Kubota D1102-B Instruction manual

KiSC issued 09, 2007 A

WORKSHOP MANUAL
DIESEL ENGINES
D1102-B,D1302-B,D1402-B,
V1502-B,V1702-B,V1902-B

KiSC issued 09, 2007 A

INTRODUCTION
• This Workshop Manual provides general description, and comprehensive
information for servicing Kubota 01102-8, 01302-8, 01402-B, V1502-B,
V1702-B, V1902-B diesel engines. It consists of five sections as following:
• Section I "Specifications and Performance Curves" covers specif ications and
performance curves.
• Section II "General Description" covers newest information on the features,
functions and constructions of these Kubota engines.
• Section ill and N "Engine" and "Electrical System" cover disassembling and
assembling procedures, checking and servicing instructions. In addition, a
troubleshooting chart with reference pages given is provided at the begin-
ning of each section, it helps you find out the cause of malfunction easily.
• Section V "Service Directions" covers all reference values and allowable
limits required for servicing.
0078P001
* KUBOTA Corporation reserves the right to change the specifications without
notice.
* No part of this manual may be reproduced without permission of KUBOTA
Corporation.

KiSC issued 09, 2007 A

CONT ENTS
Section I
Section II
Section ill
Section IV
Section V
SPECIFICATIONS AND PERFORMANCE CURVES ................................. 3
GENER AL DESCRIPTION .......................................................................... 13
1. Engine
2. Lubrication System
3. Cooling System
4. Fuel System
5. Electrical System
ENGINE ........................................................................................................ 27
1. Troubleshooting
2. Disassembly and Reassembly
3. Servicing
ELECTRICAL SYSTEM ............................................................................. 71
1. Troubleshooting
2. Alternator and Regulator
3. Starter and Glow Plug
SER VICE DIRECTIONS.............................................................................. 97
2

KiSC issued 09, 2007 A

" ;
Section I
SPECIFICATIONS AND PERFORMANCE CURVES
« ;;/. " "' p
• D1102-B .................................................................................................................... 4
• D1302-B .................................................................................................................... 5
• D1402-B ......................................................................................................................... 6
• V1502-B .................................................................................................................... 7
• V1702-B ................................................................................................................. 8
• V1902-B .................................................................................................................... 9
• DIMENSIONS .................................................................................................................. 10
3

KiSC issued 09, 2007 A

Section I
SPECIFICATIONS AND PERFORMANCE CURVES
• D1102-B
Specifications
Performance Curves
Note:
Each per formance curves, obtained i n accordance with DIN 6270
and DIN 70020, ar
e corrected to 101kPa ( 760mmHg ) , and 20° C,
60% humidity.
Note:
Each performance curves, obtained in accordance with SAE J816b,
are corrected to 101kPa
( 760mmHg ) , and 20° C, 60% humidity.
4
1400 1600 1600 2000 2200 2400 2600 2800
ENGINE tnin-1(rprn)
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190 2
1 400 1600 1800 2000 2200 2400 ?600 2800
ENGINE min-1(rpm)
Maximum Bare Speed
3000 min·
1
(rpm)
Minimum Bare Idling Speed 800 min
1
(rpm)
Combustion Chamber
Spherical Type
Fuel Injection Pump Bosch K Type mini pump
Governor
Centrifugal Ball Mechanical Governor
Injection Nozzle DN 12 SD 12
Injection li ming
0.436 rad. (25'') before T.D.C.
Injection Pressure 13.73 MPa (140 kgf/cm
2,
1991 psi)
Compression Ratio 21
Cooling System
Pressurized radiator (8.83 x 10
4
Pa, 0.9 kgf/cm
2,
12.8 psi) Forced circulation (with water pump)
Starting System Electric Starting with Cell starter (12 V, 1.0kW)
Dynamo for Charging 12 V,300 W
Fuel
Diesel Fuel No.2-D
Weight (Dry) 146 kg (321.9 lbs.)
Battery 12 V, 80AH, equivalent
Direction of Rotation
Counter-clockwise from flywheel side
Application General Power Source
Model D1102-B
Type
Vertical, water-cooled,
4-cycle diesel engine
Number of Cylinders 3
Bore x Stroke mm (inch)
Ji 76 x 82 L ( Ji 2.99 x 3.23 L)
Total Displacement cm
3
(cu.in.) 1115 (68.04)
Brake H.P.
DIN 6270-NA 14.3 kW / 2800 min·1(rpm)
(19.4 P.S./ 2800 min·
1
(rpm))
DIN 6270-NB 16.2 kW
I2800 min1(rpm)
(22.0 P.S./ 2800 min·
1
(rpm))
DIN 70020 17.7 kW
I2800 min1(rpm)
(24.0 P.S./ 2800 min·
1
(rpm))
SAE Gross H.P. 19.0 kW / 2800 min·1(rpm)
(25.5 H.P./ 2800 min
1
(rpm))
SAE Intermittent H.P. 16.8 kW / 2800 min1(rpm)
(22.5 H.P./ 2800 min
1
(rpm))
SAE Cont. H.P. 14.5 kW
I2800 min1(rpm)
(19.4 H.P./ 2800 min·
1
(rpm))

KiSC issued 09, 2007 A

• 01302-B
Specifications
Performance Curves
Note:
Each performance curves, obtained in accordance with DIN 6270
and DIN 70020, are corrected to 101kPa
( 760mmHg ) , and 20"C,
60% humidity.
Note:
Each performance curves, obtai ned in accordance with SAE J816b
are corrected to 101kPa
( 760 mmHg ) , and 20° C, 60% humidity. '
5
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r
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r
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r
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I
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LL
55
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( NF)
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200
1 90
di
..J
LJ.J
:::i
LL
1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min-
1
(rpm)
Maximum Bare Speed 3000 min-
1
(rpm)
Minimum Bare Idling Speed
800 min-
1
(rpm)
Combustion Chamber
Spherical Type
Fuel Injection Pump Bosch K Type mini pump
Governor Centrifugal Ball Mechanical Governor
Injection Nozzle DN 12 SD 12
Injection li ming 0.436 rad. (25') before T.D.C.
Injection Pressure
13.73 MPa (140 kgf/cm
2,
1991 psi)
Compression Ratio 21
Cooling System
Pressurized radiator (8.83 x 1 a4 Pa, 0.9 kgf/cm
2,
12.8 psi) Forced circulation (with water pump)
Starting System Electric Starting with Cell starter (12 V, 1.0kW)
Dynamo for Charging 12 V, 300 W
Fuel
Diesel Fuel No.2-D
Weight (Dry) 147 kg (324.1 lbs.)
Battery 12 V, 80AH, equivalent
Direction of Rotation
Counter-clockwise from flywheel side
Application General Power Source
Model D1302-B
Type
Vertical, water-cooled,
4-cycle diesel engine
Number of Cylinders 3
B o r e x S t r o k e mm (inch) ¢ 82 x 82 L ( ¢ 3.23 x 3.23 L)
Total Displacement cm
3
(cu.in.)
1299 (79.27)
Brake H.P.
D1N 6270-NA
17.3 kW I 2800 min-1(rpm)
(23.5 P.S./ 2800 min-
1
(rpm))
DIN 6270-NB
18.8 kW I 2800 min-
1
(rpm)
(25.5 P.S./ 2800 min-
1
(rpm))
DIN 70020
21.0 kW I 2800 min-
1
(rpm)
(28.5 P.S./ 2800 min-
1
(rpm))
SAE Gross H.P. 22.4 kW
I2800 min-1(rpm)
(30.0 H.P./ 2800 min-
1
(rpm))
SAE Intermittent H.P. 20.1 kW
I2800 min·1(rpm)
(27.0 H.P./ 2800 min-
1
(rpm))
SAE Cont. H.P. 17.5 kW
I2800 min-1(rpm)
(23.5 H.P./ 2800 min-
1
(rpm))

KiSC issued 09, 2007 A

• 01402-e
Specifications
Performance Curves
Note:
Each perf ormance curves, obtained in accordance with DIN 6270
and DIN 70020, are corrected to 101kPa (760mmHg
) , and 20°C,
60% humidity.
Note:
Each performance curves, obtained in accordance wi th SAE J816b,
are corrected to 101kPa
( 760 mm Hg ) , and 20° C, 60% humidity.
6
-
-
GROSS TORQUE
-+---k I I
'f--+.....L.
65
.......
-
Q
J
-i---
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CONT TORQUE
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55
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50
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LU
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0.5 aJ
0.45 ....J
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0.4
u.
1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min-
1
(rpm)
I
---
M
,_
F
--
I
MB
-i--
- --
.
-
9 0
r
--
1"-- -
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--.I'--
r
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:
0
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H-f -1- ::i=;a b ; ( N = F ) . -
+
-
=
,
i - .- "' . ._ 190
1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min-
1
(rpm)
r
-i
_
...- 200
l.l..
Maximum Bare Speed 3000 min-
1
(rpm)
Minimum Bare Idling Speed 800 min-
1
(rpm)
Combustion Chamber Spherical Type
Fuel Injection Pump Bosch K Type mini pump
Governor Centrifugal Ball Mechanical Governor
Injection Nozzle DN 12 SD 12
Injection li ming 0.436 rad. (25') before T.D.C.
Injection Pressure
13.73 MPa (140 kgf/cm
2,
1991 psi)
Compression Ratio 21
Cooling System
Pressurized radiator (8.83 x 104 Pa, 0.9 kgf/cm
2,
12.8 psi) Forced circulation (with water pump)
Starting System Electric Starting with Cell starter (12 V, 1.4kW)
Dynamo for Charging 12 V,300 W
Fuel
Diesel Fuel No.2-D
Weight (Dry) 148.2 kg (326.7 lbs.)
Battery
12 V, 110AH, equivalent
Direction of Rotation
Counter-clockwise from flywheel side
Application General Power Source
Model D1402-B
Type
Vertical, water-cooled,
4-cycle diesel engine
Number of Cylinders
3
Bore x Stroke mm (inch) ¢ 85 X 82 L ( ¢ 3.25 X 3.23 L)
Total Displacement cm
3
(cu.in.)
1395 (85.13)
Brake H.P.
DIN 6270-NA 18.4 kW
I2800 miff1(rpm)
(25.0 P.S./ 2800 miff
1
(rpm))
DIN 6270-NB
19.9 kW I 2800 min-1(rpm)
(27.0 P.S./ 2800 min-
1
(rpm))
DIN 70020
22.4 kW I 2800 min-1(rpm)
(30.5 P.S./ 2800 min-
1
(rpm))
SAE Gross H.P.
23.9 kW I 2800 min-1(rpm)
(32.0 H.P./ 2800 min·
1
(rpm))
SAE Intermittent H.P. 21.3 kW
I2800 miff1(rpm)
(28.5 H.P./ 2800 min-
1
(rpm))
SAE Cont. H.P. 18.7 kW
I2800 min·1(rpm)
(25.0 H.P./ 2800 min-
1
(rpm))

KiSC issued 09, 2007 A

• v1so2-e
Specifications
Performance Curves
Note:
Each performance curves, obtained in accordance with DIN 6270
and DIN 70020, are corrected to 101kPa
( 760mmHg ) , and 20°C,
60% humidity .
Note:
Each performance curves, obtained in accordance with SAE J816b,
are corrected to 101kPa
( 760 mm Hg ) , and 20° C, 60% humidity.
7
I I I I I
GROSS TORQUE
I
-........L I I I
70
INTERMITT ENT
TORQUE
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1400 1600 1800 2000 2200 2400 2600 2800
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LU
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u..
1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min"1(rpm)
Maximum Bare Speed
3000 min·1(rpm)
Minimum Bare Idling Speed
800 min-1(rpm)
Combustion Chamber
Spherical Type
Fuel Injection Pump Bosch K Type mini pump
Governor
Centrifugal Ball Mechanical Governor
Injection Nozzle DN 12 SD 12
Injection li ming 0.436 rad. (25'} before T.D.C.
Injection Pressure
13.73 MPa (140 kgf/cm
2,
1991 psi)
Compression Ratio 21
Cooling System
Pressurized radiator (8.83 x 104Pa, 0.9 kgf/cm
2
,
12.8 psi) Forced circulation (with water pump)
Starting System Electric Starting with Cell starter (12 V, 1.4kW)
Dynamo for Charging 12 V, 300 W
Fuel Diesel Fuel No.2-D
Weight (Dry) 175.7 kg (387.3 lbs.)
Battery 12 V, 110AH, equivalent
Direction of Rotation
Counter-clockwise from flywheel side
Application General Power Source
Model
V1502 B
Type
Vertical, water-cooled,
4-cycle diesel engine
Number of Cylinders 4
Bore x Stroke mm (inch}
ef, 76 X 82 L ( ef, 2.99 X 3.23 L}
Total Displacement cm
3
(cu.in.)
1487 (90.74)
Brake H.P.
DIN 6270-NA
19.1 kW I 2800 min-
1
(rpm)
(26.0 P.S./ 2800 min-
1
(rpm))
DIN 6270-NB
21.3 kW I 2800 min-
1
(rpm)
(29.0 P.S./ 2800 min-
1
(rpm))
DIN 70020
23.5 kW I 2800 min-
1
(rpm)
(32.0 P.S./ 2800 min-
1
(rpm))
SAE Gross H.P. 25.4 kW
I2800 min-1(rpm)
(34.0 H.P./ 2800 min-
1
(rpm))
SAE Intermittent H.P. 22.4 kW
I2800 min-1(rpm)
(30.0 H.P./ 2800 min-
1
(rpm))
SAE Cont. H.P. 19.4 kW
I2800 min-1(rpm)
(26.0 H.P./ 2800 min-
1
(rpm))

KiSC issued 09, 2007 A

• V1702-B
Specifications
Performance Curves
Note:
Each performance curves, obtained in accordance with DIN 6270
and DIN 70020, are corrected to 101kPa
( 760mmHg ), and 20° C,
60% humidity.
Note:
Each perf ormance curves, obtained in accordance with SAE J816b
are corrected to 101kPa
( 760mmHg ), and 20° C, 60% humidity. '
8
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GROSS TORQUE-
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1400 1600 1800 2000 2200 2400 2600 2800
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1
(rpm)
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----
1
-
?
·-
?
1
1 400 1 600 1 800 2000
2ioo 2400 2600 2800
ENGINE min-
1
1rpm)
Maximum Bare Speed 3000 min-
1
(rpm)
Minimum Bare Idling Speed
800 min-
1
(rpm)
Combustion Chamber
Spherical Type
Fuel Injection Pump Bosch K Type mini pump
Governor Centrifugal Ball Mechanical Governor
Injection Nozzle DN 12 SD 12
Injection li ming 0.436 rad. (25'') before T.D.C.
Injection Pressure
13.73 MPa (140 kgf/cm
2,
1991 psi)
Compression Ratio 21
Cooling System
Pressurized radiator (8.83 x 1 a4 Pa, 0.9 kgf/cm
2,
12.8 psi) Forced circulation (with water pump)
Starting System Electric Starting with Cell starter (12 V, 1.4kW)
Dynamo for Charging 12 V,300 W
Fuel
Diesel Fuel No.2-D
Weight (Dry) 177.1 kg (390.4 lbs.)
Battery 12 V, 110AH, equivalent
Direction of Rotation
Counter-clockwise from flywheel side
Application General Power Source
Model V1702-B
Type
Vertical, water-cooled,
4-cycle diesel engine
Number of Cylinders 4
B o r e x S t r o k e mm (inch) ¢ 82 X 82 L (
<h 3.23 X 3.23 L)
Total Displacement cm
3
(cu.in.)
1732 (105.69)
Brake H.P.
DIN 6270-NA
22.8 kW I2800 min-
1
(rpm)
(31.0 P.S./ 2800 min-
1
(rpm))
DIN 6270-NB
25.0 kW I2800 min-1(rpm)
(34.0 P.S./ 2800 min-
1
(rpm))
DIN 70020
27.9 kW I2800 min-
1
(rpm)
(38.0 P.S./ 2800 min-
1
(rpm))
SAE Gross H.P.
29.8 kW I2800 min-1(rpm)
(40.0 H.P./ 2800 min-
1
(rpm))
SAE Intermittent H.P. 26.9 kW I2800 min-1(rpm)
(36.0 H.P./ 2800 min-
1
(rpm))
SAE Cont. H.P. 23.1 kW I2800 min-1(rpm)
(31.0 H.P./ 2800 min-
1
(rpm))

KiSC issued 09, 2007 A

• v1so2-e
Specifications
Performance Curves
Note:
Each perf ormance curves, obtained in accordance wi th DIN 6270
and DIN 70020, are corrected to 101kPa
( 760mmHg ), and 20°C,
60% humidity.
Note:
Each performance curves, obtained in accordance with SAE J816b,
are corrected to 101kPa ( 760 mmHg ), and 20° C, 60% humidity.
9
I I I I I
GROSS TORQUE
T-t-
INTERMITIENT TORQUE
r-.
- I
CONT TORQUE-
-
--
-
90
r
-+-L
I-
80 cri
,.'.;
LL.
70 w
L
:::
J
i-....
I-
60 8
45
.v
40
a.
J:
a: 35
UJ
GROSS. B.H.P:.,.,.....
J..,;f 1......
I X- .vt
"
-o·, >S
-
30
(/)
a:
l/
[/
,-;; t L...-+-"'
...
Vj...A'. '\
L..,.,,
...-
/_
...
V
25
w
::.:
Cil
20
P' .v
;/
I/
_
1,.,1'" I I
CONT. B.H.P
a:
J:
a:
J:
15
....
FUEL (INTERMITIENT)
I
'--
0.5
0.45 LiJ
0.4 CT:
1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min-
1
(rpm)
-
-
MF
--
r
--
Me -
I
t-- ....
_
-
-
-i--,
1
1
1
i--......
M A
r
--i-
45
40
.,. .....
i...,.-
>
w
N
F
,.
V
.,....r
..-
-
_
i,..-
Cl) 35
i....--
a
a
:
...
v
N a.
v _1--"'
30
.,,,/'
.... v
w
(
.
)
z
I
/
V
I
/
25
1
........
r
.... v
y
l..-' N11
V
.... v
I/"""
L
a
L
:
. ....,",,
V
r
i
20
.,.v
i,......
-
b(
N F
)
i-.
..-
-
J
:
ch
210
Ol
200 ..J
w
190
1400 1600 1800 2000 2200 2400 2600 2800
ENGINE min-
1
(rpm)
Maximum Bare Speed 3000 min-
1
(rpm)
Minimum Bare Idling Speed
800 min-
1
(rpm)
Combustion Chamber
Spherical Type
Fuel Injection Pump Bosch K Type mini pump
Governor Centrifugal Ball Mechanical Governor
Injection Nozzle DN 12 SD 12
Injection li ming 0.436 rad. (25) before T.D.C.
Injection Pressure
13.73 MPa (140 kgf/cm
2,
1991 psi)
Compression Ratio 21
Cooling System
Pressurized radiator (8.83 x 1 Q4 Pa, 0.9 kgf/cm
2,
12.8 psi) Forced circulation (with water pump)
Starting System Electric Starting with Cell starter (12 V, 1.4kW)
Dynamo for Charging 12 V, 300 W
Fuel
Diesel Fuel No.2-D
Weight (Dry) 178.2 kg (392.2 lbs.)
Battery 12 V, 110AH, equivalent
Direction of Rotation
Counter-clockwise from flywheel side
Application General Power Source
Model V1902-B
Type
Vertical, water-cooled,
4-cycle diesel engine
Number of Cylinders 4
B o r e x S t r o k e mm (inch)
q; 85 X 82 L ( q; 3.35 X 3.23 L)
Total Displacement cm
3
(cu.in.)
1861 (113.57)
Brake H.P.
DIN 6270-NA 24.3 kW I2800 min-1(rpm)
(33.0 P.S./ 2800 min-
1
(rpm))
DIN 6270-NB
26.5 kW I 2800 min-
1
(rpm)
(36.0 P.S./ 2800 min-
1
(rpm))
DIN 70020
30.2 kW I 2800 min-
1
(rpm)
(41.0 P.S./ 2800 min-
1
(rpm))
SAE Gross H.P. 32.1 kW
I2800 min·1(rpm)
(43.0 H.P./ 2800 min-
1
(rpm))
SAE Intermittent H.P. 28.7 kW
I2800 min-1(rpm)
(38.5 H.P./ 2800 min-
1
(rpm))
SAE Cont. H.P. 24.6 kW
I2800 min-1(rpm)
(33.0 H.P./ 2800 min-
1
(rpm))

KiSC issued 09, 2007 A

i--- --- 512 mm (20. 16")
-
---- .................. i
257mm (10.12")
10mm (0.39")
• DIMENSIONS (01101-B, 01302-B, 01402-B)
----- --------------- ----- -----
0073F013
--- 580mm (22,83")-01102-B, 01302-B ------------------- i
568mm (22.36")-01402-B
240mm (9.45")
i--- --- -544mm (21.42")1- --- ........................ i
4-M8 DEPTH 12 mm (0.47")
10

KiSC issued 09, 2007 A

(V1502-B, V1702-B, V1902-B)
257mm
(1012")
0073F014
512mm
(20.16")
2-08.2
M8
662mm (26.06")-V1502-B
652mm (25.67")-V1702-B, V1902-B
11

KiSC issued 09, 2007 A

12

KiSC issued 09, 2007 A

.
· ti>
Section II
GENEIIAt. DEIGRIPf:101 ·
": ., ""' ! " ,,," .,., "'
FEATURE ............................................................. 14
1. ENGINE
2. LUBRICATION SYSTEM................................. 18
3. COOLING SYSTEM .......................................... 18
4. FUEL SYSTEM
4.1 Fuel Filter (Optional Part) .......................... 19
5. ELECTRICAL SYSTEM
5.1 Cranking System .......................................... 23
5.2 Charging System ............................................. 25
13
1.1 Cylinder Block . . . . . . . . . . . . . . . . . . 16
4.2 Fuel Pump . . . . . . . . . . . . . . . . . . . . 20
1.2 Cylinder Head . . . . . . . . . . . . . . . . . . 16
4.3 Fuel Injection Pump . . . . . . . . . . . . . . 20
1.3 Piston and Piston Rings . . . . . . . . . . . . 17 4.4 Injection Nozzle . . . . . . . . . . . . . . . . . 22
1.4 Inlet and Exhaust Valves . . . . . . . . . . . 17 4.5 Governor . . . . . . . . . . . . . . . . . . . . . 22

KiSC issued 09, 2007 A

FEATURE
The D 1102-8, 01302-B, D 1402-B, V1502-B, V1702-B, V1902-B are water-cooled, 4-cycle diesel engines, they
concentrate Kubota's foremost technologies. With Kubota's designed spherical combustion chamber, well-known Bosch
K type injection pump, well-balance designs, they feature greater power, low fuel consumption, little vibration and
limited noise.
14
0073FOI 5

KiSC issued 09, 2007 A

15

KiSC issued 09, 2007 A

\) .\, \:)
()
C
)
" " "
(
'.
)
\:)
1-2 CYLINDER HEAD
To prevent the eff ect of a i r ex pa nsi on d ue to exhausted heat,
cross-f low ty pe
i n l et a nd exha ust ports are provided. The
K u bota 's excl usive spherical combustion cha m ber (e) cha nges
the entered a
i r i nto a sw i rl i ng flow to i m prove combustion
and red uce
f uel consu m pti on. I n add i ti on, the sheathed ty pe
gl ow pl ugs (c) perm i t easy a nd q u ick engi ne start, regard l ess
of weather cond
i tion, even when the tem peratu re is -15°C
(5° F
) .
(a) Combustion Chamber
(b) Suction
(c) Exhaust
(a) Nozzle Assembly
(b) Nozzle Piece Gasket
(c) Glow Plug
(d) Cylinder Head
(e) Combustion Chamber
16
1-1 CYLINDER BLOCK
The engi ne f eatu res a h igh d u ra bi l ity tu nnel-ty pe cyl i nder
bl ock. F urthermore, d ry-type cyl
i nder l i ners a re pressure-
fitted
i nto cyl i nders a l low ef fective cool i ng, l ess d istort ion,
h igher wear-resista nce q ua l ity a nd each cyl i nder has its own
cha mber hel ps to m
i n i m i ze noise.
(
A
)
Tunnel C
y
linder Block
0011 FO
J
2
(A) Cross-Faw Type Cylinder Head
(c) (c)
0011F014
(c)
(a)
(B) Combustion Chamber
0011 F013
(e)
(bl

KiSC issued 09, 2007 A

1-3 PISTON AND PISTON RINGS
A piston of special el l i ptic shape is designed i n consideration
of explosion heat. Fu rther more, to enha nce piston's strength ,
a rib is prov ided between the piston a nd the piston boss.
Th ree piston ri ngs a re provided; two com pression ri ngs a nd
one oi l ri ng. Al l of them have d iff erent f u nct ions a nd sha pes.
Be ca ref u
l w hen reassem bl i ng.
(a) Plated Keystone Ring
(b)
Undercut Ring
(c)
Coil Expander Ring
(d)
Taper and Inside Cut Ring
V1702-B Only I
[
Engine Serial Number : 37196 and beyond ,J
(e) Valve Stem Seal
(f ) Valve Guide
(g)
Inlet Valve
(h)
Exhaust Valve
(i) Carbon Scraper
17
(A) Inlet and Exhaust Valve
(a)
(b)
(c) ------
1-4 INLET AND EXHAUST VALVES
Al I parts a re quenched a nd tempered to resist wear. Fo
r
enhanci ng the f ill i ng-u p of a ir i nto eng i ne, the i nl et va l ve
head is bigger the exha ust ( h) one. To prevent the ca rbon
ad hesion on exha ust va
l ve stem, a "carbon-scra per" ( i ) is
p
rov ided at the l ower pa rt of ex ha ust val ve g u ide.
( d) --- --«-!
(e) --
( f )
(g)
(a) Valve Cap
(b) Valve Spring Retaine
r
0011FO
J
9
(c) Valve Spring Collet
(d) Valve Spring
and Piston Rin
g
s
(
d
)
¢>

KiSC issued 09, 2007 A

The l u brication system consists of a trochoide rotor-type
driven oil pu mp, oil filter cartridge, oil pressure regulati ng
valve, oil switch a nd oi
l filter.
Oil is sucked by the oil pu mp (b) from the oi l pa n (o) through
the oil f ilter (a) , a nd the oi l is kept at 294 to 441 kPa (3.0 to
4.5 kgf/cm
2 ,
42 to 64 psi) by a n oil pressure regulati ng va lve
(c) i nstalled i n the gear case. Then oi l flows towards the f i lter
ca rtridge where it wil
l be f u rther f i ltered - To ensure the
suppl y ing of
l u bricated oil, a by-pass valve (d) is prov ided,
the va lve opens when the f
i lter element (e) is restr icted -.
From the f ilter cartridge, the pressured oil is then d istributed
i nto two parts: one pa rt wil l be f ed through cra nkshaf t
passage to the crank pi n bea ri ng a nd the other to the rocker
arm shaf
t ( i) th rough the frame. Oi l then returns to oil pa n
by force of gravity.
A n oil pressure switch ( m) is provided on the way for watch-
i ng the oil pressure drop. The oil pressure switch can be con-
nected to the termi nals of the warni ng lamp on the hour-
meter
u nit (optional part), the l ight wil l be l ight for warni ng
the operator
if the oi l pressure drops below 50 kPa (0.5
kgf /cm
2
, 7 .1 psi) .
If the warn i ng la mp rema ins l ight wh i le engine is at normal
operation, stop the engine im med iately a nd check the oil
pressure.
(a) Oil filter
(b)
Oil pump
(c)
Pressure regulating valve
(d)
By-pass valve
(e)
Filter element
(f)
Crankshaft
(g)
Piston
(h)
Idle gear
(i) Rocker arm shaft
(j) Rocker-arm
{k) Push rod
(I) Tappet
(m) Oil pressure switch
(n) Camshaft
(o) Oil pan
The cool i ng system consists of a rad iator (optional part),
centrif uga
l water pu mp, suction fa n and thermostat.
The water flow is cooled th rough the rad iator core ( b) a nd
the fa n (c) set beh
i nd the rad iator (a) pul ls cool i ng air
through the core to
i mprove cool i ng.
The pump (d) sucks the cooled water, forces it i nto the
cy
l i nder block (e) and draws out the hot water. Then the
cool
i ng is repeated. F urthermore, to control tem perature of
water, a thermostat
( h) is provided on the way. When the
thermostat opens, t he water moves d
i rectl y to rad iator, but
when it closes, the water moves toward the water pum p
th rough the by-pass
( i ) between thermostat and water pu mp.
The opening temperature of thermostat is about 82°C
(176.3°F).
(a) Radiator (f) Cylinder head
(b) Radiator core (g) Water pipe
(c) Suction fan (h) Thermostat
(d) Water pump (i) By-pass
(e) Cyl i nder block
18
(
A
)
Lubrication S
y
stem
(
i
)
Im
)
(
o
)
(
A
)
Coolin
g
S
y
stem
(g)
(
a
)
(
b
)
0073F018
0073F01
7
(
a
)

KiSC issued 09, 2007 A

(
A
)
Fuel Filte
r
(
a
)
In operation, fuel from the fuel
tank (a) enters the filter (b),
where it is cleaned and absorb-
ed
by the suction of fuel pump
(c). ( V1502-B, V1702-B,
V1902-B are available) The
pump then pushes
it to the
injection pump (d), where
it is
pressurized under high pressure
and through the injection pipe
(e),
it is delivered to each injec-
tion nozzle (f), which atom-
iies and injects it into the com-
bustion chamber at the proper
time and amount. Excessive
fuel from nozzles returns to
the fuel tank through fuel
overflow pipe (g).
(a ) Fuel Tank
(b) Fuel Fiter
(c) Fuel Pump
(d) Injection Pump
(e) Injection Pipe
(f ) Injection Nozzle
(g) Fuel Overflow Pipe
4-1 FUEL FILTER (OPTIONAL PART)
For protecting injection pump and injection nozzles from
impurities, the fuel is sent through the filter before reaching
the fuel pump.
Fuel enters the filter, passes through the filter element (d)
circumference toward the center for filtering. The filteration
granular size is from 10 to 20µm (0.01 to 0.02mm).
(a) Cock Body
(b) Retaining R i ng
(c) Filter Cup
(d) Element
19
0073F019
(A) Fuel System
(a)
(g)
(f )
(e)
OOJ1F035
-
(b)
(c)