Yamaha 20C User manual

20C
SERVICE MANUAL
MANUEL D’ENTRETIEN
MANUAL DE SERVICIO
6A9-28197-5F-B1
290524
YAMAHA MOTOR CO., LTD.
Printed in Japan
July. 2003 – 1.1 ×1 !
(E, F, S) Printed on recycled paper
E
F
ES
20C
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A20000-0
NOTICE
This manual has been prepared by the Yamaha Motor Company primarily for use by Yamaha dealers and their
trained mechanics when performing maintenance procedures and repairs to Yamaha equiment. It has been
written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts
and procedures inherent in the work, for without such knowledge attempted repairs or service to the equip-
ment could render it unsafe or unfit for use.
Because the Yamaha Motor Company, Ltd has a policy of continuously improving its products, models may dif-
fer in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorised Yamaha dealers are notified periodically of modifications and significant changes in spec-
ifications and procedures, and these are incorporated in successive editions of this manual.
20C
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
1st Edition, July 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
P/N 6A9-28197-5F-B1
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FES
A20000-0
AVANT PROPOS
La Yamaha Motor Company a élaboré
ce manuel à l’attention des concession-
naires Yamaha et de leurs mécaniciens
pour leurs travaux d’entretien et de répa-
ration sur du matériel Yamaha. Ce
manuel s’adresse à des personnes dispo-
sant de connaisances de base solides en
mécanique et en électricité sans les-
quelles elles risqueraient, au cours de
leurs travaux de réparation ou d’entre-
tien, de rendre matériel inapte ou dange-
reux à l’utilisation.
La politique dela Yamaha Motor
Company Ltd. visant à l’amélioration
constante de ses produits, il est possible
que le modèle devant faire l’objet d’une
réparation ne corresponde pas exacte-
ment au modèle présenté. N’utilisez que
l’édition la plus récente de ce manuel.
Les concessionnaires agréés Yamaha
sont régulièrement informés de toutes
les modifications importantes apportées
à notre matériel. Il est tenu compte de
ces modifications dans les éditions suc-
cessives de ce manuel.
20C
MANUEL D’ATELIER
©2003 Yamaha Motor Co., Ltd.
1ère Edition, Juillet 2003
Tous droits réservés.
Toute réimpression ou utilisation
sans la permission écrite de la
Yamaha Motor Co., Ltd.
est formellement interdite.
Imprimé aux Japon
P/N 6A9-28197-5F-B1
A20000-0
AVISO
Este manual ha sido preparado por
Yamaha Motor Company y va dirigido a
los concesionarios Yamaha y a sus
mecánicos encargados de los procedi-
mientos de mantenimiento y las repara-
ciones de los equipos Yamaha. Está
redactado de forma que pueda satisfacer
las necesidades de aquellas personas
que poseen unos conocimientos básicos
de los conceptos y procedimientos
mecánicos y eléctricos inherentes a
dichos trabajos de mantenimiento y
reparación, ya que de no poseer tales
conocimientor, las posibles reparaciones
o mantenimiento del equipo podrían
afectar adversamente a su seguridad y
operatividad.
Puesto que Yamaha Company Ltd. sigue
una política de mejora continua de sus
productos, puede que las especificacio-
nes de los modelos no coincidan con
algunos aspectos de las descripciones e
ilustraciones contenidos en esta publica-
ción. Utilice únicamente la versión más
reciente de este manual. Los concesio-
narios autorizados Yamaha reciben
periódicamente información relativa a
las modificaciones y cambios significa-
tivos introducidos en las especificacio-
nes y los procedimientos de los equipos,
información que se incorporará a las
ediciones sucesivas de este manual.
20C
MANUAL DE SERVICIO
©2003, Yamaha Motor Co., Ltd.
1aedición, Julio 2003
Reservados todos los derechos.
Se prohíbe expresamente
toda reimpresión
o utilización no autorizada
de este manual
sin el consentimiento por escrito de
Yamaha Motor Co., Ltd.
Impreso en Japón
P/N 6A9-28197-5F-B1
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A30000-0 INDEX
GENERAL INFORMATION GEN
INFO
SPECIFICATION SPEC
GENERAL SERVICE GEN
SRVC
FUEL SYSTEM FUEL
POWER UNIT POWR
LOWER UNIT LOWR
BRACKET UNIT BRKT
ELECTRICAL SYSTEM ELEC
TROUBLE-SHOOTING TRBL
SHTG
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FES
TABLE DES
MATIERES
INFORMATIONS
GENERALES
SPECIFICATIONS
SERVICE
GENERAL
SYSTEMES
D’ALIMENTATION
MOTEUR
BOITIER
D’HELICE
SUPPORT
ELECTRICITE
DEPANNAGE
INDICE
INFORMACION
GENERAL GEN
INFO
1
ESPECIFICA-
CIONES SPEC
2
MANTENIMIENTO
GENERAL GEN
SRVC
3
SISTEMA DE
ALIMENTACION
DE COMBUSTIBLE FUEL
4
MOTOR
POWR
5
UNIDAD
INFERIOR LOWR
6
UNIDAD SOPORTE
BRKT
7
SISTEMA
ELECTRICO ELEC
8
LOCALIZACION Y
REPARACION DE
AVERIAS TRBL
SHTG
9
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CONTENTS
CHAPTER 1
GENERAL INFORMATION
HOW TO USE THIS MANUAL...................................................................................1-1
MANUAL FORMAT ...............................................................................................1-1
THE ILLUSTRATIONS..........................................................................................1-1
REFERENCES .....................................................................................................1-2
SPECIFICATIONS ................................................................................................1-2
WARNINGS, CAUTIONS AND NOTES................................................................1-3
SYMBOLS.............................................................................................................1-4
IDENTIFICATION........................................................................................................1-5
SERIAL NUMBER.................................................................................................1-5
ENGINE SERIAL NUMBER..................................................................................1-5
STARTING SERIAL NUMBERS ...........................................................................1-5
SAFETY WHILE WORKING ......................................................................................1-6
FIRE PREVENTION .............................................................................................1-6
VENTILATION.......................................................................................................1-6
SELF-PROTECTION ............................................................................................1-7
OILS, GREASES AND SEALING FLUIDS ...........................................................1-7
GOOD WORKING PRACTICES...........................................................................1-8
DISASSEMBLY AND ASSEMBLY ........................................................................1-8
SPECIAL TOOLS .....................................................................................................1-10
SPECIAL TOOLS FOR TUNE-UP ......................................................................1-10
SPECIAL TOOLS FOR ENGINE SERVICE .......................................................1-10
SPECIAL TOOLS FOR CRANK JIG ASSY <P/N : 90890-02421> ....................1-10
SPECIAL TOOLS FOR LOWER UNIT SERVICE...............................................1-11
SEALING AGENTS AND LUBRICANTS ............................................................1-11
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................................................................................2-1
MAINTENANCE SPECIFICATIONS ..........................................................................2-3
POWER UNIT.......................................................................................................2-3
LOWER UNIT .......................................................................................................2-4
ELCTRICAL ..........................................................................................................2-5
DIMENSIONS .......................................................................................................2-6
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FES
CONTENU
CHAPITRE 1
INFORMATIONS
GENERALES
MODE D’UTILISATION DU
MANUEL.........................................1-1
PRESENTATION DU
MANUEL ....................................1-1
ILLUSTRATIONS.......................1-1
REFERENCES ............................1-2
SPECIFICATIONS......................1-2
AVERTISSEMENT, ATTENTION,
N.B...............................................1-3
SYMBOLES................................1-4
IDENTIFICATION.........................1-5
NUMERO DE SERIE..................1-5
NUMERO DE SERIE DU
MOTEUR.....................................1-5
NUMERO DEBUTANT LA
SERIE ..........................................1-5
MESURES DE SECURITE...........1-6
MESURES DE SECURITE
CONTRE LES INCENDIES.......1-6
AERATION .................................1-6
PROTECTION.............................1-7
HUILES, GRAISSES ET
LIQUIDES D’ETANCHEITE .....1-7
NOTES CONCERNANT L’OU-
TILLAGE ET LES PIECES ........1-8
DEMONTAGE ET
ASSEMBLAGE...........................1-8
OUTILLAGE SPECIAL ..............1-10
OUTILAGE SPECIAL – MISE AU
POINT........................................1-10
OUTILLAGE SPECIAL –
ENTRETIEN DU MOTEUR.....1-10
OUTILAG SPECIAL –
ENSEMBLE DE GABARIT DE
MANIVELLIE
<P/N. 90890-02421> .................1-10
OUTILLAGE SPECIAL –
ENTRETIEN DU BLOC
INFERIEUR ..............................1-11
LIQUIDES D’ETANCHEITE ET
LUBRIFIANTS .........................1-11
CONTENIDO
CAPITULO 1
INFORMACION
GENERAL
COMO UTILIZAR ESTE
MANUAL.........................................1-1
FORMATO DEL MANUAL.......1-1
LAS ILUSTRACIONES .............1-1
REFERENCIAS ..........................1-2
ESPECIFICACIONES.................1-2
ATENCIONES, PRECAUCIONES
Y NOTAS ....................................1-3
SIMBOLOS.................................1-4
IDENTIFICACION ........................1-5
NUMERO DE SERIE .................1-5
NUMERO DE SERIE DEL
MOTOR .......................................1-5
NUMEROS DE SERIE DE
COMIENZO ................................1-5
MEDIDAS DE SEGURIDAD ........1-6
PREVENCION CONTRA
INCENDIOS................................1-6
VENTILACION ..........................1-6
PROTECCION ............................1-7
ACEITES, GRASAS Y LIQUIDOS
PARA JUNTAS ...........................1-7
ALGUNOS CONSEJOS .............1-8
DESMONTAJE Y MONTAJE ....1-8
HERRAMIENTAS
ESPECIALES ...............................1-10
HERRAMIENTAS ESPECIALES
PARA LA PUESTA A
PUNTO......................................1-10
HERRAMIENTAS ESPECIALES
PARA EL MANTENIMIENTO
DEL MOTOR ............................1-10
HERRAMIENTAS ESPECIALES
PARA EL CONJUNTO DE
PLANTILLA DEL CIGUENAL
<P/N. 90890-02421> .................1-10
HERRAMIENTAS ESPECIALES
PARA EL MANTENIMIENTO DE
LA UNIDAD INFERIOR..........1-11
PASTAS PARA JUNTAS Y
LUBRICANTES........................1-11
CHAPITRE 2
SPECIFICATIONS
SPECIFICATIONS
GENERALES..................................2-1
SPECIFICATIONS
D’ENTRETIEN...............................2-3
BLOC DE PROPULSION ET
D’ALIMENTATION....................2-3
EMBASE .....................................2-4
ELECTRIQUES...........................2-5
DIMENSIONS.............................2-6
CAPITULO 2
ESPECIFICACIONES
ESPECIFICACIONES
GENERALES..................................2-1
ESPECIFICACIONES DE
MANTENIMIENTO ......................2-3
MOTOR .......................................2-3
COLA ..........................................2-4
SISTEMA ELECTRICO.............2-5
DIMENSIONES ..........................2-6
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TIGHTENING TORQUE .............................................................................................2-8
GENERAL TORQUES................................................................................................2-8
CHAPTER 3
GENERAL SERVICE
PREDELIVERY SERVICE ..........................................................................................3-1
CONTENTS ..........................................................................................................3-1
PACKING LISTS ...................................................................................................3-1
ELECTRIC WIRING..............................................................................................3-2
FUEL LINE............................................................................................................3-3
GEAR OIL LEVEL.................................................................................................3-4
OPERATION OF CONTROLS AND MOVING PARTS.........................................3-4
FUEL LEAKAGE ...................................................................................................3-5
WATER LEAKAGE ...............................................................................................3-5
EXHAUST LEAKAGE ...........................................................................................3-5
ENGINE AND LOWER UNIT NOISE....................................................................3-5
IDLE-SPEED.........................................................................................................3-5
IGNITION TIMING ................................................................................................3-5
MOTOR EXTERIOR .............................................................................................3-5
INSTRUCTING THE NEW OWNER.....................................................................3-5
PERIODIC SERVICE..................................................................................................3-6
MAINTENANCE SCHEDULE ...............................................................................3-6
ANODE .................................................................................................................3-6
CARBURETTOR...................................................................................................3-7
CYLINDER HEAD BOLTS, ENGINE MOUNTING BOLTS AND
FLYWHEEL NUT ..................................................................................................3-7
FUEL FILTER........................................................................................................3-7
FUEL TANK AND FUEL LINE...............................................................................3-8
GEAR OIL.............................................................................................................3-8
IDLE-SPEED.........................................................................................................3-8
IGNITION TIMING ADJUSTMENT .......................................................................3-9
CARBURETTOR CONTROL LINK ADJUSTMENT............................................3-13
PROPELLER ......................................................................................................3-13
SPARK PLUG .....................................................................................................3-14
START-IN-GEAR PROTECTION ADJUSTMENT...............................................3-14
THROTTLE CONTROL LINK ADJUSTMENT ....................................................3-14
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FES
COUPLES DE SERRAGE.............2-8
COUPLES GENERAUX................2-8
CHAPITRE 3
SERVICE GENERAL
SERVICE AVANT LIVRAISON ...3-1
CONTENU ..................................3-1
LISTE DE COLISAGE ...............3-1
CIRCUIT ELECTRIQUE............3-2
TUYAU D’ALIMENTATION .....3-3
NIVEAU DE L’HUILE DE
TRANSMISSION........................3-4
FONCTIONNEMENT DES
COMMANDES ET DES PARTIES
MOBILES....................................3-4
FUITE DE CARBURANT..........3-5
FUITE D’EAU.............................3-5
FUITE D’ECHAPPEMENT........3-5
BRUIT DU MOTEUR ET DU
BOITIER D’HELICE ..................3-5
RALENTI ....................................3-5
REGLAGE DE L’ALLUMAGE..3-5
ASPECT EXTERIEUR DU
MOTEUR.....................................3-5
INSTRUCTIONS A
L’UTILISATEUR ........................3-5
ENTRETIEN PERIODIQUE ........3-6
PERIODICITE
D’ENTRETIEN ...........................3-6
ANODE .......................................3-6
CARBURATEUR ........................3-7
BOULONS DE LA CULASSE,
BOULONS DE FIXATION DU
MOTEUR ET ECROU DU
VOLANT .....................................3-7
FILTRE A CARBURANT...........3-7
RESERVOIR ET TUYAU
D’ALIMENTATION....................3-8
HUILE DE TRANSMISSION ....3-8
RALENTI ....................................3-8
CALAGE DE L’ALLUMAGE ....3-9
REGLAGE DE LA BIELLETTE
DE COMMANDE DU
CARBURATEUR ......................3-13
HELICE .....................................3-13
BOUGIE ...................................3-14
REGLAGE DU DISPOSITIF DE
PROTECTION CONTRE LE
DEMARRAGE EN VITESSE...3-14
REGLAGE DE LA TIGE
D’ACCELERATEUR ................3-14
PARES DE APRIETE ....................2-8
TORSIONES GENERALE ...........2-8
CAPITULO 3
MANTENIMIENTO
GENERAL
MANTENIMIENTO PREVIO A LA
ENTREGA.......................................3-1
CONTENIDO..............................3-1
LISTA DE EMBALAJE..............3-1
CABLEADO ELECTRICO ........3-2
TUBO DE LLEGADA DEL
COMBUSTIBLE .........................3-3
NIVEL DE ACEITE DE LA CAJA
DE CAMBIOS.............................3-4
FUNCIONAMIENTO DE LOS
MANDOS Y LAS PIEZAS
MOVILES....................................3-4
FUGAS DE COMBUSTIBLE ....3-5
FUGAS DE AGUA......................3-5
FUGAS DE ESCAPE..................3-5
RUIDOS DEL MOTOR Y LA
UNIDAD INFERIOR ..................3-5
VELOCIDAD DE RALENTI .....3-5
PUESTA A PUNTO DEL
ENCENDIDO..............................3-5
EXTERIOR DEL MOTOR .........3-5
INSTRUCCIONES PARA EL
NUEVO PROPIETARIO.............3-5
MANTENIMIENTO
PERIODICO ...................................3-6
GUIDA DE
MANTENIMIENTO ...................3-6
ANODO.......................................3-6
CABURADOR ............................3-7
PERNOS DE LA CULATA,
PERNOS DE SUJECION DEL
MOTOR Y TUERCA DEL
VOLANTE...................................3-7
FILTRO DE COMBUSTIBLE ....3-7
DEPOSITO DE COMBUSTIBLE
Y TUBO DE LLEGADA DEL
COMBUSTIBLE .........................3-8
ACEITE DE LA CAJA DE
CAMBIOS...................................3-8
VELOCIDAD DE RALENTI .....3-8
AJUSTE DEL REGLAJE DE
ENCENDIDO..............................3-9
AJUSTE DE LA ARTICULACION
DE CONTROL DEL
CARBURADOR........................3-13
HELICE.....................................3-13
BUJIA........................................3-14
AJUSTE DE LA PROTECCION
CONTRA ARRANQUE CON
MARCHA PUESTA..................3-14
AJUSTE DE LA ARTICULACION
DE CONTROL DEL
ACELERADOR.........................3-14
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CHAPTER 4
FUEL SYSTEM
FUEL SYSTEM...........................................................................................................4-1
EXPLODED DIAGRAM ........................................................................................4-1
CLEANING AND INSPECTION ............................................................................4-3
INSTALLATION.....................................................................................................4-5
CARBURETTOR ........................................................................................................4-6
EXPLODED DIAGRAM ........................................................................................4-6
REMOVAL AND DISASSEMBLY ..........................................................................4-7
INSPECTION........................................................................................................4-8
ASSEMBLY...........................................................................................................4-9
INSTALLATION...................................................................................................4-10
CHAPTER 5
POWER UNIT
EXPLODED DIAGRAM ..............................................................................................5-1
PREPARATION FOR THE OVERHAUL ....................................................................5-2
REMOVAL ..................................................................................................................5-2
DISASSEMBLY ..........................................................................................................5-3
CHECKING THE CRANKSHAFT .......................................................................5-14
INSPECTION ............................................................................................................5-15
CYLINDER HEAD...............................................................................................5-15
CYLINDER BLOCK ............................................................................................5-16
PISTON...............................................................................................................5-17
PISTON RING ....................................................................................................5-19
PISTON PIN AND SMALL END BEARING ........................................................5-20
CRANKSHAFT....................................................................................................5-20
REED VALVE......................................................................................................5-21
THERMOSTAT....................................................................................................5-22
BALL BEARING ..................................................................................................5-22
ASSEMBLY AND ADJUSTMENT ............................................................................5-23
BEARING, OILSEAL AND O-RING ....................................................................5-23
PISTON...............................................................................................................5-23
SMALL END BEARINGS AND PISTON ASSEMBLY .........................................5-24
CRANK CYLINDER ASSEMBLY ........................................................................5-25
CYLINDER HEAD AND EXHAUST COVER ......................................................5-25
INTAKE MANIFOLD ...........................................................................................5-26
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FES
CHAPITRE 4
SYSTEME
D’ALIMENTATION
SYSTEME D’ALIMENTATION ..4-1
VUE ECLATEE...........................4-1
NETTOYAGE ET
VERIFICATION..........................4-3
INSTALLATION .........................4-5
CARBURATEUR............................4-6
VUE ECLATEE...........................4-6
DEPOSE ET DEMONTAGE ......4-7
VERIFICATION..........................4-8
ASSEMBLAGE...........................4-9
INSTALLATION .......................4-10
CHAPITRE 5
MOTEUR
VUE ECLATEE ..............................5-1
AVANT LA REVISION..................5-2
DEPOSE ..........................................5-2
DEMONTAGE ................................5-3
VERIFICATION DU
VILEBREQUIN.........................5-14
VERIFICATION...........................5-15
CULASSE..................................5-15
BLOC-CYLINDRE ...................5-16
PISTON .....................................5-17
SEGMENTS DE PISTON.........5-19
AXE DE PISTON ET BAGUE DE
PIED DE BIELLE .....................5-20
VILEBREQUIN.........................5-20
CLAPETS..................................5-21
THERMOSTAT .........................5-22
ROULEMENTS A BILLES ......5-22
ASSEMBLAGE ET REGLAGE..5-23
ROULEMENT, JOINT D’HUILE
ET JOINT TORIQUE................5-23
PISTON .....................................5-23
ROULEMENT DE PIED DE
BIELLE ET PISTON.................5-24
EMBIELLAGE DU
BLOC-CYLINDRE ...................5-25
CULASSE ET COUVERCLE
D’ECHAPPEMENT..................5-25
COLLECTEUR
D’ADMISSION.........................5-26
CAPITULO 4
SISTEMA DE
ALIMENTACION DE
COMBUSTIBLE
SISTEMA DE ALIMENTACION
DE COMBUSTIBLE......................4-1
DIAGRAMA DETALLADO ......4-1
LIMPIEZA E INSPECCION ......4-3
INSTALACION...........................4-5
CARBURADOR .............................4-6
DIAGRAMA DETALLADO ......4-6
EXTRACCION Y
DESMONTAJE ...........................4-7
INSPECCION..............................4-8
MONTAJE...................................4-9
INSTALACION.........................4-10
CAPITULO 5
MOTOR
DIAGRAMA DETALLADO..........5-1
PREPARACION PARA SU
REVISION.......................................5-2
EXTRACCION ...............................5-2
DESMONTAJE...............................5-3
COMPROBACIÓN DEL
CIGÜEÑAL...............................5-14
INSPECCION ...............................5-15
CULATA....................................5-15
BLOQUE MOTOR....................5-16
PISTON .....................................5-17
SEGMENTOS ...........................5-19
EJE DE PISTON Y COJINETE
DEL PIE DE BIELA .................5-20
CIGÜEÑAL...............................5-20
VALVULA DE LENGÜETAS ..5-21
TERMOSTATO .........................5-22
RODAMIENTO DE BOLAS ....5-22
MONTAJE Y AJUSTE.................5-23
COJINETE, RETEN DE ACEITE,
JUNTA TORICA Y ENGRANAJE
IMPULSOR DE LA BOMBA DE
ACEITE .....................................5-23
PISTON .....................................5-23
COJINETES DEL PIE DE BIELA
Y PISTON .................................5-24
COJINETES DEL CILINDRO DEL
CIGÜEÑAL...............................5-25
CULATA Y CUBIERTA DEL
ESCAPE ....................................5-25
COLECTOR DE ADMISION...5-26
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FUEL SYSTEM AND ELECTRICAL SYSTEM ...................................................5-26
INSTALLATION ........................................................................................................5-26
RECOIL STARTER...................................................................................................5-27
REMOVAL AND DISASSEMBLY ........................................................................5-28
INSPECTION......................................................................................................5-29
ASSEMBLY.........................................................................................................5-30
INSTALLATION...................................................................................................5-32
CHAPTER 6
LOWER UNIT
EXPLODED DIAGRAM ..............................................................................................6-1
REMOVAL ..................................................................................................................6-2
DISASSEMBLY ..........................................................................................................6-2
INSPECTION ..............................................................................................................6-6
GEAR CASE.........................................................................................................6-6
BEARING HOUSING............................................................................................6-6
RING-NUT ............................................................................................................6-6
WATER PUMP HOUSING ....................................................................................6-6
IMPELLER ............................................................................................................6-7
OIL-SEAL COVER ................................................................................................6-7
GEARS .................................................................................................................6-7
BEARINGS ...........................................................................................................6-7
CLUTCH DOG AND COMPONENTS...................................................................6-7
DRIVE AND PROPELLER SHAFTS ....................................................................6-8
DRIVE SHAFT SLEEVE .......................................................................................6-8
SHIFT-PLUNGER, SHIFT-SHAFT, AND BOOT ...................................................6-8
PROPELLER AND ANODE ..................................................................................6-8
ASSEMBLY AND ADJUSTMENT ..............................................................................6-9
SHIM SELECTION ...............................................................................................6-9
BACKLASH.........................................................................................................6-12
ASSEMBLY.........................................................................................................6-15
WATER PUMP INSTALLATION..........................................................................6-18
LOWER UNIT LEAKAGE CHECK......................................................................6-19
INSTALLATION ........................................................................................................6-19
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FES
CIRCUIT D’ALIMENTATION
ET EQUIPEMENT
ELECTRIQUE...........................5-26
INSTALLATION ..........................5-26
LANCEUR.....................................5-27
DEPOSE ET DEMONTAGE ....5-28
VERIFICATION........................5-29
ASSEMBLAGE.........................5-30
INSTALLATION .......................5-32
CHAPITRE 6
BOITIER D’HELICE
VUE ECLATEE ..............................6-1
DEPOSE ..........................................6-2
DEMONTAGE ................................6-2
VERIFICATION.............................6-6
BOITIER D’HELICE ..................6-6
BOITIER DE ROULEMENT......6-6
ECROU A BAGUE......................6-6
BOITIER DE LA POMPE A
EAU .............................................6-6
ROTOR ........................................6-7
COUVERCLE DU JOINT A
HUILE .........................................6-7
ENGRENAGE .............................6-7
ROULEMENTS...........................6-7
CRABOT D’EMBRAYAGE........6-7
ARBRES DE TRANSMISSION
ET D’HELICE.............................6-8
MANCHON DE L’ARBRE DE
TRANSMISSION........................6-8
PLONGEUR D’INVERSEUR,
TRINGLE D’INVERSEUR ET
SOUFFLET..................................6-8
HELICE ET ANODE ..................6-8
ASSEMBLAGE ET REGLAGE....6-9
SELECTION DES CALES
D’EPAISSEUR ............................6-9
JEU ............................................6-12
ASSEMBLAGE.........................6-15
INSTALLATION DE LA POMPE
A EAU .......................................6-18
CONTROLE D’ETANCHEITE
DU BLOC INFERIEUR............6-19
INSTALLATION ..........................6-19
SISTEMA DE ALIMENTACION
DE COMBUSTIBLE Y SISTEMA
ELECTRICO .............................5-26
INSTALACION.............................5-26
MOTOR DE ARRANQUE DE
RETROCESO ...............................5-27
EXTRACCION
DESMONTAJE .........................5-28
INSPECCION............................5-29
MONTAJE.................................5-30
INSTALACION.........................5-32
CAPITULO 6
UNIDAD INFERIOR
DIAGRAMA DETALLADO..........6-1
EXTRACCION ...............................6-2
DESMONTAJE...............................6-2
INSPECCION .................................6-6
CAJA DE ENGRANAJES ..........6-6
CAJA DE RODAMIENTOS .......6-6
TUERCA DE ANILLO ...............6-6
CAJA DE LA BOMBA DE
AGUA..........................................6-6
ROTOR ........................................6-7
CUBIERTA DE LA JUNTA DE
ACEITE .......................................6-7
ENGRANAJES............................6-7
COJINETES ................................6-7
EMBRAGUE DE DIENTES Y
COMPONENTES........................6-7
EJE MOTOR Y EJE DE LA
HELICE.......................................6-8
CAMISA DEL EJE MOTOR......6-8
EMBOLO DE CAMBIO, EJE DE
CAMBIOS Y FUELLE DE LA
VARILLA DE CAMBIO.............6-8
HELICE Y ANODO ....................6-8
MONTAJE Y AJUSTE...................6-9
SELECCION DE LAMINILLAS
DE AJUSTE.................................6-9
CONTRAPRESION ..................6-12
MONTAJE.................................6-15
INSTALACION DE LA BOMBA
DE AGUA..................................6-18
COMPROBACION DE FUGAS
EN LA UNIDAD INFERIOR ...6-19
INSTALACION.............................6-19
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CHAPTER 7
BRACKET UNIT
EXPLODED DIAGRAM ..............................................................................................7-1
REMOVAL ..................................................................................................................7-2
DISASSEMBLY ..........................................................................................................7-3
INSPECTION ..............................................................................................................7-4
MOUNTING-BOLT ................................................................................................7-4
RUBBER MOUNTS ..............................................................................................7-4
COLLAR................................................................................................................7-4
TILT LOCK PLATES .............................................................................................7-4
LEVERS................................................................................................................7-4
ASSEMBLY ................................................................................................................7-5
INSTALLATION ..........................................................................................................7-5
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS ..................................................................................8-1
WIRING DIAGRAM ....................................................................................................8-2
REMOVAL ..................................................................................................................8-3
MAGNETO BASE .................................................................................................8-3
CLEANING, INSPECTION AND REPAIR ..................................................................8-5
SPARK-PLUG .......................................................................................................8-5
PULSER COIL ......................................................................................................8-5
CHARGE COIL .....................................................................................................8-5
LIGHTING COIL (OPTION) ..................................................................................8-5
IGNITION COIL ....................................................................................................8-6
REPLACEMENT OF SPARK-PLUG CAP ............................................................8-6
CDI UNIT ..............................................................................................................8-7
RECTIFIER...........................................................................................................8-8
ENGINE STOP LANYARD SWITCH ....................................................................8-8
INSTALLATION ..........................................................................................................8-9
FLYWHEEL MAGNETO........................................................................................8-9
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FES
CHAPITRE 7
SUPPORT
VUE ECLATEE ..............................7-1
DEPOSE ..........................................7-2
DEMONTAGE ................................7-3
VERIFICATION.............................7-4
VIS DE MONTAGE....................7-4
SUPPORTS ELASTIQUES.........7-4
MANCHETTES ..........................7-4
ETRIERS DE VERROUILLAGE
D’INCLINAISON........................7-4
LEVIERS.....................................7-4
ASSEMBLAGE...............................7-5
INSTALLATION ............................7-5
CHAPITRE 8
EQUIPEMENT
ELECTRIQUE
EQUIPEMENT ELECTRIQUE ...8-1
SCHEMA DE
RACCORDEMENT........................8-2
DEPOSE ..........................................8-3
MAGNETO..................................8-3
NETTOYAGE, VERIFICATION ET
REPARATION ................................8-5
BOUGIE ......................................8-5
BOBINES D’IMPULSIONS.......8-5
BOBINE DE CHARGE...............8-5
BOBINE D’ECLAIRAGE
(Option)........................................8-5
BOBINE DE ALLUMAGE.........8-6
REMPLACEMENT DU
CAPUCHON DE LA BOUGIE ..8-6
BLOC CDI...................................8-7
REDRESSEUR............................8-8
CORDON/COUPE-CONTACT
DE SECURITE............................8-8
INSTALLATION ............................8-9
VOLANT MAGNETIQUE ........8-9
CAPITULO 7
UNIDAD SOPORTE
DIAGRAMA DETALLADO..........7-1
EXTRACCION ...............................7-2
DESMONTAJE...............................7-3
INSPECCION .................................7-4
PERNOS DE SUJECION............7-4
SOPORTES DE GOMA..............7-4
COLLARES.................................7-4
PLACAS DE TOPE DE
INCLINACION ...........................7-4
PALANCAS.................................7-4
MONTAJE.......................................7-5
INSTALACION...............................7-5
CAPITULO 8
SISTEMA
ELECTRICO
COMPONENTES
ELECTRICOS ................................8-1
DIAGRAMA DE CABLEADO .....8-2
EXTRACCION ...............................8-3
BASE DE LA MAGNETO .........8-3
LIMPIEZA, INSPECCION Y
REPARACION................................8-5
BUJIA..........................................8-5
BOBINAS PULSADORAS.........8-5
BOBINA DE CARGA.................8-5
BOBINA DE ILUMINACION
(Opción).......................................8-5
BOBINA DE ENCENDIDO .......8-6
CAMBIO DEL CASQUILLO DE
LA BUJIA....................................8-6
UNIDAD CDI..............................8-7
RECTIFICADOR ........................8-8
INTERRUPTOR DEL
ACOLLADOR DE PARADA
DEL MOTOR ..............................8-8
INSTALACION...............................8-9
MAGNETO DEL VOLANTE.....8-9
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CHAPTER 9
TROUBLE-SHOOTING
TROUBLE-SHOOTING DIAGRAM ............................................................................9-1
HOW TO TROUBLE-SHOOT ...............................................................................9-1
ENGINE IS HARD TO START OR WILL NOT START..............................................9-2
ROUGH IDLING .........................................................................................................9-6
ENGINE STALLS .......................................................................................................9-7
ENGINE WILL NOT STOP .........................................................................................9-8
GEAR SHIFTING IS IMPOSSIBLE OR HARD ..........................................................9-9
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FES
CHAPITRE 9
DEPANNAGE
TABLEAU DE DEPANNAGE .......9-1
QUE FAIRE ENCAS DE
PANNE?.......................................9-1
LE MOTEUR A DU MAL A
DEMARRER OU REFUSE DE
DEMARRER...................................9-2
LE RALENTI EST
DEFECTUEX..................................9-6
LE MOTEUR CALE ......................9-7
LE MOTEUR NE S’ARRETE
PAS ...................................................9-8
LE PASSAGE MARCHE
AV/MARCHE AR EST
IMPOSSIBLE OU DIFFICILE.....9-9
CAPITULO 9
LOCALIZATION Y
REPARACION DE
AVERIAS
DIAGRAMA DE LOCALIZACION
Y REPARACION DE AVERIAS...9-1
COMO LOCALIZAR Y
REPARAR AVERIAS..................9-1
RESULTA DIFICIL ARRANCAR
EL MOTOR, O NO ARRANCA ...9-2
VELOCIDAD DE RALENTI
DESIGUAL......................................9-6
EL MOTOR SE PARA...................9-7
EL MOTOR NO SE PARA............9-8
CAMBIO DE MARCHAS
IMPOSIBLE O DIFICIL...............9-9
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GEN
INFO
CHAPTER 1
GENERAL INFORMATION
HOW TO USE THIS MANUAL...................................................................................1-1
MANUAL FORMAT ...............................................................................................1-1
THE ILLUSTRATIONS..........................................................................................1-1
REFERENCES .....................................................................................................1-2
SPECIFICATIONS ................................................................................................1-2
WARNINGS, CAUTIONS AND NOTES................................................................1-3
SYMBOLS.............................................................................................................1-4
IDENTIFICATION........................................................................................................1-5
SERIAL NUMBER.................................................................................................1-5
ENGINE SERIAL NUMBER..................................................................................1-5
STARTING SERIAL NUMBERS ...........................................................................1-5
SAFETY WHILE WORKING ......................................................................................1-6
FIRE PREVENTION .............................................................................................1-6
VENTILATION.......................................................................................................1-6
SELF-PROTECTION ............................................................................................1-7
OILS, GREASES AND SEALING FLUIDS ...........................................................1-7
GOOD WORKING PRACTICES...........................................................................1-8
DISASSEMBLY AND ASSEMBLY ........................................................................1-8
SPECIAL TOOLS .....................................................................................................1-10
SPECIAL TOOLS FOR TUNE-UP ......................................................................1-10
SPECIAL TOOLS FOR ENGINE SERVICE .......................................................1-10
SPECIAL TOOLS FOR CRANK JIG ASSY <P/N : 90890-02421> ....................1-10
SPECIAL TOOLS FOR LOWER UNIT SERVICE...............................................1-11
SEALING AGENTS AND LUBRICANTS ............................................................1-11
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FES
GEN
INFO
1
CHAPITRE 1
INFORMATIONS
GENERALES
MODE D’UTILISATION DU
MANUEL.........................................1-1
PRESENTATION DU
MANUEL ....................................1-1
ILLUSTRATIONS.......................1-1
REFERENCES ............................1-2
SPECIFICATIONS......................1-2
AVERTISSEMENT, ATTENTION,
N.B...............................................1-3
SYMBOLES................................1-4
IDENTIFICATION.........................1-5
NUMERO DE SERIE..................1-5
NUMERO DE SERIE DU
MOTEUR.....................................1-5
NUMERO DEBUTANT LA
SERIE ..........................................1-5
MESURES DE SECURITE...........1-6
MESURES DE SECURITE
CONTRE LES INCENDIES.......1-6
AERATION .................................1-6
PROTECTION.............................1-7
HUILES, GRAISSES ET
LIQUIDES D’ETANCHEITE .....1-7
NOTES CONCERNANT L’OU-
TILLAGE ET LES PIECES ........1-8
DEMONTAGE ET
ASSEMBLAGE...........................1-8
OUTILLAGE SPECIAL ..............1-10
OUTILAGE SPECIAL – MISE AU
POINT........................................1-10
OUTILLAGE SPECIAL –
ENTRETIEN DU MOTEUR.....1-10
OUTILAG SPECIAL –
ENSEMBLE DE GABARIT DE
MANIVELLIE
<P/N. 90890-02421> .................1-10
OUTILLAGE SPECIAL –
ENTRETIEN DU BLOC
INFERIEUR ..............................1-11
LIQUIDES D’ETANCHEITE ET
LUBRIFIANTS .........................1-11
CAPITULO 1
INFORMACION
GENERAL
COMO UTILIZAR ESTE
MANUAL.........................................1-1
FORMATO DEL MANUAL.......1-1
LAS ILUSTRACIONES .............1-1
REFERENCIAS ..........................1-2
ESPECIFICACIONES.................1-2
ATENCIONES, PRECAUCIONES
Y NOTAS ....................................1-3
SIMBOLOS.................................1-4
IDENTIFICACION ........................1-5
NUMERO DE SERIE .................1-5
NUMERO DE SERIE DEL
MOTOR .......................................1-5
NUMEROS DE SERIE DE
COMIENZO ................................1-5
MEDIDAS DE SEGURIDAD ........1-6
PREVENCION CONTRA
INCENDIOS................................1-6
VENTILACION ..........................1-6
PROTECCION ............................1-7
ACEITES, GRASAS Y LIQUIDOS
PARA JUNTAS ...........................1-7
ALGUNOS CONSEJOS .............1-8
DESMONTAJE Y MONTAJE ....1-8
HERRAMIENTAS
ESPECIALES ...............................1-10
HERRAMIENTAS ESPECIALES
PARA LA PUESTA A
PUNTO......................................1-10
HERRAMIENTAS ESPECIALES
PARA EL MANTENIMIENTO
DEL MOTOR ............................1-10
HERRAMIENTAS ESPECIALES
PARA EL CONJUNTO DE
PLANTILLA DEL CIGUENAL
<P/N. 90890-02421> .................1-10
HERRAMIENTAS ESPECIALES
PARA EL MANTENIMIENTO DE
LA UNIDAD INFERIOR..........1-11
PASTAS PARA JUNTAS Y
LUBRICANTES........................1-11
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GEN
INFO E
1-1
HOW TO USE THIS MANUAL
A50000-0
HOW TO USE THIS MANUAL
MANUAL FORMAT
This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly,
adjustment and inspection, each of which is presented in a sequential, step-by-step procedure.
To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of
every page.
An Index to contents is provided on the first page of each Section.
THE ILLUSTRATIONS
Some illustrations in this manual may differ from the model you have. This is because a procedure described
may relate to several models, though only one may be illustrated. (The name of model described will be men-
tioned in the description).
To help you identify components and understand the correct procedures of disassembly and assembly,
exploded diagrams are provided. Steps in the procedures are numbered thus: 1), 2), 3). Parts shown in the
illustrations are identified thus: 1, 2, 3.
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