Yanmar 1GM10, Shop Manual

Page 1: ...YANMAR DIESEL INBOARD SHOP MANUAL ONE TWO 8 THREE CYLINDER ENGINES...

Page 2: ...n Lubrication Maintenance and Tune up Lay up and Fitting Out Single Cylinder Engines Multicyiinder Engines Fuel Injection and Governor Systems Cooling System Eiectricai System Transmission KM Series T...

Page 3: ...3 Basic hand tools 9 Parts replacement 4 Precision measuring tools 13 Torque specifications 4 Mechanic s tips 16 Fasteners 4 Bearing replacement 18 Seals 23 CHAPTER TWO TROUBLLSHO YI1NG 26 Starting sy...

Page 4: ...r assembly 71 Drlvedisc 91 Decompression mechanism 73 Crankshaft 91 Cylinder head 73 Mainbearings 93 Rocker shaft assembly 76 Camshaft 93 Valves and valve seats 77 Cylinder block 95 CHAPTER SIX MULTIC...

Page 5: ...ttery 183 Senders 195 Electrical protection 188 Warning lamps 197 Charging system 189 Alarm buzzer I 197 Starting system 190 Tachometer 197 Switches 195 CHAPTER TEN TRANSMISSION KM SERIES 199 Operatio...

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Page 8: ...dents Each Yanmar marine diesel can be identified by its indi vidual model number The model numbers for all Yanmar marine diesel engines covered in this manual are listed in Table 1 Some engine model...

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Page 14: ...ase of washers as that given to bolts nuts and other fasteners Avoid washers that are made of thin weak materi als These will deform and crush the jrst time they are torqued allowing the nut or bolt t...

Page 15: ...ted in its groove LUBRICANTS Periodic lubrication ensures long life for any type of equipment The type of lubricant used is as important as the lubrication service itself although in an emergency the...

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Page 28: ...GENERAL INFORMATION 21 Bearing Blocks Press Shaft arm Bearing Spacer Press k 4 bed...

Page 29: ...the proper tempera ture by dropping tiny drops of water on the case if they sizzle and evaporate immediately the tempera ture is correct Heat only one housing at a time CAUTION Do not heat the housin...

Page 30: ...d if possible If necessary lightly tap the bearing s into the housing with a socket placed on the outer bearing race Do not install new bearings by driving on the inner bearing race Install the bearin...

Page 31: ...8 2 cu in 1126 cc 68 7 cu in 1126 cc 68 7 cu in 1282 cc 78 2 cu in 1282 cc 78 2 cu In 6 5 hpI3400rpm 8 hpI3400rpm 13 hpI3400rpm 13 hpI3400rpm 16 hpI3400rpm 16 hpI3400rpm 20 hpI3400rprn 20 hpI3400rprn...

Page 32: ...rottle and would not restart Identify as many symptomsas possible to aid in diagno sis Note whether the engine lost power gradually or all at once what color smoke if any came from the exhaust etc Aft...

Page 33: ...s used must have one thing in common to be successful alogical system atic approach Troubleshooting diagrams for individual systems are provided within this chapter A master troubleshooting chart Tabl...

Page 34: ...hten the connections as required Recharge the battery if neces sary 2 If starter running speed does not sound nonnal clean and tighten all starter solenoid connections and the battery ground on the en...

Page 35: ...lor ring gear as required 3 If the pinion gear is in good condition the overrunning clutch mechanism in the starter may be defective Replace the starter with a new or rebuilt marine unit Starter Solen...

Page 36: ...30 CHAPTER TWO CHARGING SYSTEM TYPICAL Battery switch...

Page 37: ...ry If the engine starts remove and test the warning lamp bulb If the problem persists the alternator brushes may not be making contact Perform the System Circuitry Test in this chapter 3 Charging syst...

Page 38: ...top position 7 Turn on all accessories and crank the engine for 15 20 seconds to remove any surface charge from the battery 8 Turn off all accessories 9 Connect a tachometer to the engine Connect a ca...

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Page 40: ...t loosening is required If the engine runs worse the injector is operat ing satisfactorily If the engine runs the same the injector or the fuel injection pump is not operating properly If no fuel appe...

Page 41: ...soot when burned Either excess fuel or insufficient air can cause black smoke Some possible causes are a de fective fuel injection pump poor injector spray pattern low injection opening pressure clog...

Page 42: ...ngine to determine if the engine rotates freely Refer to Chapter Three to check governor adjustment or to Chapter Seven to repair the governor If a fuel system problem is suspected refer to troublesho...

Page 43: ...TROUBLESHOOTING 37 LUBRICATION SYSTEM 1GM AND 1GM1O MODELS Valve rocker arm support Lubricating oil suction pipe...

Page 44: ...38 CHAPTER TWO LUBRICATION SYSTEM 2GM AND 2GM20 MODELS...

Page 45: ...TROUBLESHOOTING 39 LUBRICATION SYSTEM 3GM 3GM30 3HM AND 3HM35 MODELS 3HM AND 3HM35 MODELS Filter...

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Page 47: ...Repair governor lnspect and repair Locate cause for overloadand rectify lnspect and unclog or replace Bleed air in fuel system Remove water Adjust governor Repair damaged components determine cause C...

Page 48: ...e ifmodel 3GM is called out in a procedure the procedure also applies to 3GMD and 3GMF FUEL REQUIREMENTS The recommended fuel is number 2 2 D diesel fuel Be sure the fuel is clean and free of water NO...

Page 49: ...o start the engine CAUTION Do not operate the starter for more than 15 seconds or the starter motor may be dam aged due to overheating 6 Start the engine by pushing the start button The alarm lights a...

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Page 51: ...ly five minutes for the oil in the upper end to drain back into the crankcase oil pan 1 With the boat at rest in the water and the engine off pull out the dipstick See Figure 1 for the typical locatio...

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Page 53: ...rom the fuel before it enters the fuel injection pump After every 50 hours of operation or more frequently if necessary remove and disassemble the fuel filter and clean the inside of the fuel bowl and...

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Page 56: ...the pulley grooves 6 Adjust belt tension as previouslydescribed Crankcase Breather The crankcase breather assembly vents crankcase pressure into the intake port or manifold This producesa negative pr...

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Page 59: ...system both pumps must be supplied with cooling water The following procedure provides steps to flush the coolingsystem of engines equipped with a seawatercool ing system as well as the seawater port...

Page 60: ...igure 24 2 Check the level of fluid in the system It should be level with the iron plate at the bottom of the filler neck NOTE Excess coolant above proper level will be expelled when coolant reaches o...

Page 61: ...oisonous and in gesting even a very small amount maycause illness Observe warning labels on anti freezecontainers Makesureto discard used antifreezein a safe and suitable mannerand wipe up any spills...

Page 62: ...al 4 If an excessive accumulation of scale is apparent on the interiorof the coolingsystem use an automotivecool ing system cleaner Be sure to thoroughly flush out the cooling system with freshwater a...

Page 63: ...the following 1 Compression test 2 Valve adjustment 3 Idle speed adjustment Careful and accurate adjustment is crucial to a success ful engine tune up Each procedure in this section must be performed...

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Page 65: ...not have an opening in the clutch covel Remove the starter to view the timing marks on the flywheel Fig ure 33 NOTE When thepiston is on its compressionstroke and at top dead centel both valves will b...

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Page 67: ...Check air filter Check transmission oil level Check drive belt tension Check electrical wiring Every 50 hours Clean fuel filter Every 100 hours Change engineoil Drain fuel tank Every 250 hours Replac...

Page 68: ...BTDC 25 BTDC 15 BTDC 15 BTDC 28 BTDC 28 BTDC 28 BTDC 18 BTDC 18 BTDC 28 BTDC 28 BTDC 21 BTDC 21 BTDC 0 2 m 0 008 in 0 2 m 0 008 in 0 2 m 0 008 in 0 2 m 0 008 in 0 2 m 0 008 in 0 2 rn 0 008 in 0 2 m 0...

Page 69: ...ter cooling pump NOTE Except where specified F and D series en ginesare includedwhen a basic model num ber is specijied For example ifmodel 3GM is called out in a procedure the procedure also applies...

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Page 72: ...f performed before returning the engine to service 1 Remove all coversplacedoverengineopeningsduring lay up 2 If the seawater cooling system is filled with an anti freezesolution drainthe antifreezefr...

Page 73: ...corrosion that will affect engine operation Check properly and smoothly all hoses for deterioration and clamps for tightness 16 Start and run engine Check for oil and water leaks 13 Check all through...

Page 74: ...es The intake compression ignition ex pansion and exhaust cycle occur in the same sequence for compression ignition engines as for spark ignition en gines The major differences are how the fuel is int...

Page 75: ...osed for the next 1 112 revolutions of the crankshaft Exhaust valve As the piston almost reaches the top of its When the piston almost reaches BDC the travel the injector sprays fuel into the exhaust...

Page 76: ...re 2 The precombustion chamber increases com bustionefficiency which producesgreater power with re duced emmissions Combustion first occurs in the precombustionchamber when hot compressed air enters t...

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Page 83: ...assem bly except valve removal and take the head to a dealer or machineshop for inspectionand service Since the cost is low relative to the required effort and equipment this is usually the best appro...

Page 84: ...e valves have been ground See Figure 25 Any valve with a margin less than 0 75 mm 0 030 in should be dis carded 3 Remove all carbon and varnish from the valve guides with a stiff spiral wire brush NOT...

Page 85: ...d is equipped with replaceable valve guides 6 Figure 22 The intake and exhaust valve guides are identical Take the cylinder head to a dealership or machine shop if valve guide replacement is required...

Page 86: ...If the clearance exceeds specifications Table I replace the connecting rod during reassembly 7 Remove the connecting rod bolts Lift off the cap along with the lower bearing insert 8 Use a wooden hamm...

Page 87: ...Bore with a hair dryer Separate the piston from the connecting rod PistonICylinderBore Check Unless precision measuring equipment is available have this procedure done by a machine shop 1 Measure the...

Page 88: ...ut the cylinder bore is acceptable install a new piston NOTE Provide the machine shop with the newpis ton so the cylinder can be bored to the cor rect dimension Piston Ring FitIInstallation 1 Check th...

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Page 103: ...850 mm max 2 9468in Piston top clearance 0 68 0 88mm 0 027 0 035in Piston ring side clearance Top ring 0 065 0 100mm 0 0026 0 0039in Second ring 0 035 0 070mm 0 0014 0 0028 in Oil ring 0 020 0 055 mm...

Page 104: ...1 I417in 22 000mm 0 8661 in 20 000mm 0 7874in 0 0 2 mm max 0 0008 in max 0 05 0 13mm 0 002 0 005in 0 3 mm 0 012 in 0 0 3 mm 0 0012in Mechanical 10 000 mm 0 3937in 9 9 5 mm 0 3917 in 0 025 0 060mm 0 0...

Page 105: ...ngines the camshaft is equipped with two additional bearings In addition to operating the valves the camshaft operates the fuel transfer pump and has an actuating lobe for the injection pump attached...

Page 106: ...your hands out of danger 3 Be sure the hoist is designed to lift engines and has enough load capacity for the engine 4 Be sure the hoist is securely attached to safe lifting points on the engine 5 Th...

Page 107: ...ove the gasket bolts c Bleed the fuel system at the fuel filter as described under Fuel Filter in Chapter Three d Refillthe freshwatercoolingsystem if so equipped as described in Chapter Eight VALVE C...

Page 108: ...n the upper plate 18 DECOMPRESSION MECHANISM The decompression mechanism on the valve cover forces the exhaust valves open to reduce compression pressurein the cylinders Reducingcompression pressure e...

Page 109: ...cooling system Removal and Installation 2GM models Refer to Figure 5 1 Detach the exhaust hose from the exhaust elbow 2 Loosen the hose clamps and remove the water hose from the exhaust elbow and ther...

Page 110: ...Heat exchanger 8 Cap 9 Filler neck 10 Gasket 11 Exhaust maniflold reservoir 12 End cap 13 Elbow 14 Stud 15 Hose 16 Gasket 17 Elbow 18 Drain valve 19 Remote reservoir 20 Gasket 21 Drain fitting 22 Drai...

Page 111: ...ry refer to the engine removal procedure Refer to Figure 8 for an exploded view of the cylinder head assembly To remove the cylinder head proceed as follows 1 Disconnect the negative battery cable fro...

Page 112: ...106 CHAPTER SIX...

Page 113: ...valve guide 22 Plug 23 Thermostat housing 24 Gasket 25 Cylinder head 26 Gasket 27 End cap 28 Washer 29 Sacrificial anode 30 Exhaust valve 31 intake valve Water temperature sensor Rocker stand nuts 4...

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Page 115: ...the valve clearance as described in Chapter Three 21 Reinstall the valve cover ROCKER SHAFT ASSEMBLY Each valve is actuated by a rocker arm that rides on a shaft Figure 8 Each rocker arm is equipped w...

Page 116: ...djust the valve clearance as described in Chapter Three VALVES AND VALVE SEATS Servicing the valves guides and valve seats must be done by a dealer or machine shop as special knowledge and expensive m...

Page 117: ...ped or burned valves 2 Measure the valve stems at the top center and bottom for wear A machineshop can do this when the valves are ground NOTE Check the thickness of the valve edge or m a i n after th...

Page 118: ...360 and note the space between the top of the coil and the square If it exceeds 1 4 mm 0 055 in at any point replace the spring 9 Check the valve guides for wear and looseness Refer to Tables 1 3 for...

Page 119: ...then reinstall the drain plug 3 Removethe cylinder head asdescribed in this chapter 4 Remove the oil pan 5 On 2GM 2GM20 3GM and 3GM30 models Loosen the oil pickup jam nut Figure 26 and remove the oil...

Page 120: ...combination of these 2 Remove the clip from each side of the piston pin bore Figure 30 with a small screwdriver or scribe Hold a thumb over one edge of the clip when removingit to pre vent the clip fr...

Page 121: ...rn rebore the cylinder bore and install a new piston If the piston is worn but thecylinderbore is good install a new piston NOTE Obtain the new piston and have it available so the machineshopcan bore...

Page 122: ...control ring then the compression rings The oil ring consistsof two pieces the outer ring and the inner expansion spring Assemble the oil ring on the piston so the expansionspringgap is on the opposit...

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Page 127: ...e damaged 5 Reinstall the inner rotor in the pump body Reinstall the outer rotor in the pump body 6 Measure the clearance between the inner rotor tip and outerrotortip Figure54 Comparethe resultswiths...

Page 128: ...gure59 typical valve The valve is sealedand it must be replaced as a unit assembly Oil pickup The oil pickup is located in the oil pan The pickup in cludes a strainer to prevent foreign matter from en...

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Page 132: ...rrs nicks or other sharp edges that might dam age a seal during installation NOTE Unless precision measuring equipment is available have a machine shop perform Step 3 3 Check all journals against spec...

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Page 137: ...er and drift Use several sharp blows to push the bottom of the plug inward tilting the top out Figure 81 2 Gripthetop of theplug firmly with pliers Pull theplug from its bore Figure 82 and discard NOT...

Page 138: ...t 72 mm 2 83 in 75 mm 2 95 in 72 mm 2 83 in 586 cc 35 7 cu in 636 cc 38 8 cu in 2 1 2 72 000 mm 2 8346 in 0 005 0 075 mm 0 0002 0 0030 in 75 000 75 030 mm 2 9526 2 9540 in 0 02 mm 0 0008 in 0 05 mm 0...

Page 139: ...in 9 95 mm 0 3917 in 0 010 0 040 mm 0 0004 0 0016 in 0 10 mm 0 004 in 45 45 0 75 1 1 5 mm 0 030 0 045 in 1 77 mm 0 070 In 1 25 mm 0 049 in 0 040 0 065 mm 0 0016 0 0026 In 0 045 0 070 mm 0 001S O 0028...

Page 140: ...be lift Fuel pump lobe lift Journal diameter End journal Center journal Runout Timing gear backlash Maximumallowable Push rod runout max Valve lifter TYPe Outside diameter Outside diameter min Clearan...

Page 141: ...in Oil pump inner rotor tip to outer rotor tip 0 050 0 105 mm 0 0020 0 0041 in Max 0 15 mm 0 006 in Outer rotor to pumpbody 0 050 0 105 mm 0 0020 0 0041 in Max 0 15 mm 0 006 in Rotor side clearance 0...

Page 142: ...020 0 055 mm 0 00064 0022 in 0 25 0 45 mm 0 01 0 0 018 in 0 20 0 40 mm 0 0064 016 in 0 25 0 45 mm 0 01 0 0 018 in 22 991 23 000 mm 0 9052 0 9055 in 22 995 23 008 mm 0 9053 0 9058 in 23 000 mm 0 9055...

Page 143: ...rm shaft clearance max 0 15 mm 0 006 In Rocker arm bore wear limit 14 10 mm 0 555 in Rocker arm shaft wear limit 13 90 mm 0 547 in Oil pump Inner rotor tip to outer rotor tip 0 050 0 105 mm 0 0020 0 0...

Page 144: ...apter Five The major componentsof the diesel fuel system are the fuel tank fuel filters injection pump and injection noz zle Figure 1 A feed transfer pump moves fuel from the fuel tank throughthe filt...

Page 145: ...FUEL INJECTION AND GOVERNOR SYSTEMS 139 FUEL INJECTION SYSTEM Fuel tank hose fuel pipe...

Page 146: ...the compressed air in the engine s cylinder The fuel must be broken into very small particles so that the fuel will quickly absorb heat from the compressed hot air change to a vapor then ignite The de...

Page 147: ...1 Delivery valve holder 2 O ring 3 Spring 4 Delivery valve 5 Gasket 6 Delivery valve seat 7 Barrel 8 Gasket 9 Pump body 10 Control rack 11 Shlms 12 Plunger 13 Control sleeve 14 Washer 15 Spring 16 Spr...

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Page 159: ...handle Speed control lever Fuel control rack Idleadjuster No load Governor lever 2 Crankshaft gear Governor spring Pivot point Fuel control lever Governor weight Governor sleeve Fuel injection limiter...

Page 160: ...on authorized service techni cians Refer to Chapter Threefor the idle speedprocedure Other adjustments such as no load maximumgoverned speed and fuel limiter screw setting are set by the manufacturer...

Page 161: ...in 36 Flyweight 37 Governor flyweight assembly 38 Roll pin 39 Stop cam 40 Washer 41 Lockwasher 42 Nut The governor components are contained in the timing gearcase Figure 42 typical Refer to Figure 47...

Page 162: ...ost 14 Secondary governor spring 15 Main governor spring 16 Snap ring 17 Washer 18 Control lever 19 Spring post 20 Governor lever 21 Taper pin 22 Roll pin 23 Shaft 24 Start spring 25 Needlebearing 26...

Page 163: ...lace or repair any worn parts 8 Inspect the governor springs for damage and distor tion Measurethe lengthof the main and secondarygover nor springs as shown in Figure 49 Replace either spring if its f...

Page 164: ...L1 26 mm 1 02 in L2 5 mm 0 20 in 78 mm 3 07 in 20 mm 0 79 in 23 mm 0 90 in 10 mm 0 39 in 78 mm 3 07 in 20 mm 0 79 in 23 mm 0 90 in 10 mm 0 39 in Table 3 GOVERNOR SLEEVE AND CRANKSHAFT SPECIFICATIONS...

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Page 166: ...160 CHAPTER EIGHT SEAWATER COOLING SYSTEM 1GM AND 1GMlO Mixing elbow Rubber hose I Drain Seacock except 1GM1OC...

Page 167: ...COOLING SYSTEM 161 SEAWATER COOLING SYSTEM 2GM AND 2GM20 U type mixing elbow Rubber hose Seacock except 2GM20C...

Page 168: ...162 CHAPTER EIGHT SEAWATER COOLING SYSTEM 3GM AND 3GM30 MODELS 3HM AND 3HM35 Exhaust manifold I Thermostat Thermostat switch cover Thermostat cover...

Page 169: ...6 Various configurationsof the closed coolingsystem are used but all function essentially the same The seawater systemoperationis similarto the standardcoolingsystem previouslydescribed except as fol...

Page 170: ...164 CHAPTER EIGHT CLOSED COOLING SYSTEM TYPICAL rnlxlng elbow Joint...

Page 171: ...entering the heat exchanger rerouting it back to the engine circulating pump Once the thermostatopens it closesoff the passage to the circulating pump and sends the coolant throughthe heat exchanger...

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Page 173: ...erature If the thermostat valve is not fully closed at this temperature replace it 5 Remove the thermostatfrom the water and let it cool to room temperature Make sure the valve seals tightly by holdin...

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Page 178: ...pump Refer to Table 1 for the tightening torque of the pump mounting bolts Adjust the belt tension as described in Chapter Three 3HM and 3HM35 1 If the boat is in water makesure the seacockis closed...

Page 179: ...press Force each bearing away from the locating snap ring 13 Figure 24 9 Extract or push out the seals 9 and 10 Figure 24 10 Clean all metal components with solvent then dry them with compressedair 1...

Page 180: ...Clean all metal componentsin solvent then dry them with compressed air 13 Thoroughlyclean all gasket material from all mating surfaces 14 Inspect the pump shaft for grooves in the seal contact area 1...

Page 181: ...rd the gasket 3 Extract the impeller 16 Figure 28 from the pump body and remove the drive key 8 4 Rotate the pump shaft to check the bearingsfor rough ness excessive wear or other damage Do not remove...

Page 182: ...worn body or cover will reduce pump efficiency and may damage a new im peller 15 Install the shaft seal 11 Figure 28 so the lip is to ward the impeller side of the pump body 16 If removed install the...

Page 183: ...ing pump and detach any hose bracketsthat interferewith ac cess to the water pump bolts NOTE Note the length ofthe pump retaining bolts during removal and if necessary mark them according to location...

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Page 185: ...ineral deposits or other contamination Use the cleaning solution according to the manufacturer s direc tions If extremely dirty or corroded flush out the remaining deposits with a pressure flushing de...

Page 186: ...iller neck 3 Gasket 4 Overflow tube 5 Exhaust manifoldlheat exchanger 6 Heat exchanger core 7 Cover 8 O ring 9 Gasket 10 End cap 11 Elbow 12 O ring 13 Stud 14 Washer 15 Nut 16 Drain valve 17 Plug 18 E...

Page 187: ...lean all gasket residue from the end caps and heat exchanger sealing surfaces 6 Insertan appropriate sizewire brush intoeach passage in the heat exchanger Work the brush back and forth with a vigorous...

Page 188: ...QUES Fastener N m ft lb in lb Seawater pump lGM lGMlO 9 80 All other models 25 18 Freshwater pump 20 25 177 221 Table 2 RECOMMENDED THERMOSTAT Model Opening temperature Full open temperature I All eng...

Page 189: ...most likely burn out a new alternatoras quickly as it damaged the old one If in doubt always consult an expert This chapter provides service procedures for the bat tery charging system starting system...

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Page 191: ...over the vent holes in each cap with small pieces of masking tape NOTE Keep cleaning solution out of the battery cells in Step 5 or the electrolyte will be seri ously weakened 5 Scrub the top of the b...

Page 192: ...e ball Figure 8 NOTE Do not attempt to test a battery with a hy drometer immediately after adding water to F Float Electrolyte must be 3 16 in above plates the cells Run the engine or charge the bat t...

Page 193: ...y charges Connectthe chargerto the battery negativeto negative positiveto positive If thechargeroutputis variable select a 10 12 amp setting Set the voltage selector to 12 volts and plug the chargerin...

Page 194: ...ttery Cables Poor terminal connections will cause excessive resis tance Defective cable insulation can cause partial short circuits Both conditions may result in an abnormal volt age drop in the start...

Page 195: ...e electri cal system Before replacing a fuse determine what caused it to blow and correct the problem Always carry several spare fuses of the proper amperage values onboard Never replace a fuse with o...

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Page 198: ...oke 7 Spring 8 Shims 9 Solenoid 10 Retaining ring 11 Retainer 12 Drive 13 Center plate 14 Armature 15 Frame assembly 16 Positive lead 17 Brush pos 18 Brush neg 19 Brush spring 20 Brush plate 21 Commut...

Page 199: ...uator 9 Washers 10 Shims 11 Solenoid 12 Pin 13 Stopper washer 14 Circlip 15 Retainer 16 Drive 17 Bushing 18 Center plate 19 Armature 20 Washer 21 Washer 22 Frame assembly 23 Positivelead 24 Positive b...

Page 200: ...ack and hold the brush retain ing clip then remove the brush See Figure 20 typical Repeat this step to remove the remaining brushes 6 Remove the brush holder from the armature shaft 7 Use an ohmmeter...

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Page 203: ...substitute a good bulb All warning lamps use the same type of bulb 4 If a good bulb does not light check the charging sys tem as described in Chapter Two ALARM BUZZER The alarm buzzer providesan audi...

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Page 206: ...gear o u l l n flange SHIFTER KM2A KMPC AND KM3A MODELS 1 Connector 2 Circllp 3 Spring retainer 4 Spring 5 Circllp 6 Holder 7 Cotter pin 8 Washer 9 Stud 10 Shift lever 11 Bolt 12 Seal 13 Setscrew 14 S...

Page 207: ...following procedure addresses units that are acces sible In some cases it may be necessary to remove the en gine and transmission as a unit before removing the transmission from the engine If engine r...

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Page 210: ...galling chips cracks missingpieces distortionor dis coloration from overheating If necessary replace the gears Intermediate shaft Reverse idler aear Roller bearings O ring 8 Inspect the forward and re...

Page 211: ...4 1 Shims 2 Nut LH 3 Washer 4 Roller bearing 5 Thrust washer 6 Retainer KM2P and KM3P 7 Spring cup KM2P and KM3P 8 Forward gear 9 Needle bearing 10 Inner bearing race 11 Thrust washer 12 Pin 13 Outpu...

Page 212: ...MPA KMPC AND KM3A MODELS 1 Connector 2 Circlip 6 Holder 7 Cotter pin 8 Washer 9 Stud 10 Shift lever 11 Bolt 12 Seal 13 Setscrew 14 Spring 15 Detent pin 16 Body 17 Gasket 18 Plug 19 O ring 20 Bearing 2...

Page 213: ...ion 3 Loosen the clamp bolt and remove the shift lever NOTE The setscrew and plug contain the springs and mayfly out 4 Remove the setscrew and plug then remove the springs and detent pins 5 Remove the...

Page 214: ...e it with the specifications in Ta ble 7 13 Reassemble the shifter by reversing the disassembly procedure but do not installthestop bolt until final instal lation of the shifter assembly on the transm...

Page 215: ...KM2P AND KM3PMODELS 1 Shoulder bolt 2 Connector 3 Shift lever 4 Washer 5 Nut 6 Stop bolt 7 Shims 8 Bolt 9 Seal 10 Bolt 11 Shift body 12 O ring 13 Shift shaft 14 Detent pin 15 Pin 16 Spring 17 Shifter...

Page 216: ...rocedure NOTE Note that the bolt holes in the shifter mount ing flange are suflciently large to allow movement of the flange around the bolts a Install the shifter assembly on the transmissionand tigh...

Page 217: ...he input and output shaft tapered bearings 4 Measure the distance A Figure 30 in millimeters from the mounting flange mating surface on the case to the top of each bearing race Record the measurements...

Page 218: ...tch groove centerline is 47 3 mm from the mating surface of the transmissioncase NOTE To perform the following bearing adjust mentprocedure the output shaft must be out of the case and the outer beari...

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Page 220: ...ut Output flange nut Drive disc Table 3 CLUTCH DEPTH Normal depth Wear limit 1 24 4 24 7 mm 0 961 0 972 in 29 2 29 8 mm 1 150 1 I73 in 29 9 30 2 mm 1 177 1 189 in 32 7 33 3 mm 1 287 1 311 in 24 1 mm 0...

Page 221: ...gth Actuator spring tension Standard Min Table 6 SHIFTER KMZA KM2C AND KM3A 7 80 7 85 mm 0 3071 0 3091 in 7 7 mm 0 303 in 9 986 9 995 mm 0 3931 0 3935 in 9 95 mm 0 392 in 34 mm 1 34 in 2 8 kg 6 2 Ib 2...

Page 222: ...ansmission engages the drive discattachedto theengineflywheel Becausethis is a con stant mesh transmission engine power is transmitted to all gears Power flows to the output shaft when the clutch enga...

Page 223: ...tion of the output flange 5 Unscrew the output flange retaining nut 6 Remove the oil dipstick 7 Make match marks on the shifter cover and the trans mission case so the shifter can be installed in its...

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Page 225: ...25 Shift ring 26 Shims 27 Spacer 28 Inner bearing race 29 Bearing 30 Friction plates 31 Steel plates 32 Snap ring 33 Retainer 34 Belleville washers 35 Reverse gear 36 Thrust washer 37 Bearing 38 Seal...

Page 226: ...wear corro sion or rust and mechanical damage Check the teeth for galling chips cracks missing pieces distortionor discol oration from overheating If necessary replace the gear 5 Reassemble the inter...

Page 227: ...e width of the steel plates tangs and com pare the result with the specification in Table 3 7 Measurethe width of thegroovesin the pressureplates and compare the result with the specification in Table...

Page 228: ...compare the result with the specification in Table 3 Reassembly 1 Install the Bellevillespringson the forward gear so the concave sides face each other as shown in Figure 12 Po sition the retainer 12...

Page 229: ...late 15 Install the shim spacer and inner needle bearing race on the ouput shaft using a suitable bearing driver 16 Insert the detent pins and springs into the drive plate Install the shift ring over...

Page 230: ...nstall the input shaft oil seal 8 Coat the case mating surface with RTV sealer 9 Install the mounting flange and tighten bolts evenly 10 Place the shift ring in neutral position and install the shift...

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Page 232: ...0 069 in Wear limit 1 5 mm 0 059 in Pressure plate thickness 6 4 6 6 mm 0 252 0 260 in Wear limit 6 3 mm 0 248 in Return spring end gap 16 5 17 5 mm 0 650 0 690 in Driving plate hub outer diameter min...

Page 233: ...177 thermostat 165 168 troubleshooting 34 35 36 Crankshaft multicylinder 123 126 single cylinder 91 93 block multicylinder 128 131 single cylinder 95 97 head multicylinder 105 109 Cylinder head singl...

Page 234: ...tem 86 89 main bearings 93 pistodconnecting rod assembly 79 85 push rods 79 removal precautions 70 71 replacement parts 70 rocker shaft assembly 76 serial number and code 70 timing gearcase 85 86 valv...

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Page 236: ...230 INDEX Tune up cover battery 56 multicylinder 101 engine tune up 57 60 single cylinder 71 v Valve and seats multicylinder 110 113 single cylinder 77 79 W Warning lamps 197 Wiring diagrams 231 234...

Page 237: ...al lamp Sail drive Bi lessthan 6m Tachometer Be WB Diagram Key Color Code B Black Alternator Coolant Oil Tachometer onnectora W White temp pressure sender R Red switch switch Ground L Blue 4 Frame gro...

Page 238: ...Ug Oil pmaaum w r n l n g l a m p 1J B D DiegramKey 8 Gmund 4 Framegmund No connection Color Code B Black W White R Red L Blua 0 Orange wm Whlte Black wm WhitalRed W R WhltelB1ue WB Red Black U B Bld...

Page 239: ...drive 8 1 less than6m Tachometer Buzzer B g DiagramKey Color Code B Black Alternator Coolant Oil Tachometer Connectors W White temp pressure sender R Red switch switch 5 Ground L Blue FFrame ground 0...

Page 240: ...warning lampm g Oil preaaum warninglamp Ug lessthan 6m DiagramKey Econnecto 4 Ground No connection Color Code B Black W White R Red L Blue 0 Orange WIB Whitelslack WIR WhltelRed w L WhitelBlue WB Red...