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Yanmar Yse Instruction Manual


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      rr     a
           t.:            MOOEL


1 . Description                                1

z.     lnstallation

      2.4 ExhauÝ Pipe                          4
      2-5 Intake Pipe                          5
      2-6 Remote Control System                t

     . 2-7 ElectricalSyÝem

3. A═ter Launching                             o

4. P═ecautions
             With New Engine                  10
5. Be═oreOperation
                 ..........                   11
      5-1 FuelSupply                         '11
      5-2 LubeOilSupply and Lubricatign.      12
      5-3 Checking╔uel lrijection             15

      Starting............................    16

      6-l How to Start rhe Engins             16
     . 6-2 After Starti═ ...                  17
7. DuringOperation                            18

L Stoppin9........................            20
9. Periodical
            Checks                            21

      9-1                                     22
      9-2 EverylO0 Hours                      23
      9-3 Every,ß!g.Hours                     26
            Evry500 Hours                     27
10. Adjustment,       and Re-assembly
              Stripping                                         29

      10-1 Precautions
                     duringStripping                            29
      10-2 P═ecautions
                     duringRe-assembly                          30

11. Air Venting
              of FuelInjection
                             System................             31

12. Checking           Valve....................
           FuelInjection                                        ??

13. AdjustingFuelInjectionRegulator
14. Checking          FuelIniection
           andAd.iusting          Timing ....................,...

15. Stripping          of Fuellnjection
            andRe-assembly            Pump ...............
                     V a l v e...............................
      15- 1 Deliv er v                                          ?q

      15-2 Regulator                                            39
      15-3 Plunger                                              40

16.                                                             41
                           1. DESCRIPTION
                                        OF PARTS
                                        Clut c h hous ing
                           Fuel t ank               oil         ation pump

     Aiternator                                           ll

                                                                                drai npl ug


     (only with electrical
                               Engine feet                   Enginefeet
                                  L u b eo i l d ra i np i p e
                                               Not fitted
            Startinqshaftlock pin ^           _ Eve nur {for hoistinqenoinel
                                \ )rarl|ng snatt /

                                                                          1 -il.irtate pipe
     Fl ex ible
              c ou

                                                                    Coolingwater pump
      Flex ible mountinq            /.                              (Rotarytype)
                       -   RockeÝ bbx
                             Draincock {wate═)
             PhotoshowsmodelYSE8 (typeCXlwith optionalaccessories

                                             - t-
                                     2. INSTALLATION

     2-1 Engine

     {1 )   Usehard,dry timber. An unstableengine         excessive
                                                 bed causes       vibration,
            which may resultin a brokenpropeller
                                               shaftandother damage.

                            I cm (3 '4") square.Cut out the necessary
     \21 Usetimberof at least                                      sections
            to accommodatethe clutch case.                                                      ..
     (3) Angle of inclination variesaccordingto the type of boat and the placeof
            installation,but it shouldneverexced150. lnstalling
                                                              at angleabove  this
            limit leadsto excessivelosso═ H.P.,reducing
                                                      the speed
                                                              of the boat. andto
            abnormal  wear,impairing  engineper═ormance.                                  f
     t4l    Makesurethat the engine  bed straddlesasmany ribsaspossible,and securel,      I -
            ═irmly to the hull. Leave
                                    enoughspace         the engine
                                                  beneath         bed to permittight-     Tri
            eningof the nutsfor the engineset bolts,

     (5) Great care should be taken when installingthe enginethe propelle═ shaft and
            thrust sha═'tcan be alignedproperly.

     2-2 Mounting
     (1 )   Mount the engine
                           onto the bed.

     (21 Tighten the set bolts evenly and securely. Oo not try to tighten them ═orcibly
            if the propellershaft is not correctly aligned.



                                              -2 -
\_              1      '                                       :-
        (3)     Be═oresettingthe propeller       shaft (o═
                intermediate   sha═t.if present)   to the
                engine, ═irstly checkthe clearance
                al both shaft couplings. l\4easu═e    the
                clearance  at the top, bottom, le═t
                and right of the coupling    flange  with
                a thickness gauge,  and repeat    until the
                clearance  doesnot exceed      0.2 mm
                at any point. lf the centerof the
                engine thrust *ta═t is too high,
                planethe engine    bed; if it is too low.
                inserta floor platebetween      the
                engine and  the  bed.

        (4)     Re-check
                       alrg:rnrntafter launching.

        2-3 CoolingWaterSupply System
        (1 )    Attach the V belt for the coolingwaterpump to the pulleyin the center
                                                                                    of the
                PTOshaft. Adjust the belt tensionsothat de═lection is about 5 mm whenthe
                middleof the belt is presseddown with the thumb. Adjust by looseningthe
                coolang water pump set boltsand re-positioning
                                                             the pump.

                        NB: Operatingthe coolingwater pump without waterwill resultin
                            damage to the rubberimpeller.Do not operateuntil the water

.   (2)        Fit the Kingstoncock to the hull.
    (3)        Measure   the distances   ═rom the
               Kingston   cock to the coolingwater
               pump intakeand ═Ýom the engine
               cooling water outlet to the outside
    "          o f t he hull. Cut a ═u b b e rh o s e { i .d .
               l3 mm, o.d. 20 mm) into the
               correct length.
               NB: The rubber hose is not
         .         suppliedas standard.
                                                          -3-                                i
14) Connect  the Kingstoncock to the coolingwaterpump intakewith the one hose
 '  and engine coolingwateroutlet to the outsideo═ the hull with the other hoseas
           and shortaspossible.
    straight                     Then secure tightly with metalclamps.

(5)   Thermostatfor coolingwater is equipped        for betterper═ormance
                                           asstandard                   in
      cold weather.

2-4 Exhaust
a) Drytype
(1)   Attach the dry type silencerto the exhaust  ═langeon the cylinderhead,then
      attachthe exhaust pipe to the outlet o═ the silencer.

\2)   l═ it is necessary
                      to bendthe exhaust
                                       pipe,makesurethe radiuso═ the curvature
      is at least100 mm.

(3)                   pipe centerrestat an appropriate
      Installtheexhaust                              point on the hull.

b) Wet type (optionalorder)

(1)   Attach the exhaust gaspipe to the exhaust
                                              elbow,then attachthe wet type
      silencerto the exhaustgaspipe.

l2l   Connect the outlet o═ the silencer
                                       to the outsideo═ the hull with the rubber
            hose(i.d.48 mm).

(3)   Connect the enginecoolingwateroutlet to the water intakeport o═ the wet type
             with the rubberhos.


                                  To lize PT 1%6ˇr rup9rY
     2-5 IntakePipe
                                                 En g ine room
     Fit an extension pipeto the intakepipe as
     shownin the figure. This permitsfresh        Exhaust
     air to be suckedin ═rom outsidethe engine    pr pe
     room and prevents  ═aultsdue to temper-     CÝamp
     aturerisecaused  by poor ventilationIn
     th e engt ne
                r oom .
     Usea resinor iron pipe. Avoid irregular

                 of intakepiper
            YSES: 38.6 mm
?           YS╩12. 42.7 mm

3                pipe is not supplied
     NB: Extension                  asstandard.

                   overthe intakepon to prevent
    Attach a shelter                                                    the pipe.
                                              dirt and waterfrom entering
    2-6 RemoteControlSystem
    2-1 SpeedControl Lever

    (1 )    The speed control lever can be
            operatedb'i meanso═ the remote
            control cable. Installthis in a
            convenient place.

    t2l     Lay the remotecont═ol cableas                             R emote control
            straightaspossible.Bends  should                          caote
            havea radiusof at least30 cm.

I   (3) Grease


             the coreof the remotecontrol cablebefo═einstalling.

                          st═engthby meansof the adjusting


    For ═emote control operation of the decompressionlever,connect the wire to the
    s═nall                        YSESand ySE12 (handstarting
          hole in the lever. Models                              only) areequipped
    with remotecontrol decompression   handle, (3 metercableis optional)

2.6-9     Gear Lever

A hole is providedin the gearleverto
permitthe attachment   of a connecting
rod ═o═ remotecontrol operation.
Pleaseuseit acco═ding  to the conditions
on your boat. lt can be ═itted to morse
type controlcableif a bracket═or oil
evacuation pump is fitred (bracket and oil
evacuation pump are available  asoptionals).

             System(For YSE9X,Yand YSE12X,Yonly)
2-7 Electrical

2-7-1    Parts

The elect═ical
             system comprises  the following: (1) Starter; (2) Alternator; (3) Dush
panel; (4) Wireharness; (5) Startercable(+), (-); (6) Battery; (7) Oil pressure
                      the followingmust be purchased
warninglight. O═ these.                                 asoptionals  sepaÝately:
Optionalextras(Subject to any alteration without notice)

          Charging alternator          12V. 25Al\4P.
          WireharnesF                 3 m, for wire harness
          {tor remotecontrol)
          Startercable(+), (-)
                                       '12V.   40Ah for ═requentuse
                                       ' l 2 V.7 0 A h fo r b oat not useddai l Y
          Oil pressure
                                       Oil pressu═e
                 switch                                                                    ´
                                       for hydrauliclight assembly                    '´
          Oil pressure

2.7.2     Wiring

 { 1)         the wire haÝness
        Connect                          as´o llows:
                             and terminals
        6-poleconnector               Connect to instrument panel side*

                                      - o-
             4-polecoÝlnections            Connect
                                                 to alternatorside*
             'l-poleconnection             Connect  to starterside'
             Greenterminal                 Join to oil pressute switchterminalscrew
                                           {PÝessure switch is optional extras)

             Bluete═minal                  Join with starte═cable(+) to starter

                terminar                                         (-) terminar
                                                                            to starter
          ' Please
                               to the colo═ indication
            Red ═emalete═minal             Connectto instrument pJncl side
a                                          ═or work load under 10A.

    (21     Installthe instrUment
                                panelin a convenient position. Threemeters  extension
            canbe obtainedif wi═e harnessA is too short. Select
                                                              a dry place═Ýee from

    {31 Connectthe startercables:
            Startercable(+)       Connect battery(+) terminaland starterrermrnat.
                                  Connect togetherwith the blue cord round te═minal o═ the
                                  wire harness{B)
            Starter cable (-)     Connect battery (-) terminal and Ýa═ter set bott
                                  (earthto body). Connect  together with rhe blackcord
                                  round terminalof the wire harness {B)

    Ý41 Makesureall terminals
                            are securely
                                                then coatwith grease.

    (5)     Finally,checkonce morethat all the connections

    2-7-3     Check

          the enginefor startingand turn the ignitionkey.
    Checkthat ope═ationis normal(see Section7).

               Never        engine
                      operate                   cables
                                  with thestarter    disconnected from.th&bltery,
               srnce thrsmaycausethealternator10overheal  oangerouov rOf,ffi
               with the battery                       i═ theV beltdÝiving'ffim"r-
                                          is permissible

      WiringDiagramfor ModelsYSE8,YSEl2                                                                         '.L

                                                                                                C hargi ngl i ght
                                                                                                 Oi l pressure
                                                                                                 w arni ng l i ght

h"-                                                                                *Work1gi                                  t'

                                                                                   ' undeÝ 1Ci└J switch                      '','


P        t╩7:r╚z'
         | -´1r-


                                        Sta r te r in sta lla tio n
                                        b o lt

                   A s t h e r  i s n o e a Ýth , o b ta in e a ═th co n n e ctio n fr o m the engi ne or bai tŕry.

                                  3. AFTER LAUNCHING

        (1)   Checkthat there is no water or air leak from the gland of the stern tub or the
              Kingstoncock joints.

        l2l   Check that the engineset bolts and shaft coupling are securelytightened,

        (3)   Release  the compression  with the decompression  lever and gently turn the
             engine-withthe starting handle. Comparethe resistance     when the gearlever is
              in ne$trÓlpositionand when it is in the engaged  position(forwardor reverse).
                         no appreciable
            .-l^f..i$eiŔÝs              difference,alignment is correct; however,if the resis_
                     againstturning is much strongerwhen the clutch is engaged,   re-checkthe
{        -└rLt´ce
        s-   alignment   of the propellershaftand the engine to avoidbrakage   of the
             propeller shaft and other possiblebreakdowns.



                        4. PRECAUTIONS
                                     WITH NEW ENGINE

     Overloading the engine beforeit is properlyrun in shortens
                                                              its life considerably.
     The ═irst 150 hoursof operation shouldbe treatedasa running-in   period.

     (1)      No overloadallowedduringthe ═irst 50 hoursof runningin period(Avoid
                      at speedhigherthan DIN A ratingspeed   with continuousblack

     l2l      A═ter 50 hourso═ operation,change the lubeoil in the crankcase
                                                                           and clutch
              case.Also cleanthe lubeoilfilter.

     (3) Thereafter    the crankcase
                  change            lubeoil every 100 hoursand the clutch
              caselubeoil every250 hourso═ operation.This prolongs
                                                                 enginelife.                      ?l
     (4 )     To Ýeplacethe lubeoil, first discharge
                                                   the old oil while the engineis still warm
              and cleanthe insidewith light oil. Then add the new oil.                            ˇi

                                 At 10 hoursper day operation:
                                 50 hours                                   150hours
                                                                                Every 10
                      5 days                                                    rdays (100
                    (50 hours)


                              C h a n g elu b e o il a n d             Change lube oil and
              'ˇ                                                       ctean l ube oi l Ýi l tr
                              c le a n lu b e o il═ilte r
                                 50 hours                                 30Ohou═s
                                                                                      EveÝy 25
                                                                                      doyr {25O



                            C h a n g ŕlu b e o il


__           7;t,      _
                                        5. B E FOREOP E RAT I O N

    5-1 FuelSupply

    0- t - |       FUel

              lightoil ( J l S K2 2 0 4o r e q u i v a l e n t).
    Used ies el

                             of fuel.
                S upplier                 B═andName                                                 I

                            S he l ld i e s o l i n o
                                                    er l o c a l                                    t
               S HE LL
                            equrv a re n l

               C A LT E X   Caltex diesel oil

               MOBIL        M ob i ld i e s eo
                                             l il
               ESSO         Essodiesel

           B . P .( B r it is h

    5-1-2         Fuel Tank Capacity

    F ill the fu el ta nk with dies elf uel. Tank
    capac ity is as ═ollo ws:

                  Removing Wate═ and Dirt Presentin Fuel

                Water and dirt, which lead to mal═unctioning o═ the engine, are sometimes
                p resen tin the ═uel oil.

                                                         - 11 -

          12)    Leave  the drum standingfor about
                 10 daysto allowany waterand dirt
                 to sinkto the bottom. Filter the
                 oil througha clean,═inely woven
                 cotton or silk cloth.                                        Leave standing
                 Avoid rockingor shaking  the drum.                           about 10 days

                                                                                     Throw away sediment

         5-14        DrainingFuel Tank

         To remove  the waterand dirt accumulated
         in the bottom o═ the ═uel tank, drain ═rom
         the drainplug everyday beforefilling fuel

                                                                        D rai n pl Li g

         5-2 LubeOil Supplyand Lubrication

         L u beO il

                            o═ lubeoil for crankcase
                                                   and gearbox.

                                                                              S A E N o.                   I
lt        Supplier
     1                           B r a n d Na m e
                                                     b e lo w lOo C   10 - 2ooc 20 - 350C                  )
                                                                                               over 35oC

                       S h e l l R or e lla Oil
                                                                                          40      50
          SH ╔ L L     S h e e lT a lo n a Oil           10w                              30
                                                                         20                       50
                       S h e l l R i m u la Oil        20120w         20tzut

                  R P M D e l o M a r in e Oil               't0w                           30
                                                                               20                            50
                      D e l o lM u lti- Se r vice
                                                          20120w                            30
                                                Oil                            20                            50
                                                           10w                              40
                  D e l v a cS p cia l                       low               20

                  Delvac20W.40                            20w,40            20w-40
     MO B I L
                                                           10w                              30
                  D e l v a c I 1 0 0 Se r ie s                             20-20v't                         50
                                                          20-20vÝ                           40
                                                            l0w                             30
                       1200Series                                           20-20w                           50
                                                          20-20w                            40
                  EstorHD                                    10w               20
f                                                                                           30
    ESSO          EssoLube HD                                                  20                            50
                  S t a n d a r d D i se lOil                10w               20                           50
a                                                                                           40
                  B.P.     E n e r g o l ICM
                  B.P.     V a n e llu s                                                    30
                                                         20w.30             20w.30                          50
                  B.P.      n e rg o l DS3                                                  40
                  B.P.     V a n e llu s5 3

                                                  Re m a r ks:      T h e vis cosi ty grade of the l ube oi l shoul d
                                                                    b e ch oosed to sr.ri th
                                                                                          l  ambi enl ai r
                                                                    te m p arature.
    5-2-1       Crank Case

    Remove  the oil ═ilter capand fill with lube oil up to the uppermarkingon the
    dipstick. To checkthe level,  simplyinsertthe dipstickwithout screwing  in the
    cap. Avoid overfilling  and underfilling.



Th e vo lum eof lubeoil i s a sfo l l o w s ;

5-2-2     Clutch Case

        t he lubeoilf ille r c a pa n d═i l l w i th
R e mo ve
lubeoil up to the uppermarkingon the
dipstick. Usethe same    oil asfor the crank
The volumeo═ lubeoil is asfollows:

The correctoil levelcanonly be deter-
minedwhenthe ship is level.
5-2-3     Lubrication

Lubricate the startingchain,chainwheelbearing
                                            and starting           with iube
oil beforeoperation.


    5-3 Checking

    {1 )   Openthe fuel cock. The ═uel is fed
           t h═ ought he f uel ═i l te r to th e fu e l
           injec t ionpum p.

    \2) Setthe speed
                   contÝol leverto LOW
           andt he gearleve r
                            to N E U T R AL .

    (3) Raise
            the decompression
           turn the startinghandle 5 or 6 times.
           Checkthat you canhearfuel being
    l4\    lf you cannothearfuel beinginject-
           ed like squeasing   noise,   air is present
           in t he f uel injecti o n
                                   s y s te ma n dm u s t
           be vented. Be═erto Section12.



                                                     6. STARTING

        '   6-1     How to Start the Engine

            6-1-l      ManualStarting

            (1)     Set the speed
                                control lever
                                            to LOW.

            12)     Raise  the decomp═ession        leverand turn the startinghandlevigorously5 or 6
                    ti m esunt ilt he f ly w h e e E
                                                   l ains
                                                        mo me n tu m,

            {3)     Release the decompression  leve═and continueturningthe startinghandlea
                    ═urther 2 or 3 turns. The enginemust start.
            6-1-2      ElectricStarting

            (1)                 control leverto LOW.
                    Set the speed
:           l2l     Wheninsertthe ignitionkey and turn
                    i1 to the ON position, the chargelamp
                    lred)  and the oil pressurewarning light
                    (red)light up. l═ the lightsdo not
                    behave  correctly,  checkthe electracal              Ch a r g el i ghr


            {3)     Raisethe decompression  lever. Whenturn the ignitionkey to the STARTING
                            the charge                                    warninglight (red)goes
                                       lamp (red)is up and the oil pressure
                    out. This turnsthe starter.

            1 4 ) H old t he k ey in t h i s p o s i ti o n═o r a b o u t5 s e c o n d u                  gai ns
                                                                                        s nti l the engi ne     mo'
                  mentum,then release          the decompression             lever. The enginenow sta═ts.
                  R eleaste he k ey im me d i a te l y                               to the ON posi ti on
                                                            s,o th a t i t re l u rn s
                  As engine   speed  increases,       the charge       light   (red)   and the oil pressure wa═ning
                  light (red) go out.
            (5)     l═ the enginefailsto startevenwhen the key is held in the STAR´lNG position
                    for 10 seconds. returnit to the originalpositionand allow 30 seconds
                                                                                       for the
                    batteryvoltage  recovers. Holdingthe key in the STARTINGpositron
                    continuously  leadsto ═aultsin the circuit.

            (6)     lf the enginestill failsto start,checkfuel injectionand compression.

                                                           - 16 -
    6-1-3      Startingin Cold Weaˇer

    In especiallycold weather, pour about 0.5ccof gasoline        throughthe intakepipe
    be═orestarting.Take carenot to add too muchgasoline,                       knockingand
                                                                   asthis causes
    co mpr es s ion
                  leak ageIn
                          . s te a d
                                   o fg a s o l i n eYa
                                                     , n ma rA e rosol      canal sobeused.
                                                                     { extra)
    Neitherneedbe used   when the enqine       is warm.

    6-2 AFTER Starting

    (1 )   As the engine gainsspeed,the start'
           ing chaingeardisengages.  Remove
           the startinghandleand fix the pin
           to the startingshaft.
    t2) Checkthe visualoil pressure
           tor to seethat lubeoil is circulating
           properly. With engines  usingelect'
           ric startingand equipped  with an oil
           pressure switch.checkthat the oil
           pressure warninglight (red)is o═f.

    (3) Checkthat coolingwater is comingout of the coolingwateroutlet. lf it is
           not, stop the engine    and checkthe water system               ═or blockages;    continuing
                      in t his c o n d i ti o n
           o per at ion                        re s u l ts                            i n the cool i ng
                                                         i n w e a rto th e i mpel l er               w ater
           pum p. lf c oolin g  w a te rc i rc u l a ti o ni s b a d ,re move the pump i ntakepi peand
           pÝ m e.

    t4) With engines
                                        checkthat the chargelight is off. This
           light goesout at about650 rpm and begins

    (5 )   Allow the engine  to idle for about 5 minutes              with the gearleverin the
o          NE U´ RA L pos i ti o n .T h i sa l l o w sl u b eo i l to c i rcul ateto al l metalparts, and
           is especiallynecessary   in cold weather. Puttingthe engine                 into gearimmediate-
           ly a═ter startingcancause      seizure     anddamage         to movingparts.
           Whenoperating    Ýor the first time a═ter launching,              let the engine  idle ═or 20
o          minutes,  then gradually    increase     engine    speed.

    {6 )   After checking                             the gearleverandgradually
                         that operationis normal.engage

    17l Finally ,
                c hec kt h a t n o a b n o rman                               arepresent.
                                                       , a te ro r o i l l eaks
                                              l o i s ew
                                7. DURING OP E RA TI O N

   (1 )   Neveroperate        the gearleverbe═ore
          fi r s t r educ ingeng i n e
                                     speed to SL OW
          Changing      gearat high englne   speeds
          damages      the friction discsand accel-
          erates     wear. Sudden     changesfrom
          full speed     ahead  to astern must
          always      be avoided  exceptin emer-
          The clutchshouldbe engaged          gent-
          ly and disengaged      ql]ickly. Adjust
          the speed      of the boat with the ac-                                          (|.
          celerator     lever; neverslip the clutch.

   t2)    lf the oil pressure
                            sightrotartendsto rotateslowlyor stop,lube oil is not
          circulating properly. But this is not appliedin the caseo═ low speedoperation.
          Badcirculation  indicatesthat the lube oil is old and needschanging.
          With engines  equipped with an oil pressure switch,circulationis normalif the
          oil pressure warninglight is o═f.

   (3) Checkoccasionally
                       that coolingwater is comingout of the coolingwater pipe

)i,\      outlet. l═ the ═low of water is low o═ intermittent,
          the pipingsystem   and the coolingwaterpump.
                                                             stopthe engine
                                                                          and check

   (4 )   With engines usingelect═icstarting,  checkthat the charge
          lightsup, there is a fault in the charging
                                                                   light is OFF. lf it
                                                   circuit;checkand repair.

                                              - 18 -
    (5 )   Chec kt he f uel o i l l e v e l
                                          i n th e ta n k
            and add fuel    when    it approaches        the
           lowermarking      on the fuel gauge.
           Operating    with insufficient      ═uel can
           ═esultin air entering      the ═uel iniec-
           tion system,    stopping    the engine.
           Depending     on t h e l o a d ,a fu l l fu e l
                       ═ or 3-5 h o u rso ═
           t ank las t s
           oper at ion.

    (61 O nc ea day , t ur n th e l u b eo i l fi l te r
           handle severaltimes. This Ýemoves
                       to the ═ilter plates.
           dirt adhering
    17) Checkthe coloro═ the exhaust.
           Blackexhaust   indicates     that the
           engine  is beingo v e rl o a d e d
                                            a.n d
           operation   must neverbe continued
           f or longper iodi n th i s c o n d i ti o n .

    {8 )   Depending    on the installation        and
           structure   of the hull, vibrationmay
           occurwhen engine      soeed     Ýeaches    a
           certainlevel;i.his  is due to resonsn-
           c e of t he engine a n d th e h u l l . N o te
           the c ondit ions u n d e rw h i c h th i so c .
           c ur sand av oidr u n n i n gth e e n g i n eat
           that particular  speed.                                           ol frl ter handl e
                                                               wareÝpump (RolaÝytype)
    {s)    Check ═or waier, gasanˇloit teak.


                                                     - 19 -
                                        8. STOPPING
(1 )   Al way sr educ e   g ra d u a l l y .

t2l    To s t opt he engin ep, u t th e g e a rl e v e r
                                                       i n N E U T R AL,l et the engi ne
                                                                                       i dl e,then
       setthe speed   control leverto STOP. Avoid stopping                the engine by means   o═
       the decompression    lever;  this causes      fuel to accumulate     in the combustion
       chamber    and canresultin accidents          at the next time o═ starting.

(3) W it h engines
                 us in g
                       e l e c tri c                                        the key and
                                                , rn th e k e y O FF. R emove
                                   s ta rti n gtu
       attachthe supplied

(4 )   Close the fuel cock.
(51 ln cold we ath er, dr ain of f t he c ool-
       ing water to prevent Ýreezing: Close
       the lever on the Kingston cock and
       dra in o ══ the wa ter ═ r om ins ide t he
       en gin e thro ug h the dr ar n c oc k under .
       neath the cylinder head; loosen and
       remove the cooling water pump
       intake and outlet pipes drain o═f the water
       f rom in sid e th e pi pes ,t hen t ur n ´ he engine
       severa ltimeswith t he s t ar t ing handle t o
       dischargethe water from inside the cooling
       water pump.

{6 )   Wip e of═ an y dirt w hile t he engine
       is stillwa rm.

t7l    Stop the engine at the compiession
       stroke by turning it with the start-
       ing ha nd le u ntil re s is t anc eis ═ elt .
       Do not use the decompressionlever.
       At this posiiion, the intake and
                                                                              em ov e the c ool i ng   c
       exhaust valvesaÝe closed, protecting                                 w ater pump i ntake
       the cylind er a nd v alv e s eat s═ r om                             and oul r═)t p pes and
                                                                            expel the w ater Ýrom
       m oisture .                                                          i nsi de the pump.

(8)    l═ necessary,
                   coverthe mouth of the exhaustpipewith an empty canto
       preventrain waterfrom enteringthe engine.

                                                  -2 0 -
                                                      9. P E RIODICA L
                                                                     CHE CK S
     R e g u l arc hec k ingis vi ta l i f th e e n g i n ei s to b e k e p t i n goodcondi ti on.S chedul es
     va rya c c or dingt o oper a ti n g  c o n d i ti o n s , p  o f fu e l o i l and l ubeoi l used.
                                                            ty                                       etc.,but
     the chartbelowwill serve         asa roughguide. For ═urtherdetailsre═erto the relevant

                                                                                  Da lly
                                                                                             Every100 Evety 250 Everys00

                  Check and retill                                                n
         6        Drain fuel tank
                                                                                  Q re" o Ýe re═ i l l i nq)

                  C l e a n a n d ═ e p l a c e fu e i ═ilte r e le m e n t         (cl                         (R epl :cetQ
                                                                                        ""r Q
                  C h e c k o i l l e v e l i n c═a n k ca sea n d clu tch

                  L u b r i c a t i o n ( s t a r tin gsh a ft ch a in . e tc.)

          ˇ      : f u r n l u b e o i l f i l t e r h a n d le
                           a n d cle a n lu b e o il filte r

                 C h a n g el u b e o i l i n cr a n k ca se

                 C h a n g el u b e o i l i n e lu tch ca se                                                   at
       5.        Drain                                                            a-\ ÝA
      3:         C h e c k c o o l i n g w a te r cir cu la tr o n
     F- 9        C h e c k f u e l i n j e c t i o n so u n d                     \J
                 A d j u s t f u e l i n j e c t io n r e g u la to r
                 C h e c k f u e l i n j e c t io n tim in g
                 C l e a n n e e d l e v a l v -"                                                                       (J
                 A d i u s t i n t a k e a n d e xh a u stva lve
                 C l e a n c o m b u s t i o n su r ═a ce
        E        C l e a n p r e c o m b u s tio n ch a m b e r
                 L a p i n t a k e a n d e xh a u st va lve s

                 C h e c k v a l v e s t e m sa n d va lve g u id e s
     Clean br e a t h e r v a l v e
     Chec k b e l t t e n s i o n ( c o o l i n g wa te r p u m p a n d
     Replac ea n t r c o r r o s i v ez i n c
                      p i s t o n , c h e c k r in g s
     Dis as s e m b l e                                                                                                 (J

  9-1 Daily
 9-1-1       Fueland LubeOil

 (1 )    O pent he dr ainpl u go n th e ´u e l ta n k
         and remove   the dirt and waterac-
         cumulated  at the bottom o═ the tank.

         IIB : W it h engin e u
                              s singe l e c tri c
               starting,first c!ver the starter
               and alternator  with a sheet     of
               vinyl to protectthem ═rom oil.
                                                                D rai n pl ug
 t2) C hec kt he f ueloil l e v e li n th e ra n k
        a n d r ef ill if nec es s a ry .
                                                                 (RotarY          ,
 (3) C hec kt he lubeoil te v e il n th e c ra n k
        case  and clutchcase.Re═ill up to
        th e upperm ar k in g
                            o n th e d i p s ti c k .

(4 )    ═urn the handleo═ the lube oil ═ilter
        on the outlet sideseveral
                                timesto the
        le═t or right.

9-1-2      CoolingWater

        Checkwaterflow from the cooling
        waterpump. Also checkfor water

9-1-3      Lubrication

Lubricate  the startingchain,startingchain═ree gearmetalandstartjngshaftbearing
wi th a sm all
             am ountof o i l .

    9-1-4   Fuel lniectionSound

            Cr ankt he engi n e
                              b e fo res ta rti n g
                                                  a n dc h e c kth at fuel i ni ecti oni s normal .

    9-1-5   DrainingOff the CoolingWater

            In cold weather,
                           draino═f the coolingwatera═ter operation.Draino═f the
            waterfrom inside the cylinderlhroughthe drain cock,removethe cooling
            water pump intakeand outlet pipesand expelthe water═rom insidethe
            PumP  (seeSection 8).

                                                                              / w ater pump i ntake
a                                                                               and ourl et pi pes and
                                                                                drai n off the w ater

    9-2 Y ery 100 Hours

    9-2-1   Remove                                           The ═ilteÝ is located
                   the ═uel oil ═ilter and washit in kerosene.
            belowthe fuel cock. Strip as  follows:

                                               -2 3 -
(1 )           t he ═ uel o i l p i p ea n d u n s c re w
       R em ov e                                        th e 2 n u tssecuri ng
                                                                             the fuel cocksetbol t,

(21 Pull out the fuel cock and removeit. Leave
                                             the oil gauge

                                   r t th e b a c ko f th e fu e l c ockand a 19 mm spanner
       l ns er ta 17 m m sp a n n ea                                                         at
       the hexagonal    section on the filter side.,Loosen           and remove.
       To assemble,   ═ollow the reverse     procedure.      Takespecial    carewith the 0 rings
       on the ═uel cockjoint surface.

9-2-Z     Re-tighten   the cylinderheadlock-
          nut s . Us inga si n g l e
                                   s p a n n e r,
          tightenthem securely       and evenly
          asshownin the diagram.


        T ight ening
                   t o═ q u e :

                                                                               63.7 ═t-l b

                                               1 2 .4k g ' m

                                            -2 4 -
         9-2-3       Checkthe tensionof the cooling
                     water pump andgenerator    v
                     belts. Pressdown with the thumb
                     In the cente═of the belts;normal
                     deflectionis about 5 mm. To ═e-
                     adjustthe tension, loosen the set
                     boltso═ the coolingwaterpump
                     {or alternator)
                                   and re-position it.

         9-24       Drainoff the lubeoilfrom inside
                    the crankcase      and washthe inte-
                    r ior wit h lig h to i l . T h e nf i l l w i rh
     a              lubeoil. {Thisshouldbe perform-
                    ed after the ═irst 50 hoursof
                    operationin the case          o═ a new
 a                  engr ne. l

         {1 )    Dr ainof f t he o l d l u b eo i l a fte r fi rs t
                 runningthe engine        until it is warm.
                 The drain plug is located          belowthe

         l2l     Remove   the rearcylindercoverand
                 washthe inside  o═ the crankcase
                 with light oil before═illing with
                 new oil.

         9-2-5      Clean  the insideof the lubeoil
                    ═ilte═. Remove  the 3 ═ilter cover
                    setboltsand pull out the filter.
                    Wash   thoroughlywith light oil.
                    Brusho══ dirt adhering   to the
                    filter plates.

             9-2-6    Clean the breather valve.
                      The breather valve is attached to
                      th e in sid eo f t he r ear c y linder
                      cover. Remove the breather valve
                      assemblyfrom the cover and,
                      witho ut str ipping, was h it t hor -
                      o ug hly in l ight oil.

r1                                                                                                                     I
it          9-3 Every250 Hours

            9-3-1 Checkintakeand exhaust
                                               and rockerarm clearances.

            t1) Checking
                                    shouldbe donewhen the engineis cold.                                      t
            t2)   Rem ov e   t he r o c k e rb o x c o v e r
                                                           a n dro ta teth e e ngi ne manual l y
                                                                                               unti l " otpr" ari on
                  oc c ur s .T his cl o s e st└e i n ta k ea n de x h a u sv
                                                                           t a l ves.

            {3) Checkthe clearance
                                       eachvalve,tipand rockerarm with a ═eelergauge.
                                is 0.2 mm-

            (4) lf necessary,
                           adjustthe clearance
                                             by means
                                                    of the adjustinsl╔iewbelowthe
                  rockerarm. Tightenthe locknut securely
                                                       after adiustment.
                                       '└    Fee er gauge
                                            7/ O.2mn                                                                   .a

        I                              ,Ei'
                                              L\ ' , ,


                                      l l '0/4)

        9-3-2         Change   the lubeoil in the crank
                      c as e.P um po u t th e o l d o i l fro m
                      the crankcase   while the engine         is
                      still warm. ReÝillwith new lube
              .r;*'   oil.



a      9'4 Every500 Hours
       94-1           Strip and cleanthe cylinderheadand lap the valveseats.(Consult
                                                                                   your dealer
                      if possible.)
      (1 )        Remove  the cylinderheadand strip the precombustion
                  ano valves.

       (21 Remove
                rust and carbondeposited
                                       insidethe precombustion
                                                                    on the
                            on the cylinderheadjoint surface
                  valve.s═|ats,                            and on the top o═ the piston.
                  TakeCare not to damage the metalsur═aces.

      (31 Checkthe clearance     the valvestemsandvalveguides.l═ clearance
                           between                                       is
                            wide.the cylinderheadmust be replaced.
                  Also checkthat there is su═ficientIubeoil insidethe rockeÝarm chambe═.

    "i:(4 ) Lap the valveseats.
        ... First remove             partswiln
                          the roughest
'   'ŕ*
            coarse  lapping powder. Then lap
            with a ═ine lapping powderand ═inish
            witli lubeoit.

      9.4-2           Replacthe f uel f ilter elemen´                -ŕ
                                                                     (ŕ,   -NS\
          9-4-3   Disassemble the fuel injectionvalve                  valve.Checkfuel
                                                     and cleanthe needle
                  injectiona═ter re-assembly (seeSection13).

          9-4-4                    lever(═uel injectionregulator).For details,
                  Adjustthe governor                                         see
          9-4'5   Check═uel injectiontiming {seeSection'15).

          94-6    Replace    the anticorrosive         zinc.
                  Rem ov e   t h e a n ti c o rro s i vzeinc
                  coverlocated      at the sideof the
                  coolingwateroutlet pipe
                  ( c y linder side)  a n d re p l a c eth e
F                 z inc .
                  Anticorrosive      zinc prevents        elect,
                  rolytic corrosion       inside   the engine.
                  F ailur e to replace     i t re g u l a rl y
                  leads   to serious   damage.

          94-7    Takeout the pistonand remove                          the piston
                                              carbondeposits.Also replace
                  rings(seeSection17). (consultyour dealerif possible.)


    li                                      ?2"-l1iEsfi

    lr                                                 -28-

  1 Precautions

Periodicalchecks,adjustments  and maintenance    helpensure that the engine  is kept
in good conditionat all times. In this way, faultscanbe repaired  in their early
stagesbeforedevelopinto serious   breakdowns.    Regularvisualchecking  o═ the
variouspartso═ the engineis alsoimportant.
About oncea year,the engine  must be strippedand overhauled.     Whenstripping,   be
sureto observe the ═ollowing: (Thisapplies   to engines
                                                      of commercial    application).

(1 )   Be═orestripping,thoroughlystudythe structureand functiono═ eachpart so
       asnot to wastetime or cause
                                 damage  by touchingunnecessary parts. lMakea
       noteof the methodo═ assembly of eachpart and be sureyou know how to

12) Prepare                        the strippedparts..
          a boa═don which to arrange                 Washall partsthor.
       oughly,and placethem on the boardin the correctorder.

{3) Usethe propertools. Take carenot to damage        the parts.
                                             or scratch

(4 )   To avoidlosingparts,screwnuts.washers,
                                            etc.,onto the boltsto which they
       belongwhen placingthem on the board,

(5 )                        . o te th e p o s i ti o n
       Dur ings t r ippi n gn                                         marks.The ═ol l ow i ng
                                                     o f a l i g n ment                      parts
       havealignment     marks: Connecting            rod BIG end, camshaft   gearand crankshaft
       gear,joint for thrust sha═tand propeller              shaft (or intermediate
                                                                                  shaft). Where
       necessary,   makeyourown alignment              marks.

(6) Repair
         worn sections,
                                         andother minor damage.lt                                       1
       is not necessary
                      to removelarge        entirely,but be sureto smooth
       down allr oughe d g e s .

t7l    Cleanthe inside  o═ the crankcaseand other partswhich are normallydif-
       ═icult to reach.

                                           -2 9 -
      10-2 Precautions

    , In general,       followsStrippingprocedure
               re-assembly                                Note the following:
                                                in reverse.

      (1)    Washall partsthoroughlyand alignall settingmarksto ensure

      Ý2 )   Ti ght enall nut san d b o l tse v e n l y .

     (3)           all split pins,claw washers
             ReplÓce                         and packings.

     l4l     lMakesurethat split pinsfit tightly into the holes,
                                                               and split the endsafter
,            attaching.Also be sureto bendclaw washers     properly.

     (5 )    Smear  the all bearings                                 partswith lubeoil.
                                     and other slidingand interlocking
             Ap ply m anuallyd ; o n o t u s ea c l o th .

      (6 )   Gjvespecial  attentionto the governor  gearalignmentmarksand to the adjust-
             ment of the governor  and the ═uel injectionsystem.Also take careto adjust
             ═uel injectiontimingand valveclearance   correctly,

     t7l                                          t rk s(o n c o n n e c ti ng
             Be s ur et o alignall a l i g n m e nma                         rod B IG end,gears.

     (8) A═ter re-assembly,
                         turn the engine
                                       with the starting
                                                       handleand checkthat no
                                   is produced.
                    noiseor abrasion

     {e)     Checkthat thereare no leaksin the coolingwater,fuel and lubeoil pipe

     Whenre-assemby   is complete,  checkonce morethat everything  is normal. Then
     supplyfuel and lubeoil and carryout a testoperation-lf the cylinderlinersor
     pistonhavebeenreplaced,    allow at least
                                             3 hoursoperationfor ═itting. Repair
     any ═aultsdetected at this time.                                                                   f,


              11 . AIR VE NTING OF FUE L INJ E CT I O NSYSTEM

    The Ýuel injectionsystem comprises  the fuel tank, the fuel injectionpump,the fuel
    injectionpipe and the Ýuel injectionvalve. Fuel is not injected if air is present
    wherein th is system.
    Air entersthe system whenfuel runsout andwhen the fuel injectionpump asstripp-
    ed. lt shouldbe vented  as═ollows:

     (1)    Replacethe fuel cock in the open



    l2l    Loosen  the nipples at eachend
           of the fuel iniectionpipe.
           Set the governorlever to LOW.

l   {3)     Loosen the deliveryvalveholder
           (by about two turns),and when
           bubble-═ree ═uel comesout,                                     1i
I          securely tightenthe deliveryvalve                              b
           holder,and then,a═ter attaching
           the intectionpipe,securelytighten
           the fuel pump sidenipple.

                                            -   Jt   -
  (4)    Now turn the engine   with the
         starting handle  about 30 times.
         Oil is circulated and comes  out
         from the nippleon the injection
         valveside. Whenno moreair
         bubbles   are presentin the oil.
         tightenthe   nipple.

  (5)    Continue  turningthe engine
         until you hearthe soundof fuel
         beinginjected.This indicates
         that the air hasbeencomPletely


                                            ,/- --
                    12 . CHE CK INGFUE L INJE CT I O N

     Badexhau$ color and reduced output powerare often the resulto═ unsatisfactory
     fuel injection.Checkasfollows:

     {1 )   Remove  the fuel injectionpipeand
            takeout the fuel injectionvalveas-
            semblyfrom the cylinderhead.

     t2l    Installthe valveoutsidethe engine
            asshownin the illustration.

     (3) Vent the air from the ═uel injection
!a          system(seeSection12).

     (4 )   After air venting, turn the starting
t           handle  and observe   the atomization
            of the ═uel asit is injected ═rom the
            nozzle. Keepyour facewell clear.

     (5 )   Normally,fuel is injected in a ═ine,
            cone-shapedspray   (seeillustration).



lf ═uel atomization   is abno═mal,strip the     Fuel iniection valvediagram.
═uel injectionvalveassembly    and check
that the nozzle   valvehasnot seized  due to
                                                           Fuel val ve spri ng cl amp
dirt, etc.,in the nozzlebody. The needle
valveshouldmovesmoothlyinside        the                   Fuel val vesP ri ngcl amP
nozzlebody; after stripping,   washthese                   packrng
                                   taking             9    N ozzl e spri nq adj usl i ng
partsin light oil and re-assemble.
careto keepthem clean.Then checkfuel
atomization   onc moreasexplained      above.
lf injectionis still ═aul═y, haveyour local                Springshoe
dealer  replace the injectionvalveassembly                 lnte═spindle
or adjustthe fuel injectionpressure.
(Standard   ═uel injectionpressure:
t 60 kg/cm2)



        The functiono═ the governor          is to reactaccurately       to variations  in the loadon the
        e n g i n e.T hef uel injecti o n re g u l a to rtra n s m i ts th e a cti ono═thegovernortotheÝuel
        injectionpump by regulating         the amountof ═uel supplied,            therebymajntaining
        stable   operation  at all times. The Ýegulator        must be adiusted      whenever   the ═uel pump
        is stripped    and when ═uel injectionsoundbecomes               indistinct  after long periods o═

        When═uel iniectionsoundis indistinct.    asfotlows:

        (1 )   Loosen   the connecting
               l oc k nut .

    -   12) Turn the connecting
                              screw90o coun-
t              terclockwise,so that the punch mark
               comes to the nearside.

        {3) Tightenthe locknutsecurely.

        lf adjustmentagainbecomes         necessary.      or if the ═uel iniection pump har bŕn
        si═ipped, adiust asfollows:
        {1 ) L oos en s c r ew( 2)a n d l o c k n u t{ 4 ).

        t2) Set the speed
                        control leverto H lGH.

                             screw(3), makingsurethat its bottom end doesnot
        {3) Screwin connecting
               protrudebelowthe bottom surface                       lever(5). Sel the punch
                                                       o═ the governor
               mark (6) to the cylindersideso that the groovein the screwheadis parallel
t              to t he pum padju s ti n g
                                        l e v e r(l ).

        ,0, Inserta screwdriveÝ
                              into the grooveon the tfrftthe                       spindle(7)and
                            until it tightenslightly.
        (5 )   Tightenscrew{2), holdingthe pump regutatfllever
                                                             with your teft handto
               preventit moving. Securewith locknut {8).

                 t        ,aÝ'                     -   ˇD -
(6) Tu═n the engineby handand listenfor the soundo═ fuel bejnginjected.l═ no
       soundis hear d.
                     the causei s p ro b a b l y
                                               o n e o f th e fol l ow i ng: i nsuffi ci ent
                                                                                           ai r
              regulator spindlenot screwed       in ═ar enough,      wear in valveseato═
       regulato═needle valve.

                          screw(3) 90o counterclockwise
t7l Now turn the connecting                          so that the grooveis
                      t o t h e p u mp a d j u s ti n g
       a t r ightangles                               l e v e r(1 ).

(8 )   Ti ght enloc k nut(4).

Run the engine
             and checkoperation. lf it is still unsatisfactory,
                                                                  the adjustment.

                                                                       Positiono═ punchmarkin (7)

                                                                                - , "t#.            t'

             14. CHECKINGAND ADJUSTING             TIMING

         The fuel injectionstartingpositionfor this engineis 8o - 120beforeT.D.C.(angle
         crankshaft rotation). Checkthe timing as═ollows:

         (1) Remove
                  the coverof the startermountinghole locatedbehindthe crankcase.
         i' "
         (2) Setthe speed
                        control leverto HIGH.

        , (3)
          '     Raisethe decompression   leverand gentlyturn the enginemanually.At com-
                pression stroke,lock throughthe openhatchand stopwhen the scale  readings
                on the flywhÚe.l,come into view.
         (4)    Turn the PTO shaÝtor startingshaft in the directiono═ rotation,and stop im-
J               mediately you hearthe soundof fuel beinginjected, Readoff the scale   read-
I               ingsby the notch in the edgeof the startermountinghole.
a                                                            reading.
                Repeat severaltimesand calculate the average

        Fuel injection                120 beforetheT.D.C.mark. lf timing is too lateor
        too early,adlustby reducinftrcreasing the adjustment   shimsbetween  the fuel
        injectionpump body andlthecylinderbody.
        One 1 mm adjustmelfshimaltersthe timing by 'lo. one 2 mm adjustment   shim by
                                 add shims;
        20. l═ timing is advahced,         if timing is delayed,


                                                               .          *1
            AND RE.ASSEMBLY
                          OF FUEL INJECTION

The fuel injectionpump shouldonly be stripped            for the purpose     of ═eplacing   worn
p a rts(plungeras s y .del
                       , i v e ry
                                    a s s y .,
                                             re g u l a ton          etc.). l f ═uel i nj ecti on
                                                           Ý e e dl e,                          fai l s
to occura═ter air venting  or adjustment   o═ the ═uel injectionregulator,          the delivery
valvemay be stripped    ═or cleaningor ═eplacement.
Most ═aultsin the ═irel injectionsystem    resultf═om the useoÝ impure═uel and Ýailure
to cleanthe ═uel Ýilter regularly.Regula═     maintenance        is vital.
The instruciions givenhereare intended      only to acquaint         the userwith the sructure
of the fuel injectionpump. As stated    above.    stripping     shouldneve═be attempted
unless  absolutelynecessary.

                         Partsin fuel injection

                              i -l l
                                           I Resurator                      I l F uel Ini ec ti on pum p
                                                                            2 l D el i v er y v ßl v ŕ hol ds r
                          s_i---1╦                                          3 l Oer i v s Ýy v al v ŕ s ŕar
                                                                            4 l D el i v s r y   v al v 
                                          A__-@                             5 l D el i very vßrvspri ns

                         gioi _e                                            6 l A esual toÝ body
 i                             - -'-i                                       7 IF egul ai o.        s pi .dl .

 l9                      l: -                       a l R esul Óto. sp ng
                                      -'il-l'::n:.o""-                      9l R egul Ótor         nes c l 16
 ll                      ll            .\a        I

      r*; [L*d
             *'Yd@ei l
                                    r:J     :     ,         |          |
                                                                            Ý l G as k t pac k i ng
                                                                           12 l P tunser barrer ti ght

                I          r              I l.s3          I 1l
                l"         i                                                5 l S pÝi ns
 I                                       pr-p uocv
                           lr,"r i"i""tion                 G

The fuel iniectionpump consists   of four sections:the pump body (1), the delivery
valveassembly  (2) - (5), the regulatorassembly (6) - (9) and the plunger
{ r 0 )- {15 ) .

            1$1 Delivery
            How to take apart

                (1 )          t he ═ uel i n j e c ti o n
                       Rem ov e                          pipe.

                t2l    Remove  the deliveryvalveholder(2). This reveals the deliveryvalveseat(3)
                       which accommodates   the deliveryvalve(4) and the deliveryvalvespring(5).


            (1)        Wash all partscare═ullyand assembleinsidethe deliveryvalveholdeÝ. Be sure
                       to mount the partsin the correctorder.

t           12) Re-attach   the deliveryvalveholderto the fuel pump body. Follow iry air vent.
                i ng ( s ee
                          S ec t ion1 2 ).

                15-2 Regulator
            How to take apart
        l(t1           Loosen      the pump adiusting
                                                    leversetbolt and removefrom the regulator
        '              d le ( 7) .

                (21    Loosenthe regulatorbody (6) and removeit from the fuel pump body (1).
                               spring(8) and regulator
                       Regulator                      needle(9) can now be removed,


                (1)    Wash all partscarefullyand firstly assemble
                                                                 the regulator pa═t. First smear  a
        '                                                              o═ the regulator
                       smallamountof engine   oil onto the screwsection                  spindle.

                       Assemble  the regulatorspring(8) and regulator
                                                                    needle  {9} at the tip o═ the

            l2l        Insertthe regulator spring(8) and regulatorneedle (9) in the regulatorbody
                       (6), and screwslightlythe regulatorspindle(7) in the regulator body ═rom
    I                  opposite side. lf the regulator
                                                     spindleis screwed up deeply,the regulator
                       needleseatmay be damaged.

                (3)    Screwthe regulatorspindleand checkthat it rotatessmoothly. Thengently          i
                       screw-down clockwise.                                                           I
I                                                                                                     J
       (4)    Inse═tthe fuel pump adjusring
                                          leverinto the top o═ the regulator
              adjustthe fuel regulator
                                     asexplainedin Section14.

       15-3 Plunger

       How to take apart

       (l)         the ═uel injectionpipe and the pump adjusting
              Remove                                           lever.

       t2)    Remove
                   the deliveryvalveholder{2) and removethe deliveryvalveassembly.

       (3) Remove
                the two ═uel pump body setboltsevenlyand removethe ═uel pump
             body. Parts(13) - (15) can now be stripped.
             l═ the plunger is not worn (i.e.doesnot needreplacing),
                                                                   it is not necessary
             go further. l═ the plungerir to be replaced,
                                                        however, continueas═ollows:

       {4)   Attach the ═uel pump body ro the cylinderbody in reverse
                                                                    with the setbolts.

             F it an o═fsetwrench( 19 mm) care═ullyonto the plunger
                        . (Using a s panneris lik ely t o dam aget he n u t . )

      '(1 )' fi frc e plunger  ba rre l(1 0 ),p l u n g e r
                                                          (1 3 ) a n d th e g asketpacki ng(11)
               and'´ ashall partsin cleanoil.

       l2l   Attach the fuel pump body to the cylinderbody in reverse,
             the plunger barrel('10)with the setscrew(12); makesurethat the Ýuel holesin
             the plunger barrelare positioned                   with the plunger
                                              horizontally.Secure                mount.
             ed insidethe plunger barrel. Usethe oÝ═ setwrench,asabove.

      {3)    Checkthat the plunger
                                 moveseasily. lf it is stiff, loosenthe setscrewand

      (4)    Attach the plungerspring(15) and washer
                                                   ('14)and hold the ═uel iniection
             pump against the cylinderbody. Securewith the setbolts. Be sureto tighten

                                              r .a
                                             16. CHE CK INGP IS T O N

                  Checking       the pistonand replacement
                  the pistonringsshouldbe carried     out as
                  ═o l l o w s :

                  (l)   Remove   the rockerarm chamber  and
                        the cylinderhead. Remove   carbon
                        ═rom the top of the cylinderliner.

                  t2l        the rearcoveroÝ the cylinder.

         , l(3 )        Remove        rod bolt ('l). (No lock washer
                             connecting                            is used.)
         I (4) Remove  the cap (2) o═ the crank pin metaland rotatethe flywheeluntil the
          'l   pistonis in the T.D.C.position.

                        Place a hammerhandleagainst                       rod and knock out
                                                  the end o═ the connecting                             '═ *
                        the pistonassembly
                                         towardsthe cylinderhead.

        Exa      ) the (
              min(      outer
                         uter s rrface
                                    :e of
                              surface    f the p
                                        o═         pistonand
     I' smooth
         nooth down rough       parts
                                parts    th oil-
                                       with     oil-stone,
         emove     the piston
                       p ston r
                                    with r a looloop of wire
      iras illustrated.
           illustr                       (
    -li i        ated. Clean    out the
                                    tl carbol
         re ring
     t the   ranggroov
                 grooves rsanc
                            and wash       l i g h t(
                                       in lioht
                                    1 In            oil.
     t, Take
         ake   care
               cale  not to
                         to scratch
                            scr     tl
                                    th e (

                  Piston Rings
                  The first ring is chrome,plated═or maximumprotectionagainst     wear. Whenthe plat-
    )1            ing peels. the ring must be replaced.Replace  other ringsif vertical
                  present on the slidingsur═ace or i═ therearetraces of gasleaks.Wornpiston═ings
                  cause compression    leaksandgasleaks,  leadingto reduced output power,starting
                  ═aultsanddeterioration   oÝ lube oil.


       Attach the ringsusingthe wire loop above.lVakesurethat the mark in eachpision
       ring is on the cylinderheadside,and take carenot to damage or distort the ringsby
       opening  them too far. Checkthat the ringsturn smoothlyin the ring           i═
                                                                          -erooves; they
       do not, cleanthe grooves once more.


       U si n gth e s pec ialt ool,      rh e p i s to na s
                                 in s e rt

       (l )    Se tt he ═ ly wheelt o th e T .D .C .
               Po sr t r on.

       l2l     Coatthe pistonwith new lubeoil
               and positionthe pistonring ends
               at 90o intervals.

               Insertthe pistonas illustratedwith the JIG end mark to the top. Hammqring
               in the pistondamages  the pistonrings.
       l4l     Whenthe BIG end of the connecting      rod fits into the crank,pushin the piston
               wh ile t ur ningt he ═ l y w h e e l .
       (5)     Attach the BIG end metalcapwith the mark upwards,Coat the metalwith
               n e w lubeoil.

               NB: Checkthat the metal is present            the pistof╔
                                                when inserting

       {6)                        rod boltsand tightenscurely.
               lnsertthe connecting


                             YSES                                        21.7+t-lb
                            YSE12                                        25.3 ft-lb



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