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ABBREVIATIONS

Throughout this manual, the following abbreviations are used to identify the respective parts or systems.

Abbreviated

term

Full term

ACG

Alternator

API

American Petroleum Institute

Approx.

Approximately

Assy.

Assembly

ATDC

After Top Dead Center

ATF

Automatic Transmission Fluid

ATT

Attachment

AVR

Auto Voltage Regulator

BAT

Battery

BDC

Bottom Dead Center

BTDC

Before Top Dead Center

BARO

Barometric Pressure

CKP

Crankshaft Position

Comp.

Complete

CMP

Camshaft Position

CYL

Cylinder

DLC

Data Link Connector

D-AVR

Digital Auto Voltage Regulator

EBT

Engine Block Temperature

ECT

Engine Coolant Temperature

ECM

Engine Control Module

EMT

Exhaust Manifold Temperature

EOP

Engine Oil Pressure

Exhaust

Front or Forward

GND

Ground

HO2S

Heated Oxygen sensor

IAB

Intake Air Bypass

IAC

Idle Air Control

IAT

Intake Air Temperature

I.D.

Inside diameter

IG or IGN

Ignition

Intake

INJ

Injection

Left

MAP

Manifold Absolute Pressure

MIL

Malfunction Indicator Lamp

O.D.

Outside Diameter

Optional Part

PGM-FI

Programmed-Fuel Injection

P/N

Part Number

Qty

Quantity

Right

SAE

Society of Automotive Engineers

SCS

Service Check Signal

STD

Standard

Switch

TDC

Top Dead Center

Black

Green

Brown

Light green

Yellow

Red

Orange

Pink

Blue

White

Light blue

Gray

61YG1000.book 5 ページ２０１２年２月２０日　月曜日　午後２時４３分

Содержание WT30XK4

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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