Powerhouse PH3300i, Service Manual

Page 1: ...PH3300i Digital Inverter Generator SERVICE MANUAL POWERHOUSE ...

Page 2: ...the time of approval for printing Keystone Automotive Operations Inc reserves the right to make changes without incurring any obligation whatsoever No part of this publication may be reproduced without written permission Pay special attention to statements preceded by the following words Indicates a strong possibility of severe personal injury or death if instructions are not followed Indicates a ...

Page 3: ...3 2 1 12V 10Ah AGM Starting Battery 15 3 2 2 3 6V Li ion Ignition Batteries 15 3 3 Checking the Oil Level 16 3 4 Changing Oil 17 3 5 Air Filter Inspection and Cleaning 18 3 6 Spark Plug Inspection and Cleaning 19 3 7 Valve Clearance Inspection and Adjustment 20 3 8 Evaporation Control System 21 3 9 Replacing Fuel Filter 22 3 10 Spark Arrestor 23 4 TROUBLESHOOTING 24 4 1 Starter Does Not Crank 25 4...

Page 4: ...9 5 2 1 Disassembly Installation 49 5 3 Outer Generator Housing 50 5 3 1 Disassembly Installation 50 5 4 Recoil Starter 51 5 4 1 Disassembly Reassembly 51 5 5 Starter motor 52 5 5 1 Starter Testing 52 5 5 2 Starter Removal Replacement 53 5 6 Starter Relay 54 5 6 1 Testing Starter Relay on Generator 54 5 6 2 Bench Testing the Starter Relay 55 5 7 Intake Fan Cover 56 5 8 Ignition Coil Trigger Assemb...

Page 5: ...2017 01 20 5 13 3 Valve and Spring Inspection 70 5 14 Crankshaft Camshaft Piston 71 5 14 1 Disassembly and Reassembly 71 5 14 2 Alignment of Timing Marks 72 5 14 3 Camshaft Inspection 73 5 14 4 Piston Connecting Rod 74 ...

Page 6: ...ctronic Spark plug F7RTC Carburetor Horizontal Float type Air cleaner Semi dry type Governor Electronic control Lubrication system Splash Lube oil SAE 10W 30 SF SG grade above 0 C 32 F SAE 0W 30 0W 40 below 0 C 32 F Oil capacity 1 0 L 35 oz Starting system Electric Recoil Stopping system Primary circuit ground Fuel used Automotive unleaded gasoline Alternator Alternator type Multi pole rotation ty...

Page 7: ...tage variation rate Momentary Average Average time 10 max 1 5 max 3 sec max Voltage stability 1 Frequency variation rate Momentary Average Average time 1 max 1 max 1 sec max Frequency stability 0 1 Insulation resistance 10MΩmin AC circuit protector 20A and 30A 120V DC circuit protector 10A Fuel tank capacity 16 3L 4 3 gal Continuous running time at rated load at load 10 9 hours 16 6 hours Noise le...

Page 8: ...8 PH3300i SM Rev 2017 01 20 1 3 Wiring Diagram ...

Page 9: ...recautions Be sure you have a clear understanding of all basic shop safety practices Wear appropriate clothing and personal protective equipment When performing servicing or repairs the below CAUTION steps must be followed Read the instructions before you begin any servicing be sure you have the equipment and skills required to perform the tasks safely Be sure that the engine is off before you beg...

Page 10: ...ector completely into the receptacle If the connector is a locking type be sure that it is locked securely 4 Check the connector cover for cracks or other damage and make sure the connector female terminal fits snugly into the connector Then connect the connector securely Check the connector terminal for rust Remove any rust using a fine emery paper or equivalent material before connecting the con...

Page 11: ...rton The engine serial number can be found stamped on the engine block above the oil dipstick It is visible when the engine oil access cover is removed Fig 1 2 6 Engine Maintenance Specifications Part Item Specification Service limit Engine Maximum speed without load 3600 100rpm Cylinder Sleeve I D 77 000 77 020mm 3 0315 3 0323 77 105mm 3 0356 Piston Skirt O D 76 960 76 980mm 3 0299 3 0307 76 85mm...

Page 12: ...D 18 006 18 017mm 0 7089 0 7093 18 08mm 0 712 Big end I D 33 020 33 033mm 1 3000 1 3005 33 09mm 1 303 Crankshaft Crank pin O D 32 967 32 980mm 1 2979 1 2984 32 90mm 1 295 Valves Valve clearance IN 0 10 0 02mm 0 004 001 EX 0 15 0 02mm 0 006 001 Stem O D IN 6 46 6 48mm 0 254 0 255 6 40mm 0 2520 EX 6 455 6 470mm 0 2541 0 2547 6 40mm 0 2520 Guide I D IN EX 6 500 6 530mm 0 2559 0 2571 6 56mm 0 2583 Sea...

Page 13: ...ding Resistance black black black 0 25 0 35 2 8 Torque Values Item Specification Tightening torque ft lb N m Connection rod bolt M8x40 21 24 28 32 Spark plug M12x1x13 9 11 12 15 Crankcase cover M8x35 21 23 28 31 Flywheel nut M16x1 5 66 74 90 100 Standard torque M5 Bolt nut 4 6 6 8 M6 Bolt nut 6 7 8 10 M8 Bolt nut 15 17 18 22 M10 Bolt nut 41 44 55 60 Use standard torque values for fasteners that ar...

Page 14: ...Air cleaner Check O Clean O 2 Spark Plug Clean adjust O Spark Arrester Clean O Fuel Filter Check O Replace O 2 Valve clearance Check Adjust O 3 Fuel tank strainer Clean O 2 Fuel line Check Every 2 years Replace as necessary 12V 10Ah AGM Starting Battery Clean Charge Charge monthly during long term storage Check terminals for corrosion monthly clean as needed Expected battery life is 2 years but ca...

Page 15: ...ly letting it hang from its connections Fig 3 These batteries provide power for pre start throttle location and auxiliary ignition power They are charged while the generator is running Inspect them periodically or as part of a troubleshooting procedure Remove the batteries from their tray for inspection their voltage should be 3 2 4 0V depending on the temperature If the voltage is 2 7V replace bo...

Page 16: ... the engine oil access cover and remove the cover 2 Remove the oil filler cap and check for the oil level 3 If the oil level is low add oil until it reaches the edge of the upper line on the dipstick when screwed in as shown in Fig 4 4 Re install the dipstick and the engine oil access door before restarting your generator Upper Limit Lower Limit Upper level Lower level Fig 4 ...

Page 17: ...r cap 3 Install the oil drain pipe 4 Drain dirty oil into a container Allow enough time for the oil to drain completely 5 Refill with the recommended oil and check the oil level 6 Reinstall the access cover and tighten the screw securely Engine oil capacity 1 0L 35 oz Please dispose of used motor oil in a manner that is compatible with the environment and local disposal regulations Do not throw oi...

Page 18: ...e cover 5 Wash the filter element in a non flammable or high flash point solvent and dry them thoroughly 6 Soak the filter element in clean engine oil and squeeze out any excess oil 7 Reinstall the filter element and the air filter cartridge Tighten the two cartridge screws securely 8 Reinstall the maintenance door and tighten the screws securely A dirty air filter will restrict air flow to the en...

Page 19: ... can also be caused by a faulty PCV valve built into the valve cover This will cause large amounts of engine oil to get pulled through the PCV hose collect in the air cleaner and get sucked into the carburetor If this is the case try replacing the PCV valve valve cover 2 Remove carbon or other deposits with a plug cleaner or stiff wire brush Check the sealing washer for damage 3 Measure the plug r...

Page 20: ...cker arm and the valve and measure the valve clearance see Fig 9 4 If adjustment is necessary proceed as follows a Secure the rocker arm adjustment nut and loosen the jam nut b Adjust the rocker arm nut until the desired valve clearance is attained c Secure the rocker arm nut and tighten the jam nut Recheck the clearance 5 Clean the cylinder block and valve cover 6 Replace the rubber valve cover s...

Page 21: ...must be present and connected as shown to meet CARB evaporative emission standards Use the OEM replacement hose if possible This grade of hose is commonly available at auto part stores as fuel hose if the OEM replacement hose is unavailable 380cc Carbon Canister Fuel Tank Vent Hose from Tank Air Filter case Vent Hose from Air Filter Fig 10 ...

Page 22: ...ot to introduce any debris or contaminants in the fuel system during this process Contaminants introduced here will likely end up in the carburetor 1 Remove the 6 control panel screws and carefully allow the control panel to hang out of the way 2 Remove hose clamps and remove fuel filter Fig 11 and Fig 12 3 Reassemble in reverse order Fig 11 Fig 12 ...

Page 23: ... a substantial loss in power and performance 1 Remove the exhaust grill to access the spark arrestor Fig 13 2 Remove the clamp holding the spark arrester to the muffler 3 Remove the spark arrester 4 Clean the spark arrestor with a wire or nylon brush and compressed air 5 Replace the spark arrestor if the wire mesh is perforated or torn 6 Reinstall the spark arrester 7 Reinstall the clamp holding t...

Page 24: ...p Engine with Low Oil 4 6 Engine Stops Running 4 7 Engine Speed Can t Increase or is Hunting 4 8 Engine Speed Too High 4 9 No or Low AC Output 4 10 Measuring Stator Main Output Voltage While Running 4 11 No DC Output at Battery Charge Receptacle 4 12 Starting Battery Will Not Charge 4 13 Voltage Regulator Testing 4 14 Engine Runs on or Backfires After Being Turned Off 4 15 Engine Will Start Then S...

Page 25: ...pect the battery terminal connections Replace ignition switch and or repair wiring faults found Check the ignition switch section 4 4 3 Repair ground Clean wire ends and battery terminals Remove paint dirt oil grease or corrosion from chassis grounds Check the ground between the battery negative terminal and the starter relay body the engine block and control panel Replace the starter relay sectio...

Page 26: ...vel in fuel tank Add fuel and start the engine If starting with a dry fuel system use 1 5 gallons Loosen the carburetor drain screw to verify if fuel has reached the carburetor section 5 3 1 Fig 30 Check the fuel filter section 3 9 fuel pump section 4 6 1 fuel valve fuel lines and carburetor for blockage water in fuel and or a stuck float Clean or repair as necessary Check the oil level The low oi...

Page 27: ... minute before conducting the test below 1 Remove the maintenance door 2 Look in the area circled in red in Fig 14 to acquire a clear view of the throttle plate step motor linkage Use a flashlight if necessary 3 Turn the ignition key to the ON position while maintaining a view on the throttle plate step motor linkage It should go through the pre start throttle location process immediately when the...

Page 28: ...move the maintenance door 2 Remove the spark plug cap 3 Remove the spark plug use spark plug wrench from the supplied tool kit 4 Install a compression gauge in the spark plug hole Fig 16 5 Turn the ignition switch to the START position and hold until the compression gauge no longer rises Read compression Cylinder compression 0 45Mpa 65 psi 800rpm Pressure Gauge Fig 16 ...

Page 29: ...normal No spark Abnormal Normal Still no spark Abnormal Check for spark section 4 4 1 Clean inspect and gap the plug section 4 6 Plug gap 0 6 0 7mm 0 024 0 028 Perform the spark test again using a new spark plug Replace the faulty spark plug Test the ignition switch section 4 4 3 Replace switch or repair as required Test the oil level sensor section 4 5 1 Replace or repair as required Disconnect t...

Page 30: ...ion 3 6 Clean or replace plug as necessary before checking spark Make sure you are using an F7RTC or equivalent spark plug 4 Install the spark plug into the plug cap 5 Attach a ground wire between the engine block and the negative electrode the steel body of the spark plug Fig 17 6 Crank the engine over using the ignition key and watch the spark plug gap for signs of spark A healthy ignition syste...

Page 31: ...eck the secondary resistance attach one lead of the tester to chassis ground or the ground wire of the ignition coil and the other lead to the spark plug cap The secondary coil resistance should be between 7 5 8 1kΩ 6 If the resistance is too high remove the spark plug cap and check it again through the spark plug wire itself If the resistance is within range through the spark plug wire but not th...

Page 32: ...to the table below for the ignition wire voltages at the different ignition switch positions In the OFF position verify that there is battery ground at the black and pink wires and that there is 12V positive battery voltage at the red wire 7 Turn the switch to the ON position and verify that there is battery ground at the black wire and no ground at the pink wire Verify that there is 12V positive ...

Page 33: ...ltage regulator section 4 13 Fig 30 Repair or replace the wire between the low oil sensor and the voltage regulator If the voltage from the voltage regulator is reaching the ignition indicator module and the engine is not being shut down and or the low oil light is not being illuminated then replace the ignition indicator module Good Voltage No or low voltage Replace the voltage regulator Check th...

Page 34: ...ps and the low oil light on the control panel illuminates If the engine fails to stop or the low oil light fails to illuminate refer to the flow chart in section 4 5 to diagnose the problem 4 After confirming that the engine oil is at the proper level test for continuity between the white wire of oil sensor connector and the case of the engine Fig 24 No continuity indicates a normal condition If t...

Page 35: ...section 4 6 1 Faulty Not blocked Add fuel and restart the engine No fuel Check fuel level Check the oil level sensor section 4 5 1 Sensor working Check BFP solenoid section 5 1 3 Replace the BFP solenoid section 5 1 3 Abnormal Normal Normal Perform the throttle control system test section 5 1 2 2 Check the carburetor gasket for leakage Tighten carburetor bolts or replace gasket as required Abnorma...

Page 36: ...e attached 4 Remove the screws that hold the fuel pump to the frame and carefully allow the fuel pump to hang in front of the inverter from its vacuum line 5 Using two spare pieces of fuel line 6 8 long attach one on the inlet and one on the outlet of the fuel pump Fig 26 6 Find a small open container that will safely hold a few ounces of fuel to a depth of 0 5 1 0 Put the fuel in it and place it ...

Page 37: ... Normal Check the carburetor gasket and vacuum lines for leakage Replace vacuum lines or carburetor gasket as required section 5 1 1 Abnormal Normal Measure the cylinder compression section 4 3 Abnormal Normal Perform the throttle control system test section 5 1 2 Check the fuel filter fuel valve fuel lines and tank strainer for blockage or restrictions Replace fuel filter section 3 9 Clean lines ...

Page 38: ...d and press the overload reset button If the inverter fails to reset test reset button and wires to inverter If reset button and wires are OK replace inverter section 5 10 Check all circuit breakers Are any of them tripped Disconnect the load and reset the breakers Stop the engine and check the AC receptacles for burnt contacts and loose or burnt connections Check to see if the engine feels jammed...

Page 39: ... necessary to manually adjust the throttle to make the engine run in the upper RPM range 3000 4000 RPM before checking the stator main output voltage Once set do not alter the throttle during the rest of the test 4 Check voltage between pins 1 4 between pins 2 4 and between pins 1 2 Fig 28 There should be approximately 180 300VAC at each test The three readings should be approximately equal within...

Page 40: ...ery using recommended charger Do a load test to make sure the battery maintains adequate voltage under load Clean battery terminals Replace battery if necessary Check all wire connections of the voltage regulator Test the voltage section 4 13 Replace the voltage regulator Abnormal Normal Abnormal Normal Normal Abnormal With the generator running unplug the stator low voltage winding from the volta...

Page 41: ...ld be 12 0 14 5 VDC depending on the condition of the starting battery If the voltage does not fall within this range replace the voltage regulator b Measure the control panel DC output voltage from the voltage regulator 9 pin connector Put the voltmeter positive test lead on the red black wire and the negative test lead on the yellow green wire The voltage should be 13 15 VDC If the voltage does ...

Page 42: ...eplace the black wire between the ignition indicator module and the BFP connector 5 Start the engine 6 To test if the BFP is being activated after shutdown use a voltmeter and connect the positive lead of the voltmeter to the green white wire and the negative lead to the black wire of the end of the BFP connector from the ignition indicator module 7 While the engine is running the voltage should b...

Page 43: ...nt cover Carefully maneuver the control panel back through the control panel hole in the front cover 7 Remove inverter bolts and carefully lay the inverter on its back 8 Remove the two screws from the air filter cartridge and slide it out of the air cleaner 9 Remove the two screws from the charcoal canister and move it out of the way to gain access to the air cleaner 10 Remove the six air cover sc...

Page 44: ... 35 The spring is under compression and can be easily lost if not controlled Remove the two step motor screws and carefully remove the step motor Fig 34 It is not necessary to remove the step motor bracket or the choke cable mount to change the step motor Leave the bracket and choke cable mount on and hold the fork and spring in place with a flat bladed screwdriver when pulling the step motor away...

Page 45: ...inger to check the backlash of the step motor gears There should be almost none If the backlash is in excess of 0 25 0 38mm 0 010 0 015 then replace the step motor 1 Measure the resistance of the outlet terminals of the step motor Fig 36 2 Replace the step motor if the resistance does not fall within the recommended range Resistance value Pin 1 blue Pin 2 white 145 155Ω Pin 3 red Pin 4 black 145 1...

Page 46: ...essed by removing the control panel Fig 38 2 To bench test the BFP solenoid drain the carburetor float bowl unscrew the BFP and remove it from the carburetor The needle on the end of the solenoid should be in the retracted position Fig 39 Apply 12V to one of the solenoid leads and ground to the other polarity does not matter The solenoid should make a click noise and the needle should move to the ...

Page 47: ...screws shown in Fig 40 It is not necessary to completely remove the screws 5 1 4 2 Reconnecting the Choke Cable When reinstalling the front panel make sure that the choke cable is routed so it is free and can be attached to the carburetor without restriction Without a cable attached to the choke it is spring loaded in the OFF position OPEN It should be in this position at the start of this procedu...

Page 48: ...mes installed in the factory carburetor will provide optimal performance to an altitude of 6000 feet It is unnecessary to change to a high altitude jet for altitudes 6000 feet Emulsifier Tube Main Jet BFP Solenoid Fuel Bowl Retainer Fuel Bowl Rubber Bowl Seal O Rings Fig 43 ...

Page 49: ...y Installation Remove Mounting Screws 6 Fig 44 120V 20 30 amp Circuit Breakers 120V 20amp Duplex 5 20 120V 30amp L5 30 12V DC Circuit Breaker Ignition Switch Indicator Module Module Cover USB Ports Overload Reset Button Hour Meter 12V Receptacle Ignition Key Fig 45 ...

Page 50: ...on Canister Right Cover Oil Access Cover Short Sponge Control Panel Choke Knob Starter Solenoid Exhaust Grille DC Voltage Regulator Handle Sponge Rear Cover Maintenance Door Left Cover Fixed Wheels Swivel Wheels Gas Cap Upper Frame Fuel Gauge Sight Glass Inverter Rubber Grommet Lift Handle Top Cover Gas Tank Starting Battery Fuel Knob Front Cover Fig 46 ...

Page 51: ...andle 6 Remove the six front cover screws and remove the front cover Carefully maneuver the control panel back through the control panel hole in the front cover while removing it Set the front panel aside and carefully allow the control panel to hang out of the way Fig 47 7 Remove inverter bolts and carefully lay the inverter on its back Fig 48 8 Remove the three M6 flange bolts circled in Fig 48 ...

Page 52: ...nd not the starter so that any potential sparks that may be generated during this process are not near the battery Make sure the unconnected end of the jumper cable does not come in contact with the chassis ground Touch the unconnected end of the jumper to the starter connection for the starter relay cable The starter should engage the ring gear and turn the engine at a normal cranking speed If it...

Page 53: ...e cable coming from the starter relay 5 Remove the three screws and two M6 bolts from the starter access cover and remove the cover Fig 52 It may be necessary to remove the bolts holding the upper frame to the base to allow the fuel tank to be moved up slightly to gain access to the bolt indicated with a dotted circle Also note that the cover is colored orange for the purposes of this manual but i...

Page 54: ... between the battery and starter motor terminals of the starter relay 3 Turn the ignition key to the START position Verify that there is 12V battery voltage being supplied to the spade terminal marked Start Wire from Ignition Switch in Fig 55 If there is the relay should make a single clicking sound there should then be continuity between the battery and starter motor terminals of the starter rela...

Page 55: ...negative lead to the metal body of the relay Fig 57 Resistance 4 9 5 9 Ω 2 Check the function of the start relay by connecting the spade terminal to the 12V positive battery terminal Connect the metal base or body to the negative battery terminal There should be a clicking sound as the relay is activated While the relay remains activated use the volt ohm meter to check continuity between the two l...

Page 56: ...e rear end panel and the left and right side panels 4 Remove the upper frame and the gas tank as an assembly Fig 59 5 Disconnect all wires from the stator assembly 6 Disconnect the starter motor wire and all ground wires 7 Remove 4 nuts from the engine mounting bolts 2 on each side and lift the engine assembly off the base pan Fig 60 61 8 Remove the carburetor and the intake fan cover revealing th...

Page 57: ...57 PH3300i SM Rev 2017 01 20 Fig 62 Intake Fan Cover Bolt Intake Fan Cover Bolt Intake Fan Cover Bolts ...

Page 58: ...slight resistance felt when sliding the feeler gauge in between them Adjust if necessary step 3 3 Loosen the ignition coil trigger mount bolts circled in Fig 63 and insert the feeler gauge Allow the magnetic tip of the trigger to contact the feeler gauge and retighten the bolts Recheck the gap re adjust if necessary 4 Rotate the rotor to make sure there is no interference with any other components...

Page 59: ...rging windings Measure the resistance between the two blue terminals at the 2 pin connector Resistance Blue Blue 0 20 0 60 Ω Sub windings Measure the resistance between the two sub winding terminals at the 6 pin connector Resistance White White 0 10 0 16 Ω Main windings Measure the resistance between each of the main winding terminals at the 6 pin connector Fig 64 Resistance Black Black Black 0 25...

Page 60: ...ion 5 5 2 Fig 52 53 6 Remove 4 nuts from the engine mounting bolts 2 on each side and lift the engine assembly off the base pan section 5 7 Fig 60 61 7 Remove the carburetor and the intake fan cover 8 Remove the ignition coil trigger assembly starter cup and fan Fig 65 9 Remove the M16 flange nut from the crankshaft Fig 65 10 Attach an appropriate puller to the rotor using three M6X1 bolts grade 8...

Page 61: ... as it may need minor adjustments before being put into service Steps for the adjustment and replacement of the inverter are detailed below Inverter Performance Specifications Output Voltage 0 400W load 118 124VAC 58 62Hz Rated Output continuous 3200W 30A 108 132VAC 58 62Hz Maximum Output for 2 minutes 3300W 33 3A 108 132VAC 58 62Hz Minimum Output Before Overload 3350W 33 75A 108 132VAC 58 62Hz 5 ...

Page 62: ...e of the 120V 20A duplex receptacles 5 20R Connect a load bank and power meter or ammeter if you don t have a power meter to the 120V L5 30 receptacle 3 Start the generator 4 Adjust the voltage to 122V 0 3 by turning the voltage adjustment pot screw Fig 70 clockwise to increase and counter clockwise to decrease 5 Using a load bank and power meter set the overload adjustment pot Fig 71 to trip at 3...

Page 63: ...ess the inverter Lay the inverter down Fig 72 3 Check the continuity from the red white wire Fig 72 to the red white of the ignition indicator module on the control panel The resistance should be 0 1 1 0Ω If the resistance is not in this range then repair or replace this wire before continuing 4 Check the continuity of the black wire from the Li ion battery tray section 3 2 2 Fig 3 to the 8 pin re...

Page 64: ...ve the front lift handle and then the six front cover screws Remove the front cover Carefully maneuver the control panel back through the control panel hole in the front cover 6 Remove the rear end panel the side panels and the top cover reference the Outer Generator Housing exploded view in section 5 3 7 Remove upper frame with fuel tank as one assembly Fig 74 8 Remove the muffler cover bolts and...

Page 65: ...65 PH3300i SM Rev 2017 01 20 5 12 Engine Exploded View ...

Page 66: ...pstick 15 09080552 69260 O Ring Dipstick 16 09080502 61614 Cover Crankcase 17 04090021 69261 Oil Seal 18 03050225 69614 M8 X 35 Flange Bolt 19 09080514 61984 Piston Pin Clip 20 09080513 61899 Piston Pin 21 09080512 61760 Piston 22 09080517 61985 Piston Ring Set 5 23 09080516 Second Piston Ring 24 09080515 Top Piston Ring 25 09080511 65113 Camshaft Assy 26 09080507 69266 Head Gasket 27 09080523 692...

Page 67: ...42 09070221 69564 Intake Valve Spring Retainer 43 09080520 69563 Exhaust Valve Spring Retainer 44 09080526 61988 Valve Adjustment Spacer 45 09080151 69537 Spark Plug F7RTC 46 03050295 62489 M10 x 80 Flange Bolt 47 09080508 60554 Gasket Valve Cover 177F 48 092101031 65474 Cover Valve 49 09070429 69263 Seal Valve Cover 50 03030168 Washer 51 03050929 67106 Valve Cover Bolt R1 ...

Page 68: ...arks 1 Follow steps 1 6 in section 5 1 1 to remove the front panel 2 Remove the rear end panel and the left and right side panels 3 Remove the upper frame and the fuel tank as an assembly 4 Remove the inverter section 5 10 1 5 Remove the air cleaner and carburetor section 5 1 1 6 Remove the intake fan cover section 5 7 7 Remove the muffler cover muffler exhaust fan exhaust manifold and muffler cas...

Page 69: ...er Head Bolts Cylinder Head Valve Cover Bolt and Rubber Seal Valve Cover Gasket Head Gasket Alignment Sleeves Fig 82 Cylinder Head Exhaust Valve Intake Valve Rocker Arm Studs Valve Springs Push Rods Valve Spring Retainers Jam Nuts Rocker Arm Adjustment Nuts Rocker Arms Lash Pad Guide Plate Fig 83 ...

Page 70: ...h Of Valve Spring Standard Service limit 39 1mm 1 54 37 5mm 1 48 Valve Seat Width Standard Service limit 0 8mm 0 03 1 8mm 0 07 Valve Stem Outer Diameter Standard Service limit Intake valve 6 46 6 48mm 0 254 0 255 6 40mm 0 252 Exhaust valve 6 45 6 47mm 0 254 0 255 6 40mm 0 252 ...

Page 71: ...300i SM Rev 2017 01 20 5 14 Crankshaft Camshaft Piston 5 14 1 Disassembly and Reassembly Low Oil Sensor Front Engine Seal Piston and Rod Lower Rod Cap Rod Bolts Lifters Key Crankshaft Front Crankshaft Bearing ...

Page 72: ...72 PH3300i SM Rev 2017 01 20 5 14 2 Alignment of Timing Marks Use marks to align camshaft gear and timing gear during installation Crankshaft Gear Cam Gear Timing Marks Fig 84 ...

Page 73: ...73 PH3300i SM Rev 2017 01 20 5 14 3 Camshaft Inspection Height of Camshaft Standard Service limit Intake Exhaust 31 70 31 78mm 1 248 1 251 31 0mm 1 22 ...

Page 74: ...y of Piston Rings Make sure the rings are installed with the manufacturer s label up Make sure the 1st ring and 2nd ring are not interchanged Make sure the piston rings are free to move after installation Stagger each piston ring gap 120 from each of the other rings ...

Page 75: ...er Standard Service limit 77 00 77 02mm 3 031 3 032 77 10mm 3 036 Piston Skirt Outer Diameter Standard Service limit 76 96 76 98mm 3 030 3 031 76 85mm 3 026 10mm Side Clearance Of Piston Ring Standard Service limit 0 02 0 06mm 0 001 0 002 0 15mm 0 006 ...

Page 76: ...ure the piston end clearance Standard Service limit 0 15 0 25mm 0 006 0 010 1 0mm 0 04 Piston Ring Height Standard Service limit The 1st ring 1 97 1 99mm 0 077 0 078 1 87mm 0 074 The 2nd ring 1 97 1 99mm 0 077 0 078 1 87mm 0 074 Piston Pin Outer Diameter Standard Service limit 17 99 18 00mm 0 708 0 709 17 95mm 0 707 ...

Page 77: ...tandard Service limit 18 00 18 01mm 0 708 0 709 18 05mm 0 711 Connection Rod Small End Inner Diameter Standard Service limit 18 01 18 02mm 0 709 0 709 18 08mm 0 712 Connection Rod Big End Inner Diameter Standard Service limit 33 02 33 03mm 1 300 1 300 33 1mm 1 30 ...

Page 78: ...300i SM Rev 2017 01 20 Crankshaft Neck Outer Diameter Standard Service limit 32 97 32 98mm 1 298 1 298 32 9mm 1 29 Connection Rod Big End Side Clearance Standard Service limit 0 1 0 4mm 0 004 0 016 0 8mm 0 03 ...

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