K15/K21/K25-BE1: Machine Model Serial No

K15/K21/K25-BE1
MACHINE MODEL SERIAL NO.

FG10/15/18-20 650001 and up
FG15H/18H-20 650001 and up
FG20/25/30/35A-16 700001 and up
FG20H/25H-16 700001 and up
FG20N/25N/30N-16 700001 and up
K-Series 00-1
SECTION INDEX
1. GENERAL INFORMATION
2. MAINTENANCE
3. ENGINE TUNE-UP
4. ENGINE MECHANICAL
5. ENGINE LUBRICATION & COOLING SYSTEMS
6. FUEL SYSTEM
7. ENGINE CONTROL
8. ENGINE ELECTRICAL SYSTEM
K-Series 00-3
INTRODUCTION
This maintenance manual explains the specifications, maintenance procedure, adjustment

procedure, etc. of the K15, K21, and K25 gasoline engines.
Correct handling, periodic maintenance and inspection, and proper repair and assembly
are necessary for keeping the performance of these engines high and using them safely.
Before disassembling, inspecting, repairing, or assembling the engines, carefully read this
manual and fully understand the work procedure.
The contents of this manual are for the models manufactured at the time of issue of this
manual.
The contents of this manual are subject to change for improvement of the vehicles.
00-4 K-Series
1. GENERAL INFORMATION
How to read this manual .................................... 1- 2

Precautions for safety and quality ...................... 1- 3
Precautions for work .......................................... 1- 5
Tightening torque ............................................... 1- 7
Special tools....................................................... 1-10
Outside view of engine....................................... 1-11
Main specifications............................................. 1-14
Stamping position of engine serial No................ 1-18
Troubleshooting ................................................. 1-19
K-Series 1-1
GENERAL INFORMATION HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

1. OUTLINE
This chapter explains how to read the procedures of "removal, disassembly, assembly, inspection, and ad-
justment" and "troubleshooting".
2. DEFINITION OF TERMS
k • An item or a work procedure, neglect of which can cause a death or a serious injury if neglected
• An item or a work procedure to be observed especially among those, neglect of which can cause an
injury, an accident, or a damage of the vehicle or component parts.
Reference: Supplementary explanation for the ease of work
Standard value: Permissible deviation of a value at inspection or adjustment
Limit value : The maximum or minimum which a value must not exceed at inspection or adjustment
3. DEFINITION OF UNITS
In this manual, tightening torque, pressure, etc. are indicated by the "SI unit" (International unit) first, then by
the "metric unit) in { }.
Example) Tightening torque:59 – 78 Nm {6.0 – 8.0 kgf•m}
SI unit {Metric unit}
Conversion of major units
Quantity SI unit Conventional unit Coefficient of conversion into SI
Acceleration m/s2 G 9.80665
Torque and moment Nm kgf•m 9.80665
Force N kgf 9.80665
MPa kgf/cm2 0.09809665

Pressure
kPa mmHg 0.133322
kW PS 0.735499
Power/Power efficiency
W kcal/h 1.16279
Volume cm3 cc 1
Spring constant N/mm kgf/mm 9.80665
Fuel consumption g/kW•h(*1) g/PS•h 1.3596
*1. Conventional unit may be used in SI.
4. CONTENTS OF DESCRIPTION
Precaution : Special precautions for each chapter are described at the beginning of the chapter.
Items to be prepared: Special tools, instruments, etc. to be prepared before starting the work
are described at the beginning of each chapter and troubleshooting section. General tools
generally used in maintenance shops are not described, however.
Explanation : Working method, points, special tools, and various pieces of maintenance information are de-
scribed.
Note : Visual inspection and cleaning of removed parts are not described as a rule. Perform them,
however, in the actual work.
1-2 K-Series
GENERAL INFORMATION PRECAUTIONS FOR SAFETY AND QUALITY
PRECAUTIONS FOR SAFETY AND QUALITY

• Observe the following precautions for safe and
proper maintenance.
• Only qualified and appointed persons shall in-
spect, repair, or adjust the vehicle.
• Keep the workplace and tools clean.
1. SAFE WORK
• Do not run the engine in a place which has no
exhaust ducts and which is poorly ventilated.
• Ventilate the workplace well and do not place
a combustible thing there. Take extreme
care when handling a combustible thing or a
hazardous material such as gasoline.
• Dispose of the replaced oil, parts washing oil,
etc. according to laws.
• When working on parts which become hot,
rotary parts, or sliding parts, take care not to
burn or injure yourself.
• When working in a pit or a closed place, ven-
tilate it to discharge harmful materials in ad-
vance.
• Do not work on the vehicle jacked up. When
working on it, support it by the specified parts
on wood blocks, etc.
• When lifting up the vehicle, support it by the
specified parts and apply a safety device.
• When removing a heavy part such as the en-
gine, vehicle body, etc. take care not to drop
it by unbalancing it.
• Do not smoke while maintaining the vehicle.
• When maintaining the vehicle, take off rings
and necklace to prevent a short circuit in the
electrical system.
• Before starting repair which does not need
the battery power, turn the key switch OFF
and disconnect the negative (–) terminal of
the battery.
K-Series 1-3
GENERAL INFORMATION PRECAUTIONS FOR SAFETY AND QUALITY
• Take care not to touch the hot metal parts

just after stopping the engine. While the en-
gine is still hot, do not remove the radiator
cap or another part of the coolant system.
• Use the specified proper common tools or
special tools for safe and efficient repair.
2. CORRECT WORK
• Grasp the contents of each trouble, and then troubleshoot and work efficiently.
• When removing and disassembling parts, check their normal assembly condition in advance. Make
match marks on places which do not affect the function, if necessary.
• If an oil seal, gasket, packing, O-ring, lock washer, cotter pin, self-lock nut, etc. are removed, replace
them according to the directions in their sections (Parts which must not be reused).
• When a tapered roller bearing or a needle roller bearing needs to be replaced, replace its inner race and
outer race as a set.
• Arrange the removed parts in order so that they will not be mixed up.
• Before checking or assembling the disassembled parts, clean them.
• When replacing a part, install a NISSAN genuine part.
• Use the specified oil, grease, sealant, etc.
• Before removing a pressurized pipe, hose, etc., release the pressure.
• After repairing the fuel, oil, coolant, exhaust, or vacuum system, check it for leakage securely.
1-4 K-Series
GENERAL INFORMATION PRECAUTIONS FOR WORK
PRECAUTIONS FOR WORK

1. PRECAUTIONS FOR DRAINING COOLANT
• Drain the coolant after its temperature lowers sufficiently.
2. PRECAUTIONS FOR SEPARATING FUEL PIPING

• Work in a place where there is nothing to start a fire.
• Release the fuel pressure in advance.
• After separating the fuel piping, plug it to prevent the fuel from flowing out.
3. PRECAUTIONS FOR REMOVAL AND DISASSEMBLY

• If specified, use correct special tools and pay attention. Do not apply an excessive force.
• Take extreme care not to lower the accuracy of the mating faces, sliding faces, etc.
• If necessary, cover the openings with tapes, etc. to prevent foreign matter from entering the engine.
• Make marks on the removed parts and arrange them for secure troubleshooting and assembly.
• As a rule, loosen the bolts and nuts from outside in the diagonal direction. If the loosening order is spec-
ified, observe it.
4. PRECAUTIONS FOR CHECKING, REPAIRING, AND REPLACING PARTS

• Before repairing or replacing parts, check them sufficiently according to the check procedure. Check the
new parts similarly and replace them if necessary.
5. PRECAUTIONS FOR ASSEMBLING AND INSTALLING PARTS

• When tightening the bolts and nuts, be sure to use torque wrenches.
• As a rule, tighten the bolts and nuts from inside to outside in the diagonal direction in 2 – 3 times. If the
tightening order is specified, observe it.
• Replace the gaskets, packings, oil seal, and O-rings with new ones.
• Clean each part and dry it by blowing compressed air against it. In particular, take care that the oil pas-
sages and coolant passages will not be clogged.
• Take care not to damage the sliding surfaces and mating faces, and remove all dirt, lint, etc. from them.
Apply sufficient oil to the sliding surface before assembling.
• If the coolant is drained, bleed air from the coolant system.
• After repairing, run the engine at high speed and check for leakage of the coolant, fuel, oil, grease, and
exhaust gas.
6. PARTS WHICH NEED TO BE TIGHTENED BY ANGLE TIGHTENING METHOD

• Use angle wrenches (special tools) to tighten the following parts.
• Cylinder head bolt
Check that the cylinder head, cylinder block mounting face, and cylinder head gasket are free from oil
and dirt, and then coat the threads and stem of the cylinder head bolt and tighten it.
7. PRECAUTIONS FOR USING POWER TOOLS

• Use power tools such as an air runner for disassembly only. Do not use them for assembly.
K-Series 1-5
GENERAL INFORMATION PRECAUTIONS FOR WORK
8. PRECAUTIONS FOR APPLYING

GASKET SEALANT
Separation of parts coated with gasket sealant
• After removing the mounting bolts and mounting
nuts, cut and remove the gasket sealant with seal
cutter A (special tool KV101-11100) according to
the following procedure.
[1] Drive in the seal cutter in the direction of the
arrow.
[2] Slide the seal cutter in the direction of the ar-
row.
row.
k • Take care not to damage the mating faces.

• If it is difficult to use the seal cutter, re-
move the gasket sealant by hitting it light-
ly with a plastic hammer.
k • If it is obliged to use a flat-head screwdriv-
er, take extreme care not to damage the
mating faces.
Procedure for applying gasket sealant

1. Remove the old gasket sealant sticking to the
mating faces with scraper B.
• Remove all the gasket sealant from the
grooves, mounting bolts, and bolt holes, too.
2. Wipe the mating faces with isoparaffin, etc. to re-
move water, oil, grease, and foreign matter.
3. Install the genuine gasket sealant to tube presser
C (common tool).
4. Apply the gasket sealant to the specified parts

and dimensions without breaking it.
• Apply the gasket sealant to the grooves, too,
if specified so.
• As a rule, apply the gasket sealant to the in-
side of the bolt holes. The outside of the bolt
holes may need to be coated with the gasket
sealant, however. Accordingly, refer to the
manual without fail.
• Install the parts within 5 minutes after apply-
ing the gasket sealant.
• Wipe off the projected gasket sealant imme-
diately.
• Do not retighten the bolts after installing the
parts.
• After installing the parts, wait at least 30 min-
k • If a direction is given in the manual, ob-

utes before supplying engine oil or coolant.
serve it.
1-6 K-Series
GENERAL INFORMATION TIGHTENING TORQUE
TIGHTENING TORQUE
1. STANDARD TIGHTENING TORQUE OF BOLTS
Upper line : Lubricated bolts (Threads and friction surface of seat are coated with rust-preventive oil)
Lower line : Non-lubricated bolts (Threads and seats are degreased thoroughly)
Unit: Nm{kgf•m}
Size of thread
4T (Bolt) 7T (Bolt) 9T (Bolt)
Diameter Pitch
3.82 – 4.41 {0.39 – 0.45} 6.37 – 7.45 {0.65 – 0.76} 9.22 – 10.8 {0.94 – 1.1}
M6 1
5.00 – 6.47 {0.51 – 0.66} 8.43 – 10.8 {0.86 – 1.1} 11.8 – 15.7 {1.2 – 1.6}
Hexagon head bolt/nut
9.32 – 10.8 {0.95 – 1.1} 15.7 – 17.7 {1.6 – 1.8} 22.6 – 25.5 {2.3 – 2.6}
M8 1.25
12.7 – 15.7 {1.3 – 1.6} 20.6 – 26.5 {2.1 – 2.7} 29.4 – 37.3 {3.0 – 3.8}
19.6 – 22.6 {2.0 – 2.3} 32.4 – 38.2 {3.3 – 3.9} 47.1 – 53.9 {4.8 – 5.5}
1.25
25.5 – 33.3 {2.6 – 3.4} 43.1 – 54.9 {4.4 – 5.6} 61.8 – 78.5 {6.3 – 8.0}
M10
18.6 – 21.6 {1.9 – 2.2} 30.4 – 36.3 {3.1 – 3.7} 44.1 – 52 {4.5 – 5.3}
1.5
24.5 – 31.4 {2.5 – 3.2} 41.2 – 52 {4.2 – 5.3} 58.8 – 74.5 {6.0 – 7.6}
4.9 – 5.69 {0.5 – 0.58} 8.14 – 9.51 {0.83 – 0.97} 11.8 – 13.7 {1.2 – 1.4}
M6 1
5.98 – 7.65 {0.61 – 0.78} 9.81 – 12.7 {10 – 1.3} 14.7 – 18.6 {1.5 – 1.9}
11.8 – 13.7 {1.2 – 1.4} 19.6 – 23.5 {20 – 2.4} 28.4 – 33.3 {2.9 – 3.4}
M8 1.25
Flange bolt
14.7 – 18.6 {1.5 – 1.9} 24.5 – 31.4 {2.5 – 3.2} 35.3 – 45.1 {3.6 – 4.6}
24.5 – 29.4 {2.5 – 3.0} 41.2 – 48.1 {4.2 – 4.9} 59.8 – 69.6 {6.1 – 7.1}
1.25
30.4 – 39.2 {3.1 – 4.0} 51.0 – 64.7 {5.2 – 6.6} 73.6 – 93.2 {7.5 – 9.5}
M10
23.5 – 27.5 {2.4 – 2.8} 39.2 – 46.1 {4.0 – 4.7} 56.9 – 65.7 {5.8 – 6.7}
1.5
29.4 – 37.3 {3.0 – 3.8} 49.0 – 61.8 {5.0 – 6.3} 69.6 – 89.2 {7.1 – 9.1}
k • Do not apply the above tightening torque to special bolts and nuts.
k • The following marks are in relief on the heads of bolts to which the above tightening torque can
be applied.
4T --- 4
7T --- 7
9T --- 9
Tightening torque of tapered screws

Unit: Nm{kgf•m}
Material of Aluminum Cast iron
fixed part
Size Standard value Max. value Standard value Max. value
R1/8 7.8 {0.796} 11.8 {1.2} 15.7 {1.6} 21.6 {2.2}
R1/4 19.6 {2.0} 29.4 {3.0} 34.3 {3.5} 44.1 {4.5}
R3/8 39.2 {4.0} 54.9 {5.6} 53.9 {5.5} 73.5 {7.5}
K-Series 1-7
2. TIGHTENING TORQUE OF ENGINE PARTS

Tightening torque of each part of engine
Unit: Nm{kgf•m}
Fixed part Standard value Max. value
Cylinder head (coated with oil) Shown separately
Main bearing cap (coated with oil) Shown separately
Crank pulley bolt (coated with oil) 220.5 {22.5} 240.1 {24.5}
Flywheel bolt (coated with oil) 132 {13.47} 142 {14.49}
Connecting rod nut (coated with oil) 31.4 {3.2} 37.3 {3.81}
Rear plate bolt 44.1 {4.5} 58.8 {6.0}
Cam sprocket bolt 39.2 {4.0} 49 {5.0}
Oil filter stud 29.4 {3.0} 39.2 {4.0}
Oil filter element 14.7 {1.5} 20.6 {2.1}
Spark plug 19.6 {2.0} 29.4 {3.0}
Engine slinger bolt 22.6 {2.31} 25.5 {2.6}
Rocker cover nut 13.7 {1.4} 15.7 {1.6}
Water temperature gauge 15.7 {1.6} 19.6 {2.0}
Oil pressure switch 15.7 {1.6} 21.6 {2.2}
Exhaust manifold nut 41.2 {4.2} 48.1 {4.91}
Straight screw plug (installed to head top) 44.1 {4.5} 53.9 {5.5}
Oil pan drain plug 29.4 {3.0} 39.2 {4.0}
Fuel tube flare nut 16.0 {1.63} 23.0 {2.35}
Thermo housing air relief plug 6.37 {0.65} 7.45 {0.76}
1-8 K-Series
Cylinder head
For general service, the cylinder head bolts may be
tightened by angle tightening process (5) shown in
the figure at left instead of torque tightening to 68.6
Nm {7.0 kgf•m}.
Main bearing cap Tightening order

Cap bolt : 83.4 – 93.2 Nm {8.51 – 9.51 kgf•m}
a Apply rust-preventive oil or engine oil to the
threads and stem of each bolt.
a Never use a power tool such as an air runner.
K-Series 1-9
GENERAL INFORMATION SPECIAL TOOLS
SPECIAL TOOLS
Tool No. Tool name Sketch drawing
KV111-03000 Pulley puller

(For removal of crank pulley)
ST052-40001 Engine attachment
ST050-1S000 Engine stand assembly

[1] ST050-11000 Engine stand
[2] ST050-12000 Stand
KV101-041S0 Crankshaft main bearing cap puller

[1] KV101-04110 Crankshaft main bearing puller
[2] ST165-12001 Adapter
[3] ST167-01001 Adapter
ST120-70000 Valve lifter
ST152-4S000 Front oil seal drift

KV101-05500 Rear oil seal drift
ST152-43000 Drift rod
1-10 K-Series
GENERAL INFORMATION OUTSIDE VIEW OF ENGINE
OUTSIDE VIEW OF ENGINE

GASOLINE SPECIFICATION
K-Series 1-11
GASOLINE AND LPG SPECIFICATION
1-12 K-Series
LPG SPECIFICATION
K-Series 1-13
GENERAL INFORMATION MAIN SPECIFICATIONS
MAIN SPECIFICATIONS
MAIN SPECIFICATIONS
Model name of engine Unit K15
Method of engine control Carburetor specification
Fuel specification Gasoline Gasoline and LPG
Total displacement cc 1,486
Shape of combustion chamber Bathtub
Valve mechanism OHV
Bore x Stroke mm 75.5 × 83
Compression ratio 9.0
Compression pressure MPa{kgf/cm2}/rpm 1.42{14.5}/250
Method of engine speed control Pneumatic governor
Fuel (* 1) Lead-free regular At 20P
Max. output kW{HP}/rpm 27.2{36.5}/2.,500
Max. torque Nm{kgf•m}/rpm 113{11.5}/1,600
Intake opening (B.T.D.C.) 14
Valve opening/clos- Intake closing (A.B.D.C.) 30

ing timing degree
Exhaust opening (B.B.D.C.) 32
Exhaust closing (A.T.D.C.) 12
Intake (Hot) 0.38

Valve clearance mm
Exhaust (Hot) 0.38
Ignition order 1-3-4-2
Ignition timing (for idling) BTDC° 4
On-machine idling ATM 750 – 900

speed rpm
MTM 750 – 900
On-machine high ATM AX : 2,890 BX : 2,970

idling speed rpm
MTM AX : 2,890 BX : 2,970
Allowable max. Momentary under no load 3,600

engine speed rpm
Continuous under load 3,000
Type of PTO Silent chain drive, side PTO method
Engine oil Specification 10W-30 (SJ class)

(at delivery)
Quantity l 3.7 (including filter)
Dimensions of engine (Length x Width x Height) (* 2) mm 706.7 × 588.6 × 720
Mass of engine (Without coolant, with oil) (*2) kg 146
*1 : Fuel
• Gasoline: Use lead-free regular gasoline having octane number of 91 or higher.
• LPG: Use LPG of 30P or higher in cold season and LPG of 100P or higher when ambient temperature is
-5°C or lower.
*2 : Since the dimensions and mass of the engine depend on the specification, use them as reference values.
1-14 K-Series
Gasoline and
Fuel specification LPG Gasoline
LPG
Valve mechanism OHV
Bore x Stroke mm 89 × 83
Compression pressure MPa{kgf/cm2}/rpm — 1.2{12.5}/250
Fuel (* 1) At 20P Lead-free regular At 20P
Max. output kW{HP}/rpm — 34.6{46.3}/2,450
Max. torque Nm{kgf•m}/rpm — 152{15.5}/1,600
Valve opening/ Intake closing (A.B.D.C.) 30

closing timing degree
Intake (Hot) 0.38

Valve clearance mm
Exhaust (Hot) 0.38
Ignition timing (for idling) BTDC° — 2
On-machine ATM — 750 – 900

idling speed rpm
MTM — 750 – 900
On-machine ATM — 2,940

high idling rpm
speed MTM — 2,940

engine speed rpm

(at delivery)
Dimensions of engine (Length x Width x Height) (* 2) mm — 706.7 × 588.6 × 720
*1 : Fuel
-5°C or lower.
K-Series 1-15
Gasoline and
LPG
Valve mechanism OHV
Method of engine speed control — Pneumatic governor
Max. torque Nm{kgf•m}/rpm — 186{19}/1,600

closing timing deglee
Intake (Hot) 0.38

Valve clearance mm
Exhaust (Hot) 0.38

idling speed rpm
MTM — 750 – 900

high idling rpm
speed MTM — 2,820

engine speed rpm

(at delivery)
*1 : Fuel
-5°C or lower.
1-16 K-Series
Main specifications of ignition system
Model name of engine K15 K21 K25
Method of engine control Carburetor type Carburetor type Carburetor type
Gasoline Gasoline Gasoline

Fuel specification Gasoline and LPG LPG Gasoline and LPG LPG Gasoline and LPG
Ignition system Contactless type Contactless type Contactless type

(*1) (*1) (*1)
MITSUB-
Distributor ISHI ELEC. T6T87777 T6T87778 T6T87779
(With built-in ignition coil) Model name
NGK
Model name FR2A-D FR2A-D FR2A-D
Spark plug
Gap 0.9 0.9 0.9
(mm)
*1. Fully transistorized
Fuel system and speed control system
Fuel specification Gasoline Gasoline LPG Gasoline Gasoline LPG Gasoline Gasoline
and LPG and LPG and LPG
Carbure- Carbure- Carbure-

Carbure- tor + Carbure- tor + Carbure- tor +
Fuel system tor LPG Mixer tor LPG Mixer tor LPG
adapter adapter adapter
First idle First idle

Automatic of hot Automatic of hot Automatic
Starting aid choke valve of water choke valve of water choke valve of
hot water type type hot water type type hot water type
Method of idling load control FICD — FICD — FICD
Pneumatic Pneumatic Pneumatic

Method of engine speed control governor governor governor
Table of exhaust gas cleaning units
Gasoline Gasoline Gasoline

Fuel specification Gasoline and LPG LPG Gasoline and LPG LPG Gasoline and LPG
Blow-by gas control system Closed type Closed type Closed type
K-Series 1-17
GENERAL AND SPECIFICATIONS STAMPING POSITION OF ENGINE SERIAL No.
STAMPING POSITION OF ENGINE SERIAL No.

• The engine serial No. is stamped on part A of the
cylinder block (hatched part).
1-18 K-Series
GENERAL INFORMATION TROUBLESHOOTING
TROUBLESHOOTING
For details, see each section.
Trouble Possible causes Remedy Application
• Trouble in capacitor Replace Q

• Electric leakage through rotor cap Clean or replace
and rotor Q
• Trouble in spark plug Clean, adjust gap, or replace Q
Trouble in ignition system • Improper ignition timing Adjust Q

• Trouble in ignition coil Replace Q
• Disconnection of high-tension Replace
cable Q
• Looseness of disconnection of pri- Repair or replace

mary wire Q
• Insufficient of fuel Add fuel Q

• Dirt of fuel filter Replace Q
• Clogging or dirt of fuel piping Clean Q
Trouble in fuel system
(For LPG specification,
• Malfunction of fuel pump Repair or replace Q
see chapter of 6)
• Malfunction of carburetor choke Test and adjust
valve Q
• Improper carburetor float level Adjust Q

• Idling trouble Adjust Q
• Improper tightening of spark plug Tighten spark plug to proper
or defective gasket torque or replace it Q
• Improper grade of engine oil or Replace with oil of proper grade

lowering of viscosity Q
• Improper valve clearance Adjust Q

• Gas leakage through valve seat Remove head and fit valves Q
• Stiffness of valve stem Repair or adjust cylinder head and
valve Q
• Breakage or deterioration of valve Replace valve spring

Lowering of compression spring Q
pressure
• Gas leakage through head gasket Replace head gasket Q
• Wear of stiffness of piston ring Replace piston ring Q
• Wear of piston ring or cylinder Overhaul engine (Troubleshoot-
ing procedure)
a. Put a little engine oil in ignition
plug hole and measure com-
pression pressure
b. If pressure rises, cause is in Q
cylinder or piston ring
c. If pressure does not change,
gas leaks through valve, cylin-
der head, or head gasket
K-Series 1-19
1. ADJUSTMENT OF ENGINE
Trouble Cause Remedy
Looseness of bearing Replace

Seizure of bearing Replace
Rattle of bearing or
crank Bend of crankshaft Repair or replace
Uneven wear of journal Repair
Excessive end play Replace center bearing
Rattle of piston and Play of piston pin Replace piston pin or bushing
connecting rod Play of piston on cylinder Select proper one
Breakage of piston ring Replace
Misalignment of rod Align accurately
Noise from engine
Excessive play in axial direction Replace bearing thrust plate

Rattle of cam shaft
Roughness of tooth surface Repair
Breakage of gear Replace
Improper tension Adjust
Breakage or fatigue of chain Replace
Noise of timing chain Wear of sprocket Replace
Fatigue or breakage of tension adjuster Replace
Excessive clearance between cam shaft and bearing Replace
Improper valve clearance Adjust
Fatigue of adjustment screw Replace
Rattle of moving valve Wear of rocker surface Replace

system Wear of valve guide Replace guide
Fatigue of valve spring Adjust
Seizure of valve Repair or replace
Improper end play Replace
Rattle of water pump
Breakage of impeller Replace
Improper clearance Adjust
Insufficient clearance between valve stem and guide Clean stem and increase guide
diameter with reamer
Stiffness of valve
Fatigue or breakage of spring Replace
Other mechanical trouble
Seizure or breakage of valve stem Replace or clean

Fuel of low quality Use fuel of good quality
Deterioration of valve spring Replace
Sharpened valve edge Replace valve
Burn of valve seat Narrow valve seat Repair valve seat
Overheating Repair or replace
Overrun Operate within proper speed range
Stiffness of valve guide Repair
1-20 K-Series
Insufficient engine oil Add new oil or replace oil

Dirty engine oil Clean crankcase and replace oil filter
Oil of low quality Use oil of specified quality
Wrong combination of piston and connecting rod Repair or replace
Excessive wear of Improper piston ring clearance Select and adjust properly
cylinder and piston Breakage of piston ring Replace
Dirt of air cleaner Clean
Too dense mixture of gasoline and air Adjust
Stiffness of choke valve Clean and adjust
Overuse of choke valve Start correctly
Insufficient engine oil Add new oil

Lowering of oil pressure Repair
Oil of low quality Use specified oil
Roughness of crankshaft surface Grind surface and replace bearing
Malfunction of Clogging of oil passage Clean
connecting rod
Wear or breakage of bearing Replace
Improper bearing Repair
Misalignment of connecting rod Repair or replace
Malfunction of Uneven wear of crankshaft journal Repair
crankshaft bearing Clogging of oil passage on crankshaft Clean
Breakage of bearing Replace
K-Series 1-21
• Improper grade of engine oil Replace oil with proper oil

• Battery has been discharged Charge battery
• Damage of battery Replace battery
• Looseness of fan belt Adjust tension
• Trouble in charging system Check
• Trouble in starting system Repair
• Trouble in starting switch Repair or replace
• Trouble in starting motor Repair or replace
Starting motor cannot (Troubleshooting procedure table for starting
rotate engine or its motor circuit)
rotating speed is low When starting switch is turned ON while
headlamp is turned ON, if headlamp is put
out or dimmed,
a: Check battery
b: Check wiring and its connection
c: Check starting motor

When starting switch is turned ON while
headlamp is turned ON, if headlamp keeps
bright,
a: Check wiring between battery and start-
ing motor
b: Check starting switch
Possible causes of this trouble are as follows
True cause is trouble in ignition system or fuel —
system in many cases, however
• Trouble in ignition system (Troubleshooting procedure)
• Trouble in fuel system Check spark plug according to the following
procedure
Starting motor rotates • Valve mechanism does not operate normally Disconnect each high tension cable and
engine but engine keep it at about 10 mm from metallic part of
does not start • Lowering of compression pressure engine and rotate engine. Check all cables
from plug No. 1
(For LPG specifica- If good sparks are generated,
tion, see chapter of 6) a. Check spark plug
b. Check ignition timing
c. Check fuel system
d. Check compression pressure
If good sparks are not generated,
a. Check primary current
b. If current is high, check primary wire for
short circuit
• Clogging or breakage of carburetor jet Clean or replace
• Improper adjustment of idling Adjust
• Clogging of air cleaner Replace cleaner element
Idling trouble
(For LPG specifica-

tion, see chapter of 6) • Breakage of manifold gasket or carburetor Replace gasket or insulator
insulator
• Improper adjustment of carburetor float level Adjust
Lowering of compres- Explained above (See page 1 – 23)
sion pressure —
Engine output does Adjust

not rise to proper level —
1-22 K-Series
Trouble in ignition • Improper ignition timing Adjust

system • Trouble in spark plug Clean, adjust, or replace
• Trouble in carburetor choke valve Adjust
• Clogging of fuel pipe Clean
• Clogging or dirt of fuel filter Replace
(For LPG specifica- • Malfunction of fuel pump Repair or replace
tion, see chapter of 6)
• Clogging of carburetor jet or needle valve Disassemble and clean
• Insufficient opening of throttle valve Adjust
• Malfunction of fuel pump Adjust
• Clogging of air cleaner Replace element
Trouble in air intake
system • Air leakage through manifold gasket or Replace gasket or insulator
carburetor insulator
• Insufficient coolant Add coolant
• Looseness of fan belt Adjust belt tension
Idling trouble
• Wear or looseness of fan belt Replace

• Trouble in thermostat Replace
• Trouble in water pump Replace
• Clogging of or leakage from radiator Clean, repair, or replace
Overheating
• Defective radiator cap Replace
• Air in cooling system piping Retighten each part of cooling system piping
and bleed air
• Improper grade of engine oil Replace oil with oil of proper grade
• Improper ignition timing Adjust
• Defective carburetor (Fuel-air mixture is Overhaul carburetor
thin)
Overcooling • Trouble in thermostat Replace
• Improper octane number Replace fuel with fuel of specified octane
number
Other trouble • Improper tire inflation pressure Inflate tire to specified pressure
• Dragging of brake Adjust
• Slip of clutch Adjust
• Overload on engine Operate under light load
Rattle caused by Noise from engine
• Knocking caused by accumulated carbon Remove cylinder head and remove carbon
• Knocking caused by improper ignition timing Adjust ignition timing
Knocking
• Knocking caused by improper octane Use fuel of specified octane number
number of fuel
• Early ignition (Use of wrong spark plug) Use specified spark plug
• Strong and dull sound comes out of engine Cause if wear or breakage of bearing or
mechanical system
during acceleration uneven wear of crankshaft

• To find out rattling part, let each cylinder Replace bearing and adjust or replace crank-
Rattle of crankshaft misfire shaft
bearing
• If abnormal sound stops when a certain
cylinder misfires, that cylinder is source of —
abnormal sound
K-Series 1-23
• Rattle comes out of engine during acceleration at Take remedy for crankshaft bearing
little shorter intervals than rattle of crank
Rattle caused by mechanical system
Rattle of connecting
rod • To find out rattling part, let each cylinder misfire —
• If abnormal sound stops mostly when a certain —
cylinder misfires, that cylinder is source of rattle
• If raps increase as engine speed rises and Cause is excessive wear of cylinder and
Rattle of piston and decrease as engine is warmed, they are caused output is lowered and oil is consumed
cylinder by piston and cylinder more
• To find out rattling part, let each cylinder misfire Engine must be overhauled
• This rattle is heard at top and bottom dead cen- Cause is wear of piston pin hole or pis-
ters of piston ton pin
Rattle of piston pin
• To find out rattling part, let each cylinder misfire Piston and piston pin assembly must be
replaced
Noise from water • This noise is caused by wear or breakage of Replace water pump
pump bearing at uneven sliding part
• Wear of ring groove of piston and piston ring Replace piston and piston ring
Excessive oil
consumptio
Oil leakage • Deterioration of valve oil seal lip Replace valve oil seal
• Wear of valve stem Replace valve
• Use of oil of improper quality Use specified oil
Other troubles
• Overheating of engine Explained above
• Excessive idling speed Adjust to specified speed
Excessive fuel
consumption
See explanation for

lowering of output • Trouble in return of throttle Adjust
Other troubles
For LPG specification, • Fuel leakage Repair fuel piping and retighten joints
see chapter of 6
• Use of oil of improper quality Replace with specified oil

• Overheating Explained above
• Malfunction of oil pump regulator valve Overhaul or replace oil pump
Lowering of oil pres- • Malfunction of oil pump Overhaul or replace oil pump
sure • Malfunction of oil filter Replace
Troubles caused by other factors
• Increase of clearance of sliding parts Overhaul and replace worn parts

• Clogging of oil strainer Clean
• Trouble in oil gauge pressure switch Replace
• Lowering of oil pressure Explained above
• Oil of low quality or foreign matter in oil Replace oil cleaner element and oil with
proper ones
Excessive wear of
sliding parts • Insufficient capacity of air cleaner Check cleaner element
• Overheating or overcooling Explained above
• Improper fuel-air ratio Check fuel system
Scuffing of sliding • Insufficient clearance Adjust clearance as specified

parts • Overheating Explained above
1-24 K-Series
2. LPG FUEL SYSTEM OF ENGINE

• Looseness of pipe joints Tighten

• Malfunction of vaporizer Repair and adjust
Abnormal smell • Defective fitting of plunger rubber seat of solenoid Clean and fit
valve and valve seat or foreign matter between them
• Malfunction of lock-off mechanism Adjust
• Looseness of pipe joints Retighten and adjust
• Primary chamber pressure is too high while engine is Clean and adjust
Excessive fuel con- idling
sumption • Clogging of air cleaner Clean
• Improper adjustment of main adjustment screw of Adjust
LPG mixer
• Looseness of pipe joints or clogging of filter Clean and retighten
• Improper adjustment of primary and secondary Adjust
chamber pressures of vaporizer
Lowering of output
• Improper adjustment of main adjustment screw of Adjust
LPG mixer
• Use of improper fuel Use proper fuel
• Clogging of fuel passage Clean
• Improper opening of vaporizer idle adjustment screw Adjust
or carburetor throttle valve or malfunction of electri-
Fuel leakage
Unstable or improp- cally controlled throttle

erly adjusted idling
• Malfunction of vaporizer valve (Closed improperly) Clean and adjust or replace
• Malfunction of vaporizer Adjust
Hunting of engine
• Improper adjustment of idling speed Adjust
• Insufficient fuel level Add fuel
• Improper operation Check that manual valve is open
• Malfunction of solenoid valve Check and repair wiring, switches,
Trouble in start of and solenoid valves
engine
• Malfunction of vaporizer Replace
• Trouble in water pump Repair and adjust
• Improper adjustment of idling speed Adjust
• Improper adjustment of primary and secondary Adjust
• Leakage through primary and secondary valve seats Clean and adjust or replace
of vaporizer
• Breakage of diaphragm Replace
Malfunction of vapor-
izer • Foreign matter in vaporizer Clean and adjust
• Leakage caused by looseness of set screw Tighten
• Overcooling of vaporizer (Accumulation of water Check, clean and adjust
scales, breakage of hose, or defective circulation of
coolant)
• Accumulation of tar on valve Remove tar and clean
K-Series 1-25
2. MAINTENANCE
Maintenance of engine......................................... 2-2
K-Series 2-1
MAINTENANCE MAINTENANCE OF ENGINE
MAINTENANCE OF ENGINE
1. SPECIFICATIONS
Model name of engine
Item K15 K21 K25
at line H l 3.7
Quantity of oil
at line L l 2.7
(Capacity of oil filter) l 0.3
Deflection of fan belt (When Standard mm 11 – 13

pressed with about 98N {10 kgf}) value
Standard MPa{kgf/
Compression value cm2}/rpm 1.27{13.0}/250 1.23{12.5}/250 1.27{13.0}/250
Testing and adjusting
Distance between cylinders Limit value kgf/cm2/rpm 1.0/300
Spark plug gap Standard mm 0.8 – 0.9

value
Distributor (fully transistorize) air Standard

gap value mm 0.35 – 0.45
Intake Standard mm 0.38

value
Valve clearance (Hot)
Exhaust Standard mm 0.38
value
Thermostat opening Standard

temperature (STD) value °C 76.5
Idling speed and ignition timing Standard BTDC°/rpm 4/750 – 900 2/750 – 900 0/750 – 900
value
Cylinder head
Cylinder head Strain limit

(Material: Aluminum alloy) value mm 0.1
Strain limit
Top of block value mm 0.1
Bore Standard mm 75.50 – 75.55 89.00 – 89.05

value
Cylinder block
Wear of inside of cylinder Limit value mm 0.2
Standard
Ellipse of cylinder value mm Max. 0.02
Taper of cylinder Standard mm Max. 0.02

value
Ellipse and taper of cylinder Limit value mm 0.1
2-2 K-Series

Item K15 K21 K25
Type Thermal flow type
Piston Material Aluminum alloy
Outside Standard mm 75.465 – 75.515 88.965 – 89.015

diameter value
Clearance between piston and Standard mm 0.025 – 0.045

cylinder (Selective fitting) value
Outside diameter of piston pin Standard mm 19.993 – 19.998

value
Fitting level of piston pin Standard Movable with finger

value
Top Standard mm 0.28 – 0.43

value
Second Standard mm 0.45 – 0.60

value
Piston
Closed gap of piston

ring Oil Standard mm 0.20 – 0.60
value
Limit Standard
value of value mm 1.00
each
Standard mm 0.045 – 0.080

Top value
Limit value mm 0.10
Clearance between Standard mm 0.030 – 0.070

piston ring and ring Second value
groove
Limit value mm 0.10

Oil value
Limit value mm —
Distance between centers of both Standard mm 152.470 – 152.530 143.970 –-
end holes value 144.030
Diameter of big end hole Standard mm 48.0 – 48.013

value
Diameter of small end hole Standard mm 19.965 – 19.978

value
Bend (in 100 mm) Limit value mm 0.05

Connecting rod
Torsion (in 100 mm) Limit value mm 0.05

Thrust clearance at big end value
Limit value mm 0.40

Oil clearance at big end value
Limit value mm 0.10
Quantity difference Standard g Max. 4

(Combination of piston) value
K-Series 2-3

Item K15 K21 K25
Bend Limit value mm 0.05

value
End play
Limit value mm 0.20
Standard
Dimensions of journal mm 62.942 – 62.955
Crankshaft
value
Standard dimensions of pin Standard mm 44.961 – 44.974

value
Standard
value mm 0.020 – 0.073
Oil clearance at journal
Limit value mm 0.10
Oil clearance at pin Standard mm 0.032 – 0.066

value
Facial runout of flywheel Limit value mm 0.10

Flywheel
Facial runout of ring gear Limit value mm 0.50
Facial runout Limit value mm 0.30
Standard
value mm 36.750 – 36.800 (Both intake and exhaust)
Height of cam
Wear limit mm 36.5
value
Standard
Front value mm 45.434 – 45.447
Dimensions of Standard
journal Center value mm 43.897 – 43.910
Rear Standard mm 41.218 – 41.231

value
Camshaft

value
End play
Limit value mm 0.40

value
Front
Limit value mm 0.10
Standard
value mm 0.038 – 0.064
Oil clearance at Center
journal
Limit value mm 0.15

value
Rear
Limit value mm 0.10
2-4 K-Series

Item K15 K21 K25
Intake Standard mm 38.0 – 38.3

Outside diameter of value
head Standard
Exhaust value mm 32.0 – 32.3

Outside diameter of value
valve stem Standard
Exhaust mm 6.945 – 6.960
value
Standard
Intake value mm 7.0 – 7.018
Inside diameter of
valve guide Standard
Exhaust mm 7.0 – 7.018
value
Intake value
Valve
Clearance between Limit value mm 0.10

valve stem and valve
guide Standard mm 0.040 – 0.073
Exhaust value
Limit value mm 0.10
Clearance between valve lifter Standard
and lifter guide value mm 0.016 – 0.052
Clearance between crankshaft Standard mm 0 – 0.038

and flywheel value
Clearance between rocker shaft Standard mm 0.020 – 0.054
and rocker arm value
Standard
Intake value mm 0.38 ± 0.03
Clearance between
valve (Hot) Standard
Exhaust mm 0.38 ± 0.03
value
Intake Standard
Free length and value mm 45.9
exhaust
Intake
When compressed for and Standard mm/N {kgf} 25.0/347.0 – 391.2 {35.4 – 39.9}
opening valve exhaust value
Intake
When installed with and Standard mm/N {kgf} 33.8/177.9 – 200.7 {18.1 – 20.5}
valve close exhaust value
Valve spring
Intake
Leaning and Limit value mm 1.5
exhaust
Clearance between valve lifter Standard
and lifter guide value mm 0.016 – 0.052
Clearance between crankshaft Standard

and flywheel value mm 0 – 0.038
Clearance between rocker shaft Standard mm 0.020 – 0.054

and rocker arm value
Intake manifold Strain limit mm 0.1
Exhaust manifold Strain limit mm 0.3
K-Series 2-5
2. TIGHTENING TORQUE
Unit: Nm{kgf•m}
Size of thread
Diameter Pitch
3.82 – 4.41 {0.39 – 0.45} 6.37 – 7.45 {0.65 – 0.76} 9.22 – 10.8 {0.94 – 1.1}
M6 1
5.00 – 6.47 {0.51 – 0.66} 8.43 – 10.8 {0.86 – 1.1} 11.8 – 15.7 {1.2 – 1.6}
9.32 – 10.8 {0.95 – 1.1} 15.7 – 17.7 {1.6 – 1.8} 22.6 – 25.5 {2.3 – 2.6}
M8 1.25
12.7 – 15.7 {1.3 – 1.6} 20.6 – 26.5 {2.1 – 2.7} 29.4 – 37.3 {3.0 – 3.8}
19.6 – 22.6 {2.0 – 2.3} 32.4 – 38.2 {3.3 – 3.9} 47.1 – 53.9 {4.8 – 5.5}
1.25
25.5 – 33.3 {2.6 – 3.4} 43.1 – 54.9 {4.4 – 5.6} 61.8 – 78.5 {6.3 – 8.0}
M10
18.6 – 21.6 {1.9 – 2.2} 30.4 – 36.3 {3.1 – 3.7} 44.1 – 52 {4.5 – 5.3}
1.5
24.5 – 31.4 {2.5 – 3.2} 41.2 – 52 {4.2 – 5.3} 58.8 – 74.5 {6.0 – 7.6}
4.9 – 5.69 {0.5 – 0.58} 8.14 – 9.51 {0.83 – 0.97} 11.8 – 13.7 {1.2 – 1.4}
M6 1
5.98 – 7.65 {0.61 – 0.78} 9.81 – 12.7 {10 – 1.3} 14.7 – 18.6 {1.5 – 1.9}
11.8 – 13.7 {1.2 – 1.4} 19.6 – 23.5 {20 – 2.4} 28.4 – 33.3 {2.9 – 3.4}
M8 1.25
Flange bolt
14.7 – 18.6 {1.5 – 1.9} 24.5 – 31.4 {2.5 – 3.2} 35.3 – 45.1 {3.6 – 4.6}
24.5 – 29.4 {2.5 – 3.0} 41.2 – 48.1 {4.2 – 4.9} 59.8 – 69.6 {6.1 – 7.1}
1.25
30.4 – 39.2 {3.1 – 4.0} 51.0 – 64.7 {5.2 – 6.6} 73.6 – 93.2 {7.5 – 9.5}
M10
23.5 – 27.5 {2.4 – 2.8} 39.2 – 46.1 {4.0 – 4.7} 56.9 – 65.7 {5.8 – 6.7}
1.5
29.4 – 37.3 {3.0 – 3.8} 49.0 – 61.8 {5.0 – 6.3} 69.6 – 89.2 {7.1 – 9.1}
The following marks are in relief on the heads of bolts to which the above tightening torque can be
applied.
4T --- 4
7T --- 7
9T --- 9
2-6 K-Series
Unit: Nm{kgf•m}
Cylinder head (coated with oil) See page 2-9
Crank pulley bolt (coated with oil) 220.5 {22.5} 240.1 {24.5}
Spark plug 19.6 {2.0} 29.4 {3.0}
Rocker cover nut 13.7 {1.4} 15.7 {1.6}
Exhaust manifold nut See page 2-9
Thermo housing air relief plug 6.37 {0.65} 7.45 {0.76}
K-Series 2-7
3. MAINTENANCE SCHEDULE
Sure maintenance and service work are necessary for keeping the initial performance of the engine.
1) Execution of inspection
Inspect each forklift at the earlier time of the specified number of elapsed months and operating hours.
--- Inspecting time
Inspection of engine
Number of
elapsed months 1 2 3 4 5 6 7 8 9 10 11 12
No. Inspection item
100 operating
hours 2 4 6 8 10 12 14 16 18 20 22 24
1 Clearance of intake and exhaust valves A A A
2 Belt tension of auxiliary device I I I I I I I I I I I I
3 Engine oil (*1) R’ R’ R’ R’ R’
4 Oil filter (*1) R’ R’ R’ R’ R’
5 Engine coolant
6 Fuel filter (*1) C C C C C
7 Idling speed of engine A A
8 Ignition timing A A A A A A A A A A A A
9 Spark plug I I I I I I
10 Distributor point, cap, and rotor I I I I I I
11 Inside of distributor (*1) C
12 PCV valve (*1) I I I I
13 PCV hose I I I I
Inspection of engine (Model of LPG specification)
Number of 1 2 3 4 5 6 7 8 9 10 11 12
elapsed months
No. Inspection item
100 operating 2 4 6 8 10 12 14 16 18 20 22 24
hours
1 Gas leakage through pipe joints (*2) I I I I I I I I I I I I
2 Breakage of pipe joints I I I I I I I I I I I I
3 Tar in vaporizer D D D D D D D D D D D D
4 LPG filter C C C R
*1. When the forklift is used in dusty places or contaminated environments, it must be maintained at shorter pe-
riods.
*2. When replacing the LPG cylinder, apply soap water to the pipe joint to check for gas leakage.
Meaning of abbreviation:I : Inspect. Repair and replace, if necessary.
R : Replace
A : Adjust
C : Clean
D : Discharge
T : Tighten (Retighten)
R' : Replace, every 500 hours (every 3 months), engine oil, oil filter
2-8 K-Series
4. OILS, GREASES, AND THEIR QUANTITY

1) Oil and LLC
Item Specification Remarks
Engine oil Gasoline (*1) 10W-30 (SJ class) See SAE viscosity index table. (SE and SH may be used.)
Antifreeze — — KOMATSU genuine long-life coolant
*1. Each forklift is filled with this oil when delivered.
2) Quantity of supplied oil (Rough standard)
Item Quantity (l)
K15 3.7 (Including oil in filter)
Engine oil K21 3.7 (Including oil in filter)
K25 3.7 (Including oil in filter)
5. INSPECTION AND SERVICE OF

PARTS ON FORKLIFT
1) Tightening head bolts
Tighten the head bolts in the order shown at left
from the central one to the outer ones.
Tighten the head bolts by the method shown at
left.
: 68.6 Nm {7.0 kgf•m}
(Bolts may be tightened by process
[5] for servicing)
k • Check the tightening angle with an angle
wrench (special tool) or a protractor. Do
not check it visually.
2) Retightening manifold bolts and nuts

k • When working on the manifold, wait until
it is cooled to avoid burning yourself.
3) Tightening torque of manifold bolts and nuts
Model Nm {kgf•m}
K15 41.2 – 48.1 {4.2 – 4.91}
K21 41.2 – 48.1 {4.2 – 4.91}
K25 41.2 – 48.1 {4.2 – 4.91}
(Never use a power tool such as an air runner to

tighten the bolts and nuts.)
K-Series 2-9
4) Adjusting clearance of intake and exhaust

valves
• Adjust the clearance while the valves are hot.
1. Warm up the engine until the coolant tempera-
ture gauge indicates the center, and then stop it.
2. Remove the rocker cover.
3. Rotate the crankshaft.
k • When rotating the crankshaft with the
starting motor, disconnect the high-ten-
sion cable from the ignition coil.
4. Set the piston of the No. 1 cylinder to the com-
pression top dead center and adjust valves [1],
[2], [3], and [5].
5. Rotate the crankshaft again to set the piston of
the No. 4 cylinder to the compression top dead
center and adjust valves [4], [6], [7], and [8].
Clearance of intake and exhaust valves at hot
state
(mm)
Model Intake Exhaust
K15 0.38 0.38
K21 0.38 0.38
K25 0.38 0.38
5) Testing and adjusting auxiliary device belt

k • Check that the engine is stopped. Clean
your hands.
1. Visually check the fan belt for wear, damage,
cracking, etc. The belt must not be in contact
with the groove bottom.
2. Press the belt at the center between the pulleys
to check that tension is applied.
Deflection of belt: 11 – 13 mm
Pressing force: 98 N {10 kgf}
6) Replacing oil and oil filter

1. Warm up the engine.
2. Remove the oil pan drain plug and oil filler cap to
drain the oil.
k • When the engine and engine oil are hot,
k • Milky oil indicates that coolant is mixed in

take care not to burn yourself.
k • il of very low viscosity indicates that gas-

it. Take a proper remedy in this case.
oline is in it. Take a proper remedy in this

case.
2-10 K-Series
3. Wipe around the discharge hole and install the

drain plug.
Oil pan drain plug:
29.4 – 39.2 Nm {3.0 – 4.0 kgf•m}
4. Replace the oil filter.
• Using oil filter wrench A (special tool ST193-
20000), remove the oil filter.
• Wipe the oil filter mounting face with clean
cloth.
• Apply a little amount of engine oil to the lip of

the new oil filter.
• Screw in oil filter (1) with the hand until it

reaches cylinder block boss (3), and then
tighten it further by 2/3 turns.
1. Oil filter
2. Stud
3. Cylinder block boss
4. Relief valve
5. Supply lubricating oil by the standard quantity.

Standard quantity of oil
Including filter 3.7 l
Excluding filter 3.4 l
6. Start the engine and check around the drain plug

and oil filter for leakage. If any oil is leaking, re-
install the oil filter.
7. Run the engine. After the coolant temperature
gauge reaches almost the center, stop the en-
gine. Wait for several minutes and check the oil
level. Add oil, if necessary.
K-Series 2-11
3. ENGINE TUNE-UP
Specifications ..................................................... 3- 2
Tightening torque ............................................... 3- 3
Troubleshooting ................................................. 3- 4
Testing and adjusting engine ............................. 3- 9
Special tools....................................................... 3-22
K-Series 3-1
ENGINE TUNE-UP SPECIFICATIONS
SPECIFICATIONS
Model name of engine Unit K15 K21 K25
Item
Intake mm 0.38
Valve clearance
(Hot)
Exhaust mm 0.38
Belt deflection mm 11-13
Force to press belt N{kgf} 98 {10}
Including
oil filter l 3.7
Quantity of engine oil
Excluding l 3.4
oil filter
Standard
value MPa{kgf/cm2}/rpm 1.27 {13.0}/250 1.23 {12.5}/250 1.27 {13.0}/250
Compression pressure
Min. value MPa{kgf/cm2}/rpm 1.07 {11.0}/250 1.03 {10.5}/250 1.07 {11.0}/250
Spark plug model name FR2A-D
Plug gap mm 0.9
Distributor cap mm 0.35 – 0.45
Resistance of high tension cable z Max. 30,000
Ignition timing/Idling speed B.T.D.C °/rpm 4/750 – 900 2/750 – 900 0/750 – 900
No-load max. speed rpm (Momentary) rpm 3,600
Max. speed under load rpm 3,000
3-2 K-Series
ENGINE TUNE-UP TIGHTENING TORQUE
TIGHTENING TORQUE
Unit: Nm{kgf•m}
Cylinder head bolt See figure at right
Manifold nut 41.2 – 48.1 {4.2 – 4.91}
Oil pan drain plug 29.4 – 39.2 {3.0 – 4.0}
Spark plug 19.6 – 29.9 {2.0 – 3.0}
Cylinder head
For general service, the cylinder head bolts may be
tightened by angle tightening process [5] shown in
the figure at left instead of torque tightening to 68.6
Nm {7.0 kgf•m}.
Apply rust-preventive oil or engine oil to the threads
and stem of each bolt.
K-Series 3-3
ENGINE TUNE-UP TROUBLESHOOTING
TROUBLESHOOTING
• Improper grade of engine oil Replace oil with proper oil

• Battery has been discharged Charge battery
• Damage of battery Replace battery
• Trouble in charging system Check
• Trouble in starting system Repair
• Trouble in starting switch Repair or replace
• Trouble in starting motor Repair or replace
Starting motor cannot (Troubleshooting procedure table for starting
rotate engine or its motor circuit)
rotating speed is low When starting switch is turned ON while
headlamp is turned ON, if headlamp is put
out or dimmed,
a: Check battery
b: Check wiring and its connection

When starting switch is turned ON while
headlamp is turned ON, if headlamp keeps
bright,
a: Check wiring between battery and start-
ing motor
b: Check starting switch
Possible causes of this trouble are as follows
True cause is trouble in ignition system or fuel —
system in many cases, however
• Trouble in ignition system (Troubleshooting procedure)
• Trouble in fuel system Check spark plug according to the following
procedure
Starting motor rotates • Valve mechanism does not operate normally Disconnect each high tension cable and
engine but engine keep it at about 10 mm from metallic part of
does not start • Lowering of compression pressure engine and rotate engine. Check all cables
from plug No. 1
(For LPG specifica- If good sparks are generated,
tion, see chapter of 6) a. Check spark plug
b. Check ignition timing
c. Check fuel system
d. Check compression pressure
a. Check primary current
b. If current is high, check primary wire for
short circuit
3-4 K-Series
Application
Trouble Possible causes Remedy
Common Cab spec-
ification
• Trouble in capacitor Replace Q

• Electric leakage through rotor cap Clean or replace
and rotor Q
• Trouble in spark plug Clean, adjust gap, or replace Q

Trouble in ignition • Improper ignition timing Adjust Q
system
• Trouble in ignition coil Replace Q
• Disconnection of high-tension Replace
cable Q
• Looseness of disconnection of pri- Repair or replace

mary wire Q
• Insufficient of fuel Add fuel Q

• Dirt of fuel filter Replace Q
• Clogging or dirt of fuel piping Clean Q
Trouble in fuel system • Malfunction of fuel pump
(For LPG specifica-
Repair or replace Q
tion, see 6)
• Malfunction of carburetor choke Test and adjust
Q
valve
• Improper carburetor float level Adjust Q

• Idling trouble Adjust Q
• Improper tightening of spark plug Tighten spark plug to proper
or defective gasket torque or replace it Q
• Improper grade of engine oil or Replace with oil of proper grade

lowering of viscosity Q
• Improper valve clearance Adjust Q

• Gas leakage through valve seat Remove head and fit valves Q
• Stiffness of valve stem Repair or adjust cylinder head and
valve Q
• Breakage or deterioration of valve Replace valve spring

Lowering of compres- spring Q
sion pressure
• Gas leakage through head gasket Replace head gasket Q
• Wear of stiffness of piston ring Replace piston ring Q
• Wear of piston ring or cylinder Overhaul engine (Troubleshoot-
ing procedure)
a. Put a little engine oil in ignition
plug hole and measure com-
pression pressure
b. If pressure rises, cause is in Q
cylinder or piston ring
c. If pressure does not change,
gas leaks through valve, cylin-
der head, or head gasket
K-Series 3-5
• Clogging or breakage of carburetor jet Clean or replace

• Improper adjustment of idling Adjust
(For LPG specifica- • Clogging of air cleaner Replace cleaner element
tion, see chapter of 6) • Breakage of manifold gasket or carburetor Replace gasket or insulator
insulator
• Improper adjustment of carburetor float level Adjust
Lowering of compres- — Explained above (See page 1 – 23)
sion pressure
Engine output does Adjust
not rise to proper —
level.
Trouble in ignition • Improper ignition timing Adjust

system • Trouble in spark plug Clean, adjust, or replace
• Trouble in carburetor choke valve Adjust
• Clogging of fuel pipe Clean
• Clogging or dirt of fuel filter Replace
(For LPG specifica- • Malfunction of fuel pump Repair or replace
tion, see chapter of 6)
• Clogging of carburetor jet or needle valve Disassemble and clean
• Insufficient opening of throttle valve Adjust
• Malfunction of fuel pump Adjust
Idling trouble
• Clogging of air cleaner Replace element

Trouble in air intake
system • Air leakage through manifold gasket or Replace gasket or insulator
carburetor insulator
• Looseness of fan belt Adjust belt tension
• Wear or looseness of fan belt Replace
• Trouble in thermostat Replace
• Trouble in water pump Replace
• Clogging of or leakage from radiator Clean, repair, or replace
Overheating
• Defective radiator cap Replace
• Air in cooling system piping Retighten each part of cooling system piping
and bleed air
• Improper grade of engine oil Replace oil with oil of proper grade
• Improper ignition timing Adjust
• Defective carburetor (Fuel-air mixture is Overhaul carburetor
thin)
Overcooling • Trouble in thermostat Replace
• Improper octane number Replace fuel with fuel of specified octane
number
Other trouble • Improper tire inflation pressure Inflate tire to specified pressure
• Dragging of brake Adjust
• Slip of clutch Adjust
3-6 K-Series
• Overload on engine Operate under light load

Noise from engine
• Knocking caused by accumulated carbon Remove cylinder head and remove carbon
Knocking • Knocking caused by improper ignition timing Adjust ignition timing

• Knocking caused by improper octane Use fuel of specified octane number
number of fuel
• Early ignition (Use of wrong spark plug) Use specified spark plug
• Strong and dull sound comes out of engine Cause if wear or breakage of bearing or
during acceleration. uneven wear of crankshaft
• To find out rattling part, let each cylinder Replace bearing and adjust or replace crank-
Rattle of crankshaft misfire shaft
bearing
• If abnormal sound stops when a certain
cylinder misfires, that cylinder is source of —
abnormal sound
Rattle caused by mechanical system
• Rattle comes out of engine during accelera- Take remedy for crankshaft bearing
tion at little shorter intervals than rattle of
crank
Rattle of connecting • To find out rattling part, let each cylinder
rod misfire —
• If abnormal sound stops mostly when a cer-

tain cylinder misfires, that cylinder is source —
of rattle
• If raps increase as engine speed rises and Cause is excessive wear of cylinder and out-
decrease as engine is warmed, they are put is lowered and oil is consumed more
Rattle of piston and caused by piston and cylinder
cylinder
• To find out rattling part, let each cylinder Engine must be overhauled
misfire
• This rattle is heard at top and bottom dead Cause is wear of piston pin hole or piston pin
centers of piston
Rattle of piston pin
• To find out rattling part, let each cylinder Piston and piston pin assembly must be
misfire replaced
Noise from water • This noise is caused by wear or breakage of Replace water pump
pump bearing at uneven sliding part
• Wear of ring groove of piston and piston ring Replace piston and piston ring
Excessive oil
consumption
Oil leakage • Deterioration of valve oil seal lip Replace valve oil seal
• Wear of valve stem Replace valve
• Use of oil of improper quality Use specified oil
Other troubles
• Overheating of engine Explained above
• See explanation for • Excessive idling speed Adjust to specified speed
Excessive fuel
consumption
lowering of output
• Other troubles • Trouble in return of throttle Adjust
For LPG specifica- • Fuel leakage Repair fuel piping and retighten joints
tion, see chapter of
6
K-Series 3-7

• Overheating Explained above
Lowering of oil pres- • Malfunction of oil pump Overhaul or replace oil pump
sure • Malfunction of oil filter Replace
Troubles caused by other factors

• Trouble in oil gauge pressure switch Replace
• Oil of low quality or foreign matter in oil Replace oil cleaner element and oil with
proper ones
Excessive wear of
sliding parts • Insufficient capacity of air cleaner Check cleaner element
• Overheating or overcooling Explained above
Scuffing of sliding • Insufficient clearance Adjust clearance as specified

parts • Overheating Explained above
3-8 K-Series
ENGINE TUNE-UP TESTING AND ADJUSTING ENGINE
TESTING AND ADJUSTING ENGINE

1. ENGINE UNIT
1) Retightening cylinder head bolts
Retighten the cylinder head bolts in the order at
left while the engine is cold.
Cylinder head bolt:
68.6 Nm {7.0 kgf•m}
2) Retightening manifold nuts

To prevent the intake air and exhaust gas from
leaking, retighten the nuts of the intake and ex-
haust manifolds.
Manifold nut:
41.2 – 48.1 Nm {4.2 – 4.91 kgf•m}
(At 1 month or 200 operating hours)
3) Adjusting valve clearance

Adjust the valve clearance while the engine is
stopped and still hot.
1. Run the engine to warm it up sufficiently, and
then stop it.
2. Remove the rocker cover
3. Rotate the crankshaft.
1) Set the piston of the No. 1 cylinder to the
compression top dead center and adjust the
clearance of valves [1], [2], [3], and [5] in step
(1) in the figure at right.
2) Set the piston of the No. 4 cylinder to the
compression top dead center and adjust the
clearance of valves [4], [6], [7], and [8] in step
(2) in the figure at right.
4) Adjusting valve clearance in hot state

Intake and exhaust valve: 0.38 mm
K-Series 3-9
5) Testing and adjusting auxiliary device belt

1. Visually check the fan belt for cracking, wear, oil
leakage, etc. (The belt must not be in contact
with the groove bottom.)
2. Press the belt at the center between the pulleys
to check that tension is applied.
Deflection of belt: 11 – 13 mm
Pressing force: 98 N {10 kgf}
6) Replacing oil and oil filter

1. Run the engine and warm it up sufficiently.
2. Remove the oil filler cap and drain plug of the oil
pan to drain the oil.
3. After draining the oil, install the set of the drain
plug and washer.
k • When the engine and engine oil are hot,
take care not to burn yourself.
• Milky oil indicates that coolant is mixed in
it.
• Oil of very low viscosity indicates that
gasoline is in it.
Oil pan drain plug:
29.4 – 39.2 Nm {3.0 – 4.0 kgf•m}
4. Using oil filter wrench A (special tool ST193-
20000), remove the oil filter.
5. Wipe the oil filter mounting face with clean cloth.
6. Apply a little amount of engine oil to the lip of the

new oil filter.
7. Screw in the oil filter with the hand until it reaches
the cylinder block boss, and then tighten it further
by 2/3 turns.
3-10 K-Series
8. Supply lubricating oil according to the recom-

mend specification and check the oil level with
the oil level gauge.
Quantity of engine oil Unit: l

With filter 3.7
Without filter 3.4
k • Check that the oil pressure lamp lights up

before the engine is started and goes off
after the engine is started.
9. Start the engine and check around the drain plug
and oil filter for leakage. If any oil is leaking, the
parts around the leaking point are not installed
correctly.
10. Warm up the engine sufficiently. Stop the engine
and wait for several minutes. Check the oil level
and add oil, if necessary.
k • When checking the oil level, set the en-
gine horizontally.
7) Replacing coolant
k • Do not drain the coolant while the engine
k • When using antifreeze, read the usage

is still hot. You may be scalded.
printed on its container and mix it with wa-

ter.
If the engine has been removed, drain the coolant
through the plug of the cylinder block.
8) Cleaning outside of radiator

Clean the outside with compressed air.
9) Testing coolant hoses and their connections

Check the hoses for looseness of connections
and deterioration, and then tighten or replace
them, if necessary.
K-Series 3-11
10) Testing compression pressure

1. Warm up the engine sufficiently, and then stop it.
2. Remove the spark plug of the tested cylinder.
3. Press the compression gauge correctly to the
plug hole of the tested cylinder.
4. Open the throttle valve fully. Press the throttle
pedal to the end.
5. Rotate the engine and read the gauge.
(Measure both carburetor type and electronic
control type by the same method.)
• Rotate the engine at about 250 rpm.
• Measure the pressure as quickly as possible.
Standard compression pressure
K15 1.27 MPa {13.0 kg/cm2}/250 rpm
K21 1.23 MPa {12.5 kg/cm2}/250 rpm
K25 1.27 MPa {13.0 kg/cm2}/250 rpm
6. The compression pressure difference between

the cylinders must not exceed 98 kPa {1 kgf/cm²}/
250 rpm. If the compression pressure of a cylin-
der is low, supply a little amount of oil through the
spark plug hole and measure again.
• If the pressure rises after the oil is supplied,
the piston ring is worn or damaged.
• If the pressure does not rise after the oil is
supplied, the valve is stiff or is not seated nor-
mally.
• If the pressure of 2 adjacent cylinders lowers
and it does not rise after the oil is supplied, air
is leaking through the gasket. In this case, oil
and water enter the combustion chamber.
• If the engine speed does not reach the spec-
ified level, measure the specific gravity of the
electrolyte.
3-12 K-Series
2. IGNITION AND FUEL SYSTEMS

1) Cleaning or replacing air cleaner element
Dry paper filter type
Clean and replace the filter element at the speci-
fied intervals. If the forklift is used in dusty plac-
es, clean and replace the filter element more
frequently.
2) Fuel filter
Cleaning and replacing
Check, clean, and replace the fuel filter at the
specified intervals.
Testing fuel piping
(Hoses, tubes, joints, etc.)
Check that the fuel piping is installed properly
and check it for leakage, cracking, breakage,
looseness of joints, etc. Replace broken or de-
fective parts.
1. Cover mounting nut
2. Cover
3. Fuel pump
K-Series 3-13
3) Testing mixer
4) Testing link mechanism and valves 1. AAS air adjustment screw

• Remove the air horn and check the link system 2. FICD negative pressure piping
and inside visually. 3. FICD push rod
• Check the throttle shaft by the hand. It must not 4. Throttle lever
move.
• Check the operation of the throttle valve and Reference
choke valve. (Opening and closing) • If the air adjustment screw (1) is turned to the left,
5) Maintaining mixer the engine speed is increased.
• If the mixer is very dirty, disassemble and clean (The throttle opening angle is fixed to 0.5°. Do
it. not change it.)
• If the link mechanism is worn very much or bro-
ken, replace it.
• If the throttle valve shaft is worn very much or
bent, replace it.
6) Testing FICD (idling speed increasing device)
1. Warm up the engine sufficiently.
2. Check that the hot water heater is warmed up.
• Remove the DIST VC hose and plug the mixer
side.
3. Check that FICD is not in contact with the throttle
lever of the carburetor.
4. Adjust the idling speed with air adjustment screw
(1).
Idling speed: 850 rpm
a Return the DIST VC hose.
3-14 K-Series
7) Testing carburetor
1. Choke hot water heater
2. Accelerator pump
3. Idling adjustment screw
4. Throttle adjustment screw
5. Throttle drum
6. Fuel cut solenoid valve
7. FICD negative pressure piping
8. Idling adjustment screw
9. Throttle adjustment screw
10. Throttle lever
11. FICD push rod
8) Testing link mechanism and valves

• Remove the air horn and check the link system
and inside visually.
• Check the throttle shaft by the hand. It must not
move.
• Check the operation of the throttle valve and
choke valve. (Opening and closing)
9) Maintaining carburetor
• If the carburetor is very dirty, disassemble and
clean it.
• If the link mechanism is worn very much or bro-
ken, replace it.
• If the throttle valve shaft is worn very much or
bent, replace it.
1. Warm up the engine sufficiently.
2. Check that the hot water heater is warmed up.
a Remove the DIST VC hose and plug the mix-
er side.
3. Check that FICD is not in contact with throttle le-
ver (10) of the carburetor.
4. Adjust the idling speed with throttle adjustment
screw (9) and idling adjustment screw (8).
Idling speed: 850 rpm
a In case of the gasoline-LPG type, adjust the
idling speed with the throttle adjustment
screw (9) and adjust the mixing ratio with the
idling adjustment screw (8) of the vaporizer.
Reference
• If the idling adjustment screw (8) is turned to the
left, the air-fuel mixture becomes thin.
a Return the DIST VC hose.
K-Series 3-15
5. Adjust the ignition timing on the idling speed side.

Ignition timing:
• K15 : BTDC 4°
• K21 : BTDC 2°
• K25 : BTDC 0°
6. Remove the negative piping from the FICD and
plug the piping part to prevent air leakage.
7. Under this condition, the push rod of the FICD is
pushing the throttle lever of the carburetor.
Then, adjust the engine speed to 1,200 – 1,500
rpm with the adjustment screw of the throttle le-
ver.
8. After adjusting, connect the negative pressure
piping and check that the idling speed of the en-
gine is normal.
11) Testing and replacing spark plug

1. Testing
• Visually check the electrodes for dirt, dam-
age, and wear. Visually check the insulator
for burn.
• Using the plug gap gauge, check that the
spark gap is as specified.
Standard value: 0.9 mm
• If the gap is out of the standard, adjust it.
• If the spark plug is defective, replace it.
2. Installation
• Carry out installation in the reverse order to
removal.
: 19.6 – 29.4 Nm {2.0 – 3.0 kgf•m}
12) Testing distributor

13) Testing ignition coil
• Using a circuit tester, measure the resistance be-
tween primary coil terminals [1] and [2] and be-
tween secondary coil terminals [1] and [2].
Resistance of primary coil : 0.9 – 1.2 z
Resistance of secondary coil : 20 – 29 z
14) Testing pickup coil

• Using a circuit tester, measure the resistance of
the pickup coil.
Specified resistance: 420 – 540 z
3-16 K-Series
• Move a flat-head screwdriver to the right and left

near the core of the pickup coil and check that the
pointer of the circuit tester moves.
15) Testing distributor cap and carbon terminal

• If the hemisphere surface of the terminal is worn,
replace the cap.
16) Testing rotor head

• Check the rotor head for cracking and breakage.
17) Testing signal core rotor

• Check the signal core rotor for bend and break-
age.
18) Testing negative pressure control mecha-

nism
• Using a negative pressure pump, apply negative
pressure to the diaphragm and check that the link
is pulled.
19) Testing reassembled distributor

Measure the clearance between the signal core
rotor and pickup coil.
Specified clearance: 0.35 – 0.45 mm
20) Cleaning inside of distributor

Blow out dirt from the inside of the distributor with
dry compressed air.
21) Measuring engine speed

The adapter wiring harness for measuring the en-
gine speed is prepared for the distributor of the
Model K engine having the ignition coil in it.
K-Series 3-17
1. Remove distributor connector (12) from the cou-

pling.
2. Connect adapter wiring harness (13) for ignition

coil (Special tool No. EG111-40000) between the
distributor connector and coupling.
• Connect power terminal (red) (15) of the ta-
chometer to the positive (+) terminal of bat-
tery (14) and connect power terminal (black)
(16) to the negative (–) terminal with clips.
• Connect measurement (green) terminal clip
(17) to the measurement wire at the center of
the adapter wiring harness.
3-18 K-Series
22) Testing and adjusting ignition timing, idling speed, and air-fuel mixing ratio
a. The idling speed is adjusted when the forklift is delivered and does not need to be adjusted usually. If it needs
to be adjusted for some reason, adjust it according to the following procedure.
b. Do not tighten the idling adjustment screw fully. If it is tightened so, its tip will be damaged, and that can
cause a trouble.
Start
Preparation
1. Check that the following Run engine and warm it up
parts are normal. sufficiently. Warm up hydraulic
Ignition system oil and torque converter oil, too.
Levels of lubricating oil
and coolant Run engine at idling speed for 2
Valve clearance minutes.
Fuel level during idling
2. Set the gearshift lever in
neutral. Race engine at 2,000 -- 3,000
rpm 2 -- 3 times without applying
load, then run it at idling speed.
Test idling speed.

Idling speed: 750 -- 900 rpm
OK NG (Gasoline and gasoline-LPG
specifications)
Adjust engine speed with
throttle adjustment screw.
(LPG specification)
Adjust engine speed with air
Test ignition timing and idling adjustment screw.
speed
Ignition timing
(deg. before top dead center)
K15: 4°, K21: 2°, K25: 0°
OK NG
Rotate distributor to adjust
ignition timing.
Race engine at 2,000 -- 3,000

rpm 2 -- 3 times without applying
load, then run it at idling speed.
Adjust idling speed with throttle

adjustment screw.
End
K-Series 3-19
23) Testing and adjusting air-fuel mixing ratio
Start
Test and adjust idling speed and ignition timing.
Return idling adjustment screw about 2 turns from fully closed position.
Adjust engine speed with throttle adjustment screw.
Increase engine speed to maximum with idling adjustment screw.

(In case of LPG specification, adjust with mixture adjustment screw and
air adjustment screw.)
Does engine speed rise after idling adjustment screw is rotated?

YES
NO
Adjust idling speed with idling adjustment screw.
End
24) Governor unit

The governor is adjusted when the forklift is de-
livered and does not need to be adjusted usually.
If it needs to be adjusted for some reason, adjust
it according to the following procedure.
25) Adjusting no-load maximum engine speed

1. Set the directional lever in neutral.
2. Run the engine and open the throttle valve fully
and check the engine speed.
No-load maximum engine speed (rpm)
K15 AX: 2,890
K21 2,940 ± 50
K25 2,820 ± 50
3. If the engine speed is out of the specified range,

adjust it with the adjustment handle of the gover-
nor.
1. Alignment mark
2. Adjustment screw
3. Adjustment handle
3-20 K-Series

1. Run the engine and warm it up sufficiently.
2. Check that FICD is not in contact with the throttle
lever of the carburetor.
3. Adjust the idling speed with the throttle adjust-
ment screw.
Idling speed: 700 ± 50 rpm
4. Adjust the ignition timing for idling speed.
Ignition timing:
K15: BTDC 4°
K21: BTDC 2°
K25: BTDC 0°
5. Remove the negative piping from the FICD and
plug the piping part to prevent air leakage.
6. Under this condition, the push rod of the FICD is
pushing the throttle lever of the carburetor.
Then, adjust the engine speed to 1,200 – 1,500
rpm with the adjustment screw of the throttle le-
ver.
7. After adjusting, connect the negative pressure
piping and check that the idling speed of the en-
gine is normal.
K-Series 3-21
ENGINE TUNE-UP SPECIAL TOOLS
SPECIAL TOOLS
EG111-40000 Ignition coil adapter wiring harness

(For testing engine speed)
3-22 K-Series
4. ENGINE MECHANICAL
Precautions for work .......................................... 4- 2

Outside view of engine....................................... 4- 4
Main specifications............................................. 4- 7
Adjustment values.............................................. 4-10
Tightening torque ............................................... 4-14
Troubleshooting ................................................. 4-17
Special tools....................................................... 4-19
Removal and installation of engine .................... 4-20
Servicing engine................................................. 4-22
K-Series 4-1
ENGINE MECHANICAL PRECAUTIONS FOR WORK

1. PRECAUTIONS FOR DRAINING COOLANT
• Drain the coolant after its temperature lowers sufficiently.
2. PRECAUTIONS FOR SEPARATING FUEL PIPING

• Work in a place where there is nothing to start a fire.
• Release the fuel pressure in advance.
• After separating the fuel piping, plug it to prevent the fuel from flowing out.
3. PRECAUTIONS FOR REMOVAL AND DISASSEMBLY

• If specified, use correct special tools and pay attention. Do not apply an excessive force.
• Take extreme care not to lower the accuracy of the mating faces, sliding faces, etc.
• If necessary, cover the openings with tapes, etc. to prevent foreign matter from entering the engine.
• Make marks on the removed parts and arrange them for secure troubleshooting and assembly.
• As a rule, loosen the bolts and nuts from outside in the diagonal direction. If the loosening order is spec-
ified, observe it.
4. PRECAUTIONS FOR CHECKING, REPAIRING, AND REPLACING PARTS

• Before repairing or replacing parts, check them sufficiently according to the check procedure. Check the
new parts similarly and replace them if necessary.
5. PRECAUTIONS FOR ASSEMBLING AND INSTALLING PARTS

• When tightening the bolts and nuts, be sure to use torque wrenches.
• As a rule, tighten the bolts and nuts from inside to outside in the diagonal direction in 2 - 3 times. If the
tightening order is specified, observe it.
• Replace the gaskets, packings, oil seal, and O-rings with new ones.
• Clean each part and dry it by blowing compressed air against it. In particular, take care that the oil pas-
sages and coolant passages will not be clogged.
• Take care not to damage the sliding surfaces and mating faces, and remove all dirt, lint, etc. from them.
Apply sufficient oil to the sliding surface before assembling.
• If the coolant is drained, bleed air from the coolant system.
• After repairing, run the engine at high speed and check for leakage of the coolant, fuel, oil, grease, and
exhaust gas.
6. PARTS WHICH NEED TO BE TIGHTENED BY ANGLE TIGHTENING METHOD

• Use angle wrenches (special tools) to tighten the following parts.
• Cylinder head bolt
Check that the cylinder head, cylinder block mounting face, and cylinder head gasket are free from oil
and dirt, and then coat the threads and stem of the cylinder head bolt and tighten it.
7. PRECAUTIONS FOR USING POWER TOOLS

• Use power tools such as an air runner for disassembly only. Do not use them for assembly.
4-2 K-Series
ENGINE MECHANICAL PRECAUTIONS FOR WORK
8. PRECAUTIONS FOR APPLYING

GASKET SEALANT
1) Separation of parts coated with gasket seal-
ant
• After removing the mounting bolts and mounting
nuts, cut and remove the gasket sealant with seal
cutter A (special tool KV101-11100) according to
the following procedure.
[1] Drive in the seal cutter in the direction of the
arrow.
row.
row.
k • Take care not to damage the mating faces.

k • If it is difficult to use the seal cutter, re-
move the gasket sealant by hitting it light-
ly with a plastic hammer.
k • If it is obliged to use a flat-head screwdriv-
er, take extreme care not to damage the
mating faces.
2) Procedure for applying gasket sealant

1. Remove the old gasket sealant sticking to the
mating faces with scraper B.
• Remove all the gasket sealant from the
grooves, mounting bolts, and bolt holes, too.
2. Wipe the mating faces with isoparaffin, etc. to re-
move water, oil, grease, and foreign matter.
3. Install the genuine gasket sealant to tube presser
C (common tool).
4. Apply the gasket sealant to the specified parts

and dimensions without breaking it.
• Apply the gasket sealant to the grooves, too,
if specified so.
• As a rule, apply the gasket sealant to the in-
side of the bolt holes. The outside of the bolt
holes may need to be coated with the gasket
sealant, however. Accordingly, refer to the
manual without fail.
• Install the parts within 5 minutes after apply-
ing the gasket sealant.
• Wipe off the projected gasket sealant imme-
diately.
• Do not retighten the bolts after installing the
parts.
• After installing the parts, wait at least 30 min-
k • If a direction is given in the manual, ob-

utes before supplying engine oil or coolant.
serve it.
K-Series 4-3
ENGINE MECHANICAL OUTSIDE VIEW OF ENGINE
OUTSIDE VIEW OF ENGINE

1. GASOLINE SPECIFICATION
4-4 K-Series
2. GASOLINE AND LPG SPECIFICATION
K-Series 4-5
3. LPG SPECIFICATION
4-6 K-Series
ENGINE MECHANICAL MAIN SPECIFICATIONS
MAIN SPECIFICATIONS
MAIN SPECIFICATIONS
Fuel specification Gasoline Gasoline and LPG
Valve mechanism OHV
Bore x Stroke mm 75.5 × 83
Compression pressure MPa{kgf/cm2}/rpm 1.42{14.5}/250
Fuel (* 1) Lead-free regular At 20P
Max. output kW{HP}/rpm 27.2{36.5}/2,500
Max. torque Nm{kgf•m}/rpm 113{11.5}/1,600
Valve opening/clos- Intake closing (A.B.D.C.) 30

ing timing degree
Intake (Hot) 0.38

Valve clearance mm
Exhaust (Hot) 0.38
On-machine idling ATM 750 – 900

speed rpm
MTM 750 – 900
On-machine high ATM AX : 2,890 BX : 2,970

idling speed rpm
MTM AX : 2,890 BX : 2,970

engine speed rpm

(at delivery)
Dimensions of engine (Length x Width x Height) (* 2) mm 706.7 × 588.6 × 720
*1 : Fuel
-5°C or lower.
K-Series 4-7
Gasoline and
LPG
Valve mechanism OHV
Max. torque Nm{kgf•m}/rpm — 152{15.5}/1,600

closing timing degree
Intake (Hot) 0.38

Valve clearance mm
Exhaust (Hot) 0.38
Ignition timing (for idling) BTDC° — 2

idling speed rpm
MTM — 750 – 900

high idling rpm
speed MTM — 2,940

engine speed rpm

(at delivery)
*1 : Fuel
-5°C or lower.
4-8 K-Series
Gasoline and
LPG
Valve mechanism OHV
Method of engine speed control — Pneumatic governor
Max. torque Nm{kgf•m}/rpm — 186{19}/1,600

closing timing deglee
Intake (Hot) 0.38

Valve clearance mm
Exhaust (Hot) 0.38

idling speed rpm
MTM — 750 – 900

high idling rpm
speed MTM — 2,820

engine speed rpm

(at delivery)
*1 : Fuel
-5°C or lower.
K-Series 4-9
ENGINE MECHANICAL ADJUSTMENT VALUES
ADJUSTMENT VALUES
Item K15 K21 K25
Valve mechanism
Standard
Intake value mm 0.38
Valve clearance
(in hot state)
Standard
Exhaust value mm 0.38

value
Outside diameter of
head
Exhaust Standard mm 32.0 – 32.3
value
Standard
Overall length of
valve
value

value
Outside diameter of
valve stem
Standard
Exhaust value mm 6.945 – 6.960
Free length of Intake Standard

valve spring and value mm 45.9
exhaust
Compression length Intake Standard

when valve is open and value mm/N {kgf} 25.0/347.0 – 391.2 {35.4 – 39.9}
exhaust
Installed length of Intake

valve spring (when and Standard mm/N {kgf} 33.8/177.9 – 200.7 {18.1 – 20.5}
valve is closed) exhaust value
Valve
Leaning of valve Intake Standard

spring and value mm 1.5
exhaust
Standard
value mm 0.015 – 0.048
Intake
Clearance between Limit value mm 0.10
valve stem and valve
guide Standard mm 0.040 – 0.073
value
Exhaust
Limit value mm 0.10
Standard
Width of valve seat
value
Intake
Angle of valve seat and Standard 44° 23' – 45° 07'
exhaust value
Standard
Intake value 45° 15' – 45° 45'
Angle of valve face
Exhaust Standard 44° 30' – 45°
value
4-10 K-Series

Item
Standard
value mm 0.15 – 0.23
End play
Limit value mm 0.40
Front Standard mm 45.434 – 45.447

value
Dimensions Standard
of journal Center value mm 43.897 – 43.910
Rear Standard mm 41.218 – 41.231

value
Standard
Camshaft
mm 0.025 – 0.051
value
Front
Limit value mm 0.10

Oil clearance value
Center
at journal
Limit value mm 0.15
Standard
value mm 0.025 – 0.051
Rear
Limit value mm 0.10
Standard mm 36.750 – 36.800 (Both intake and exhaust)

value
Height of cam
Wear limit
value mm 36.5
Standard
value mm 0.05 – 0.18
End play
Limit value mm 0.20
Crankshaft
Dimensions of journal Standard mm 62.942 – 62.955

value
Standard
Standard dimensions of pin value mm 44.961 – 44.974
Standard
value mm 0.020 – 0.073
Oil clearance at journal
Limit value mm 0.10
Facial runout drive plate
Facial runout of flywheel Limit value mm 0.10
Outside diameter runout

and flywheel
drive plate Limit value mm 0.20
Facial runout of ring gear Limit value mm 0.50
Facial runout Limit value mm 0.30
K-Series 4-11

Item
Distance between centers of both Standard mm 152.47 – 152.53 143.970 –-

end holes value 144.030
Diameter of big end hole Standard mm 48.0 – 48.013

value
Diameter of small end hole Standard mm 19.965 – 19.978

value
Bend (in 100 mm) Limit value mm 0.05

Connecting rod
Torsion (in 100 mm) Limit value mm 0.05

Thrust clearance at big end value
Limit value mm 0.40

Oil clearance at big end value
Limit value mm 0.10
Quantity difference Standard g Max. 5

(Combination of piston) value
Type Thermal flow type
Piston Material Aluminum alloy
Outside Standard mm 75.465 – 75.515 88.965 – 89.015

diameter value
Clearance between piston and Standard mm 0.025 – 0.045

cylinder value
Outside diameter of piston pin Standard mm 19.993 – 19.998

value
Fitting level of piston pin Standard Movable with finger

value
Top Standard mm 0.25 – 0.35 0.28 – 0.43

value
Second Standard mm 0.15 – 0.25 0.45 – 0.60

Closed gap of piston value
Piston
ring
Oil Standard mm 0.20 – 0.60
value
Limit value mm 1.00

of each

Top value
Limit value mm 0.10
Clearance between Standard mm 0.03 – 0.07

piston ring and ring Second value
groove
Limit value mm 0.10
Standard mm —
Oil value
Limit value mm —
Outside diameter of pin Standard mm 19.993 – 19.998

value
4-12 K-Series

Item
Cylinder head
Valve guide Standard mm 7.000 – 7.018 (Common to intake and exhaust)

value
Clearance between valve stem Limit value mm 0.10 (Common to intake and exhaust)
and valve guide
Standard
value mm 75.5 – 75.55 89.00 – 89.05
Bore of cylinder
Wear limit mm 0.2
Taper and ellipse of bore Standard mm 0.2

Cylinder block
value
Top surface Limit value mm 0.05
Intake manifold Limit value mm 0.1

Strain
Exhaust manifold Limit value mm 0.3
Cylinder head Limit value mm 0.1
Cylinder block Limit value mm 0.1
K-Series 4-13
ENGINE MECHANICAL TIGHTENING TORQUE
TIGHTENING TORQUE
1. STANDARD TIGHTENING TORQUE OF BOLTS
Unit: Nm{kgf•m}
Size of thread
Diameter Pitch
3.82 – 4.41 {0.39 – 0.45} 6.37 – 7.45 {0.65 – 0.76} 9.22 – 10.8 {0.94 – 1.1}
M6 1
5.00 – 6.47 {0.51 – 0.66} 8.43 – 10.8 {0.86 – 1.1} 11.8 – 15.7 {1.2 – 1.6}
9.32 – 10.8 {0.95 – 1.1} 15.7 – 17.7 {1.6 – 1.8} 22.6 – 25.5 {2.3 – 2.6}
M8 1.25
12.7 – 15.7 {1.3 – 1.6} 20.6 – 26.5 {2.1 – 2.7} 29.4 – 37.3 {3.0 – 3.8}
19.6 – 22.6 {2.0 – 2.3} 32.4 – 38.2 {3.3 – 3.9} 47.1 – 53.9 {4.8 – 5.5}
1.25
25.5 – 33.3 {2.6 – 3.4} 43.1 – 54.9 {4.4 – 5.6} 61.8 – 78.5 {6.3 – 8.0}
M10
18.6 – 21.6 {1.9 – 2.2} 30.4 – 36.3 {3.1 – 3.7} 44.1 – 52 {4.5 – 5.3}
1.5
24.5 – 31.4 {2.5 – 3.2} 41.2 – 52 {4.2 – 5.3} 58.8 – 74.5 {6.0 – 7.6}
4.9 – 5.69 {0.5 – 0.58} 8.14 – 9.51 {0.83 – 0.97} 11.8 – 13.7 {1.2 – 1.4}
M6 1
5.98 – 7.65 {0.61 – 0.78} 9.81 – 12.7 {10 – 1.3} 14.7 – 18.6 {1.5 – 1.9}
11.8 – 13.7 {1.2 – 1.4} 19.6 – 23.5 {20 – 2.4} 28.4 – 33.3 {2.9 – 3.4}
M8 1.25
Flange bolt
14.7 – 18.6 {1.5 – 1.9} 24.5 – 31.4 {2.5 – 3.2} 35.3 – 45.1 {3.6 – 4.6}
24.5 – 29.4 {2.5 – 3.0} 41.2 – 48.1 {4.2 – 4.9} 59.8 – 69.6 {6.1 – 7.1}
1.25
30.4 – 39.2 {3.1 – 4.0} 51.0 – 64.7 {5.2 – 6.6} 73.6 – 93.2 {7.5 – 9.5}
M10
23.5 – 27.5 {2.4 – 2.8} 39.2 – 46.1 {4.0 – 4.7} 56.9 – 65.7 {5.8 – 6.7}
1.5
29.4 – 37.3 {3.0 – 3.8} 49.0 – 61.8 {5.0 – 6.3} 69.6 – 89.2 {7.1 – 9.1}
k • The following marks are in relief on the heads of bolts to which the above tightening torque can
be applied.
4T --- 4
7T --- 7
9T --- 9
Tightening torque of tapered screws

Unit: Nm{kgf•m}
Material of Aluminum Cast iron
fixed part
Size Standard value Max. value Standard value Max. value
R1/8 7.8 {0.796} 11.8 {1.2} 15.7 {1.6} 21.6 {2.2}
R1/4 19.6 {2.0} 29.4 {3.0} 34.3 {3.5} 44.1 {4.5}
R3/8 39.2 {4.0} 54.9 {5.6} 53.9 {5.5} 73.5 {7.5}
4-14 K-Series
2. TIGHTENING TORQUE OF ENGINE PARTS

1) Tightening torque of engine parts
Unit: Nm{kgf•m}
Cylinder head (coated with oil) Shown separately
Main bearing cage (coated with oil) Shown separately
Crank pulley cap (coated with oil) 220.5 {22.5} 240.1 {24.5}
Flywheel bolt (coated with oil) 132 {13.47} 142 {14.49}
Connecting rod nut (coated with oil) 31.4 {3.2} 37.3 {3.81}
Rear plate bolt 44.1 {4.5} 58.8 {6.0}
Cam sprocket bolt 39.2 {4.0} 49 {5.0}
Oil filter stud 29.4 {3.0} 39.2 {4.0}
Spark plug 19.6 {2.0} 29.4 {3.0}
Rocker cover bolt 13.7 {1.4} 15.7 {1.6}
Exhaust manifold nut 41.2 {4.2} 48.1 {4.91}
Straight screw plug (installed to top of head) 44.1 {4.5} 58.9 {5.5}
Fuel tube flair nut 16.0 {1.63} 23.0 {2.35}
Thormo-housing relief plug 6.37 {0.65} 7.45 {0.76}
K-Series 4-15
2) Cylinder head
For general service, the cylinder head bolts may
be tightened by angle tightening process [5]
shown in the figure at left instead of torque tight-
ening to 68.6 Nm {7.0 kgf•m}.
3) Main bearing cap

a Cap bolt:
83.4 – 93.2 Nm {8.51 – 9.51kgf•m}
a Apply rust-preventive oil or engine oil to the
threads and stem of each bolt.
a Never use a power tool such as an air runner.
4-16 K-Series
ENGINE MECHANICAL TROUBLESHOOTING
TROUBLESHOOTING
1. ADJUSTMENT OF ENGINE

Rattle of bearing or
crank Bend of crankshaft Repair or replace
Uneven wear of journal Repair
Excessive end play Replace center bearing
Rattle of piston and Play of piston pin Replace piston pin or bushing
connecting rod Play of piston on cylinder Select proper one
Breakage of piston ring Replace
Misalignment of rod Align accurately
Noise from engine
Excessive play in axial direction Replace bearing thrust plate

Rattle of cam shaft
Roughness of tooth surface Repair
Breakage of gear Replace
Improper tension Adjust
Breakage or fatigue of chain Replace
Noise of timing chain Wear of sprocket Replace
Fatigue or breakage of tension adjuster Replace
Excessive clearance between cam shaft and bearing Replace
Fatigue of adjustment screw Replace
Rattle of moving valve Wear of rocker surface Replace

system Wear of valve guide Replace guide
Fatigue of valve spring Adjust
Seizure of valve Repair or replace
Improper end play Replace
Rattle of water pump
Breakage of impeller Replace
Improper clearance Adjust
Insufficient clearance between valve stem and guide Clean stem and increase guide
diameter with reamer
Stiffness of valve Fatigue or breakage of spring Replace
Seizure or breakage of valve stem Replace or clean

Fuel of low quality Use fuel of good quality
Deterioration of valve spring Replace
Sharpened valve edge Replace valve
Burn of valve seat Narrow valve seat Repair valve seat
Stiffness of valve guide Repair
K-Series 4-17
ENGINE MECHANICAL TROUBLESHOOTING

Dirty engine oil Clean crankcase and replace oil filter
Oil of low quality Use oil of specified quality
Wrong combination of piston and connecting rod Repair or replace
Excessive wear of Improper piston ring clearance Select and adjust properly
cylinder and piston Breakage of piston ring Replace
Dirt of air cleaner Clean
Too dense mixture of gasoline and air Adjust
Stiffness of choke valve Clean and adjust
Overuse of choke valve Start correctly
Insufficient engine oil Add new oil

Roughness of crankshaft surface Grind surface and replace bearing
Malfunction of Clogging of oil passage Clean
connecting rod
Misalignment of connecting rod Repair or replace
Malfunction of Uneven wear of crankshaft journal Repair
crankshaft bearing Clogging of oil passage on crankshaft Clean
Breakage of bearing Replace
4-18 K-Series
ENGINE MECHANICAL SPECIAL TOOLS
SPECIAL TOOLS
ST052-40001 Engine attachment
ST050-1S000 Engine stand assembly

[1] ST050-11000 Engine stand
[2] ST050-12000 Stand
KV101-041S0 Crankshaft main bearing cap puller

[1] KV101-04110 Crankshaft main bearing puller
[2] ST165-12001 Adapter
[3] ST167-01001 Adapter
ST120-70000 Valve lifter
ST152-4S000 Front oil seal drift

KV101-05500 Rear oil seal drift
ST152-43000 Drift rod
K-Series 4-19
ENGINE MECHANICAL REMOVAL AND INSTALLATION OF ENGINE
REMOVAL AND INSTALLATION OF ENGINE

k • Pay attention to safety and do not perform difficult work.
• Do not perform the work while the temperature the exhaust system and coolant is high.
• Lift up the engine on the specified points.
• For the work items other than the engine, see the related sections.
1. REMOVAL
[Outline of work]
• Remove the transmission, and then lift off the engine.
[Preparation work]
1. Drain the coolant through the radiator drain plug.
2. Remove the following parts
• Undercover and battery
• Radiator, shroud, and radiator hose
• Auxiliary device belt and cooling fan
3. Remove the accelerator cable from the throttle drum and move it.
[Left side of engine compartment]

4. Remove the air duct and air cleaner case.
[Right side of engine compartment]

5. Disconnect the vacuum hose (for brake booster and differential lock) from the engine.
6. Remove the fuel hose.
k • Install a plug immediately to stop the fuel.
7. Disconnect all the wiring harness connectors from the engine and move them toward the chassis.
8. Remove the starting motor.
9. Remove the transmission.
[Removal work]
10. Install the hooks of the chain block to the front and rear engine slinger to support the engine.
k • When installing the hooks to the slingers, take care that the hooks and chains will not interfere
with the chassis and piping.
11. Remove the mounting nuts of the right and left engine mount insulators.
12. Adjusting the position frequently, lift off the engine.
k • While working, check that all the wires and pipes are disconnected.
• Take care that the engine will not interfere with the parts on the chassis.
4-20 K-Series
ENGINE MECHANICAL REMOVAL AND INSTALLATION OF ENGINE
2. INSTALLATION
Taking the following care, carry out installation in the reverse order to removal.
• Take care that each mount insulator will not be stained with oil or damaged.
• Securely insert each positioning pin to the hole of the mating part.
• While each mount insulator is not interfering with other parts, tighten its bolts and nuts.
3. TESTING
• Before starting the engine, check the levels of the coolant, oil, and grease, and add up to the respective spec-
ified levels, if necessary.
• Start the engine and check that it does not make abnormal sounds or vibrations.
• Warm up the engine sufficiently and check that the coolant, oil, grease, fuel, and exhaust gas are not leaking.
K-Series 4-21
ENGINE MECHANICAL SERVICING ENGINE
SERVICING ENGINE
1. DISASSEMBLY OF ENGINE
When working, use correct tools and do not dam-
age the parts. If engine attachment (1) (special
tool) is installed and engine stand (2) (special
tool) is used, you can work easily.
1. Preparation for disassembly of engine

• Drain the coolant and engine oil.
2. Installation of engine attachment
Remove the following parts from the cylinder
block and install engine attachment (1) (special
tool).
• Oil filter
• Engine mount bracket (Right side)
• Fuel tube (and fuel pump in case of carbure-
tor type)
• Oil pressure switch
• Remove the alternator adjustment bar and al-
ternator.
• Using the mounting holes of engine attach-
ment (special tool), tighten the mounting
bracket bolts at least 4 places.
3. Removal of exterior parts and electric parts
Set the engine on the engine stand (2) (special
tool) and remove the following parts.
• Ignition system wiring
• Distributor
• Spark plug
• Oil level gauge
• Cooling fan and pulley
• Starting motor
• Clutch and flywheel
• Rear plate
• Rocker cover
• Crank pulley
• Remove carburetor.
4-22 K-Series
• Remove oil pump drive shaft (together with

distributor).
4. Removal of manifold
• Remove the mounting bolts of the manifold
and head.
• Remove the set of the intake and exhaust
manifolds.
5. Removal of rocker cover and gasket

• Remove the rocker cover mounting nuts.
• Remove the rocker cover.
6. Removal of rocker shaft assembly

• Loosen 4 valve rocker shaft bolts (1) and re-
move valve rocker shaft (2).
• Pull out the push rods.
• Remove and arrange the push rods and oth-
er parts by the cylinders, intake system, and
exhaust system.
• When removing valve rocker shaft (2), short-
en coil springs (3) a little and bind them with
wires A (ø0.5 – 0.8), and then loosen the
bolts so that you can reinstall the rocker shaft
easily. Loosen 4 bolts (1) evenly.
K-Series 4-23
7. Removal of cylinder head assembly

• Pull out the push rods.
• Loosen the cylinder head bolts according to
the figure on the right.
• Remove the cylinder head.
8. Remove the oil pan

Remove the sealant, too.
9. Remove the oil pump and strainer together.
4-24 K-Series
10. Disassembly of PTO unit
1. Crank pully bolt

2. Oil seal
3. Front cover mounting bolt
4. Ball bearing
5. Sprocket (Driven side)
6. Chain
7. Timing sprocket
8. PTO (Drive side)
9. Bush
10. Front cover
11. Crank pully
• Remove the crank pully bolt (1).

• Remove the crank pully (11).
• Remove front cover (12).

• When removing the cover, remove the bolts
and hit the cover lightly with a plastic ham-
mer.
a When installing the cover, apply sealant
(gasket sealant) to the mounting face.
K-Series 4-25
11. Remove the PTO sprockets on the hydraulic

pump side and crankshaft side, PTO chain, and
bearing together.
k • Take care not to damage the chain.
12. When separating the sprocket and bearing on

the hydraulic pump, use the special tools and a
press.
ST3D0-31000: Bearing puller
ST223-60002 : Bearing drift
13. Timing chain cover

• Remove the front oil seal.
• Using the front oil seal drift (special tool), re-
move the timing chain cover from the front
cover.
Special tools:
ST1524-S000: Front oil seal drift
ST1524-3000 : Drift rod
4-26 K-Series
14. Remove the timing chain cover.

15. Remove the chain tentioner (13).
16. Loosen cam sprocket bolt.
17. Pull out cam sprocket (15), crank sprocket (14),
and chain (16) together.
18. If a shim is installed to the crank gear, remove it.
19. Removal of camshaft
• Remove the locating plate.
• Set the cylinder block upside down and lower
the valve lift and pull it out.
• Pull out 2 mounting bolts of the camshaft lo-
cating plate, and then pull out the camshaft.
Take care not to scratch the bearing metal.
• Arrange the parts by the cylinders.
20. Removal of piston and connecting rod
• Remove the connecting rod cap and push out
the piston toward the head with the grip of a
hammer, etc. Take care not to drop the pis-
ton.
• Pull out the piston toward the cylinder block
top deck and install the rod cap to prevent
confusion.
• Arrange the parts by the cylinders.
k • Arrange the connecting rod caps and
bearings by the cylinders to prevent con-
fusion.
21. Loosen the flywheel bolt and remove the fly-
wheel.
22. Remove the rear plate.
23. Removal of crankshaft
• Remove the 4 bolts (18) and rear oil seal re-
tainer (17).
• Remove the main bearing cap bolts and re-
move the bearing cap, hitting it lightly with a
wooden hammer, etc.
k • Arrange the bearing pushes to prevent
confusion of their locations.
K-Series 4-27
24. Using rear oil seal drift A (special tool), remove

the oil seal from oil seal retainer (17).
Special tool A: KV101-05500
25. Remove the crankshaft and bearings.

After removing the bearings, place their respec-
tive caps on the side of the block to prevent con-
fusion.
26. Disassembly of cylinder head

• Using valve lifter B (special tool), remove the
valve spring.
Special tool B: ST120-70000
• When removing the valve lip seal, use the lip
seal puller (special tool).
k • When removing the valve, replace the lip
seal. (Do not reuse the lip seal.)
• Arrange the removed valves, valve collets,
valve retainers, and valve springs by the cyl-
inders.
27. Disassembly of piston and connecting rod
• Disassemble the piston and connecting rod.
• Remove the piston rings.
The oil ring is of combined type. Remove its
upper and lower rails and expander in order.
k • Arrange the pistons, pins, connecting
rods, and pushes to prevent confusion of
combinations.
4-28 K-Series
28. Remove the piston pin.

The piston pin is press fitted to the connecting
rod.
Remove the snap ring first and warm the piston
to 80°C, and then remove the piston pin with pis-
ton pin press stand C (special tool ST130-
30001).
k • Keep the pistons, piston pins, piston
rings, and connecting rods by the cylin-
der.
2. TESTING AND REPAIRING

1. General precautions
• Check each part for damage, distortion,
bend, play, etc. If fault exceeds the limit, re-
pair or replace the parts.
• Before cleaning the cylinder head and block,
check them for traces of water leakage.
• Remove all water scales, sealant, carbon,
etc. from each part.
k • When using a carbon scraper, brush, etc.,
take care not to scratch the sliding surfac-
es.
• After cleaning the oil passages of each part,
blow compressed air against them to check
that they are not clogged.
• Take care not to confuse the combined parts.
• When keeping cleaned parts for a long time,
apply oil to their finished surfaces to prevent
rusting.
2. Intake manifold water jacket
• Check the water jacket connector. If it is
leaking, repair or replace it.
• Check the water hoses. If they are deterio-
rated or damaged, replace them. If water is
leaking through a joint, retighten the clamp.
K-Series 4-29
3. Cylinder head
1) Removal of carbon
Remove carbon from the combustion chamber
and manifold mounting faces. At this time, check
for damage and breakage.
Remove oil, water scales, gasket, sealant, car-
bon, etc. with a scraper.
k • Take care that pieces of the gasket will not
enter the oil and water passages.
2) Measuring strain of cylinder head

• Check the cylinder head visually for cracking and
damage.
• Using straightedge D and feeler gauge E to mea-
sure the strain at 6 places on the underside of the
cylinder head. If the strain exceeds the limit, re-
pair with a surface grinder or replace.
Change of cross level : Max. 0.1 mm
Grinding limit : Max. 0.2 mm
3) Contact of valve seat

• Before performing the following procedure,
check that the dimensions of the valve guide and
valve are in the standard range.
• Apply DAIKATOL PL-1 to the contact surface of
the valve seat to check the contact of the valve.
• Check that the contact surface is not broken
along the periphery.
• If the contact is defective, fit the valve and check
again. If the contact is still defective, replace the
cylinder head.
4-30 K-Series
4. Cylinder block
Measure the strain of the top of the cylinder block
in the lengthwise and crosswise directions.
Measuring strain of cylinder block
• Remove carbon and other foreign matter
from the cylinder block.
(Use straightedge D and feeler gauge E to
measure the strain.)
• Check the surface for cracking and damage.
• Measure the strain at 6 places on the top of
the cylinder block. If the strain exceeds the
limit, repair with a surface grinder or replace.
Strain limit: 0.1 mm
(mm)
Item Standard Limit value

value
Lengthwise 0.05 0.10

Cylinder block
surface
Crosswise 0.02 0.04
5. Measuring cylinder bore

• Using the cylinder bore gauge, measure the
bore at 3 places in directions A and B as
shown in the figure.
• Decide the grade from the measured dimen-
sion in the thrust direction at 65 mm from the
top deck.
Max. difference between A and B: Roundness

Max. difference between top, middle, and bot-
tom: Taper
(mm)
Item Standard value Repair limit
K15 75.5 – 75.55 75.7
Cylinder bore
K21.K25 89.0 – 89.05 89.20
Roundness — 0.2
Taper — 0.2
Difference between — 0.2
cylinder bores
K-Series 4-31
6. Boring and honing

1) Select a piston of a proper size according to the
wear of the inside wall of the cylinder.
Measure the skirt diameter of the piston, and
then bore the cylinder to increase the bore by
0.02 mm.
• Select the piston and cylinder so that the

clearance between them will be 0.025 –
0.045 mm. Measure the clearance at the
normal temperature. If any cylinder needs to
be bored, bore all the cylinders.
2) Calculate of bore of each cylinder
• Diameter of skirt of oversize piston (service
part): Measure dimension H.
• Decide the boring diameter for the cylinder
from dimension H of the piston.
Boring diameter: R = H + C – M
Boring allowance: M = 0.02 mm
Clearance between piston and cylinder
: C = 0.025 – 0.045 mm (20 °C)
R = H + (0.005 – 0.025) mm
• Bore the cylinder to dimension R.
Service pistons list
STD
0.50 OS
1.00 OS
3) Precautions for boring

• Set the cutting depth to about 0.05 mm. Do
not cut much at a time but cut gradually.
• When measuring the bore of the cut cylinder,
note that it is changed by the cutting heat.
• To avoid deformation caused by the cutting
heat, bore the cylinders in the order of No. 2,
4, 1, and 3.
• Make a mark on each piston so that it will be
combined with the proper cylinder.
4-32 K-Series
4) After honing, measure the taper and roundness

of the bore.
5) Measure clearance between piston and cylinder
Enter the piston upside down in the cylinder with-
out installing the piston pin and insert a feeler
gauge of 0.04 mm on the sliding side of the piston
and pull it with a spring balance vertically. If the
clearance is proper, the balance reads 0.5 – 1.5
kg.
Oversize piston
(mm)
Diameter
Piston size
K15 K21, K25
STD 75.465 – 75.515 88.965 – 89.015
0.50 OS 75.965 – 76.015 89.465 – 89.515
1.00 OS 76.465 – 76.515 89.965 – 90.015
Standard values of piston and cylinder
Standard clearance mm 0.025 – 0.045 [20 °C]
Pulling out force of N{kgf} 4.9 – 14.7 {0.5 – 1.5}

feeler gauge
Thickness of feeler
gauge used mm 0.04
7. Measuring wear of piston

• Check the sliding surface of the piston. If it
has traces of seizure, wear, etc., replace it.
• Measuring clearance between piston ring
groove and piston ring
Measure the clearance between the piston
ring groove and piston ring. If it exceeds the
limit, replace the piston and piston ring to-
gether.
(mm)
Item Standard value Limit value
Top ring 0.045 – 0.080 0.1
Second ring 0.030 – 0.070 0.1
Oil ring 0.065 – 0.135
K-Series 4-33
8. Piston ring
• Measuring closed gap of piston ring
• Put the piston ring in the cylinder bore and
measure its closed gap.
(mm)
Standard value
Limit
Item value
K15 K21, K25
Top ring 0.25 – 0.30 0.28 – 0.43 1.0
Second ring 0.15 – 0.25 0.45 – 0.60 1.0
Combined
rail 0.20 – 0.60 0.20 – 0.60 1.0
Measure the closed gap of the piston ring with feeler

gauges. If it exceeds 1 mm, replace the piston ring.
If it is 0.15 mm or less, repair the ends of the piston
ring with an oilstone or replace the piston ring.
k • When replacing only the piston ring with-
out repairing the cylinder bore, measure
its closed gap at the lower part of the cyl-
inder where the cylinder wall is less worn.
9. Piston pin
1) Fitting of piston and piston pin
• The piston pin must rotate at the normal temper-
ature or it must be inserted smoothly.
• If the piston pin is defective, replace it and piston
as an assembly.
Engine model K15, K21, K25
Outside diameter of piston 19.993 – 19.998 mm

pin
10. Connecting rod

1) Measuring bend and torsion
• Measure the bend and torsion of the connecting
rod with a connecting rod aligner. If the bend or
torsion exceeds the limit, replace the connecting
rod.
Service limit : Bend ; 0.05 mm (in 100 mm)
Torsion ; 0.05 mm (in 100 mm)
k • Distance between centers of both end
holes: 152.47 – 152.53 mm (K15, K21)
143.97 – 144.03 mm (K25)
(mm)
(B) 0.05
Bend, torsion, parallelism
(in 100 mm) 0.025
(T) 0.05
4-34 K-Series
11. Weight of connecting rod

1) Adjusting weight
• When replacing a connecting rod, take care that
the difference of weight between the connecting
rod assemblies will be 4 g or less.
2) Measuring thrust clearance of connecting rod
• Using feeler gauges, measure the thrust clear-
ance.
• Measure the side clearance of the connecting
rod. If it exceeds the limit, replace the connecting
rod.
Standard clearance: 0.1 – 0.3 mm
Clearance limit : 0.4 mm
12. Bushings of connecting rod

• Check each bushing for bend, melting, tears,
etc. If it is damaged, replace it.
• Using Plastigauge G, measure the oil clear-
ance.
1) Measuring oil clearance
• How to use Plastigauge G is shown below.
a. Wipe off oil and dust from the inside and out-
side of the bearing and journal surface. Us-
ing rule F, cut Plastigauge G a little shorter
than the width of the bearing and place it on
the journal surface, avoiding the oil hole.
b. Install the bearing cap and tighten it to the
specified torque.
k • Never rotate the crankshaft while the Plas-
tigauge is on the journal surface.
K-Series 4-35
c. Remove the cap and measure the width of

the Plastigauge with the scale printed on the
bag of the Plastigauge.
d. If the oil clearance is larger than the limit, use
an undersize bearing. At this time, the jour-
nal or pin should be ground.
2) Standard values
(mm)
Standard oil Limit of oil Cap tightening
Item clearance clearance torque
Apply oil.
Main 0.02 – 0.073 0.1 83.4 – 93.2 Nm
bearing {8.51 – 9.51 kgf•m}
Connecting 0.032 – Apply oil.

rod bearing 0.066 0.1 31.4 – 37.3 Nm
{3.2 – 3.81 kgf•m}
• If the oil clearance is larger than the limit, grind

the journal and pin with a surface grinder and use
an undersize bearing.
3) Undersize bearings list
(mm)
Connecting rod bearing
Main bearing
K15, K21, K25 Pin diameter
STD STD 44.974 – 44.96
0.08 44.894 – 44.8
0.02 0.12 44.854 – 44.89
0.25 0.25 44.724 – 44.71
0.50
0.75
1.00
13. Crankshaft and bearing

1) Testing crankshaft
• Check the journal and pin of the crankshaft for
damage and wear, and then repair or replace.
Measure the diameter at 4 places of each journal

or pin with a micrometer.
Limit of ellipse and taper of journal and pin: 0.03
k • The ellipse is the difference between the

mm
measured values in directions X and Y

shown in the figure at left.
The taper is the difference between the
measured values in directions A and B
shown in the figure at left.
(mm)
Ellipse and taper 0.01 0.03
4-36 K-Series
2) Measuring bend
• Apply a dial gauge to the center journal and ro-
tate the crankshaft. The bend is 1/2 of the value
measured at this time. If the bend exceeds the
limit, replace the crankshaft.
(mm)
Bend of crankshaft 0.02 0.05
3) Measuring end play of crankshaft

• Measure the end play of the crankshaft just after
tightening the bolts to the specified torque.
• Install the crankshaft and measure the end play.
• If the end play exceeds the limit, replace the main
bearing center bushing.
4) Measurement of end play of main bearing
(mm)
End play 0.05 – 0.18 0.2
5) Crush height of main bearing

• While main bearing (19) is installed, tighten the
bearing cap to the specified torque, and then re-
move it. At this time, the bearing end must be
projected.
Standard: There is crush height H.
6) Crankshaft main bearing

• Test the main bearing bushings.
• The main bearing bushings are classified into 2
types as shown below.
No. 1, 2, 4, 5 are the same.
No. 3 (center) has a thrust bushing.
a Check each bearing set for flaw, fatigue, flaking,
bend, etc. If it has any fault, replace it.
K-Series 4-37
7) Main bearing cap and bearing

• Measuring oil clearance
1. Remove the cap and measure the width of the
Plastigauge with the scale printed on the bag of
the Plastigauge.
2. If the oil clearance is larger than the limit, use an
undersize bearing. At this time, the journal or pin
should be ground.
• Standard values
(mm)
Item Standard oil Limit of oil Cap tightening

clearance clearance torque
Apply oil
Main 0.02 – 0.06 0.1 83.4 – 93.2 Nm
bearing {8.51 – 9.51 kgf•m}
• Main bearing specifications list

(mm)
Undersize Crank journal diameter
0.02 62.922 – 62.935
0.25 62.692 – 62.705
0.50 62.422 – 62.455
0.75 62.192 – 62.205
1.00 61.942 – 61.955
14. Camshaft
1) Testing bend of camshaft
• Apply a dial gauge to the center journal and ro-
tate the camshaft. The bend of the camshaft is 1/
2 of the value measured at this time.
• If the bend exceeds the limit, replace the cam-
shaft.
2) Measuring bend of camshaft
(mm)
Bend of camshaft Max. 0.02 0.05
3) Testing camshaft journal

• Check the camshaft journal for damage, uneven
wear, etc. If it has any fault, replace the cam-
shaft.
• If the wear measured with a micrometer is larger
than the limit, replace the camshaft.
4) Testing camshaft journal
(mm)
Camshaft journal Standard value Limit value
Taper and ellipse Max. 0.01 0.03
Wear of journal — 0.05
4-38 K-Series
5) Measuring cam height

• Apply slide calipers to the cam nose and mea-
sure the cam height.
(mm)
Cam height
(Intake and 36.750 – 36.800 36.5
exhaust)
• Check the oil pump and distributor drive gear,

too. If they are worn extremely or damaged, re-
place the cam shaft.
6) Valve timing
The figure at left is applicable to all the cylinders.
If the valves of any cylinder are out of the speci-
fication, the cam nose is worn or damaged. In
this case, replace the camshaft.
7) Testing cam bushing
• Check the cam bushing for bend, melting, tears,
etc.
• If the cam bushing has any fault, replace it.
8) Measuring clearance of camshaft journal
• Measure the inside diameter of the camshaft
bushing and outside diameter of the camshaft
journal. If any fault is detected, replace the cam-
shaft bushing.
(mm)
Journal
Item No. Standard value Service limit
#1
0.025 – 0.051 0.1
Clearance #3
#2 0.038 – 0.064 0.15
#1 45.472 – 45.485
Inside diameter #2 43.948 – 43.961
of bushing
#3 41.256 – 41.269
#1 45.434 – 45.447
Outside diameter #2 43.897 – 43.910
of journal
#3 41.218 – 41.231
• When replacing the cam bushing, match the oil

holes accurately.
K-Series 4-39
15. Timing sprocket

• Check the cam gear for facial runout.
• Place the camshaft and cam sprocket as-
sembly on V-blocks and measure the facial
runout of the sprocket. If the facial runout ex-
ceeds 0.1 mm, repair or replace the sprocket.
Check the teeth and boss, too. If they are
worn excessively or damaged, replace the
sprocket.
16. Front cover and timing chain housing
• Check the housing mounting face and oil
seal. If they have a fault or damage, repair or
replace the timing chain housing.
17. Valve lifter
• Check the body and cam contact surface of
the valve lifter. If they are worn excessively,
damaged, or melted, replace the valve lifter.
Check the installation of the valve lifter to the
cylinder block, too. If the valve lifter is not in-
stalled properly, replace it.
• Check that valve lifter coated with oil enters
the hole slowly by its weight.
Measuring valve lifter
(mm)
Item Standard value Limit

(range) value
Clearance between valve

lifter and cylinder block hole 0.016 – 0.052 0.1 Measuring bend of push rod
18. Push rod

• Check the push rod. If it is worn excessively,
twisted, or broken, replace it. If it is bent
more than 0.05 mm, repair or replace it.
19. Rocker shaft
• Check the rocker shaft for wear, damage,
bend, etc. If it is worn more than 0.05 mm, re-
place it.
20. Rocker arm and adjustment bolt
• Check the contact points of rocker arm (20)
and adjustment bolt (21) against the valve
stem and rocker shaft (22). If excessive wear
is detected or the clearance of the rocker
shaft exceeds the limit, replace the rocker
arm (adjustment bolt).
(mm)
Limit
Item Standard value value
Clearance between rocker 0.020 – 0.054 0.1

arm and shaft
4-40 K-Series
21. Flywheel
• Check the sliding surface of the flywheel and
the teeth of the ring gear.
• If the flywheel is broken or worn excessively,
repair or replace the flywheel.
• If the ring gear of the flywheel is worn a little,
change its mounting position by 45 degrees.
When replacing the ring gear, heat a new ring
gear to 180°C and install it by shrink fit.
1) Measuring facial runout
• Using a dial gauge, rotate the crankshaft to
measure the facial runout of the flywheel.
• Facial runout limit J is the allowable maxi-
mum value measured at right angles to the
clutch sliding face of the flywheel.
Facial runout limit of flywheel
Facial runout limit J: Max. 0.1 mm
3. ASSEMBLY OF ENGINE
1. General precautions for assembly
• Apply sufficient oil to the sliding parts before
installing.
• Clean each part sufficiently. In particular,
clear the oil passages.
• Replace the gaskets, packings, and oil seals
with new ones, as a rule.
• Be sure to replace the lock plates.
• If tightening torque or tightening order is
specified, be sure to observe it and check the
clearance of each part.
• Be sure to install the bolts, nuts, and washers
correctly (to their original positions.)
• When fitting packings and gaskets, use gas-
ket sealant properly. If it is specified to use
gasket sealant, be sure to use it.
• The tools and work stands used must be free
from dust, soil, oil, etc.
K-Series 4-41
2. Install the piston and connecting rod.

• Install each connecting rod and piston as-
sembly to the specified cylinder.
• Using piston pin press stand C (special tool
ST130-30001), press fit the piston pin to the
piston with a force of 4.9 – 14.7 kN {0.5 – 1.5
t}. At this time, apply a little amount of oil to
the pin and small end of the connecting rod.
• The front mark K of the piston is in the round

hollow of the piston top.
• Install the connecting rod to the piston so that
its projection L will be on the left side when
seen from the front side.
3. Installation of piston rings

• Install the top ring, 2nd ring, and oil ring to the
correct positions.
• Install the oil ring, 2nd ring, and top ring in or-
der.
• The sliding surface of the top ring is plated

with chromium.
• Install the compression ring with manufactur-
er's mark M up.
• The rails of the combined ring are the same.
4-42 K-Series
4. Installation of valve and valve spring

• Set the lip seal with valve oil seal drift (special
tools) and insert the valve, and then install
the valve spring and valve spring retainer in
order.
• Using valve lifter N (special tool), compress
the spring and insert collet.
k • Do not change the combination of each
valve and cylinder. The sliding parts of
different cylinders are worn differently.
• Install the valve spring with the short-
pitch end (painted for distinction) on the
cylinder head side.
• Check that the valve is seated properly
and nothing is caught in it.
5. Assembly of rocker shaft
• Apply engine oil to the sliding surface of the

valve rockers against the rocker shaft and as-
semble as shown in the figure.
• There are 2 types in the valve rockers. Take
care of the positional relation between the
rocker shaft and painted mark of each valve
rocker.
• After assembling, shorten the coil springs a
little and bind the rocker arms with wires P so
that you can install the rocker shaft easily.
Wire P: ø0.5 – ø0.8
K-Series 4-43
6. Installation of cam bushings

Installation of rear bushing
• Using drift Q, drive in rear bushing (23). At this
time set the arrow up and match it to the oil hole
of the cylinder block.
• Since the rear part of the bushing is a little thick-
er, it is press fitted to the block.
7. Installation of crankshaft
• Install the main bearing bushing to the cap.
• The main bearing bushings are classified into
2 types as shown below.
No. 1, 2, 4, 5 are the same.
No. 3 (center) has a thrust bushing.
• Install the crankshaft.
• Install the main bearing cap.
• Install the front bearing cap flush with the cyl-
inder block.
• Apply engine oil to the cap bolts and tighten
them to the specified torque from inside to
outside as shown in the figure at left.
• After tightening each bolt, check that the
crankshaft rotates lightly.
: 83.4 – 93.2 Nm {8.5 – 9.5 kgf•m}
Reference:
• Cranking torque: Max. 14.7 Nm {1.5 kgf•m}
k • The front side is indicated by the arrow (in
relief) and the positions are indicated by
the stamped numbers.
8. Installation of rear oil seal retainer

• Install the oil seal to rear oil seal retainer (17).
Use special tool A (KV101-05500) to drive in
the oil seal.
4-44 K-Series
• Install rear oil seal retainer (17) to the cylin-

der block.
• Tightening torque of rear oil seal
retainer bolt (18):
20.6 – 26.5 Nm {2.1 – 3.7 kgf•m}
k • When installing the rear oil seal retainer,

apply gasket sealant to it as shown in the
figure.
• Once the retainer is stuck and the bolts
are tightened, do not retighten or remove
and retighten those bolts.
• Apply gasket sealant along the groove of
the sticking face without making a void
and apply it to the bolt holes without pro-
jecting it from the inside end face as
shown in the right figure.
• Install the retainer within 5 minutes after
applying the gasket sealant.
• Leave the retainer for at least 30 minutes
after installing it.
Precautions before applying gasket sealant:
• Remove all water, oil, grease, dirt, dust, etc. from
the installing faces (both sides).
• When removing and installing the retainer again
after installing it once, remove all the gasket seal-
ant from the flange face, installing faces, and
mounting screws.
9. Installation of piston
1) Install the bearing to the connecting rod.
2) Install the connecting rod and piston sub-assem-
bly for each cylinder. At this time, check that cyl-
inder No. of the sub-assembly and that of the
cylinder are the same.
3) Install the piston with the front mark toward the
front.
4) Set the crank pins to the top dead center bottom
dead center.
5) Using piston ring compressor R (special tool
EM034-70000), insert the piston in the cylinder
block.
k • Do not mistake the front direction of the
piston.
6) When installing, match the match marks of the
connecting rod and connecting rod cap.
k • Install silicone rubber tubes, etc. to the
ends of the connecting rod bolts so that
the crank pins will not be damaged when
piston is inserted in the cylinder block.
K-Series 4-45
7) Tighten the connecting rod cap.

Connecting rod cap bolt:
31.4 – 37.3 Nm {3.2 – 3.8 kgf•m}
(K15, K21, K25)
10. Installation of valve lifter

• Install the valve lifter in the correct direction.
Apply a little amount of oil to it and push it in
the cylinder block hole with the fingers.
11. Installation of camshaft
1) Put the camshaft in the cam hole softly, taking
care not to damage the bearing bushing.
2) Tighten the locating plate bolt to the specified
torque.
M6 with stem of 16.7 :
8.43 – 10.8 Nm {0.86 – 1.1 kgf•m}
12. Installation of timing chain and sprocket

1) Tighten the cam bolt.
: 39.2 – 49 Nm {4.0 – 5.0 kgf•m}
2) Check the height of the ends of the cam gear and
crank gear. If necessary, adjust it by inserting
shims on the crankshaft side.
3) Install the sprocket and timing chain simulta-
neously, matching their match marks as shown in
the figure.
13. Installation of timing chain tensioner

• Install chain tensioner (24).
• When installing chain tensioner (24), match
its oil hole to that of the block and set the ten-
sioner spindle shoe (made of synthetic rub-
ber) in parallel with the chain.
k • If the shoe is installed in the opposite di-
rection, the tensioner bolt cannot be tight-
ened and the tensioner will be broken.
M6 with stem of 35 :
8.43 – 10.8 Nm {0.86 – 1.1 kgf•m}
4-46 K-Series
14. Installation of timing chain housing

• When installing the timing chain housing, ap-
ply gasket sealant to it as shown in the figure.
15. Testing and installation of hydraulic pump

sprocket and chain
PTO unit
Testing
• Sprocket (Hydraulic pump side)
If the teeth have harmful flaws or extreme wear or
if the spline has stepped wear, replace the
sprocket.
• Sprocket (Crankshaft side)
If the teeth have harmful flaws or extreme wear,
replace the sprocket.
• Ball bearing
If the bearing has play or a hitch, replace it.
• Chain
If the chain has a harmful flaw on its link or it is
lengthened extremely (and abnormal sound or
rattle is heard when the tilt lever is operated) or it
is worn extremely, replace it.
Assembly
• Install the oil seal to the front cover.
Using the front oil seal drift (Special tool: ST152-
4S000), drive in the oil seal.
k • Apply grease to the lip of the oil seal and
drive in the oil seal, taking care not to lean
it.
• Install the bearings to the sprocket on the loading
pump side.
The bearings in front and rear of the sprocket are
the same. Install them with the press used for
disassembly.
K-Series 4-47
• Install the sprocket and chain assembly.

Install the chain to the sprocket and install them
as an assembly to the crankshaft and timing
chain housing.
• Wipe off the used grease from the spline of the
hydraulic pump and apply new molybdenum
grease.
• Install the front cover.
• Install crank pulley bushing (25) for the crank an-
gle sensor.
• When installing the front cover, apply gasket

sealant to it as shown in the figure.
a See INSTALLATION OF REAR OIL SEAL
RETAINER.
M8 bolt with stem of 25.7T :
20.6 – 26.5 Nm {2.1 – 2.7 kgf•m}
16. Installation of crank pulley

1) Install the crank pulley, matching its mounting
claw to the groove of the bushing.
2) Fit the washer, apply engine oil to the crank pul-
ley bolt, and tighten the crank pulley bolt.
Crank pulley bolt:
220.5 – 240.1 Nm {22.5 – 24.5 kgf•m}
17. Installation of cylinder head

1) Drive dowels (2 pieces) into the head bolt holes
at both ends of cylinder block top.
2) Place the copper plate on the block top with the
head gasket side on the block side.
4-48 K-Series
3) Place the cylinder head, apply engine oil to the

cylinder bolts, and tighten the cylinder bolts to the
specified torque according to the order shown in
the figure at right.
k • Check the tightening angle with an angle
wrench (special tool) or a protractor. Do
not check it visually.
• For service, the cylinder head bolts may be tight-
ened to 68.6 Nm {7.0 kgf•m} in above process [5].
4) Installation of push rods
18. Installation of rocker shaft assembly

1) Place each push rod securely on the receiving
part of the valve lifter.
2) Install the rocker shaft assembly.

: 17.64 – 21.56 Nm {1.8 – 2.2 kgf•m}
k • Tighten the rocker shaft mounting bolts
from inside to outside evenly.
K-Series 4-49
3) Adjust the valve clearance.

Valve clearance (intake and exhaust): 0.38 mm
(in hot state)
k • The valve clearance must be adjusted in
the hot state. It should be adjusted tem-
porarily in the cold state, however, for the
ease of the final adjustment.
4) Install the rocker cover.
: 13.7 – 15.7 Nm {1.4 – 1.6 kgf•m}
19. Installation of engine exterior parts

• Install the oil pressure switch.
• Installation of oil pump (for all types) and dis-
tributor (for carburetor type)
1) Set the crank angle to the top dead center of cyl-
inder No. 1.
2) Insert the distributor so that the center of its

flange hole will be almost at the screw hole on the
cylinder block side. (Do not turn the distributor.)
3) Match the groove of the drive shaft of the engine

lubricating oil pump.
• Set the groove of the oil pump shaft at part U
vertically.
4-50 K-Series
4) Match the gear mark of the distributor to the short

mark on the housing side.
k • Do not match the gear mark to the gear
mounting pin or long mark.
5) Tighten the mounting bolts temporarily.
6) After installing to the chassis, adjust the ignition
timing with a timing light. Then, tighten the
mounting bolt permanently.
Idling speed and ignition Carburetor specification
timing (BTDC°/rpm) K15 4/850
K21 2/850
K25 0/850
7) Installation of oil pan

• When installing the oil pan, apply gasket
sealant to its flange as shown in the following
figure.
• Tighten the oil pan bolts to the specified

torque according to the order shown at right.
• Oil pan mounting bolt (M6 with stem
of 12 7T) :
8.43 – 10.8 Nm {0.86 – 1.1 kgf•m}
8) Installation of flywheel housing (or rear plate)
• Install the flywheel housing.
• Housing bolt
44.1 – 58.8 Nm {4.5 – 6.0 kgf•m}
9) Installation of flywheel
• Install the flywheel.
• Flywheel bolt:
132 – 142 Nm {13.47 – 14.49 kgf•m}
(Apply engine oil to the seat and threads of
the bolt.)
• Rotate the crankshaft and check the runout
of the flywheel with a dial gauge.
Measuring point Limit value
Part X 0.1 mm
K-Series 4-51
20. Other parts

• Install the fuel pump and piping (Carburetor
type).
• Install the oil filter.
(For the installation method, see page 2-10.)
• Install the oil level gauge. (Only carburetor
type)
• Install the thermostat.
• Install the thermal transmitter and heater

connector.
• Install the spark plug.
: 18 – 24 Nm {1.8 – 2.4 kgf•m}
• Installation of distributor negative pressure
control tube (Carburetor type)
• Installation of high-tension cable
• Remove the engine from the engine attach-
ment.
• Install the left engine mount bracket.
• Install the right engine mount bracket.
• Install the alternator and adjustment bar.
• Install the fan belt and fan.
• Adjust the fan belt.
(For the adjustment procedure, see chapter
2.)
4-52 K-Series
5. ENGINE LUBRICATION & COOLING SYSTEMS
Lubrication system ............................................... 5-2

Engine cooling system ......................................... 5-6
K-Series 5-1
ENGINE LUBRICATION & COOLING SYSTEMS LUBRICATION SYSTEM
LUBRICATION SYSTEM
1. SPECIFICATIONS
Main specifications
Lubrication method Forced supply method
Oil pump Spur gear type
Oil filter Full-flow cartridge type
2. ADJUSTMENT VALUES
Oil pump Unit: mm
Clearance between pump gears and body Max. 0.4
Backlash between pump gears Max. 0.5
Vertical clearance of pump gears Max. 0.3
3. OIL PRESSURE
Oil pressure Unit: kPa {kgf/cm2}
At idle 98 {1.0}
Discharge pressure
(Oil temperature: 80°C)
At 2,000 rpm 274 – 313 {2.8 – 3.2}
4. TIGHTENING TORQUE Unit: Nm {kgf•m}

Oil pump mounting bolt 15.7 – 17.7 {1.6 – 1.81}
Oil pump cover bolt 6.37 – 7.45 {0.65 – 0.76}
Oil pan bolt 6.37 – 7.45 {0.65 – 0.76}
Oil pan drain plug 29.4 – 39.2 {3.0 – 4.0}
5-2 K-Series
5. TROUBLESHOOTING
• Cracking or breakage of pump body cover Replace

• Oil leakage through gasket and oil seal Replace
• Oil leakage through near spindle support Replace seal and O-ring or check and
replace spindle support if necessary
• Oil leakage through near distributor Replace seal and O-ring or check and
replace distributor if necessary
• Oil leakage through between timing chain Disassemble and reassemble and apply
housing and cylinder block gasket sealant again
• Oil leakage caused by looseness of rocker Retighten
Oil leakage cover mounting nuts
• Oil leakage caused by looseness of oil Retighten
pan mounting bolts
• Oil leakage through crankshaft front oil Replace
seal
• Oil leakage through crankshaft rear oil Replace
seal
• Oil leakage through regulator valve Retighten or replace
• Oil leakage through blind plug of lubrica- Replace of retighten
tion system
• Looseness of oil filter Retighten
• Overheating Shown above
• Malfunction of oil pump Overhaul or replace oil pump
• Defective installation of oil pump Retighten
• Breakage of oil pump gasket Replace
• Malfunction of oil filter Replace
Lighting of engine caution
lamp
• Looseness of rocker shaft bracket Retighten mounting bolts
• Trouble in pressure switch of oil pressure Replace
gauge
• Malfunction of oil pressure switch Replace
• Insufficient oil in oil pan Add oil and remove cause of reduction of oil
• Looseness of oil pan drain plug or break- Retighten or replace
age of gasket
• Trouble in electrical system Check electric circuit
Noise • Increase of backlash of pump rotor Replace
K-Series 5-3
6. LUBRICATION SYSTEM DRAWING
5-4 K-Series
7. OIL PUMP
Disassembly drawing
Testing
1. Check the following parts for wear and breakage.
• Body and cover of pump
• Pump gear
• Drive spindle
The gear and body of the pump cannot be re-
paired separately. If either gear or body of the
pump is worn or broken, replace the drive shaft
set or oil pump set.
2. Using feeler gauges, check the following clear-

ances.
If any of these clearances exceeds the limit, re-
place the drive shaft set or oil pump set.
Clearance between pump gears and body:
Max. 0.4 mm
Backlash between pump gears: Max. 0.5 mm
Vertical clearance of pump gears: Max. 0.3 mm
3. Check the regulate valve spring of the oil pump.

If it is damaged, replace it or the pump unit.
Free length: 41.5 ± 1 mm
Limit value: 40.0 mm
K-Series 5-5
ENGINE LUBRICATION & COOLING SYSTEMS ENGINE COOLING SYSTEM
ENGINE COOLING SYSTEM

1. SPECIFICATIONS
Cooling method Cooling with forcibly circulated water
Water pump Centrifugal type
Thermostat Wax pellet type
2. ADJUSTMENT VALUES
Water pump Unit: mm
Deflection of fan belt
11 – 13
(When pressed with 98 N {10 kgf})
Thermostat
Item Standard specification
Valve opening angle °C 76.5
Max. lift mm/°C 8/90
3. TIGHTENING TORQUE Unit: Nm {kgf•m}

Water pump mounting bolt M8 15.7 – 17.7 {1.6 – 1.81}
Water pump mounting bolt M6 6.37 – 7.45 {0.65 – 0.76}
Thermostat housing bolt 15.7 – 17.7 {1.6 – 1.81}
5-6 K-Series
4. TROUBLESHOOTING
• Water leakage through water pump shaft Replace water pump assembly
seal
• Water leakage through packing of water Retighten or replace packing
pump mounting face
• Water leakage through radiator cap Replace packing or assembly
• Water leakage through water temperature Retighten or replace
Water leakage sensor
• Looseness of connecting parts Retighten
• Damage of head gasket Replace and check dirtiness of engine oil
• Cracking of cylinder block Replace and check dirtiness of engine oil
• Cracking of cylinder head Replace
• Looseness of head bolts Retighten
• Insufficient flow in coolant circuit Remove dirt and rust from coolant circuit
and check hose clamps
Defective circulation of cool-
ant • Malfunction of water pump Replace
• Malfunction of thermostat Replace
• Many impurities in coolant Use clean soft water
Corrosion
• Insufficient cleaning of coolant circuit Flush circuit frequently at fixed intervals
• Radiator fin clogged with mud or dirt Clean with compressed air
• Defective ignition timing and valve timing Adjust ignition timing and valve clearance
• Dirt and sludge in engine oil Clean inside of engine and add oil
• Malfunction of water pump Replace
Overheating • Looseness of fan belt Adjust tension
• Clogging of radiator Clean inside of radiator
• Low accuracy of water temperature gauge Replace
• Air in cooling circuit Bleed air
• Dirtiness of coolant Use clean soft water
Overcooling
• Defective water temperature sensor Replace
• Abnormal sound from water pump Replace
Noise mechanical seal
• Wear or breakage of water pump bearing Replace
K-Series 5-7
5. COMPOSITION OF COOLING SYSTEM
6. WATER PUMP
1. Open the drain plug of the radiator and receive
the coolant in a proper container.
2. Remove the radiator shroud.
3. Loosen the fan belt.
• Loosen the alternator adjustment bolt.
• Move the alternator fully toward the engine.
• Remove the fan and fan pulley.
• Remove the water pump and gasket togeth-
er.
5-8 K-Series
Testing
The water pump cannot be disassembled. If it has
any trouble, replace it.
1. Check the vanes of the water pump for rust and
pitting.
2. Check the end play and operation of the water

pump bearings.
Installation
1. Install the water pump by carrying out installation
in the reverse order to removal. Be sure to use a
new gasket.
2. Adjust the fan belt tension.
(For the adjustment values, see chapter 2)
k • When supplying new coolant, be sure to
loosen the air bleeding plug.
• After supplying new coolant, be sure to
tighten the air bleeding plug.
7. THERMOSTAT
Removal
1. Disconnect the radiator upper hose from the wa-
ter outlet to discharge the coolant.
2. Remove the water inlet and thermostat.
K-Series 5-9
Testing
Test the thermostat according to the following proce-
dure, and then replace it if necessary.
1. Check the seating condition of the valve at the
normal temperature. The valve must be in con-
tact with the seat.
2. Put the thermostat in a container and heat it to
check the valve opening temperature and maxi-
mum lift of the valve.
k • Do not touch the thermostat, container,
and water while they are still hot. You may
be scalded.
3. Check that the valve closing temperature is about
5°C lower than the valve opening temperature.
Perform this check, too, when installing a new
thermostat to the engine.
Installation
Carry out installation in the reverse order to removal.
Be sure to use a new water inlet gasket.
5-10 K-Series
6. FUEL SYSTEM
Unit layout .......................................................... 6- 2

Service data and specifications.......................... 6- 6
Troubleshooting for LPG fuel system ................. 6- 7
Fuel system disassembly and assembly............ 6- 8
Structure and operation of vaporizer.................. 6-11
K-Series 6-1
FUEL SYSTEM UNIT LAYOUT
UNIT LAYOUT
GASOLINE ONLY SPECIFICATION
GASOLINE AND LPG SPECIFICATION
6-2 K-Series
LPG ONLY SPECIFICATION
K-Series 6-3
LAYOUT OF VACUUM PIPING

Carburetor type
1) LPG specification
2) Gasoline specification
6-4 K-Series
RUN-ON PREVENTION VC HOSE

(ONLY LPG SPECIFICATION AND GASOLINE AND LPG SPECIFICATION)
1) Hose piping drawing
2) Gasoline piping
K-Series 6-5
FUEL SYSTEM SERVICE DATA AND SPECIFICATIONS
SERVICE DATA AND SPECIFICATIONS

1. CARBURETOR SPECIFICATION
Fuel pump: Min. 1,100 ml (at 2,000 rpm)
Fuel pump discharge pressure: 16.7 – 23.5 kPa {0.17 – 0.24 kgf/cm2}
Fuel discharge pressure: Atmospheric pressure
Vaporizer (with secondary chamber and built-in water heater)
1) Carburetor
Engine model K15 K21 K25
Carburetor model 210030-40 210030-41 210030-42

Automatic choke Automatic choke Automatic choke
Type of choke valve valve (Hot water valve (Hot water valve (Hot water
auto-return type) auto-return type) auto-return type)
Inlet diameter mm 57 57 57
Outlet diameter mm 30 30 30
Large 22 24 26
Venturi diameter Small (Inside diameter/
12/16.5 12/16.5 12/16.5
Outside diameter)
Main jet #110 #116 #122
Main air bleed #80 #60 #60
Slow jet #44 #48 #54
Slow air bleed (No. 1/No. 2) #80/#240 #80/#140 #80/#150
High position (H1) from float chamber top mm 22 22 22
Low position (H2) from S/V nozzle hole bottom mm 14.9 14.9 14.9
2) Governor
Type Pneumatic
Speed control method By quantity of air-fuel mixture
Control mechanism Negative pressure type
Allowable momentary max. engine speed under no load rpm 3,600
Allowable continuous engine speed under load rpm 3,000
Allowable number of hunting times 3 (Max.)
6-6 K-Series
FUEL SYSTEM TROUBLESHOOTING FOR LPG FUEL SYSTEM
TROUBLESHOOTING FOR LPG FUEL SYSTEM

Trouble Causes Remedy
Looseness of pipe joints Tighten

Malfunction of vaporizer Repair and adjust
Fuel leakage Defective fitting of plunger rubber seat of sole- Clean and fit
noid valve and valve seat or foreign matter
between them
Malfunction of lock-off mechanism Adjust
Looseness of pipe joints Retighten and adjust
Primary chamber pressure is too high while Clean and adjust
Excessive fuel con- engine is idling
sumption Clogging of air cleaner Clean
Improper adjustment of main adjustment screw Adjust
of LPG mixer
Looseness of pipe joints or clogging of filter Clean and retighten
Improper adjustment of primary and secondary Adjust
Low output
Improper adjustment of main adjustment screw Adjust
of LPG mixer
Use of improper fuel Use proper fuel
Clogging of fuel passage Clean
Improper opening of vaporizer idle adjustment Adjust
screw or carburetor throttle valve
Unstable or improp-
erly adjusted idling
Malfunction of vaporizer valve (Closed improp- Clean and adjust or replace
erly)
Malfunction of vaporizer Adjust
Hunting of engine
Improper adjustment of idling speed Adjust
Insufficient fuel level Add fuel
Improper operation Check that manual valve is open
Malfunction of solenoid valve Check and repair wiring, switches, and solenoid
Trouble in start of valves
engine
Malfunction of vaporizer Replace
Trouble in water pump Repair and adjust
Improper adjustment of idling speed Adjust
Improper adjustment of primary and secondary Adjust
Leakage through primary and secondary valve Clean and adjust or replace
seats of vaporizer
Breakage of diaphragm Replace
Malfunction of
Foreign matter in vaporizer Clean and adjust
vaporizer
Leakage caused by looseness of set screw Tighten
Overcooling of vaporizer (Accumulation of water Check, clean and adjust
scales, breakage of hose, or defective circulation
of coolant)
Accumulation of tar on valve Remove tar and clean
K-Series 6-7
FUEL SYSTEM FUEL SYSTEM DISASSEMBLY AND ASSEMBLY
FUEL SYSTEM DISASSEMBLY

P/REO – Fuel hose
AND ASSEMBLY
Fuel hose
Install the fuel hose according to the following proce-
dure.
1. Tighten the clamp at least 1 mm apart from the
hose end while the hose end is at the position
shown in the figure.
2. Secure the hose insertion allowance of at least
28 mm.
3. Tighten the clamp at least 1 mm apart from the
hose end while the fuel tube assembly is installed
the engine.
4. After installing the fuel hose, its bending radius
must be at least 70. Fuel tube – Fuel hose
5. After installing the fuel hose, it must not be twist-
ed.
6. After installing the fuel hose, the level difference

(offset) between the pipes must not exceed 3
mm.
Precaution for tightening clamp

The clamp must not be set over the bulge of the fuel
tube. (If it may be set over the bulge, stop the work.)
6-8 K-Series
1. OUTLINE DRAWING OF LPT DEVICE (LPG SPECIFICATION AND GASOLINE/LPG

SPECIFICATION)
K-Series 6-9
2. PARTS AROUND CARBURETOR AND PNEUMATIC GOVERNOR (CARBURETOR

SPECIFICATION)
1. Air horn 7. Insulator

2. Nut 8. Insulator
3. O-ring 9. Pneumatic governor
4. Spacer 10. Wave washer
5. O-ring 11. Nut
6. Stud 12. Carburetor
6-10 K-Series
FUEL SYSTEM STRUCTURE AND OPERATION OF VAPORIZER
STRUCTURE AND OPERATION OF VAPORIZER

1. PRIMARY (PRESSURE REDUCING) CHAMBER
In this chamber, the high-pressure fuel from the LPG cylinder is reduced to about 29.4 kPa {0.3 kgf/cm2} and
vaporized.
1. Primary (Pressure reducing) chamber A. From LPG cylinder

2. Primary diaphragm B. To secondary chamber
3. Hook
4. Primary diaphragm spring
5. Primary valve lever
6. Primary valve
7. Primary valve seat
• The fuel is supplied from the LPG cylinder phragm spring (4) becomes higher than the fuel
through the LPG solenoid valve to vaporizer A. pressure and the primary diaphragm (2) is
• To reduce the fuel pressure, the fuel from the so- pushed down.
lenoid valve is supplied through the clearance • Accordingly, hook (3) pushes down one side of
between primary valve (6) and primary valve seat primary valve lever (5) to open primary valve (6)
(7) to the primary pressure reducing chamber. and let the fuel flow in.
• Since the pressure of the fuel supplied to the pri- • The pressure in the primary chamber is kept at
mary chamber is higher than 29.4 kPa {0.3 kgf/ about 29.4 kPa {0.3 kgf/cm2} by repeating the
cm2}, primary diaphragm (2) pushes up dia- above operation.
phragm spring (4).
• Accordingly, hook (3) moves to raise one side of
primary valve lever (5). As a result, the force to
press primary valve (6) against primary valve
seat (7) is increased to stop the flow of the fuel.
• If the fuel in the primary chamber is consumed
and the pressure in the primary chamber lowers
below 29.4 kPa {0.3 kgf/cm2}, the tension of dia-
K-Series 6-11
• Set the primary valve lever (5) to the value shown

in the figure at right.
1) Testing pressure
Test the pressure in the primary chamber accord-
ing to the following procedure.
1. Remove the test hole plug of the primary cham-
ber and install a pressure gauge through a proper
connector.
2. Start the engine and test the pressure in the pri-
mary chamber.
Standard pressure:
19.6 – 35.3 kPa {0.20 – 0.36 kgf/cm2}
3. If the measured pressure is out of the specified
range, adjust it with the pressure adjustment
screw.
k • When reinstalling the test hole plug, apply
sealant to it to maintain airtightness.
2) Adjusting idling speed of carburetor/LPG spec-

ification
1. Set the idling adjustment screw of the vaporizer
so that the engine speed will be highest.
2. Adjust the idling speed into the specified range
with the throttle adjustment screw of the carbure-
tor.
3. Repeat above steps 1 and 2 until the idling speed
is stabilized most.
3) Removing impurities
• LPG contains incombustible materials (such as
tar). If they are left, they are accumulated in the
vaporizer and can cause a malfunction of the fuel
system.
• To prevent this, open the drain plug to discharge
those materials periodically while the engine is
hot. When the engine is cooled down, those ma-
terials are solidified.
6-12 K-Series
4) Disassembly, assembly, and testing

After assembling all the parts, check all the joints
for leakage.
5) Disassembly of primary chamber 1. Primary pressure adjusting screw

1. Remove the cover mounting screws of the prima- 2. Primary diaphragm spring
ry chamber to remove the cover (17). 3. Primary diaphragm
2. Remove the primary diaphragm spring (2). 4. LPG inlet connector
3. Remove the primary diaphragm (3) carefully in 5. LPG outlet connector
the opposite direction to the flow-in direction of 6. Pressure test hole plug
the LPG. 7. Secondary valve lever assembly
4. Remove the primary valve lever (16) as a assem- 8. Idle adjusting screw
bly. 9. Secondary chamber cover
5. Blow off dust and dirt from all the removed parts 10. Secondary diaphragm
with dry compressed air. 11. Negative pressure lock diaphragm
6. Wipe off sulfur and tar from the parts. 12. Negative pressure lock spring
7. Assemble the parts in the reverse order to disas- 13. Body
sembly. 14. Drain valve
k • Check that the diaphragm hook is secure-
15. Radiator hose
16. Primary valve lever assembly
ly engaged with the lever.
17. Primary chamber cover
• While assembling, pull up lever (16) and
supply compressed air of about 392 kPa
{4 kgf/cm2} through the inlet of the vapor-
izer to check that the primary valve is
seated normally. If air leaks, replace the
parts.
K-Series 6-13
2. OUTLINE
The vaporizer has 3 functions of vaporizing the fuel, The hot water in the radiator is used to prevent freez-
reducing the fuel pressure, and keeping the pressure ing of the vaporizer caused by the heat of vaporiza-
constant. tion of the fuel.
Vaporizer of carburetor specification
6-14 K-Series
3. SECONDARY VALVE CHAMBER

In this chamber, the fuel pressure is reduced to
almost the atmospheric pressure to prevent fuel
from flowing in too much for the air sucked in the
carburetor.
1. Secondary valve seat A. From primary chamber

2. Vacuum lock-off diaphragm spring B. Gas outlet
3. Vacuum lock-off chamber
4. Vacuum lock-off diaphragm
5. Secondary diaphragm
6. Balance spring
7. Secondary (Pressure reducing) chamber
8. Secondary valve lever
9. Balance lever
10. Secondary valve lever spring
11. Secondary valve
Each part: • As a result, secondary valve (11) opens and the

LPG pipe flare nut: 18 – 26 Nm {1.8 – 2.7 kgf•m} fuel flows in.
Hot water pipe clamp: 35 – 83 Nm {3.5 – 8.5 kgf•cm} While the engine is stopped, negative pressure is
Clamp between hose and adapter: not applied from the air intake manifold. Accord-
53 – 113 Nm {5.4 – 11.6 kgf•cm} ingly, secondary diaphragm (5) is pressed down
by valve lever spring (10). As a result, the sec-
• The fuel reduced to about 29.4 kPa {0.3 kgf/cm2} ondary valve is closed to stop the fuel from flow-
is supplied through the clearance between sec- ing in.
ondary valve (11) and valve seat (1) to the sec-
ondary chamber (7), where it is reduced to
almost the atmospheric pressure.
• While the engine is running, secondary dia-
phragm (5) is raised by the negative pressure
from the air intake manifold. Secondary valve le-
ver (8) is also raised to move secondary dia-
phragm (5).
K-Series 6-15
1) Vacuum lock-off mechanism

• If the engine is started, vacuum lock-off dia-
phragm (4) is pulled toward the vacuum lock-off
chamber (3), and then the secondary valve lever
(8) moves against the vacuum lock-off dia-
phragm spring.
• This operation gives a stress to the balance
spring (6) installed to secondary valve balance
lever (9) and also give a stress to secondary
valve lever spring (10) to lift up secondary valve
(11) a little from valve seat (1).
As a result, the fuel flows from the primary cham-
ber to the secondary chamber and the engine
starts.
• While the engine is running, vacuum lock-off dia-
phragm (4) is pulled toward the vacuum lock-off
chamber (3). As a result, the secondary valve le-
ver (8) operates, regardless of the position of the
vacuum lock-off diaphragm (4).
2) Removal and installation

1. Fully close the LPG cylinder outlet valve.
2. Run the engine until the fuel in the fuel piping is
used up.
3. Drain all the coolant from the engine.
4. Remove the hot water piping from the vaporizer.
5. Remove the connector and negative pressure
piping of the vaporizer.
6. Remove the bolts mounting the vaporizer to the
bracket, and then remove the vaporizer.
7. Carry out installation in the reverse order to re-
moval.
k • When installing the LPG connector after
removing it from the vaporizer, use the
special sealant.
• Set the secondary valve lever to the value shown

in the figure at right.
6-16 K-Series
3) Disassembly, testing, and assembly of sec-

ondary chamber
1. Remove the secondary valve chamber cover.
2. Remove the secondary diaphragm. Take care
not to scratch it.
3. Remove the secondary valve lever assembly and
spring.
4. Remove the negative pressure diaphragm and
spring.
5. Check that the removed parts are normal.
6. Carry out installation in the reverse order to re-
moval.
• Check that the secondary diaphragm and sec-

ondary valve lever are connected securely.
• Supply air of about 392 kPa {4 kgf/cm2} through
the fuel inlet of the primary chamber to check for
leakage. If leakage is detected, replace the sec-
ondary valve lever assembly.
K-Series 6-17
7. ENGINE CONTROL
Precautions for work ............................................ 7-2

Troubleshooting ................................................... 7-3
Blow-by gas control system ................................. 7-6
K-Series 7-1
ENGINE CONTROL PRECAUTIONS FOR WORK

1. GENERAL PRECAUTIONS FOR MAIN-
TENANCE WORK
• Even if the key switch is turned OFF, the bat-
tery voltage can break the control unit. Ac-
cordingly, when disconnecting and connecting
the wiring harness of the control unit, turn the
key switch OFF and disconnect the cable from
the negative (–) terminal of the battery.
• If the lead pins of a circuit tester are applied

to parts near each other, they may touch
each other. If they touch each other, a short
circuit is made and the battery voltage may
be applied to the control unit to break the
power transistors in the control unit. Accord-
ingly, select measuring points which are
apart from each other as long as possible.
7-2 K-Series
ENGINE CONTROL TROUBLESHOOTING
TROUBLESHOOTING
K-Series 7-3
TROUBLES, ENGINE SYSTEM, AND AUXILIARY DEVICE PARTS SYSTEM

A summary of the troubles which can occur in the engine unit is shown below for reference in troubleshooting.
(The following is a multipurpose table and some items may apply to the engine of the forklift.)
assembly in start
Trouble
Unstable idling
Failure in start
Engine stall
Differential
operation
Defective
Others
Idling is unstable when engine is cold
Idling is unstable when engine is hot
Hunting during constant speed run

Features of trouble, point of
check, etc.
Hunting during acceleration
During loaded operation

Defective engine pickup
Much fuel consumption

Defective acceleration
F idling does not work
When engine is cold
During deceleration
Idling speed is high
When engine is hot
Contents of trouble
Fuel does not burn
Idling speed is low
Insufficient output
of engine
w: Possibility of
During travel
During idling
Overheating
occurrence is strong
Fuel burns
Q: Possibility of
After-burn
Knocking
occurrence is medium Backfire
E: Possibility of
occurrence is little
• • Air-fuel ratio becomes lean.
Air sucked through oil level
gauge QE QQ E E E • • Air-fuel ratio correction
value becomes high.
• • Suction negative pressure
Air sucked through oil filler
cap QE QQ E E E in intake manifold becomes
low.
Air sucked through blow-by
QE Q E Q Q Q Q Q EE QQ Q E * Check with suction negative
hose (downstream of PCV) pressure gauge.
* Problem of air sucked
Air sucked through intake
manifold and gasket QE Q E Q Q Q Q Q EE QQ Q E through intake system is
common generally.
PCV kept open Q QE QQQQ Q • Abnormal sound (peep) may
be heard.
Clogging of fuel strainer QE QEQ Q Q Q Q Q Q EQ Q • This often occurs at high tem-
perature and high load,
depending on type of clog-
Clogging of air cleaner ele-
ment QQQQQ Q ging.
Air-fuel mixture
Defective gasoline pres-

sure regulator EQ Q Q QQQQQQQ QQQQ • Various troubles occur,
depending on fuel pressure.
Bad properties of gasoline EQ Q Q Q Q Q Q Q Q QE QQQQ E • Various troubles occur,
depending on properties.
• Startability in cold season
Improper LPG (In cold sea-
son, propane ratio) QQQQ Q Q Q Q Q Q QE QQQQ E varies with propane ratio.
• Use LPG of specified pro-
pane ratio.
• If pressure is low, output is
insufficient at high speed and
Defective pressure regula-
tor valve of LPG vaporizer EQ Q Q QQQQQQQ QQQQ high load.
• If pressure rises abnormally,
relief valve operates and right
engine stall occurs.
• Engine stalls during warm-up
Clogging of hot water cir-
cuit of LPG vaporizer QQ QQQQQQQ QQQQ operation and cannot be
started easily, depending on
fuel temperature.
• This often occurs at high tem-
Clogging of filter of LPG
stop valve QE QEQ Q Q Q Q EQ E perature and high load,
depending on type of clog-
ging.
• Air-fuel ratio becomes lean
Babble deposit QQ QEQ Q Q Q Q Q Q QQQQ E and air-fuel ratio correction
value becomes high.
Wrong connection of con-
nector E EE EE EE EE EE E E EE EE E • Check wiring for forcibly bent
part.
• Check cylinders for lifted con-
Spark
nector. If connector of every

Incomplete connection of
connector EQ Q Q QQQQQQQ QQQQQ Q cylinder is not connected
completely, engine cannot be
started easily.
7-4 K-Series
assembly in start
Trouble
Unstable idling
Failure in start
Engine stall
Differential
operation
Defective
Others
Idling is unstable when engine is cold
Idling is unstable when engine is hot
Hunting during constant speed run

Features of trouble, point of
check, etc.
Hunting during acceleration
During loaded operation

Defective engine pickup
Much fuel consumption

Defective acceleration
F idling does not work
When engine is cold
During deceleration
When engine is hot
Contents of trouble Idling speed is high

Fuel does not burn
Idling speed is low
Insufficient output
of engine
w: Possibility of
During travel
During idling
Overheating
occurrence is strong
Fuel burns
Q: Possibility of
After-burn
Knocking
Backfire
occurrence is medium
E: Possibility of
occurrence is little
Improper adjustment of
ignition timing QQ Q Q Q Q Q Q Q Q Q Q QEQ Q Q —
• Check spark plug for abnor-
Spark
Defective spark plug QQ QQQQQQQ E EE mal gap, wear of electrodes,

stain (wetting and sooting),
and damage of insulator.
Leakage through high-ten-
sion parts EQ Q Q QQQQQQQ QQQ Q Q • Trouble varies with degree of
leaking.
• Trouble varies with contact
Compression
Bad contact of valve EQ w w wwwwwww QQQQQ condition and number of

faulty cylinders.
pressure
Wear of piston ring EQ w w wwwwwww QQQ Q • Trouble varies with wear and
number of faulty cylinders.
• Soon after engine stalls, it
Clogging of catalyst and
exhaust system EQ Q QQQQQQQ QQQQ Q can be restarted in many
cases.
• Engine may stall when power
Low idling base speed EE EE QQQQ steering load or working load
is applied during deceleration
or idling.
Dragging of brake QQQ Q • Tires become hot.
High belt tension QQQQ Q —
Large A/C load Q Q E EE EE QEQ Q Q • Too much refrigerant

Others
• A/T oil is insufficient or oil

Large A/T load E E QE Q specifications are improper
(This occurs in cold season,
in particular).
• Hydraulic relief valve is
Large hydraulic pump load E EE Q Q EE E Q defective or oil specifications
are improper (This occurs in
cold season, in particular).
Foreign matter (Dirt) in fuel
tank EQ Q Q QQQQQQQ QQQQ • This occurs often when fuel
level is low.
Breakage of fan or defec-
tive water pump Q • Abnormal sound is heard in
many cases.
Clogging of radiator or con-
denser Q —
In addition to the above, check the following items.

• Check the tension of each wiring harness.
• Check the connection of each connector.
• Check the ground wire for looseness.
• Check the battery terminals for looseness and corrosion.
• Check the coolant and oil.
• Check the fan belt for looseness.
K-Series 7-5
ENGINE CONTROL BLOW-BY GAS CONTROL SYSTEM
BLOW-BY GAS CONTROL SYSTEM

1. SYSTEM DIAGRAM
2. CHECK OF COMPONENT PARTS

1) Blow-by control valve
1. While the engine is idling, remove the blow-by
control valve and hose together from the rocker
cover.
2. If the valve is operating normally, hisses are
heard through the air passage.
3. Blow air into and suck the INT side of the blow-by
control valve to see if the valve is opened.
When air is blown in: Valve is closed.
When valve is sucked: Valve is opened.
7-6 K-Series
8. ENGINE ELECTRICAL SYSTEM
Adjustment values.............................................. 8- 2
Troubleshooting ................................................. 8- 3
Distributor (Carburetor type) .............................. 8- 3
Starting motor..................................................... 8- 8
Alternator............................................................ 8-13
K-Series 8-1
ENGINE ELECTRICAL SYSTEM ADJUSTMENT VALUES
ADJUSTMENT VALUES
Part Item Contents
• Built-in ignition coil Resistance of primary coil : 0.9 – 1.2 z

Resistance of secondary coil : 20 – 29 z
Distributor • Pickup assembly Resistance of pickup coil: 420 – 540 z
• Air gap between signal rotor and 0.35 – 0.45 mm

pickup assembly
• Dimensions of brush 10.0 – 18.0 mm (Wear allowance: 8 mm)

Starting motor
• Pressure of brush spring 13.7 – 17.6 N {1.4 – 1.8 kgf}
• Stator Resistance between lead wires: Max. 1 z

Resistance between stator core and lead wires: c
• Rotor coil Standard resistance between slip rings: 2.9 z

Standard resistance between slip ring and rotor core: c
Alternator
Standard outside diameter of slip ring: 14.4 mm
• Slip ring Limit: 14.0 mm
Projection from holder:

• Brush Standard value : 10.0 mm
Limit : 2.0 mm
8-2 K-Series
ENGINE ELECTRICAL SYSTEM TROUBLESHOOTING, DISTRIBUTOR (CARBURETOR TYPE)
TROUBLESHOOTING, DISTRIBUTOR (CARBURETOR TYPE)
• Battery is discharged. Check and repair charging system, check and adjust fan
belt tension, or replace battery.
• Trouble in starting system wiring Check and repair or replace starting switch.
Repair or replace.
(Troubleshooting procedure for starting motor circuit)
Starting motor cannot When starting switch is turned ON while headlamp is
rotate engine or its turned ON, if headlamp is put out or dimmed,
rotating speed is low. a: Check battery.
b: Check wiring and its connection.
• Trouble in starting motor c: Check starting motor.
When starting switch is turned ON while headlamp is
turned ON, if headlamp keeps bright,
a: Check wiring between battery and starting motor.
b: Check starting switch.
c: Check starting motor.
(Troubleshooting procedure for ignition system)

Check spark plug according to the following procedure.
Disconnect each high tension cable and keep it at about
10 mm from metallic part of engine and rotate engine.
Check all cables from plug No. 1. If it is difficult to see
sparks, install a new spark plug to high tension cable end
and contact its threaded part to metallic part, and then
• Trouble in ignition system rotate engine and check sparks.
Starting motor rotates If good sparks are generated,
engine but engine does (Since fuel system may have trouble. a: Check spark plug.
not start. See section of fuel system.) b: Check ignition timing.
c: Check fuel system.
d: Check cylinder compression.
a: Check primary current.
b: If current is high, primary wire may have short
circuit. Replace in this case.
c: Charging coil is defective. Replace.
d: If high tension cable is broken, replace it.
DISTRIBUTOR (CARBURETOR TYPE)

Ignition system
k • Before starting the work, turn the ignition
switch OFF and disconnect the battery ca-
ble.
K-Series 8-3
ENGINE ELECTRICAL SYSTEM DISTRIBUTOR (CARBURETOR TYPE)
1. STRUCTURE
Fully transistorized type
1. Pickup coil 9. Vacuum control

2. Signal rotor 10. Breaker plate
3. Rotor shaft 11. Heat sink
4. Governor weight 12. IC igniter
5. Governor spring 13. Cover
6. Governor weight 14. Rotor
7. Ignition coil 15. Cap assembly
8. Housing
8-4 K-Series
2. DISASSEMBLY
• Remove the cap assembly mounting bolt and
rotor cover.
• Remove the terminal screws of the pickup

coil and connector connected to the IC igniter
(2 pieces each).
• Remove the mounting screws of the IC ignit-
er and pickup coil (2 pieces each).
• Slide the connector along the housing, and it
is separated from the housing.
k • Do not place the pickup coil on a place
where iron dust may stick to it.
• Remove heat sink mounting bolts (1) and

breaker plate bolts (2), and then remove the
heat sink.
• Remove vacuum control mounting bolts (3)

and disconnect coupler A of the vacuum con-
trol link and breaker plate, and then remove
the vacuum control and breaker plate from
the housing assembly.
K-Series 8-5
• The figure at left shows the housing assem-

bly. If the governor needs to be removed, re-
move the pin at the bottom of the shaft with a
punch and pull out the shaft. If the ignition
coil needs to be removed, remove bolts (4)
and remove the coil from the housing.
3. TESTING
1) Testing ignition coil
• Measure the resistance of the primary coil and
secondary coil.
Resistance of primary coil (between terminals [1]
and [2])
Standard value : 0.9 – 1.2 z
Resistance of secondary
coil (Between terminals [1]
and [2])
Standard value : 20 – 29 z
2) Pickup assembly
• Using a circuit tester, measure the resistance of
the pickup coil.
Standard value: 420 – 540 z
• Pass a screwdriver by the core of the pickup as-
sembly and check that the pointer of the circuit
tester moves.
3) Carbon contact
• If the spherical part at the end is worn totally, re-
place the cap assembly.
4) Cap rotor
• Check the cap rotor for cracking and damage.
5) Signal rotor
• Check the signal rotor for damage and bend.
6) Vacuum control
• Apply negative pressure to the diaphragm with a
vacuum pump and check that the link is sucked.
8-6 K-Series
4. ASSEMBLY
• Taking the following care, carry out installa-
tion in the reverse order to removal.
• Apply grease to the link of the vacuum control
M3 screw:
0.59 – 0.88 Nm {6 – 9 kgf•cm}
• Tightening torque each part.
M4 screw:
1.57 – 2.94 Nm {16 – 30 kgf•cm}
• The shaft must be rotated smoothly with the
fingers.
5. TESTING AFTER ASSEMBLY

• Measure air gap B between signal rotor (5)
and pickup assembly.
Standard value: 0.35 – 0.45 mm
K-Series 8-7
ENGINE ELECTRICAL SYSTEM STARTING MOTOR
STARTING MOTOR
k • Before working on the electrical system, turn the key switch securely and disconnect the battery
cables.
1. SPECIFICATIONS OF STARTING MOTOR

Item Specification
Model name M000T-65381
Type With built-in reduction gears
Output 1.2 KW
2. DISASSEMBLY DRAWING
1) Names of main parts of starting motor
Symbol Name Symbol Name

[1] Front bracket [9] Armature
[2] Overrunning clutch [10] Yoke assembly
[3] Lever [11] Connector brush holder assembly
[4] Internal gear [12] Rear blanket
[5] Packing [13] Switch assembly
[6] Shaft gear [14] Hexagon bolt
[7] Gear assembly [15] Flange screw
[8] Packing
8-8 K-Series
2) Dry clutch specification

• Installation starting motor
3) Wet clutch specification

• Installation starting motor
K-Series 8-9
3. DISASSEMBLY AND TESTING

1) Electromagnetic switch
• Sliding condition of plunger (rusting, stain, and
deformation)
• Breakage and fatigue of return spring
• Roughness of main contact (burn)
• Operation of electromagnetic switch
(Condition of magnet coil)
• Attractive operation of plunger (Operation of
series coil)
Connect the coils as shown in the figure at left. If
the coils are normal, the plunger is strongly at-
tracted by the series coil and shunt coil.
• Holding operation of plunger (Operation of
shunt coil)
Disconnect the wire from terminal M under the
above condition. If the shunt coil is normal, the
plunger is kept under the current condition.
2) Pinion mechanism
• Damage and wear of pinion gear tooth tips
Check the outside. If the tooth tips are damaged
or worn extremely, replace the pinion gear.
• Sliding condition of pinion gear (rusting, stain,
and damage of spline)
Check the sliding operation of the pinion gear. If
the condition is extremely bad, replace the pinion
gear.
• Breakage and fatigue of pinion spring
Check the pinion spring. If it is damaged or fa-
tigued extremely, replace it.
• Sliding condition of pinion spring (fulcrum of le-
ver)
Check the sliding condition of the pinion spring. If
the condition is extremely bad, replace the pinion
spring.
• Operating condition of overrunning clutch (slip
and seizure)
Rotate the pinion gear in the drive direction with
the hand. If it is free or locked in both directions,
the overrunning clutch is defective. Replace the
overrunning clutch in this case.
8-10 K-Series
3) Field coil
Check continuity of the field coil.
Judgment
If the field coil has continuity, it is normal.
If it does not have continuity, it is broken. Re-
place it in this case.
• Check continuity between the field coil and

ground.
Judgment
If there is continuity, the field coil is shorted. Re-
place the field coil in this case.
If there is not continuity, the field coil is normal.
k • If a compound-wound motor is used, its
field core is connected to the ground for
the structural reason. Take care.
4) Armature coil
• Check continuity between the commutators.
Judgment
If there is continuity between the commutators,
the armature coil is normal.
If there is not continuity between the commuta-
tors, the armature coil is broken. In this case, re-
place the armature coil.
• Check continuity between the armature coil and

ground.
Judgment
If there is continuity, the armature coil is shorted.
Replace armature coil in this case.
If there is not continuity, the armature coil is nor-
mal.
K-Series 8-11
5) Commutator
Wear of brush mm 10.0 – 18.0

(up to wear allowance of 8)
Pressure of brush N{kgf} 13.7 – 17.6 {1.4 – 1.8}

spring
• If the surface of the commutator is roughened,

polish it with sandpaper of #500 or #600.
• If the depth the high mica of the commutator to
the insulator is 0.2 mm or less, repair the high mi-
ca.
4. ASSEMBLY AND TESTING

• Check the armature coil and field ball core for in-
terference.
• Check the starting motor (no-load performance).
Working procedure
• Connect an ammeter to the positive (+) terminal
the battery and terminal B.
• Connect terminal B to terminal S by the test wire.
• Connect a voltmeter to terminal B and the body
of the starting motor.
• Connect negative (–) terminal of the battery to
the body of the starting motor by the test wire.
Judgment
• The pinion gear must jump out and the starting
motor must revolve.
8-12 K-Series
ENGINE ELECTRICAL SYSTEM ALTERNATOR
ALTERNATOR
Type: 23100 FF110

Output: 50A
1. STRUCTURE OF ALTERNATOR
K-Series 8-13
2. DISASSEMBLY
1) Pulley
• Fix the hexagon part of the shaft with a socket
wrench and loosen the pulley nut to remove the
pulley.
k • Be sure to use a hexagon socket. A
dodecagon wrench may break the corners
of the shaft and may slip.
2) Rear end cover

• Remove the rear end cover screws and the nut of
terminal B, and then remove the rear end cover.
3) Brush holder
• Remove the screws and brush holders.
4) IC regulator
• Remove the screws and IC regulator.
k • Different screws have different lengths.
Arrange the removed screws so that you
can install them to their original positions.
8-14 K-Series
5) Rectifier
• Remove the screws fixing the rectifier and lead
wires of the stator, and then remove the rectifier.
6) Rear end frame

• Remove the bolts and nuts and rear end frame.
7) Rotor
• Set the drive end frame horizontally on blocks
and push out the rotor with a press.
8) Retainer plate
• Remove the screws and retainer plate.
K-Series 8-15
9) Bearings
• Drive end side
• Set the drive end frame horizontally on blocks
and push out the bearing with a jig and a press.
• Slip ring side

• Using a puller, remove the bearing.
k • The bearing used is for high speed revolu-

tion. Accordingly, be sure to use the
specified one and do not give a shock to
it.
3. TESTING
1) Bearing
• Rotate the bearing with your fingers.
• Check that the bearing is free from an abnormal
sound or a hitch.
• If the bearing has a fault, replace it.
2) Stator
• Check the resistance between lead wires with a
circuit tester.
Standard value: Max. 1 z
• Check the resistance between stator core and
lead wires.
Standard value: c
• If the stator has a fault, replace it.
k • It is very rare that the stator coil is broken.
Accordingly, if there is not continuity,
check the joints of the lead wires.
8-16 K-Series
3) Rotor coil
• Measure the resistance between the slip rings
with a circuit tester.
Standard value: 2.9 z
• Measure the resistance between the slip ring and
the rotor core.
Standard value: c
• If the rotor coil has a fault, replace it.
4) Slip ring
• Check the slip ring for dirt and flaw.
• If the slip ring is dirty, wipe it with cloth soaked in
alcohol.
• If there is a slight flaw, eliminate it with sandpaper
(#500 – #600).
• Measure the outside diameter of the slip ring.
Outside diameter of slip ring:
Standard value; 14.4 mm
Service limit; 14.4 mm
• If the wear exceeds the service limit, replace the
slip ring.
5) Brush
• Measure the length of the brush projected from
the brush holder.
Projection of brush:
Standard value; 10.0 mm
Service limit; 2.0 mm
• If the wear exceeds the service limit, replace the
brush.
• Check that the brush moves lightly in the brush
holder.
6) Rectifier
• Check the continuity of each diode of the rectifier
with a circuit tester in the kz range.
• If the diode has continuity in either direction and
does not in the opposite direction, it is normal.
k • Never use a 500V megger tester since it
breaks the rectifier.
K-Series 8-17
Reference:
• The condition of the rectifier cannot be judged by
the resistance in the normal direction. For the
characteristic reason of the diode, the current in
the normal direction varies largely with the
source voltage. Accordingly, the tester reads dif-
ferent values, depending on its type and the re-
sistance range used. Judge the condition of the
rectifier, therefore, by the difference between the
resistance in the normal direction and that in the
opposite direction.
7) IC regulator
Check the continuity between terminals B and F
of the IC regulator with a circuit tester in the kz
range.
• If there is continuity in either direction and not in
the opposite direction, the IC regulator is normal.
k • Never use a 500V megger tester since it
breaks the IC regulator.
Reference:
• If a constant-voltage power supply which can
change the output voltage between 10 V and 20
V is available, you can check the IC regulator unit
according to the following procedure.
k • If the IC regulator is connected wrongly, it
may be broken even when a voltage is ap-
plied for a short time. Accordingly, check
the wiring carefully before starting the
check.
• Connect the IC regulator unit, constant-voltage
power supply, voltmeter, lamp, etc.
• (Turn SW1 and SW2 OFF.)
• Set the source voltage to 12 V.
• Turn SW1 ON. At this time, check that L1 lights
up brightly and L2 lights up dimly.
• Then, keep SW1 ON and turn SW2 ON. At this
time, check that L1 goes off and L2 lights up
brightly.
• Under this condition, increase the source voltage
gradually from 12 V. Check that L2 goes off
when the source voltage is 14.5 ± 0.6 V.
8-18 K-Series

K15/K21/K25-BE1: Machine Model Serial No

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K15/K21/K25-BE1

MACHINE MODEL SERIAL NO.

5. ENGINE LUBRICATION & COOLING SYSTEMS

8. ENGINE ELECTRICAL SYSTEM

This maintenance manual explains the specifications, maintenance procedure, adjustment

How to read this manual .................................... 1- 2

HOW TO READ THIS MANUAL

Conversion of major units

Quantity SI unit Conventional unit Coefficient of conversion into SI

Acceleration m/s2 G 9.80665

Torque and moment Nm kgf•m 9.80665

Force N kgf 9.80665

MPa kgf/cm2 0.09809665

Spring constant N/mm kgf/mm 9.80665

Fuel consumption g/kW•h(*1) g/PS•h 1.3596

*1. Conventional unit may be used in SI.

PRECAUTIONS FOR SAFETY AND QUALITY

• Take care not to touch the hot metal parts

PRECAUTIONS FOR WORK

2. PRECAUTIONS FOR SEPARATING FUEL PIPING

3. PRECAUTIONS FOR REMOVAL AND DISASSEMBLY

4. PRECAUTIONS FOR CHECKING, REPAIRING, AND REPLACING PARTS

5. PRECAUTIONS FOR ASSEMBLING AND INSTALLING PARTS

6. PARTS WHICH NEED TO BE TIGHTENED BY ANGLE TIGHTENING METHOD

7. PRECAUTIONS FOR USING POWER TOOLS

8. PRECAUTIONS FOR APPLYING

k • Take care not to damage the mating faces.

Procedure for applying gasket sealant

4. Apply the gasket sealant to the specified parts

k • If a direction is given in the manual, ob-

Tightening torque of tapered screws

R1/8 7.8 {0.796} 11.8 {1.2} 15.7 {1.6} 21.6 {2.2}

R1/4 19.6 {2.0} 29.4 {3.0} 34.3 {3.5} 44.1 {4.5}

R3/8 39.2 {4.0} 54.9 {5.6} 53.9 {5.5} 73.5 {7.5}

2. TIGHTENING TORQUE OF ENGINE PARTS

Fixed part Standard value Max. value

Cylinder head (coated with oil) Shown separately

Main bearing cap (coated with oil) Shown separately

Flywheel bolt (coated with oil) 132 {13.47} 142 {14.49}

Rear plate bolt 44.1 {4.5} 58.8 {6.0}

Cam sprocket bolt 39.2 {4.0} 49 {5.0}

Oil filter stud 29.4 {3.0} 39.2 {4.0}

Oil filter element 14.7 {1.5} 20.6 {2.1}

Spark plug 19.6 {2.0} 29.4 {3.0}

Engine slinger bolt 22.6 {2.31} 25.5 {2.6}

Rocker cover nut 13.7 {1.4} 15.7 {1.6}

Water temperature gauge 15.7 {1.6} 19.6 {2.0}

Oil pressure switch 15.7 {1.6} 21.6 {2.2}

Exhaust manifold nut 41.2 {4.2} 48.1 {4.91}

Oil pan drain plug 29.4 {3.0} 39.2 {4.0}

Fuel tube flare nut 16.0 {1.63} 23.0 {2.35}

Thermo housing air relief plug 6.37 {0.65} 7.45 {0.76}

Main bearing cap Tightening order

KV111-03000 Pulley puller

ST052-40001 Engine attachment

ST050-1S000 Engine stand assembly

KV101-041S0 Crankshaft main bearing cap puller

ST120-70000 Valve lifter

ST152-4S000 Front oil seal drift

OUTSIDE VIEW OF ENGINE

GASOLINE AND LPG SPECIFICATION

Method of engine control Carburetor specification

Fuel specification Gasoline Gasoline and LPG