82YG7500.

book 1 ページ ２０１３年１２月１７日 火曜日 午後１時４０分

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How to use this manual

A Few Words About Safety
How to use this manual

SERVICE INFORMATION
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.

Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.

For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.

Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.

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CONTENTS
SPECIFICATIONS 1
SERVICE INFORMATION 2
MAINTENANCE 3
TROUBLESHOOTING 4
COVER 5
FUEL SYSTEM 6
GOVERNOR SYSTEM 7
IGNITION SYSTEM 8
STARTING SYSTEM 9
PUMP 10
ENGINE REMOVAL/INSTALLATION 11
CYLINDER HEAD 12
CRANKCASE 13
MUFFLER 14
WIRING DIAGRAMS 15
INDEX
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How to use this manual

INTRODUCTION
This manual covers the service and repair procedures for Honda WB30XH2 water pump.
All information contained in this manual is based on the latest product information available at the time of printing. We reserve the
right to make changes at anytime without notice.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic,
mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and
tables.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to this Honda product, other property, or the environment.

SAFETY MESSAGES
Your safety, and the safety of others, are very important. To help you make informed decisions, we have provided safety messages
and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated with servicing these products. You must use your own good judgement.
You will find important safety information in a variety of forms, including:
• Safety Labels – on the product.
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:

You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

• Instructions – how to service these products correctly and safely.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda products.

© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: January 2014

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How to use this manual

SERVICE RULES
• Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design
specifications may damage the unit.
• Use the special tools designed for the product.
• Install new gaskets, O-rings, etc. when reassembling.
• When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless
a particular sequence is specified.
• Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before assembly.
• After assembly, check all parts for proper installation and operation.
• Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the
threads and ruin the hole.
Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The
use of incorrect tools and fasteners will damage the unit.

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it will be explained specifically in the text without the use of the symbols.

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use marine grease (water resistant urea based grease).

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant.

Use automatic transmission fluid.

x ( ) Indicates the diameter, length, and quantity of metric bolts used.

page 1-1 Indicates the reference page.

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How to use this manual

ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbreviated Full term
term
ACG Alternator
API American Petroleum Institute
Approx. Approximately
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
AVR Auto Voltage Regulator
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
D-AVR Digital Auto Voltage Regulator
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EX Exhaust
F Front or Forward
GND Ground
HO2S Heated Oxygen sensor
IAB Intake Air Bypass
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center

BI Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
BU Blue W White Lb Light blue Gr Gray

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1. SPECIFICATIONS

SERIAL NUMBER LOCATION ················· 1-2 PERFORMANCE CURVES ······················ 1-4

SPECIFICATIONS·································· 1-2 DIMENSIONAL DRAWINGS ···················· 1-5

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SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS

The engine serial number is located on the cylinder barrel.

The frame serial number is located on the frame.
Refer to these numbers when ordering parts and when making technical inquiries.

ENGINE SERIAL NUMBER

FRAME SERIAL NUMBER

SPECIFICATIONS
DIMENSIONS AND WEIGHTS
Model WB30XH2
Description code WACC
Type DF1, DFX1
Overall length 510 mm (20.1 in)
Overall width 385 mm (15.2 in)
Overall height 435 mm (17.1 in)
Dry weight 25 kg (55 lbs)
Operating weight 27 kg (60 lbs)

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SPECIFICATIONS
ENGINE
Engine model GX160H1
Description code GCAAH
Type 4 stroke, overhead valve, single cylinder, inclined by 25°
Displacement 163 cm3 (9.9 cu–in)
Bore x stroke 68.0 x 45.0 mm (2.68 x 1.77 in)
Compression ratio 8.5 ± 0.3
Ignition system Transistor magneto ignition
Ignition timing B.T.D.C. 25° ± 3 /300 - 4,200 min-1 (rpm)
Spark plug BPR6ES (NGK), W20EPR-U (DENSO)
Lubrication system Forced spray
Oil capacity 0.58 liter (0.61 US qt, 0.51 Imp qt)
Recommended oil SAE 10W – 30 API service classification SE or later
Cooling system Forced air
Starting system Recoil starter
Stopping system Ignition primary circuit ground
Carburetor Horizontal type, butterfly valve
Air cleaner Dual type
Governor Mechanical centrifugal
Breather system Flat valve type
Fuel tank capacity 3.1 liters (0.82 US gal, 0.68 Imp gal)
Fuel used Regular unleaded gasoline with a pump octane rating 86 or higher

WATER PUMP
Model WB30XH2
Type Self priming centrifugal pump
Drive system Direct connection engine
Suction port diameter 80 mm (3.1 in)
Discharge port diameter 80 mm (3.1 in)
Maximum total head 23 m (75.9 ft)
Maximum suction head 7.5 m (24.7 ft)
Maximum discharge capacity 1,100 liters
(290.6 US gal, 242.0 Imp gal) /min
Maximum self-feed time 150 sec /5 m (16.4 ft)
Operating hours
1.9 Hr
(at rated load without refueling)

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SPECIFICATIONS
PERFORMANCE CURVES

(m)

25

20
TOTAL HEAD LIFT

15

10

0
200 400 600 800 1000 1200 ℓ/min

50.0 100.0 150.0 200.0 250.0 300.0 US gal/min

50.0 100.0 150.0 200.0 250.0 Imp gal/min

DISCHARGE CAPACITY

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SPECIFICATIONS
DIMENSIONAL DRAWINGS
Unit: mm (in)

435 (17.1)
510 (20.1)

385 (15.2)

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MEMO
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2. SERVICE INFORMATION

MAINTENANCE STANDARDS ················· 2-2 TOOLS ················································ 2-5

TORQUE VALUES ································· 2-3 HARNESS AND TUBE ROUTING ············· 2-7

LUBRICATION & SEAL POINTS ·············· 2-4

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SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION

Unit: mm (in)
Part Item Standard Service limit
Engine Maximum speed (at no load) 3,900 ± 100 min-1 (rpm) –
Idle speed + 200
1,400 min-1 (rpm) –
– 150
Cylinder compression 0.49 – 0.69 MPa (5.0 – 7.0 kgf/cm2, 71 –
–
100 psi)/600 min-1 (rpm)
Cylinder head Warpage – 0.10 (0.004)
Cylinder Sleeve I.D. 68.000 – 68.015 (2.6772 – 2.6778) 68.165 (2.6837)
Piston Skirt O.D. 67.965 – 67.985 (2.6758 – 2.6766) 67.845 (2.6711)
Piston-to-cylinder clearance 0.015 – 0.050 (0.0006 – 0.0020) 0.12 (0.005)
Piston pin bore I.D. 18.002 – 18.008 (0.7087 – 0.7090) 18.048 (0.7105)
Piston pin Pin O.D. 17.994 – 18.000 (0.7084 – 0.7087) 17.954 (0.7068)
Piston pin-to-piston pin bore
0.002 – 0.014 (0.0001 – 0.0006) 0.08 (0.003)
clearance
Piston rings Ring side clearance Top 0.035 – 0.070 (0.0014 – 0.0028) 0.15 (0.006)
Second 0.045 – 0.080 (0.0018 – 0.0032) 0.15 (0.006)
Ring end gap Top 0.200 – 0.350 (0.0079 – 0.0138) 1.0 (0.04)
Second 0.350 – 0.500 (0.0138 – 0.0197) 1.0 (0.04)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 1.0 (0.04)
Ring width Top 0.950 – 0.970 (0.0374 – 0.0382) 0.93 (0.037)
Second 0.940 – 0.960 (0.0370 – 0.0378) 0.92 (0.036)
Connecting Small end I.D. 18.005 – 18.020 (0.7089 – 0.7094) 18.07 (0.711)
rod Big end side clearance 0.1 – 0.4 (0.004 – 0.016) 1.1 (0.04)
Big end I.D. 30.020 – 30.033 (1.1819 – 1.1824) 30.066 (1.1837)
Big end oil clearance 0.040 – 0.063 (0.0016 – 0.0025) 0.12 (0.005)
Crankshaft Crankpin O.D. 29.970 – 29.980 (1.1799 – 1.1803) 29.92 (1.178)
Crankshaft runout – 0.10 (0.004)
Cylinder barrel Camshaft holder I.D. 14.000 – 14.018 (0.5512 – 0.5519) 14.048 (0.5531)
Crankcase Camshaft holder I.D.
14.000 – 14.018 (0.5512 – 0.5519) 14.048 (0.5531)
cover
Valves Valve clearance IN 0.15 ± 0.02 (0.006 ± 0.001) –
EX 0.20 ± 0.02 (0.008 ± 0.001) –
Valve stem O.D. IN 5.468 – 5.480 (0.2153 – 0.2157) 5.318 (0.2094)
EX 5.425 – 5.440 (0.2136 – 0.2142) 5.275 (0.2077)
Valve guide I.D. IN/EX 5.500 – 5.512 (0.2165 – 0.2170) 5.572 (0.2194)
Guide-to-stem IN 0.020 – 0.044 (0.0008 – 0.0017) 0.10 (0.004)
clearance EX 0.060 – 0.087 (0.0024 – 0.0034) 0.12 (0.005)
Valve guide
IN 4.8 – 5.2 (0.19 – 0.20) –
installation height
Valve seat width IN/EX 0.70 – 0.90 (0.028 – 0.035) 2.0 (0.08)
Valve spring free length 30.5 (1.20) 29.0 (1.14)
Valve spring perpendicularity – 1.5° max.
Camshaft Cam height IN/EX 27.603 – 27.703 (1.0867 – 1.0907) 27.450 (1.0807)
Camshaft O.D. 13.966 – 13.984 (0.5498 – 0.5506) 13.916 (0.5479)
Carburetor Main jet #70 –
Pilot screw opening 2 turns out –
Float height 13.7 (0.54) –
Spark plug Gap 0.70 – 0.80 (0.028 – 0.031) –
Spark plug cap Resistance (20°C/68°F) 7.5 – 12.5 kΩ –
Ignition coil Air gap 0.2 – 0.6 (0.01 – 0.02) –
Primary resistance 0.6 – 0.9 Ω –
Secondary resistance 5.6 – 6.9 kΩ –

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SERVICE INFORMATION
TORQUE VALUES
ENGINE TORQUE VALUES
Torque values
Item Thread Dia. (mm) Remark
N·m kgf·m lbf·ft
Crankcase cover bolt M8 x 1.25 24 2.4 18
Cylinder head bolt M8 x 1.25 24 2.4 18 Apply engine oil to
the threads and
seating surface.
Engine oil drain plug bolt M10 x 1.25 18 1.8 13
Connecting rod bolt M7 x 1.0 12 1.2 9 Apply engine oil to
the threads and
seating surface.
Rocker arm pivot bolt M8 x 1.25 (Special bolt) 24 2.4 18 Apply engine oil to
the threads and
pivot.
Rocker arm pivot lock nut M6 x 0.5 (Special nut) 10 1.0 7
Spark plug M14 x 1.25 (Special) 18 1.8 13
Oil level switch joint nut M10 x 1.25 10 1.0 7
Flywheel nut M14 x 1.5 (Special nut) 75 7.5 55 Apply engine oil to
the threads and
seating surface.
Fuel tank nut/bolt M6 x 1.0 10 1.0 7
Fuel tank joint M10 x 1.25 2 0.2 1.5
Air cleaner mount nut M6 x 1.0 9 0.9 6.6
Muffler nut M8 x 1.25 24 2.4 18
Recoil starter set screw M6 x 1.0 (Special bolt) 5.4 0.6 4.0
Sediment cup M24 x 1.0 3.9 0.4 2.9

WATER PUMP TORQUE VALUES

Torque values
Item Tread Dia. (mm)
N·m kgf·m lbf·ft
Impeller M16 x 1.5 25 2.5 18

STANDARD TORQUE VALUES

Torque values
Item Thread Dia. (mm)
N·m kgf·m lbf·ft
Screw M4 2.1 0.2 1.5
M5 4.3 0.4 3.2
M6 9 0.9 6.6
Bolt and nut M5 5.3 0.5 3.9
M6 10 1.0 7
M8 22 2.2 16
M10 34 3.5 25
M12 54 5.5 40
Flange bolt and nut M5 5.3 0.5 3.9
M6 12 1.2 9
M8 23 2.3 17
M10 40 4.1 30
SH (Small head) flange bolt M6 9 0.9 6.6
CT (Cutting threads) flange bolt (Retightening) M5 5.4 0.6 4.0
M6 12 1.2 9

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SERVICE INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
Material Location Remarks
Engine oil Crankshaft pin and gear teeth
Piston outer surface, ring groove and piston pin hole
Piston pin outer surface
Piston ring entire surface
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft cam profile and journal
Valve lifter pivot, pivot end and slipper surface
Valve stem sliding surface and stem end
Valve rocker arm tappet surface and pivot
Rocker arm pivot threads and pivot
Flywheel nut threads and seating surface
Governor weight holder gear and sliding surface
Governor holder shaft journal
Governor arm shaft journal
Cylinder head bolt threads and seating surface
Multi-purpose grease Oil seal lips
Control lever sliding surface
Recoil starter case reel sliding surface
Recoil starter ratchet sliding surface
Recoil starter ratchet guide inside
Use molybdenum oil solution Camshaft cam profile When installing a new
(mixture of the engine oil and camshaft
molybdenum grease in a ratio
of 1:1)
LOCTITE® 638 or equivalent Limiter cap inside
ThreeBond® 1216E Crankcase cover mating surface
or equivalent

WATER PUMP
Location Material Remarks
Mechanical seal and casing mating surface Sealant

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SERVICE INFORMATION
TOOLS
SPECIAL TOOLS
Float level gauge Attachment, 32 x 35 mm Attachment, 37 x 40 mm
07401-0010000 07746-0010100 07746-0010200

Attachment, 52 x 55 mm Pilot, 25 mm Driver

07746-0010400 07746-0040600 07749-0010000

Valve seat cutter, 45° 24.5 mm (EX) Valve seat cutter, 45° 27.5 mm (IN) Valve seat cutter, 32° 25 mm (EX)
07780-0010100 07780-0010200 07780-0012000

Valve seat cutter, 32° 28 mm (IN) Valve seat cutter, 60° 30 mm (IN/EX) Cutter holder, 5.5 mm
07780-0012100 07780-0014000 07781-0010101

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SERVICE INFORMATION
Valve guide driver Mechanical seal attachment Valve guide reamer, 5.510 mm
07942-8920000 07948-9540000 07984-2000001

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SERVICE INFORMATION
HARNESS AND TUBE ROUTING
CYLINDER BARREL RIBS

ENGINE WIRE
HARNESS

TO ENGINE
STOP
SWITCH

CYLINDER BARREL RIBS

HIGH-TENSION CORD ENGINE WIRE

HARNESS

CARBURETOR INSULATOR

CORD HOOK

IGNITION COIL CONNECTOR

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SERVICE INFORMATION

BREATHER TUBE

CARBURETOR
INSULATOR

HIGH-TENSION CORD

CARBURETOR INSULATOR

FUEL TUBE

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SERVICE INFORMATION
ENGINE STOP SWITCH
WITHOUT OIL LEVEL SWITCH AND OIL ALERT UNIT:

CLAMP

ENGINE WIRE
HARNESS

ENGINE WIRE HARNESS

ENGINE STOP SWITCH WIRE
CONNECTOR

WITH OIL LEVEL SWITCH AND OIL ALERT UNIT:

OIL LEVEL SWITCH

HARNESS CLIP
CONNECTOR

OIL ALERT UNIT

CONNECTOR

ENGINE STOP
SWITCH WIRE
CLAMP

ENGINE WIRE ENGINE WIRE OIL LEVEL SWITCH

OIL LEVEL SWITCH
HARNESS HARNESS CONNECTOR
CONNECTOR
CONNECTOR

To ignition coil To oil alert unit

OIL ALERT
UNIT WIRES

Y Bl

Bl

ENGINE STOP ENGINE WIRE

Bl Y
SWITCH WIRE HARNESS Y
CONNECTOR

To engine To oil level switch

ENGINE WIRE stop switch
HARNESS
CONNECTOR OIL ALERT UNIT
OIL ALERT UNIT CONNECTOR
OIL LEVEL
CONNECTOR
SWITCH WIRE HARNESS CLIP

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MEMO
82YG7500.book 1 ページ ２０１３年１２月１７日 火曜日 午後１時４０分

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3. MAINTENANCE

MAINTENANCE SCHEDULE ··················· 3-2 VALVE CLEARANCE CHECK/

ADJUSTMENT ······································ 3-7
ENGINE OIL LEVEL CHECK/CHANGE······ 3-3
COMBUSTION CHAMBER CLEANING······ 3-9
AIR CLEANER
CHECK/CLEANING/REPLACEMENT ········ 3-4 FUEL TANK AND FILTER CLEANING······· 3-9

SPARK PLUG CHECK/ADJUSTMENT ······ 3-5 FUEL TUBE CHECK ···························· 3-10

SPARK PLUG REPLACEMENT ··············· 3-6 IMPELLER CHECK ······························ 3-10

SEDIMENT CUP CLEANING···················· 3-6 IMPELLER CLEARANCE CHECK ·········· 3-11

IDLE SPEED CHECK/ADJUSTMENT ········ 3-7 PUMP INLET VALVE CHECK ················ 3-12

3-1
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MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE

REGULAR SERVICE PERIOD (2)

Perform at every indicated month or operating hour interval,
whichever comes first. Refer to
Item
First Every Every Every page
Each use month or 3 months or 6 months or year or
20 hrs. 50 hrs. 100 hrs. 300 hrs.
Engine oil Check-Level 3-3
Change 3-3
Air cleaner Check 3-4
Clean (1) 3-4
Replace (*) 3-4
Spark plug Check-Adjust 3-5
Replace 3-6
Sediment cup Clean 3-6
Idle speed Check-Adjust 3-7
Valve clearance Check-Adjust 3-7
Combustion chamber Clean After every 500 hrs. 3-9
Fuel tank and filter Clean 3-9
Fuel tube Check Every 2 years (Replace if necessary) 3-10
Impeller Check 3-10
Impeller clearance Check 3-11
Pump inlet valve Check 3-12

(1) Service more frequently when used in dusty areas.

(2) For commercial use, log hours of operation to determine proper maintenance intervals.
(*) Replace paper element type only.

3-2
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MAINTENANCE
ENGINE OIL LEVEL CHECK/CHANGE
CHECK
Place the water pump on a level surface.
[1]
Remove the oil filler cap [1] and verify the oil level is at
the top of the oil filler neck [2]. [2]
If the oil level is low, fill with recommended oil to the top
of the oil filler neck (page 3-3).
Check that the oil filler packing [3] is in good condition;
replace it if necessary.
Install and tighten the oil filler cap securely.

[3]

CHANGE
Place the water pump on a level surface and place a
[2] [4]
suitable container under the drain plug bolt [1].
Remove the oil filler cap [2], drain plug bolt, and drain
plug washer [3], and drain the oil into a suitable
container.
Please dispose of used oil in a manner that is
compatible with the environment. We suggest you take
used oil in a sealed container to your local recycling
center or service station for reclamation. Do not throw it
in the trash, pour it on the ground, or pour it down a
drain.

Used engine oil contains substances that have [1] [3]

been identified as carcinogenic. If repeatedly left in
contact with the skin for prolonged periods, it may
cause skin cancer. Wash your hands thoroughly SAE VISCOSITY GRADES
with soap and water as soon as possible after
contact with used engine oil.

Install the drain plug bolt with a new drain plug washer
and tighten it to the specified torque.
TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)
Add the specified amount of recommended oil into the
engine.
ENGINE OIL CAPACITY:
0.58 liter (0.61 US qt, 0.51 Imp qt) AMBIENT TEMPERATURE

RECOMMENDED OIL:
SAE 10W-30 API service classification SE or later
After adding the oil, check the oil level.
Check that the oil filler packing [4] is in good condition,
replace it if necessary.
Install and tighten the oil filler cap securely.
Make sure there are no oil leaks.

3-3
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MAINTENANCE
AIR CLEANER
CHECK/CLEANING/REPLACEMENT
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.

Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
CHECK/REPLACEMENT
Remove the following:
[1]
– Wing nut [1]
– Air cleaner cover [2]
– Wing nut [3] [2]
– Element Assy.
– Grommet [4]
– Inner filter (Paper) [5]
– Outer filter (Foam) [6]
Carefully check both filters for holes or tears and
replace if damaged.
Clean the filters if they are to be reused (page 3-4).
Installation is in the reverse order of removal.

[3]
[4]

[5]

[6]

CLEANING
FOAM
Clean the filter [1] in warm soapy water, rinse, and allow
[1] Wash Dip
to dry thoroughly, or clean with a non-flammable
solvent and allow to dry thoroughly.
Dip the filter in clean engine oil, and squeeze out all the
excess oil. Dry thoroughly
Excess oil will restrict air flow through the foam element
and may cause the engine to smoke at startup.

Squeeze thoroughly

3-4
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MAINTENANCE
PAPER
Tap the inner filter [1] lightly several times on a hard
[1]
surface to remove excess dirt, or blow compressed air
lightly (206 kPa (2.11 kgf/cm2, 30 psi) or less) through
the paper filter from the inside out. Never try to brush
the dirt off; brushing will force dirt into the fibers.

SPARK PLUG CHECK/ADJUSTMENT

Remove the spark plug (page 3-6).
[1] [2]
Clean the spark plug [1] electrodes with a wire brush [2]
or special plug cleaner.
Check the following and replace if necessary.
– Insulator [3] and sealing washer [4] for damage
– Center electrode [5] and side electrode [6] for wear
– Burning condition, coloration
RECOMMENDED SPARK PLUG:
BPR6ES (NGK) / W20EPR-U (DENSO)
Measure the plug gap with a wire-type feeler gauge.
PLUG GAP: 0.70 – 0.80 mm (0.028 – 0.031 in)
If the measurement is out of the specification, adjust by [4]
bending the side electrode.
Install the spark plug (page 3-6).
[5]

[6]
[3]

3-5
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MAINTENANCE
SPARK PLUG REPLACEMENT
REMOVAL

The engine and the muffler become very hot during

operation and remain hot for a while after stopping
the engine. Be careful not to touch the muffler while
it is hot. Allow it to cool before proceeding.

Disconnect the spark plug cap [1] and remove the spark
[2]
plug [2].

Clean around the spark plug base with compressed air

before removing the spark plug, and be sure that no
debris is allowed to enter into the combustion chamber.
INSTALLATION
Install and hand tighten the spark plug to the cylinder
head.
RECOMMENDED SPARK PLUG:
BPR6ES (NGK) / W20EPR-U (DENSO) [1]
Tighten the spark plug to the specified torque.
TORQUE: 18 N·m (1.8 kgf·m, 13 lbf·ft)
Connect the spark plug cap.

SEDIMENT CUP CLEANING

[1]

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Turn the fuel valve lever [1] to the OFF position.

Remove the following:
– Sediment cup [2]
– O-ring [3]
Clean the sediment cup with nonflammable solvent.
Install a new O-ring and sediment cup.
Tighten the sediment cup to the specified torque.
TORQUE: 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft)
Check the installation part of the sediment cup for any
sign of fuel leakage.

[3]

[2]

3-6
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MAINTENANCE
IDLE SPEED CHECK/ADJUSTMENT
Ensure the governor arm and governor arm shaft are
installed correctly (page 7-4).
Use a tachometer with graduations of 50 min-1 (rpm) or
smaller that will accurately indicate 50 min-1 (rpm)
change.

Fill the pump housing with water before starting.

Start the engine and allow it to warm up to normal
operating temperature.
Turn the throttle stop screw [1] to obtain the specified
idle speed.
[1]
+ 200
IDLE SPEED: 1,400 min-1 (rpm)
– 150

VALVE CLEARANCE CHECK/

ADJUSTMENT

Inspect and adjust the valve clearance while the engine

is cold.
CHECK
Disconnect the spark plug cap [1] and remove the [1]
[4] [2]
following:
– Breather tube [2]
– Head cover bolt (6 x 12 mm) [3]
– Head cover [4]
– Head cover packing [5]

[3]
[5]

Set the piston near top dead center of the cylinder

[1] [3]
compression stroke (both valves fully closed) by pulling
the recoil starter slowly. When the piston is near top
dead center of the compression stroke, the triangle
mark [1] on the starter pulley [2] will align with the top
hole [3] on the recoil starter case [4]. Pull slowly.

If the exhaust valve is open, use the recoil starter to turn

the crankshaft one additional turn and align the triangle
mark on the starter pulley with the top hole on the recoil
starter case again.

[4] [2]

3-7
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MAINTENANCE
Insert a thickness gauge [1] between the valve rocker
arm [2] and valve stem [3] to measure the valve
clearance. [1] [3] [2]

VALVE CLEARANCE:
IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in)
EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in)
If adjustment is necessary, proceed as follows.

[2]

[3]

ADJUSTMENT
Hold the rocker arm pivot [1] and loosen the lock nut [2].
[3] [1]
Insert a thickness gauge [3] between the valve rocker
arm and the valve stem.
Adjust by turning the adjusting screw until there is a
slight drag on the feeler gauge.
VALVE CLEARANCE:
IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in)
EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in)
Hold the rocker arm pivot and retighten the lock nut to
the specified torque.
TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)
[2]
Recheck the valve clearance, and if necessary, readjust
the clearance.
Replace the head cover packing with a new one and
install the removed parts in the reverse order of
removal.

Route the high-tension cord and breather tube properly

(page 2-7).

3-8
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MAINTENANCE
COMBUSTION CHAMBER CLEANING
Remove the cylinder head (page 12-3).
[1]
Clean any carbon deposits from the combustion
chamber [1].
Installation is in the reverse order of removal.

FUEL TANK AND FILTER CLEANING

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Remove the fuel tank (page 6-3).

[3]
Remove the fuel tank joint [1] and O-ring [2] from the
fuel tank [3].
Clean the fuel tank joint and fuel tank with non-
flammable solvent, and allow them to dry thoroughly.
Check the screen of the fuel tank joint for clogs or
damage, replace if necessary.
Install a new O-ring to the fuel tank joint and install them
to the fuel tank.
Tighten the fuel tank joint to the specified torque.
[2]
TORQUE: 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
Install the fuel tank (page 6-3).
[1]
After installation, check for any signs of fuel leakage.

3-9
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MAINTENANCE
FUEL TUBE CHECK

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Remove the fan cover (page 5-2).

[1]
Check the fuel tube [1] for deterioration, cracks or signs
of leakage.
Replace if necessary.

IMPELLER CHECK
Remove the volute case [1] (page 10-4).
Check the impeller [2] for damage or contamination and
replace if necessary. [2]

[1]

3-10
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MAINTENANCE
IMPELLER CLEARANCE CHECK
Remove the volute case [1] (page 10-4).
Measure the depth of the volute case by using the
depth gauge or vernier caliper.

[1]

Measure the height of the impeller [1] vanes from the

casing cover [2].

[2]
[1]

3-11
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MAINTENANCE
Subtract the height of the impeller [1] from the depth of
the volute case [2] to obtain the impeller clearance [3].

IMPELLER CLEARANCE:
0.50 – 0.90 mm (0.020 – 0.035 in) [2]
If not, adjust clearance by adding or removing adjuster [1]
shims [4] (page 10-5).
[3]

[4]

IMPELLER

VOLUTE CASE

PUMP INLET VALVE CHECK

Remove the inlet pipe [1] (page 10-3).
Check the pump inlet valve [2] for damage or [2]
contamination and replace if necessary.

[1]

3-12
82YG7500.book 1 ページ ２０１３年１２月１７日 火曜日 午後１時４０分

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4. TROUBLESHOOTING

BEFORE TROUBLESHOOTING ··············· 4-2 WATER PUMP TROUBLESHOOTING ······· 4-6

ENGINE TROUBLESHOOTING ················ 4-2

4-1
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TROUBLESHOOTING
BEFORE TROUBLESHOOTING
TROUBLESHOOTING

• Check that the connectors are connected securely.

• Check for sufficient fresh fuel in the fuel tank.
• Read the circuit tester's operation instructions carefully, and observe the instructions during inspection.

ENGINE TROUBLESHOOTING
ENGINE LOCKED UP
Remove the pump case and volute case, and Jammed Remove any foreign materials.
check the pump condition.

Not jammed

Remove the spark plug and check for water or oil Abnormal Disassemble the cylinder head and replace the
in the combustion chamber. faulty part(s) (page 12-4).

Normal

Remove the recoil starter (page 9-2) and check Cannot be cranked Disassemble the cylinder barrel and replace the
whether the engine cranks. faulty part(s) (page 13-4).

Cranks

Inspect the recoil starter (page 9-5). Abnormal Replace the faulty part(s).

4-2
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TROUBLESHOOTING
ENGINE WON’T START
• Check the oil level before troubleshooting (page 3-3).

Loosen the carburetor drain screw and check the Check for clogged fuel tank joint or fuel tube
fuel flow from the fuel tank (page 6-3). No fuel (page 3-9, 3-10).

Fuel

Perform the spark test (page 8-9). Perform the IGNITION SYSTEM
No spark TROUBLESHOOTING (page 8-3).

Spark
Check the cylinder compression (page 12-5). Compression Check the valve clearance (page 3-7) and then
is too high perform the cylinder compression test. If the
cylinder compression is too high, remove carbon
deposits in the combustion chamber (page 3-9).
Check the decompressor operation of the
camshaft (page 13-12).

Check the valve clearance (page 3-7), and then

perform the cylinder compression test.
If the cylinder compression is too low, perform a
leak down test.
If there is no air leakage in the engine, check the
Compression following.
is too low - Valve spring free length (page 12-7)
- Valve seat width (page 12-6)
- Valve face irregularly worn (page 12-7)
- Decompressor operation (page 13-12)
- Piston ring side clearance (page 13-8)
- Piston ring width (page 13-9)
- Piston ring end gap (page 13-9)
- Piston skirt O.D. (page 13-7)
- Cylinder sleeve I.D. (page 13-6)

If spark plug is correct, clean and dry the

Check the spark plug (page 3-5). electrodes and then restart the engine, taking care
Wet that the choke valve is not closed too much.
If the engine does not start and the electrodes are
wet again, check the carburetor float valve
(page 6-7).
Dry
Disassemble the carburetor to clean the
carburetor parts, jets and nozzles
(page 6-6, 6-7).

4-3
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TROUBLESHOOTING
ENGINE SURGES

Check the air cleaner element (page 3-4). Clogged or saturated Clean or replace the air cleaner element
(page 3-4).

Clean

Check the valve clearance (page 3-7). Abnormal Adjust the valve clearance (page 3-7).

Normal
Inspect the spark plug and adjust the spark plug
Check the spark plug (page 3-5). Abnormal
gap (page 3-5). Replace if necessary (page 3-6).

Normal

Check the carburetor for any obstructions Clogged Disassemble and clean the carburetor
(page 6-6). (page 6-6, 6-7).

Clean

Check for secondary air leak. Air leaking Check around the air intake joint and carburetor;
replace the insulator and/or gasket if necessary.

No air leaking
Compression
Check the cylinder compression (page 12-5). is too high Check for carbon deposits in the combustion
chamber (page 3-9).

Check that the cylinder head bolts are correctly

torqued (page 12-3).
Compression Check for defective cylinder head gasket, valves,
is too low or valve seats (page 12-3, 12-6, 12-7).
Normal Check for worn piston, piston rings, or cylinder
(page 13-6).

Check that the governor system is installed Abnormal Adjust or replace the faulty part(s).
correctly (page 7-2).

Normal

Check the ignition coil air gap (page 8-8). Abnormal Adjust the ignition coil air gap (page 8-8).

Normal

Check the ignition coil (page 8-10).

Replace the ignition coil if abnormalities are found,
and recheck.

4-4
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TROUBLESHOOTING
ENGINE DOES NOT STOP WHEN
ENGINE STOP SWITCH IS TURNED OFF

Check the engine stop switch (page 8-11). Replace the engine stop switch (page 8-7).
Abnormal

Normal

Check the wire harness connecting the engine Replace the engine wire harness.
stop switch and the ignition coil for open or short No continuity
circuit.

Continuity

Check the ignition coil primary side (page 8-10).

Replace the ignition coil if abnormalities are found,
and recheck.

ENGINE DOES NOT STOP WHEN ENGINE OIL

LEVEL IS LOW (WITH OIL LEVEL SWITCH AND
OIL ALERT UNIT TYPE ONLY)

Check the oil level switch (page 8-10). Replace the oil level switch (page 8-7).
Abnormal

Normal

Check the oil alert unit (page 8-11). Replace the oil alert unit (page 8-8).
Abnormal

Normal

Check the wire harness connecting the oil level Replace the engine wire harness.
switch and ignition coil for open or short circuit. No continuity

Continuity

Check the ignition coil primary side (page 8-10).

Replace the ignition coil if abnormalities are found,
and recheck.

4-5
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TROUBLESHOOTING
WATER PUMP TROUBLESHOOTING

No self-feed Priming water too low Increase.

Mechanical seal damaged Replace (page 10-6).

Inlet valve damaged Replace (page 10-3).

Suction hose damaged Replace (page 10-3).

Air leak Tighten parts.

Mounting faulty Correct.

Strainer clogged Clean out.

Strainer damaged Replace (page 10-3).

Discharge amount or Air leak Tighten parts.

pressure too low

Mounting faulty Correct.

Strainer clogged Clean out.

Impeller clearance excessive Adjust (page 3-11).

Pump RPM too low Adjust throttle or governor

(page 3-7, 7-4).

Lift head too high Correct.

Suction/discharge hoses too small and/or too long. Correct.

4-6
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TROUBLESHOOTING

Self-feed time too long Priming water too low Increase.

Mechanical seal damaged Replace (page 10-6).

Inlet valve damaged Replace (page 10-3).

Suction hose damaged Replace (page 10-3).

Air leak Tighten parts.

Pump RPM too high Adjust throttle or governor

(page 3-7, 7-4).

Strainer clogged Clean out.

Lift head too high Correct.

Suction hose too long. Correct.

Noise or vibration Mounting faulty Correct.

Strainer damaged Replace (page 10-3).

Lift head too high Correct.

Suction hose too small and/or too long. Correct.

4-7
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MEMO
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5. COVER

FAN COVER
REMOVAL/INSTALLATION ····················· 5-2

5-1
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COVER
FAN COVER REMOVAL/INSTALLATION
COVER

When installing, route the tube and wires properly (page 2-7).

ENGINE WIRE HARNESS CONNECTOR

(With oil level switch and oil alert unit)

ENGINE WIRE HARNESS CONNECTOR

(With out oil level switch and oil alert unit)

OIL ALERT UNIT CONNECTOR

(With oil level switch and oil alert unit)

FAN COVER
INSTALLATION:
Be careful not to clip the fuel tube.

BOLT (6 x 12 mm) (4)

5-2
82YG7500.book 1 ページ ２０１３年１２月１７日 火曜日 午後１時４０分

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6. FUEL SYSTEM

TOOL··················································· 6-2 CARBURETOR BODY CLEANING ··········· 6-7

FUEL TANK REMOVAL/INSTALLATION ··· 6-3 CARBURETOR INSPECTION ·················· 6-7

AIR CLEANER PILOT SCREW REPLACEMENT ·············· 6-8

REMOVAL/INSTALLATION ····················· 6-4
CHOKE REPLACEMENT ························ 6-9
CARBURETOR
REMOVAL/INSTALLATION ····················· 6-5 CARBURETOR STUD BOLT
REPLACEMENT ···································· 6-9
CARBURETOR
DISASSEMBLY/ASSEMBLY···················· 6-6

6-1
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FUEL SYSTEM
TOOL
FUEL SYSTEM

Float level gauge

07401-0010000

6-2
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FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Remove the fan cover(page 5-2).

[1]
Place a suitable container under the carburetor.
Turn the fuel valve lever [1] to the ON position.
Loosen the drain screw [2] and drain the fuel.
When installing, route the tube properly (page 2-7).

[2]

FUEL FILLER CAP FUEL FILLER CAP PACKING

CHECK:
Check for deterioration or cracks.

FUEL TANK

O-RING

FUEL TANK JOINT

2 N·m (0.2 kgf·m, 1.5 lbf·ft)
CHECK:
Check the screen of the fuel tank
joint for clogs or damage.
NUT (6 mm) (2)
10 N·m (1.0 kgf·m, 7 lbf·ft)

BOLT (6 x 29 mm)
10 N·m (1.0 kgf·m, 7 lbf·ft)

FUEL TUBE
CHECK:
Check for deterioration or cracks.

6-3
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FUEL SYSTEM
AIR CLEANER
REMOVAL/INSTALLATION

WING NUT

AIR CLEANER COVER

WING NUT
GROMMET

INNER FILTER (PAPER)

OUTER FILTER (FOAM)

BOLT (6 x 20 mm)

AIR CLEANER
COLLAR ELBOW SEAL

AIR CLEANER ELBOW

REMOVAL/INSTALLATION:
Remove and install the air
cleaner elbow with the fuel
valve lever in the OFF
position and the choke lever
BREATHER TUBE in the CLOSE position.
Before installation, clean the
inside of the air cleaner
elbow.

CARBURETOR SPACER
INSTALLATION:
Before installing, check for damage.
Note the installation direction.

AIR CLEANER COLLAR (2) AIR CLEANER ELBOW NUT (6 mm) (2)
Viewed from air cleaner side 9 N·m (0.9 kgf·m, 6.6 lbf·ft)

6-4
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FUEL SYSTEM
CARBURETOR
REMOVAL/INSTALLATION

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

Remove the air cleaner (page 6-4).

Set a commercially available tube clamp to the fuel
tube.
Loosen the drain screw of the carburetor to drain the
fuel completely (page 6-3).

GOVERNOR ROD/
THROTTLE RETURN SPRING
REMOVAL/INSTALLATION:
Pull the carburetor to a point where
the groove [1] of the throttle arm
lines up with the governor rod [2],
and then lift the governor rod out of
the hole of the throttle arm and
unhook the throttle return spring [3].

[2]

FUEL TUBE TUBE CLAMP [3]

[1]

TUBE CLIP

INSULATOR PACKING
CARBURETOR INSULATOR
INSTALLATION:
Before installing, clean the passage [1]
thoroughly with compressed air.
Install the carburetor insulator with the
vent groove facing toward the carburetor.
After installing, clamp the high-tension
cord [2] and fuel tube [3] to the carburetor CARBURETOR PACKING
insulator.

[3]

[2] DRAIN SCREW

CARBURETOR

[1]

6-5
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FUEL SYSTEM
CARBURETOR DISASSEMBLY/ASSEMBLY

Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.

To prevent serious eye injury, always wear safety

goggles or other eye protection when using
compressed air.

Remove the carburetor (page 6-5).

Before disassembly, clean the outside of the carburetor.

PILOT JET SET SCREW LEVER SETTING PLATE

ASSEMBLY: (3 x 6 mm) (2)
Before installing, clean VALVE LEVER
thoroughly with the jet SPRING
cleaning special tool and
low-pressure compressed CHOKE LEVER
air. O-RING FUEL VALVE LEVER
Lightly lubricate the O-ring [1]
[1] to ensure easy installation THROTTLE STOP SCREW
into the carburetor body. NOTE 1: FUEL VALVE
PACKING
PILOT SCREW
CHECK:
MAIN NOZZLE NOTE 2:
SPRING PIN Replace if necessary.
ASSEMBLY: UPPER
Before installing, clean SIDE
thoroughly with the jet CARBURETOR BODY
cleaning special tool and
low-pressure compressed
air. LIMITER CAP

MAIN JET O-RING

NOTICE:
Tampering is a violation of Federal and California Law.
ASSEMBLY: UPPER
Before installing, clean thoroughly with the SIDE SEDIMENT CUP
jet cleaning special tool and low-pressure FLOAT 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft)
compressed air.

FLOAT CHAMBER FLOAT PIN

ASSEMBLY:
O-RING FLOAT VALVE
Install the float chamber to the
carburetor body at an angle as shown.
0 – 30° FLOAT VALVE SPRING

SET BOLT GASKET

DRAIN SCREW GASKET

SET BOLT DRAIN SCREW

NOTE 1 IDLE SPEED ADJUSTMENT page 3-7

NOTE 2 PILOT SCREW REPLACEMENT/INSTALLATION page 6-8

6-6
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FUEL SYSTEM
CARBURETOR BODY CLEANING

To prevent serious eye injury, always wear safety

goggles or other eye protection when using
compressed air.

• Some commercially available chemical cleaners are

very caustic. These cleaners may damage plastic
parts such as the O-ring, the float, and the float seat
of the carburetor. Check the container for
instructions. If you are in doubt, do not use these
products to clean Honda carburetors.
• High air pressure may damage the carburetor body.
Use low air pressure (206 kPa (2.11 kgf/cm2, 30 psi)
or less) when cleaning passages and ports.
Clean the carburetor body with non-flammable solvent.
[8]
Clean thoroughly the following passages and ports with
low-pressure compressed air.
– Pilot screw hole [1]
– Pilot jet hole [2]
– Pilot air jet [3]
– Main air jet [4]
– Transition ports [5]
– Pilot outlet [6]
– Main nozzle holder [7] [5]
– External vent port [8]
– Internal vent port [9]

[6]

[9]
[3]

[1]

[2] [4]
[7]

CARBURETOR INSPECTION
FLOAT LEVEL HEIGHT
Place the carburetor in the position as shown. Measure
the distance between the float top and carburetor body
when the float just contacts the seat without
compressing the float valve spring.

TOOL:
Float level gauge [1] 07401-0010000

FLOAT HEIGHT: 13.7 mm (0.54 in)

If the measured float height is out of specification,
check the float valve and float valve spring (page 6-8).
If the float valve and float valve spring are normal,
replace the float (page 6-6).
[1]

6-7
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FUEL SYSTEM
FLOAT VALVE
Check the float valve and its seat [1] for wear or
contamination.
Check the valve seat [2] for clogs.
Before installation, check for wear or a weak float valve
spring [3]. [1]
[2]
Check the operation of the float valve.

[3]

OK CLEAN REPLACE

PILOT SCREW REPLACEMENT

Leave the pilot screw [1] and limiter cap [2] in place
Pilot screw will break at narrow point.
during carburetor cleaning. Remove only if necessary
for carburetor repair.
Removal of the limiter cap requires breaking the pilot
screw. A new pilot screw and limiter cap must be
installed.
When the limiter cap has been broken off, remove the
broken pilot screw.
[2]
Place the spring on the replacement pilot screw, and
install it on the carburetor.
[1]
Turn the pilot screw in until it is lightly seated and then
turn the screw out the required number of turns.
Pilot screw opening: 2 turns out
Refer to the table above for carburetor pilot screw initial STOP [1]
opening setting.
Apply LOCTITE® 638 or equivalent to the inside of the
limiter cap and then install the cap so the stop prevents
the pilot screw from being turned counterclockwise.
Be careful to avoid turning the pilot screw while
installing the limiter cap. The pilot screw must stay at its
required setting.
[2]

6-8
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FUEL SYSTEM
CHOKE REPLACEMENT
Remove the carburetor (page 6-5).
Pull out the choke valve plate [1]. [2]
Remove the choke shaft [2] and install a new choke
[3]
shaft.
Insert a new choke valve plate into the slit [3] of the
choke shaft.
Be sure the choke shaft is in the position between the
projections [4] of the choke valve plate.

[1]

[2]

[4]

[4]
[2]

[1]

CARBURETOR STUD BOLT

REPLACEMENT
Remove the carburetor (page 6-5). [1]
Thread two nuts onto the carburetor stud bolt [1] and
tighten them together, and then use a wrench to turn
the stud bolt out.
Install and tighten new stud bolts until they are fully
seated.

6-9
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MEMO
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7. GOVERNOR SYSTEM

GOVERNOR ARM/CONTROL BASE GOVERNOR ADJUSTMENT ···················· 7-4 7

REMOVAL/INSTALLATION ····················· 7-2
GOVERNOR
CONTROL BASE DISASSEMBLY/ASSEMBLY···················· 7-5
DISASSEMBLY/ASSEMBLY···················· 7-3
MAXIMUM SPEED ADJUSTMENT············ 7-6

7-1
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GOVERNOR SYSTEM
GOVERNOR ARM/CONTROL BASE
GOVERNOR SYSTEM

REMOVAL/INSTALLATION
Remove the following:
– Air cleaner (page 6-4)
– Fuel tank (page 6-3)
After installation, adjust the following:
– Governor (page 7-4)
– Idle speed (page 3-7)
– Maximum speed (page 7-6)

GOVERNOR SPRING NUT (6 mm)

INSTALLATION: INSTALLATION:
Hook the governor spring to the hole Tighten torque shall be 3 N·m (0.3
on the control lever as shown. kgf·m, 2.2 lbf·ft) minimum and 0.5
GOVERNOR ARM mm (0.02 in) minimum shall be
kept for the clearance as shown.

More than 0.5 mm (0.02 in)

GOVERNOR ARM BOLT

BOLT (6 x 12 mm) (3)

GOVERNOR ROD/
THROTTLE RETURN SPRING
REMOVAL/INSTALLATION:
Pull the carburetor to a point where
the groove [1] of the throttle arm
lines up with the governor rod [2]
and then lift the governor rod out of
the hole of the throttle arm and
unhook the throttle return spring [3].

[2]
[1]

CONTROL BASE

[3]

7-2
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GOVERNOR SYSTEM
CONTROL BASE
DISASSEMBLY/ASSEMBLY
Remove the control base Assy (page 7-2).

LOCK NUT (6 mm) CONTROL LEVER WASHER

INSTALLATION: INSTALLATION:
After installation the control base Assy., Install the control lever washer
measure force at 10 mm (0.4 in) from by aligning the cutout of the
the tip of the control lever [1] by pulling. control lever washer with the
Adjust by turning the lock nut [2] so that claw of the control base.
the gauge shows 19.6 ± 4.9 N (2.0 ±
0.5 kgf) when the control lever starts to
move.

[2]

10 mm
(0.4 in)
LEVER SPRING
INSTALLATION:
[1]
Note the installation
direction.

CONTROL ADJUST SPRING

CLAW
CONTROL LEVER

CONTROL LEVER SPACER

SCREW (5 x 25 mm)

CONTROL BASE

7-3
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GOVERNOR SYSTEM
GOVERNOR ADJUSTMENT
Loosen the nut (6 mm) [1] of the governor arm.
Turn the governor arm [2] clockwise to fully open the
carburetor throttle valve [3].
Rotate the governor arm shaft [4] as far as it will go in
the same direction the governor arm moved to open the
throttle valve.
Make sure the carburetor throttle valve is fully open.
Tighten the nut and then make sure that the clearance is normal.

[2]

[4] [1]
[3]

7-4
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GOVERNOR SYSTEM
GOVERNOR
DISASSEMBLY/ASSEMBLY
Remove the crankshaft (page 13-4).

GOVERNOR WEIGHT (2)

CHECK:
After installing the governor weights,
check to be sure they move freely.

GOVERNOR WEIGHT PIN (2) GOVERNOR HOLDER CLIP

INSTALLATION: WASHER (6 mm)
GOVERNOR WEIGHT HOLDER Install firmly into the
groove of the
(Gear and sliding surface)
governor holder shaft.

GROOVE
WASHER (6 mm)

LOCK PIN
INSTALLATION:
Install firmly into the
groove of the governor
arm shaft.

GOVERNOR ARM SHAFT

(Journal)
WASHER (6 mm)

GOVERNOR SLIDER
INSTALLATION:
Spread the governor weights to install
the governor slider.
GOVERNOR HOLDER SHAFT
CHECK:
(Journal)
After installing the governor slider,
check to be sure it moves smoothly.

GROOVE

7-5
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GOVERNOR SYSTEM
MAXIMUM SPEED ADJUSTMENT
Use a tachometer with graduations of 50 min-1 (rpm) or
smaller that will accurately indicate 50 min-1 (rpm)
changes.
Start the engine and allow it to warm up to normal
operating temperature.
Move the control lever [1] to run the engine at the
specified maximum speed, and hold the control lever.
Make sure the carburetor throttle valve [2] is fully open. [3]

Turn the screw [3] of the control base to obtain the

specified maximum speed.
MAXIMUM SPEED: 3,900 ± 100 min-1 (rpm)
[1]

[2]

7-6
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8. IGNITION SYSTEM

SYSTEM DIAGRAM ······························· 8-2 OIL ALERT UNIT

REMOVAL/INSTALLATION
(IF EQUIPPED)······································ 8-8 8
IGNITION SYSTEM
TROUBLESHOOTING ···························· 8-3
IGNITION COIL AIR GAP
IGNITION COIL CHECK/ADJUSTMENT··························· 8-8
REMOVAL/INSTALLATION ····················· 8-4
SPARK TEST········································ 8-9
COOLING FAN/FLYWHEEL
REMOVAL/INSTALLATION ····················· 8-5 SPARK PLUG CAP INSPECTION············· 8-9

OIL LEVEL SWITCH IGNITION COIL INSPECTION ················ 8-10

REMOVAL/INSTALLATION
(IF EQUIPPED) ······································ 8-7 OIL LEVEL SWITCH INSPECTION
(IF EQUIPPED)···································· 8-10
ENGINE STOP SWITCH
REMOVAL/INSTALLATION ····················· 8-7 ENGINE STOP SWITCH INSPECTION ···· 8-11

OIL ALERT UNIT INSPECTION

(IF EQUIPPED)···································· 8-11

8-1
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IGNITION SYSTEM
SYSTEM DIAGRAM
IGNITION SYSTEM

WITHOUT OIL LEVEL SWITCH AND OIL ALERT UNIT

Bl
Bl

ENGINE STOP SWITCH

IG E
OFF
ON

Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light blue
SPARK PLUG IGNITION COIL ENGINE STOP SWITCH G Green Lg Light green
R Red P Pink
W White Gr Gray

WITH OIL LEVEL SWITCH AND OIL ALERT UNIT

Bl
Bl

ENGINE STOP SWITCH

IG E
Bl

OFF
ON

Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light blue
SPARK PLUG IGNITION COIL ENGINE STOP SWITCH OIL ALERT UNIT OIL LEVEL SWITCH G Green Lg Light green
R Red P Pink
W White Gr Gray

8-2
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IGNITION SYSTEM
IGNITION SYSTEM TROUBLESHOOTING
NO OR WEAK SPARK AT SPARK PLUG
Check the following before troubleshooting:
– Loose connectors
– Spark plug (page 3-5)
– Engine oil level (page 3-3)

WITH OIL ALERT UNIT ONLY: Replace the oil level switch (page 8-7).
Abnormal
Check the oil level switch (page 8-10)/oil alert unit Replace the oil alert unit (page 8-8).
(page 8-11).

Normal

Check for continuity between the engine wire Replace the engine wire harness.
Abnormal
harness connectors.

Normal

Check the engine stop switch (page 8-11). Replace the engine stop switch (page 8-7).
Abnormal

Normal

Check the ignition coil (page 8-10). Replace the ignition coil (page 8-4).
Abnormal

Normal

Check the spark plug cap (page 8-9).

If necessary, replace the spark plug cap (page 8-4).

8-3
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IGNITION SYSTEM
IGNITION COIL
REMOVAL/INSTALLATION
Remove the following:
– Fan cover (page 5-2)
– Carburetor (page 6-5)
When installing, route the engine wire harness and
high-tension cord properly (page 2-7).
After installation, check the ignition coil air gap (page 8-8).

ENGINE WIRE HARNESS

BOLT (6 x 25 mm) (2)

HIGH-TENSION CORD
IGNITION COIL
SPARK PLUG CAP

IGNITION COIL CONNECTOR

8-4
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IGNITION SYSTEM
COOLING FAN/FLYWHEEL
REMOVAL/INSTALLATION
REMOVAL
Remove the ignition coil (page 8-4).

WOODRUFF KEY
SIDE PLATE

MAGNET PART

BOLT (6 x 22 mm)

STARTER PULLEY

COOLING FAN
NUT (14 mm)
(Threads and seating surface)
75 N·m (7.6 kgf·m, 55 lbf·ft)
REMOVAL:
Hold the flywheel [1] with a commercially
available strap wrench [2], being careful not
FLYWHEEL
to damage the magnet part.
REMOVAL: Remove the flywheel nut (14 mm) [3].
Use the commercially available tool [1] to remove the flywheel.

[2]
[1]

[1]

[3]

8-5
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IGNITION SYSTEM
INSTALLATION

• Clean the tapered parts [1] of dirt, oil, grease, and

[4] [3] [2] [6]
other foreign material before installation.
• Be sure there are no metal parts or other foreign
material on the magnet part [2] of the flywheel.
Set the woodruff key [3] in the key groove [4] of the
crankshaft securely.
Set the flywheel [5] by aligning the key slot [6] with the
woodruff key on the crankshaft.

[1] [5]

Attach the cooling fan [1] to the flywheel [2] by aligning

Align [1] Align [3]
the four projections of the cooling fan with the holes of
the flywheel.
Attach the starter pulley [3] by aligning the following:
– Holes of the pulley and tabs of the cooling fan
– Tab of the pulley and hole of the flywheel

[2] Align

Apply a light coat of oil to the threads and the seating

[3]
surface of the nut [1] and loosely tighten the nut.
Hold the flywheel [2] with a commercially available strap
wrench [3], being careful not to damage the magnet
part.
Tighten the flywheel nut to the specified torque.
TORQUE: 75 N·m (7.6 kgf·m, 55 lbf·ft)
[2]

[1]

8-6
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IGNITION SYSTEM
OIL LEVEL SWITCH REMOVAL/
INSTALLATION (IF EQUIPPED)
Disconnect the oil alert unit connector.
Remove the camshaft (page 13-4).

Take care not to drop the valve lifter.

OIL LEVEL SWITCH

NUT (10 mm)

10 N·m (1.0 kgf·m, 7 lbf·ft)
O-RING

BOLT (6 x 12 mm) (2)

ENGINE STOP SWITCH

REMOVAL/INSTALLATION

Remove the engine stop switch only if necessary for

engine stop switch or fan cover replacement. Align
Remove the fan cover (page 5-2).
Straighten the tab [1] of the engine stop switch [2] and
remove the engine stop switch.
Install the engine stop switch to the fan cover, aligning
its groove with the boss of the fan cover.
Bend the tab until it is fully seated on the fan cover so
the engine stop switch is held.

The tab is used for ground terminal. [1] [2]

Install the fan cover (page 5-2).

8-7
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IGNITION SYSTEM
OIL ALERT UNIT REMOVAL/
INSTALLATION (IF EQUIPPED)
Disconnect the oil alert unit connectors [1]. [3]
[4] [2]
Remove the 6 x 12 mm bolt [2] and oil alert unit [3].
Install the oil alert unit and bolt.
Hold the oil alert unit against the boss [4] of the stay,
and then tighten the bolt.

Route the wire harness properly (page 2-9).

[1]

IGNITION COIL AIR GAP

CHECK/ADJUSTMENT
Remove the fan cover (page 5-2).
[2] 0.2 – 0.6 mm (0.01 – 0.02 in)
Insert the thickness gauge [1] of proper thickness
between the ignition coil [2] and the flywheel [3].
IGNITION COIL AIR GAP:
0.2 – 0.6 mm (0.01 – 0.02 in)

• Avoid the magnet part of the flywheel when

adjusting.
• Adjust the ignition coil air gap equally on both sides.
If measured clearance is out of specification, adjust the
air gap. 0.2 – 0.6 mm
Loosen the two 6 x 25 mm bolts [4]. [3] (0.01 – 0.02 in)
[1]
Insert the thickness gauge of proper thickness between
the ignition coil and flywheel.
Push the ignition coil firmly against the flywheel and
tighten the ignition coil bolts securely.
Remove the thickness gauge.

[4]

8-8
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IGNITION SYSTEM
SPARK TEST
[2]

Never hold the high-tension cord with wet hands

while performing this test.

Check for the following before conducting the spark

test. [4]
• Faulty spark plug
• Loose spark plug cap
• Water in the spark plug cap (leaking the ignition coil
secondary voltage) [3]
• Loose ignition coil connector
Disconnect the spark plug cap [1] from the spark plug [1]
[2].
Connect a known-good spark plug [3] to the spark plug
cap and ground the spark plug to the cylinder head
cover bolt [4].
Turn the engine stop switch to "ON" position.
Crank the engine by pulling the recoil starter and check
whether sparks jump across the electrodes.

SPARK PLUG CAP INSPECTION

Measure the resistance of the spark plug cap by
attaching one ohmmeter probe to the terminal in the
spark plug cap and the other to the high-tension cord
terminal.

RESISTANCE: 7.5 – 12.5 kΩ (20°C/68°F)

If measured resistance is out of specification, replace
the spark plug cap (page 8-4).

8-9
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IGNITION SYSTEM
IGNITION COIL INSPECTION
Remove the fan cover (page 5-2).
PRIMARY SIDE
Disconnect the ignition coil connector [1].
[3]
Measure the resistance of the primary coil by attaching
one ohmmeter probe to the ignition coil wire terminal [2]
and the other at the iron core [3].
RESISTANCE: 0.6 – 0.9 Ω
If measured resistance is out of specification, replace
the ignition coil (page 8-4).

[1] [2]

SECONDARY SIDE
Disconnect the spark plug cap from the high-tension
[1] [2]
cord [1].
Measure the resistance of the secondary coil by
attaching one ohmmeter probe to the high-tension cord
and the other at the iron core [2].
RESISTANCE: 5.6 – 6.9 kΩ
If measured resistance is out of specification, replace
the ignition coil (page 8-4).

OIL LEVEL SWITCH INSPECTION

(IF EQUIPPED)
Check the oil level (page 3-3).
Disconnect the oil alert unit connector [1].
Check the continuity between the oil level switch
connector and engine ground.
There should be no continuity when the engine is full of
oil.
Drain the engine oil completely (page 3-3).
Check the continuity between the oil level switch
connector and engine ground.
There should be continuity.
Check the continuity between the oil level switch
connector and engine ground while filling the engine [1]
with oil.
The ohmmeter reading should go from continuity to no
continuity as the oil is filled.
If the correct continuity is not obtained, replace the oil
level switch (page 8-7).

8-10
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IGNITION SYSTEM
ENGINE STOP SWITCH INSPECTION
Remove the engine stop switch connector [1] from the
engine wire harness.
Check the continuity between the terminals at each
switch position.
Switch position Continuity
ON No
OFF Yes
If the correct continuity is not obtained, replace the
engine stop switch (page 8-7).

[1]

OIL ALERT UNIT INSPECTION

(IF EQUIPPED)
Remove the oil alert unit (page 8-8).
[2] [3]
Check the continuity between the terminals, and oil
alert unit body.
Unit: kΩ
(+)
Bl [1] Y [2] Body [3]
Bl [1] – 0.5 – 10
(–) Y [2] 0.5 – 10 –
Body [3] –

[1]

8-11
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MEMO
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9. STARTING SYSTEM

RECOIL STARTER RECOIL STARTER

REMOVAL/INSTALLATION ····················· 9-2 DISASSEMBLY/ASSEMBLY···················· 9-3

RECOIL STARTER INSPECTION ············· 9-5 9

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STARTING SYSTEM
RECOIL STARTER
STARTING SYSTEM

REMOVAL/INSTALLATION

RECOIL STARTER

BOLT (6 x 10 mm) (3)

9-2
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STARTING SYSTEM
RECOIL STARTER
DISASSEMBLY/ASSEMBLY

• Wear gloves and eye protection.

• During disassembly/assembly, take care not to
allow the return spring to come out.

DISASSEMBLY
Remove the recoil starter (page 9-2).

SPRING RETAINER RECOIL STARTER CENTER SCREW

(Inside) 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)
(Threads)

FRICTION PLATE

FRICTION SPRING

RATCHET (2) RATCHET SPRING (2)

(Sliding surface)

RECOIL STARTER PULLEY

STARTER RETURN SPRING

STARTER GRIP

RECOIL STARTER CASE

(Pulley sliding surface)

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STARTING SYSTEM
ASSEMBLY
Pass the recoil starter rope [1] through the hole [2] of
[2]
the recoil starter pulley [3], and then tie the rope as
shown.
Wind the recoil starter rope onto the recoil starter pulley
counterclockwise as shown.

[3] [1]

Hook the outer hook [1] of the starter return spring [2] to
[2] [3] [1]
the groove [3] of the recoil starter pulley [4], and then
install the starter return spring by winding it.

[4]

Apply grease to the starter pulley sliding surface [1] of

[3]
the recoil starter case [2].
Set the recoil starter pulley [3] to the recoil starter case
by aligning the inner hook [4] of the starter return spring
[1]
with the boss [5] of the recoil starter case as shown.

[4]

[2] [5]

Apply grease to the ratchets [1].

[1] [1] [2]
Install the ratchet springs [2] and ratchets to the recoil
starter pulley [3] as shown.

[2] [3]

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STARTING SYSTEM
Apply grease to the inside of the spring retainer [1].
[2]
Apply locking agent (Threebond ® 2430 or equivalent)
to the threads of the center screw [2]. [1]

Set the friction spring [3], friction plate [4], and spring [4]
retainer to the recoil starter pulley in the direction as
shown.
Hold the spring retainer and tighten the center screw to
the specified torque.
TORQUE: 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft)

[3]

Turn the recoil starter pulley [1] 2 turns

counterclockwise to preload the starter return spring. [1]
Be sure to hold the recoil starter pulley.

Pass the recoil starter rope [1] through hole [2] of the
[4] [2]
recoil starter case, starter grip [3], and then tie the rope
as shown. Be sure to hold the recoil starter pulley [4].
Check the recoil starter operation (page 9-5).

[3] [1]

RECOIL STARTER INSPECTION

RECOIL STARTER OPERATION
Remove the recoil starter. (page 9-2).
[2] [1]
Pull the starter grip [1] several times to inspect that the
ratchets [2] are operated properly (the ratchet ends
come out from the spring retainer [3]).

[3]

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STARTING SYSTEM
STARTER PULLEY
Remove the recoil starter. (page 9-2).
[2]
Inspect the square holes [1] of the starter pulley [2] for
deformation.

[1]

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10. PUMP

TOOLS ·············································· 10-2 IMPELLER/CASING COVER

REMOVAL/INSTALLATION ··················· 10-5
INLET PIPE/OUTLET PIPE
REMOVAL/INSTALLATION ··················· 10-3 MECHANICAL SEAL REPLACEMENT ···· 10-6

CASING/VOLUTE CASE 10
REMOVAL/INSTALLATION ··················· 10-4

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PUMP
TOOLS
PUMP

Attachment, 32 x 35 mm Driver Mechanical seal attachment

07746-0010100 07749-0010000 07948-9540000

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PUMP
INLET PIPE/OUTLET PIPE
REMOVAL/INSTALLATION
HOSE COUPLING PACKING
FILLER CAP
INSTALLATION:
Install the hose coupling packing [1]
SEAL RING
in the groove [2] of the hose clamp
ring.
OUTLET PIPE
[1]

BOLT (10 x 32 mm) (4)

[2]

INLET VALVE
HOSE COUPLING (2) INSTALLATION:
OUTLET
PACKING Check the inlet valve for breakage or
damage. Align the tab [1] on the inlet
valve with the groove [2] of the inlet pipe.

[1] ALIGN [2]

HOSE CLAMP RING (2)

INLET PIPE

BOLT (10 x 32 mm) (4)

HOSE COUPLING PACKING

INSTALLATION:
Install the hose
[1]
coupling packing
[1] in the groove
[2] of the hose
clamp ring.
HOSE BAND (3) [2]

SUCTION HOSE
(Commercially available)

STRAINER

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PUMP
CASING/VOLUTE CASE
REMOVAL/INSTALLATION
Remove the engine (page 11-2).

STUD BOLT (3)

VOLUTE CASE
INSTALLATION:
Check the mating surface
for damage and nicks.
SHORT
LONG
CAP NUT (6 mm) (3)

SEAL RING

O-RING (71 x 5.7 mm)

CASING SEAL RING

DRAIN CAP
CASING

BOLT (10 x 32 mm) (4)

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PUMP
IMPELLER/CASING COVER
REMOVAL/INSTALLATION
Remove the ignition coil (page 8-4).
Remove the casing (page 10-4).

CASING COVER

SEALING WASHER (4)

ADJUSTER SHIM

BOLT (8 x 28 mm) (4)

RUBBER RING

FLOATING SEAT
INSTALLATION:
Check the seat surface for damage, nicks.
Apply soapy water to the rubber ring and
install the floating seat in the rubber ring.
Push the rubber ring and the floating seat into
the impeller by finger pressure.
After installing, check to be sure the seat and
rubber ring are fully seated and are not tilted.
IMPELLER
REMOVAL: INSTALLATION:
Hold the flywheel [1] with a Hold the flywheel [1] with a commercially
commercially available strap available strap wrench [2], being careful
wrench [2], being careful not to not to damage the magnet part [3].
damage the magnet [3] part. Tighten the impeller to the specified torque.
Remove the impeller. 25 N·m (2.5 kgf·m, 18 lbf·ft)
After installation, check the impeller clearance:
NOTE1:
[2] [2]

[3]
[1] [1]

[3]

NOTE 1 IMPELLER CLEARANCE CHECK page 3-11

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PUMP
MECHANICAL SEAL REPLACEMENT
Drive out the mechanical seal [1] from the inside using
the special tools. [2]

TOOLS:
Driver [2] 07749-0010000 [1]
Attachment, 32 x 35 mm [3] 07746-0010100
[3]

Apply liquid sealant to the outside surface of a new

mechanical seal [1]. [2]

Drive the mechanical seal until it is fully seated on the

end using the special tools.
TOOLS: [1]
Driver [2] 07749-0010000 [3]
Mechanical seal attachment [3] 07948-9540000
After installing, check to be sure the seal is fully seated
and is not tilted in the casing cover.

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11. ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL/INSTALLATION······· 11-2

11

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ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL/INSTALLATION

FRAME

NUT (8 mm) (4)

BOLT (8 x 32 mm) (2)

(Engine side)
NUT (6 mm) (4)
BOTTOM RUBBER (4)
ASSEMBLY:
Check for cracking, deformation or other
damage before installation.
BOLT (8 x 25 mm) (2)
Install by aligning with the hole in the frame.
(Pump side)

SCREW (6 mm) (4)

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12. CYLINDER HEAD

TOOLS ·············································· 12-2 CYLINDER HEAD/VALVES

INSPECTION ······································ 12-5
CYLINDER HEAD
REMOVAL/INSTALLATION ··················· 12-3 VALVE GUIDE REPLACEMENT············· 12-8

CYLINDER HEAD VALVE GUIDE REAMING ····················· 12-9

DISASSEMBLY/ASSEMBLY·················· 12-4
VALVE SEAT RECONDITIONING·········· 12-10
12

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CYLINDER HEAD
TOOLS
CYLINDER HEAD

Valve seat cutter, 45° 24.5 mm (EX) Valve seat cutter, 45° 27.5 mm (IN) Valve seat cutter, 45° 32 mm (EX)
07780-0010100 07780-0010200 07780-0012000

Valve seat cutter, 32° 28 mm (IN) Valve seat cutter, 60° 30 mm (IN/EX) Cutter holder, 5.5 mm
07780-0012100 07780-0014000 07781-0010101

Valve guide driver Valve guide reamer, 5.510 mm

07942-8920000 07984-2000001

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CYLINDER HEAD
CYLINDER HEAD
REMOVAL/INSTALLATION
Set the piston at top dead center of the cylinder compression stroke (page
3-7).
Remove the following:
– Fan cover (page 5-2)
– Carburetor (page 6-5)
– Control base (page 7-2)
– Muffler (page 14-2)
After installation, inspect following:
– Valve clearance (page 3-7)
– Cylinder compression (page 12-5)

(Threads and seating surface)

BOLT (8 x 60 mm) (4)
24 N·m (2.4 kgf·m, 18 lbf·ft)
REMOVAL/INSTALLATION:
CYLINDER HEAD COVER PACKING Loosen and tighten the bolts in a
crisscross pattern in 2 – 3 steps.

CYLINDER HEAD COVER

PUSH ROD (2)

BOLT (6 x 12 mm) (4)

CYLINDER HEAD

BOLT (6 x 12 mm) (2)

SHROUD

CYLINDER HEAD GASKET

DOWEL PIN (2)

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CYLINDER HEAD
CYLINDER HEAD
DISASSEMBLY/ASSEMBLY
Remove the cylinder head (page 12-3).

INTAKE/EXHAUST VALVE SPRING RETAINER

(Sliding surface and stem end)
REMOVAL:
EXHAUST VALVE
Push down and slide the valve spring [1]
retainer [1] to the side so that the valve INSTALLATION:
stem [2] slips through the hole at the side Do not interchange with the
of the valve spring retainer. intake valve.
Do not remove the valve spring retainer The exhaust valve is smaller
while the cylinder head is installed to the than the intake valve.
cylinder barrel, or the valve will drop into
the cylinder. SPARK PLUG
[2]
INSTALLATION: 18 N·m (1.8 kgf·m, 13 lbf·ft)
The exhaust valve retainer has a larger
center recess than the intake valve
retainer, so it can accept the valve rotator.

EXHAUST VALVE GUIDE CYLINDER HEAD

INTAKE VALVE GUIDE

VALVE GUIDE CLIP

VALVE ROTATOR
(Exhaust valve only)
INSTALLATION:
If the valve
rotator is not
installed, the (Sliding surface
exhaust valve and stem end)
may drop into INTAKE VALVE
the cylinder INSTALLATION:
when starting Do not interchange
the engine. with the exhaust
valve.
VALVE STEM SEAL The intake valve is
larger than the
exhaust valve.

PUSH ROD GUIDE PLATE

VALVE SPRING (2)

ROCKER ARM PIVOT BOLT (2)

24 N·m (2.4 kgf·m, 18 lbf·ft)

(Threads and pivot) VALVE ROCKER ARM (2) (Tappet surface and pivot)
ROCKER ARM PIVOT (2) INSTALLATION:
Before installing the rocker arm, check for wear on the surfaces of
LOCK NUT (2) the rocker arm that contact the pivot bolt, push rod, and valve stem.
10 N·m (1.0 kgf·m, 7 lbf·ft)

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CYLINDER HEAD
CYLINDER HEAD/VALVES
INSPECTION
CYLINDER COMPRESSION CHECK
Start the engine and warm up to normal operating
[1]
temperature.
Turn off the engine stop switch to stop the engine.
Turn the fuel valve lever to the OFF position, and then
loosen the drain screw of the carburetor to drain the fuel
completely (page 6-3).
Remove the spark plug (page 3-6).
Pull the recoil starter several times to expel unburned
gas.
Attach a commercially available compression gauge [1]
to the spark plug hole.
Pull the recoil starter forcefully to measure stable
cylinder compression.
CYLINDER 0.49 - 0.69 MPa
COMPRESSION: (5.0 - 7.0 kgf/cm2, 71 - 100 psi)/
600 min-1 (rpm)

CYLINDER HEAD WARPAGE

Check the spark plug hole and valve areas for cracks.
[1]
Clean any gasket material from the cylinder head
[2]
mating surface and check the cylinder head warpage
using a straightedge [1] and thickness gauge [2].

Be careful not the damage the mating surface.

SERVICE LIMIT: 0.10 mm (0.004 in)
If the measurement is more than the service limit,
replace the cylinder head (page 12-4).

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CYLINDER HEAD
VALVE SEAT WIDTH
Remove the carbon deposits from the combustion
VALVE LAPPER
chamber (page 3-9).
(Commercially available)
Inspect each valve face for irregularities.
If necessary, replace the valve (page 12-4).
Apply a light coat of Prussian Blue or erasable felt-
tipped marker ink to each valve seat.
Insert the valve, and snap it closed against its seat
several times. Be sure the valve does not rotate on the
seat.
The transferred marking compound will show any area
of the valve face that is not concentric.
Measure the valve seat width of the cylinder head.
STANDARD:
IN/EX: 0.70 – 0.90 mm (0.028 – 0.035 in)
SERVICE LIMIT:
IN/EX: 2.0 mm (0.08 in)
If the measurement is more than the service limit,
recondition the valve seat (page 12-10).
Check whether the valve seat contact area of the valve TOO LOW
is too high.
If the valve seat is too high or too low, recondition the
valve seat (page 12-10). VALVE SEAT
WIDTH

TOO HIGH

VALVE GUIDE I.D.

Ream the valve guide to remove any carbon deposits
[2] HANDLE
before measuring the guide I.D. [1].
(Commercially
TOOL: available)
Valve guide reamer 5.510 mm [2] 07984-2000001

• Turn the valve guide reamer (special tool) clockwise,

never counterclockwise.
• Continue to rotate the special tool while removing it
[1]
from the valve guide.

Measure and record each valve guide I.D.

STANDARD: 5.500 – 5.512 mm (0.2165 – 0.2170 in)

SERVICE LIMIT: 5.572 mm (0.2194 in)

If the measured valve guide I.D. is more than the
service limit, replace the valve guide (page 12-8).

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CYLINDER HEAD
VALVE FACE/VALVE STEM O.D.
Inspect each valve face [1] for irregularities.
[2]
If necessary, replace the valve.
Inspect each valve [2] for bending or abnormal stem
wear.
If necessary, replace the valve (page 12-4).
Measure and record each valve stem O.D.
STANDARD:
IN: 5.468 – 5.480 mm (0.2153 – 0.2157 in)
EX: 5.425 – 5.440 mm (0.2136 – 0.2142 in)

SERVICE LIMIT:
IN: 5.318 mm (0.2094 in) [1]
EX: 5.275 mm (0.2077 in)
If the measurement is less than the service limit,
replace the valve (page 12-4).

GUIDE-TO-STEM CLEARANCE
Subtract each valve stem O.D. from the corresponding
guide I.D. to obtain the guide-to-stem clearance.
STANDARD:
IN: 0.020 – 0.044 mm (0.0008 – 0.0017 in)
EX: 0.060 – 0.087 mm (0.0024 – 0.0034 in)

SERVICE LIMIT:
IN: 0.10 mm (0.004 in)
EX: 0.12 mm (0.005 in)
If the calculated clearance is more than the service limit,
replace the valve and valve guide as a set (page 12-8).

VALVE SPRING FREE LENGTH/

PERPENDICULARITY
Measure the valve spring free length.

STANDARD: 30.5 mm (1.20 in)

SERVICE LIMIT: 29.0 mm (1.14 in)

If the measured length is less than the service limit,
replace the valve spring (page 12-4).
Measure the valve spring perpendicularity.
SERVICE LIMIT: 1.5° max.
If the measured perpendicularity is more than the
service limit, replace the valve spring (page 12-4).

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CYLINDER HEAD
PUSH ROD RUNOUT
Check both ends of the push rod for wear.
Check the push rod for straightness.
If necessary, replace the push rod (page 12-3).

VALVE GUIDE REPLACEMENT

Chill the replacement valve guides in the freezer
section of a refrigerator for about an hour.
Use a hot plate or oven to heat the cylinder head evenly
to 150°C (302°F).

To avoid burns, use heavy gloves when handling

the heated cylinder head.

• Do not use a torch to heat the cylinder head;

warpage of the cylinder head may result.
• Do not get the cylinder head hotter than 150°C
(302°F); excessive heat may loosen the valve seat.

Remove the heated cylinder head from the hot plate

and support it with wooden blocks. [2]

Drive the valve guides [1] out of the cylinder head from
the combustion chamber side.
TOOL:
Valve guide driver [2] 07942-8920000

When driving the valve guides out, be careful not to

damage the cylinder head.

[1]

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CYLINDER HEAD
Remove the new valve guides [1] from the refrigerator
IN: [2] EX:
one at a time as needed.
Install the valve guides from the valve spring side of the
cylinder head.
TOOL:
Valve guide driver [2] 07942-8920000
Drive the exhaust valve guide until new valve guide clip
[3]
[3] is fully seated as shown.
Drive the intake valve guide to the specified height
(measured from the end of the valve guide to the
cylinder head as shown).
IN VALVE INSTALLATION HEIGHT: [1]
4.8 – 5.2 mm (0.19 – 0.20 in)
After installing the valve guide, check the guide for
damage.
Replace the valve guide if damaged.
Let the cylinder head cool to room temperature.
Ream the valve guide (page 12-9).

VALVE GUIDE REAMING

For best results, be sure the cylinder head is at room
HANDLE
temperature before reaming valve guides.
(Commercially
Coat the reamer and valve guide with cutting oil. available)
TOOL:
Valve guide reamer 5.510 mm [1] 07984-2000001
Rotate the reamer clockwise through the valve guide COMBUSTION
the full length of the reamer. CHAMBER SIDE [1]

• Turn the special tool (valve guide reamer) clockwise,

never counterclockwise.
• Continue to rotate the special tool while removing it VALVE SPRING SIDE
from the valve guide.
Thoroughly clean the cylinder head to remove any
cutting residue.
Check the valve guide bore; it should be straight, round,
and centered in the valve guide. Insert the valve and
check operation. If the valve does not operate
smoothly, the guide may have been bent during
installation.
Replace the valve guide if it is bent or damaged (page
12-8).
Check the valve guide-to-stem clearance (page 12-7).

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CYLINDER HEAD
VALVE SEAT RECONDITIONING
Inspect the valve seat contact area (page 12-6).
Using a 45° seat cutter, remove any roughness or
irregularities from the seat. 45°

If the contact area is too low on the valve, the seat must
be raised using a 60° interior cutter. TOO LOW

If the contact area is too high on the valve, the seat 60°
must be lowered using a 32° flat cutter.

TOO HIGH

32°

Valve seat cutters [1]/grinder or equivalent valve seat

refacing equipment is recommended to correct a worn
valve seat.

• Turn the cutter clockwise, never counterclockwise.

• Continue to turn the cutter as you lift it from the valve
seat.
TOOLS:
Cutter holder, 5.5 mm 07781-0010101
Valve seat cutter, 45° 27.5 mm (IN) 07780-0010200
Valve seat cutter, 45° 24.5 mm (EX) 07780-0010100
Valve seat cutter, 32° 28 mm (IN) 07780-0012100 [1]
Valve seat cutter, 32° 25 mm (EX) 07780-0012000
Valve seat cutter, 60° 30 mm (IN/EX) 07780-0014000
Make a light pass with the 45° cutter to remove any
possible burrs at the edge of the seat.
Be sure that the width of the finished valve seat is within
specification.
STANDARD:
IN/EX: 0.70 – 0.90 mm (0.028 – 0.035 in)

45°

Lap the valves into their seats, using a commercially

VALVE LAPPER
available valve lapper and lapping compound.
(Commercially available)
After lapping, wash all residual compound off the
cylinder head and valve.

• Do not push the valve against the seat with force

during lapping. Apply a light pass with the valve
lapper.
• Avoid lapping the valve in the same position as it
causes uneven wear. Lap the valve by turning the
lapper slowly.
• Take care not to allow the lapping compound to
enter the gap between the stem and guide.

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13. CRANKCASE

TOOLS ·············································· 13-2 PISTON

DISASSEMBLY/ASSEMBLY·················· 13-5
CRANKCASE COVER
REMOVAL/INSTALLATION ··················· 13-3 CRANKCASE COVER/CYLINDER BARREL/
PISTON/CONNECTING ROD/CRANKSHAFT/
CRANKSHAFT/PISTON CAMSHAFT INSPECTION····················· 13-6
REMOVAL/INSTALLATION ··················· 13-4
CRANKSHAFT BEARING/OIL SEAL
REPLACEMENT ································· 13-13

13

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CRANKCASE
TOOLS
CRANKCASE

Attachment, 37 × 40 mm Attachment, 52 × 55 mm Pilot, 25 mm

07746-0010200 07746-0010400 07746-0040600

Driver
07749-0010000

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CRANKCASE
CRANKCASE COVER
REMOVAL/INSTALLATION
Drain the engine oil (page 3-3).
Remove the casing cover (page 10-5).

DOWEL PIN (2)

CASE COVER PACKING

OIL FILLER CAP

OIL FILLER CAP

(With oil level gauge)

OIL FILLER CAP PACKING (2)

CHECK:
Replace if necessary.
BOLT (8 x 32 mm) (6)
24 N·m (2.4 kgf·m, 18 lbf·ft)

CRANKCASE COVER
INSTALLATION:
Be careful not to damage the oil seal lips.

13-3
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CRANKCASE
CRANKSHAFT/PISTON
REMOVAL/INSTALLATION
Remove the following:
– Fuel tank (page 6-3)
– Flywheel (page 8-5)
– Cylinder head (page 12-3)
– Crankcase cover (page 13-3)

PISTON (Outer surface and big end bearing)

INSTALLATION:
Install the piston Assy. to the cylinder barrel with the mark
[1] on the piston head toward the push rod hole [2] of the
cylinder head.
VALVE LIFTER (2)
[1] (Pivot, pivot end and slipper surface)
[2] REMOVAL:
Mark the valve lifters so that the
intake and exhaust sides can be
distinguished.
INSTALLATION:
Attach the valve lifters to the
cylinder barrel immediately before
installing the camshaft.

CYLINDER BARREL
(Cylinder inner surface)

CONNECTING ROD LOWER

(Big end bearing)
INSTALLATION:
Set the connecting rod lower with
the oil dipper toward the camshaft. CAMSHAFT
(Cam journal and profile)
INSTALLATION:
Install the timing gear [1] of the
crankshaft and camshaft [2] by
aligning the punch marks [3].

[3]
CONNECTING ROD BOLT (2)
(Threads and seating surface) CRANKSHAFT
12 N·m (1.2 kgf·m, 9 lbf·ft) (Pin and gear teeth)
INSTALLATION:
Be careful not to damage the oil seal lips.
[1] [2]

13-4
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CRANKCASE
PISTON
DISASSEMBLY/ASSEMBLY
Remove the piston. (page 13-4).

MAKER MARK
PISTON RING SET (Entire surface)
INSTALLATION: TOP RING
To install the oil ring, install the spacer [1] first,
and then install the side rails [2].
Be sure that the top ring [3] and second ring [4]
are not interchanged.
Install the top ring and second ring on the piston
with the maker mark side facing up.
Check that the piston rings rotate smoothly after
installing them. 120° SECOND RING
Space the piston ring end gaps 120° apart, and 120°
do not align the ring end gaps with the piston pin 120°
bore.
SIDE RAIL
[3]

[4] 10 mm (0.4 in)

OIL RING
[2] (COMBINATION RING)

SPACER
[1]
10 mm (0.4 in) SIDE RAIL
[2]

PISTON PIN
(Outer surface)

MARK

PISTON

PISTON PIN CLIP (2)

INSTALLATION:
Install by setting one end of the piston pin
clip in the groove of the piston pin bore,
holding the other end with long needle nose CONNECTING ROD UPPER
pliers, and rotating the clip in. (Small end bearing)
Do not align the end gap [1] of the piston pin
INSTALLATION:
clip with the cutout [2] of the piston pin bore.
Set the connecting rod upper with
[1] the long end toward the mark on
the piston head.

LONG END

[2]

13-5
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CRANKCASE
CRANKCASE COVER/CYLINDER
BARREL/PISTON/CONNECTING ROD/
CRANKSHAFT/CAMSHAFT
INSPECTION
CAMSHAFT HOLDER I.D.
CRANKCASE COVER SIDE
Measure the camshaft holder I.D. of the crankcase
cover.
STANDARD: 14.000 – 14.018 mm (0.5512 – 0.5519 in)

SERVICE LIMIT: 14.048 mm (0.5531 in)

If the measurement is more than the service limit,
replace the crankcase cover (page 13-3).
Inspect the camshaft O.D. (page 13-12).

CYLINDER BARREL SIDE

Measure the camshaft holder I.D. of the cylinder barrel
assembly.

STANDARD: 14.000 – 14.018 mm (0.5512 – 0.5519 in)

SERVICE LIMIT: 14.048 mm (0.5531 in)

If the measurement is more than the service limit,
replace the cylinder barrel (page 13-4).
Inspect the camshaft O.D. (page 13-12).

CYLINDER SLEEVE I.D.

Measure and record the cylinder I.D. at three levels in
both the "X" axis (perpendicular to crankshaft) and the
"Y" axis (parallel to crankshaft). Take the maximum X
reading to determine cylinder wear and taper.

STANDARD: 68.000 – 68.015 mm Y TOP

(2.6772 – 2.6778 in)
SERVICE LIMIT: 68.165 mm (2.6837 in)
MIDDLE
If the measurement is more than the service limit,
replace the cylinder barrel (page 13-4).
Inspect the piston skirt O.D. (page 13-7). BOTTOM

13-6
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CRANKCASE
PISTON SKIRT O.D.
Measure and record the piston O.D. at a point 10 mm
(0.4 in) from the bottom of the skirt and 90° to the 90°
piston pin bore.

STANDARD: 67.965 – 67.985 mm

(2.6758 – 2.6766 in)
SERVICE LIMIT: 67.845 mm (2.6711 in)
If the measurement is less than the service limit,
replace the piston (page 13-5).
Inspect the cylinder sleeve I.D. (page 13-6).

10 mm
(0.4 in)

PISTON-TO-CYLINDER CLEARANCE
Subtract the piston skirt O.D. from the cylinder sleeve
I.D. to obtain the piston-to-cylinder clearance.

STANDARD: 0.015 – 0.050 mm

(0.0006 – 0.0020 in)
SERVICE LIMIT: 0.12 mm (0.005 in)
If the calculated clearance is more than the service
limit, replace the piston (page 13-5) and recheck the
clearance.
If the clearance is still more than the service limit with
the new piston, replace the cylinder barrel (page 13-4).

PISTON PIN BORE I.D.

Measure and record the piston pin bore I.D. of the
piston.
STANDARD: 18.002 – 18.008 mm
(0.7087 – 0.7090 in)
SERVICE LIMIT: 18.048 mm (0.7105 in)
If the measurement is less than the service limit,
replace the piston (page 13-5).
Inspect the piston pin O.D. (page 13-8).

13-7
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CRANKCASE
PISTON PIN O.D.
Measure and record the piston pin O.D. at three points
(both ends and middle). Take the minimum reading to
determine piston pin O.D.
STANDARD: 17.994 – 18.000 mm
(0.7084 – 0.7087 in)
SERVICE LIMIT: 17.954 mm (0.7068 in)
If the measurement is less than the service limit,
replace the piston pin (page 13-5).
Inspect the piston pin bore I.D. (page 13-7).
Inspect the connecting rod small end I. D. (page 13-10).

PISTON PIN-TO-PISTON PIN BORE

CLEARANCE
Subtract the piston pin O.D. from the piston pin bore
I.D. to obtain the piston pin-to-piston pin bore
clearance.
STANDARD: 0.002 – 0.014 mm (0.0001 – 0.0006 in)

SERVICE LIMIT: 0.08 mm (0.003 in)

If the calculated clearance is more than the service limit,
replace the piston pin (page 13-5) and recheck the
clearance.
If the clearance is still more than the service limit with
the new piston pin, replace the piston (page 13-5).

PISTON RING SIDE CLEARANCE

Measure the clearance between each piston ring and
ring groove of the piston using a feeler gauge.

STANDARD:
Top: 0.035 – 0.070 mm (0.0014 – 0.0028 in)
Second: 0.045 – 0.080 mm (0.0018 – 0.0032 in)
SERVICE LIMIT:
Top: 0.15 mm (0.006 in)
Second: 0.15 mm (0.006 in)
If any of the measurements is more than the service
limit, inspect the piston ring width (page 13-9).
If the piston ring width is normal, replace the piston
(page 13-5) and reinspect the clearance.
If necessary, replace the piston rings (top, second, oil)
as a set and reinspect the clearance.
If any of the measurements is still more than the service
limit with the new piston rings, replace the piston (page
13-5).

13-8
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CRANKCASE
PISTON RING WIDTH
Measure each piston ring width.

STANDARD:
Top: 0.950 – 0.970 mm (0.0374 – 0.0382 in)
Second: 0.940 – 0.960 mm (0.0370 – 0.0378 in)
SERVICE LIMIT:
Top: 0.93 mm (0.037 in)
Second: 0.92 mm (0.036 in)
If any of the measurements is less than the service
limit, replace the piston rings (top, second, oil) as a set
(page 13-5).

PISTON RING END GAP

Before inspection, check whether the cylinder sleeve
I.D. is within the specification (page 13-6).
Measure each piston ring [1] end gap using a feeler
gauge.
STANDARD:
Top: 0.200 – 0.350 mm
(0.0079 – 0.0138 in)
Second: 0.350 – 0.500 mm
(0.0138 – 0.0197 in)
Oil (side rail): 0.20 – 0.70 mm
(0.008 – 0.028 in)
SERVICE LIMIT:
Top: 1.0 mm (0.04 in) [1]
Second: 1.0 mm (0.04 in)
Oil (side rail): 1.0 mm (0.04 in)
If any of the measurements is more than the service
limit, replace the piston rings (top, second, oil) as a set
(page 13-5).

CONNECTING ROD BIG END SIDE

CLEARANCE
Measure the clearance between the connecting rod big
end and crankshaft using a feeler gauge.
STANDARD: 0.1 – 0.4 mm (0.004 – 0.016 in)

SERVICE LIMIT: 1.1 mm (0.04 in)

If the measurement is more than the service limit,
replace the connecting rod (page 13-5) and recheck the
clearance.
If the clearance is still more than the service limit with
the new connecting rod, replace the crankshaft (page
13-4).

13-9
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CRANKCASE
CONNECTING ROD SMALL END I.D.
Measure the connecting rod small end I.D.
STANDARD: 18.005 – 18.020 mm
(0.7089 – 0.7094 in)
SERVICE LIMIT: 18.07 mm (0.711 in)
If the measurement is more than the service limit,
replace the connecting rod (page 13-5).
Inspect the piston pin O.D. (page 13-8).

CONNECTING ROD BIG END I.D.

Set the connecting rod lower to the connecting rod
upper and tighten the connecting rod bolts to the
specified torque.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Measure the connecting rod big end I.D.
STANDARD: 30.020 – 30.033 mm
(1.1819 – 1.1824 in)
SERVICE LIMIT: 30.066 mm (1.1837 in)
If the measurement is more than the service limit,
replace the connecting rod (page 13-5).

CRANK PIN O.D.

Measure the crank pin O.D. of the crankshaft.

STANDARD: 29.970 – 29.980 mm

(1.1799 – 1.1803 in)
SERVICE LIMIT: 29.92 mm (1.178 in)
If the measurement is less than the service limit,
replace the crankshaft (page 13-4).

13-10
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CRANKCASE
CONNECTING ROD BIG END OIL
CLEARANCE
Clean all oil from the crank pin and connecting rod big
end surface.
Place a piece of plastigauge on the crank pin, install the
connecting rod upper and the connecting rod lower, and
tighten the connecting rod bolts to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Do not rotate the crankshaft while the plastigauge is in

place.

Remove the connecting rod and measure the

plastigauge.
STANDARD: 0.040 – 0.063 mm (0.0016 – 0.0025 in)

SERVICE LIMIT: 0.12 mm (0.005 in)

If the clearance is more than the service limit, inspect
the connecting rod big end I.D. (page 13-10) and the
crank pin O.D.
If necessary replace the part that is not within the
service limit and reinspect the clearance.

CRANKSHAFT RUNOUT
Set the crankshaft on V-blocks and measure the runout
using a dial indicator.

SERVICE LIMIT: 0.10 mm (0.004 in)

If the measured runout is more than the service limit,
replace the crankshaft.

15.0 mm (0.59 in) 14.0 mm (0.55 in)

13-11
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CRANKCASE
CAMSHAFT CAM HEIGHT
Measure the cam height of the camshaft.

STANDARD:
IN/EX: 27.603 – 27.703 mm (1.0867 – 1.0907 in)
SERVICE LIMIT:
IN/EX: 27.450 mm (1.0807 in)
If the measurement is less than the service limit,
replace the camshaft (page 13-4).

CAMSHAFT O.D.
Measure the O.D. of the camshaft.

STANDARD: 13.966 – 13.984 mm (0.5498 – 0.5506 in)

SERVICE LIMIT: 13.916 mm (0.5479 in)

If the measurement is less than the service limit,
replace the camshaft (page 13-4).

DECOMPRESSOR WEIGHT
Check for worn and weakened spring.
If the return spring [1] is worn or weakened, replace the
weight return spring.
Check that the decompressor weight moves smoothly.
If the decompressor weight does not move correctly,
replace the camshaft (page 13-4).

[1]

13-12
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CRANKCASE
CRANKSHAFT BEARING
Turn the inner race of the bearing with your finger and
check for play.
Replace the bearing if it is noisy or has excessive play.

CRANKSHAFT BEARING/OIL SEAL

REPLACEMENT
CRANKSHAFT BEARING
CRANKCASE SIDE/CYLINDER BARREL SIDE
Remove the oil seal and drive out the crankshaft
bearing. [4]

Drive a new crankshaft bearing [1] until it is fully seated

on the end using the special tools.
TOOLS:
Attachment, 52 x 55 mm [2] 07746-0010400 [1]
Pilot, 25 mm [3] 07746-0040600
Driver [4] 07749-0010000 [2]

[3]

13-13
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CRANKCASE
CRANKSHAFT OIL SEAL
CRANKCASE SIDE
Remove the oil seal.
[3]
Drive a new oil seal [1] in the position as shown using
the special tools.
INSTALLATION HEIGHT: 5.5 mm (0.22 in)
[1]
TOOLS: [2]
Attachment, 37 x 40 mm [2] 07746-0010200
Driver [3] 07749-0010000
CYLINDER BARREL SIDE
Remove the oil seal.
Drive a new oil seal [1] in the position as shown using
the special tools.
INSTALLATION HEIGHT: 1.5 mm (0.06 in)

TOOLS:
Attachment, 37 x 40 mm [2] 07746-0010200
Driver [3] 07749-0010000

13-14
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14. MUFFLER

MUFFLER REMOVAL/INSTALLATION···· 14-2 EXHAUST PIPE STUD BOLT

REPLACEMENT ·································· 14-3

14

14-1
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MUFFLER
MUFFLER REMOVAL/INSTALLATION
MUFFLER

The muffler becomes very hot during operation and

remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot.
Allow it to cool before proceeding.

SCREW (5 x 8 mm) (4)

MUFFLER PROTECTOR

MUFFLER

NUT (8 mm) (2)

24 N·m (2.4 kgf·m, 18 lbf·ft)

EXHAUST PIPE GASKET

14-2
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MUFFLER
EXHAUST PIPE STUD BOLT
REPLACEMENT
Remove the muffler (page 14-2).
Thread two nuts onto the exhaust pipe stud bolt [1] and
tighten them together, and then use a wrench to turn [1] SPECIFIED LENGTH
the stud bolt out.
Install and tighten the new stud bolts until they are the
specified length.
SPECIFIED LENGTH: 15 mm (0.6 in)

14-3
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MEMO
82YG7500.book 1 ページ ２０１３年１２月１７日 火曜日 午後１時４０分

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15. WIRING DIAGRAMS

WITHOUT OIL LEVEL SWITCH AND WITH OIL LEVEL SWITCH AND
OIL ALERT UNIT ································· 15-2 OIL ALERT UNIT ································· 15-2

15

15-1
82YG7500.book 2 ページ ２０１３年１２月１７日 火曜日 午後１時４０分

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WIRING DIAGRAMS
WITHOUT OIL LEVEL SWITCH AND
WIRING DIAGRAMS

OIL ALERT UNIT

Bl
Bl

ENGINE STOP SWITCH

IG E
OFF
ON

Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light blue
SPARK PLUG IGNITION COIL ENGINE STOP SWITCH G Green Lg Light green
R Red P Pink
W White Gr Gray

WITH OIL LEVEL SWITCH AND

OIL ALERT UNIT

Bl
Bl

ENGINE STOP SWITCH

IG E
Bl

OFF
ON

Bl Black Br Brown
Y Yellow O Orange
Bu Blue Lb Light blue
SPARK PLUG IGNITION COIL ENGINE STOP SWITCH OIL ALERT UNIT OIL LEVEL SWITCH G Green Lg Light green
R Red P Pink
W White Gr Gray

15-2
82YG7500.book 1 ページ ２０１３年１２月１７日 火曜日 午後１時４０分

INDEX
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INDEX
AIR CLEANER CHECK/CLEANING/REPLACEMENT···3-4 INLET PIPE/OUTLET PIPE
A

AIR CLEANER REMOVAL/INSTALLATION ················6-4 REMOVAL/INSTALLATION··································· 10-3

BEFORE TROUBLESHOOTING ······························4-2 LUBRICATION & SEAL POINTS ······························2-4
B L

CARBURETOR BODY CLEANING ···························6-7 MAINTENANCE SCHEDULE···································3-2

C M

CARBURETOR DISASSEMBLY/ASSEMBLY··············6-6 MAINTENANCE STANDARDS ································2-2

CARBURETOR INSPECTION ·································6-7 MAXIMUM SPEED ADJUSTMENT ···························7-6
CARBURETOR REMOVAL/INSTALLATION ···············6-5 MECHANICAL SEAL REPLACEMENT ···················· 10-6
CARBURETOR STUD BOLT REPLACEMENT············6-9 MUFFLER REMOVAL/INSTALLATION···················· 14-2
CASING/VOLUTE CASE OIL ALERT UNIT INSPECTION
O

REMOVAL/INSTALLATION ··································· 10-4 (IF EQUIPPED)··················································· 8-11

CHOKE REPLACEMENT········································6-9 OIL ALERT UNIT REMOVAL/INSTALLATION
COMBUSTION CHAMBER CLEANING ·····················3-9 (IF EQUIPPED)·····················································8-8
CONTROL BASE DISASSEMBLY/ASSEMBLY ···········7-3 OIL LEVEL SWITCH INSPECTION
COOLING FAN/FLYWHEEL (IF EQUIPPED)··················································· 8-10
REMOVAL/INSTALLATION ·····································8-5 OIL LEVEL SWITCH REMOVAL/INSTALLATION
CRANKCASE COVER REMOVAL/INSTALLATION···· 13-3 (IF EQUIPPED)·····················································8-7
CRANKCASE COVER/CYLINDER BARREL/PISTON/ PERFORMANCE CURVES ·····································1-4
P

CONNECTING ROD/CRANKSHAFT/CAMSHAFT PILOT SCREW REPLACEMENT······························6-8

INSPECTION ····················································· 13-6 PISTON DISASSEMBLY/ASSEMBLY ····················· 13-5
CRANKSHAFT BEARING/OIL SEAL PUMP INLET VALVE CHECK································ 3-12
REPLACEMENT ··············································· 13-13 RECOIL STARTER DISASSEMBLY/ASSEMBLY·········9-3
R

CRANKSHAFT/PISTON RECOIL STARTER INSPECTION ····························9-5

REMOVAL/INSTALLATION ··································· 13-4 RECOIL STARTER REMOVAL/INSTALLATION ··········9-2
CYLINDER HEAD DISASSEMBLY/ASSEMBLY ········ 12-4 SEDIMENT CUP CLEANING···································3-6
S

CYLINDER HEAD REMOVAL/INSTALLATION·········· 12-3 SERIAL NUMBER LOCATION ·································1-2

CYLINDER HEAD/VALVES INSPECTION················ 12-5 SPARK PLUG CAP INSPECTION ····························8-9
DIMENSIONAL DRAWINGS····································1-5 SPARK PLUG CHECK/ADJUSTMENT ······················3-5
D

ENGINE OIL LEVEL CHECK/CHANGE ·····················3-3 SPARK PLUG REPLACEMENT ·······························3-6

E

ENGINE REMOVAL/INSTALLATION ······················ 11-2 SPARK TEST ·······················································8-9

ENGINE STOP SWITCH INSPECTION ··················· 8-11 SPECIFICATIONS·················································1-2
ENGINE STOP SWITCH REMOVAL/INSTALLATION···8-7 SYSTEM DIAGRAM
ENGINE TROUBLESHOOTING ·······························4-2 IGNITION SYSTEM ···········································8-2
EXHAUST PIPE STUD BOLT REPLACEMENT········· 14-3 TOOLS
T

FAN COVER REMOVAL/INSTALLATION ··················5-2 CRANKCASE ················································· 13-2

F

FUEL TANK AND FILTER CLEANING·······················3-9 CYLINDER HEAD ··········································· 12-2

FUEL TANK REMOVAL/INSTALLATION ···················6-3 FUEL SYSTEM ·················································6-2
FUEL TUBE CHECK ············································ 3-10 PUMP ··························································· 10-2
GOVERNOR ADJUSTMENT ···································7-4
G

SERVICE INFORMATION···································2-5 16
GOVERNOR ARM/CONTROL BASE TORQUE VALUES ················································2-3
REMOVAL/INSTALLATION ·····································7-2 VALVE CLEARANCE CHECK/ADJUSTMENT ············3-7
V

GOVERNOR DISASSEMBLY/ASSEMBLY ·················7-5 VALVE GUIDE REAMING····································· 12-9

HARNESS AND TUBE ROUTING ····························2-7 VALVE GUIDE REPLACEMENT ···························· 12-8
H

IDLE SPEED CHECK/ADJUSTMENT························3-7 VALVE SEAT RECONDITIONING ························ 12-10

I

IGNITION COIL AIR GAP CHECK/ADJUSTMENT ·······8-8 WATER PUMP TROUBLESHOOTING ······················4-6
W

IGNITION COIL INSPECTION ······························· 8-10 WIRING DIAGRAMS

IGNITION COIL REMOVAL/INSTALLATION···············8-4 WITH OIL LEVEL SWITCH AND
IGNITION SYSTEM TROUBLESHOOTING ················8-3 OIL ALERT UNIT············································· 15-2
IMPELLER CHECK ············································· 3-10 WITHOUT OIL LEVEL SWITCH AND
IMPELLER CLEARANCE CHECK ·························· 3-11 OIL ALERT UNIT············································· 15-2
IMPELLER/CASING COVER
REMOVAL/INSTALLATION ··································· 10-5

16-1