Honda FJ500 Manual
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62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分
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How to use this manual
A Few Words About Safety
How to use this manual
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the
way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda FJ500

  • Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2: Table Of Contents

    62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING FUEL SYSTEM GOVERNOR SYSTEM IGNITION SYSTEM STARTING SYSTEM MUFFLER ENGINE REMOVAL/INSTALLATION CLUTCH CYLINDER HEAD CYLINDER BLOCK HANDLE ROTOR/TRANSMISSION TECHNICAL FEATURE INDEX...
  • Page 3 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS, AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 4 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
  • Page 5 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator Air Fuel Ratio American Petroleum Institute Approx. Approximately Assy.
  • Page 6: Specifications

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ·····················1-2 DIMENSIONAL DRAWINGS························· 1-5 SPECIFICATIONS ·········································1-3 WIRING DIAGRAM ······································· 1-7...
  • Page 7 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SPECIFICATIONS SERIAL NUMBER LOCATION SPECIFICATIONS The engine serial number [1] is located on the cylinder block. The frame serial number [2] is located on the handle column. Refer to these numbers when ordering parts and when making technical inquiries.
  • Page 8 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SPECIFICATIONS SPECIFICATIONS DIMENSIONS AND WEIGHTS Model FJ500 Description code FAAC Type code Overall length* 1,395 mm (54.9 in) 1,435 mm (56.5 in) Overall width 925 mm (36.4 in) 610 mm (24.0 in) 925 mm (36.4 in) 610 mm (24.0 in)
  • Page 9 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SPECIFICATIONS FRAME Model FJ500 Type code Rotor type French rotor – French rotor – Standard handle height 960 mm (37.8 in) 970 mm (38.2 in) (with rotor operation position) Handle height adjustment 840 – 1,075 mm (33.1 – 42.3 in) 805 –...
  • Page 10 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SPECIFICATIONS DIMENSIONAL DRAWINGS SER, SE TYPE Unit: mm (in) *1,395 (54.9) 300 (11.8) Each dimension shall be determined when tines with each rotor is on level surface with engine bed in a level position. *: Dimensions of overall length and overall height shall be determined when locating tightening position of handle pipe middle of movable range in vertical direction.
  • Page 11 62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SPECIFICATIONS DER, DE TYPE Unit: mm (in) *1,435 (56.5) 300 (11.8) Each dimension shall be determined when tines with each rotor is on level surface with engine bed in a level position. *: Dimensions of overall length and overall height shall be determined when locating tightening position of handle pipe middle of movable range in vertical direction.
  • Page 12 62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SPECIFICATIONS WIRING DIAGRAM Bl: BLACK G: GREEN UNIT SPARK PLUG IGNITION COIL ENGINE STOP SWITCH...
  • Page 13 62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MEMO...
  • Page 14: Service Information

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ·····················2-2 TOOLS ·························································· 2-5 TORQUE VALUES ········································2-3 CABLE/HARNESS ROUTING ······················ 2-7 LUBRICATION & SEAL POINT ····················2-4 TUBE ROUTING ··········································· 2-8...
  • Page 15 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION ENGINE Unit: mm (in) Part Item Standard Service limit Engine Idle speed – 1,250 – 1,550 min (rpm) Maximum engine speed (at no load) 3,800 (rpm) – –200 Cylinder compression 0.59 MPa –...
  • Page 16 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SERVICE INFORMATION FRAME Unit: mm (in) Part Item Standard Service limit V-belt Distance L between upper and lower 43 – 49 (1.7 – 1.9) – belt runs Belt stopper 1.0 – 3.0 (0.04 – 0.12) –...
  • Page 17 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SERVICE INFORMATION STANDARD TORQUE VALUES Torque values Remarks Item Tread Dia. N·m kgf·m lbf·ft Screw 4 mm 5 mm 6 mm Bolt and nut 5 mm 6 mm 8 mm 10 mm 12 mm Flange bolt and nut 6 mm 8 mm...
  • Page 18 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SERVICE INFORMATION FRAME Material Location Remarks Transmission oil Transmission oil filler cap O-ring whole surface Shell Alvania grease RA or Clutch lever pin (8 mm) sliding surface equivalent Change lever holder change lever sliding surface Handle column pivot change lever holder sliding surface Tension arm shaft tension arm sliding surface...
  • Page 19 62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SERVICE INFORMATION Pilot, 22 mm Pilot, 25 mm Pilot, 28 mm 07746-0041000 07746-0040600 07746-0041100 Driver Driver, 22 mm I.D. Valve guide driver, 5.5 mm 07749-0010000 07746-0020100 07742-0010100 Valve guide reamer, 5.510 mm 07984-2000001...
  • Page 20 62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SERVICE INFORMATION CABLE/HARNESS ROUTING THROTTLE LEVER HOSE BAND CLAMP THROTTLE CABLE ENGINE STOP SWITCH WIRE ENGINE STOP SWITCH WIRE IGNITION COIL WIRE 50 mm (2.0 in) 90 mm 40 mm (3.5 in) (1.6 in) 100 mm IGNITION COIL WIRE (3.9 in)
  • Page 21 62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead SERVICE INFORMATION TUBE ROUTING FUEL TUBE SUPPORTER RUBBER FUEL TUBE 20 mm (0.8 in) TUBE CLIP Direction the knob toward the fuel valve lever side. FUEL VALVE LEVER HIGH TENSION CODE BREATHER TUBE Handle side 0 –...
  • Page 22: Maintenance

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE························3-2 SPARK PLUG CHECK/ADJUSTMENT/ REPLACEMENT ··········································· 3-8 ENGINE OIL LEVEL CHECK ························3-3 THROTTLE CABLE CHECK/ ADJUSTMENT ·············································· 3-9 ENGINE OIL CHANGE··································3-4 ENGINE IDLE SPEED CHECK/ AIR CLEANER CHECK/CLEANING/ ADJUSTMENT ·············································· 3-9 REPLACEMENT············································3-5 CLUTCH CABLE CHECK/ADJUSTMENT ···...
  • Page 23 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE REGULAR SERVICE PERIOD (1) Perform at every indicated month or operating hour interval, whichever comes first. Refer to ITEM page Every Every After First month Every year Each use 3 months 6 months storage or 20 hrs.
  • Page 24 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE ENGINE OIL LEVEL CHECK • Check the engine oil level with the engine stopped. Place the tiller on a firm level surface with the rotor set on the ground so that the engine becomes level. Remove the oil filler cap/dipstick [1] and wipe the dipstick clean.
  • Page 25 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE ENGINE OIL CHANGE • Drain the used engine oil while the engine is warm. Warm oil drains quickly and completely. Remove the front wheel (page 15-14). DER, DE TYPE: Place the tiller on a firm level surface, and place a suitable container [1] under the engine oil drain bolt (10 x 15 mm) [2].
  • Page 26 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE AIR CLEANER CHECK/CLEANING/REPLACEMENT • A dirty air cleaner element will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in dusty areas, clean the air cleaner element more often than specified in the "MAINTENANCE SCHEDULE"...
  • Page 27 62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE BOLTS AND NUTS TIGHTNESS Check that all chassis nuts and bolts are tighten to their correct torque values (page 2-3). Check that all split pins, safety clips, hose clamps and cable stays are in place and properly secured. CLUTCH LEVER FUNCTION •...
  • Page 28 62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE SEDIMENT CUP CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Turn the fuel valve lever [1] to the "DRAIN"...
  • Page 29 62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE SPARK PLUG CHECK/ADJUSTMENT/REPLACEMENT If the engine has been running, the engine will be very hot. Allow it to cool before proceeding. Clean any dirt from around the spark plug [1]. Disconnect the spark plug cap [2]. Remove the spark plug with a spark plug wrench.
  • Page 30 62V42000.book 9 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE THROTTLE CABLE CHECK/ADJUSTMENT Check for any deterioration or damage to the throttle cable [1]. Check the throttle lever [2] for smooth operation. Measure the throttle lever freeplay at the lever tip. FREEPLAY:5.0 – 10 mm (0.20 – 0.4 in) If the throttle lever freeplay is incorrect, loosen the lock nut [3] and turn the adjusting nut [4] in or out as required.
  • Page 31 62V42000.book 10 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE ADJUSTMENT Push the lock lever [1] and measure the clutch lever [2] freeplay at the lock lever arm [3] and handlebar bracket [4]. FREEPLAY:2.0 – 4.0 mm (0.08 – 0.16 in) If adjustment is necessary, loosen the lock nut [5] and turn the adjusting bolt [6] in or out as required.
  • Page 32 62V42000.book 11 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE BELT TENSION ADJUSTMENT Loosen four engine mounting bolts (8 x 35 mm)/nuts (8 mm) [1]. See below for chart, adjust the distance [1] until the correct distance L [2] is obtained. SPECIFIED DISTANCE L: 43 – 49 mm (1.7 – 1.9 in) Distance L Distance –4.0 mm (0.16 in)
  • Page 33 62V42000.book 12 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE BELT STOPPER ADJUSTMENT With the clutch engaged, measure the clearance C: 1.0 – 3.0 mm between the V-belt [1] and three belt stoppers [2]. A: 1.0 – 3.0 mm (0.04 – 0.12 in) (0.04 –...
  • Page 34 62V42000.book 13 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE Set the piston near top dead center of the cylinder compression stroke (both valves fully closed) by pulling the recoil starter slowly. When the piston is near top dead center of the compression stroke, the " " mark [1] on the starter Pull slowly.
  • Page 35 62V42000.book 14 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE COMBUSTION CHAMBER CLEANING Remove the cylinder head (page 12-3). Clean any carbon deposits from the combustion chamber [1]. Install the cylinder head (page 12-3). FUEL TANK AND FILTER CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
  • Page 36 62V42000.book 15 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MAINTENANCE FUEL TUBE CHECK Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Wipe up spills immediately. • Handle fuel only outdoors. Remove the fan cover (page 7-3).
  • Page 37 62V42000.book 16 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MEMO...
  • Page 38: Troubleshooting

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING···················4-2 ENGINE TROUBLESHOOTING ··················· 4-3 GENERAL SYMPTOMS AND POSSIBLE FRAME TROUBLESHOOTING ···················· 4-3 CAUSES ························································4-2...
  • Page 39 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Check that the engine stop switch wire connector and ignition coil wire connector are connected securely. • Check for sufficient fresh fuel in the fuel tank. GENERAL SYMPTOMS AND POSSIBLE CAUSES HARD STARTING •...
  • Page 40 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead TROUBLESHOOTING ENGINE TROUBLESHOOTING HARD STARTING 1. Spark Plug Inspection Inspect the spark plug (page 3-8). Is the spark plug in good condition? – GO TO STEP 2. – • Faulty spark plug • Incorrect spark plug gap •...
  • Page 41 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MEMO...
  • Page 42: Fuel System

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 5. FUEL SYSTEM TOOL ·····························································5-2 CARBURETOR REMOVAL/ INSTALLATION ············································ 5-5 FUEL TANK REMOVAL/INSTALLATION ····5-3 CARBURETOR DISASSEMBLY/ ASSEMBLY ··················································· 5-6 AIR CLEANER REMOVAL/ INSTALLATION·············································5-4...
  • Page 43 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead FUEL SYSTEM TOOL FUEL SYSTEM Float level gauge 07401-0010000...
  • Page 44 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the sediment cup [1] and O-ring [2].
  • Page 45 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead FUEL SYSTEM AIR CLEANER REMOVAL/INSTALLATION • When installation, route the breather tube properly (page 2-8). HOSE BAND: NOTE 6, 7, 8 WELD BEADS WIDTH HIGH TENSION CORD TIGHTENING THROTTLE WIDTH CABLE THROTTLE AIR CLEANER COVER NUT CABLE WELD BEADS AIR CLEANER...
  • Page 46 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead FUEL SYSTEM CARBURETOR REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Turn the fuel valve to the "OFF"...
  • Page 47 62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead FUEL SYSTEM GOVERNOR ROD REMOVAL/INSTALLATION Pull the carburetor toward a point where the groove [1] in the throttle arm [2] lines up with the governor rod [3], and lift the rod out of its hole and unhook the throttle return spring [4].
  • Page 48 62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead FUEL SYSTEM CHOKE LEVER PILOT JET: NOTE 7, 8 CHOKE LEVER PIN CHOKE SHAFT WASHER DUST SEAL O-RING CARBURETOR BODY: NOTE 5 (Whole surface) THROTTLE STOP SCREW MAIN NOZZLE: NOTE 7 CHOKE PLATE BOWL VENT BAFFLE BAFFLE SCREW (3 x 7 mm) 0.8 N·m (0.08 kgf·m, 0.6 lbf·ft) MAIN JET (MAIN JET NUMBER: #68):...
  • Page 49 62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead FUEL SYSTEM VALVE SEAL INSTALLATION Install the valve seal [1] into the float chamber [2] with its rib [3] side facing out, while aligning the hole of the valve seal with boss of the float chamber. LUBRICATION FUEL VALVE COVER/FUEL VALVE When reassembly, apply silicone grease to the fuel...
  • Page 50 62V42000.book 9 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead FUEL SYSTEM FLOAT LEVEL HEIGHT INSPECTION Place the float chamber [1] in the position as shown, and measure the distance between the float top [2] and float chamber when the float just contacts the float valve without compressing the valve.
  • Page 51 O-rings, float and float valve seats. Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors. • High air pressure may damage the carburetor. Use low pressure settings when cleaning passages and ports.
  • Page 52: Governor System

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 6. GOVERNOR SYSTEM CONTROL BASE/GOVERNOR ARM GOVERNOR ADJUSTMENT ························ 6-3 REMOVAL/INSTALLATION··························6-2 GOVERNOR REMOVAL/INSTALLATION···· 6-4...
  • Page 53 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead GOVERNOR SYSTEM CONTROL BASE/GOVERNOR ARM REMOVAL/INSTALLATION GOVERNOR SYSTEM Remove the following: – Fuel tank (page 5-3) – Air cleaner (page 5-4) Move the throttle lever to the "LOW" position and disconnect the throttle cable [1] from the control base [2].
  • Page 54 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead GOVERNOR SYSTEM GOVERNOR ADJUSTMENT Remove the fuel tank (page 5-3). Loosen the governor arm nut (6 mm) [1] and then move the governor arm [2] so that the throttle is completely open. Rotate the governor arm shaft [3] as far as it will go in the direction that it was just turned by the governor arm.
  • Page 55 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead GOVERNOR SYSTEM GOVERNOR REMOVAL/INSTALLATION Remove the crankshaft (page 13-3). • Be sure to install the governor before installing the crankshaft. GROOVE LOCK PIN (8 mm): NOTE 1 (Journal) GOVERNOR SHAFT WASHER (6 mm) GOVERNOR WEIGHT PIN (2) THRUST WASHER (6 mm) CLIP: NOTE 3 WASHER (6 mm)
  • Page 56: Ignition System

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 7. IGNITION SYSTEM BEFORE TROUBLESHOOTING···················7-2 IGNITION COIL AIR GAP CHECK/ ADJUSTMENT ·············································· 7-6 IGNITION SYSTEM TROUBLESHOOTING···································7-2 IGNITION COIL INSPECTION ······················ 7-6 FAN COVER REMOVAL/INSTALLATION····7-3 SPARK PLUG CAP INSPECTION················ 7-7 IGNITION COIL REMOVAL/ SPARK TEST ················································ 7-7 INSTALLATION·············································7-3 ENGINE STOP SWITCH REMOVAL/ FLYWHEEL REMOVAL/INSTALLATION ·····7-4...
  • Page 57: Before Troubleshooting

    62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead IGNITION SYSTEM BEFORE TROUBLESHOOTING IGNITION SYSTEM • Check that the engine stop switch wire connector and ignition coil wire connector are connected securely. • Check that the engine stop switch is "ON" position. IGNITION SYSTEM TROUBLESHOOTING HARD STARTING 1.
  • Page 58: Fan Cover Removal/Installation

    62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead IGNITION SYSTEM FAN COVER REMOVAL/INSTALLATION FAN COVER BOLT (6 x 12 mm) (4) IGNITION COIL REMOVAL/INSTALLATION Remove the following: – Fuel tank (page 5-3) – Carburetor (page 5-5) • After installation, route the high tension cord properly (page 2-8). •...
  • Page 59: Flywheel Removal/Installation

    62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead IGNITION SYSTEM FLYWHEEL REMOVAL/INSTALLATION • When disassembling and reassembling, take care not to damage the fan blade. Remove the ignition coil (page 7-3). WOODRUFF KEY: NOTE 3 BOLT (6 x 20 mm) SIDE PLATE FLYWHEEL: NOTE 1, 2 COOLING FAN: NOTE 2 STARTER PULLEY: NOTE 2...
  • Page 60 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead IGNITION SYSTEM Remove the flywheel [1] with a commercially available flywheel puller [2]. • Do not hit the flywheel with a hammer. • Avoid the magnet section when attaching the flywheel puller. FLYWHEEL INSTALLATION Clean the tapered parts [1] of dirt, oil, grease, and other foreign material before installation.
  • Page 61: Ignition Coil Air Gap Check

    62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead IGNITION SYSTEM IGNITION COIL AIR GAP CHECK/ADJUSTMENT • Avoid the magnet part of the flywheel when adjusting. • Adjust the ignition coil air gap equally on both side. 0.20 – 0.60 mm (0.008 – 0.024 in) Remove the fan cover (page 7-3) Measure the ignition coil air gap clearance.
  • Page 62: Spark Plug Cap Inspection

    62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead IGNITION SYSTEM SECONDARY SIDE Disconnect the spark plug cap from the high tension cord [1]. Measure the resistance of secondary coil by attaching one ohmmeter probe to the high tension cord and the other at the iron core [2]. RESISTANCE: 5.63 –...
  • Page 63 62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead IGNITION SYSTEM ENGINE STOP SWITCH REMOVAL/INSTALLATION • When installation, route the wire harness properly (page 2-7). ENGINE STOP SWITCH: NOTE 1 ENGINE STOP SWITCH COVER ENGINE STOP SWITCH COVER CABLE BAND (4) SCREW (5 x 14) (2) 3 N·m (0.3 kgf·m, 2.2 lbf·ft) ENGINE STOP SWITCH WIRE CORD BINDER...
  • Page 64: Starting System

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 8. STARTING SYSTEM RECOIL STARTER REMOVAL/ RECOIL STARTER DISASSEMBLY/ INSTALLATION·············································8-2 ASSEMBLY ··················································· 8-3 RECOIL STARTER INSPECTION ················ 8-6...
  • Page 65 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER REMOVAL/INSTALLATION STARTING SYSTEM RECOIL STARTER: NOTE 1, 2 BOLT (6 x 10 mm) (3) NOTE 1 RECOIL STARTER INSPECTION page 8-6 NOTE 2 RECOIL STARTER DISASSEMBLY/ASSEMBLY page 8-3...
  • Page 66 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER DISASSEMBLY/ASSEMBLY DISASSEMBLY • Wear gloves and eye protection. • During disassembly, take care not to allow the return spring to come out. Remove the recoil starter (page 8-2). SPRING RETAINER RECOIL STARTER CENTER SCREW FRICTION PLATE FRICTION SPRING...
  • Page 67 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead STARTING SYSTEM ASSEMBLY • Wear gloves and eye protection. • During disassembly, take care not to allow the return spring to come out. Pass the recoil starter rope [1] through the hole [2] in the recoil starter pulley [3] and then tie the rope as shown.
  • Page 68 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead STARTING SYSTEM Apply grease to the ratchet [1] sliding surface. Install the ratchet springs [2] and ratchets to the recoil starter pulley [3] as shown. Apply grease to the inside of the spring retainer [1]. Set the friction spring [2], friction plate [3] and spring retainer to the recoil starter pulley in the direction as shown.
  • Page 69 62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead STARTING SYSTEM RECOIL STARTER INSPECTION RECOIL STARTER OPERATION Remove the recoil starter (page 8-3). Pull the starter grip [1] several times to inspect that the ratchets [2] are operated properly (the ratchet ends come out from the spring retainer [3]). STARTER PULLEY Remove the recoil starter (page 8-3).
  • Page 70: Muffler

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 9. MUFFLER MUFFLER REMOVAL/INSTALLATION········9-2...
  • Page 71 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MUFFLER MUFFLER REMOVAL/INSTALLATION MUFFLER The engine and muffler become very hot during operation and they remain hot for a while after operation. The muffler removal must be made while the engine is cold. Remove the belt cover stay (page 11-2). MUFFLER PROTECTOR MUFFLER PROTECTOR SCREW (5 x 8 mm) (4) 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
  • Page 72: Engine Removal/Installation

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 10. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ·········10-2 10-1...
  • Page 73 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION • When installation, route the wire harness properly [2] / [3] (page 2-7) Remove the following: – Air cleaner (page 5-4) – Belt cover (page 11-2) Remove the V-belt [1], engine stay bolt (8 x 20 mm) [2] and washer (8 mm) [3].
  • Page 74: Clutch

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 11. CLUTCH PULLEY/V-BELT REMOVAL/ INSTALLATION···········································11-2 11-1...
  • Page 75 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CLUTCH PULLEY/V-BELT REMOVAL/INSTALLATION CLUTCH After installation, adjust the V-belt tension (page 3-10). BRACKET WASHER BELT COVER STAY GROMMET: NOTE 3 HEX BOLT (6 x 8 mm) ENGINE BOLT (6 x 12 mm) STAY RUBBER HOLDER UPPER BELT STOPPER BELT STOPPER C...
  • Page 76 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CLUTCH DRIVE PULLEY REMOVAL/INSTALLATION • Take care not to damage the drive pulley with the strap wrench. Hold the drive pulley [1] with a commercially available strap wrench [2] and remove the drive pulley bolt (8 x 22 mm) [3].
  • Page 77 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MEMO...
  • Page 78: Cylinder Head

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 12. CYLINDER HEAD TOOLS·························································12-2 CYLINDER HEAD/VALVES INSPECTION··············································· 12-5 CYLINDER HEAD REMOVAL/ INSTALLATION···········································12-3 VALVE GUIDE REPLACEMENT ················ 12-8 CYLINDER HEAD DISASSEMBLY/ VALVE GUIDE REAMING ·························· 12-9 ASSEMBLY ·················································12-4 VALVE SEAT RECONDITIONING············ 12-10 12-1...
  • Page 79 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD TOOLS CYLINDER HEAD Valve guide driver, 5.5 mm Seat cutter, 27.5 mm (45° IN) Seat cutter, 24.5 mm (45° EX) 07742-0010100 07780-0010200 07780-0010100 Flat cutter, 28 mm (32° IN) Flat cutter, 25 mm (32° EX) Interior cutter, 30 mm (60°...
  • Page 80 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD REMOVAL/INSTALLATION Set the piston at top dead center of the cylinder compression stroke (page 3-12). Remove the following: – Engine (page 10-2) – Control base/governor arm (page 6-2) – Carburetor (page 5-5) –...
  • Page 81 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD CYLINDER HEAD DISASSEMBLY/ASSEMBLY Remove the cylinder head (page 12-3). INTAKE VALVE SPRING VALVE STEM SEAL RETAINER: NOTE 1 (Seating surface and stem end) EXHAUST VALVE GUIDE: EXHAUST VALVE: NOTE 2, 6, 8 NOTE 3, 4 VALVE SPRING (2) INTAKE VALVE GUIDE: NOTE 3, 4...
  • Page 82: Installation

    62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD VALVE SPRING RETAINER REMOVAL/INSTALLATION • Do not remove the valve spring retainers while the cylinder head is installed to cylinder block, or the valve will drop into the cylinder. Removal REMOVAL Push down and slide the valve spring retainer [1] to the side so that the valve stem slips through the hole at the side of the valve spring retainer.
  • Page 83: Tools

    62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD VALVE SEAT WIDTH Inspect each valve for face irregularities. If necessary, replace the valve (page 12-4). Apply a light coat of Prussian Blue or erasable felt- tipped marker ink to each valve seat. Insert the valve, and snap it using a lapping tool [1] closed against its seat several times.
  • Page 84 62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD VALVE FACE/VALVE STEM O.D. Inspect each valve face [1] for irregularities. If necessary, replace the valve. Inspect each valve [2] for bending or abnormal stem wear. If necessary, replace the valve. Measure and record each valve stem O.D. STANDARD: IN: 5.468 –...
  • Page 85: Valve Guide Replacement

    62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD PUSH ROD RUNOUT Check both ends of the push rod for wear. Check the push rod for straightness. If necessary, replace the push rod. VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour.
  • Page 86: Valve Guide Reaming

    62V42000.book 9 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD Remove new valve guides [1] from the refrigerator one at a time as needed. Install new valve guide clip [2] to the exhaust valve guide and drive it until the valve guide clip is fully seated as shown from the valve spring side of the cylinder head.
  • Page 87: Valve Seat Reconditioning

    62V42000.book 10 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD VALVE SEAT RECONDITIONING Check the valve seat width (page 12-6). Valve seat cutters [1]/grinder or equivalent valve seat refacing equipment is recommended to correct a worn valve seat. • Turn the cutter clockwise, never counterclockwise. •...
  • Page 88 62V42000.book 11 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER HEAD Lap the valves into their seats, using a commercially available lapping tool [1] and lapping compound. After lapping, wash all residual compound off the cylinder head and valve. • Do not push the valve against the seat with force during lapping.
  • Page 89 62V42000.book 12 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MEMO...
  • Page 90: Cylinder Block

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 13. CYLINDER BLOCK TOOLS·························································13-2 CRANKCASE COVER/CYLINDER BLOCK/ PISTON/CONNECTING ROD/CRANKSHAFT/ CAMSHAFT INSPECTION·························· 13-6 CRANKCASE COVER/CRANKSHAFT/ CAMSHAFT/PISTON REMOVAL/ INSTALLATION···········································13-3 CRANKSHAFT BEARING/OIL SEAL REPLACEMENT ······································· 13-12 PISTON DISASSEMBLY/ASSEMBLY········13-5 13-1...
  • Page 91: Tools

    62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK TOOLS CYLINDER BLOCK Attachment, 37 x 40 mm Attachment, 52 x 55 mm Pilot, 25 mm 07746-0010200 07746-0010400 07746-0040600 Driver 07749-0010000 13-2...
  • Page 92 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK CRANKCASE COVER/CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/INSTALLATION Drain the engine oil (page 3-4). Remove the cylinder head (page 12-3). (Outer surface and big end bearing) PISTON: NOTE 2, 3, 5 MARK PUSH ROAD HOLE (Cylinder inner surface) CYLINDER BLOCK: NOTE 3 (Lips) OIL SEAL...
  • Page 93 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK CAMSHAFT INSTALLATION • Install the valve lifters [1] immediately before installing the camshaft [2]. Apply engine oil to the two valve lifters slipper surface, stem and stem end. Install the valve lifters to the cylinder block [3]. Apply engine oil to the camshaft cam profile and journal.
  • Page 94: Installation

    62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK PISTON DISASSEMBLY/ASSEMBLY Remove the piston (page 13-3). MAKER MARK (Whole surface) TOP RING PISTON RING SET: NOTE 1 INSTALLATION: To install the oil ring, install the spacer [1] first, and then install the side rails [2]. Be sure that the top ring [3] and second ring [4] are not interchanged.
  • Page 95: Crankcase Cover/Cylinder Block

    62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK CRANKCASE COVER/CYLINDER BLOCK/PISTON/CONNECTING ROD/CRANKSHAFT/CAMSHAFT INSPECTION CAMSHAFT HOLDER I.D. Measure the camshaft holder I.D. CRANKCASE COVER CYLINDER BLOCK SIDE: SIDE: STANDARD: 14.000 – 14.018 mm (0.5512 – 0.5519 in) SERVICE LIMIT: 14.048 mm (0.5531 in) If the measurement is more than the service limit, replace the crankcase cover and cylinder block.
  • Page 96 62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK PISTON-TO-CYLINDER CLEARANCE Subtract the piston skirt O.D. from the cylinder sleeve I.D. to obtain the piston-to-cylinder clearance. STANDARD: 0.015 – 0.050 mm (0.0006 – 0.0020 in) SERVICE LIMIT: 0.12 mm (0.005 in) If the calculated clearance is more than the service limit, replace the piston and recheck the clearance.
  • Page 97 62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK PISTON RING WIDTH Measure each piston ring width. STANDARD: Top: 0.95 – 0.97 mm (0.037 – 0.038 in) Second: 0.94 – 0.96 mm (0.037 – 0.038 in) SERVICE LIMIT: Top: 0.93 mm (0.037 in) Second: 0.92 mm (0.036 in) If any of the measurements is less than the service limit, replace the piston rings (top, second, oil) as a set.
  • Page 98 62V42000.book 9 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK CONNECTING ROD SMALL END I.D. Measure the connecting rod small end I.D. STANDARD: 18.005 – 18.020 mm (0.7089 – 0.7094 in) SERVICE LIMIT: 18.07 mm (0.711 in) If the measurement is more than the service limit, replace the connecting rod upper.
  • Page 99 62V42000.book 10 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK CONNECTING ROD BIG END OIL CLEARANCE Clean all oil from the crankpin and connecting rod big end surface. Place a piece of plastigauge [1] on the crankpin, install the connecting rod upper and the connecting rod lower. Apply engine oil to the connecting rod bolt [2] threads and seating surface.
  • Page 100 62V42000.book 11 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft. STANDARD: IN: 27.500 – 27.900 mm (1.0827 – 1.0984 in) EX: 27.547 – 27.947 mm (1.0845 – 1.1003 in) SERVICE LIMIT: IN: 27.45 mm (1.081 in) EX: 27.50 mm (1.083 in) If the measurement is less than the service limit, replace the camshaft.
  • Page 101 62V42000.book 12 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead CYLINDER BLOCK CRANKSHAFT BEARING/OIL SEAL REPLACEMENT CRANKSHAFT BEARING Drive out the bearing (6205) from the cylinder block Cylinder block side: CYLINDER BLOCK SIDE: (page 13-3). Drive out the bearing (6205) from the crankcase cover Crankcase cover (page 13-3).
  • Page 102: Handle

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 14. HANDLE HANDLE COLUMN ASSEMBLY REMOVAL/ CLUTCH LEVER DISASSEMBLY/ INSTALLATION···········································14-2 ASSEMBLY ················································· 14-5 HANDLE COLUMN DISASSEMBLY/ THROTTLE LEVER DISASSEMBLY/ ASSEMBLY ·················································14-3 ASSEMBLY ················································· 14-7 14-1...
  • Page 103 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead HANDLE HANDLE COLUMN ASSEMBLY REMOVAL/INSTALLATION HANDLE Remove the following: – Air cleaner (page 5-4) – Belt cover stay (page 11-2) Move the throttle lever to the "LOW" position and disconnect the throttle cable [1] from the control base [2].
  • Page 104 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead HANDLE HANDLE COLUMN DISASSEMBLY/ASSEMBLY SER, SE TYPE Remove the handle column assembly (page 14-2). Disassemble the following: – Engine stop switch (page 7-8) – Clutch lever (page 14-5) – Throttle lever (page 14-7) R. HANDLE GRIP: NOTE 2 HANDLE PIPE L.
  • Page 105 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead HANDLE DER, DE TYPE Remove the handle column assembly (page 14-2). Disassemble the following: – Engine stop switch (page 7-8) – Clutch lever (page 14-5) – Throttle lever (page 14-7) BOLT (10 x 60 mm) (2): NOTE 3 HANDLE PIPE R.
  • Page 106 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead HANDLE CLUTCH LEVER DISASSEMBLY/ASSEMBLY Front LOCK PIN: NOTE 1 HANDLE PIPE RETURN SPRING INSTALLATION: Hook the return spring [1] ends as shown. CLUTCH CABLE Short COLLAR (Sliding surface) Long CLUTCH LEVER PIN (8 mm) LOCK LEVER RETURN SPRING LOCK LEVER ARM...
  • Page 107 62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead HANDLE LOCK LEVER INSTALLATION Before installation, make the special pin [1] as shown. Set the lock lever return spring [2] onto the clutch lever as shown. Insert the special pin to the clutch lever holes and return spring.
  • Page 108 62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead HANDLE THROTTLE LEVER DISASSEMBLY/ASSEMBLY After reassembly, perform the "THROTTLE CABLE CHECK/ADJUSTMENT" (page 3-9). SCREW (5 x 20 mm) WASHER (6 mm) THROTTLE LEVER COVER THROTTLE LEVER SPRING THROTTLE LEVER (Sliding surface) THROTTLE LEVER CONTROL PLATE BAND (2): NOTE 1 THROTTLE LEVER STAY HEX NUT (5 mm)
  • Page 109 62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MEMO...
  • Page 110: Rotor/Transmission

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 15. ROTOR/TRANSMISSION TOOLS·························································15-2 TRANSMISSION REMOVAL/ INSTALLATION ·········································· 15-7 ROTOR REMOVAL/INSTALLATION (SER, DER TYPE) ·······································15-3 TRANSMISSION DISASSEMBLY/ ASSEMBLY ················································· 15-8 ROTOR DISASSEMBLY/ASSEMBLY (SER, DER TYPE) ·······································15-4 FENDER REMOVAL/INSTALLATION······ 15-13 ROTOR ASSEMBLY CHECK FRONT WHEEL REMOVAL/INSTALLATION (SER, DER TYPE) ·······································15-6 (DER, DE TYPE) ·······································...
  • Page 111 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION TOOLS ROTOR/TRANSMISSION Pilot, 22 mm Pilot, 28 mm Driver 07746-0041000 07746-0041100 07749-0010000 Driver, 22 mm I.D. 07746-0020100 15-2...
  • Page 112 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION ROTOR REMOVAL/INSTALLATION (SER, DER TYPE) • The right side rotors and left side rotors can be removed in the same manner. • After installation, make sure that the right and left rotors are symmetry (page 15-6). L.
  • Page 113 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION ROTOR DISASSEMBLY/ASSEMBLY (SER, DER TYPE) L. ROTOR • When reassembly, assemble the tines with its identification marks ("G" and "H") facing outward. Tine G shape: Tine H shape: IDENTIFICATION MARKS ROTOR NUT (8 mm) (4) 26.5 N·m (2.7 kgf·m, 20 lbf·ft) TINE G TINE H...
  • Page 114 62V42000.book 5 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION R. ROTOR • When reassembly, assemble the tines with its identification marks ("G" and "H") facing inward. Tine G shape: Tine H shape: IDENTIFICATION MARKS TINE H ROTOR NUT (8 mm) (4) 26.5 N·m (2.7 kgf·m, 20 lbf·ft) TINE H TINE G TINE G...
  • Page 115 62V42000.book 6 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION ROTOR ASSEMBLY CHECK (SER, DER TYPE) Check that the tines are assembled properly as shown. • The right rotors and left rotors are symmetry. R. MAIN ROTOR (Outside view): R. EXTENSION ROTOR (Outside view): "G"...
  • Page 116 62V42000.book 7 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION TRANSMISSION REMOVAL/INSTALLATION Remove the following: – Handle column assembly (page 14-2) – Engine (page 10-2) – Rotor (SER, DER TYPE) (page 15-3) – Fender (page 15-13) – Front wheel (DER, DE TYPE) (page 15-14) •...
  • Page 117 62V42000.book 8 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION TRANSMISSION DISASSEMBLY/ASSEMBLY COUNTERSHAFT/INPUT SHAFT (SER, SE TYPE) • The transmission case cannot be separated. For ease of transmission disassembly/reassembly, turn the transmission case as shown in the figure. • When assembling the transmission, position all gears in the case and then insert the shafts. •...
  • Page 118 62V42000.book 9 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION COUNTERSHAFT/INPUT SHAFT (DER, DE TYPE) • The transmission case cannot be separated. For ease of transmission disassembly/reassembly, turn the transmission case as shown in the figure. • When assembling the transmission, position all gears in the case and then insert the shafts. •...
  • Page 119 62V42000.book 10 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION FINAL SHAFT/WHEEL SHAFT INTERNAL CIRCLIP (52 mm) WATER SEAL (25 x 52 x 9.5 mm): NOTE 2, 3 O-RING (47.5 x 2.5 mm) RADIAL BALL BEARING DISTANCE COLLAR (6205): NOTE 1 RADIAL BALL BEARING (6203): NOTE 1 WHEEL SHAFT WASHER (17 mm) FINAL SHAFT...
  • Page 120 62V42000.book 11 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION RADIAL BALL BEARING INSPECTION Clean the bearing with solvent and dry it thoroughly. Turn the inner race or outer race of the radial ball bearing with your finger and check for play. If it is noisy or has excessive play, replace the radial ball bearing (page 15-8).
  • Page 121 62V42000.book 12 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION OIL SEAL (15 x 35 x 7 mm) Drive a new oil seal (15 x 35 x 7 mm) [1] from outside until it is flush with the transmission case surface by using the special tools. TOOL: Driver, 22 mm I.D.
  • Page 122 62V42000.book 13 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION FENDER REMOVAL/INSTALLATION SUB FENDER REMOVAL/INSTALLATION Remove the belt cover (page 11-2). Left side only: LEFT SIDE shown: Remove the nut (6 mm) [1], bolts (6 x 12 mm) [2] and washers [3]. Remove the sub fender [4]. Installation is in the reverse order of removal.
  • Page 123 62V42000.book 14 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead ROTOR/TRANSMISSION FRONT WHEEL REMOVAL/INSTALLATION (DER, DE TYPE) NUT (10 mm) (2) BOLT (10 x 40 mm) (2) FRONT WHEEL BEAM GUIDE WASHER Note the installation direction. FRONT WHEEL ARM SIDE RETURN SPRING (2) WASHER (8 mm) CASTLE NUT (8 mm): NOTE 1 (Sliding surface) FRONT WHEEL ARM SHAFT...
  • Page 124: Technical Feature

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 dummytext 16. TECHNICAL FEATURE ONE TOUCH DRAIN SYSTEM ···················16-2 16-1...
  • Page 125 62V42000.book 2 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead TECHNICAL FEATURE ONE TOUCH DRAIN SYSTEM TECHNICAL FEATURE FEATURE The function to drain the fuel from the float chamber has been combined with the fuel valve lever. CONSTRUCTION One touch drain system assembly consists of the float chamber [1], valve seal [2], O-ring [3], fuel valve [4], wave washer [5], spring [6], stopper button [7], fuel valve cover [8], valve cover screws (3 x 5 mm) [9], fuel valve lever [10], fuel valve lever screw (3 x 11 mm) [11].
  • Page 126 62V42000.book 3 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead TECHNICAL FEATURE FUNCTION "ON" POSITION When the fuel valve lever [1] is turned to "ON" position, the fuel passed the fuel tube [2] from the fuel tank flows in the float chamber [3], through the groove [4] in the fuel valve [5]. "OFF"...
  • Page 127 62V42000.book 4 ページ 2012年12月7日 金曜日 午前9時17分 dummyhead dummyhead MEMO...
  • Page 128: Index

    62V42000.book 1 ページ 2012年12月7日 金曜日 午前9時17分 INDEX dummytext INDEX AIR CLEANER CHECK/CLEANING/REPLACEMENT ···3-5 HANDLE COLUMN ASSEMBLY REMOVAL/ AIR CLEANER REMOVAL/INSTALLATION ···················5-4 INSTALLATION ···························································· 14-2 BEFORE TROUBLESHOOTING HANDLE COLUMN DISASSEMBLY/ASSEMBLY········ 14-3 IGNITION SYSTEM ····················································7-2 IGNITION COIL AIR GAP CHECK/ADJUSTMENT ········ 7-6 TROUBLESHOOTING ···············································4-2 IGNITION COIL INSPECTION ·······································...
  • Page 129 Actual power output for the engine installed in the final machine will vary depending on numerous factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables. Honda Motor Co., Ltd. 2019.5...
  • Page 130 MAINTENANCE STANDARDS • 62V4200: page 2-2, 5-7 SER2/SE2/DER2/DE2 TYPE: Unit: mm (in) Part Item Standard Service limit Piston Skirt O.D. 67.980 – 67.990 (2.6764 – 2.6768) 67.845 (2.6711) Piston-to-cylinder clearance 0.010 – 0.035 (0.0004 – 0.0014) 0.12 (0.005) Piston pin bore I.D. 18.002 –...
  • Page 131 CRANKSHAFT BEARING/OIL SEAL REPLACEMENT • 62V4200: page 13-12 CRANKSHAFT BEARING (SER2/SE2/DER2/DE2 TYPE) CRANKCASE COVER SIDE Remove the oil seal and drive out the crankshaft bearing. Drive a new crankshaft bearing [1] until it is fully seated on the end using the special tools.
  • Page 132 2 500 tr/min (couple net maxi.). La puissance des moteurs de grande série peut varier par rapport à la valeur indiquée. La puissance réelle du moteur équipant la machine au final varie en fonction de nombreux facteurs, notamment le régime de service du moteur en utilisation, les facteurs environnementaux, l'entretien, et d'autres variables. Honda Motor Co., Ltd. 2019.05...
  • Page 133 STANDARDS D'ENTRETIEN • 63V4200: page 2-2, 5-7 TYPE SER2, SE2, DER2, DE2 Unité : mm Pièce Élément Standard Limite de service Piston Dia. ext. de jupe 67,980 – 67,990 67,845 Jeu piston-cylindre 0,010 – 0,035 0,12 Dia. int. d'alésage d'axe de piston 18,002 –...
  • Page 134 REMPLACEMENT DU PALIER/BAGUE D'ETANCHEITE DE VILEBREQUIN • 63V4200: page 13-12 PALIER DE VILEBREQUIN (TYPE SER2, SE2, DER2, DE2) COTE COUVERCLE DE CARTER MOTEUR Déposez la bague d'étanchéité et enlevez le palier de vilebrequin. Enfoncez un nouveau palier de vilebrequin [1] jusqu'à ce qu'il soit complètement placé...
  • Page 135 (max. Nettodrehmoment). Die Werte anderer Motoren aus der Serienproduktion können hiervon abweichen. Die tatsächliche Leistungsabgabe des im Endprodukt verbauten Motors ist von zahlreichen Faktoren wie Betriebsdrehzahl des Motors in der Anwendung, Umweltbedingungen, Wartung und anderen Variablen abhängig. Honda Motor Co., Ltd. 2019.05...
  • Page 136 WARTUNGSSTANDARDS • 64V4200: Seite 2-2, 5-7 AUSFÜHRUNGEN SER2, SE2, DER2, DE2: Einheit: mm Teil Artikel Sollwert Verschleißgrenze Kolben Kolbenmantel, AD 67,980 – 67,990 67,845 Spiel des Kolbens im Zylinder 0,010 – 0,035 0,12 Kolbenbolzenbohrung, ID 18,002 – 18,008 18,048 Kolbenringe 1.
  • Page 137 KURBELWELLENLAGER / ÖLDICHTRING AUSTAUSCH • 64V4200: Seite 13-12 KURBELWELLENLAGER (AUSFÜHRUNGEN SER2, SE2, DER2, DE2) IM KURBELGEHÄUSEDECKEL Den Öldichtring entfernen und das Kurbelwellenlager austreiben. Ein neues Kurbelwellenlager [1] mit Spezialwerkzeug eintreiben, bis das Ende aufsitzt. WERKZEUGE: Vorsatz, 52 x 55 mm [2] 07746-0010400 Führung, 25 mm [3] 07746-0040600...
  • Page 138 Los motores de producción en cadena pueden tener valores diferentes a este. La potencia real para el motor instalado en la máquina final dependerá de diversos factores, incluidos la velocidad de trabajo del motor en la aplicación, las condiciones ambientales, el mantenimiento, así como otras variables. Honda Motor Co., Ltd. 2019,05...
  • Page 139 ESTÁNDARES DE MANTENIMIENTO • 65V4200: página 2-2, 5-7 TIPO SER2, SE2, DER2, DE2 Unidad: mm Pieza Elemento Estándar Límite de servicio Pistón D.E. del faldón 67,980 – 67,990 67,845 Holgura entre el pistón y el cilindro 0,010 – 0,035 0,12 D.I.
  • Page 140 SUSTITUCIÓN DEL COJINETE/RETÉN DE ACEITE DEL CIGÜEÑAL • 65V4200: página 13-12 COJINETE DEL CIGÜEÑAL (TIPO SER2, SE2, DER2, DE2) LADO DE LA TAPA DEL CÁRTER MOTOR Extraiga el retén de aceite y el cojinete del cigüeñal. Monte un cojinete del cigüeñal nuevo [1] hasta que esté completamente asentado en el extremo, utilizando las herramientas especiales.
  • Page 141 The changed instructions are shown in OUTLINE OF CHANGES Note this supplement is applicable only to the frame serial numbers listed in the table shown below. Model Frame serial number FJ500 FAAC-2000322 and subsequent Honda Motor Co., Ltd. 2019. 06...
  • Page 142 PULLEY/V-BELT REMOVAL/INSTALLATION After installation, adjust the V-belt tension (page 3-10). BRACKET WASHER BELT COVER STAY GROMMET: NOTE 3 HEX BOLT (6 x 8 mm) ENGINE BOLT (6 x 12 mm) STAY RUBBER HOLDER UPPER BELT STOPPER BELT STOPPER C BOLT (8 x 16 mm) WASHER (8 mm) TRANSMISSION SIDE...
  • Page 143 Les instructions modifiées sont indiquées dans DESCRIPTIF DES MODIFICATIONS Noter que ce supplément n’est applicable qu’aux numéros de série de châssis énumérés dans le tableau indiqué ci- dessous. Modéle Numéro de série de châssis FJ500 FAAC-2000322 et suivants Honda Motor Co., Ltd. 2019. 06...
  • Page 144 DEPOSE/POSE DE LA POULIE/COURROIE TRAPEZOIDALE Après repose, régler la tension de la courroie trapézoïdale (page 3-10). RONDELLE DE SUPPORT SUPPORT DE COUVERCLE DE COURROIE ŒILLET : NOTE 3 VIS HEX (6 x 8 mm) SUPPORT VIS (6 x 12 mm) MOTEUR SUPPORT CAOUTCHOUC...
  • Page 145 GEÄNDERTE KOMPONENTEN Die geänderten Anweisungen sind in eingeschlossen. ÜBERSICHT ÜBER ÄNDERUNGEN Es ist zu beachten, dass dieser Nachtrag nur für die in der nachfolgenden Tabelle aufgeführten Seriennummern gilt. Modell Seriennummer FJ500 FAAC-2000322 und höher Honda Motor Co., Ltd. 2019. 06...
  • Page 146 RIEMENSCHEIBE / KEILRIEMEN AUSBAU / EINBAU Nach dem Einbau die Keilriemenspannung einstellen (Seite 3-10). HALTERUNGSSCHEIBE RIEMENABDECKUNGSTRÄGER DURCHFÜHRUNG: HINWEIS 3 SECHSKANT- SCHRAUBE (6 x 8 mm) SCHRAUBE MOTOR- (6 x 12 mm) TRÄGER GUMMI- HALTER OBERER RIEMENANSCHLAG RIEMENAN- SCHLAG C SCHRAUBE (8 x 16 mm) SCHEIBE (8 mm) ZUM GETRIEBE...
  • Page 147 PERFIL DE LOS CAMBIOS Tenga presente que este suplemento sólo es aplicable a los números de serie del bastidor enumerados en la tabla mostrada a cotinuación. Modelo Número de serie del bastidor FJ500 FAAC-2000322 y subsiguientes Honda Motor Co., Ltd. 2019. 06...
  • Page 148 MONTAJE/DESMONTAJE DE LA POLEA/CORREA TRAPEZOIDAL Después de la instalación, ajuste la tensión de la correa trapezoidal (página 3-10). ARANDELA DEL SOPORTE SOPORTE DE LA CUBIERTA DE LA CORREA ARANDELA PASACABLES: NOTA 3 TORNILLO HEXAGONAL (6 x 8 mm) SOPORTE TORNILLO (6 x 12 mm) DEL MOTOR SOPORTE DE CAUCHO...

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