GOLF, TURF AND SPECIALTY PRODUCTS SERVICE MANUAL CARBURETED SUZUKI 970 CC ENGINE. Part No

Transcription

1 GOLF, TURF AND SPECIALTY PRODUCTS SERVICE MANUAL CARBURETED SUZUKI 970 CC ENGINE Part No

2 CU 20001Textron Inc. Lincoln, Nebraska All Rights Reserved. Printed in U.S.A.

3 SECTION TABLE OF CONTENTS PAGES 1 Troubleshooting Engine Fuel System Engine Cooling System Ignition System

4 2

5 SECTION 1 TROUBLESHOOTING 3

6 1.1 ENGINE Dead battery Bad starter solenoid Position correctly Faulty fuel systems Fuel pump not working correctly Dirty or clogged carburetor Engine internal malfunction 4

7 Wrong type of engine oil Low compression Ignition timing malfunction Fuel system malfunction Air intake system malfunction 5

8 Electrical system malfunction Fuel system malfunction Engine malfunction Fuel system malfunction Kinked, leaky or damaged fuel hoses and lines Ignition system malfunction 6

9 Ignition system malfunction Fuel system malfunction Fuel detonation Ignition system malfunction Fuel system malfunction Air entering engine through leaking intake manifold or carburator gaskets 7

10 Detonation Engine malfunction Ignition system malfunction Fuel system malfunction Cooling system malfunction Lubrication system malfunction 8

11 Noise due to pistons, rings, pins or cylinder malfunction Fill to full mark Ignition system malfunction Defective or loose connection of high tension cord Fuel system malfunction Engine malfunction 9

12 Badly worn valves or valve guide bushings 1.2 CARBURETOR 1.3 EXHAUST AND MUFFLER Poor exhaust system performance 1.4 CLUTCH 10

13 1.5 TRANSMISSION Transmission slipping out of gear Transmission won t disengage 11

14 Too much clutch pedal play, resulting in a dragging clutch Worn gear shift and select or joint bushing 1.6 DIFFERENTIAL Insufficient or wrong type of gear oil (Constant noise) Insufficient or wrong type of gear oil 12

15 SECTION 2 ENGINE 13

16 2.1 GENERAL DESCRIPTION, 14

17 15

18 16 Heating by hot water is employed for the inlet manifold in order to facilitate fuel carburation and ensure uniform distribution of the mixture. The higher combustion efficiency of this engine is largely explained by this inlet manifold feature.

19 17

20 ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL

21 2.3 ENGINE REMOVAL Disconnect negative ( ) and positive (+) cables from battery terminals. Remove engine cover and front seats. Disconnect lead wires and battery positive cable from starter motor. Disconnect battery negative cable from transmission. 19

22 20 Remove engine with transmission to rear side so cooling fan does not touch fan shroud, and hoist car and take down engine with transmission.

23 2.4 ENGINE DISASSEMBLY Be sure all components are removed and reassembled the same way. Also, be sure all original hardware is used with the same component it was removed from. When removing distributor and distributor gear case, engine oil in distributor gear case may come out. Place pan or similar product under distributor gear case to catch oil. Be careful in handling aluminum alloy parts. They are softer than steel or cast iron parts and their finished surfaces are easily scratched or damaged. Remove distributor gear case. 21

24 7) 5) Remove crankshaft pulley, with wrench attached to flywheel so that crankshaft will not turn. 8) 6) 9) Remove the camshaft timing belt pulley and key, while holding camshaft in place. 22

25 10) 13) 14) Remove exhaust manifold and its gasket. 11) 1. Crankshaft timing belt pulley 2. Timing belt guide 3. Key Remove timing belt inside cover. 15) Remove oil filter. Be careful not to spill oil when removing the filter. 12) 16) Remove bypass hose from water inlet pipe. 23

26 17) 18) Remove intake manifold with carburetor. 21) Loosen 8 valve adjusting screws. Do not remove screws from rocker arms. 19) 22) Loosen 10 screws securing rocker arm shaft. 20) Remove cylinder head cover. 23) 24

27 24) Remove camshaft thrust plate, and carefully remove camshaft through rear of cylinder head. Use valve spring compressor to compress valve spring so valve retainers can be removed. 25) 1. Valve stem oil seal 2. Blade screw driver 3. Valve spring seat 25

28 Drive valve guide out from combustion chamber side to valve spring side. 27) 28) 26) Remove flywheel; as shown. 29) Remove oil pan. 26

29 30) 33) 34) 31) 32) Install rubber hose over threads of rod bolts. This is to prevent damage to bearing journal and cylinder wall when removing connecting rod. 1. Guide hoses 27

30 Remove inner gear and outer gear. 1. Outer gear 2. Inner gear 35) 36) 37) Remove crankshaft bearing caps, and remove crankshaft. 1. Gear plate 28

31 2.5 INSPECTION OF ENGINE COMPONENTS Distortion of head surface: During and immediately after disassembly, inspect cylinder block and head for evidence of water leakage or damage and, after washing them clean, inspect very closely. Wash all disassembled parts clean, removing grease, slime, carbon and scales, before inspecting them to determine whether repair is necessary or not. Be sure to remove scale from water jackets. Leakage of combustion gases from the cylinder head is often due to a warped gasket surface; such leakage results in reduced power output and hence a higher cost of fuel per mile. Do not use any sharp edged tool to scrape off the carbon. Be careful not to scuff or nick metal surfaces when removing carbon. This applies to valves and valve seats, too. 29

32 Distortion of manifold seating faces: Check the seating faces of cylinder head where it contacts the intake and exhaust manifolds. Use a straightedge and thickness gauge, to determine whether these faces should be corrected or the cylinder head replaced. If the limit is exceeded, replace shaft, arm, or both. 30

33 Wear of rocker arm and adjusting screw: If the tip 1 of adjusting screw is badly worn, replace screw. Arm must be replaced if the cam riding face 3 is badly worn. 1. Tip of adjusting screw 2. Rocker arm 3. Cam riding face If bore gauge is not available, check end deflection of the valve stem in place with a dial gauge fixed in position. Move stem end in the directions 1 and 2 to measure end deflection. If deflection exceeds its limit, replace valve and valve guide. 31

34 1. Valve head thickness Produce a contact pattern on each valve in the usual manner, namely, by giving a uniform coat of marking compound (red lead paste) to valve seat and by rotating tapping seat with valve head. Valve lapper (tool used in valve lapping) must be used. 32

35 VALVE LAPPING: Lap valve on seat in two steps, first with coarse lapping compound applied to its face and the second with a fine compound, each time using a valve laper according to usual lapping method. 1. Valve seat cutter 33

36 34

37 35

38 36 Distortion of cylinder block: Using a straightedge and a thickness gauge, check cylinder block for distortion and, if result exceeds specified limit, correct it.

39 Remove carbon from pistion crown and ring grooves, using a soft metal scraping tool. 37

40 38

41 Large end thrust clearance: Check the large end of each connecting rod for thrust clearance, with the rod fitted and connected to its crank pin in the normal manner. If the clearance measured is found to exceed the limit, the connecting rod or the crankshaft, whichever is responsible for the excessive clearance, must be replaced. Inspect small end of each connecting rod for wear and evidence of crack or any other damage, paying particular attention to the condition of its bushing. Check piston pin clearance in small end. Replace connecting rod if its small end is badly worn or damaged or if the clearance checked exceeds the limit. 39

42 Connecting rod Large End Bearings Make up the large end in the normal manner, with bearing shells in place and by tightening the cap to the specification. 40

43 1. Thrust bearing 41

44 Each of the five bearing caps has an arrow marked on it. Be sure to position each cap with its arrow pointing to front of engine and to match it (by the cylinder number) to its journal. Remember, the four cylinders are numbered, 1, 2, 3, and 4, as counted from front of engine. Mount the crankshaft in the usual manner, tightening the bearing caps to the specified torque value. (It is assumed that a gaging plastic piece is pinched at each journal.) Do not rotate the crankshaft when gaging plastic is in place. 42

45 Carefully inspect the oil seals removed in disassembly, examining the lip portion 1 of each oil seal for wear and damage. New oil seals must be used in re assembly. Inspect the friction surface (the surface in contact with clutch disc) for wear and damage. Most of surface flaws, if any, can be removed by simple machining. a badly damaged flywheel must be replaced. Inspect oil seal lip for damage. Replace as necessary. Inspect the teeth for wear and for evidence of cracks, chipping or any other damage. Replace the ring gear if its teeth are found in bad condition. 43

46 3.6 ENGINE REASSEMBLY Apply oil sliding and rubbing surfaces of engine part just before using them in re assembly. Have liquid packing ready for use. Loctite 515 or equivalent is specified for it. Use it wherever its use is specified in order to insure leak free (oil and water) workmanship of re assembly.. 1. Outer gear 2. Inner gear Tightening torque is specified for important fasteners mainly botls and nuts of the engine and other components. Use torque wrenches and constantly refer to the specified values given on page

47 When fitting crankshaft bearing caps to journals after setting the crankshaft in place, be sure to point the arrow mark (on each cap) toward front side of engine. Fit tem sequentially in the ascending order, 1, 2, 3, 4 and 5, starting from front (pulley) side. 1. Thrust bearing 2. Oil groove 1. Crankshaft pulley side 2. Clutch side After cutting, apply Loctite 515 or equivalent. 45

48 1. Punch mark Before fitting the pump case, apply Loctite 515 or equivalent on the mating surfaces around the oil discharging port of both the oil pump case and the cylinder block. Re assemble components of oil pump assembly according to following procedure, if previously disassembled. 46

49 After cutting the gasket edges, apply Loctite 515 or equivalent. Oil ring spacer gap Oil ring rail gap 2nd ring gap Front mark 1st ring gap Oil ring rail gap See figure below. Installation position of piston pin circlip Circlip or Flywheel side Crankshaft pulley side 1. Guide hose Install piston rings to piston. Before fitting rings to piston, check to be sure that first ring has RN mark and second ring R mark, the marked side of each ring (1st and 2nd) comes on top side. After mounting the three rings, distribute their end gaps as illustrated in following figure. Use piston ring compressor to compress rings. Guide connecting rod into place on the crankshaft. Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore. 47

50 Two stoppers 1 2 determine the position of each large end bearing cap relative to the big end. At the time of installing these caps, be sure to locate stopper 1 of cap in the direction of stopper 2. After installing piston and connecting rods, double check to be sure that the arrows on piston crowns are all pointing to pulley (front side of engine). 1. Crankshaft pulley side 2. Flywheel side 48

51 Tighten cap nuts to specifications. After fitting all four large end bearing caps, start tightening them uniformly, being sure to equalize tightness between right and left on each cap. The sequence here is similar to that for crankshaft bearing caps. Install oil pan and its new gasket and tighten the securing bolts to specifications. When tightening bolts, start tightening at the center: move the wrench outward, tightening one bolt at a time. The first step of flywheel installation is to check to be sure that locating pin 1 is studded in the crankshaft. Install flywheel to crankshaft. Lock flywheel, and tighten flywheel bolts to specifications. 1. Locating pin 49

52 Drive in new valve guide until valve guide installer contacts cylinder head. After installation, make sure that valve guide protrudes by 14 mm from cylinder head. 1. Flywheel bolts 2. Input shaft end bearing 1. Valve guide protrusion (14 mm) Before installing new valve guide into cylinder head, ream guide hole with 12 mm reamer to remove burrs, making sure that guide hole diameter after reaming comes within specified range. 1. Valve guide 50

53 Install new valve stem seal to valve guide. After applying engine oil to seal and spindle of valve stem seal installer fit oil seal to spindle, and then install seal to valve guide by pushing tool by hand. After installation, check to be sure that seal is properly fixed to valve guide. Do not reuse oil seal. Be sure to install new oil seal. When installing, never tap or hit tool with a hammer. Install seal to guide only by pushing tool with hand. Tapping or hitting tool may cause damage to seal. 1. Valve stem seal 1. Large pitch 2. Small pitch 3. Valve spring retainer side 4. Valve spring seat side 51

54 Using valve lifter tool, compress valve spring and fit two valve retainers to groove provided in valve stem. 1. TOP mark 2. IN mark 3. Locating pin 1. Valve cotters 2. Valve spring retainer Install cylinder head onto cylinder block. Tighten cylinder head bolts gradually with torque wrench, following sequence in Figure below. Finally tighten bolts to specified torque. Rear side Front side Apply engine oil to lobes and journals on camshaft, and oil seal on cylinder head. 52

55 1. Stepped end 4. Exhaust valve side 2. Stepped end 5. Front side (Camshaft pulley side) 3. Intake valve side 6. Rear side (Flywheel side) 1. Camshaft thrust plate Valve clearance is adjusted after all parts are assembled. So it is not adjusted at this point. Leave rocker arm adjusting screw as loose as possible. See figure below. 53

56 1. Camshaft pulley side 2. Flywheel side Install water inlet pipe and its new gasket to cylinder block. Be sure to angle it as shown in figure below. Clean cylinder block mating surface before installation. Clean cylinder head mating surface before installation. Two bolts 1, need Loctite 515 or equivalent, because the bolt holes for the two exted into the interior of cylinder head. Apply the Loctite 515 or equivalent to the threads of these screws before installing them. 54

57 Install key and camshaft timing belt pulley. When installing pulley, direct its punch marked side to timing belt outside cover side. Tighten pulley bolt to specified torque Refer to figure below for proper installation of these parts. 1. Wrench 2. Camshaft timing belt pulley 3. Timing belt inside cover 4. Punch mark 1. Timing belt pulley 2. Guide 3. Punch mark 55

58 3. Punch mark 4. Embossed mark 5. Key way 1. Valve adjusting screw 2. Lock nut 6. Drive side of timing belt 7. Direction of crankshaft 1. Punch mark 2. Embossed mark 56

59 After installing belt, hook spring on the water pump bolt and tensioner as shown in below figure. The spring, with its own tension, adjusts belt tension to the specified value. Clean cylinder head mating surface before installation. Install crankshaft pulley. Fit keyway on pulley to key of crankshaft timing belt pulley, and tighten bolt to specification. Secure flywheel so is doesn t turn during this procedure. 1. Punch mark 5. Key way 2. Embossed mark 6. Bolt 3. Punch mark 7. Bolt 4. Embossed mark 1. Crankshaft pulley 2. Pulley bolt 57

60 Install clutch disc and cover and torque to specification. 1. Pin 2. Clutch housing upper plate 58

61 2.7 ENGINE INSTALLATION 59

62 2.8 ENGINE MAINTENANCE SERVICE Remove distributor cap and check that rotor is positioned as shown in following figure. If rotor is out of place, turn crankshaft clockwise once (360 ). In this state, check valve lashes at valves 1, 2, 5, and 7. Rotate crankshaft exactly one turn, and check the same at valves 3, 4, 6 and 8. 60

63 Check Engine Oil Check Engine Oil Filter Test Engine Coolant Thickness gauge Install compression gauge into spark plug hole. Measuring valve lashes 61

64 1. Oil pressure switch Compression pressure value is measured by using compression tester. Install oil pressure gauge to vacated threaded hole. 62

65 A low vacuum reading means that any combination of following malfunctions is the cause, which must be corrected before releasing machine to customer: Install vacuum gauge, as shown in below figure. Install engine tachometer. 63

66 RECOMMENDED TORQUE SPECIFICATIONS

67 SECTION 3 FUEL SYSTEM 65

68 3.1 CARBURETOR 1. Float 2. Slow jet 3. Needle valve ass y 4. O ring 5. O ring 6. Idle mixture adjusting screw 7. Fuel cut solenoid valve 8. Carburetor body 9. Idle speed adjusting screw 10. Main jet 11. Acceleration pump 12. Enrichment jet 13. Enrichment 14. Choke opener 15. Bowl vent valve 16. Float chamber body 66

69 The main device of this system is an accelerator pump for making the carburetor respond without delay to the accelerator pedal depressed abruptly while the engine is running its low speed range or is idling. The actuating lever of this pump is linked to the throttle shaft so that, as throttle valve opens quickly, the pump lever pushes up the diaphragm, thereby closing suction ball valve and opening discharge ball valve. Consequently, the fuel in the pump is forced out of pump nozzle into the venturi. 67

70 68

71 1. Slow jet 2. Fuel cut solenoid valve 3. Bypass port 4. Slow air jet No Venturi air leak 6. Slow air jet No Main air jet No Main air jet No Main air bleed pipe 10. Min air chamber 11. Choke valve 12. Throttle valve 13. Inner venturi 14. Main jet 15. Filter 16. Needle valve 17. Air vent 18. Air vent hole (For carburetor without bowl vent valve) 19. Accelerator pump nozzle 20. Fuel nipple 21. Accelerator pump suction ball valve 22. Accelerator pump diaphram 23. Enrichment jet 24. Accelerator pump weight 25. Accelerator pump discharge ball valve 26. Enrichment valve 27. Vacuum jet 28. To intake manifold 29. Idle mixture adjusting screw 30. Idle port 31. Bowl vent valve 32. To canister 33. To intake manifold 34. To air cleaner case 69

72 When the choke knob is pulled fully, the choke valve is closed tight by spring force. At the same time, the fast idle lever holds the throttle valve at the optimum opening for the cold engine start. Removal or disassembly of carburetor must be carried out in a well ventilated place where no fire is used nearby. 1. Choke valve 3. Fast idle lever 5. Throttle lever 2. Throttle valve 4. Choke lever 1. Choke valve 5. Jet (Black) 2. Choke shaft 5 1 Yellow side 3. Choke opener lever 6. BVSV 4. Choke opener 70

73 CARBURETOR OVERHAUL This section outlines procedure to be used for overhauling carburetor after removal from engine. For removal and installation of carburetor from and to engine, refer to previous page. When servicing carburetor, keep lighted cigarette and any other fire source away from carburetor, as it contains gasoline. 1. Carburetor body 5. Needle valve seat 2. Float chamber body 6. Washer (shim) 3. Float 7. Filter 4. Needle valve All air bleed holes and fuel jets. 1. Hose 2. Enrichment 3. Screw Don t put drills or wires into fuel passages and metering jets for cleaning. This can damage in passages and jets. 71

74 1. Air vent hole 4. Slow air jet No Main air jet No Slow air jet No Main air jet No Float chamber body 4. Acceleration pump discharge port 2. Enrichment jet 5. Acceleration pump suction port 3. Enrichment outlet port 6. Fuel feed port 1. Carburetor body 5. Acceleration pump nozzle 2. Main jet 6. Fuel feed port (Needle valve fitted) 3. Enrichment pipe 7. Fuel feed port 4. Air vent hole 72

75 Remove air cleaner case and check to be sure that, when the choke valve is fully colosed, and that, when the knob is pushed in, it returns to original position. Connect vacuum pump gauge to the disconnected hose. 1. Choke opener 2. Vacuum hose 3. Choke valve (A): Vacuum pump gauge 73

76 1. BVSV 2. Cool water 3. Blow air (nozzle) 4. No air (nozzle) 5. Thermometer 6. Filter 1. Jet 2. Yellow side (A): Vacuum pump gauge 1. BVSV 2. Water 3. Bolw air (nozzle) 4. Air (nozzle) 5. Thermometer 6. Filter Reinstall BVSV to intake manifold. Before installing, wind sealing tape on its threads. 74

77 1. Shim(s) 2. Needle valve seat 3. Carburetor body 4. Float 5. Needle valve 1. Tongue of float 2. Needle valve 3. Carburetor body 75

78 76 (Engine in normal operating temperature.)

79 1. Pump nozzle 2. Carburetor 77

80 78

81 SECTION 4 ENGINE COOLING SYSTEM 79

82 80

83 4.1 GENERAL DESCRIPTION 81

84 82 1. Pressure valve 2. Vacuum valve 3. To water reservoir tank 4. Pressure relief 5. Vacuum relief 6. From water reservoir tank

85 1. Air bleed valve 83

86 SECTION 5 IGNITION SYSTEM 84

87 5.1 DESCRIPTION The ignition system is of contact pointless type (full transistorized type). The principal components of the ignition system are the spark plugs, ignition coil, and distributor. The distributor has a rotor, an ignitor, a signal generator, a vacuum advancer and a centrifugal advancer. The signal generator is to generate the ignition signal and consists of signal rotor, a magnet and a pickup coil. The signal rotor is attached to the distributor shaft, and the magnet and the pickup coil are attached to the generator base plate. When the distributor shaft rotates, the magnetic flux passing through the pickup coil varies due to the change in air gap between the pickup coil and the signal rotor. As a result, the alternating current voltage is induced in the pickup coil. The voltage induced turns on and off the ignitor which switches off the ignition coil primary current. Thus, the high voltage is induced in the secondary winding of ignition coil and ignition sparks are generated at the spark plugs Spark plug 2. Distributor 3. Distributor rotor 4. Signal rotor 5. Generator 6. Ignitor 7. Ignition coil 8. Ignition switch 9. Battery Diagnosis Condition Possible cause Correction Engine cranks, but will not run No spark Defective spark plug Leaky high tension cords Cracked rotor or cap Defective signal generator or ignitor Mis adjusted signal rotor air gap Defective ignition coil Loose connection or disconnection of high tension cords or lead wires Blown fuse Mis adjusted ignition timing Adjust the gap, or replace Replace defective cords Replace Replace Adjust Replace Connect securely Replace and repair Adjust 85

88 5.2 DISTRIBUTOR Vacuum controller 2. Distributor cap 3. Seal 4. Distributor housing 5. Distributor driven gear 6. Pin 7. O ring 8. Rotor 9. Signal generator dust cover 10. Ignitor dust cover 11. Signal generator 12. Ignitor 13. Signal rotor

89 5.3 MAINTENANCE SERVICES 3 2 IGNITION COIL Resistance measurement 1. Disconnect negative cable at battery. 2. Disconnect lead wires and high tension cord at ignition coil Measure primary coil resistance. Using an ohmmeter, measure the resistance between positive (+) and negative ( ) terminals. Primary coil resistance at 20 C Ω 4. Measure secondary coil resistance. Using an ohmmeter, measure the resistance between positive (+) terminal and high tension terminal. Secondary coil resistance at 20 C Ω 1. Signal rotor 2. Generator 3. Signal rotor air gap 3. If the gap is not to specification, adjust it. Remove ignitor and loosen two screws securing generator. Using a blade ( ) screw driver, move the generator and adjust the gap to specification. After adjustment, tighten two screws and recheck the gap. Install ignitor, rotor and distributor cap. 5. Connect lead wires and high tension cord, and negative cable at battery. DISTRIBUTOR Checking and adjusting signal rotor air gap 1. Ignitor 2. Generator 3. Generator screw 4. Signal rotor air gap 5. Blade screw driver 4 5 Signal rotor air gap mm ( in) Check the air gap and adjust it as necessary. 1. Remove distributor cap and rotor Using a thickness gauge, measure the air gap, between signal rotor tooth and generator. 3 87

90 Checking ignitor and generator 1. Turn ignition switch ON. 2. Using voltmeter, confirm that battery voltage (approx. 12V) is applied to ignition coil positive (+) and negative ( ) terminals respectively. 6. Insert blade ( ) screwdriver between signal rotor and generator tooth and move it in and out repeatedly. The voltmeter indicator should fluctuate a little (about V) when the driver is inserted. If not, replace ignitor with generator because it is defective.! CAUTION This inspection must be done in a well ventilated area. Never touch the center high tension cord because high voltage is applied to the cord when the driver is inserted. 3. Disconnect center high tension cord at distributor cap and ground it. 3! CAUTION Be sure to ground high tension cord to the place away from carburetor or other fuel systems Remove distributor cap and rotor. 5. Rotate crankshaft so signal rotor teeth do not contact generator tooth Signal rotor teeth 2. Generator tooth 1. Blade screw driver 2. Generator tooth 3. Signal rotor 4. High tension cord 5. Negative terminal 88

91 Checking centrifugal advancer After removing distributor cap, turn the rotor clockwise by finger and release it. Check that the rotor returns smoothly counter clockwise by spring force. Removal 1. Disconnect negative cable at battery. 2. Disconnect vacuum hose and lead wire coupler. 3. Disconnect high tension cord at spark plug. NOTE: DO NOT bend or pull the high tension cords to avoid inside damage. Grip the rubber boot when removing or installing the cords. 4. Remove distributor assembly from distributor gear case after removing distributor flange bolt. Disassembly 1. Remove distributor cap and then rotor. Checking vacuum advancer Remove distributor cap. Disconnect vacuum hose from vacuum controller, and connect a vacuum pump gauge to the controller. Apply the vacuum (about 400 mm Hg) and release it. Check that the generator base plate with generator moves smoothly. If the plate does not move smoothly, check the plate or the vacuum controller. 2. Remove igniter with generator Ignitor 2. Ignitor screw 3. Generator 2 1. Generator base plate 2. Generator 3. Vacuum controller 4. Vacuum 3. Remove vacuum controller and then generator base plate. 89

92 1 1. Install generator base plate to distributor housing. Fit four clips on base plate into four grooves of distributor case as shown in figure below Vacuum controller 2. Screw 3. Snap washer 4. Base plate screw 5. Generator base plate Generator base plate 2. Groove 3. Clip 4. Base plate washer 5. Base plate screw 1 Inspection [Generator base plate] Check the base plate for smooth rotation. If it does not rotate smoothly, replace it. NOTE: Do not disassemble the base plate. 2. Install vacuum controller. 3. Install generator to base plate. Adjust the signal rotor air gap to specification as previously outline. 4. Install ignitor to distributor housing. 5. Install rotor, cap seal and distributor cap. Installation 1. Turn over crankshaft in normal direction to align 8 (B.T.D.C.) timing mark to timing match mark. The 8 mark is the one provided on flywheel. Normal direction of crankshaft is clockwise as viewed from crankshaft pulley side. [Distributor cap and rotor] Check cap and rotor for cracks and their electric terminals for corrosion and wear. Replace as necessary. Assembly! CAUTION After aligning marks 1 and 2, remove cylinder head cover to visually confirm that rocker arms are not riding on camshaft cam at No. 1 cylinder. If arms are found to be riding on cams, turn over crankshaft 360 to align the two marks. 90

93 B.T.D.C. timing mark 2. Timing match mark Distributor flange 2. Mounting bolt 3. Rotor Turn rotor to make the center 3 of rotor align with mark 4 embossed on distributor housing Install cap seal and cap, and hook the two clamps securely. 5. Securely connect high tension cord to distributor cap terminals and spark plugs. NOTE: Make sure to clamp high tension cords so that they do not contact other parts Rotor center 4. Embossed line Insert the distributor into the gear case in such a way that the center of distributor flange will coincide with the distributor mounting bolt hole provided in the distributor gear case. When inserting the distributor completely, position of distributor rotor becomes as shown in figure below. Secure the distributor in place tentatively by making the mounting bolt finger tight. 1. No. 1 cylinder 2. No. 2 cylinder 3. No. 3 cylinder 4. No. 4 cylinder 5. Clamp 1 6. Connect vacuum hose to vacuum controller, and coupler of lead wires. 7. Connect negative cable at battery. 8. Start engine and adjust ignition timing by using timing light as outlined on following page. After adjustment, tighten the distributor mounting bolt. 91

94 5.4 IGNITION TIMING Ignition timing Ignition order 8 B.T.D.C. at 900 r/min CHECKING 1. Start engine and warm it up to normal operating temperature. 2. After warming up, check to be sure that the idle speed is within specification. If idle speed is out of specification, adjust it by turning the idle speed adjusting screw of carburetor. 3. Connect the timing light to the high tension cord of No. 1 cylinder. 4. With the engine running at specified idle speed, direct the timing light to flywheel. If the 8 B.T.D.C. timing mark on the flywheel appears aligned to the timing match mark on transmission case, the ignition is properly timed. ADJUSTING If the ignition timing is out of specification, adjust it. Loosen the distributor mounting bolt and turn the distributor housing in place to advance or retard the timing. Turning the housing counter clockwise advances the timing, and vice versa. After adjustment, tighten the mounting bolt and recheck the timing. 1. Distributor mounting bolt 2. Timing is retarded 3. Timing is advanced B.T.D.C. mark 2. Timing match mark 3. Flywheel 92

95