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DISASSEMBLY, REASSEMBLY, INSPECTION, AND MAINTENANCE 3-1
Disassembly, Reassembly, Inspection, and Maintenance
Table of Contents
3
Carburetor....................................................................3-2
Construction and Function...................................3-2
Disassembly, Cleaning, and Reassembly Precau-
tions......................................................................3-3
Adjustment............................................................3-4
Carburetor with Fuel Cutoff Valve........................3-6
Governor Mechanism..................................................3-7
Governor Operating Mechanism..........................3-7
Governor Gear Assembly Installation...................3-8
Governor Arm Installation (Setting the Governor)3-8
Air Cleaner.................................................................3-10
Element Cleaning...............................................3-10
Cooling System.........................................................3-11
Fuel Tank and Filter...................................................3-12
Ignition System..........................................................3-13
Description of Function.......................................3-13
Spark Inspection.................................................3-14
Spark Plug Cleaning and Inspection..................3-14
Ignition Coil Inspection.......................................3-15
Igniter Inspection................................................3-16
Flywheel Disassembly and Reassembly............3-17
Ignition Coil Reassembly (Air Gap Adjustment).3-18
Key Switch (engine switch) Inspection...............3-18
Charging System.......................................................3-19
Charging System Inspection...............................3-19
ACG Inspection...................................................3-19
Rectifier Inspection.............................................3-19
Regulator Inspection...........................................3-20
Starter System...........................................................3-21
Starter Motor Construction.................................3-21
Solenoid (Starter Motor) Wiring Inspection........3-22
Starter Motor Inspection.....................................3-23
Recoil Starter.............................................................3-25
Disassembly........................................................3-25
Reassembly........................................................3-25
Cylinder Head............................................................3-26
Compression Inspection.....................................3-26
Disassembly........................................................3-26
Cleaning and Inspection.....................................3-27
Reassembly........................................................3-27
Valve System.............................................................3-28
Hydraulic Lash Adjuster (HLA)...........................3-28
Valve Clearance Inspection and Adjustment......3-31
Automatic Compression Release (ACR) Device In-
spection..............................................................3-32
Valve Disassembly and Reassembly..................3-32
Valve Guide Inspection.......................................3-33
Valve Inspection..................................................3-33
Valve Spring Inspection......................................3-34
Valve Seat Inspection and Lapping....................3-35
Valve Seat Correction.........................................3-35
Rocker Arm and Rocker Shaft............................3-36
Pushrod Inspection.............................................3-36
Piston and Connecting Rod......................................3-37
Disassembly........................................................3-37
Reassembly........................................................3-37
Piston Inspection................................................3-39
Piston Pin Inspection..........................................3-40
Piston Ring Inspection........................................3-40
Connecting Rod Inspection................................3-41
Cylinder Block and Crankcase Cover.......................3-43
Cylinder Inspection.............................................3-43
Crankcase Cover................................................3-43
Ball Bearing........................................................3-44
Oil Seal...............................................................3-45
Plain Bearing Area Inspection............................3-45
Lubrication System....................................................3-46
Lubrication Method.............................................3-46
Oil Pump Disassembly and Reassembly...........3-47
Oil Pump Inspection...........................................3-48
Oil Level Warning Device...................................3-49
Breather..............................................................3-52
Air Filter (cartridge type).....................................3-52
Crankshaft.................................................................3-54
Disassembly........................................................3-54
Crankshaft Inspection.........................................3-55
Crankshaft Axial Play Adjustment......................3-55
Reassembly........................................................3-56
Balancer.....................................................................3-57
Reciprocal Movement Balancer (FE400, 350, 290,
250).....................................................................3-58
Uniaxial Rotation Balancer (FE170)...................3-59
Camshaft...................................................................3-61
Disassembly........................................................3-61
Inspection........................................................... 3-61
Reassembly........................................................3-62
Camshaft Axial Play Adjustment........................3-63