shown in the illustration B Bundle 1 5 or more volumes other than the wire of the carburetor C Install the grommet all the way to the back of the fan case groove ...

Page 189: ...WIRE ROUTING DIAGRAM 7 45 1 2 3 4 5 6 7 8 9 10 SPECIFICATIONS MEMO ...

Page 190: ...APPENDIX CIRCUIT DIAGRAM G M B L S OFF RUN START B B R R W Y Y Gy B W Y R W B G 1 2 3 4 5 6 7 e 8 8 9 0 q w ...

Page 191: ...unit 1 3 Oil warning light option 10 Rectifier regulator 4 Engine switch option 11 Stator coil assembly 5 Battery 12 V option 12 TCI unit 2 6 Tachometer hour meter option 13 Starter relay 7 Starter motor B Black W White G Green Gy Gray R Red B W Black White Y Yellow ...

Page 192: ...MEMO ...

Page 193: ...7D5 28197 E0_cover indd 3 4 2019 03 12 10 04 33 ...

Page 194: ...SERVICE MANUAL EH63 EH64 EH65 EH72 7D5 28197 E0 2019 03 1 7D5 28197 E0_cover indd 1 2 2019 03 12 10 04 33 ...

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