Scag Power Equipment STT-791DFI Manuel de service

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FD671D/FD711D
FD750D
FD791D (DFI)
4–stroke liquid-cooled v-twin gasoline engine
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of
Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such
changes to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.
© Kawasaki Heavy Industries, Ltd., 2000, 2001 Forth Edition (1) : Jul. 10, 2001 (K)
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Résumé du contenu

Page 1 - Service Manual

FD671D/FD711DFD750DFD791D (DFI)4–stroke liquid-cooled v-twin gasoline engineService ManualAll rights reserved. No parts of this publication may be rep

Page 2 - LIST OF ABBREVIATIONS

1-6 GENERAL INFORMATIONGeneral SpecificationsItemsFD791D (DFI)Type of engineLiquid-cooled, Horizontal shaft, OHV, 4-stroke, 90V-twin, Gasoline en-gine.

Page 4 - Foreword

LUBRICATION SYSTEM 5-1Lubrication SystemTable of Contents5Exploded View...

Page 5 - General Information

5-2 LUBRICATION SYSTEMExploded ViewEO: Apply engine oil.G: Apply grease.L: Apply a non-permanent locking agent.T1: 6 Nm (0.6 kg m, 52 in lb)T2: 15 Nm

Page 6 - 1-2 GENERAL INFORMATION

LUBRICATION SYSTEM 5-3Engine Oil Flow Chart

Page 7 - GENERAL INFORMATION 1-3

5-4 LUBRICATION SYSTEMSpecificationsItemStandardEngine Oil:Grade API service classification; SF, SG, SH, or SJ classViscosity SAE40, SAE30, SAE10W-30 /

Page 8 - 1-4 GENERAL INFORMATION

LUBRICATION SYSTEM 5-5Engine Oil and Oil FilterCAUTIONEngine operation with insufficient, deteriorated, or contami-nated engine oil will cause accelera

Page 9 - GENERAL INFORMATION 1-5

5-6 LUBRICATION SYSTEMEngine Oil and Oil Filter•Remove the oil filler cap and pour in the specified type and amountof oil.Engine Oil :Grade: API Service

Page 10 - 1-6 GENERAL INFORMATION

LUBRICATION SYSTEM 5-7Pressurized Lubrication SystemThe engine lubrication circuit is a pressurized system consistingof a positive displacement pump w

Page 11 - GENERAL INFORMATION 1-7

5-8 LUBRICATION SYSTEMOil Pump and Relief ValveOil Pump, Relief Valve Removal•Remove the crankcase cover (see Camshaft/Crankshaft chapter).•Unscrew th

Page 12 - 1-8 GENERAL INFORMATION

LUBRICATION SYSTEM 5-9Oil Pump and Relief Valve•Measure the inside diameter [A] of the pump housing with a insidemicrometer at several points.If the i

Page 13 - GENERAL INFORMATION 1-9

GENERAL INFORMATION 1-7Periodic Maintenance ChartTo ensure satisfactory operation over an extended period of time, any engine requires normal maintena

Page 14 - 1-10 GENERAL INFORMATION

5-10 LUBRICATION SYSTEMOil Pump and Relief ValveIf cleaning does not solve the problem, replace the relief valve parts.If necessary, put the ball in p

Page 15 - Fuel System

LUBRICATION SYSTEM 5-11Oil Screen FilterThe oil screen filter cannot be disassembled, if any damage for theoil screen filter is noticed replace it with

Page 17 - FUEL SYSTEM 2-3

CAMSHAFT/CRANKSHAFT 6-1Camshaft/CrankshaftTable of Contents6Exploded View...

Page 18 - 2-4 FUEL SYSTEM

6-2 CAMSHAFT/CRANKSHAFTExploded ViewEO: Apply engine oil.G: Apply grease.S: Follow the specific tightening sequence.SS: Apply silicone sealant.T1: 22 N

Page 19 - FUEL SYSTEM 2-5

CAMSHAFT/CRANKSHAFT 6-3SpecificationsItemService LimitCamshaft, Tappet:Cam lobe height Intake33.594 mm (1.3226 in.)Exhaust 33.594 mm (1.3226 in.)Camsha

Page 20 - 2-6 FUEL SYSTEM

6-4 CAMSHAFT/CRANKSHAFTCrankcaseCrankcase Cover Removal•Set the engine on a clean surface while parts are being removed.•Drain the oil (see Lubricatio

Page 21 - FUEL SYSTEM 2-7

CAMSHAFT/CRANKSHAFT 6-5Crankcase(Crankcase installation)•Check to see that the crankcase dowel pins [A] are in place on thecrankcase as shown in the fi

Page 22 - 2-8 FUEL SYSTEM

6-6 CAMSHAFT/CRANKSHAFTCrankcase•A coolant leaks into the engine through:A loose cylinder headA cracked or porous castingThe push rod compartment•Give

Page 23 - FUEL SYSTEM 2-9

CAMSHAFT/CRANKSHAFT 6-7Crankcase•The service bushing is to be reinstalled using a bushing tool as shown.•Coat the bushing and flange surface with light

Page 24 - 2-10 FUEL SYSTEM

1-8 GENERAL INFORMATIONTorque and Locking AgentThe following tables lists the tightening torque for the major fasteners, and the parts requiring use o

Page 25 - FUEL SYSTEM 2-11

6-8 CAMSHAFT/CRANKSHAFTBreatherThe function of the breather is to create a vacuum in the crankcasewhich prevents oil from being forced out of the engi

Page 26 - 2-12 FUEL SYSTEM

CAMSHAFT/CRANKSHAFT 6-9Camshaft, TappetCamshaft, Tappet Removal•Remove the crankcase cover (see Crankcase Cover Removal).•Turn the crankcase up side d

Page 27 - FUEL SYSTEM 2-13

6-10 CAMSHAFT/CRANKSHAFTCamshaft, Tappet•Measure the inside diameter [A] of the camshaft bearing on thecrankcase at several points. This bearing is no

Page 28 - 2-14 FUEL SYSTEM

CAMSHAFT/CRANKSHAFT 6-11Crankshaft, Connecting RodConnecting Rod Removal•Remove:Piston (see Engine Top End Chapter)Connecting Rod Installation•Install

Page 29 - FUEL SYSTEM 2-15

6-12 CAMSHAFT/CRANKSHAFTCrankshaft, Connecting Rod•Measure connection rod twist.With the big-end arbor still on the V blocks, hold the connection rodh

Page 30 - 2-16 FUEL SYSTEM

CAMSHAFT/CRANKSHAFT 6-13Crankshaft, Connecting RodCrankshaft Runout•Measure the crankshaft runout.Set the crankshaft in a flywheel alignment jig or on

Page 32 - 2-18 FUEL SYSTEM

ELECTRICAL SYSTEM 7-1Electrical SystemTable of Contents7Exploded View...

Page 33 - FUEL SYSTEM 2-19

7-2 ELECTRICAL SYSTEMExploded ViewG: Apply grease.L: Apply a non-permanent locking agent.T1: 15 Nm (1.5 kg m, 11 ft lb)T2: 20 Nm (2.0 kg m, 15 ft lb)T

Page 34 - 2-20 FUEL SYSTEM

ELECTRICAL SYSTEM 7-3SpecificationsItemStandard Service LimitCharging System:Regulated output voltage Battery voltage to 15 V DC –––Alternator stator c

Page 35 - FUEL SYSTEM 2-21

GENERAL INFORMATION 1-9Special ToolsCompression Gauge: 57001–221Piston Ring Pliers: 57001–115Piston Ring Compression Grip: 57001–1095Piston Ring Compr

Page 36 - 2-22 FUEL SYSTEM

7-4 ELECTRICAL SYSTEMWiring DiagramNOTEPortion surrounded by shows KHI procurement parts.

Page 37 - FUEL SYSTEM 2-23

ELECTRICAL SYSTEM 7-5Wiring DiagramFD791D (DFI Model)NOTEPortion surrounded byshows KHI procurement parts.

Page 38 - 2-24 FUEL SYSTEM

7-6 ELECTRICAL SYSTEMWire Harness

Page 39 - FUEL SYSTEM 2-25

ELECTRICAL SYSTEM 7-7PrecautionsThere are a number of important precautions that are musts whenservicing electrical systems. Learn and observe all the

Page 40 - 2-26 FUEL SYSTEM

7-8 ELECTRICAL SYSTEMCharging SystemFlywheel, Stator Coil Removal•Remove:RadiatorCooling FanStarter MotorFan Drive Sheave/Hub•Hold the flywheel [A] wit

Page 41 - FUEL SYSTEM 2-27

ELECTRICAL SYSTEM 7-9Charging SystemCharging System Operational Inspection•Check battery condition.NOTEAlways check battery condition before condemnin

Page 42 - 2-28 FUEL SYSTEM

7-10 ELECTRICAL SYSTEMCharging SystemUnregulated Stator Output•Disconnect the stator coil connector.•Connect AC voltmeter to the stator pins.•Start th

Page 43 - FUEL SYSTEM 2-29

ELECTRICAL SYSTEM 7-11Ignition SystemIgnition SystemThis engine ignition is controlled by a solid state ignition assemblyand requires no periodic main

Page 44 - 2-30 FUEL SYSTEM

7-12 ELECTRICAL SYSTEMIgnition SystemIgnition Coil Inspection•Remove the ignition coils (see Ignition Coil Removal).•Measure the primary winding resis

Page 45 - FUEL SYSTEM 2-31

ELECTRICAL SYSTEM 7-13Electric Starter SystemStarter Motor Removal•Disconnect the wires shown [A].•Remove the mounting bolts [C] and pull the starter

Page 46 - 2-32 FUEL SYSTEM

1-10 GENERAL INFORMATIONSpecial ToolsOil Filter Wrench : 57001–1249Hand Tester: 57001–1394Kawasaki Bond (Silicone Sealant) : 56019–120Read Wire ECU Ad

Page 47 - FUEL SYSTEM 2-33

7-14 ELECTRICAL SYSTEMElectric Starter System•Set the hand tester to the R x 1 position and connect the leads asshown.If the tester does not read clos

Page 48 - 2-34 FUEL SYSTEM

ELECTRICAL SYSTEM 7-15Electric Starter System•Connect the starter motor, battery and ammeter as shown.[A] Ammeter[B] Voltmeter[C] Battery[D] Switch[E]

Page 49 - FUEL SYSTEM 2-35

7-16 ELECTRICAL SYSTEMElectric Starter System•Pull the armature [A] from the yoke [B].•Separate the front and rear stoppers each other using a screw d

Page 50 - 2-36 FUEL SYSTEM

ELECTRICAL SYSTEM 7-17Electric Starter System•Inspect the rubber insert [B] and/or boot [A] for visible damage.If they are damaged, replace them.•Fit

Page 51 - FUEL SYSTEM 2-37

7-18 ELECTRICAL SYSTEMElectric Starter SystemStarter Motor Brush Inspection•Measure the overall length of each brush [A].If the brushes are shorter th

Page 52 - 2-38 FUEL SYSTEM

ELECTRICAL SYSTEM 7-19Electric Starter System•Support the armature in an alignment jig at each end of the shaft asshown. Position a dial indicator per

Page 53 - FUEL SYSTEM 2-39

7-20 ELECTRICAL SYSTEMElectric Starter System•Set the multimeter selector switch to the R 1 position andmeasure the resistance between the negative br

Page 54 - 2-40 FUEL SYSTEM

TROUBLESHOOTING 8-1TroubleshootingTable of Contents8Engine Troubleshooting Guide...

Page 55 - FUEL SYSTEM 2-41

8-2 TROUBLESHOOTINGEngine Troubleshooting GuideIf the engine malfunctions, check if the way the engine is used is correct. If engine malfunctions even

Page 56

TROUBLESHOOTING 8-3Engine Troubleshooting Guide

Page 57 - Cooling System

FUEL SYSTEM 2-1Fuel SystemTable of Contents2Exploded View...2-3Specifications...

Page 58 - 3-2 COOLING SYSTEM

8-4 TROUBLESHOOTINGEngine Troubleshooting Guide

Page 59 - COOLING SYSTEM 3-3

TROUBLESHOOTING 8-5Engine Troubleshooting Guide

Page 60 - 3-4 COOLING SYSTEM

8-6 TROUBLESHOOTINGEngine Troubleshooting Guide

Page 61 - COOLING SYSTEM 3-5

TROUBLESHOOTING 8-7Engine Troubleshooting GuideFD791D (DFI Model) Trouble shootingTrouble shooting guide shows the relationship between systams and in

Page 62 - 3-6 COOLING SYSTEM

8-8 TROUBLESHOOTINGStarter Motor Troubleshooting Guide1. Disconnect spark plug cap, and ground the cap terminal.2. Turn engine switch to “START” posit

Page 63 - COOLING SYSTEM 3-7

2-2 FUEL SYSTEMSensor Resistance inspection...2-39Water Temperature Sensor (Fault Code 13)...2-39Removal/Installation...

Page 64 - 3-8 COOLING SYSTEM

FUEL SYSTEM 2-3Exploded View1. Pilot Screw Assy2. Pilot Jet3. Main Jet (#105)4. Main Jet (#105)T1: 0.7 N m (0.07 kg m, 6 in lb)T2: 2.0 N m (0.2 kg m,

Page 65 - COOLING SYSTEM 3-9

2-4 FUEL SYSTEMExploded ViewFD791D (DFI Model)1. Throttle Body Assy2. Electrical Control Unit (ECU)3. Fuel Injectors4. Fuel Pressure Regulator5. Inlet

Page 66 - 3-10 COOLING SYSTEM

FUEL SYSTEM 2-5Exploded View1. Other than DFI ModelT1: 8 N m (0.8 kg m, 69 in lb)

Page 67 - COOLING SYSTEM 3-11

LIST OF ABBREVIATIONSA ampere(s) lb pound(s)ABDC after bottom dead center m meter(s)AC alternating current min minute(s)ATDC after top dead center N n

Page 68 - 3-12 COOLING SYSTEM

2-6 FUEL SYSTEMSpecificationsItemStandardFD671D FD711D FD750DCaburetors Specifications:Make/ type MIKUNI BW26Throttle bore diameter 26 mm (1.02 in.)Vent

Page 69 - COOLING SYSTEM 3-13

FUEL SYSTEM 2-7SpecificationsItemStandardFD791D (DFI Model)Digital Fuel Injection SystemIdle SpeedLow idle speed 1550 rpmHigh idle speed 3600 rpmThrott

Page 70 - 3-14 COOLING SYSTEM

2-8 FUEL SYSTEMGovernor Link MechanismControl Panel Assembly Removal•Remove:Air Cleaner (see Air Cleaner Body Removal)Muffler (see Muffler Assembly Remo

Page 71 - COOLING SYSTEM 3-15

FUEL SYSTEM 2-9Governor Link MechanismGovernor Arm Installation•Insert the bracket [A] onto the governor shaft [B] thoroughly to thebottom of the wood

Page 72 - 3-16 COOLING SYSTEM

2-10 FUEL SYSTEMGovernor Link MechanismGovernor Shaft Removal•Remove:Camshaft (see Camshaft/Crankshaft chapter)•Unscrew the governor arm clamp nut, an

Page 73 - COOLING SYSTEM 3-17

FUEL SYSTEM 2-11CarburetorFuel and Air FlowThe main system of the carburetor consists of the main jet [A], mainnozzle [B], and the main air passage (m

Page 74 - 3-18 COOLING SYSTEM

2-12 FUEL SYSTEMCarburetorLow Idle Speed Adjustment•Disconnect all possible external loads from the engine.•Start the engine and warm it up thoroughly

Page 75 - COOLING SYSTEM 3-19

FUEL SYSTEM 2-13CarburetorHigh Altitude OperationAt high altitude, the standard carburetor air-fuel mixture will beexcessively rich. Performance will

Page 76 - 3-20 COOLING SYSTEM

2-14 FUEL SYSTEMCarburetor•Remove:Air Cleaner and Related Parts (see Air Cleaner Removal)Radiator (see Radiator Removal)Cooling Fan and Fan Belt (see

Page 77 - Engine Top End

FUEL SYSTEM 2-15CarburetorCarburetor Disassembly/Assembly•Refer to the illustration shown for disassembly and assembly.•There are several passage plug

Page 78 - 4-2 ENGINE TOP END

EMISSION CONTROL INFORMATIONTo protect the environment in which we live, Kawasaki has incorporated crankcase emission (1) and exhaust emission(2) cont

Page 79 - ENGINE TOP END 4-3

2-16 FUEL SYSTEMCarburetorCarburetor CleaningClean the carburetor in a well-ventilated area, and take carethat there is no spark or flame anywhere near

Page 80 - 4-4 ENGINE TOP END

FUEL SYSTEM 2-17Carburetor•With the float [A] assembly installed onto the carburetor body [B], holdthe carburetor upside down at an eye level. Gently s

Page 81 - ENGINE TOP END 4-5

2-18 FUEL SYSTEMIntake ManifoldIntake Manifold Removal•Remove:Air Cleaner (see Cleaner Body Removal)CarburetorControl Panel Assembly•Drain the coolant

Page 82 - 4-6 ENGINE TOP END

FUEL SYSTEM 2-19Fuel PumpThe fuel pump cannot be disassembled, if any damage for the pumpis appeared replace it with a new one.[A] Fuel Pump[B] Inlet

Page 83 - ENGINE TOP END 4-7

2-20 FUEL SYSTEMAir CleanerElement Removal•Remove:Air Cleaner Case Nut [A]Upper-case [B]Cleaner Case [C]•Remove:Wing Nut [A]Foam Element [B]Paper Elem

Page 84 - 4-8 ENGINE TOP END

FUEL SYSTEM 2-21Air CleanerCleaner Body Removal•Remove the elements. (see Element Removal)•Remove the cleaner body mounting bolts [A] and take off the

Page 85 - ENGINE TOP END 4-9

2-22 FUEL SYSTEMDigital Fuel Injection (DFI) SystemGovernor Link MechanismControl Panel Assembly Removal•Remove:Air Cleaner (see Air Cleaner Body Remo

Page 86 - 4-10 ENGINE TOP END

FUEL SYSTEM 2-23Digital Fuel Injection (DFI) SystemGovernor Arm Installation•Insert the bracket [A] onto the governor shaft [B] thoroughly to thebotto

Page 87 - ENGINE TOP END 4-11

2-24 FUEL SYSTEMDigital Fuel Injection (DFI) SystemThrottle Body Assy DisassemblyNOTEDo not attempt to remove the throttle valve and shaft unless they

Page 88 - 4-12 ENGINE TOP END

FUEL SYSTEM 2-25Digital Fuel Injection (DFI) SystemHigh Idle Speed AdjustmentNOTEHigh idle speed adjustment should be made after the idle speedadjustm

Page 89 - ENGINE TOP END 4-13

ForewordThis manual is designed primarily for use by trainedmechanics in a properly equipped shop. However, itcontains enough detail and basic informa

Page 90 - 4-14 ENGINE TOP END

2-26 FUEL SYSTEMDigital Fuel Injection (DFI) SystemIntake Manifold (DFI) Installation•Before assembling the manifold, install the cylinder heads on ea

Page 91 - ENGINE TOP END 4-15

FUEL SYSTEM 2-27Digital Fuel Injection (DFI) SystemDFI System

Page 92 - 4-16 ENGINE TOP END

2-28 FUEL SYSTEMDigital Fuel Injection (DFI) SystemDFI System Wiring DiagramNOTEPortion surrounded by shows KHI procurement pars.1.ECU (Electronic Con

Page 93 - ENGINE TOP END 4-17

FUEL SYSTEM 2-29Digital Fuel Injection (DFI) SystemTerminal Numbers of ECU Connectors(View from wire side)#11.#1 Injector Signal#21.#2 Injector Signal

Page 94 - 4-18 ENGINE TOP END

2-30 FUEL SYSTEMDigital Fuel Injection (DFI) SystemElectrical Control Unit (ECU)CAUTIONNever drop the ECU, especially on a hard surface. Such ashock t

Page 95 - ENGINE TOP END 4-19

FUEL SYSTEM 2-31Digital Fuel Injection (DFI) SystemECU Power Source Inspection•Set the tester [A] to the DC25 V range and connect it to the adapter[B]

Page 96 - 4-20 ENGINE TOP END

2-32 FUEL SYSTEMDigital Fuel Injection (DFI) SystemMeasure the operating voltage with the engine stopped, and with theconnector joined.•Turn the ignit

Page 97 - ENGINE TOP END 4-21

FUEL SYSTEM 2-33Digital Fuel Injection (DFI) SystemFuel Injectors (#1, #2)CAUTIONNever drop the injector, especially on a hard surface. Such ashock to

Page 98 - 4-22 ENGINE TOP END

2-34 FUEL SYSTEMDigital Fuel Injection (DFI) SystemAudible Inspection•Start the engine.•Apply the tip of a screwdriver [A] to the injector [C]. Put th

Page 99 - ENGINE TOP END 4-23

FUEL SYSTEM 2-35Digital Fuel Injection (DFI) SystemInjector Resistance Inspection•Disconnect the connector from the injector [A] (see Injector Removal

Page 100

GENERAL INFORMATION 1-1General InformationTable of Contents1Before Servicing...

Page 101 - Lubrication System

2-36 FUEL SYSTEMDigital Fuel Injection (DFI) SystemFuel Pressure Regulator InspectionNOTEBe sure the battery is fully charged.•Loosen the fuel pressur

Page 102 - 5-2 LUBRICATION SYSTEM

FUEL SYSTEM 2-37Digital Fuel Injection (DFI) SystemHow to Read Fault CodesFault codes are shown by a series of long and short blinks of the Self Diagn

Page 103 - LUBRICATION SYSTEM 5-3

2-38 FUEL SYSTEMDigital Fuel Injection (DFI) SystemInstallation•Push the sensor [A] into the grommet [B] until the flange of sensor[C] touches the grom

Page 104 - 5-4 LUBRICATION SYSTEM

FUEL SYSTEM 2-39Digital Fuel Injection (DFI) SystemSensor Resistance inspection•Remove the inlet air temperature sensor (see this section).•Suspend th

Page 105 - LUBRICATION SYSTEM 5-5

2-40 FUEL SYSTEMDigital Fuel Injection (DFI) SystemNOTEThe output voltage changes according to the coolant temperaturein the engine.If the output volt

Page 106 - 5-6 LUBRICATION SYSTEM

FUEL SYSTEM 2-41Digital Fuel Injection (DFI) SystemSpecial Tool - ECU Adapter: 57001–1400•Set the tester [A] to the DC 10 V range, and connect it to t

Page 108 - 5-8 LUBRICATION SYSTEM

COOLING SYSTEM 3-1Cooling SystemTable of Contents3Exploded View...

Page 109 - LUBRICATION SYSTEM 5-9

3-2 COOLING SYSTEMExploded ViewG: Apply grease.T1: 6 Nm (0.6 kg m, 52 in lb)T3: 20 Nm (2.0 kg m, 15 ft lb)T5: 1.2 Nm (0.12 kg m, 11 in lb)

Page 110 - 5-10 LUBRICATION SYSTEM

COOLING SYSTEM 3-3Exploded View1. Thermo Switch2. Thermostat3. Drain PlugEO: Apply engine oil.G: Apply grease.L: Apply a non-permanent locking agent.S

Page 111 - LUBRICATION SYSTEM 5-11

1-2 GENERAL INFORMATIONBefore ServicingBefore starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Pho

Page 112

3-4 COOLING SYSTEMSpecificationsItemStandard*Coolant:Type Permanent type of antifreeze for aluminum engine and radiatorColor GreenMixed ratio 50% solut

Page 113 - Camshaft/Crankshaft

COOLING SYSTEM 3-5Cooling SystemThis engine is equipped with a highly efficient pressurized coolingsystem using a thermostat to maintain an optimum ope

Page 114 - 6-2 CAMSHAFT/CRANKSHAFT

3-6 COOLING SYSTEMCoolantCoolant Deterioration•Visually inspect the coolant in the radiator.If whitish cotton-like wafts are observed, aluminum parts

Page 115 - CAMSHAFT/CRANKSHAFT 6-3

COOLING SYSTEM 3-7CoolantTo avoid burns do not remove the radiator cap or try to changethe coolant when the engine is still hot. Wait until it coolsdo

Page 116 - 6-4 CAMSHAFT/CRANKSHAFT

3-8 COOLING SYSTEMCoolantVisual Leak InspectionAny time the system slowly loses water, inspect for leaks. Small leaksmay appear only a rust, corrosion

Page 117 - CAMSHAFT/CRANKSHAFT 6-5

COOLING SYSTEM 3-9CoolantFlushingOver a period of time, the cooling system accumulates rust, scale,and lime in the water jacket and radiator. When thi

Page 118 - 6-6 CAMSHAFT/CRANKSHAFT

3-10 COOLING SYSTEMWater PumpWater Pump Removal•Remove:Muffler (see Muffler Assembly Removal)•Loosen the hose clamp [A] and disconnect the water hose [B

Page 119 - CAMSHAFT/CRANKSHAFT 6-7

COOLING SYSTEM 3-11Water Pump•Install the mounting bolts and tighten them in the order shown.Torque - Water Pump and Cover Mounting Bolts: 20 N m (2.0

Page 120 - 6-8 CAMSHAFT/CRANKSHAFT

3-12 COOLING SYSTEMWater PumpPumps Parts Inspection•Clean all parts except plastic and rubber parts in a bath of high flash-point solvent and dry them

Page 121 - CAMSHAFT/CRANKSHAFT 6-9

COOLING SYSTEM 3-13RadiatorRadiator RemovalAlways allow the engine to cool before removing the radiatorcap. Then remove the cap slowly and carefully t

Page 122 - 6-10 CAMSHAFT/CRANKSHAFT

GENERAL INFORMATION 1-3Before Servicing(15) Cotter PinReplace any cotter pins that were removed with new ones, as removal deforms and breaks them.(16)

Page 123 - CAMSHAFT/CRANKSHAFT 6-11

3-14 COOLING SYSTEMRadiator•Check the radiator filler neck for signs of damage.•Check the condition of the top [A] and bottom [B] sealing seats in thefi

Page 124 - 6-12 CAMSHAFT/CRANKSHAFT

COOLING SYSTEM 3-15RadiatorRadiator Hose Installation Notes•Install the radiator hoses being careful to follow bending direction (seeExploded View). A

Page 125 - CAMSHAFT/CRANKSHAFT 6-13

3-16 COOLING SYSTEMCooling Fan, Fan BeltThe only service on the cooling fan is to be srue the fan blades arenot deformed, and the blade tips are far e

Page 126

COOLING SYSTEM 3-17Cooling Fan, Fan BeltCooling Fan, Fan Belt Removal•Remove:Radiator (see Radiator Removal)•Remove the radiator guide.Unscrew the mou

Page 127 - Electrical System

3-18 COOLING SYSTEMCooling Fan, Fan BeltCooling Fan, Fan Belt Installation•Install the cooling fan as “AISHIN” raised lettering [A] on the fan bossfac

Page 128 - 7-2 ELECTRICAL SYSTEM

COOLING SYSTEM 3-19ThermostatThermostat Removal and Installation•Drain the coolant (see Coolant Draining).•Loosen the hose clamps [A], and pull off th

Page 129 - ELECTRICAL SYSTEM 7-3

3-20 COOLING SYSTEMThermo SwitchWhen coolant temperature rises above 111 C (232 F), the thermoswitch detects this and turns on a warning light on dash

Page 130 - 7-4 ELECTRICAL SYSTEM

ENGINE TOP END 4-1Engine Top EndTable of Contents4Exploded View...

Page 131 - ELECTRICAL SYSTEM 7-5

4-2 ENGINE TOP ENDExploded ViewEO: Apply engine oil.G: Apply grease.T1: 22 Nm (2.2 kg m, 16 ft lb)T2: 21 Nm (2.1 kg m, 15 ft lb)T5: 11 Nm (1.1 kg m, 9

Page 132 - 7-6 ELECTRICAL SYSTEM

ENGINE TOP END 4-3Exploded ViewS: Follow the specific tightening sequence.T3: 27 N m (2.8 kg m, 20 ft lb)T4: 20 Nm (2.0 kg m, 15 ft lb)

Page 133 - ELECTRICAL SYSTEM 7-7

1-4 GENERAL INFORMATIONModel IdentificationCylinder Number Designation:No.1 Cyl. is on the oil filter side.No.2 Cyl. is on the electric starter side.

Page 134 - 7-8 ELECTRICAL SYSTEM

4-4 ENGINE TOP ENDSpecificationsItemService LimitCylinder Head:Cylinder compression (MIN) [1171 kPa (170 psi)] (MIN)Cylinder head warp 0.06 mm (0.002 i

Page 135 - ELECTRICAL SYSTEM 7-9

ENGINE TOP END 4-5Cylinder HeadCompression Measurement•Before measuring compression, do the following.Be sure the battery is fully charged.Thoroughly

Page 136 - 7-10 ELECTRICAL SYSTEM

4-6 ENGINE TOP ENDCylinder Head•When removing the cylinder head, set the flywheel at top dead center(T.D.C) of power stroke each cylinder.When setting

Page 137 - ELECTRICAL SYSTEM 7-11

ENGINE TOP END 4-7Cylinder Head•Install the head bolts noting the position of different length bolts.•Then tighten the head bolts to the specification

Page 138 - 7-12 ELECTRICAL SYSTEM

4-8 ENGINE TOP ENDCylinder HeadValve Mechanism Removal/Installation•Remove the cylinder head assembly. (see Cylinder Head AssemblyRemoval)NOTEWhen rem

Page 139 - ELECTRICAL SYSTEM 7-13

ENGINE TOP END 4-9Cylinder Head•Valve Installation.Apply engine oil to the valve stem to avoid damaging the stem seal.Check to see that the valve move

Page 140 - 7-14 ELECTRICAL SYSTEM

4-10 ENGINE TOP ENDCylinder Head•Check the cylinder head for cracks or other damage.•Cracks not visible to the eye may be detected by coating thesuspe

Page 141 - ELECTRICAL SYSTEM 7-15

ENGINE TOP END 4-11ValvesValve Clearance InspectionNOTEValve clearance must be checked when the engine is cold (at roomtemperature).•Remove the rocker

Page 142 - 7-16 ELECTRICAL SYSTEM

4-12 ENGINE TOP ENDValvesValve Seat Inspection•Remove the valve. (see Valve Mechanism Removal/Installation)•Inspect the valve seats for damage.If the

Page 143 - ELECTRICAL SYSTEM 7-17

ENGINE TOP END 4-13Valves•Setting the valve seat cutter holder [A] in position, operate the cutter[B] with one hand. Do not apply too much force to th

Page 144 - 7-18 ELECTRICAL SYSTEM

GENERAL INFORMATION 1-5General SpecificationsItemsFD671D, FD711D, FD750DType of engineLiquid-cooled, Horizontal shaft, OHV, 4-stroke, 90V-twin, Gasolin

Page 145 - ELECTRICAL SYSTEM 7-19

4-14 ENGINE TOP ENDValves•Use a 30 seat cutter [A] to narrow the seat width to the STD width.Turn the seat cutter one turn at a time while pressing do

Page 146 - 7-20 ELECTRICAL SYSTEM

ENGINE TOP END 4-15ValvesValve Stem Runout•Support the valve in V blocks at each end of the stem.•Position a dial gauge perpendicular to the stem.•Tur

Page 147 - Troubleshooting

4-16 ENGINE TOP ENDCylinder, PistonPiston Removal•Split the crankcase (see Camshaft/Crankshaft chapter).•Remove the camshaft (see Camshaft/Crankshaft

Page 148 - 8-2 TROUBLESHOOTING

ENGINE TOP END 4-17Cylinder, PistonPiston Installation•Install the expander [A] in the piston oil ring groove so that theexpander ends [B] touch toget

Page 149 - TROUBLESHOOTING 8-3

4-18 ENGINE TOP ENDCylinder, PistonUsing the piston ring compressor grip [A] and the belt [B], insert thepiston and connecting rod into the cylinder.L

Page 150 - 8-4 TROUBLESHOOTING

ENGINE TOP END 4-19Cylinder, PistonPiston Cleaning•Remove the piston and piston rings (see Piston and Ring Removal).CAUTIONNever clean the piston head

Page 151 - TROUBLESHOOTING 8-5

4-20 ENGINE TOP ENDCylinder, PistonPiston Ring End Gap•Remove the piston rings.•Push each ring (one at a time) in the cylinder bore to a point closeto

Page 152 - 8-6 TROUBLESHOOTING

ENGINE TOP END 4-21Cylinder, PistonPiston Diameter•Measure the outside diameter of the piston 11 mm (0.43 in.) up fromthe bottom of the piston at a ri

Page 153 - TROUBLESHOOTING 8-7

4-22 ENGINE TOP ENDCylinder, PistonChange to a honing stone for finishing, the final bore diameter shouldbe as shown in the table.Be sure the correct st

Page 154 - 8-8 TROUBLESHOOTING

ENGINE TOP END 4-23MufflerMuffler Assembly Removal•Unscrew the flange nuts [A], and remove the spring washers andengine hook [B] (Only No.1 Cylinder side

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