CONTENTS
SERVICING
1. GENERAL .........................................................................................................S-1
[1] ENGINE IDENTIFICATION........................................................................S-1
(1) Model Name and Engine Serial Number ..............................................S-1
(2) Cylinder Number ...................................................................................S-2
[2] GENERAL PRECAUTION .........................................................................S-3
[3] TIGHTENING TORQUES ..........................................................................S-4
(1) Tightening Torques for Special Use Screws, Bolts and Nuts ...............S-4
(2) Tightening Torques for General Use Screws, Bolts and Nuts ..............S-4
[4] TROUBLESHOOTING ................................................................................S-5
[5] SERVICING SPECIFICATIONS ................................................................S-8
[6] MAINTENANCE CHECK LIST................................................................S-16
[7] CHECK AND MAINTENANCE................................................................S-18
(1) Daily Check Points..............................................................................S-18
(2) Check Points of Initial 50 Hours..........................................................S-20
(3) Check Points of Every 50 Hours .........................................................S-21
(4) Check Points of Every 100 Hours .......................................................S-22
(5) Check Point of Every 150 Hours.........................................................S-24
(6) Check Points of Every 200 Hours .......................................................S-26
(7) Check Points of Every 400 hours........................................................S-28
(8) Check Points of Every 500 Hours .......................................................S-29
(9) Check Points of Every 1 or 2 Months..................................................S-32
(10)Check Point of Every Year..................................................................S-33
(11)Check Point of Every 800 Hours.........................................................S-34
(12)Check Points of Every 1500 Hours.....................................................S-35
(13)Check Points of Every 3000 Hours.....................................................S-37
(14)Check Points of Every 2 Years ...........................................................S-38
[8] SPECIAL TOOLS.....................................................................................S-42
2. ENGINE BODY ..............................................................................................S-50
[1] CHECKING AND ADJUSTING ...............................................................S-50
[2] DISASSEMBLING AND ASSEMBLING..................................................S-52
(1) Draining Oil and Coolant.....................................................................S-52
(2) External Components .........................................................................S-52
(3) Cylinder Head and Valves ..................................................................S-53
(4) Timing Gears, Camshaft and Fuel Camshaft......................................S-57
(5) Piston and Connecting Rod ................................................................S-63
(6) Crankshaft...........................................................................................S-66
[3] SERVICING ..............................................................................................S-69
(1) Cylinder Head and Valves ..................................................................S-69
(2) Timing Gears, Camshaft and Fuel Camshaft......................................S-75
(3) Piston and Connecting Rod ................................................................S-79
(4) Crankshaft...........................................................................................S-82
(5) Cylinder...............................................................................................S-88
3. LUBRICATING SYSTEM ...............................................................................S-90
[1] CHECKING ...............................................................................................S-90
[2] SERVICING ..............................................................................................S-91
4. COOLING SYSTEM .......................................................................................S-92
[1] CHECKING AND ADJUSTING ...............................................................S-92
KiSC issued 08, 2012 A
