Kawasaki Gas Engines

COMPONENTTECHNICAL

MANUAL

Litho in U.S.A

John DeereLawn & Grounds Care Division

John Deere K SeriesLiquid-cooled Engines

CTM39 (Oct93)Replaces CTM39 (28JAN91)

INTRODUCTION

4/7/95 1 - 1

This component technical manual is written for anexperienced technician. It covers recommended repairprocedures, starting with the engine removed from themachine and on a workbench or engine stand. Somecomponents may be serviced in the machine.Determine the repair procedure before removing theengine. Use this manual in conjunction with themachine technical manual. It is a part of a total productsupport program. Use the Fundamental Of Service(FOS) manual as reference for fundamentals of serviceand basic theory of operation.

The manual is organized so that all the information ona particular system is kept together. The order ofgrouping is as follows:

• Table of Contents • Safety • Specifications • Theory of Operation • Repair

Note: Depending on the particular section or systembeing covered, not all of the above groups maybe used.

Each section will be identified with a symbol rather thana number. The pages within a section will beconsecutively numbered.

All information, illustrations and specifications in thismanual are based on the latest information available atthe time of publication. The right is reserved to makechanges at any time without notice.

We appreciate your input on this manual. To help, thereare postage paid post cards included at the back. If youfind any errors or want to comment on the layout of themanual please fill out one of the cards and mail it backto us.

COPYRIGHT© 1993JOHN DEERE HORICON WORKS

Horicon, Wisconsin All rights reservedl

Information Specifications and

Intake, Muffler & Breather

Cylinder Head & Valves

Power TrainCamshaft, Crankshaft &

Lubrication System

Cooling System

Electrical System

Component Analysis

Fuel System & Governor

Safety

Miscellaneous

Cylinder Block, Pistons & Rods

Troubleshooting

Flywheel

SAFETY

1 - 2 4/7/95

HANDLE FLUIDS SAFELY-AVOID FIRES

• BE PREPARED FOR EMERGENCIES

When you work around fuel, do not smoke or work nearheaters or other fire hazards.

Store flammable fluids away from fire hazards. Do notincinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, anddebris.

Do not store oily rags; they can ignite and burnspontaneously.

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulanceservice, hospital, and fire department near yourtelephone.

TS227

TS291

HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can causeserious injury. Potentially hazardous chemicals usedwith John Deere equipment include such items aslubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specificdetails on chemical products: physical and healthhazards, safety procedures, and emergency responsetechniques. Check the MSDS before you start any jobusing a hazardous chemical. That way you will knowexactly what the risks are and how to do the job safely.Then follow procedures and recommended equipment.

• DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten theenvironment and ecology. Potentially harmful wasteused with John Deere equipment include such items asoil, fuel, coolant, brake fluid, filters, and batteries. Useleakproof containers when draining fluids. Do not usefood or beverage containers that may misleadsomeone into drinking from them. Do not pour wasteonto the ground, down a drain, or into any watersource. Inquire on the proper way to recycle or disposeof waste from your local environmental or recyclingcenter, or from your John Deere dealer.

TS1133TS1132

SAFETY

4/7/95 1 - 3

USE SAFE SERVICE PROCEDURES

• WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipmentappropriate for the job.

Prolonged exposure to loud noise can causeimpairment or loss of hearing. Wear a suitable hearingprotective device such as earmuffs or earplugs toprotect against objectionable or uncomfortable loudnoises.

.

• SERVICE MACHINES SAFELY

Tie long hair behind your head. Do not wear a necktie,scarf, loose clothing, or necklace when you work nearmachine tools or moving parts. If these items were toget caught, severe injury could result.

Remove rings and other jewelry to prevent electricalshorts and entanglement in moving parts.

• USE PROPER TOOLS

Use tools appropriate to the work. Makeshift tools andprocedures can create safety hazards. Use power toolsonly to loosen threaded parts and fasteners. Forloosening and tightening hardware, use the correct sizetools. DO NOT use U.S. measurement tools onmetric fasteners. Avoid bodily injury caused by slippingwrenches. Use only service parts meeting John Deerespecifications.

TS228

TS206

• WORK IN CLEAN AREA

• Before starting a job

1. Clean work area and machine:2. Make sure you have all necessary tools to do your

job. 3. Have the right parts on hand.4. Read all instructions thoroughly; do not attempt

shortcuts.

• ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely. Use aportable safety light for working inside or under themachine. Make sure the bulb is enclosed by a wirecage. The hot filament of an accidentally broken bulbcan ignite spilled fuel or oil.

• WORK IN VENTILATED AREA

Engine exhaust fumes can cause sickness or death. Ifit is necessary to run an engine in an enclosed area,remove the exhaust fumes from the area with anexhaust pipe extension.

If you do not have an exhaust pipe extension, open thedoors and get outside air into the area.

TS220

SAFETY

1 - 4 4/7/95

• REMOVE PAINT BEFORE WELDING OR HEATING

Avoid potentially toxic fumes and dust. Hazardousfumes can be generated when paint is heated bywelding, soldering, or using a torch. Do all work outsideor in a well ventilated area. Dispose of paint andsolvent properly. Remove paint before welding orheating: If you sand or grind paint, avoid breathing thedust. Wear an approved respirator. If you use solvent orpaint stripper, remove stripper with soap and waterbefore welding. Remove solvent or paint strippercontainers and other flammable material from area.Allow fumes to disperse at least 15 minutes beforewelding or heating.

• AVOID HARMFUL ASBESTOS DUST

Avoid breathing dust that may be generated whenhandling components containing asbestos fibers.Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestosfibers are brake pads, brake band and liningassemblies, clutch plates, and some gaskets. Theasbestos used in these components is usually found ina resin or sealed in some way. Normal handling is nothazardous as long as airborne dust containingasbestos is not generated.

Avoid creating dust. Never use compressed air forcleaning. Avoid brushing or grinding materialcontaining asbestos. When servicing, wear anapproved respirator. A special vacuum cleaner isrecommended to clean asbestos. If not available, applya mist of oil or water on the material containingasbestos. Keep bystanders away from the area.

REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See themachine operator's manual for correct safety signplacement.

TS201

LIVE WITH SAFETY

Before returning machine to customer, make suremachine is functioning properly, especially the safetysystems. Install all guards and shields.

TS231

CONTENTS SPECIFICATIONS & INFORMATION

4/7/95 2 - 1

CONTENTS

Page

SPECIFICATIONS & INFORMATION

BASIC ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ENGINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ENGINE MODEL CONFIGURATION CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ENGINE SERIAL NUMBER PLATE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CARBURETOR SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TEST & ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 5REPAIR SPECIFICACATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FD440V/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15GASOLINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18FD440V/501V/590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

INTERNAL ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

NOTES SPECIFICATIONS & INFORMATION

2 - 2 4/7/95


4/7/95 2 - 3

BASIC ENGINE SPECIFICATIONS

ENGINE APPLICATIONS

NOTE: Refer to the engine application chart to identify product-model/engine type-model relationship.

Lawn Tractors

Machine Engine Model No.

LX178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD440V - AS00LX188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD501V - AS00

Lawn And Garden Tractors

285 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS00285 w/Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS01320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS00425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS02445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS01

Front Mowers

F911 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS00F725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS03

Golf And Turf Equipment

1800 Utility Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS042243 Professional Greensmower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS022653 Professional Utility Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS046X4 Gator Utility Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS11

ENGINE FD440VAS00

FD501VAS00

FD590V-AS00/02

FD590V-AS03

FD620DAS04/11

FD620DASO2

FD620DAS00/01

HORSEPOWER 11.1 kW (15 HP)

12.6kW (17 HP)

13.4 kW (18 HP)

14.9kW (20 HP)

13.4 kW (18 HP)

14.9kW(20 HP)

16.4 kW(22 HP)

CYLINDER 2 2 2 2 2 2 2

CYCLE 4 4 4 4 4 4 4

BORE 67 mm (2.64 in.)

67 mm (2.64 in.)

74 mm (2.90 in.)

74 mm (2.90 in.)

76 mm (2.99 in.)

76 mm (2.99 in.

76 mm (2.99 in.

STROKE 62 mm (2.44 in.)

62 mm (2.44 in.)

68 mm (2.66 in.)

68 mm (2.66 in.)

68 mm (2.66 in.)

68 mm (2.66 in.)

68 mm (2.66 in.)

DISPLACEMENT

437 cm3

(26.7 cu. in.)

437 cm3

(26.7 cu. in.)

585 cm3

(35.7 cu. in.)

585 cm3

(35.7 cu. in.)

617 cm3

(35.7 cu. in.)

617 cm3

(35.7 cu. in.)

617 cm3

(35.7 cu. in.)


2 - 4 4/7/95

ENGINE MODEL CONFIGURATION CHANGES

FD590V

The following is a list of the major differences betweenthe model configurations of the FD590V-AS00 throughthe FD590V-AS03.

• The FD590V-AS00 is the first configuration used and its first application was in the 285 Lawn and Garden Tractor.

• FD590V-AS01 was converted to a electronic fuel injection system. The carburetor was replaced by a throttle body and a water temperature sensor was added.

• FD590V-AS02 engine is used in the 2243 Triplex Professional Greensmower.

• FD590V-AS03 is used in the F725 Front Mower. The power was increased from 18 to 20 horsepower. To obtain the higher horsepower the following components were changed:

• A larger redesigned intake manifold • The cylinder head induction passage and combustion

chamber was redesigned.• A larger carburetor is used.

NOTE: The FD440V, FD501V and FD590V are vertical shaft engines. The FD620D is a horizontal shaft engine.

FD620D

The differences in horsepower are due to the following:

• rpm that the engine must run for the application.• the efficiencies of fuel injection on the FD620 - AS01.

ENGINE SERIAL NUMBER PLATE LOCATIONS

NOTE: Refer to the engine model designation on the engine serial number plate to identify repair information covered in the Component Technical Manual

FD440V/FD501V/FD590V:

The engine serial number (A) is located on the side ofthe cooling air duct.

FD620D:

The engine serial number (A) is located on thecrankcase cover.

M53952

M53953

TEST & ADJUSTMENT SPECIFICATIONS SPECIFICATIONS & INFORMATION

4/7/95 2 - 5

CARBURETOR SERIAL NUMBER LOCATIONS

FD440V/FD501V/FD590V:

The carburetor serial number (A) is located on the topof carburetor.

M53957

FD620D:

The carburetor serial number (A) is located on the sideof carburetor.

M53958

TEST & ADJUSTMENT SPECIFICATIONS

Engine:

Oil pressure sensor activates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 kPa (14.2 psi)Oil pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276 kPa (40 psi)Oil filter bypass valve opening pressure . . . . . . . . . . . 78.5—117.5 kPa (11.4—17.1 psi)Cylinder compression pressure (minimum) . . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi)Maximum compression pressure variation between cylinders . . . . . . . .138 kPa (20 psi)Crankcase vacuum (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1 in.) waterIntake and exhaust valve clearance (cold) . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)Intake and exhaust valve adjustment interval . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hrs.Valve clearance adjusting nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in)

Fuel/Air System:

Fuel Pump Minimum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 ml (3.5 oz) in 15 secondsMinimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 kPa (1.5 psi)

Carburetor SLOW idle mixture screw initial setting. . . . . . . . . . . . . . . . . . . . . . . . .1 TurnCarburetor SLOW idle stop screw setting

. . . . . . . . . . . . . . . 50 rpm less than throttle control arm SLOW idle stop screw settingThrottle Cable Throttle control arm SLOW idle stop screw setting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1175+25 / -50 rpmThrottle control arm FAST idle stop screw setting . . . . . . . . . . . . . . . . . . 3650 ± 75 rpmAir Restriction Indicator

Normal restriction vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . .102—178 mm (4—7 in.)Maximum restriction vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 mm (15 in.)

Fuel Tank Check valve opening pressure (maximum) . . . . . . . . . . . . . . . . . . . . . . 3 kPa (0.4 psi)

Cooling System:

Radiator capMaximum test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 kPa (17 psi)Minimum pressure after 15 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . .90 kPa (13 psi)Opening pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83–96 kPa (12–14 psi)Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 kPa (11 psi)

Thermostat Begin-to-open temperature . . . . . . . . . . . . . . . . . . . . . . . approximately 63°C (145°F)Full-open temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 80°C (176°F)Full-closed temperature . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 63°C (145°F)

SPECIFICATIONS & INFORMATION REPAIR SPECIFICACATIONS

2 - 6 4/7/95

REPAIR SPECIFICACATIONS

FD440V/501V

Crankcase

Oil Capacity

With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 L (3.59 pt) Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 L (3.20 pt) Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)

Fuel System

Carburetor Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.) Intake Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.) Fuel Pump Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

CYLINDER HEAD AND VALVES

Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)Rocker Arm

Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.) Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.)Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.)Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)

Valves and Springs

Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.) Minimum Valve Stem O.D. Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.93 mm (0.194 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.92 mm (0.193 in.) Maximum Valve Guide I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.06 mm (0.199 in.)Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.) Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . 0.50 - 1.10 mm (0.020 - 0.043 in.)Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

Cylinder Head

Maximum Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)Cap Screw Torque In Sequence (Lubricated) Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.)Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.)

FLYWHEEL

Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (66 lb-ft)

CAMSHAFT AND TAPPETS

Camshaft

Minimum End Journals O.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.91 mm (0.548 in.)Minimum Lobe O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.43 mm (0.962 in.)Minimum Fuel Pump Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.760 in.)Maximum Cover Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.05 mm (0.553 in.)Maximum Crankcase Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 14.07 mm (0.554 in.)

REPAIR SPECIFICACATIONS SPECIFICATIONS & INFORMATION

4/7/95 2 - 7

PISTON, CONNECTING ROD AND CRANKSHAFT

Piston

Maximum Ring Groove Clearance

Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Not Measured

Maximum Ring End Gap

Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Not Measured Minimum Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.)Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.04 mm (0.631 in.)

Distance from bottom of piston skirt

Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.)Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm (2.6358 - 2.6364 in.)Piston-to-Cylinder Bore Clearance. . . . . . . . . . 0.015 - 0.150 mm (0.00059 - 0.0059 in.)

Connecting Rod

Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.)Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)

Crankshaft

Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.92 mm (1.178 in.)Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 30.93 mm (1.218 in.)Maximum T.I.R. (Total Indicated Runout) . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

Plain Bearings

Maximum Crankcase and Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . 30.09 mm (1.185 in.)

CYLINDER BLOCK

Cylinder Bore

Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.98 - 67.00 mm (2.637 - 2.638 in.)Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.06 mm (2.640 in.)

Rebore Cylinder

Oversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm (2.656 - 2.657 in.)

LUBRICATION SYSTEM

Oil Pump

Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.)Maximum Rotor Shaft Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.)Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.592 in.)Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.)Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (0.748 in.)

GOVERNOR

Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.)

IGNITION AND CHARGING SYSTEM

See Ignition and Charging Specifications in this Group.


2 - 8 4/7/95

ELECTRIC STARTER

See this group for continuity checks.

Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.)Maximum No Load Starter Draw . . . . . . . . . . . . . . . . . . . . . 50 amps at 6000 rpm (min)

COOLING SYSTEM

Engine Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 L (2.2 qt)

Thermostat

Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)

Water Pump

Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.94 mm (0.391 in.)Maximum Pump and Crankcase Housing Bore I.D. . . . . . . . . . . . . 10.09 mm (0.397 in.)Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.) Crankcase Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

Over-flow Reservoir

Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)


4/7/95 2 - 9

FD590V

Crankcase

Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 L (4.44 pt)Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)

FUEL SYSTEM

Carburetor Nut Torque(M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.)(M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (133 lb-in.)

Intake Manifold

Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.)

Fuel Pump

Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)


Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)Rocker Arm

Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.) Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.)Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.)

Push Rod

Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)Valves and Springs

Minimum Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.)Minimum Valve Stem O.D.Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.)Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.)Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . 0.50 - 1.10 mm (0.020 - 0.043 in.)Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.)Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

Cylinder Head

Maximum Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)Cap Screw Torque In Sequence (Lubricated)Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)

FLYWHEEL

Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 - 118 N•m (72 - 87 lb-ft)


2 - 10 4/7/95


Camshaft

Minimum End Journals O.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.91 mm (0.626 in.)Minimum Lobe O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.23 mm (0.993 in.)Minimum Fuel Pump Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.760 in.)Maximum Cover and Crankcase Bearing I.D. . . . . . . . . . . . . . . . . 16.07 mm (0.633 in.)

PISTON, CONNECTING ROD, AND CRANKSHAFT

Piston

Maximum Ring Groove ClearanceTop and Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)Oil Ring Not MeasuredMaximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.040 in.)Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.98 mm (0.668 in.)Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.04 mm (0.671 in.)Distance from bottom of piston skirt Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.)Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm (2.9108 - 2.9114 in.)Piston-to-Cylinder Bore Clearance. . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.)

Connecting Rod

Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.)Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.)End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

Crankshaft

Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.91 mm (1.335 in.)Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 33.93 mm (1.336 in.) Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

Plain Bearings

Maximum Crankcase and Cover I.D . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)

CYLINDER BLOCK

Cylinder Bore


Rebore Cylinder

Oversize Diameter0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46 - 74.48 mm (2.934 - 2.935 in.)

LUBRICATION SYSTEM

Oil Pump

Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.)Maximum Rotor Shaft Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.) Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.592 in.)Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.)Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.770 in.)


4/7/95 2 - 11

GOVERNOR

Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.)



ELECTRIC STARTER



COOLING SYSTEM

Engine Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.04 L (3.2 qt)Thermostat

Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)

Water Pump

Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.94 mm (0.391 in.)Maximum Pump and Crankcase Housing Bore I.D. . . . . . . . . . . . . 10.09 mm (0.397 in.)Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.)Crankcase Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

Over-flow Reservoir

Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)


2 - 12 4/7/95

FD620D

Crankcase

Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 L (3.2 pt) Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)

FUEL SYSTEM

Carburetor Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)Intake Manifold

Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.)


Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Rocker Arm

Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.)Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.)Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.)Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)

Valves and Springs

Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.)Minimum Valve Stem O.D.Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.)Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.)Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . 0.50 - 1.10 mm (0.020 - 0.043 in.)Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.)Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°

Cylinder Head

Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)Cap Screw Torque In Sequence (Lubricated)Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.)Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)

FLYWHEEL

Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N•m (80 lb-ft) Sheave Half Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)


Camshaft

Minimum End Journals O.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.91 mm (0.626 in.)Minimum Lobe O.D. Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.21 mm (0.993 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.46 mm (1.002 in.)Maximum Cover and Crankcase Bearing I.D. . . . . . . . . . . . . . . . . 16.07 mm (0.633 in.)


4/7/95 2 - 13

PISTON, CONNECTING, AND RODCRANKSHAFT

Piston

Maximum Ring Groove Clearance

Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.)Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.050 in.)Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.98 mm (0.668 in.)Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.04 mm (0.671 in.)Distance from bottom of piston skirt(Area to measure piston O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.)Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm (2.989 - 2.990 in.)Piston-to-Cylinder BoreClearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.)

Connecting Rod

Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.)Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

Crankshaft

Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.91 mm (1.335 in.)Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 33.93 mm (1.336 in.)Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)Plain BearingsMaximum Crankcase Cover I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.)

CYLINDER BLOCK

Cylinder Bore


Rebore Cylinder


LUBRICATION SYSTEM

Oil Pump

Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.)Maximum Rotor Shaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.)Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.592 in.)Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.)Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.770 in.)

GOVERNOR

Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.)




2 - 14 4/7/95

ELECTRIC STARTER



COOLING SYSTEM

Sheeve/Half Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)

Thermostat

Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65°C (148°F)Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80°C (176°F)

Water Pump


METRIC TORQUE VALUES SPECIFICATIONS & INFORMATION

4/7/95 2 - 15

METRIC TORQUE VALUES

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya

SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft

M6 48 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35

M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70

M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109

M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300

M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410

M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580

M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800

M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000

M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500

M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000

M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750

M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500

Ts1163

4.8

8.8 9.8

10.9

12.9

5 10

12

PropertyClassandHeadMarkings

PropertyClassandNutMarkings

4.8

4.8

55

8.8

8.8

9.8

9.8

10.9

10.9 12.9

12.9

12.9

12

1210 10

10

1010

DO NOT use these values if a different torque value ortightening procedure is given for a specific application.Torque values listed are for general use only. Checktightness of fasteners periodically.

Shear bolts are designed to fail under predeterminedloads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or highergrade. If higher grade fasteners are used, these shouldonly be tightened to the strength of the original. Makesure fasteners threads are clean and that you properlystart thread engagement. This will prevent them fromfailing when tightening.

Tighten plastic insert or crimped steel-type lock nuts to

approximately 50 percent of the dry torque shown inthe chart, applied to the nut, not to the bolt head.Tighten toothed or serrated-type lock nuts to the fulltorque value.a “Lubricated” means coated with a lubricant such asengine oil, or fasteners with phosphate and oilcoatings. “Dry” means plain or zinc plated without anylubrication.b Grade 2 applies for hex cap screws (not hex bolts) upto 152 mm (6-in.) long. Grade 1 applies for hex capscrews over 152 mm (6-in.) long, and for all other typesof bolts and screws of any length.

SPECIFICATIONS & INFORMATION GASOLINE SPECIFICATIONS

2 - 16 4/7/95

GASOLINE SPECIFICATIONS

IMPORTANT: To avoid engine damage:DO NOT mix oil with gasolineUse only clean oil and fuelUse clean approved containers and funnels.Store oil and fuel in an area protected from dust, moisture and other contamination.

Unleaded fuel is recommended because it burnscleaner and leaves less unburned deposits in enginecombustion chamber. Regular leaded gasoline with ananti-knock index of 87 or higher may be used.Use ofgasohol is acceptable as long as the ethyl alcoholblend does not exceed 11 percent. Unleaded gasoholis preferred over leaded gasohol.

Fill fuel tank at end of each day's operation. Fill only tobottom of filler neck.

c CAUTION:

Handle fuel with care, it is highly flammable. DO NOT refuel machine:

• Indoors. Always fill fuel tank outdoors.

• While you smoke.

• When machine is near and open flame or sparks.

• When engine is running. STOP engine.

• When engine is hot. Allow it to cool.

Help prevent fires:

• Fill fuel tank only to bottom of filler neck.

• Clean oil, grease and dirt from machine.

• Clean up spilled fuel immediately.

• Do not store machine with fuel in tank in a building where fumes may reach an open flame or spark.

To prevent fire and explosion caused by static electric discharge while you fill tank:

• Use approved, non-metal fuel container.

• When using a funnel, MAKE SURE it is PLASTIC.

• Avoid using a funnel which has a metal screen or filter.

FUEL STORAGEKeep fuel in a clean container in a protected area.Water and sediment must bromated before fuel gets tothe engine. Do not use deicers to remove water fromfuel. Do not depend on fuel filters to remove water.

If possible, install a water separator at the storage tankoutlet.

IMPORTANT: Keep all dirt, scale, water or other foreign material out of fuel.

If vehicle is either stored or used during the winter, addTY6295 John Deere Gasoline Storage Stabilizer or anequivalent to the fuel. Follow directions on can.

LUBRICANT SPECIFICATIONS SPECIFICATIONS & INFORMATION

4/7/95 2 - 17

LUBRICANT SPECIFICATIONS

ENGINE OILUse oil viscosity based on the expected air temperaturerange during the period between oil changes.

The following oil is preferred:

• John Deere PLUS-4®

Other oils may be used if they meet one of thefollowing:

• API Service Classification SG• API Service Classification SF• CCMC Specification G4Oils meeting Military Specification MIL-L-46167B maybe used as arctic oils.

OIL FILTERSFiltration of oils is critical to proper lubrication. Alwayschange filters regularly.

Use filters meeting John Deere performancespecification.

TS1411

ENGINE COOLANTUse ethylene glycol base coolant. These coolantsusually have labels stating “For Automobile and LightDuty Service.” These products are also often labeledfor use in aluminum engines. Check container labelbefore using.

IMPORTANT: To prevent engine damage, DO NOT use pure antifreeze or more than 50% antifreeze in the cooling system. DO NOT mix or add any other type additives to the cooling system.

Mix approximately 50 percent antifreeze with 50percent distilled or deionized water. This mixture willprovide freeze protection to -340 F (-37 0 C).

Certain geographical areas may require lowertemperature protection. See the label on yourantifreeze container or consult your John Deere dealerto obtain the latest information and recommendations.

The recommended antifreeze provides:

• Adequate heat transfer.• Corrosion-resistant environment within the cooling

system.• Compatibility with cooling system hose and seal

material.• Protection during cold and hot weather operations.

SYNTHETIC LUBRICANTSSynthetic lubricants may be used in John Deereequipment if they meet the applicable performancerequirements (industry classification and/or militaryspecification) as shown in this group.

The recommended temperature limits and service or oilchange intervals should be maintained as shown in theoperator’s manual.

Avoid mixing different brands, grades, or types of oil.Oil manufacturers blend additive in their oils to meetcertain specifications and performance requirements.Mixing different oils can interfere with the properfunctioning of these additives and degrade lubricantperformance.

SPECIFICATIONS & INFORMATION COMPONENT LOCATION

2 - 18 4/7/95

COMPONENT LOCATION

FD440V/501V/590V

Right-Hand Side Shown

NOTE: Bare block components are similar between engines, someperipheral components may be different between applications.

Air Cleaner Cover

Radiator Outlet

Breather

Fuel Pump

Control Plate

Water Pump

Rocker Arm CoverSpark Plug Lead

Cylinder Head

Ignition Coil

Drain Plug

Oil Filter

Oil Dipstick

Oil Pressure Switch

Hose

M45816

Hose

COMPONENT LOCATION SPECIFICATIONS & INFORMATION

4/7/95 2 - 19

COMPONENT LOCATION - FD440V/501V/590V - Continued

Left-Hand Side Shown

Radiator Cap

Overflow

Radiator

Overflow Reservoir

Fan Housing

Regulator/Rectifier

Crankcase

Ignition ModuleStarter Solenoid

Starter

Radiator Screen

Radiator Inlet

Thermostat Cover

Spark Plug Lead

Cylinder Head

Rocker Arm Cover

Coolant TemperatureSwitch

Ignition Coil

M45645

Hose

Hose

SPECIFICATIONS & INFORMATION INTERNAL ENGINE COMPONENTS

2 - 20 4/7/95

INTERNAL ENGINE COMPONENTS

Side View Cutaway

Air Cleaner

Foam ElementPaper Element

Valve Seat

Intake Valve

Valve Guide

Valve Springs

Exhaust Valve

Camshaft

Water Pump Gear

Water Pump Impeller

Governor FlyweightsGovernor Gear

Oil Pump

Crankshaft

Crankshaft

Flywheel

Fan

Valve Cover

Camshaft GearOil Screen

Stator

Gear

M45646

Air Cleaner

INTERNAL ENGINE COMPONENTS SPECIFICATIONS & INFORMATION

4/7/95 2 - 21

INTERNAL ENGINE COMPONENTS - Continued

Top View Cutaway

Breather Cover

Push Rod

Tappet

Camshaft

Connecting Rod Cap

Connecting Rod

Piston

Piston Pin

Piston Rings

Adjusting Screw

Rocker Arm

Rocker Arm Shaft Throttle Control Plate

CarburetorBreather Hose

and Lock Nut

Stator

Oil Pressure Sensor

Oil Filter

Regulator/Rectifier

Pulsar Coil

Starter Motor

Starter Solenoid

M45647

SPECIFICATIONS & INFORMATION INTERNAL ENGINE COMPONENTS

2 - 22 4/7/95

ENGINE COMPONENTS - FD620D

Cutaway - FD620D

The FD620D engine components are similar to the horizontal shaft enginesexcept for the orientation of the oil pickup screen.

Differences of the external components consist of an optional fan driveand a down draft carburetor.

Governor Arm

Pistons

Fan Belt

CrankcaseBreather Chamber

Connecting

Oil Filter

OuterSheaveHalve

Flywheel

Cylinder Block

Crankshaft

Camshaft

Tappets

Carburetor

Governor

Camshaft Gear

Rocker Arms

Valves

Cylinder

Push Rods

Coolant Pump Gear

Rod

CrankshaftOil PumpGear

Gear

Head

Muffler

Drive Gear

Drive

M54274

CONTENTS INTAKE, EXHAUST & BREATHER

Page

4/7/95 3 - 1

CONTENTS

INTAKE, EXHAUST & BREATHER

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

INTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INTAKE, EXHAUST & BREATHER AIR CLEANER

3 - 2 4/7/95

AIR CLEANER

FD440V/FD501V/FD590V

IMPORTANT: Carefully remove air cleaner cover and elements.Inspect inside paper element and intake passage for signs of dust.If present, replace elements and test engine compression orinspect for damage.Do not clean paper element with solvent or compressed air.

Any time air cleaner base is removed, check for free choke operation during reassembly.

FD620D

Air Cleaner CoverFoam ElementWash with detergent and water, Replace if stretched or torn.Oil lightly with engine oil. Squeeze out excess,Paper Element

Do Not clean. Replaceif oily, dirty or damagedin any way or directlight can be seenthrough paper.

M53973

Breather Hose

Mounting Screws (3)

Use medium strengthThread Lock and Sealer

Tighten evenly.

To Air FilterRestrictionIndicator

Foam ElementWash with detergent and water, Replace if stretched or torn.Oil lightly with engine oil. Squeeze out excess.

Paper ElementDo Not clean.Replace if oily, dirtyor damaged in anyway or direct light canbe seen through M57331

INTAKE MANIFOLD INTAKE, EXHAUST & BREATHER

4/7/95 3 - 3

INTAKE MANIFOLD

REMOVAL1. Remove carburetor and governor control panel.

Side Draft Carburetor Configuation Shown

IMPORTANT: To prevent warpage, loosen bolts 1/4turn at a time, in sequence, until all bolts areloose.

Torquing Sequence

2. Visually inspect manifold passages for corrosion, cracks, porous castings or deposits. Clean orreplace as necessary.

Air Horn(If equipped)

GasketReplace

CarburetorSee Fuel Systemfor repair

Stud

Intake Elbow

Gasket

Intake Mainiflod

Intake Gasket

17 N•m(12 lb-ft)

17 N•m(12 lb-ft)

Manifold Bolts6 N•m(52 lb-in.)

M57355

2

5 1 4 8

637

Manifold BoltsTighten in 3 N•m increments.

Final Torque 6 N•m (52 lb-in.)

M46862

NOTE: Cracks not visible to the eye may be detectedby coating suspected area with a mixture of25% kerosene and 75% light engine oil. Wipearea dry and immediately apply a coat of zincoxide dissolved in wood alcohol. If cracks arepresent, the coating will become discolored atthe crack location.

INSTALLATION1. Before installing manifold, install cylinder heads and

tighten head bolts in sequence to half the ratedtorque value.

2. Install intake manifold and tighten bolts in two steps to a final torque of 6 N•m (52 lb-in.).

3. Tighten cylinder head bolts to 21 N•m (15 lb-ft.).

MUFFLER

NOTE: Muffler design may vary between applications.

• Clean exhaust pipe flanges and install new gasketbefore installing muffler.

• Use medium strength, Thread Lock and Sealer onstuds and nuts.

• Loosely tighten flange nuts.• If equipped with extra supporting brackets, also

loosely tighten mounting bolts.• Tighten flange nuts first then mounting bolts.

GasketReplace

Mounting Bolt

Nut

Lock Washer

Stud14 -19 N•m(10 -13.5 lb-ft)

6-7.5 N•m(52-69 lb-in.)

6-7.5 N•m(52-69 lb-in.)

M46434

INTAKE, EXHAUST & BREATHER BREATHER

3 - 4 4/7/95

BREATHER

OPERATIONThe breather controls crankcase pressure, preventingoil from being forced out passed the piston rings, oilseals and gaskets. The reed valve limits air flow out ofthe crankcase caused by piston movement, then blocksreturn air flow creating a vacuum in the crankcase.

Oil ladden air enters the breather chamber where it isdirected through a mase, separating most of the oilfrom the air. The oil drains back to the crankcase andthe air vents back the the intake air in the air cleaner.

Drain Hole

Gasket

Reed ValveBack Plate

Cover

Air Vent to Intake

M54277

REPAIRInspect reed valve for breakage, hairline cracks ordistortion, replace if necessary.

• Inspect the backing plate for damage or a roughcontact surface, replace if necessary.

• Inspect the valve seating surface for damage, repairif necessary.

• breather reed valve tip air gap of 0.2 mm (0.008in.).

M51757

Reed ValveSeating Surface

Backing Plate

CONTENTS FUEL SYSTEM & GOVERNOR

Page

4/7/95 4 - 1

CONTENTS

FUEL SYSTEM & GOVERNOR

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SIDE DRAFT CARBURETOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DOWN DRAFT CARURETOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CLEAN AND REBUILD CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FLOAT LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MECHANICAL FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

THROTTLE BODY REPAIR - FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

THROTTLE BODY REPAIR - FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

NOTES FUEL SYSTEM & GOVERNOR

4 - 2 4/7/95

CARBURETOR FUEL SYSTEM & GOVERNOR

4/7/95 4 - 3

CARBURETOR

SPECIFICATIONS

Side Draft:

Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)Intake Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)Choke & Throttle Plate Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.88 N•m (7.8 lb-in.)

Down Draft:

Throttle Shaft Retaining Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 N•m (17 lb-in.)Drain Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 N•m (10 lb-in.)Choke &Throttle Valve Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.88 N•m (7.8 lb-in.)Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 N•m (87 lb-in.)Main Jet & Main Air Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 N•m (8.9 lb-in.)Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)

Carburetor Repair Kits

• Gasket Kit• Jet Kit

TROUBLESHOOTING

Problem orSymptom

Eng

ine

is s

lugg

ish

Bla

ck s

mok

y ex

hau

st

Run

wor

se w

hen

war

m

Spa

rk p

lug

foul

ed b

lack

Run

s be

tter

with

out a

ir c

lea

ner

Eng

ine

will

not

sta

rt, p

lug

wet

Spa

rk p

lug

burn

ed w

hite

Eng

ine

spe

ed u

nst

able

(su

rgin

g)

Loss

of p

ower

Eng

ine

ove

rhea

ts

Eng

ine

is h

ard

to s

tart

wh

en c

old

Check or Solution

Mixture too rich ● ● ● ● ● ● ●

Mixture too lean ● ● ● ● ●

Check and clean air cleaner ● ● ● ● ● ●

Clean under engine shrouding ● ● ● ●

Adjust Idle mixture and check engine performance. ● ● ● ● ●

Choke is not completely open. Adjust. ● ● ● ● ●

Inlet needle and seat leaking ● ● ● ●

Choke is not completely shut. Adjust. ●

Clean Carburetor ● ● ● ● ● ●

FUEL SYSTEM & GOVERNOR CARBURETOR

4 - 4 4/7/95

THEORY OF OPERATIONCarburetors operate on the principles that air movingthrough a tube will speed up with a resulting drop inpressure when it passes through the venturi. The lowpressure at the venturi allows normal air pressure inthe float bowl to force fuel through the main jet and upinto the carburetor throat where it is atomized by thehigh speed flow of air and carried into the engine.

Float System:

The float and inlet needle valve controls the inlet of fuelinto the carburetor. It is continually opening andclosings the inlet needle valve to maintains a constantfuel supply and level.

Proper level is important because it will effect the abilityof atmospheric pressure to force the transfer of fuelthrough the passages

Pilot System:

The pilot system meters fuel/air mixture while engine isidling and running under light load.

At idle, the throttle plate will be nearly closed. Only thepilot outlet port is uncovered. There is not enough airvolume or velocity to draw fuel through the main circuit.Fuel flow is metered by the pilot jet. Some air is alsometered by a pilot air jet and allowed to mix with thepilot fuel for better atomization.Some pilot air jets arelock into the correct position with a clip and capscrew.Tis is done to align internal passages. The pilotjet and pilot air jet are not adjustable.

The pilot mixture air screw only adjusts the mixture outthe pilot outlet and does not effect the transitionports.Each transition port is uncovered as the throttleopens, allowing more fuel flow.

Main Jet System:

The main circuit functions when the engine is at partialto full throttle (throttle plate full open), moderate toheavy loads. In this condition, air flows very quicklythrough the venturi, creating a very low pressure areaat the end of the main nozzle. Air pressure in the bowlnow can push fuel up through the main jet and out thenozzle. At the same time, air is also drawn through themain air jet, into a cavity surrounding the main nozzlecalled the emulsion tube. Here the fuel is mixed with airbubbles created by the small holes, Raw fuel and airbegin atomizing.

The main jet and main air jet are not adjustable. Onlythe main jet can be removed and replaced by adifferent size to compensate for higher or lower altitudeoperation. The engine and it’s application determinethe size of the main jet used in each carburetor.

Choke Operation:

The choke plate restricts most of the air flow though thecarburetor to provide a very fuel rich mixture forstarting. Because of the restriction and very lowpressure area in carburetor throat, fuel is forced thoughall ports (main and pilot). Air is mixed with the main airjet and pilot air jets as previously described. The fuel/air mixture is richer because there is less air flowthrough the venturi.

Fuel Shut-off Solenoid:

It’s purpose is to help control engine backfire.

When the ignition key is turned on, the solenoidretracts a plunger that was plugging the main jet oraccess passage to the main jet, and allows fuel to entermain jet or cavity.

When the engine is turned off, the fuel shut-off solenoidreleases the plunger, closing off fuel flow. This allowsthe engine to starve for fuel, preventing excess fuel thatmight have ignited during engine shutdown.


4/7/95 4 - 5

Side Draft Carburetor with Fuel Shut-off Solenoid

Down Draft Carburetor with Fuel Shut-off Solenoid


4 - 6 4/7/95

SIDE DRAFT CARBURETOR REPAIR

Refer to the illustration and the following notes for disassembly and assembly.

c CAUTIONGasoline is extremely flammable. Do not smoke. Always work in aventilated area away from open flame or spark producing equipment, thisincludes equipment that utilizes pilot lights.

RestrictionIndicator Fitting

Intake

Use Thread Sealant

17 N•m12 lb-ft)

Nuts

GasketUse Thread

Choke ShaftReplace Carburetor if worn

Throttle ShaftReplace carburetor

Idle Mixture ScrewNo damage to tapered end.

Pilot Jet

Spring

Use Thread Lock & SealerChoke Plate

EmulsionVent Hose

Main Jet

Needle

GasketFloat

Drain ScrewPin

Bowl Screw

Intake Manifold

Gasket

(12 lb-ft)17 N•m

Replace

Intake Elbow

Seal

Washer

Seal

Carburetor Body

Note position before

Tube

Adapter

if worn

removingBushing

Main Air Jet

Pilot Air JetIdle Stop Screw

Lock & Sealer

M56705


4/7/95 4 - 7

DOWN DRAFT CARURETOR REPAIRRefer to the illustration and the following notes for disassembly and assembly.

J

Air Horn (If equipped)

O-Ring

Choke Plate

Choke Shaft

Needle ValveGasket

Float Pin

Float

Pilot Jet

Carburetor Body

High Altitude Main Jet

Fuel Shut-off Solenoid

Throttle Plate

Throttle Shaft

Seal

SpringLow Idle Screw

Idle Mixture Screw

Drain Screw

Main Jet

Retainer

(If Equipped)

Springs

Washer

Collars

2.9 N•m(26 lb-in.)

2 N•m(17 lb-in.)

M57347

Cap Screws


4 - 8 4/7/95

CLEAN AND REBUILD CARBURETORThere are a n umber of plates or boll plugs on/in thecarburetor that should not be removed.

• Turn the idle mixture screw in and note the numberof turns required to lightly seat it before removingit.

NOTE: If all rubber or plastic parts cannot be removedfor cleaning, use a solvent, with a high flashpoint, that will not damage these parts whencleaning.

• Remove rubber or plastic parts from the carburetor.Immerse all the carburetor metal parts in acarburetor cleaning solution.

• Rinse the parts in water and dry with compressedair, do not use rags or paper to dry parts. Lint canplug the tiny passages in the carburetor.

• Inspect the carburetor body for damage. Ensure thesealing surfaces and flanges are smooth and freeof nicks and burrs.

• Turn the idle mixture screw in until lightly seatedand back it out the same number of turns countedduring disassembly.

• Install the choke valve with the metering holetowards the fuel inlet joint of the carburetor.

• Ensure the float pin extends the same distance onboth sides of the float hinge bracket whenreassembling the carburetor.

• Ensure the throttle and choke valves move freelyand that the shaft bosses are not elongated orworn. If shaft bosses have any of these conditions,replace the carburetor.

• Inspect the inlet needle for wear or damage. The tipshould be smooth, without any grooves, scratchesor tears. If worn or damaged, replace the floatassembly and carburetor body as a set.

• Inspect the idle mixture screw for wear or damage,replace it if necessary.

FLOAT LEVEL ADJUSTMENT

NOTE: Plastic floats are non-adjustable.

1. Hold air horn upside down at eye level with float assembly installed.

2. Gently support float with a finger and lower it slowly until the float arm tab just touches the float valveneedle.

3. The float lower surface should be parallel with the body mating surface.

4. If necessary, bend float arm tab to adjust float level.

GOOD REPLACE

Air Horn

Mating Surface

Float

Needle

Tap

M57333

MECHANICAL FUEL PUMP FUEL SYSTEM & GOVERNOR

4/7/95 4 - 9

MECHANICAL FUEL PUMP

THEORY OF OPERATION

Function:

Transfer fuel from the fuel tank to the carburetor.

Theory of Operation:

The fuel pump is a mechanical drive type unit. A camon the camshaft of the engine moves actuating plunger.This plunger moves pivot arm which is connected todiaphragm. A spring is also connected to thediaphragm.

As the contact point of the plunger on the cam changesfrom the base to the tip during rotation, the plungermoves outward. This rotates the pivot arm and pulls thediaphragm downward increasing the volume of thepump chamber. This creates a low pressure area andfuel is drawn in from the fuel tank past inlet valve.When the contact point of the plunger changes fromthe tip to the base on the plunger moves inward andthe pivot arm rotate the opposite direction. This allowsthe spring to push the diaphragm upward and reducethe volume in the pump chamber. Fuel is forced out ofthe pump chamber past outlet valve to the carburetor.

The maximum pressure that the pump can developcontrolled by the strength of the spring. This designprevents over pressurizing the fuel being delivered thecarburetor.

Plunger

From Tank

To Carburetor Outlet Valve

Inlet Valve

Diaphragm

Spring

Outlet Chamber

Inlet Chamber

M49793

REPAIR

Disconnect fuel line and remove fuel pump and rod.

Inspect pump and insulator for wear or damage.Replace as necessary.

Check push rod for bend using V-blocks and a dialindicator. Install push rod, insulator and fuel pump.

Pump Push Rod Specifications

Maximum Bend. . . . . . . . . . . . . . 0.05 mm (0.002 in.)

Fuel Pump

M51693

Push RodGasket

Insulator

Cap Screw14 -19 N•m(10 - 13 lb-ft) M57334

FUEL SYSTEM & GOVERNOR GOVERNOR

4 - 10 4/7/95

GOVERNOR

THEORY OF OPERATION

IMPORTANT: Do not remove flyweight assembly or shaft unless damaged. Removal damages the assembly.

Sleeve

Inner FlangeThrust

Groove

Shaft

Oil Seal Governor Shaft

Crankcase

Shaft Arm

Projections

Flyweight Assembly

Washer

Throttle Shaft

Sleeve

Governor Arm

Do Not remove unless damaged.

32.2 - 32.8 mm(1.267 - 1.291 in.)

Link and Spring

GovernorSpring

Lips towardengine. Press in 1.0 mm (0.04 in.) below crankcase surfaces.

Clamp Nut7.8 N•m(69 lb-in.)

M57332


The governor controls engine speed. Governed enginespeed is a balance between governor spring tension,set by the throttle control, and actual engine speed,countered by centrifugal force of the governorflyweights. As tension is applied to governor spring,governor arm opens carburetor throttle shaft,increasing engine rpm. As engine speed increases,flyweight assembly, driven by the crankshaft, pusheson governor shaft, rotating governor arm, closingthrottle shaft, reducing rpm.

REPAIR1. Remove camshaft2. Use two suitable pry-bars to pry flyweights assembly

from shaft. Do Not damage crankcase sealingsurfaces.

3. Unscrew governor arm clamp nut and remove

governor arm.4. Turn governor shaft 1/4 turn clockwise to remove

shaft.5. Replace shaft seal. Press in to dimensions,6. Install governor shaft by properly positioning it

between the two projections on crankcase.

NOTE: Install sleeve into governor and install as anassembly.

7. Push assembly onto shaft until it snaps into place. Check assembly for freedom of movement

8. Install governor arm loose in governor shaft.9. Hold top of governor arm counterclockwise to open

throttle plate. 10. Turn governor shaft fully counterclockwise to end of

its travel. Check dimension from arm to end of shaft.11. Tighten arm clamp nut.

FUEL INJECTION SYSTEM FUEL SYSTEM & GOVERNOR

4/7/95 4 - 11

FUEL INJECTION SYSTEM

THEORY OF OPERATIONThe fuel injected engines uses a digital fuel injectionsystem to control fuel delivery to the injector.

FD590V Shown

The following sensors and circuits monitor engineoperating conditions.

• throttle sensor (FD590V)• air temperature sensor• coolant temperature sensor• starter voltage circuit• engine speed circuit• battery voltage circuit• altitude compensation (Optional on FD590V)

These sensors send digital signals to a computer in thefuel injection module. The computer processes thesesignals and determines the correct amount of fuel toinject to match the present engine operating conditions.

A fuel control circuit that consists of a fuel pump andfuel pump relay are also controlled by the injectionmodule computer to provide the correct fuel delivery.

Fuel system pressure is controlled by the fuel pressureregulator.

The FD620D uses a injection system that is similar inoperation to of that of the FD590V with the followingdifferences.

• There is an additional air pressure sensor tocompensate for altitude.

• The ignition module is combined with the fuelinjection module so there is only one module.

• All the sensors are used to help adjust enginetiming, unlike the FD590V where only the enginespeed effected timing.

• Throttle sensor is no longer used. Engine speed issensed by the pulser

• Only one pulser is used. It controls ignition timing,injection timing and engine speed. The flywheelhas four tabs that are used by the single pulser.

• This injection system has self-diagnosis that checks

Throttle Body

Fuel Injection

Fuel Pressure Regulator

Throttle Sensor

InjectorM70805

Air TemperatureSensor

Module

all sensors.

NOTE: For more information on fuel injection testing,see the appropriate vehicle technical manual.

FUEL INJECTOR

THEORY OF OPERATION

Function:

Injects fuel into the throttle body at the correct time andduration.


The fuel injector is a solenoid operated type valve withsingle point injection. Fuel is injected into the throttlebody when the solenoid is energized by the computer.The amount of fuel injected depends on the length oftime the injector valve is open and on fuel pressure.

High pressure fuel from the fuel pump flows throughfilter to the inlet passage. High pressure fuel also flowsout the outlet passage to the pressure regulator. Thepressure regulator maintains the correct fuel pressureneeded for injection. When the solenoid is energized,the solenoid core pulls the valve open against springtension. High pressure fuel is injected in the throttlebody through the nozzle. After a precise amount of fuelis injected, the computer de-energizes the solenoid.Spring tension closes valve guickly to preventadditional leakage.

Nozzle

Valve

Spring Filter

Fuel Inlet Solenoid

Core

Electrical Terminal

Fuel Outlet M45335

FUEL SYSTEM & GOVERNOR FUEL INJECTOR

4 - 12 4/7/95

REPAIR

NOTE: See electrical system for electrical tests.

IMPORTANT: Do not drive against tip. Plastic covercan crack and nozzle will be damaged. Do notdrop injector.

1. Remove injector retainer. Grip end of injector, twist and pull.

IMPORTANT: Always install new o-rings oninjector when injector is removed.

2. Replace injector o-rings and clean fuel screen.3. Lubricate o-rings with clean engine oil.4. Install injector in the same orientation as removed.

O-rings

Screen

Replace

Clean M48181

FUEL PRESSURE REGULATOR

THEORY OF OPERATION

Function:

Maintains a constant differential in pressure betweenfuel pressure at the injector and air pressure in thethrottle body.Therefore, the amount of fuel injected isdetermined by the opening time of the injector.


The pressure regulator is an overflow type regulator.The spring chamber is connected to the throttle boby toinsure that they are operating at the same air pressure.High pressure fuel from the injector flows to thepressure regulator inlet and fills the fuel chamber. Ahose from the vacuum inlet is connected to the intakemanifold. This allows the air pressure in the springchamber and intake manifold to be equal.

When intake manifold vacuum increases, the springchamber vacuum also increases and overcomes springtension allowing the diaphragm to move upward. Withthe valve connected to the diaphragm, the valve movesupward and allows more fuel to flow out the outlet andreturn to the fuel tank. This lowers the fuel pressure. Asintake manifold vacuum decreases, the spring chambervacuum decreases and the spring returns thediaphragm to the original position. The valve restrictsfuel flow to return and fuel pressure increases.

Spring

To Throttle Body

Diaphragm

Valve

Fuel Chamber

Return to Tank

Inlet From

Valve Support

Spring Chamber

Injector

M44227

THROTTLE BODY FUEL SYSTEM & GOVERNOR

4/7/95 4 - 13

REPAIR

IMPORTANT: Relieve fuel pressure beforedisconnecting fuel line.

Remove fuel lines, vacuum line and regulator.

FD590V Fuel Regulator

FD620D Fuel Regulator

Test Regulator:

Apply vacuum to vaccum port of regulator. Regulatormust hold vaccum.

M57358

Regulator

M57359

Regulator

M57360

O-ring

Replace regulator if defective. Install new o-ring onregulator inlet and install regulator.

NOTE: Valve will not move without maximum fuelpressure on inlet.

THROTTLE BODY

THEORY OF OPERATION

NOTE: The throttle body and fuel pressure regulatorfor both the FD590 and FD620 work under thesame principles.

Function:

Injects and atomizes the fuel into the intake air for theproper combustion.

FD590D Throttle Body

Operation:

An electric fuel pump, controled by the computer,supplies fuel to the inlet of the throttle body to theinjector. The fuel pressure regulator holds the fuelunder pressure in the injector. The computer recievessignals from the throttle sensor and other sensors thencontrols the time the injector is open. The injectorinjects the atomized into the throat of the throttle body.

Excess fuel not used by the injector flows through thepressure regulator back to the fuel tank.

The FD620 has an extra passage in the throttle bodythe allows for a means to relieve the fuel pressure inthe fuel lines before any work is done on the system.

Fuel Inlet Throttle Sensor

Fuel Pressure Regulator

Injector

Throttle Body

Return to Tank M57361

FUEL SYSTEM & GOVERNOR THROTTLE BODY

4 - 14 4/7/95

FD620 Throttle Body

THROTTLE BODY REPAIR - FD590VRemove Throttle Body

1. Disconnect:• Fuel inlet hose• Fuel Return Hose• Injector• Breather Hose• Throttle Cable

Close openings using caps and plugs.

2. Remove cap screws from air shrouding and throttle body retaining nuts.

3. Disconnect governor linkage as throttle body is being removed.

Fuel Inlet

Fuel Return to TankFuel Pressure Relief Plug

Throttle Body Injector Regulator

M57362

Return

Fuel Inlet

Cap Screws

Stud & Nut (2)

M48179

Injector

4. Mark position of throttle sensor before removal. This will aid in obtaining approximate idle speed whenreassembled.

5. Remove throttle plate and throttle shaft only if there is evidence of wear.

NOTE: Some individual components can be replacedwithout removing throttle body.Disassemble throttle body only if necessary.Such as: fuel leakage, or componentmalfunction.Remove regulator and temperature sensor.

6. Use thread Lock and Sealer on throttle plate screws.7. Assemble all parts. Install new O-rings and gaskets.8. Install throttle body and connect governor linkage.

Tighten nuts and air shrouding cap screws.9. Connect throttle cable and all hoses.

THROTTLE BODY REPAIR - FD620D

Throttle Body

Throttle Sensor

Throttle Shaft

Throttle

Pressure RegulatorO-Ring

Air Temperature Sensor

Injector

Retainer

Plate

M48180

M57363

THROTTLE BODY FUEL SYSTEM & GOVERNOR

4/7/95 4 - 15

Do not remove throttle shaft unless it appears to be worn or damaged.

If throttle shaft is worn, check throttle body bushing. If worn, replace throttle body.

The throttle plate must be perfectly centered in bore when closed. It must alsooperate freely when plate screws are tightened.

c CAUTIONRelieve fuel pressure before removing any fuelline or components.Loosen Fuel Pressure Relief Valve Plug.

GasketReplace

Fuel Pressure Relief Plug

O-ringsStud(2)

Injector

O-ring SealReplace if damaged.

Throttle Body

Injector Cover

Throttle Shaft

Throttle Plate

Low Idle

Plate Screw

SealNutInstall lips out

Use Thread Lock

SpringStop Screw

Shaft Retainer

Lubricate o-rings withClean screen.Twist and pull to remove.

2 N•m(17 lb-in.)

0.8 N•m(8 lb-in.)

15 N•m (133 lb-in.)

17 N•m(12 lb-ft)

engine oil.

Tighten evenly.Cover Cap Screws

Fuel Regulator

M57338

FUEL SYSTEM & GOVERNOR THROTTLE BODY

4 - 16 4/7/95

CONTENTS CYLINDER HEAD & VALVES

Page

4/7/95 5 - 1

CONTENTS

CYLINDER HEAD & VALVES

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

HEAD AND VALVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4VALVE, VALVE SEAT AND GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

VALVE SPRING FREE LENGTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PUSH ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

NOTES CYLINDER HEAD & VALVES

5 - 2 4/7/95

SPECIFICATIONS CYLINDER HEAD & VALVES

4/7/95 5 - 3

SPECIFICATIONS

Cylinder Head

Compression (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi)Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (.002 in.)Cap Screw Torque In SequenceInitial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.)Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)Spark Plug Torque

FD440V//FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)

Rocker Arm

Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.)Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.)Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.)

Push Rod

Maximum Runnout (bend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.03 in.)

Valves and Springs

Valve ClearanceFD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (.010 in.)Spring Free LengthFD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.)Minimum Valve Stem O.D.IntakeFD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.93 mm (0.194 in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.)ExhaustFD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.92 mm (0.193 in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.)Maximum Valve Guide I.D.FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.06 mm (0.199 in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.)Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . 0.5 -1.10 mm (.020-.043 in.)Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in.)Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45o Minimum Valve MarginFD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.)Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30o

CYLINDER HEAD & VALVES CYLINDER HEAD

5 - 4 4/7/95

CYLINDER HEAD

REMOVAL

IMPORTANT: Loosen cylinder head bolts 1/4 turnat a time, in the sequence shown, to avoidwarping the cylinder head

Mark position of all valve train parts so they canbe reinstalled in their original position.

Special Bolt

1

2

3

4

5

M46437

CLEANING AND INSPECTION

NOTE: Use tools that will not gouge or damage thecylinder head.

1. Scrape heads to remove carbon deposits or use a de-carbonizing agent.Clean head with a suitable solvent and dry withcompressed air.

2. Lay a straight edge along the sealing surface of head and measure warpage with a thickness gauge atseveral different points. If warpage exceeds servicelimit, repair or replace cylinder head.

3. Check cylinder head for cracks.4. Apply clean engine oil to all contact surfaces and

assemble cylinder head.

HEAD AND VALVE COMPONENTS

Circlip

Rocker Arm Shaft

Rocker ArmAdjuster Screw

Seals

Bottom Retainer

Springs

Top Retainer

Keepers

GasketReplace

Valve Cover

Head Bolts

Cover

Intake Valve

Exhaust Valve

Head Gasket

Guide Pin

Lock Nut

Cap Screws

Minimum Diameter: 11.95 mm(0.470 IN.)

9 N•m(79 lb-in.)

21 N•m(15 lb-ft)

Minimum I.D.:12.074 mm(0.4754 in.)

Cylinder HeadWarp(max):0.06 mm

(0.002 in.)

Check Free Length

Replace

M57335

VALVE, VALVE SEAT AND GUIDE CYLINDER HEAD & VALVES

4/7/95 5 - 5

VALVE, VALVE SEAT AND GUIDE

INSPECTION

A - Valve Margin (Min.)FD440V/FD501V . . . . . . . . . . . . . 0.50 mm (0.020 in.)FD590v/FD620D . . . . . . . . . . . . . . 0.6 mm (0.024 in.)

B - Valve Seating Width. . . . . . . . . . . . . . . . . . . 0.5 - 1.1 mm (0.02 - 0.043 in.)C - Valve Stem Diameter (Min.)Intake:FD440V/FD501V . . . . . . . . . . . . . 4.93 mm (0.194 in.)FD590V/FD620D . . . . . . . . . . . . . 5.94 mm (0.234 in.)Exhaust:FD440V/FD501V . . . . . . . . . . . . . 4.92 mm (0.193 in.)FD590V/FD620D . . . . . . . . . . . . . 5.92 mm (0.233 in.)

Intake: . . . . . . . . . . . . . . . . . . . 5.945 mm (0.2341 in.)Exhaust: . . . . . . . . . . . . . . . . . 5.925 mm (0.2332 in.)

D - Guide I.D. (Max.)FD440V/FD501V . . . . . . . . . . . . . 5.06 mm (0.199 in.)FD590V/FD620D . . . . . . . . . . . . . 6.05 mm (0.238 in.)

Valve Stem Run out (Max.) . . . . 0.05 mm (0.002 in.)

A

45°

B45°

C

D M57341

• Valve guides are not replaceable. If worn, replacehead.

• If grinding the valve and valve seat is necessary,follow tool manufacturer’s instructions carefully.

• Lap valves after grinding with lapping compoundand recheck valve seating surface for correct widthand evenness of seating pattern.

.

• If seats are warped or distorted beyondreconditioning, replace cylinder head.

• Check valve seating pattern for correct width andevenness all the way around.

• Clean and measure valve stem at three pointsalong length of stem.

VALVE SPRING FREE LENGTH• Inspect valve spring for pitting, rust and burrs.

FREE LENGTH SPECIFICATIONS (MIN)

FD440/501V . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.)FD590V/FD620D . . . . . . . . . . . 29.70 mm (1.170 in.))

Correct Seat Position

Seat Too DeepSeat Too High

M18615

M50036

CYLINDER HEAD & VALVES VALVE, VALVE SEAT AND GUIDE

5 - 6 4/7/95

PUSH ROD INSPECTION

INSTALLATION

IMPORTANT: Handle head gaskets carefully toavoid removing the sealing agents from thesurface during handling.

Use a torque wrench when tightening cylinderhead bolts in sequence shown.

NOTE: For easier assembly turn flywheel until camlobes are at their lowest position. Install thepush-rods in their original positions. This willallow head to be installed without compressingvalve springs.

Torque should be applied in 3 N•m (27 lb-in.)increments.

• Tighten cylinder head bolts to half the requiredtorque.

• Install manifold before applying a final torque of 21N•m (186 lb-in.).

• Adjust Valve Clearance.

Push RodMaximum run-out : 0.8 mm

(0.03 in.)

M50044

Special Bolt

1

2

3

4

5

M46437

CONTENTS CYLINDER BLOCK, PISTONS & RODS

Page

4/7/95 6 - 1

CONTENTS

CYLINDER BLOCK, PISTONS & RODS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

REMOVE PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

INSPECT REPLACE CRANKSHAFT PLAIN BEARINGS . . . . . . . . . . . . . . . . . . . 8

REPLACE CRANKSHAFT JOURNAL BUSHING AND SEALS . . . . . . . . . . . . . . . 9

INSPECT BLOCK CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DEGLAZE CYLINDER BORE 10

REBORE CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

REMOVE AND INSTALL PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

CHECK PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

INSPECT PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

INSPECT CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ASSEMBLE CONNECTING ROD AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . 14

NOTES CYLINDER BLOCK, PISTONS & RODS

6 - 2 4/7/95

SPECIFICATIONS CYLINDER BLOCK, PISTONS & RODS

4/7/95 6 - 3

SPECIFICATIONS

FD440V/FD501V

CYLINDER BLOCK

Cylinder Bore


Rebore CylinderOversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm (2.656 - 2.657 in.)

Plain Bearings

Maximum Crankcase and Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . 30.09 mm (1.185 in.)

Piston

Maximum Ring Groove ClearanceTop Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Not MeasuredMaximum Ring End GapTop Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Not Measured Minimum Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.)Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.04 mm (0.631 in.)Distance from bottom of piston skirtHeight of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.)Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm (2.6358 - 2.6364 in.)Piston-to-Cylinder Bore Clearance. . . . . . . . . . 0.015 - 0.150 mm (0.00059 - 0.0059 in.)

Connecting Rod

Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.)Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)

CYLINDER BLOCK, PISTONS & RODS SPECIFICATIONS

6 - 4 4/7/95

FD590V

CYLINDER BLOCK

Cylinder Bore


Rebore Cylinder

Oversize Diameter0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46±74.48 mm (2.934±2.935 in.)

Plain Bearings

Maximum Crankcase and Cover I.D . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)

Piston

Maximum Ring Groove ClearanceTop and Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)Oil Ring Not MeasuredMaximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.040 in.)Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.98 mm (0.668 in.)Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.04 mm (0.671 in.)Distance from bottom of piston skirt Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.)Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm (2.9108 - 2.9114 in.)Piston-to-Cylinder Bore Clearance . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.)

Connecting Rod

Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.)Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.)End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

SPECIFICATIONS CYLINDER BLOCK, PISTONS & RODS

4/7/95 6 - 5

FD620D

CYLINDER BLOCK

Cylinder Bore


Rebore Cylinder


Piston

Maximum Ring Groove ClearanceTop Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.)Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.050 in.)Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.98 mm (0.668 in.)Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.04 mm (0.671 in.)Distance from bottom of piston skirt(Area to measure piston O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.)Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm (2.989 - 2.990 in.)Piston-to-Cylinder BoreClearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.)

Connecting Rod

Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.)Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

Plain Bearings

Maximum Crankcase Cover I.D.. . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.)

CYLINDER BLOCK, PISTONS & RODS REPAIR

6 - 6 4/7/95

REPAIR

CRANKCASE DISASSEMBLY1. Drain crankcase.2. Remove water pump.

NOTE: Crankcase is pinned by oil filter and opposite side. Do not force cover.

FD440V/FD501V FD590V/FD620D

3. Remove crankcase cover and gasket..

4

3

21

6

5

1

23

4

5

67

8

M53974 M517207

REPAIR CYLINDER BLOCK, PISTONS & RODS

4/7/95 6 - 7

COMPONENTS

Fan Drive Coupling 15 N•m(130 lb-in)

Nut

Washer

Flywheel

Stator

Seal

Bushing

Breather Assembly

Oil Filter

Oil PressureSensor

CylinderBlock

Lifters

Camshaft

Piston

Piston Rings

Crankshaft

Rod Cap

FD440/501V: 12 N•m (106 lb-in.)FD590/620: 21N•m (186 lb-in. )

Seal

Crankcase

Crankcase Cap Screws21 N•m (186 lb-in.)

Oil Pump Assembly

Governor

Gasket

Oil Pick-upScreen

Flyweight

FD440/501: 90 N•m (66 lb-ft)FD590/620: 110 N•m (80 lb-ft)

Crankshaft Gear

Gear PinPiston Pin

M57345


6 - 8 4/7/95

REMOVE PISTONS

NOTE: Note location of the arrow match mark on the piston head in relation to “Made in Japan” on the connecting rod. No. 1 piston is opposite no.2. Keep parts together as a set.

1. Turn the crankshaft to expose the connecting rodend caps. Mark the end caps for reassembly in thesame position as removed.

2. Remove carbon and/or ridge from the top of thecylinder bore with a suitable ridge remover andremove the piston and connecting rod through thetop of the cylinder bore.

M46447

Match Marks

Flywheel Side

Large Chamfers

Raised Letters(MADE IN JAPAN)

INSPECT & REPLACE CRANKSHAFT PLAIN BEARINGS

Measure crankshaft bearings in crankcase andcrankcase cover. Replace block, cover or shells, ifequipped, if diameter is greater than specifications.(See this group.)

BEARING I.D. SPECIFICATIONS (MAX)Crankcase and Cover

FD440/501V . . . . . . . . . . . . . . 30.09 mm (1.185 in.)FD590V . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)FD620D Crankcase Cover . . . . . . . . . 34.07 mm (1.341 in.) Crankcase . . . . . . . . . . . . . . 34.11 mm (1.343 in.)

M50072


4/7/95 6 - 9

REPLACE CRANKSHAFT JOURNAL BUSHING AND SEALS1. Place crankcase on bench with oil seal side up.

Crankcase Seal

2. Remove oil seal.

NOTE: Do not re-use oil seal. Replace with new.

• The service bushing is to be reinstalled using a bushing tool as shown.

• Coat the bushing and flange surface with a light film of oil, Press in the new bushing flush with the flange surface.

• No finish reaming is required

M44227

M46455Support Block

Bushing Tool

Flange Surface

New Bushing

To Design a Bushing Tool

Bushing Tool Dimensions(A) . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575 in.)(B) . . . . . . . . . . . . . . . . . . . . . . . . 26 mm (1.024 in.)(C) . . . . . . . . . . . . . . . . . . . . . . 33.8 mm (1.331 in.)

3. Remove bearing shell using a bushing, bearing andseal driver set and press.

4. Apply a light coat of oil on outside diameter of newbearing shell.

5. Install new bearing shell flush with crankcase flangesurface.

6. Remove crankshaft oil seal and press in a new sealwith spring loaded lip towards inside of the engineand outside edge of seal flush with flange surface.

7. Pack space between seal lip and dust lip with hightemperature grease.

8. Install new seal with flange flush with case.

B

A

C

M46456

M46445

High TemperatureGrease

Lip SealDust Lip

Spring LoadedLip

Flange Surface


6 - 10 4/7/95

INSPECT BLOCK CYLINDERS1. Clean and check block for cracks.2. Cracks not visible to the eye may be detected by

coating the suspected area with mixture of 25percent kerosene and 75 percent light engine oil.

3. Wipe area dry and immediately apply coating of zincoxide dissolved in wood alcohol. If crack is present,coating becomes discolored at the defective area.Replace block if any cracks are found.

4. Measure cylinder bore parallel with crankshaft andright angles to crankshaft at top and bottom of ringtravel.

5. If cylinder bore exceeds wear limit, replace cylinderblock or rebore cylinder.

NOTE: Before reboring, check availablity of oversize piston and rings. They must be installed.

CYLINDER BORE SPECIFICATIONS

Standard Wear Limit

FD440V FD501V. . . . . . . . . . . . . . . . . . . . . . . . . . . 66.98 - 67.00 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . (2.637 - 2.638 in.)Wear Limit. . . . . . . . . . . . . . . 67.06 mm (2.640 in.)

FD590V. . . . . . . . . . . . . . . . . . . . . . . . . . . 73.98 - 74.00 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . (2.915 - 2.916 in.)

Wear Limit . . . . . . . . . . . . . . . 74.07 mm (2.918 in.)FD620D

. . . . . . . . . . . . . . . . . . . . . . . . . . . 75.98 - 76.00 mm

. . . . . . . . . . . . . . . . . . . . . . . . . (2.9913 - 2.9921 in.)Wear Limit . . . . . . . . . . . . . . . 76.07 mm (2.997 in.)

M54745

DEGLAZE CYLINDER BORE1. Deglaze cylinder bore using a rigid hone with a 220

to 300 grit stone.2. Use hone as instructed by manufacturer to obtain

45° crosshatch pattern as shown.

IMPORTANT: Do not use gasoline, kerosene, or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls.

3. Clean cylinder walls using clean white rags andwater. Continue to clean cylinder until white ragsshow no discoloration.

REBORE CYLINDER BLOCK

IMPORTANT: Check stone for wear or damage. Use correct stone for the job.

NOTE: The cylinder block can be rebored to use 0.50 ( 0.020 ) oversize pistons and rings. Have a reliable repair shop rebore the block, or use a drill press and honing tool.

1. Rebore cylinder with a honing tool to initial and finalbore specifications.

2. Align center of bore to press center. Set the press tooperate from 200±250 rpm.

3. Lower and raise hone until ends extend 20±25 mm(0.75±1.0 in.) past ends of cylinder.

4. Turn adjusting nut on hone until stones contactcylinder wall at narrowest point.

45° - 60°

M82412a


4/7/95 6 - 11

5. Coat inside of cylinder with honing oil. Turn hone byhand. If you cannot turn it, hone is too tight.

6. Start drill press. Move hone up and down in cylinderapproximately 20 times per minute to get 40 -60°cross-hatch pattern.

7. Check cylinder diameter regularly during honing.Stop press before measuring. Remove hone fromcylinder.

CYLINDER INITIAL BORE SPECIFICATIONS

Piston Oversize: 0.50 mm (0.020 in.)

FD440V/FD501V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.656 -2.657 in. )FD590V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46 - 74.48 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.934 - 2.935 in. )FD620D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.46 - 76.48 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . (3.012 - 3.013 in. )

8. Hone the cylinder an additional 0.028 - 0.030 mm(0.0011 - 0.0012 in.) for final bore specifications.This allows for 0.020 mm (0.0008 in.) shrinkagewhen cylinder cools.

IMPORTANT: DO NOT use gasoline or commercial solvents to clean cylinder bores. Solvents will not remove metal particles produced during honing.

9. Clean the cylinder thoroughly using soap, warmwater and clean rags. Continue to clean cylinderuntil white rags show no discoloration.

10. Apply oil to cylinder walls.

REMOVE AND INSTALL PISTON RINGS1. Remove piston rings with a piston ring expander.2. Inspect piston. Clean piston ring grooves. Check

piston ring end gap.

NOTE: FD590V and FD620D engines are equipped with a second compression ring. Install ring with mark facing up

3. Install top compression ring and second ring, ifequipped, with R or NPR mark facing up. Ringsshould turn freely in grooves.

4. Oil ring: Install spacer, then side rails. Put side railend gaps 180° apart.

CHECK PISTON RING END GAPBefore installing rings on piston, check end gap incylinder bore.

Install each ring squarely in bore approximately 25.4mm (1.0 in.) down from top of cylinder.

Check end gap. Replace ring if end gap is more thanspecifications.

END GAP SPECIFICATIONS (MAX)

Compression Rings

FD440V/501/590V . . . . . . . . . . . . 1.00 mm (0.040 in.)FD620D . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.050 in.)Oil Rings . . . . . . . . . . . . . . . . . . . . . . . Not Measured

M80429

First CompressionRing

SecondCompressionRing

Side Rails

Spacer

M53962


6 - 12 4/7/95

INSPECT PISTON

IMPORTANT: Do not use a caustic cleaning solution or a wire brush to clean piston.

1. Remove all deposits from the piston.

2. Clean carbon from piston ring grooves with a ringgroove cleaner. If cleaning tool is not available,break an old ring and use it carefully to cleangroove.

3. Check that oil return passages in grooves are open.4. Inspect piston for scoring or fractures. Replace

piston if damaged.

NOTE: Inspect clearance visually. Replace piston if clearance appears excessive.

5. Check ring grooves for wear at several points aroundpiston. Replace piston if clearance is greater thanspecification.

RING SIDE CLEARANCE SPECIFICATION (MAX)

Top Ring:

FD440V/FD501V/ FD590V . . . . . 0.10 mm (0.004 in.)FD620D . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

Second Ring:

M29916

M38102

FD440V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAFD590V . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)FD620D . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)

Oil Control Rings:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Meassured

IMPORTANT: Note location of arrow match mark on piston head in relation to MADE IN JAPAN on connecting rod. No. 1 piston is opposite of No. 2 piston. Keep parts together as a set.

6. Remove piston pin and connecting rod.7. Measure piston pin outer diameter and piston pin

bore.

PISTON AND PISTON PIN SPECIFICATIONS

Piston Pin O.D. (MIN)

FD440/501V . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.)FD590V/FD620D . . . . . . . . . . . . 16.98 mm (0.668 in.)

Piston Pin Bore I.D. (MAX)


“Made in Japan”

Connecting RodPiston Pin

C-ringReplace

Arrow

M50063

M50064 M80427


4/7/95 6 - 13

10. Measure piston O.D. (B) perpendicular to piston pinbore at approximate specified distance (A) from bottomof piston skirt.

12. Subtract piston O.D. measurement (B) fromcylinder bore measurement to determine piston-to-cylinder bore clearance.

13. Replace piston and/or rebore cylinder block if notwithin specifications.

Distance (A)

FD440/501V. . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.) FD590V/FD620D . . . . . . . . . . . . . . 11 mm (0.433 in.)

Piston O.D. (B)

FD440V . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm. . . . . . . . . . . . . . . . . . . . . . . . . (2.6358 - 2.6364 in.)

FD590V . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm. . . . . . . . . . . . . . . . . . . . . . . . . (2.9108 - 2.9114 in.)

FD620D . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . (2.989 - 2.990 in.)

Piston-to-Cylinder Bore Clearance

FD440V . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.150 mm. . . . . . . . . . . . . . . . . . . . . . . . (0.00059 - 0.0059 in.)

FD590V/FD620D . . . . . . . . . . . . . . . 0.030 - 0.170 mm. . . . . . . . . . . . . . . . . . . . . . . . (0.00118 - 0.0067 in.)

INSPECT CONNECTING RODInstall connecting rod cap. Tighten to specification.

CAP TORQUE SPECIFICATIONS

FD440/501V. . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)FD590V/FD620D . . . . . . . . . . . . . . 21 N•m (186 lb-in.)Clean and inspect rod. Replace if scored.

A

BM80248

Measure connecting rod crankshaft bearing and pistonpin bearing. Replace connecting rod if eithermeasurement is greater than specifications.

CONNECTING ROD BEARING I.D.SPECIFICATIONS (MAX)

Crankshaft Piston Bearing

FD440/501V. . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.)FD590V/ FD620D. . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 IN.)

Piston Pin Bearing

FD440/501V. . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.)FD590v/FD620D. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.)

Crankshaft Bearing

Piston Pin Bearing

M50066


6 - 14 4/7/95

ASSEMBLE CONNECTING ROD AND PISTON

NOTE: With pistons installed, No. 1 piston is designated by the large chamfer on connecting rod facing toward flywheel.

No. 2 piston is designated by the large chamfer onconnecting rod facing away from flywheel.

The arrow match mark on both piston heads shouldpoint toward the flywheel.

IMPORTANT: Do not reuse piston pin retaining rings.

IMPORTANT: No. 1 piston, align arrow match mark (A) on piston head with MADE IN JAPAN (B) on connecting rod.No. 2 piston, align arrow match mark on piston head opposite MADE IN JAPAN on connecting rod.

“Made in Japan”

Connecting RodPiston Pin

C-ringReplace

Arrow

M50063

CONTENTS CAMSHAFT, CRANKSHAFT & FLYWHEEL

Page

4/7/95 7 - 1

CONTENTS

CAMSHAFT, CRANKSHAFT & FLYWHEEL

SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3INSPECT CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INSPECT CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REMOVE AND INSTALL TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

NOTES CAMSHAFT, CRANKSHAFT & FLYWHEEL

7 - 2 4/7/95

SPECIFICATION CAMSHAFT, CRANKSHAFT & FLYWHEEL

4/7/95 7 - 3

SPECIFICATION

Crankshaft - FD440/501V

Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.92 mm (1.178 in.)Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 30.93 mm (1.218 in.)Maximum T.I.R. (Total Indicated Runout) . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

Crankshaft - FD590V/FD620D

Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.91 mm (1.335 in.)Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 33.93 mm (1.336 in.)Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

Block and Crankcase Plain Bearings

Maximum Crankcase Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.)

Camshaft

Bearing JournalsFD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.91 mm (0.548 in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.91 mm (0.626 in.)

Lobes JournalFD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.43 mm (0.962 in.)FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.23 mm (0.993 in.)FD620D

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.21 (0.993 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.46 mm (1.002 in.)

Fuel Pump Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.760 in.)

Connecting Rod Cap Bolt Torque

FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

CAMSHAFT, CRANKSHAFT & FLYWHEEL CAMSHAFT

7 - 4 4/7/95

CAMSHAFT SPECIFICATIONS (MIN)

Bearing Journals


Cam Lobes Journal

FD440/501V . . . . . . . . . . . . . . . . 24.43 mm (0.962 in.)FD590V . . . . . . . . . . . . . . . . . . . 25.23 mm (0.993 in.)FD620D

Intake. . . . . . . . . . . . . . . . . . . . . . . 25.21 (0.993 in.)Exhaust . . . . . . . . . . . . . . . . . 25.46 mm (1.002 in.)

Fuel Pump Lobe . . . . . . . . . . . . 19.50 mm (0.760 in.)

INSPECT CAMSHAFT BEARINGSMeasure camshaft bearings in cylinder block andcrankcase cover. Replace block or cover if diameter isgreater than specification.

Cylinder Block Bearing

Crankcase Cover Bearing

M51723

M51724

CAMSHAFT

REMOVAL

IMPORTANT: Align timing marks to preventdamage to tappets when removing camshaft.

1. Rotate crankshaft until timing marks (A) align.2. Remove and inspect camshaft.

INSTALLATION3. Lubricate journals.4. Align timing marks and install camshaft.

INSPECT CAMSHAFTInspect camshaft for worn or broken teeth and looserivets holding gear to camshaft. Replace camshaft ifloose.

Measure journals cam lobes. Replace camshaft if lessthan specifications.

NOTE: On FD440V and FD590V engines, measurefuel pump lobe. Not used on FD620D.

Timimg Marks

M44227

PTO sideJournal

Cam LobesFlywheel SideJournal

Fuel Pump Lobe M51722

CRANKSHAFT CAMSHAFT, CRANKSHAFT & FLYWHEEL

4/7/95 7 - 5

Camshaft Bearing Specifications (Max)

Cylinder Block Bearing

FD440V . . . . . . . . . . . . . . . . . . . 14.07 mm (0.554 in.)FD590V/FD620D . . . . . . . . . . . . 16.07 mm (0.633 in.)Crankcase Cover Bearing

FD440/501V . . . . . . . . . . . . . . 14.05 mm (0.553 in.)FD590V/FD620D . . . . . . . . . . 16.07 mm (0.633 in.)

REMOVE AND INSTALL TAPPETS1. Remove camshaft.

NOTE: Mark tappets so they can be installed in theiroriginal guides during assembly

.

2. Remove tappets.Replace if scored.3. Install tappets in original positions.

M53975

Tappets

CRANKSHAFT

REMOVAL1. Remove camshaft.

IMPORTANT: Mark connecting rod caps so theycan be reinstalled in the same location.

2. Remove connecting rod caps and push pistons to top of cylinder. Remove crankshaft.

IMPORTANT: A bent crankshaft must be replaced;it cannot be straightened.

INSPECTION1. Check crankshaft alignment (T.I.R).

• Place crankshaft into an alignment jig. Using dialindicators, rotate crankshaft slowy.

Maximum Crankshaft Bend

All. . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

Rod Caps

M53975

M80432

CAMSHAFT, CRANKSHAFT & FLYWHEEL CRANKSHAFT

7 - 6 4/7/95

2. Clean and inspect crankshaft. Measure crankshaft main bearing journals and connecting rod journal.

NOTE: Under-size connecting rod is not available forFD440/501V engine. Replace crankshaft ifmeasurements are less than specifications.

On FD590Vand FD620D engines, connectingrod journal can be resized to accept under-sized rod. Have grinding done by a reliablerepair shop. Before sending crankshaft forgrinding, inspect journal radii for cracks.

Crankshaft Specifications (Min)

Main Bearing JournalFD440/501V . . . . . . . . . . . . . . 29.92 mm (1.178 in.)FD590V/ FD620D. . . . . . . . . . 33.91 mm (1.335 in.)

Connecting Rod JournalFD440/501V . . . . . . . . . . . . . . 30.93 mm (1.218 in.)FD590V/ FD620D. . . . . . . . . . 33.91 mm (1.336 in.))

Resizing Specifications -FD590V/FD620D

A . . . . . . . . . . 33.48 - 33.47 mm (1.3181 - 1.3176 in.)B . . . . . . . . . . . . . . 2.30 - 2.70 mm (0.090 - 0.110 in.)C . . . . . . . . . . . . . . . . . . . . . 44.50 mm Max 1.752 in.)D . . . . . . . . . . 34.00 - 33.95 mm (1.3386 - 1.3366 in.)

M51729

M57348

A

B

C

D

INSTALLATION1. Cover keyway on flywheel end of crankshaft with

tape to prevent seal damage when installingcrankshaft.

2. Put a light film of oil on crankshaft bearing surfaces.3. Pack grease in oil seals and install crankshaft.4. Install connecting rod caps and torque.

Connecting Rod Cap Bolt Torque

FD440/501V . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)FD590V/FD620D . . . . . . . . . . . . . 21 N•m (186 lb-in.)

CONTENTS LUBRICATION SYSTEM

Page

4/7/95 8 - 1

CONTENTS

LUBRICATION SYSTEM

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4OIL PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

DISASSEMBLE AND ASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSPECT OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

NOTES LUBRICATION SYSTEM

8 - 2 4/7/95

SPECIFICATIONS LUBRICATION SYSTEM

4/7/95 8 - 3

SPECIFICATIONS

Oil Pump

Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.)Maximum Rotor Shaft Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.)Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.592 in.)Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.)Minimum Relief Valve Spring Free Length

FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.05 - 21.55 mm (0.829 - 0.848 in.)FD590VFD/620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.770 in.)

Inner and Outer Rotor ClearenceMaximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)Pump Housing DepthMaximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.230 mm (1.6063 in.)

Outer Rotor Thickness (Max.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.830 mm (0.3870)

LUBRICATION SYSTEM LUBRICATION SYSTEM OPERATION

8 - 4 4/7/95

LUBRICATION SYSTEM OPERATIONA positive displacement gerotor pump is used topressurize the lubrication system. The lubricationsystem is protected by an oil pressure relief valve, lowoil pressure switch, and a oil filter with bypass.

The oil pump (F) draws oil (B) from the sump throughscreen (G). Pressure oil (A) from the pump flows to theoil pressure relief valve (E). If oil pressure exceeds 296kPa (43 psi), the relief valve opens allowing oil to returnto sump. Relief valve is not adjustable.

Pressure oil from the relief valve flows to the oil filter .

COMPONENTS

Rocker Arms and Valves

Pick-up Screen

Oil PumpOil Pressure

Oil Filter

Oil Pressure Sensor

Camshaft

Crankshaft

Piston

Connecting Rod

Water Pump Gear

M57349

Tappets

Relief Valve

Governor

Crankshaft Main Bearings

Gear

The filter contains a bypass valve which opens if theelement becomes plugged to insure engine lubrication.

An oil pressure switch mounted above the oil filter turnson a warning light if oil pressure is below 28 kPa (4 psi).Filtered pressure oil flows through a passage in the oilsump to the crankshaft main bearing (PTO side).Drilled passages in the crankshaft distribute oil fromthe main bearing to the connecting rod journals, andcrankshaft main bearing (flywheel side). A drilledpassage in the connecting rods allow oil from theconnecting rod journal to lubricate the piston andcylinder walls.

OIL PUMP REPAIR LUBRICATION SYSTEM

4/7/95 8 - 5

OIL PUMP REPAIR

DISASSEMBLE AND ASSEMBLE

FD440V Shown

IMPORTANT: Oil pressure relief valve spring andball will be loose when pump cover is removed.

1. Remove oil pump assembly, relief valve spring and ball.

2. Remove, clean or install a new oil pick-up screen.

3. Install oil pressure relief valve ball, spring and oil pump assembly.

IMPORTANT: Fill rotor housing with engine oil forinitial lubrication.

4. Install cover so that hole in cove plate is centered over relief valve. Tighten cover screws evenly.

Oil Pick-up Screen

Screen Cover

Oil Pump Assembly

M53966

7.8 N•m(69 lb-in.)

Cover Cap Screws

Pins

Spring

Ball

Plate HoleGear Inner Rotor

Outer Rotor

M57350

INSPECT OIL PUMP

NOTE: Rotors and rotor shaft are replace as a kit. Ifany of the parts show signs of wear or arescored, replace.

M53967

Gear

Cover

Pin (Two used)

Rotor Shaft

Inner Rotor

Outer Rotor

Oil Pressure Relief Valve

Ball

Cover

Screen

Spring

LUBRICATION SYSTEM OIL PUMP REPAIR

8 - 6 4/7/95

Measure parts per the oil pump specifications. Replacecrankcase if bearing surfaces are worn or scoredgreater than specifications. If parts show signs ofpremature wear, check condition of pick-up screen andsealing area around screen.

OIL PUMP SPECIFICATIONS

Rotor Shaft

Minimum Shaft O.D. . . . . . . . . 10.92 mm (0.430 in.)Maximum Bearing I.D. . . . . . . . 11.07 mm (0.436 in.)

Outer Rotor

Minimum Rotor O.D. . . . . . . . . 40.43 mm (1.592 in.)Maximum Bearing I.D. . . . . . . . 40.80 mm (1.606 in.)Thickness (Max.) . . . . . . . . . . . . . 9.830 mm (0.3870)

Inner and Outer Rotor ClearenceMaximum. . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)

Pump Housing DepthMaximum . . . . . . . . . . . . . 10.230 mm (1.6063 in.)

Spring Free Length Specifications (MIN)FD440/501V . . . 21.05 - 21.55 mm (0.829 - 0.848 in.)FD590V/FD620D . . . . . . . . . . . 19.50 mm (0.770 in.)

Shaft BearingOuter Rotor Bearing

M44227

CONTENTS COOLING SYSTEM

Page

4/7/95 9 - 1

CONTENTS

COOLING SYSTEM

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3COOLING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TEST THERMOSTAT 8

COOLANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

COOLANT PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

COOLING FAN AND BRACKET -FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

COOLING FAN DRIVE BELT ADJUSTMENT - FD620D . . . . . . . . . . . . . . . . . . . 10

NOTES COOLING SYSTEM

9 - 2 4/7/95

SPECIFICATIONS COOLING SYSTEM

4/7/95 9 - 3

SPECIFICATIONS

Engine Coolant Capacity

FD440/FD501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 L (2.2 qt)FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.04 L (3.2 qt)FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 L (1 qt)

Thermostat

FD440/501/590Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)

FD620DBegin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65°C (148°F)Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80°C (176°F)

Water Pump


Over-flow Reservoir

Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)

Sheave/Half - FD620D

Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)

COOLING SYSTEM COOLING SYSTEM OPERATION

9 - 4 4/7/95

COOLING SYSTEM OPERATION

Function:

Remove heat from engine.


The engine is liquid-cooled and uses a pressurized, fin-type radiator, water pump, and thermostat to regulateengine temperature. The cooling system is protectedby a coolant temperature switch that warns theoperator if the engine temperature becomes too high.The water pump is driven off the camshaft gear (H)

When the engine temperature is cold, below 82°C(180°F), the thermostat (R) is closed. The closed |thermostat stops coolant flow into the radiator(A). Nowthe water pump (J) must draw coolant from the bypasshose (O) which is between the cylinder head and thewater pump. An impeller (I) forces the low temperaturecoolant (U) through the cylinder block coolantpassages (N) to the piston coolant passage (L).Coolant flows around the piston coolant passage, andthen through the right cylinder head, intake manifold(M), and left cylinder head to the bypass hose. Theengine heat is transferred to the coolant and thecoolant temperature increases. Since the hightemperature coolant (T) bypasses the radiator, theengine warms up to operating temperature quickly.

When the engine temperature is 82°C (180°F), thethermostat begins to open and is fully open at 95°C(203°F). High temperature coolant from the left cylinderhead flows through the thermostat to the radiator. Theradiator is cooled by a radiator fan (E) that is mountedto the flywheel (G). The radiator fan pulls in air from thefront of the engine and forces the air upward throughthe radiator fins. The coolant temperature decreasesas the coolant flows from the radiator inlet to the outlet.With the thermostat open, the water pump draws lowtemperature coolant from the radiator through theradiator outlet hose (K) instead of the bypass hose.The low temperature coolant is circulated through theengine to provide constant cooling.

A coolant temperature switch (Q) mounted in the leftcylinder head turns on a warning light if coolanttemperature is above 111°C (232°F).

The radiator cap (B) maintains a constant pressure of88 kPa (13 psi) inside the radiator which actually raisesthe boiling point of the coolant. The radiator capcontains a pressure valve and a vacuum valve. Whenthe coolant is hot and pressure is above 88 kPa (13psi), the pressure valve opens allowing some coolant toflow to the overflow reservoir. After the engine isstopped, the coolant cools and the pressure inside theradiator decreases to a partial vacuum. The vacuumopens the vacuum valve and some coolant from theoverflow reservoir flows back to the radiator

COMPONENTS COOLING SYSTEM

4/7/95 9 - 5

COMPONENTS

High Temperature Coolant Low Temperatire Coolant

Radiator

Radiator Cap

Outlet Hose

Piston Coolant

Intake Manifold

Cylindar Block

ImpellerWater Pump Gear

Cylinder Block

Bypass Hose

Cylinder Head

Coolant

Thermostat

Inlet Hose

Fan

Temperature Switch

Coolant Passage

Coolant PassageCoolant Passage

Passage

M44227

COOLING SYSTEM REPAIR

9 - 6 4/7/95

REPAIR

FD440V/501V

*FD440V: Studs are coated with LOCTITE. To remove studs, install nut and strike stud sharply with a hammer to loosen.

c CAUTIONReduce compressed air to less than 210 kPa (2 bar) (30 psi) when usingfor cleaning purposes. Clear area of bystanders, guard against flyingchips, and wear personal protection equipment including eye protection.

Screen

Radiator

Reservoir

Top Half Air Duct

Over Flow Tube

Damper Bushings

Studs*

Return Hose

Bottom Half Air Duct

Thermostat

Bypass Hose

Coolant Pump

Outlet Hose

Cover

M57353

Replace if hardor cracked.

Clean.

Clean. Straightenbent fins.

See Pump Repair.See Test.

4 N•m(31 lb-in.)

6 N•m(53 lb-in,)

6 N•m(53 lb-in,)

6 N•m(53 lb-in,)

ThermostatHousing

Fan Extension

Retaining Clip

REPAIR COOLING SYSTEM

4/7/95 9 - 7

FD590V

c CAUTION Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using forcleaning purposes. Clear area of bystanders, guard against flying chips, andwear personal protection equipment including eye protection.

ScreenRadiator

Reservoir

Over Flow Tube

Bracket

Fan

Return Hose

Top Half Air Duct

Thermostat

Fan Extension

Bottom Half Air Duct

Seal

Dampner BushingReplace if hard orcracked.

Clean. Straightenbent fins

M57352

Replace if crackedor deformed.

15 N•m(10 lb-ft)

6 N•m(53 lb-in.)

6 N•m(53 lb-in.)

6 N•m(53 lb-in.) 6 N•m

(53 lb-in.)

O-Ring

Intake Elbow

Thermostat Housing

Must sit in groove.

Retaining Clip

COOLING SYSTEM COOLANT PUMP

9 - 8 4/7/95

THERMOSTAT

NOTE: FD440/501V: Remove both halves of coolingair duct.

FD590V Shown

FD620D Shown

M51700

Thermostat Housing

M53946

ThermostatHousing

TEST THERMOSTATCheck thermostat using a thermostat tester. Heatthermostat in water to check opening temperature.Replace, if not according to specifications.

THERMOSTAT SPECIFICATIONS

FD440/501VBegin Opening . . . . . . . . . . . . . . . . . . . 82°C (180°F) Fully Open. . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)FD620D

Begin Opening . . . . . . . . . . . . . . . . . 65°C (148°F) Fully Open . . . . . . . . . . . . . . . . . . . . 80°C (176°F)

COOLANT PUMP

REMOVAL & INSTALLATION

Disconnect hoses and remove pump assembly, notingposition and lenght of cap screws.

TORQUE SPECIFICATIONS

Mounting Cap Screws . . . . . . . . . . 8 N•m (70 lb-in.)Cap Screw (B)* . . . . . . . . . . . . . 21 N•m (186 lb-in.)

*Cap screw (B) attaches crankcase cover to crankcase.

M51701

C

B

A

D

Drain Plug

COOLANT PUMP COOLING SYSTEM

4/7/95 9 - 9

COOLANT PUMP REPAIR

IMPORTANT: Leakage from water pump will draininto engine block and could cause enginedamage. If there if any doubt of the condition ofwater pump, replace it as a complete assembly.

1. Remove gear with a puller.2. Remove impeller assembly from shaft. Disassemble

impeller assembly.3. Measure outside diameter of shaft. If less than

specifications or shows any signs of corrosion,replace it.

4. Measure pump shaft bore in housing. Replace housing if greater than specifications.

5. Drive old mechanical seal from housing.

Spur Gear

Pin

Washer

Housing

Mechanical

PinImpeller

Oil Seal

Mating

O-Ring

Shaft

Ring

Seal

M44227

NOTE: Mechanic seal is sealed into place and will bedifficult to remove.

When installing impeller assembly to housing,coat mating surfaces with clean water.

6. Install new mechanical seal.

PUMP SPECIFICATIONS (MIN)

Shaft O.D. (MIN) . . . . . . . . . . . . . 9.94 mm (0.391 in.)Housing Shaft Bore/ I.D. (MAX) . . . . . . . . . . . . . . . . . . 10.09 mm (0.397 in.)

Oil Seal Shaft

Impeller

Machnical SealCoat mating surfaces with clean coolantM51707

COOLING SYSTEM COOLANT PUMP

9 - 10 4/7/95

COOLING FAN AND BRACKET -FD620D

15 N•m

Outer Fan Drive Sheave

Shim(S)Add to loosen belt.Remove to tighten.

IFanInstall with ridges on inside diameter of fan pointing away from engine.

Spacer

Pulley

Mountng Flange

Belt Tension245 - 391 N(55 - 88 lb)

Bearing

Bracket

Snap Ring

Bearing

Nut

Washers

M57354

(130 lb-in.)

IMPORTANT: Bearings are a pressed fit. Removeonly if being replaced.

To avoid pinching fan belt between flywheel andouter sheave half, rotate flywheel whiletightening outer sheave half mounting capscrews.

1. Heat mounting bracket with bearings (E) in hot oil to remove bearings. Tap bearings from mountingbracket.

2. Install bearings using a bushing, bearing and seal driver set and a press.

c CAUTIONDO NOT heat oil over 182°C (360°F). Oil fumes oroil can ignite above 193°C (380°F). Use athermometer. DO NOT allow a flame or heatingelement to come in direct contact with the oil.Heat the oil in a well-ventilated area.

COOLING FAN DRIVE BELT ADJUSTMENT - FD620DApply approximately (force) pressure between fan anddrive sheave. If deflection is not within 12 - 19 mm(0.472 - 0.748 in.), remove drive sheave and add shimsto loosen belt or remove shims to tighten belt.

CONTENTS ELECTRICAL SYSTEM

Page

4/7/95 10 - 1

CONTENTS

ELECTRICAL SYSTEM

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REPLACE STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4REPLACE PULSER COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REPLACE IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REPLACE IGNITION MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5STARTER SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ANALYZE STARTER CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BENCH TEST SOLENOID SHIFT STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSPECT STARTER - SOLENOID SHIFT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TEST FEILD WINDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TEST STARTER ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TEST STARTER SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUEL INJECTION TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUEL INJECTION AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8

FUEL INJECTION AIR PRESSURE SENSOR - FD620D . . . . . . . . . . . . . . . . . . . . 9

FUEL INJECTION THROTTLE SENSOR - FD590D . . . . . . . . . . . . . . . . . . . . . . . 9

ALTITUDE COMPENSATION SWITCHCIRCUIT - OPTIONAL FD590D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

NOTES ELECTRICAL SYSTEM

10 - 2 4/7/95

SPECIFICATION ELECTRICAL SYSTEM

4/7/95 10 - 3

SPECIFICATION

CHARGING SYSTEM

CapacityFD440/501/590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 AmpsFD620D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 AmpsStator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 VAC @ 3000 RPM

INJECTOR

FD590D

Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 - 12.9 OhmsFD620D

Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 Ohms

IGNITION SYSTEM

Pulser Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 - 1.0 VAC

ELECTRIC STARTER

Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.)

Maximum No Load Starter Draw

FD440/501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 amps at 6000 rpm (min)FD590/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 amps at 6000 rpm (min)

ELECTRICAL SYSTEM STATOR OPERATION

10 - 4 4/7/95

STATOR OPERATIONThe charging system is a permanent magnet andstator design.

As the flywheel rotates, a permanent magnet in theflywheel induces AC current in the stator windings. Thiscurrent flows to the regulator-rectifier where it isconverted to DC current needed to charge the battery.

REPLACE STATOR

FD590V Stator Shown

1. Remove: • flywheel• Wire clamp(s) • stator wiring lead pins from connector• Cut wire tie from wiring harness and remove stator

2. Install stator and connect wiring leads to plug.

REPLACE PULSER COILS

NOTE: Pulser coils are mounted in a fixed position.

Some application only use one pulser coil.

FD590 Pulser Coil

ConnectorClamp

M51685

Stator

Pulser Coil

M51686

1. Remove:• cooling air duct or flywheel guard• FD590V: radiator support brackets • FD620D: fan bracket• Remove pulser coil(s)• wire ties from wiring harness.

2. Disconnect wiring harness from ignitor.3. Install coils.4. Install fan or radiator brackets.5. Connect plug to ignitor.6. Install new wire ties where needed.

REPLACE IGNITION COILS

FD590V Ignition Coil

1. Disconnect plug wire from spark plug lead and primary wire leads from coil.

2. Remove ignition coil.3. Install ignition coil and connect wiring leads.

M52688

CoilWire Leads

REPLACE IGNITION MODULE ELECTRICAL SYSTEM

4/7/95 10 - 5

REPLACE IGNITION MODULE

NOTE: Module may not be mounted on engine onsome applications.

Note position of ground wire. Module must begrounded

1. Disconnect connectors and remove ignition module.2. When installing ignition, put wire lead under cap

screw. 3. Install ignition module and connect plugs.

STARTER SERVICE PARTS KITSThe following kits are available through your partscatalog:

• Brush Kit• Clutch Kit

ANALYZE STARTER CONDITION1. The starter overheats because of:

• Long cranking.• Armature binding.

2. The starter operates poorly because of:• Armature binding.• Dirty or damaged starter drive. • Badly worn brushes or weak brush springs.• Excessive voltage drop in cranking system. • Battery or wiring defective.• Shorts, opens, or grounds in armature.

NOTE: Starter repair is limited to brushes, end caps,and starter drive. Fields in starter arepermanent magnets and are not serviceable. Ifhousing or armature is damaged, replacestarter

M51960

GroundLead

Connectors

ModuleIgnition

BENCH TEST SOLENOID SHIFT STARTER

NOTE: Perform bench test before disassemblingstarter motor to determine cause of problem.

IMPORTANT: Never operate motor longer than 20seconds. Allow at least two minutes for coolingand battery recovery before operating again.Overheating, caused by excessive operation,will seriously damage starting motor.

1. Remove starter from engine.

2. Connect battery to starter using heavy duty cables and remote starter switch as shown.

When switch is activated, starter should engage andrun.

SPECIFICATIONS

Terminal Voltage (Min) . . . . . . . . . . . . . . . . 11.5 volts Starter Motor RPM (Min) . . . . . . . . . . . . . . 6000 rpm Current Draw (Max) . . . . . . . . . . . . . . . . . . . 50 amps

Results:

• IF SOLENOID CHATTERS; hold-in winding isopen-circuited.

• IF NOTHING HAPPENS; either the solenoid pull-in winding is open-circuited or mechanical partsare sticking.

• IF SOLENOID ENGAGES, BUT MOTOR DOES NOTRUN; check solenoid switch continuity, brushes,armature and field windings.

Solenoid cannot be repaired, replace it.

+_

MB

S

12V Battery

Battery Terminal

Starter Frame

RemoteSwitch

Switch Terminal

ELECTRICAL SYSTEM INSPECT STARTER - SOLENOID SHIFT TYPE

10 - 6 4/7/95

INSPECT STARTER - SOLENOID SHIFT TYPE

NOTE: Mark body and end cover to aid reassembly.

Front Cover

Solenoid

Shift Lever

Washer

PinionRetaining Clip

Pinion Stopper Half

Pinion

Armature

End Cover

Insulator

Brush Spring

Brushes

Brush HolderCase with

M53943

Stopper Half

Retaining Bolt

Field Windings

Always replace with new

1. Mark body and covers to aid alignment for reassembly.

2. Separate pinion stopper halves to remove retaining clip to remove starter drive.

3. Test and inspect starter parts for wear or damage.4. Replace brushes as a set if length of any one is less

than 6 mm (0.240 in.).Brushes must be soldered to field windings

5. Apply very light coat of multipurpose grease to:• sliding surfaces of armature and solenoid shift lever

pivots. • armature shaft spline. • points where shaft contacts cover.

6. Assemble starter. Hook solenoid plunger over shift fork.

Brush Assembly Tips:

• With front cover facing down in vise, assemble frontcover, armature and body.

• Assemble brush holder over armature. • Install brushes against armature. • Squeeze springs into place.• install insulator and cover.

TEST FEILD WINDINGS

NOTE: Field winding case is a tie point for manyseparate field coils. It may be difficult to detect one bad coil.If rpm was slow and armature tests are normal,replace field coil assembly.

Replace field coil if not according to specifications.

Test For Open

M57356

To Solenoid

Field Brushes

Armature Brushes

Continuity betweenbrushes and to case

Continuity betweenbrushes and solenoidlead. Open to case.

StarterCase

TEST STARTER ARMATURE ELECTRICAL SYSTEM

4/7/95 10 - 7

TEST STARTER ARMATURE

IMPORTANT: Do not clean armature with solvent.Solvent can damage insulation on windings.Use only mineral spirits and a brush.

1. Locate short circuits by rotating armature on a growler while holding a hacksaw blade or steel stripon armature. The hacksaw blade will vibrate in areaof short circuit.

2. Shorts between bars are sometimes caused by dirt or copper between bars. Inspect for this condition.

3. If test indicates short circuited windings, clean the commutator of dust and fillings. Check armatureagain. If test still indicates short circuit, replacearmature.

4. Using an ohmmeter, test each individual armature windings for grounded or open circuits.

Armature windings are connected in parallel, so eachcommutator bar needs to be checked.

• If test either test fails, armature must be replaced

M24861

Test For Grounds Test For Open

M50112, M50113

TEST STARTER SOLENOID

NOTE: If bench test indicated solenoid problems, usean ohmmeter or test light to check solenoid.

1. Test solenoid terminals for continuity. There should be no continuity.

2. Depress switch arm. There should be continuity when arm is fully depressed.

3. Test for open circuits between terminal and tab There should be continuity.

4. Test for open circuits between tabs and body. There should be continuity.

If solenoid fails any test, it is defective and must bereplaced.

When installing solenoid, hook switch arm over shiftfork, so that when solenoid is activated it will pull shiftfork in.

High Current Terminals

Solenoid BodySwitchArm

SolenoidTerminal

M51705

ELECTRICAL SYSTEM TEST STARTER ARMATURE

10 - 8 4/7/95

FUEL INJECTOR TEST

NOTE: Also see Fuel Injector in Fuel System andGovernor section.

Measure resistance across terminal. If out ofspecification replace.

Resistance Specification

at 20° C(68° F). . . . . . . . . . . . . . . . . 11.1 - 12.9 ohmsConnect jumper wire from battery ground to fuelinjector terminal. Briefly and repeatedly connect apositive wire from battery to other injector terminal.Injector must click each time wire contact is made. Noclick, replace injector.

FUEL INJECTION TEMPERATURE SENSOR

Function:

Monitors coolant temperature for computer todetermine the amount of fuel delivery for starting a coldengine or warm engine operation.

Replace temperature sensor and gasket as needed.Do not attempt to turn plastic connector. Use a threadsealer.

Terminals

M48181

Coolant Temperature Sensor

M48182

FUEL INJECTION AIR TEMPERATURE SENSOR

Function

Monitors coolant temperature for computer todetermine the amount of fuel delivery for starting a coldengine or warm engine operation.

FD590D Air Temperature Sensor

FD620D Air Temperature Sensor

When changing sensor make sure sensor and gromentare sealed and in place. Sensor is on clean air side offilter.

M44227

Sensor

M57364

Air Temperature Sensor

TEST STARTER ARMATURE ELECTRICAL SYSTEM

4/7/95 10 - 9

FUEL INJECTION AIR PRESSURE SENSOR - FD620D

Function:

The computer uses the signal from this sensor todetermine throttle plate position and engine load.

Make sure vacuum hose is not pinched, cracked or anypin holes. Connections must be tight to throttle bodyand sensor.

Air Pressure Sensor

M57336

FUEL INJECTION THROTTLE SENSOR - FD590D

Function:

Mechanically senses throttle shaft position whichcalibrates the fuel injection computer to the throttleplate position

Adjustment:1. Set throttle shaft at slow idle position. Turn slow idle

screw out so throttle plate is completely closed.2. With sensor connected to vehicle wiring harness,

read voltage of white wire. Adjust sensor untilvoltage reads between 0.35 - 0.38 volts.

3. Hold throttle sensor in this position and tighten cap screws.

4. Open and close throttle plate several times and recheck voltage. Readjust if necessary.

5. Replace sensor if voltage can not be obtained.6. Readjust slow idle stop screw.

ALTITUDE COMPENSATION SWITCH CIRCUIT - OPTIONAL FD590D

Function:

The altitude compensation switch circuit allows the fuelinjection module computer to adjust the fuel-air mixturewhen the unit is operated above 1500 m (4918 ft.). Theunit must be operated above 1500m (4918 ft.) for thealtitude compensation switch to operate.

When the unit is operated below 1500m (4918 ft.), thealtitude compensation switch is closed and provides apath to ground to energize the circuit. When the unit isoperated above 1500m (4918 ft.), the altitudecompensation switch opens breaking the path toground which denergizes the circuit. This leans thefuel-air mixture for high altitude operation.

M57367

Throttle Sensor

ELECTRICAL SYSTEM TEST STARTER ARMATURE

10 - 10 4/7/95

CONTENTS TROUBLESHOOTING

Page

4/7/95 11 - 1

CONTENTS

TROUBLESHOOTING

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PERFORMANCE DAIGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CRANKCASE VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

NOTES TROUBLESHOOTING

11 - 2 4/7/95

TROUBLESHOOTING TROUBLESHOOTING

4/7/95 11 - 3

TROUBLESHOOTING

Problem or Symptom

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Check or Solution

Weak or faulty spark plug

Faulty high tension leads

Faulty ignition Module

Faulty ignition coil

Faulty pulser coil

Contaminated fuel or faulty fuel supply system

Fuel shut-off solenoid not allowing fuel into main jet

Defective fuel pump

Air being drawn in through a hole in the fuel line(s)

Fuel shut-off valve closed (Inline valve)

Clogged fuel line or filter

Fuel tank vent line clogged

Vapor lock

Improper use of choke

Air filter restricted

Defective breather valve

Float level too high

Poor compression. Worn piston/piston rings stuck or not seated. Worn cylinder bore

Cylinder head loose


11 - 4 4/7/95

Worn or burn valves or improper clearance

Worn valve stem(s) or valve guide(s)

Warped cylinder head

Broken valve spring

Defective head gasket

Low oil level

Too much oil in crankcase

Carburetor out of adjustment

Air/fuel passages clogged

Carbon deposits in exhaust pipe/muffler

Carbon deposits in combustion chamber

Lack of coolant

Governor linkage out of adjustment

Faulty governor spring

Governor gear assembly binding or broken

Air being drawn through carburetor or intake manifold flanges

Incorrect timing gear alignment

Plugged oil ring groove

Oil leakage along governor shaft

Defective oil seal

Drain-back hole in breather chamber plugged

Problem or Symptom

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Check or Solution


4/7/95 11 - 5

Incorrect oil viscosity

Carburetor flange loose or leaking at gasket

Carburetor body and throttle shaft worn

Intake valve burned or sticking

Excessive engine load

Fan belt slippage

Defective radiator hose or clamp

Broken or missing fan shroud

Defective radiator

Cracked or porous casting

Loose stud bolts and cap screw

Engine overheating

Damaged water pump seals

Improperly installed gasket

Improper or defective radiator cap

Battery weak or discharged

Problem or Symptom

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Check or Solution

TROUBLESHOOTING DIAGNOSIS

11 - 6 4/7/95

DIAGNOSIS

STARTING MOTOR

Test Conditions:

• Known good battery

Test/Check Point Normal If Not Normal

Engine will Not Crank

1. Starter solenoid(Solenoid does not click)

Solenoid clicks when key is in start position

See cranking and neutral start circuits of product technical manual. Check wire connections at battery and solenoid switch terminals of solenoid. Check solenoid, starter motor and engine to battery ground.Faulty solenoid - test and replace

2. Starter motor(Solenoid clicks but starter doesnot rotate)

Starter motor should crank engine Disconnect all external drives.Rotate engine by hand to check for seized engineCheck starter solenoid to starter motor connectionRemove and test starter motor.

3. Starter Motor(Starter rotates but engine doesnot crank)

Engine cranking Worn pinion or ring gear. ReplaceIncorrect starter alignment or starter drive cover broken.Faulty starter drive clutch. Replace.

Engine Cranks Slow

4. Starter Motor Engine cranking at a minimum of 250 rpm.

Check solenoid to motor connection. Test or repair starter.Engine seizing. Repair engine.

Starter Does not disengage

5. Starter Drive (Starter motor continues to run)

Disengages when key is returned to run.

Faulty ignition switch. ReplaceFaulty solenoid. Replace

6. Starter Drive(Starting motor disengages)

Retracts when motor disengages Faulty pinion and ring gearStarter shift fork binding

Engine cranking speed goodbut will not start

Starts and runs with no performance complaints

Continue testing

DIAGNOSIS TROUBLESHOOTING

4/7/95 11 - 7

ENGINE

Test Conditions:

• Engine cranking speed above specification


ENGINE WILL NOT START

Conditions:

• Engine cranking

1. Spark plugRemoved and grounded againstblock

Hot blue sparkNo sparks between high tension wire and block

Spark: Go to step 5.Spark at spark tester but not plug: Faulty spark plug. ReplaceCheck high tension cap and high tension lead condition.

Spark plug not wet Plug dry:No fuel, see carburetor or fuel injection system test.No fuel in tank.Plug Wet: See Carburetion Checks

Conditions:

• Engine not cranking• Ignition on

2. Ignition coil and spark plug(Test both coil)

Battery voltage at positive terminal of coil. Spark at spark plug when negative terminal is grounded.

No voltage at Coil:Check engine harness connection. No battery voltage at connector, see product technical manual.Battery voltage at harness connector:Repair or replace engine harnessVoltage at positive terminal of coil and no spark when negative coil is grounded:Test and replace coil.No spark with engine cranking: Check ignition module connections and continue testing.

Condition;

• Engine cranking• Pulser coil disconnected

3. Pulser Coil(s) connectors 0.1 - 1.0 volts AC output from each coil.

No voltage: replace pulser coilsVoltage: check ignition module connections and ground.

4. Ignition module or fuel injection module

Voltage to module See product technical manual.Replace module with known good one.


11 - 8 4/7/95

PERFORMANCE DIAGNOSIS

ENGINE HARD TO START

5. Compression Test Compression above 1171 kPa (170 psi). Maximum difference between cylinders 97 kPa (14 psi)

Compression OK: See carbureted or fuel injected fuel system diagnosis.Compression low:Add oil to cylinders and retest.No Change in Compression:Check valve adjustment cylinder head, gasket, valves and valve springs.Change in Compression:Check piston, cylinder and rings


1. Spark plugs Not oil or wet Check the following:• Spark plugs.• High tension wire & ignition

coil(s)• One faulty pulser• Check air cleaner for plugging or

for intake leaks.• Compression

See carburetor or fuel injection system diagnosis.

2. Lubrication system Correct oil level and viscosityOil not contaminated with coolant or gasoline.

Correct oil levelChange oil and determine cause for contamination.

3. Muffler Little to no smoke.No sound of restriction.

Excessive black smoke:• Check for plugged air cleaner.• Too much oil in crankcase.• Defective breather valve.• Excessive carbon in exhaust

port or muffler.See carbureted or fuel injection system diagnosis.


DIAGNOSIS TROUBLESHOOTING

4/7/95 11 - 9

COMPRESSION TEST

REASON:

To determine the condition of pistons, rings, cylinderwalls and valves

Equipment:

• JDM59 Compression Gauge

1. Remove both spark plugs and install compressiongauge.

2. Ground high tension leads or disconnect positivelead from ignition coil.

3. Hold throttle shaft open.

IMPORTANT: DO NOT overheat starting motor during test. Starter duty is 5 seconds on, 10 seconds off.

4. Crank engine for three to five compression strokes.5. Record pressure readings for each cylinder.

Compression Specifications

Minimum . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi)Minimum difference between cylinders

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)

Results:

• Above specification, adjust valves and check fuel and intake air systems. Check exhaust for restriction.

• Below specification, squirt clean engine oil into cylinders and repeat test.

• Pressure increases significantly, check piston rings and cylinder walls for wear or damage,

• Pressure does NOT increase after retest, check for leaking valves, valve seeats or cylindwer head gaskets.

6. Reconnect ignition coils and install spark plugs

M56385

CRANKCASE VACUUM TEST

Reason:

To check operation of breather and condition of seals,gaskets, rings, piston and cylinders walls.

Equipment:

• JTO5701 Hose Clamp• JTO5703 Barb Fitting• JTO5699 Line• JTO5698 U-Tube Manometer

Procedure:

1. Park machine on level surface, key switch OFF,transmission in NEUTRAL, and LOCK park brake.

2. Put small end of barb fitting (A) into line (B) andfasten with hose clamp (C).

3. Install large end of barbed fitting into dipstick tube.

IMPORTANT: DO NOT make connection between manometer (D) and engine line (B) BEFORE engine is running or fluid in manometer could be drawn into crankcase. DO NOT turn engine OFF until line (B) has been disconnected from manometer (D).

C

A

B

M57357

M56365

D

B


11 - 10 4/7/95

4. START and run engine at SLOW idle.5. Connect line (B) to U-Tube Manometer Kit (D).6. Run engine at FAST idle.7. Record crankcase vacuum reading. Manometer

should show a minimum vacuum of 25 mm (1.0in.) of water.

8. Run engine at SLOW idle. DO NOT TURN ENGINEOFF!

9. Disconnect clear tube (B) from manometer.10. Turn engine OFF.11. Remove barbed fitting and install dipstick.

OIL PRESSURE TEST

Reason:

To determine condition of lubrication system.

Equipment:

• JT05577 Pressure Gauge Assembly• JT03017 Hose Assembly• JT03349 Connector

Procedure:

1. Check engine oil level, bring level to full mark..

2. Disconnect oil pressure switch wiring lead (A).3. Remove oil pressure switch (B).

c CAUTIONEngine components are HOT. Be careful not totouch, especially the exhaust pipe or muffler,while making adjustments. Wear protective eyeglasses and clothing.

M56383

A

B

4. Install JT03349 Connector (C).5. Connect JT03017 Hose Assembly (D) and JT05577

Pressure Gauge Assembly (E).6. Crank engine and check oil pressure. No oil

pressure, determine cause before starting engine.

IMPORTANT: If pressure reading is below 69 kPa (10 psi), STOP ENGINE IMMEDATELY and determine cause.

7. Run engine at FAST idle and check. Minimum oilpressure 276 kPa (40 psi).

8. Run engine at FAST idle until at operatingtemperature.

9. Install oil pressure switch and switch wiring lead.Use John Deere Pipe Sealant with TEFLON(medium strength), or equivalent, on switch threads.

Results:

If oil pressure is BELOW specifications, inspect orreplace the following:

• Oil pressure relief valve for broken or worn spring• Oil pressure relief valve for stuck or damaged

valve.• Worn or damaged oil pump. • Oil pump suction screen or oil passages plugged.• Excessive wear of connecting rod and main

bearing journals.

Results:

If crankcase vacuum is LESS than specification, checkthe following:

• Breather reed valve clearance and condition,• Seals and gaskets for leakage,• Valve cover gasket for leakage,• Valve and valve seats for wear or damage.• Head warpage.• Rings, piston, and cylinder walls for wear or

damage.

M56384

C D

E

CONTENTS COMPONENT ANALYSIS

Page

4/7/95 12 - 1

CONTENTS

COMPONENT ANALYSIS

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

RING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PISTON WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CRANKSHAFT AND CONNECTING ROD WEAR . . . . . . . . . . . . . . . . . 4

NOTES COMPONENT ANALYSIS

12 - 2 4/7/95

ANALYZE VALVES COMPONENT ANALYSIS

4/7/95 12 - 3

ANALYZE VALVESLead deposits on the intake valve are caused byexhaust gas leakage past the valve. This indicates thatthe valve is not seating properly.

Grind intake valve and reface the seat to correct thiscondition.

NOTE: Be sure to reset valve clearance after grinding valves.

Valve stem corrosion is caused by moisture in theengine. Moisture in the fuel-air-mixture can condenseinside the engine when the engine is stopped andcools down.

Valve corrosion can also occur during storage. Foggingor pouring oil in the combustion chamber beforestoring, helps prevent valve corrosion.

Corroded or pitted valves collect deposits and maycause sticking valves. Replace badly corroded or pittedvalves.

Exhaust valves are designed to function intemperatures exceeding 2760°C (5000°F). However,when operating at high temperatures for long periods oftime, valve burning may occur.

Valves running too hot will show a dark discoloration ofthe valve stem into the area protected by the valveguide. Another indication is distortion of the valvemargin and valve face. Valve inserts may also begin toburn away.

M29934

Lead Deposits

M5563

Valve StemCorrosion

IMPORTANT: Do not run the engine with blower housing removed.

Poor engine cooling due to dirt or obstructions is acommon cause for overheating an engine and thevalves. Remove blower housing and clean the enginecooling fins.

Other causes for valves running hot are worn valveguides or valve springs, incorrect valve clearance, leanfuel-air mixture and incorrect or overheated spark plug.

Using old or stale gasoline is a common cause forsticky valves.

This gummy deposit can be seen on the valve. Whenthis condition exists, the carburetor may also containgum deposits and will require a complete cleaning.

Always use fresh gasoline and drain fuel tank, lines,and carburetor before storing machine.

Exhaust valves are designed to function intemperatures exceeding 2760°C (5000°F). However,when operating at high temperatures for long periods oftime, valve burning may occur. Valves running too hotwill show a dark discoloration of the valve stem into thearea protected by the valve guide. Another indication isdistortion of the valve margin (A) and valve face (B).Valve inserts may also begin to burn away.

Other causes for valves running hot are worn valveguides or valve springs, incorrect valve clearance, leanfuel-air mixture and incorrect or overheated spark plug.

M30024

Valve Margin Valve Face

M29936

Gummy (Sticky)Deposit

COMPONENT ANALYSIS ANALYZE PISTON RING WEAR

12 - 4 4/7/95

ANALYZE PISTON RING WEARRings of the wrong size or rings having improper endgap will not conform to the shape of the cylinder. Thisresults in high oil consumption and excessive blow-by.

Ring end gaps should be staggered on the pistonduring installation. End gaps in alignment can alsocause oil consumption and blow-by.

Light scuffing or scoring of both rings and piston occurswhen unusually high friction and combustiontemperatures approach the melting point of the pistonmaterial.

When this condition exists, it is due to one or more ofthe following probable causes:

• Dirty cooling shroud and cylinder head.• Lack of cylinder lubrication.• Improper combustion.• Wrong bearing or piston clearance.• Too much oil in crankcase causing fluid friction.

The engine operating at abnormally high temperaturesmay cause varnish, lacquer or carbon deposits to formin the piston grooves making the rings stick. When thishappens, excessive oil consumption and blow-by willoccur.

Engine overheating and ring sticking is usually causedby one or more of the following:

• Overloading• Incorrect ignition timing.• Lean fuel mixture.• Dirty cooling fins.• Incorrect oil.• Low oil supply.• Stale fuel.

M29943

Vertical scratches across the piston rings are due to anabrasive in the engine. Abrasives may be airborne,may have been left in the engine during overhaul ormay be loose lead and carbon deposits.

When this condition exists, check for one or more of thefollowing:

• Damaged, collapsed or improperly installed air filter.

• Loose connection or damaged gasket between air cleaner and carburetor.

• Air leak around carburetor-to-cylinder block gasket.• Air leakage around throttle shaft.• Failure to properly clean cylinder bore after

reconditioning engine.

Abrasive particles in engine oil causes scratches onside rails of oil control ring. Inner spacer wear ordistortion may cause:

• High oil consumption.• Increased deposits in combustion chamber.• Sticking compression rings.

Increased oil consumption may be caused by:

• Worn side rails with low tension.• Worn or distorted inner spacer.

M29944

Varnish, Lacquer or Carbon Deposits

M29945

Vertical Scratches

ANALYZE PISTON RING WEAR COMPONENT ANALYSIS

4/7/95 12 - 5

ANALYZE PISTON WEARDetonation, is abnormal combustion causing excessivetemperature and pressure in the combustion chamber.Commonly called carbon knock, spark knock or timingknock, detonation occurs as the compressed fuel-airmixture ignites spontaneously to interrupt the normalignition.

The following is a list of possible causes for detonation:

• Lean fuel mixture.• Low octane fuel.• Advanced ignition timing.• Engine lugging.• Build-up of carbon deposits on piston or cylinder

head, causing excessive compression.• Wrong cylinder head or milling of head increasing

compression ratio.

Pre-ignition is the igniting of the fuel-air mixture prior toregular ignition spark. Pre-ignition causes internalshock, resulting in pings, vibration, detonation andpower loss. Severe damage to piston rings and valvesresults from pre-ignition.

Check the following for causes of pre-ignition:

• Internal carbon deposits.• Incorrect spark plug (high heat range).• Broken ceramic in spark plug.• Sharp edges on valves.

M38101

Spacer

Side Rails

M29947

.

Check rod and piston alignment when piston shows adiagonal wear pattern extending across the skirt of thepiston. Contact with the cylinder wall shows on bottomof skirt at left and ring lands on the right.

A cylinder bored at an angle to the crankshaft can alsogive improper ring contact with cylinder causing:

• Rapid piston wear.• Uneven piston wear.• Excessive oil consumption.

A broken retaining ring caused the damage shown.Retaining rings loosen or break due to:

• Rod misalignment.• Excessive crankshaft end play.• Crankshaft journal taper.• Weak retaining rings.• Incorrectly installed retaining rings.

Inertia can cause a broken retaining ring to beat out thepiston and cylinder, causing extensive damage.

M30039

Damaged Area

M29948

DiagonalWearPattern

M29949

DamagedArea

COMPONENT ANALYSIS ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR

12 - 6 4/7/95

ANALYZE CRANKSHAFT AND CONNECTING ROD WEARCheck connecting rod and cap for damage or unusualwear patterns.

Lack of lubrication or improper lubrication can causethe connecting rod and cap to seize the crankshaft.

When the rod and cap seize to the crankshaft, theconnecting rod and piston may both break causingother internal damage. Inspect block carefully beforerebuilding engine.

Crankshaft and connecting rod damage can resultfrom:

• Engine run low on oil or without oil. • Oil not changed regularly. • Bearing cap installed incorrectly.

INDEX

4/7/95 INDEX - 1

AAir Cleaner Service 3 - 2Analyze Crankshaft & Connecting

Rod Wear 12 - 6Analyze Piston Ring Wear 12 - 4Analyze Piston Wear 12 - 5Analyze Starter Condition 10 - 5Analyze Valves 12 - 3

BBasic Engine Specifications 2 - 3Breather Operation 3 - 4Breather Repair 3 - 4Breather Service 3 - 4

CCamshaft Bearing Inspection 7 - 4Camshaft Installation 7 - 4Camshaft Removal 7 - 4Camshaft Service 7 - 4Camshaft Specifications 7 - 4Camshaft, Crankshaft & Flywheel

Specifications 7 - 3Carburetor Operation 4 - 4Carburetor Serial Number Locations 2 - 5Carburetor Specifications 4 - 3Clean and Rebuild Carburetor 4 - 8Component Location 2 - 18Compression Test 11 - 9Connecting Rod & Piston Assembly 6 - 14Connecting Rod Bearing Specifications 6 - 13Connecting Rod Inspection 6 - 13Coolant Pump Removal & Installation 9 - 8Coolant Pump Repair 9 - 9Coolant Pump Service 9 - 8Coolant Pump Specifications 9 - 9Cooling System Components 9 - 5Cooling System Operation 9 - 4Cooling System Repair 9 - 6Cooling System Specifications 2 - 5, 9 - 3Crankcase Disassembly 6 - 6Crankcase Vacuum Test 11 - 9Crankshaft Inspection 7 - 5Crankshaft Installation 7 - 6Crankshaft Journal Bushing & Seal

Replacement 6 - 9Crankshaft Plain Bearings Inspection

& Replacement6 - 8Crankshaft Removal 7 - 5Crankshaft Service 7 - 5Cylinder Block, Piston & Rod

Components 6 - 7Cylinder Block, Piston & Rod

Specifications 6 - 3Cylinder Bore Specifications 6 - 10Cylinder Head & Valve Specifications 5 - 3Cylinder Head Cleaning and Inspection 5 - 4Cylinder Head Removal 5 - 4Cylinder Head Service 5 - 4Cylinder Head Specifications 5 - 3Cylinder Initial Rebore Specifications 6 - 11Cylinder Inspection6 - 10

DDeglaze Cylinder Bores . . . . . . . . . . . . . . . . . . . . 6 - 10Down Draft Carburetor Repair . . . . . . . . . . . . . . . . 4 - 7

EElectrical System Specifications . . . . . . . . . . . . . . 10 - 3Engine Applications . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7Engine Oil Specifications . . . . . . . . . . . . . . . . . . . 2 - 17Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 - 5

FFD440/501V Engine Repair Specifications . . . . . . . 2 - 6FD440V/501V Cooling System Repair . . . . . . . . . . 9 - 6FD440V/501V/590V Engine

Component Locations . . . . . . . . . . . . . . . 2 - 18FD440V/FD501V Cylinder Block,

Piston & Rod Specifications . . . . . . . . . . . . 6 - 3FD440V/FD501V/FD590V Engine

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2FD590D Altitude Compensation Switch

Circuit Operation . . . . . . . . . . . . . . . . . . . 10 - 9FD590D Fuel INjection Throttle Sensor

Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 9FD590V Cooling System Repair . . . . . . . . . . . . . . . 9 - 7FD590V Cylinder Block, Piston & Rod

Specifications . . . . . . . . . . . . . . . . . . . . . . . 6 - 4FD590V Engine Repair Specifications . . . . . . . . . . . 2 - 9FD590V Engine Throttle Body Repair . . . . . . . . . . 4 - 14FD620D Cooling Fan & Bracket . . . . . . . . . . . . . . 9 - 10FD620D Cooling Fan Belt Adjustment . . . . . . . . . 9 - 10FD620D Cylinder Block, Piston & Rod

Specifications . . . . . . . . . . . . . . . . . . . . . . . 6 - 5FD620D Engine Air Cleaner . . . . . . . . . . . . . . . . . . 3 - 2FD620D Engine Component Locations . . . . . . . . . 2 - 22FD620D Engine Repair Specifications . . . . . . . . . 2 - 12FD620D Engine Throttle Body Repair . . . . . . . . . . 4 - 14FD620D Fuel Injection Air Pressure

Sensor Operation . . . . . . . . . . . . . . . . . . . 10 - 9Float Level Adjustment . . . . . . . . . . . . . . . . . . . . . . 4 - 8Fuel Injection Air Temperature Sensor

Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8Fuel Injection System Operation . . . . . . . . . . . . . . 4 - 11Fuel Injection System Service . . . . . . . . . . . . . . . . 4 - 11Fuel Injection Temperature Sensor

Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8Fuel Injector Operation . . . . . . . . . . . . . . . . . . . . . 4 - 11Fuel Injector Repair . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12Fuel Injector Test . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8Fuel Pressure Regulator Operation . . . . . . . . . . . 4 - 12Fuel Pressure Regulator Repair . . . . . . . . . . . . . . 4 - 13Fuel Pressure Regulator Service . . . . . . . . . . . . . 4 - 12Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16Fuel System Troubleshooting . . . . . . . . . . . . . . . . . 4 - 3Fuel/Air System Specifications . . . . . . . . . . . . . . . . 2 - 5

GGasoline Specifications . . . . . . . . . . . . . . . . . . . . . 2 - 16Governor Operation . . . . . . . . . . . . . . . . . . . . . . . 4 - 10Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10Governor Service . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10

INDEX

INDEX - 2 4/7/95

HHandling Asbestos . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4Head and Valve Components . . . . . . . . . . . . . . . . . 5 - 4Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6

IIgnition Coil Replacement . . . . . . . . . . . . . . . . . . . 10 - 4Ignition Module Replacement . . . . . . . . . . . . . . . . . 10 - 5Intake Manifold Installation . . . . . . . . . . . . . . . . . . . . 3 - 3Intake Manifold Removal . . . . . . . . . . . . . . . . . . . . . 3 - 3Intake Manifold Service . . . . . . . . . . . . . . . . . . . . . . 3 - 3Internal Engine Components . . . . . . . . . . . . . . . . . 2 - 20

LLubricant Specifications . . . . . . . . . . . . . . . . . . . . . 2 - 17Lubrication System Components . . . . . . . . . . . . . . . 8 - 4Lubrication System Operation . . . . . . . . . . . . . . . . . 8 - 4Lubrication System Specifications . . . . . . . . . . . . . . 8 - 3

MManual Fuel Pump Repair . . . . . . . . . . . . . . . . . . . . 4 - 9Mechanical Fuel Pump Operation . . . . . . . . . . . . . . 4 - 9Mechanical Fuel Pump Service . . . . . . . . . . . . . . . . 4 - 9Metric Torque Valves . . . . . . . . . . . . . . . . . . . . . . . 2 - 15Model Configuration Changes . . . . . . . . . . . . . . . . . 2 - 4Muffler Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3

OOil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10Oil Pump Disassembly & Assembly . . . . . . . . . . . . . 8 - 5Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5Oil Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5Oil Pump Specifications . . . . . . . . . . . . . . . . . . . . . . 8 - 6

PPerformance Diagnosis . . . . . . . . . . . . . . . . . . . . . 11 - 8Piston & Piston Pin Specifications . . . . . . . . . . . . . 6 - 12Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8Piston Ring End Gap Check . . . . . . . . . . . . . . . . . . 6 - 11Piston Rings Removal and Installation . . . . . . . . . . 6 - 11Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Proper Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . 1 - 2Proper Welding Procedures . . . . . . . . . . . . . . . . . . . 1 - 4Proper Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Pulser Coil Replacement . . . . . . . . . . . . . . . . . . . . 10 - 4Push Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6Push Rod Specifications . . . . . . . . . . . . . . . . . . . . . 5 - 3

RRebore Cylinder Block . . . . . . . . . . . . . . . . . . . . . . 6 - 10Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6Ring End Gap Specifications . . . . . . . . . . . . . . . . . 6 - 11Ring Land Side Clearance Specifications . . . . . . . 6 - 12Rocker Arm Specifications . . . . . . . . . . . . . . . . . . . . 5 - 3

SSafe Chemical Handling . . . . . . . . . . . . . . . . . . . . . . 1 - 2Safe Fluid Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2Serial Number Plate Locations . . . . . . . . . . . . . . . . . 2 - 4Side Draft Carburetor Repair . . . . . . . . . . . . . . . . . . 4 - 6Solenoid Shift Starter Inspection . . . . . . . . . . . . . . 10 - 6Starter Armature Test . . . . . . . . . . . . . . . . . . . . . . . 10 - 7Starter Field Windings Test . . . . . . . . . . . . . . . . . . 10 - 6Starter Service Parts Kits . . . . . . . . . . . . . . . . . . . . 10 - 5Starter Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . 10 - 7Starting Motor Diagnosis . . . . . . . . . . . . . . . . . . . . 11 - 6Stator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4Stator Replacement . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17

TTappet Removal & Installation . . . . . . . . . . . . . . . . . 7 - 5Test & Adjustment Specifications . . . . . . . . . . . . . . . 2 - 5Thermostat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8Thermostat Specifications . . . . . . . . . . . . . . . . . . . . 9 - 8Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8Throttle Body Service . . . . . . . . . . . . . . . . . . . . . . 4 - 13Trhottle Body Operation . . . . . . . . . . . . . . . . . . . . . 4 - 13Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3

VValve & Spring Specifications . . . . . . . . . . . . . . . . . 5 - 3Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . 5 - 5Valve, Valve Seat and Guide Inspection . . . . . . . . . 5 - 5Valve, Valve Seat and Guide Service . . . . . . . . . . . 5 - 5

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Kawasaki Gas Engines