iv 4st 25/30 2016
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1) Ignition Timing Controls …………………… 4-21
2) Ignition and Combustion Orders ………… 4-21
3) Ignition Timing ……………………………… 4-21
4) Operations ………………………………… 4-21
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1)
Fuel Pump (Low Pressure Mechanical Pump)
…… 4-23
2) Vapor Separator …………………………… 4-23
3) Fuel Regulator ……………………………… 4-24
4) Fuel Cooler ………………………………… 4-24
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1) Air Intake System ………………………… 4-25
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1)
Inspection of Fuel Supply System Piping
…… 4-26
2) Inspection of Filter ………………………… 4-26
3) Inspection of Fuel Pump ………………… 4-28
4) Inspection of Fuel Connector …………… 4-28
5) Measuring fuel pressure ………………… 4-29
6) Inspection of Fuel Regulator ……………… 4-30
7) Draining Fuel ……………………………… 4-31
8) Disassembly of Vapor Separator ………… 4-31
9) Inspection of Vapor Separator …………… 4-32
10) Reassembly of Vapor Separator ………… 4-33
11)
Inspection of ISC (Idle Speed Control)
……… 4-33
12) Inspection of Idle Speed ………………… 4-33
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Engine…………………………………………… 5-3
Recoil Starter…………………………………… 5-4
Magneto ………………………………………… 5-5
Electric Parts …………………………………… 5-6
Fuel System …………………………………… 5-8
Intake Manifold ………………………………… 5-10
Pully • Timing belt ……………………………… 5-12
Cylinder head • Oil pump……………………… 5-13
Cylinder • Crank case ………………………… 5-15
Piston • Crankshaft …………………………… 5-16
Top Cowl………………………………………… 5-17
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1) Inspection of Compression Pressure …… 5-18
2) Inspection of Oil Pressure ………………… 5-19
3) Inspection of Valve Clearance …………… 5-20
4) Removing Power Unit……………………… 5-21
5) Removing Timing Belt and Pulley………… 5-24
6) Inspection of Timing Belt ………………… 5-25
7) Installation of Pulley and Timing Belt …… 5-26
8) Removing Cylinder Head ………………… 5-29
9) Inspection of Valve Spring ………………… 5-31
10) Inspection of Valve ………………………… 5-32
11) Inspection of Valve Guide ………………… 5-32
12) Inspection of Valve Seat…………………… 5-33
13) Correction of Valve Seat ………………… 5-34
14)
Inspection of Rocker Arm and Rocker Arm Shaft
…… 5-36
15) Inspection of Cam Shaft ……………… 5-37
16) Inspection of Cylinder Head ………… 5-38
17) Inspection of Oil Pump ……………… 5-39
18) Installation of Valves ………………… 5-40
19) Installation of Cam Shaft …………… 5-41
20) Installation of Rocker Arm Shaft …… 5-41
21) Installation of Oil Pump ……………… 5-42
22) Installation of Cylinder Head ………… 5-43
23) Disassembly of Cylinder Block ……… 5-44
24) Inspection of Piston Outer Diameter 5-45
25) Inspection of Cylinder Inner Diameter 5-45
26) Inspection of Piston Clearance ……… 5-45
27)
Inspection of Piston Ring Side Clearance
5-46
28) Inspection of Piston Rings …………… 5-46
29) Inspection of Piston Pins …………… 5-47
30)
Inspection of Connecting Rod Small End Inner Diameter
5-47
31)
Inspection of Connecting Rod Big End Side Clearance
… 5-47
32) Inspection of Crankshaft……………… 5-48
33) Inspection of Crank Pin Oil Clearance 5-49
34)
Inspection of Crankshaft Main Journal Oil Clearance
5-50
35)
Inner Diameter of Cylinder/Crank Case Bearing Holder (Inner Diameter Code)
5-51
36)
Thickness of Bearing (Color of Inner Diameter Code)
5-51
37)
Assembling Piston and Connecting Rod
5-52
38) Installation of Power Unit …………… 5-56
39) Removing Recoil Starter …………… 5-58
40) Disassembly of Recoil Starter ……… 5-58
41) Inspection of Recoil Starter ………… 5-59
42) Installation of Recoil Starter ………… 5-60
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Gear Case ………………………………… 6-4
Drive System & Water Pump …………… 6-5
Shift ………………………………………… 6-7
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1) Draining Gear Oil……………………… 6-8
2) Removing Propeller…………………… 6-8
3) Removing Lower Unit ………………… 6-9
4) Disassembly of Water Pump ………… 6-9
5) Inspection of Water Pump …………… 6-10
6)
Removing Propeller Shaft Housing Ass'y
6-10
7) Disassembly of Propeller Shaft Ass'y 6-11
8) Inspection of Propeller Shaft ………… 6-11
9) Assembly of Propeller Shaft Ass'y … 6-11
10)
Disassembly of Propeller Shaft Housing
6-12
11) Inspection of Propeller Shaft Housing 6-13
12) Assembly of Propeller Shaft Housing 6-14
13) Removing Pump Case (Lower) ……… 6-15
14) Disassembly of Pump Case (Lower) 6-15
15) Assembly of Pump Case (Lower) …… 6-15
16) Removing Clutch Cam and Cam Rod 6-15
17)
Disassembly of Clutch Cam and Cam Rod
6-15
18)
Inspection of Cam Rod and Clutch Cam
6-16
19)
Assembly of Cam Rod and Clutch Cam
6-16
