INTRODUCTION This Service Manual offers instructions on standard service procedures (disassembly and reassembly) for Yanmar Diesel Engine models L40AE, L48AE, L60AE, L70AE, L75AE, L90AE and L100AE. More detailed information is given particularly in the sections of the construction and function of each engine part. Before servicing these engines, make sure you read this manual carefully. The information contained in this manual will be updated periodically to incorporate improvements in the quality and performance of our engines. Before beginning your service work: To insure efficient service and repairs, the following pre-service steps should be taken: 1. Check your customer control book (1) When was the engine last serviced? (2) What is the engine's service history? a. How offen was the engine serviced (after how many months or hours of operation)? b. What problems has the engine had in the past? 2. Stock control (spare parts) (1) Keep a good stock of engine parts and other items necessary for efficient servicing. (2) Keep a copy of the check/service parts list and plenty of parts cards on hand, 3. Keep an accurate service record (diary, notes, etc.) (1) Work (manpower) table (2) Check list (including service parts list) (3) Parts measurement data } Maintenance of pertormance (4) Operation data and quality 4, Tools and equipment required for service (1) Tools (2) Meters and instruments (3) OthersService Information 1. GENERAL SAFETY STOP THE ENGINE BEFORE SERVICING 1) PREVENTING FIRES «Never add fuel to the fuel tank while the engine is running. Wipe away all fuel spills with a clean cloth, «Keep gasoline, kerosene, matches, other explosives and inflammables away from the engine, since the temperature around the exhaust silencer is very high during operation. «To prevent fire hazards and to provide adequate ventilation, keep the engine at least 3 ft (1m) away from the building and other equipment during operation. 2) PREVENTING EXHAUST GAS INHALATION «Note that exhaust gas contains carbon monoxide (CO), nitrogen oxide (NOx), hydrocarbon (HC), sulfar oxide (SOx), and particulates. ‘+ Never use the engine in poorly ventilated locations such as indoors, inside of tunnels and $0 on. If indoor operation is unavoidable, provide proper ventilation so that people and cattie will not be affected. 3) PREVENTING BURNS ‘* Never touch the exhaust silencer, muffler cover or engine body while the engine is running or hot. 4) PRECAUTIONS FOR THE BATTERY ‘* The battery electrode is essentially dilute sulfuric acid, which injures the human body and damages clothes. Should it touch the body or clothes, immediately wash it away. If it enters your eye, hasten to consult the doctor. * Never use fire near the battery during charging, which generates hydrogen. * Charge the battery in a well ventilated place. 5) OTHERS Wear safety shoes, working clothes, etc. before servicing the engine. Do not service the engine under the influence of alcohol. Keep children and pets away from the engine in operation. Do not have access to rotary part during operation, which is extremely dangerous.2. SERIAL NUMBER LOCATION Engine serial number (E/#) is indicated in the engine nameplate, and is stamped on the crankcase cover, Before ordering service parts, be sure to check serial number and identify necessary paris by nos. (Parts may not have interchangeability as a result of a change in the specification.) 3. SERVICE RULES 1. Use genuine YANMAR parts. Parts that do not meet YANMAR’s design specification may damage the engine, In disassembling the engine in trouble, exactly locate the cause of trouble. Remove or disassemble only the parts specified in the troubleshooting procedure. 3. Use the special tools designed for this engine. 4, Install new gasket, O-ring, cotter pins, etc. when reassembling. 5. When torquing bolts or nuts, tighten them to the specified torque diagonally. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation, yCONTENTS Gross Sectional Views... 12. Service standard .1 Tools, Meter i. Tools .. 2._Meters, Instruments and Service Accessories 3._ Instruments... 3.2 Tightening Torque a8 Maintenace Schedule. Procedures (ie Ressenbly Procedures... 3.6 Recoil Starter .. and_Instruments 4. Checking and Servicins f a 4.8 Cylinder Sleeve and Cylinder Block. 49 Lubrication System % 4.12_Electrical System. 4 Wiring Diagram. fF Motor... nerator (Dynamo), Regulator and Rectifier 4.13 Adjustment 5, Toroubleshooting. 6. Test Ru 7. Helical inserting Part for Repair Appendix 1 Difference Between Parts under Spec. S and D. Appendix 2 Detail of Special Tools...‘Speci ications 1. Specifications 1.1 Specifications Model L40AE — L48AE — D S [DE | SE| D S| DE | SE_ ‘Single-cylinder, verti¢al-4 cycle air-cooled diesel Cooling system Forced air cooling by flywheel fan Combustion system Direct injection system Starting system Recol saner | SROMOIC T Recol serter | ,grrana naar Number of cylinders - Bore x Stroke | mm (In) (eer 2 185) (e756 2185) [Displacement 4 (cu.in.) Oteg(i214) | ~~ 0211(12.88) Output | Continuous eae iz 2.8 (3.8) 3.4 (4.2) [Maximum 3.1 (4.2) 3.5 (4.7) Speed (PTO shatt) rpm | 3600 | 1800 | 3600 | 1800 | 3600 | 1800 | 3600 | 1800 Speed at no-ioad, maxin eee eee ‘Compression ratio 20.0 19.9 prosnat PTO poston Grank| Gam [Crank] Gam [Crank | Gam | Crank] Cam ‘Direction of revolution Counterclockwise viewed from PTO shaft Fuel injection pump Bosch type, YANMAR PFE-M type Fuel injection timing (FiD) | bTDC 148 + Fuel oi | Fuel injection nozzle I Hole nozzle, YANMAR YDLLA-P type Fuel injection pressure [Mea tem) 19.6 (200) Fuel oil selection | Diese! fuel BS 2869 At or equivalent Fuel oil fiter | Paper element, FO tank buit-in type Fuel oil tank capacity AUS gal) 2.5 (0.66) [Type of bscaton _pash Sear Tae faker oP CRinbe Lubicating | Lubricating oil fiter Resin, 60 mesh zl oil Lubricating oil selection ‘SAE 10W30, API grade CC or higher Lubricating oil capacity | US gal.) etlective 825 07 Air cleaner Wet type paper element filter (Oil-bath type: Option) Exhaust silencer 7 H ~_ Expansion silencer with cover Governor “| _____Allspeed type, mechanical Ergin denne ght [mm in) Ree: SENSEI He SIE Hex teste] Dry weight kg (ib) | 25.5 (66.2) | 31.0(68.3) | 255 (66.2) | 31.0 (683) Permissible angle of inclination deg. | i Balancer shatt I Single shaftSpecifications Model US0AE L70AE tem D |S | be| se | D | S | DET SE Type Single-cylinder, vertical-4 cycle air-cooled diesel Cooling system Forced air cooling by flywheel fan | ‘Combustion system Direct injection system | Starting system Roca stator | hte Fecoi starter | iach saree Number of cylinders - Bore x Stroke | mm (in.) (e950 2441) (eorteeen) Displacement 7 euin) 0.273 (16.66) (0.296 (18.06) Continuous: 4.0 (5.5) 4.4 (6.0) Ouput Maximum eee 4460) 4367) Speed (PTO shaft) mpm | 3600 | 1800 | 3600 | 1800 | 3600 | 1800 | 3600 | 1800 ‘Speed at no-load, max/min ron EE RO eB Oo i Oa Compression ratio 19.5 PTO position Crank] Gam [Crank] Cam Crank] Cam |Crank’ Cam PTO shalt | Direction of revolution CCounterclockwise viewed trom PTO shalt Fuel injection pump. Bosch type, YANMAR PFE-M type HH Fuel injection timing (FID) | bTOC 14" Fuel injection nozzle Hole nozzle, YANMAR YDLLA-P type Fuel oil Fuel injection pressure _|Mpa igi 19.6 (200) _ Fuel oil selection Diesel fuel BS 2869 A1 or equivalent Hy Fuel oll filter Paper element, FO tank built-in type J Fueloiltank capacity —_|#(US gal) 3.5 (0.92) "ype of briaton so aan a a ee Lubicating Lubricating of filter Resin, 60 mesh oil Lubricating oil selection ‘SAE 10W30, API grade CC or higher Lubricating oil capacity _|¢(US gal) etloctive 0.4 (0.71) Air cleaner Wet type paper element fer (Oi-bath type: Option) Exhaust silencer Expansion silencer with cover Governor HI All speed type, mechanical crores urate xray | mn) | Babee 5% 41489 (1S de teaver Dry weight kg (ib) [33.5 (739) | 39.0 (86.0) | 33.5 (73.9) | 99.0 (86.0) Permissible angle of inclination deg. 20 (momentary 30) Balancer shaft Single shaftSpecitications Model L75AE— LS0AE- ttem Ds [oe [se [> |S | ce [Se Type Single-cylinder, vertical-4 cycle air-cooled diesel Cooling system Forced air cooling by flywheel fan ‘Combustion system Direct injection system Starting system : ia Recoil starter | ygrsodnitor [Recoil starter] wan rao stator Number of cylinders - Bore x Stroke mm (in.) (9.150 2756) (ose 256) Displacement 7 (cu.in.) ~~ 0.351 (21.42) (0.387 (23.62) Continuous 4.8 (6.5) 5.9 (8.0) Output Maximum KW (HP) 55 (75) 660.0) “| ‘Speed (PTO shaft) tpm 3600 | 1800 | 3600 1800 | 3600 | 1800 | 3600 | 1800 ‘Speed at no-load, max/min tm Pra on Fae Gono” tol 20 ‘Compression ratio 202 18.9 PTO position Crank] Cam [Crank| Cam [Crank] Cam [Crank] Cam PTO shaft Direction of revolution Counterclockwise viewed from PTO shaft Fuel injection pump Bosch type, YANMAR PFE-M type Fuel injection timing (FID) | bTDC 134 = Fuel injection nozzle Hole nozzle, YANMAR YDLLA-P type Fueloll [Fuel injection pressure [Moa tte 1916 (200) Hi Fuel ol selection Diesel fuel BS 2869 At or equivalent Fuel oil fitter zm Paper element, FO tank built-in type Fuel oil tank capacity US gal) 5.5 (1.45) Sweetin | ocean era 7 Lubricating oil fiter 7 Resin, 60 mesh Lubicating eg oT — peakhndt | oil Lubricating oil selection SAE 10W30, API grade CC or higher Lubricating oll capacity -#(US gal) see 180 Air cleaner ‘Wet type paper element filter (Oil Exhaust silencer I Expansion silencer with cover ‘Governor I 7 All speed type, mechanical Eng dense (argh xwiahcHeign) | mm (in) BEBE G42 S470. aaa (1.406 18808» 19.49) Dry weight kg (ib) | 48.5 (106.9) | 54.0 (719.0) | 48.5 (106.8) | 54.0 (119.0) | Permissible angle of inclination deg. 20 (momentary 30) a Fee Balancer shaft Single shaftSpecifications Model | LIOOAE- Item D s DE, SE Type Single-cylinder, vertical-4 cycle air-cooled diese! Cooling system Forced air cooling by flywheel fan Combustion system, Direct injection system ‘Starting system Recolstaror | ERT Number of eylinders - Bore x Stroke | mm (in.) (03802756) Displacement 7 (cuiny 0.406 (24,76) Continuous 66 (6.0) Output Maximum kwtHPy 7.4 (10.0) ‘Speed (PTO shaft) fpm 3600 1800 3600 ‘Speed at no-load, max/min wpm | SOF TO | a0 | ‘Compression ratio 19.3 7 PTO position Crank Cam Crank Cam PTO shaft Direction of revolution ~ “Counterclockwise viewed from PTO shaft Fuel injection pump. Bosch type, YANMAR PFE-M type Fuel injection timing (FID) | _bTOC 13 _| Fuel injection nozzle Hole nozzle, YANMAR YDLLA-P type Fuel oil | Fuel injection pressure [Mpa teen) 19.6 (200) i Fuel oil selection Diesel fuel BS 2869 At or equivalent Fuel oil filter Paper element, FO tank built-in type _ | Fuel oil tank capacity _ 4(US gal.)) 5.5 (1.45) "oe uve soul SAAN OE ee Lubicating |_Lubricating oil fiter Resin, 60 mesh oil Lubricating oil selection ‘SAE 10W30, API grade CC or higher Lubricating oil capacity |/(US gal, effective oe oe Aircleaner ‘Wet type paper element filter (Oitbath type: Option) | Exhaust silencer Expansion silencer with cover Governor All speed type, mechanical Eapesnetretogmnnamstogy [mil | BSE SNS 18 ans Dry weight kg (ib) | 48.5 (106.9) I 54.0 (119.0) Permissible angle of inclination ‘deg. ____ 20 (momentary 30) Balancer shaft ‘Single shaft‘Speciti nS 1.2 Cross Sectional Views Breather Decompression lever Air cleaner Exhaust valve" Fries! (Progra cooing fan) Piston: Crankease cover Silfoer bot. FRocoll starter Ubricatng of iter (S-spec. shgine) (© spec.: incorporated in the crankcase cover)Spocifications Longitudinal sectional view Fuel tank Fuel fiter wire net Mutter Fuel injection nozzle +) Fue! flor ‘Connecting roc Ful cock oO Fue injection pump Camshatt Balancer shat ea 7 ~ ‘Speed contrSpecifications Plan view Camshaft P.T.O. (S spec.) Crankshaft P.T.0. (D spec.)Sorvice Standards 2. Service Standards Unit: mm (in) Parts | Mode! ‘Standard Service mit | Remarks Intakefoxhaust valve seats iSSESEEnEIEE Seat angio Tome 60"-90" - | ‘LAQAE~ 15-3.0 | ee | trooae | (0.089-0-116) 7 | Intakefexhaust valves & valve guides osa7 | 1 ieee (@.012-0.028) es | 5,500-5.515 5.58 | (0.2165-02171) (0.2197) Intakes | 6.0-6.015 6.08 Valve guide LD. | Eehaust (0.2362-0.2368) (2394) 7.0-7.015 7.08 (0.2756-0.2762) (0.2787) | 5.488-5.475 | 5.40 (02152-02186) (2126) | 5.90 Hue 960-5. (202) | | ee 690 2740-0.2745) 2717) Valve stem 0.0. © d © [ wana, | 5.450-5.460 5.40 LéaAE | 2146-02150) | (02126) Leona, | 5.945-5.960 5.90 | Exhaust | L7ONe | _(0.2341-0.2346) (2823) | L7sae~ | 8.945-6.960 630, Liooae | (@:734-2:740) e277) | Valve spring 7 7 1 T | L4oae 28(1.102) | 28.5 (1.048) ee eee Free length \eone, 33 (1.299) 31.5 (1,240) L75AE~ vr 40(1.575) | 98.5 (1.585)Service Standaris Unit: mm Parts Model Standard ‘Service limit Remarks Valve spring : LaoAe, a MaoAE | 0.75 (0.090) Le0Ae, Inclination {SKE | 06 (0.024) - L75AE- = L7SAE~ | <1.0 0.090) Lone, Laaae as Leone, | 1.27-1.58 String contr gn) oa | eases = L7sag~ | 1.80-251k9 Lroae (8.97-5.51 Ib) ae Intake/exhaust valve rocker-arm, rocker shaft and push rods Laoag- | 11.989-12.000 11.90 IWEX valve rocker “Lroae | (0.4720-04724) (0.4685) aim shaft 0.0. L7sae- | 14.989-15.000 14.90 LYOOAE | _(0.5901-0.5906) (0.5866) Laoae- | 12.016-12.094 12.10 L7OAE | (0.4731-0.4708) (0.4764) INEX valve rocker arm ID. L75AE- | 18.016-15.034 15.10 LHOoAE | _(0.5912-0.5019) (0.5945) Laone- | 128.8-1902 a Lasae | (6.110-5.126) LeOAE- | 162.3-162.7 = Push rod length L7OAE | _ (6.380-8.406) L75AE- | 1968-1972 i LHOOAE | (7.748-7.764) a Laon < 0.05 03 Push od distortion LHOOAE (6.0020) (0.0118) Valve clearance Laoae~ | “015 Intake and exhaust Lrooae | (0.0059) feService Standards EERE Units mm (in Pars Model Standard Servic limit Remarks Valve opening/closing timing (ane | a6rbT.0.C. - U75AE- =) zorpT.D0. - LYOOAE Intake z ame: | se anoe - Closed Use: | aranoe a wore | eerpane, a ‘Open L76AE~ 59°. B.0.6 7 oe LHOOAE waate- | ae aro - Crosed ate | ap aroc, i Po usoae | 67965 (26758 | 67.68(2.6646) | frescuitg Lasne 69,965 (2.7546) | 69.70(2.7441) Leone | 74.065 (2.9514 | 74.70 (29410) Piston 0.0. L7oac | 79.985 (3.1482) | 77.70 (9.0590) L7sne | 7.9965(3.1482) | 79.70 (3.1978) 1 Z tooae | 99.905(.0057) | 99:70 0.20859) Liooae | 95,985 (33844) | 85,70 (2.8740) fee LAOAE- 0.04-0.08, _ | Clearance between piston and LBOAE _|_ (0.00187-0.00206)_| sleeve 1 005-0.07 LOOAE | (e.00187-0,00276) 7 | LaOAE/ | 18.985-10.996 19.07 Uasaz | (0.7474-0.7479) (0.7508) Piston pin hole 1D LsoAe/ | 20.980-20.006 2.07 eed L7ORE | (Gc26%-0.6266) 0.5) L7SAE= | _ 22.080-22.006 2307 Li00AE | (08048-0.9054) (0.9083) L.0.004-0.015T ==5 L:Looee fi Clearance between piston pin hole L40nE | (0.0002-0.0006) 7: Tight ft ‘and piston pt eee LaBAE~ | L.0.005-0.017T 4 LooAE | (€.0002-0.0007) 10Service Standards " Unit: mm (in Pars Mode! Standara Service limit Remarks Piston pin LA0AE, | 18992-19000 | 1892 Lasse | (0.7477-0.7480) | (0.7448) : L6OAE, | 20.901-21.000 20.81 Piston pin 0.0. L70AE (0.8264~0.8268) (0.8232) L75AE~ | 22.991-23.000 22.91 LrooaE | (0.9052-0.9085) (0.8020) Piston and rings 7 “string side clearance LAOAE- | 0.065-0.005 0.15 (cing width and ring groove) LrooAe | _(0.0026-0.0037) (0.0059) 2nd ring side clearance LAOAE- | 0.03-0.065 015 (cing wiath and ring groove) LiooaE | (0.0012-0.0026) (0.0059) Oilring side clearance LA0AE- | 002-0055 | 0.15 {ing width and ring groove) Ltocaé | — (0.0008-0.0022) (0.0059) Piston ring 27-28 252 LAE | (0.1069-0.1141) (@.0982) | 30-32 277 | L4BAE | (o.118t-0.1260) 0.1081) L6OAE~ 32-34 297 t7oae | _(0.1260-0.1999) (0.1169) T dimensions |— Pree Sor | 33-3. ss | me | odttinn | widen | | 34-36 3.17, | L90AE | (o.1999-0.1417) (0.124) | 7 36-38 337 LHOOAE | (0.1417-0.1496) (0.1327) | L40AE~ | 1.470-1.485 1.36 Badimensions | LyoQAE | (0.0579-0.0585) (0.0535) | 275-295 275 WAOAE | (0.1088-0.1161) (0.1083) 30-32 277 LABAE | (0.1181-0.1260) (0.1081) L6OAE/ 32-04 297 song |_L70AE_|_(0-1260-0.1938) (0.1169) T dimensions 33-35 307 : U76AE | (0.1300-0.1378) (0.1209) ae j ; a7 34-36 L90AE | (0.1939-0.1417) (0.1248) 36-38 337 LYOOAE | (0.1417-0.1496) (0.4927) _ Laoae- | 1.470-1.490 1.96. _ | L70AE | _(0.0579-0.0567) (0.0835) B dimensions - USAE~ | 1.970-1.990 1.86, Lrooae | _(0.0776-0.0768) (0.0732)dfeHHESPESPEEEERE SEE Het eee CeCe EES SBS Unit: mm in.) [ Parts Model ‘Standard | _Service limit Remarks Piston ring 26-28 2.49 L4QAE | (0.1024-0.1102) (0.0980) 20-24 1.99) \4eaz | (0.0787-0.0945) (0.0783) LEOAE/ 21-25 2.07 Teimensions | [7oae | (0.0827-0.0984) (0.0815) Gilring 24-28 237 LISAE | (0.0945-0.1102) (0.0933) LSOAE 25-29 247 LiooAE | (0.0964-0.1141) (0.0972) LaonE- | 3.470-3.480 3.36 LTOAE | (0.1368-0.1374) (0.1323) Belmensions T 75ae~ | 3.970-9.80 3.86 Lrooae | (0.1569-0.1571) (0.1520) LaQAE~ 0.20-0.95 10 tstring LIOOAE | — (0.0078-0.0138) (0.0394) Pa "| LOA 0,30-0.45 10 End gap 2nd ring LIOgAE | (0.0118-0.0177) (0.0394) La0nE- [015-0235 10 il ring LIOOAE | (0.0059 - 0.0138) (0.0394) Connecting rod H LAoAe, | 19.012-19.024 19.10 LaBAE | (0.7486-0.7480) (0.7520) 7 Leoae, | 21.014-21 028 21.10 L7OAE | (0.8273-0.8279) (0.8807) t7eae- | 29.025-20,038 23.10 ‘Smal end hole L1ooAE | _(0.9065-0.9070) (0.9094) (piston pin) tore, | 0,015-0.090 Lasae_ | (0.0008-0.0012) 7 Leoae, | 0.017-0.034 Ciictearance | [79a (0.0007-0.0019) = L7sae- | 0.028-0.044 Lrooae | _(0.0011-0.0017) i Laoag, | 30.007-30.015 30.08 z Lasae | (1.1814-1.1817) (1.1848) 0 Leone, | 96.007-26.015 36.08 x 7 (VV direction)| L70AE | (1.4176-1.4179) (1.4208) Large end hole L7sae~ | 40,000-40.042 40.08 (Crank pin) LIOORE | (1.5748-1,5765) (1.5780) v Laoae- | 0.025-0.050 ee Lroae | _(0:0010-0.0020) Oilctearance | w7sae- | 0.033-0.062 _ i Liooae | _(0.0013-0.0024) 12Unit: mm Go { Parts Model_ ‘Standard Service limit Remarks Crankshaft and Wain bearing Laoag, | 29,965-29.982 LaBAE | (1.1797-1.1804) Pino, | L60AE, | 36.905-35.982 _L7OAE | (14158-1.4166) rank pin LsAe- | 99.065-39.982 Uiooae | (,5734-1.5741) wane | aes-0085 0010-0. it dearance | eae tee - UsAE- | 0.033-0.052 LiooAe | _(0.0013-0.0028) | Laoag, | s0.002~90.015 29.91 LagAE | (1,1812-1.1817) (176) [ Leoae, | 35.002-36.018 24.91 Joumal©.0. | tyoae | (13780-1.3787) (13744) Gear cover t7sae~ | 40,002-40,018 39.91 Side | Uiooae | (15749-15755) (13713) Crank Laoag, | 0.025-0.058 jourent cctearance |_MMOAE | (@.0010-0.0029) cit Lads | LEOAE~ 0.025-0.081 (0.0067) | Lrooae | (0.0010-0.0024) Laoag, | 20.002-20.015 a Taead | (1.1812-1.1817) Flywnee! Leone, | 36.007-36.018 side JoumalO.D. U7oae | (1.3782-1.3787) = | 40,007-40.018 1 (1.5751-1.5755) i 29,990-20,000 ot '607-1.1811) i 34,908-35.000 Pom (1.3775-1.3780) 7 39,988-40.000 a Journal | Fywhee! (1.5769-1.5748) ea ns 10.002-0.025 oe Tight fit (0.00008-0.0010) Fiting 0.007-0.030 i (0.0003-0.0012) _ 13Service Standards Unit: mm (in) Parts Mode! ‘Standard ‘Service limit Remarks Camshaft T LA0AE- | 14.989-15.000 14.92 ShaftO.0. — Lrooae | _ (0.8901-0.5806) (0.5874) ce Needle bearing on | tsoae~ | 15.016-15.036 zy eyinder block sice | 82904. | Ligne | _(0,5912-0.5919) taoae- | 0.016-0.045 = Oilclearance | Lro0AE | (0.0006-0.0018) aon, | 24,980-24.983 24.90 | Lagae’ | _(0,9835-0.9840) (0.9809) Ball bearing on 10, | LS0AE, | —29,980-29,999 20.90 crankcase coverside | S®"°°- — Lrone’ | (1.1808-1.1808) (1.172) L7sac- | 34,090-34.993 34.90 Uiooae | (1.9772-13777) 4.3740) Laoae, | 24.990-25.000 25.02 [aga | (0.9839-0.9849) (0.9850) js LBOAE, | 29,990-90.000 3002 Bearing LD. | L7oae | _(1.1807-1.1811) (4.1819) L75AE~ | _94.980-95.000 35.02 Ball bearing on Lrooae | _(1.976-1.5780) (13787) crankoase cover side tions! aga oi Leone, | 1.0.020-0.090T 0.08-0.10 | L: Loose fit clearance | L70AE | (0.0008-0.0012) | (0.0081-0,0038) |: Tight ft L75AE- LORE Thrust clearance Laoa- | 0.040-0.280 045 {Gap of axial crection) LIODAE | _(0.0016-0.0110) _ (017) Tappet z : Laone- | _6.960-6.980 687 StemO.D. | Lrooae | _(0.2740-0.2748) (0.2705) ‘Tappets for IN/ Hole da. Laoae~ | 7.000-7.015 7.98 EX. valves (Cylinder blood | L100AE | _ (0.2756-0.2762) (0.2780) 7 LAQAE~ | 0.020-0.055 os Oliciearance | LYooae | _(0.0008-0.0022) ry Laoae~ | 23.972-23.908 23.89 ‘ Lrooae | _(0.9438-0.9446) (0.9408) | ‘Tappets for fuel Hole ca Laone~ |” 24,000-24.038 24.06 injection pump (Cylinder lock) | L100AE | (0.9449-0:9462) ©9472) Laoae~ | 0.007-0.061 Z Ollclearance | Lioae | (0.0003-0.0024) 14Service Standards Unit: mm (in) Parts Model ‘Standard ‘Service limit Remarks Crankcase cover Lagae, | 34.000-24.026 - Lasaé | (1.3386-1.3306) tw. Le0Ae, | — 39,000-39.005 oe L7OAE | _(1.5354-1.5364) # L75ae~ | 44,000-44.025 = Liooae | _(1.7325-1.7333) L4oAE, | 34.070-94.105 oe Lasae | (1.3413-1.5427) = Bearing .0 | Leone. | —39,070-99.105 a Plain) Lore | _(1.5982-1.5996) ranks L75AE | 44,085-44.120 a Scanng oat Giooae | _¢.7956-1.7370) Laone- | 0,045-0.105 at Tightfit L70AE | (0.0018-0.0041) Fitting L75AE~ | 0.080-0.120 a LIOOAE —_(0.0024~0.0047) La0ae, 30 30.13 Lise | 1.1811) (1.1862) Bearing metal || LeOAE, | 35 35.18 1D. (Plain meta} L7OAE (1.3780) (13831) U75AE~ | 40 40.13 LYOoAE (1.5748) 4.5800) 7 L4AE~ | 51,945-51.965 = LéBAE | (2.0451-2.0455) ie LOOAE, | 61,940-61,960 a . L7OAE | (2.4908-2.4994) U75AE~ | 71.935-71.055 a LYOoAE | (@.8321-2.8328) LaoAe, 51.987-52,000 ot Tight fit LABAE |_(2.0467-2.0472) L6QAE~ | 61.987-62.000 a Dian part Sayles | L7OAE | (2.4404-2.4409) L7saz- | 71.987-72,000 = Liooae | 2.8361-2.8046) Laoag, | 0.022-0.055 - LaBaé | (0.0009-0.0022) teoAe, | 0.027-0.060 a Fitting LIOAE | _(0.0011-0.0024) L75AE~ | 0.032-0.065 Ee LIOOAE | _(0.0013-0.0026) 15‘Service Standards ——— Unit: mm (i. Paris Model Standard I Remarks: Gylinder block Laoag, | 71.9905-72.0005 Lasae | (2.043-2.8350) | tb. Le0AE, | 79.980-79.996 | 7 L7oAE | (8.1488-2.1494) | 175AE- | — 89.984-90.000 LIOOAE | (35427-35433) Laoag, | 71.967-72.000 Laan | (2.8341-2.6946) i Crankshaft Ballbearing | Le0ae, | — 79.987-20.000 beaving part ©. t7oae | (@-t491-3.1496) L7sae- | — 83.985-90.000 Looe | _@.5427-2.5439) Laoag, | 0.0225-0.0095 LaBAE | (0.00088-0.00037) | Fini Leone, | 0,008-0.020 9 L7oAE | _(0.00035-0.00078) | L7sac, | 0015-0016 LiooAE | (0.00088-0.00062) usoag, | 20957-20.978 | [Eee eer rE (pure Liooaé | (2st-o8259) | 68,000-68.030 Lanne | 6771-26783) 70.000-70.080 L4BAE | 27559-27571) t 75000-75030 | LsOAE | 2.9528-2.9599) 78,000-78.030 Oyfinder sleeve LD. tree | Fae eo) 80,000-80.030 USAE | (3.1496-3.1509) 84,000-84.030 LeOAE | (@.3071-2.3083) 86.000-86.030 LOOAE | (3.3858-3.3870) 16Service Standards Unit: mm Gn) Parts Model Standard ‘Service tit Remarks it pump (Trochold pump) Outerrotr | L40AE- | 28.96-26.98 28.90 oD. LHOOAE | _(1.1402-1.1409) (1.1378) Housing LD. | L4oae~ | 29.100-29.121 23.18 (Crankcase ove) LiOQAE | (1.1457—1.1465) (1.1488) Necntocsngio | LA0AE~ | 0,120-0.161 ce ardouterroer | LIOOAE | (0.0047-0.0063) oD. | eee ‘Outer and nner | L4QAE~ 7.97-8.00 7.90 tehor with LiooAe | (0.8138-0.3150) (08110) LAQAE~ 8.02-8.05 8.10 Housing dept | L400AE | _(0:9187-0.3169) (0.3189) Clearance bot | | ween housing | LAQAE~ 002-008 | - andinevouter | LiQ0AE | (0.0008-0.0031) rotors | Clearance between the inner and outer | L40AE~ <0.14 0.25 rotor | Looe (0.0055) 40.0098) Cylinder compression pressure at 8000 | L4OAE~ | 2042 kPa (30 kgl/om®) | 2452 kPa (25 kgi/em*) rpm engine spoed (turn the starter motor)| LTOOAE 427 psi) [356 psi} ‘Cylinder compression pressure at 500 | LAOAE~ | 2452 KPa (25 kal/em") 1961 KPa (20 kom?) rpm engine speed (pull the recoil starter) | L1OOAE. [256 psi] (264 psi} 73. Disassembly and Reaseembly 3.1 TOOLS, METERS AND INSTRUMENTS Disassembly and Reaseembly Keep the following tools, jigs, and other service items on hand to ensure accurate measurement and diagnosis and efficient servicing. 1. Tools Name of tool Description (YANMAR Code No.) illustration YANMAR service tool set_—_| Type A (including 65 tools) (955000-00001) ‘Type 6 (including 46 tools) (85500-00002) Piston inserting tool ‘Commercially available Hexagonal wrench (955500-02476) For ¢60~125 Bore Pliers (28180-000130) (included in YANMAR service tool set) ‘Shaft pliers (28190-000020) (included in YANMAR service tool set) Piston ring remover | (135410-92140) Cleaning needle for fuel | Wire (use $0.19) injection valve Commercially available Pinvise Commercially available (28210-00010)Disassembly and Reaseembly ‘Name of ool ~ Description (YANMAR Code No) ustration Flywhest end nut wrench* | Special-purpose too! for ightening the crankshaft end rut. (14250-92101) Of Flywheel extractor (s14250-82121) Wodel Bot [pos | Nut__[pes) TAOAE -L70AE | 26116. | 3 | 26716 | 6 | 50454 ‘050002 L75AE-L100AE | * 4 c 2 SE | | | | il seal fiting too!” oe ‘Applicable part Gylinder block |” Sidecover Code (Crankshaft) | (Crank & Cam shaft 114250-92511 a LAOAE, L4SAE 114350-92311 |LA0AE ~L70AE| L6OAE, L70AE 114650-62310 ~~ U7SAE =L100AE (Oi seal iting guide* After insertion of seat into crankcase cover, use this tool to install crankcase cover on cylinder block. sig for inserting crankshaft and camshaft ol sls Code ‘Applicable Model 114250-02301 | LAOAE'S, L48AE-S, LA0AE-D, 714368-92800 i 14350-92301 14368-92300 | L6QAE-DE, L7OAE-DE | | [iitaes0-s2300 LSOAE'S, LIGOAE-S | | {"¥¥4868-92300 Valve stem seal iting tol” | yg, 7 LAOAE, L4BAE | 114250-92950 _ LGOAE, L70AE | 114360-92950 T75AE-TOOAE | 174650-92950_| "Dimensions of stem seal fitting tool are detailed in Appendix 2. 19 2a fiting tool, oil seal fitting guide, flywheel tightening handle, flywheel extractor and valve2. Meters, Instruments, and Service Accessories (Necessary for middle- and small-size engine service shops) Disassembly and Reaseembly ~ Typical sizes — Instrument Name. Description Hilustration Dial gouge mm Gn “To measure bonding and Tev. [0.04 (6.0004) ‘gap of the shaft, Range [0-8 (0-0.197) etorton ete. QD [0-10 (0-039 | ago SJ ‘Test indicator _mm (in. To measure positions too | idiv. | 0.01 (0.0004) _| narrow and too for aed Farge [0-038 (0-0084) Toma delicate. | a) Magnet stand fm (©) 9 attach cit incicators to Wain bar ‘Sub bar various positions for easy (ea. xlength)_| (ia. xlength) | accurate viewing, waxi7 | toxtes | | (0.472 x 6.929) | (0.994 x 6.496) | a tax toa 12x 165, | SB (0.561 7.206) | (0.472 6.496) Micrometer Range mm (tn) To measure the O.D. of 0-25 (6-098) the erenkshatt, piston, ‘26-50 (0.984-1.969) piston pin, etc. 50-75 _(1.960-2.953) finder mm (in.) To measure the |.D. of the. ee 10-18 (0384-0.708) | cylinder liners ant + ; | ¥aa5(0:700-1.978) beaings. ——>-() [35-80 (1278-2.962) ‘50-100 (1.969-3.937) Verrier catpers Tomeasure utsie | ameter, depth, thickness, wie, ete a Vy Depth micrometer Tomeasure value sitkage | and liner projection. min) ‘To measure the incintion eae Size | 100 (8.097) of valve springs and ‘squareness of various: pars. V-block Use when measuring the Size [100 x50 x55 bending of a shaft. (3.937 x 1.9685 x 2.165 in.)|Disassembly and Reaseembly (Vana cade te) istration Torque wrench Size Use when tightening sm in.) bolts and nuts with a speed torques. (0.296-0.551) (21.7-578) 78 (0591) | 300-1,600 Wales | 2171527) 21 (0.827) Plastigage ‘To measure ol clearance between crankpin and main bearing. Type ‘Applicable clearence mm (n.) Plastigage PG-i (Green) __0.025-0.076 (0.001-0.003) PR-1 (Ried) | 0.051-0.152 (0.002-0.006) PB-1 (Gray) | 0.102-0.220 (0.004-0.008) Thickness gauge _| To measure clearances between piston rings and piston grooves or | betwaen shat couplings during instalation. Battery electrolyte To inspect antireeze solution and tester i electrolyte for spectic gravity, and (25500-00013) charging condition. ean Compression gauge | L40AE ~Li00AE 3 sure inthe oylnder. Too set TOL-87190060 Nozzle tester Pressure gauge: 0-500 kg/cm? To inspect spray condition and (737600-93502) the injection pressure ofthe fuel injection valve High pressure pipe 124203-89400) | Color check law election) || Penetrant 450 c2 (27S eu.in) | Usein detecting ion ae, renee | 2 CO Developer 45006 (27.5 eu, in) A Set product = ao (@ bottios) Cleaning agent | 450 06 (27.5 cu. In) (@75500-004560) _| | (@7550-004520) WS 21Disassembly and Reaseembly 3. Instruments (Select the appropriate thermometer and tachometer from among the following types.) Instrument Name (Yanmar code No.) Description Mustration Thermometer | Digital type Instantaneously measures temperature in each cylinder using a select switch. Model: BT-800 {955000-08000) ‘Sensor CAG4 {@55000-08640) Tachometer | Photoslectic ype Revolving body Reflecting tape is applied to the outside (non-contacting) of the rotating parts to measure RPMs. Capable of measuring RPM of reduc- 1 Model HT-441 tion gears, step-up gears, and pulleys. | (@8500H-T4410) Reflecting Tape Rellecting tape (10 pieces) (955000-01041) High-pressure fuel | Measures engine RPM's using pulse system, pipe clamping type Model: GE-450 (955000-01045) ircuit tester To measure resistance, DC voltage, AC voltage, DC current, and for continuity testing.Disassembly and Reaseembly 3.2 TIGHTENING TORQUES Standard bolts and nuts tightening torque: M6 70-100 kg-om (6.1-7.2 Ib-f) M8 180-200 kg-cm (13-14.5 lb-ft) ‘Where specified torque be Thread No. | Tightening torque Romarks applied Model ia. xpitch ‘kg-cm (Ib-f) LAOAE-L70AE Me x1.25 (ERR) | Hexagonal dimension: 12 Valve rocker arm support = L75AE-L100AE M10 x15 (er iceeey | Hexagonal dimension: 14 1200-1300, ane LAOAE-L7ONE went (g68-040) | Hexagonal dimension: 24 "2200-2300 i ee L75AE-LIO0AE i815 (aorta) UoAE, Leone | 14MBx10 | (28-229 | Hexagonal mension: 10 ‘Crankease cover bolts s LeOAE-L100RE | 13-MB x 1.25 (70-230, _| Hexagonal dimension: 12 Sifener bolts on crankcase T “| 200-230 cover LAOAE-LIG0AE MB x 1.25 (ane LAOAE, L4BAE MB 1.28 prenrs Hoad stud bolts . iz 1805150 |e 7 ud bolts (stud side)* | L6OAE, L70AE 4M > 1.25 (eros) | Apply ‘screw locking agent L7SAE-LIOOAE | M10 x1.5 rae ‘Apply oto the face ofthe L40AE, L4BAE 4-M8 x 1.28 nee) threaded part ; Hexagonal dimension: 12 : - 420-460 : Gylinder head nuts" L6OAE, L70AE 4M x 1.25; 204-33) | Hexagonal dimension: 14 L7SAE-LIOOAE | 4M10x1.5 aoa) | Hexagonal dimension: 17 “400-450 : FO nozzle case nut LORE-LICOAE | +-0505-40UNS-28 | ggg-spgy | Metanonal dimension: 18 FOpurpdelvoryhader | LAORE-L100AE | wai | 309-950, | Hexagonal mension: 17 FO pump stud bolts Gee i (stud sidey* LAOAE-LI00KE | 9M x10 ‘Apply “screw locking agent” FO pump nuts LAQAE-L100AE 3.MBx1.0 Hexagonal dimension: 10 FO nozzle bolts (stud side)* | L40AE-L100AE 2.M6 x 1.0 ‘Apply “screw locking agent” FO injection nozzle nuts L4OAE-LIO0AE | 2M6x1.0 Hexagonal dimension: 10 7] eee ‘Apply ol to the face of the LUOAE-L7OAE | M710 (eet ian Connecting rod bolts & nuts* -2) _| Hexagonal dimension: 10 375-405 LSAE-LI0OAE | 2MBx10 ERE _| Hevagonal dimension: 13 Notes: 1. For bolts and nuts marked *, apply engine oif to the thread and seat. 2. For bolts and nuts marked *, apply screw locking agent to the thread before threading them. 233.3 MAINTENANCE SCHEDULE Disassembly and Reaseembly Periodical maintenance is the key to a smooth-running, long-lasting engine. The table below shows when checks should be carried out. © Check, Add @ Replace ‘Operating FOUTS | Every Every Every Every Every Every ttem day 20 - 50 hrs yoows | 200hrs | 500hrs | 1000hrs Check ten (Head bolt Chock and retihton al bots a uonenea) ° ‘Check and add engine oil ° | tat (2nd and Change engine ol a x e ‘Cheok and add fuel oi ° Replace as, ‘Clean and replace ol iter | requierd. e asses ‘Air eleaner Paper _| (in dusty conditions, the element should be replaced more frequenty)._@ every 800 hours element (Type) {Oi bath] 7 Clean fuel fitor (replace. Oo ment) ‘Check for oil leakage ° “(engine oi, tet ol) ‘Check injection nozzle ° Check injection pump ° Adjust valve clearance of (1st) intake and exhaust valves | © | Inspection and retacing of intake and exhaust valve ° seats Replace piston ring e Check the surfaces of brush ° (for YOR and slip ring generator) Chee oer sear ‘Check the battery once a month and add electrolyte if necessary. Drain fel from F.0. tank Monthy | (Replace if Check uel piping | wean oO Clean sperk arrester ° (option)Disassembly and Reaseembly 3.4 DISASSEMBLY PROCEDURES Basic procedures © Gather the required tools, jigs and meters. ¢ Have a notebook, ete, ready for recording service information. « Fill containers with cleaning solution for cleaning parts. Prepare a special place for parts and contain- ers. Drain old lubricating oil from engine. Arrange disassembled parts. Keep all bolts and nuts with their relative parts to make sure they are not reassembled incor- rectly. «Determine exactly what the problem is before disassembly. Never remove unnecessary parts. 1. Fuel tank 1) Pull the overflow pipe out toward the tank. 2) Release the hose clamp on the pump side of the fuel pipe. 3) Remove the fuel tank stay (upper part). 4) Remove the fuel tank. (Pull the oil pipe on the pump side up and out.) ‘ Release the hose clamp on the pump side. Removing the fuel tank 2. Exhaust silencer 1) Remove the flange nuts. 2) Remove the stay bolt. SRG Removing the exhaust silencer 3. Air clearner 1) Remove the air cleaner cover. 2) Pull out the filter element. 3) Remove the cleaner case. Removing the alr cleaner 4, Recoil starter ‘The recoil starter does not have to be removed every time. Remove only when necessary. 5. Cooling fan case Remove the cooling fan case.Disassembly and Reaseembly ‘Starter pulley Removing the cooling fan case 6. Starter pulley Remove the starter pulley. 7. Air intake bend Remove the air intake bend. Removing the air intake bend 8. Starting motor. (Only for starter motor specification.) Remove the starting motor. 9. Valve rocker arm cover Remove the valve rocker arm cover. 10. Valve rocker arm assembly Remove the valve rocker arm assembly. Removing the valve rocker arm assembly 11, Push rods Pull out the push rods. 42, Fuel injection valve 1) Remove the fuel injection pipe. 2) Remove the fuel injection valve. «If the valve is tight, loosen the nuts using a wrench with the fuel injection pipe set. ‘* Be carefuly not to damage the nozzle gasket (insulator) and nozzle spacer. Nozzle gasket Fuel injection valve disassembled 26Disassembly and Reaseembly 13. Cylinder head 1) Remove the cylinder head ‘¢ Keep the combustion surface faced up. 15. 1) Remove the oil pump cover. 2) Remove the oil fiter cover. Crankcase cover 3) Remove the crankcase cover. Removing the cylinder heed 16. 14, Fuel injection pump 1) Remove the fuel injection pump. ‘© Remove the pump together with the base plate. ‘© Make sure the hooking of control lever in rack before disassembly. «Pull out any remaining flat tappet. Removing the fuel pump 27 « Step 1) and 2) should only be done when necessary. ‘* Be carefuly not to damage the oll seal. Removing the crankcase cover Camshaft Pull out the camshaft © Check the timing mark. Keep exhaust and intake tappets sepa- rate. They may fall down when pulling out the camshaft and may be confused. Removing the camshaftDisassembly and Reaseembly 17. Balancer shaft Pull out the balancer shaft. Zo 7 9 S14 y fe LTS) Removing the flywheet ace USL i te 20. Crankshaft Removing the balancer shaft 1) Remove the flywheel key. 2) Remove the bearing holder. 18, Piston and connecting rod assembly 3) Pull out the crankshaft. 1) Remove the connecting rod tightening nuts. «© Be carefully not to damage the oil seal. 2) Remove the big end cap. (GE a 3) Move the crankshaft to the top of the stroke and pull out the piston. «Remove carbon deposited on the upper inside surface of the sleeve (when ex- tracting the piston). «Make sure the main bearing is in the proper position, Removing the rod bolts and nuts. 19. Flywheel Pulling out the crankshaft 1) Loosen the lock nut. 2) Remove the flywheel. «Use flywheel extractor (special tool). « Securely thread in the extractor bolts.Disassembly and Reaseembly 21. Governor or speed control device Remove the governor or speed control de- vice if necessary. 3.5 REASSEMBLY PROCEDURES Before reassembly Throughly clean and check all parts. «Apply new engine oil to the sliding and rotat- ing parts. Use new packings and O rings. Use liquid packing agents to prevent oil leakage. ‘* Make sure the clearance between parts (for oil, thrust, etc.) is correct. ‘© When reassembling, line up matching marks on parts. * Use the proper bolts, nuts, and washer, Tighten the major bolts and nuts to the speci- fied torque. (Be especially careful with aluminum alloy parts. These are easily dam- aged.) «Apply engine oil to threaded parts and flange faces, before tightening the major bolts to the specified torque. 4. Governor or speed control device Reassemble the governor or speed cotrol device, if it has been removed. 2, Crankshatt 1) Insert the crankshatt. 2) Attach the key (flywheel) to the crankshaft. 3) Install the bearing holder. « Make sure that the crankshaft has been inserted as far as it will go. + Grease the oil seal lips. «Apply oil to the crankshaft journal and pin. © Damage or scratches on the governor lever shaft can cause hunting and other troubles. Be sure to check the position to retain the regulator spring before re- moval. Installing the bearing holder 3, Flywheel Tighten the flywheel with the retaining tool. Tightening the flywheel Flywheel Tightening Torque kg-cm (Ib-ft) L40AE-L70AE 1,200-1 ,300(66.8-94.0) L75AE-L100AE 2,200-2,00(159.1-166.3) 4. Piston and connecting rod 1) Insert the piston and connecting rod as- sembly, move the crankshaft to Top Dead Center. The mark on the piston head should face the crankcase cover side.Disassembly and Reaseombly 2) Install the big end cap. (Always use a washer for the tightening nuts.) Apply oil to the crank pin. Install the rings in the proper direction. Apply oil to the outer surface of the pis- ton and the inner surface of the sleeve. Make sure the main bearing is in the proper position. ‘Check Whether the rod bolts retainer is in position. oe . Connecting Rod Tightening Torque —_kg-cm (Ib-ft) L40AE-L70AE | 180-210 (13.0-15.2) L75AE-L100AE | 375-425 (27.1-30.7) Installing the connecting rod big-end cap 5, Camshaft, Balancer shaft 4) Insert the tappets. 2) Insert the camshaft. 3) Insert the balancer shaft, Inserting the balancer shaft ‘* Do not confuse exhaust and intake tap- pets. «Make sure the gears’ matching marks are lined up. . Fuel injection pump reassembly (Temporarily fix in proper position) Line up the injection volume marks (marking- off) and attach the control lever to the gover- nor lever fork. Reassembly the fuel injection pump with a nut, for positioning purposes only. « Make sure the adjusting shims are used correctly. Installing the fuel injection pump 7. Crankease cover 1) Place an aluminum packing between the surface of the crankcase and the crankcase cover. 2) Reassemble the crankcase cover. (Tighten bolts in the sequence shown in the below figure. Tighten bolts diagonally) «To protect the oil seal, attach the jig for inserting the oil seal to the shaft prior to insertion. ‘Apply grease to the lips of the oll seal. Apply oil to the crank and camshafts. Make sure that the oil pump drive gears are properly engaged. 30Disassembly and Reaseembly Attaching the crankcase cover and tightening three orders Case Cover Tightening Torque kg-om (lb-ft) LAOAE, L4BAE 100-120 (7.2-8.7) L6QAE-L100AE 200-280 (14.5-16.6) 3) Stiffener bolts have been added on the crankcase cover to reduce vibration and noise. For an engine with stiffener bolts, tighten them after the bolts on the periph- ery of the crankcase cover are tightened. Stiffener Bolts Tightening Torque __kg-cm (lb-ft) L40AE-LI00AE 200-230 (14.5-16.6) 8. Fuel injection pump reassembly (final) Tighten the fuel injection pump See page 58, ‘Fuel Injection Volume fi tation.” Fuel injection Pump Tightening Torque kg-om (Ib-ft) 100-120 (7.2-8.7) L40AE-L100AE 9. Cylinder head 1) Place a gasket packing on the cylinder blook. 2) Attach an O-ting. 3) Reassemble the cylinder head. ‘© Make sure that the nozzle insulation 31 packing and spacer are in position. * Before reassembling the valve spring, place its identification mark (white paint) toward the cylinder head, (L75AE— LIO0AE) Tightening the bolts of the cylinder head Tighten separatery with two times. Cylinder Head Tightening Torque _kg-om (\b-ft) 7 NG Final First LADAE, L4BAE [150 (10.8) | 260-320 (20.2-23.1) LOOAE, L70AE _|220 (15.9) | 420-460 (30.4 -33.3) L75AE-L100AE |300 (21.7) | 540-580 (39.0-41.9) 10, Push rods Insert the push rods. ‘¢ Ascertain that the tappets are properly in- serted. 11. Valve rocker arm assembly 1) Reassemble the valve rocker arm assem- bly. 2) Adjust the valve clearance. InJEx.-valve head clearance: 0.15 mm (0.006 inJcold state) ¢ Be careful not to lose or damage the knock pin.Disassembly and Reaseombly Valve Rocker Arm Tightening Torque kg-om (Ib-ft) L40AE-L70AE 200-230 (14.5-16.6) L75AE-L100AE 430-470 (31.1-34.0) a) me Nozzle gasket Install the fuel Injection valve Fuel Injection Valve Tightening Torque kg-cm (Ib-ft) L40AE-L100AE 100-120 (7.2-8.7) 14. Intake bend Install the intake bend. ‘« Make sure the intake bend packing Is in position. Tightening the valve rocker arm 15. Cooling fan case 12. Valve rocker arm cover Install the valve rocker arm cover. 1) Install the starter pulley. Make sure the packing is in position. 2) Install the cooling fan case. (Re-atiach the recoil if it has been re- 13. Fuel injection valve moved.) 1) Insert the fuel injection valve. » Attach the seal rubber to the case. 2) Install the injection pipe. ‘* Make sure the collar and fancase sup- porting rubber are in the proper position. (Check injection timing. See page 60.) 3) Tighten the injection valve. ¢ Make sure the fuel injection valve faces to the proper direction. * Replace the nozzle gasket. 32Disassembly and Reaseembly 16. Air cleaner 18, Exhaust silencer 4) Attach the air cleaner case. Install the exhaust silencer. 2) Install the element. «The silencer cover does not have to be 3) Install the cover. removed. ‘e Make sure the intake bend and packings «Model L75AE ~ L100AE have not a rear in position. cover. Paper case foment cover ‘Air cleaner Exhaust silencer 19. Fuel tank 1) Connect the fuel pipe to the fuel injection pump. 2) Attach the fuel tank using the upper stay. 3) Insert the fuel return pipe to the fuel tank © Make sure the fuel tank supporting rubber (vibration absorbing rubber) stays in place. {(0i1 bath type air cleaner) {b) Intake bend 17. Starting motor (Only for model with starting motor) Install the starting motor. Installing the fuel tank 333.6 RECOIL STARTER The recoil starter will not be trouble in normal usage. However, should it break, or when it must be lubricated, disassemble and reassemble it according to the following procedures: (Tools used: box wrench, pliers, screw driver) 1. Disassembling procedures ~ 1) Remove the recoil starter from the engine. (Use box wrench.) 2) Pull out the grip and draw out the starter fope for approx. 30 om. When the reel's notch came at the outlet of the starter rope, fasten the reel’s turning by your thumb and draw up the starter rope inside the recoil starter using a screwdriver as shown in Fig, (a). Then, wind back the rope until the reel stops to tum by turning the reef with your thumb at the reel's notch. LADAE + L48AE Eng Trust washer, op (b) L6OAE + L70AE Disassembly and Reaseembly (@) 3) Remove the parts as shown in Fig. (b)~(d). To remove the E-ring, fasten the shaft by the pliers, and twist the E-ring left and right. © Model L60AE/L70AE have an additional slide plate. Model L40AE/L48AE and L75AE to LIO0AE have only the friction plate (Model L6OAE to 100AE differ in the recoil starter complete and tightening nut (E-ring) both of which are used for the threaded recoil shaft.) L75AE-L100AE Lock nut Soring washer ~ washer Washer 8 @® _— Friction plate Return spring. — F' a Spring Top scrowDisassembly and Reaseembly y 4) Remove the reel from the starter case as shown in Fig. (e). Take out the reel slowly while turning it lightly to the left and right to remove the spring. Take care not to take out the reel quickly. Otherwise, the spring may jump out its housing. (If the spring runs out of position, put it in the starter case as illustrated in Fig. (f)) {e) . Assembling procedures 1) Check that the spring is set correctly in the starter case housing. Adjust the shape of the inner end of the spring to locate it at about 4 mm from the starter shaft for mak- ing the reel's hook engages with the spring correctly. (The inner end of the spring can be simply reshaped by pliers for a length of about 10 mm.) ‘Spring outside end Good Hock of rel 2) Wind the starter rope around the reel to the arrow mark direction as shown in Fig. (9). Take out the rope from reel’s notch at the 2.5 turns, fit the reel’s hook to the inner end of the spring, and reassemble the reel cor- rectly into the starter case, (The reel’s hook can't be seen on reassembly, so take care to reassemble correctly as the improper ex- ample shown in Fig. (f).) 9) 3) Hold the starter rope as shown in Fig. (h). Wind it 4 turns in the arrow direction while securely holding the reel so that the rope may not be reversed. Lead the starter rope from the inside to outside. Slowly turn the reel in reverse. 4) Assemble the removed parts in the reverse order of the disassembly in Fig. (g). When setting the friction plate, first set the return spring slightly lit and then insert it into the mating hole of the friction plate, as shown in Fig. (h) and (i). Tur the friction plate a little to the arrow direction. When the ratchet boss aligns with the guide, assemble the thrust washer and the E-ring (nut for LG0AE and upper mod- els) while securely pressing down the fric~ tion plate to the reel. (Place the E-ring in the groove of the starter shaft once manu- ally, and then fasten it with the pliers.)Reassembly Hole for rturn spring () L75AE-L100AE This completes the disassembly and reassembly. For cautions sake, be sure to check that all the parts are reassembled correctly according to the following procedures. 3. Checks after reassembly 1) Pull out the starter rope a ite by pulling the grip 2 or 3 times. @When the grip is too heavy to pull, check whether the parts are reassem- bled correctly. @® When the ratchet does not move, check whether the friction spring is reassem- bled. 2) Pull out the starter rope for the full stroke with drawing the grip. @ When the starter rope is left inside the reel or the starter rope will not return at all, an undue force is applied to the spring. In this case, rewind the starter rope one or two tums according to the procedures under Fig. (a). @When the return of the starter rope is weak, or the grip hangs down in the midway, lubricate the friction parts with several drips of engine oil. When the failure can't be corrected still, rewind the starter rope one or two tums. (Check whether an undue force is applied to the spring, according to the procedure in © above.) @When the spring is detached from the teel’s hook and the starter rope can't be wound inside the reel, follow the reassmbly procedure again.Checking at icing 4. Checking and Servicing 4.1 CYLINDER HEAD 1. Combustion surfaces Remove the fuel injection valve, intake valve, and exhaust valve. Clean the valve combus- tion surface and check for crack and other damage. Use the color penetrant to check for minute cracks. 2. Intake and exhaust valve seats The valve seats are cold-itted in the cylinder head to improve its wear resistance. Clean off carbon deposited on the valve seats since carbon build-up, excessive wear and corrosion can cause compression leaks. Valve seats are chilled by the liquid nitrogen and inserting to the cylinder head. (temperature difference: 190°-200°C (374-392°F) Sat with Valve seat mm (in) Model L40AE —L100AE fem Standard | Service limit Seat angle(@) | __60°-90° = | 1.5-3.0mm Seat width | (0.059-0.118 in.) i 37 i SY Intake/exhaust valve assembly 3. Intake/exhaust valves, and valve guides 1) Check the valve stem for wear and distor- tion and replace If necessary. Do not confuse the intake and exhaust valve stems. 2) Check the valve sinkage. Replace worn- out valves (See service limits below). SinkChecking and Servicing mm (in.) [Wore] L4QAE-L100AE tem Standard | Service limit : 03-07 14 Valve sinkage | (0.012-0.028) (0.043) In/Ex. Valve guide and valve stem me (in) ea Valve guide 1.0. Valve stem 0.D. Model Intake Exhaust Intake: Exhaust 5.465-5.475, 5,450-5.460 Lae Standard 55-5515 (0.2165-0.2171) (osise-d2iee) | (02146-02150) Service limit 558 (0.2197) 5.40 (0.2126) 5,960-5.975 5,945-5.960 Leoae | Standard 6.0-6.015 (0.2362-0.2368) (0.2346-0.2952) | (0.2341-0.2346) UTOAE [Service imit | _ 6.08 (0.2304) 5.90 (0.2323) 960-6: ,945-6.9% LISAE | standard 7.0-7.018 (0.2756-0.2762) (ooroaeras) (onrseo2r40) LIOOAE | Service limit 7.08 (0.2787) 6.90 (0.2717) CAUTION: 1. The intake/exhaust valve guides are provided Ceca with a valve stem seal. Stem seals cannot fexcdg was) be reused, and must be replaced with new ones. 2. When inserting the intake and exhaust valve apply lub. oil to valve stem. Valve guide I Te Lagae Lesa = 98 mm (9740 in} LEOAE - C7OAE = 6.5 mm (0.3946 in UPSAE~C100AE =13.5mm(0.5915in) (Valve stem seal) 38Checking and Servici 4, Valve spring 1) Check the valve spring for flaw and corro- sion. 2) Measure the free length. 3) Measure the spring inclination (how far the spring inclines to the left or right). 4) Measure the spring tension (on a spring tension tester). arable pitch Applied fo U7 1D mark (white painted) Precaution for assembling the valve ‘spring. (Applicable to L75AE to L100AE) Place the identification mark (white painted) of the valve spring toward the cylinder head. 5. Measuring the top clearance 1) Remove the cylinder head. Place high-qual- ity fuses (61.2 x about 10 mm (0.39 inch) at three points on the upper part of the piston. 2) Reassemble the gasket packing and the head. Tighten them to the specified torque in the specified tightening order. 3) Press down the fuses with the piston by turning the crankshaft in its normal direc- tion. 4) Remove the cylinder head and take out collapsed fuses. Measure the thickness of three crushed fuses. Instead of removing the cylinder head, thread a string tied to the fuse through the nozzle hole, pull it out to bring the fuse on the cylinder head as shown in the figure below, and apply step (3) described above. 5) The top clearance is the average of the three measured thicknesses. Obtain the mean value of the three thicknesses. Valve spring mm (n.) Mode! LAQAE, L48AE L6OAE, L70AE L75AE-L100AE item Standard | Service mit | Standard [Service fimit_|~ Standard | Service limit 28 26.5 33 315 40 39.5 Free length(A) (1.102) (1.043) (1.299) (1.240) (1.575) (1.555) <0.75 <10 Inclination(B) i (0.030) oat 7 (0.039) oe Spring tension 1.1414 fe sae 1,80-2.51 a pertimm kg (Id) | (2.51~3.09) (3.97-5.51) 39Checking and Servicing mm (in) 6, Intake and exhaust valve rocker arms Modei TAOAE-LIO0AE and push rods ftem PEECEEEEE EE semanas 1) Valve rocker arm shafts 05-07 Measure the O.D. of the shaft and the |.D. Top clearance (0.0197-0.0276) of the valve rocker arm. Replace the valve rocker arm shaft or valve rocker arms if it exceeds the service limits. INJEX. Valve rocker arm mm (in) Model] L40AE-L70AE L75AE-L100AE Item Standard [Service limit] Standard __| Service limit O.D. of IN. &EX. | 44.989-42,000 | 11.90 | 14,989-15.000 | 14.90 bo ltaaeateny (0.4720-0.4724) | (0.4685) | (0.5901-0.5906)| (0.5866) LD. of IN. & EX. 12.016-12.034 | 12.10 | 15.016-15.034 | 15.10 valve rocker arms | (0.4731-0.4738) | (0.4764) | (0.5912-0.5919)| (0.5945) 2) Push rods Check the push rod length and distortion. Push rod mem (in.) Tem Push rod length Push rod distortion Model Standard Service limit Standard | _ Service limit L40AE, L48AE 130.2 (6.110 — 5.126) LEOAE, L70AE }-162.7 (6.390-6.406) - < 0.05 (0.0020) | 0.3 (0.0118) L75AE-LIO0AE | 196.8-197.2 (7.748-7.764) 40Checking ar icing 7. Adjusting the valve clearance 1) The valve clearance should be adjusted while the engine is in the cold state. ‘Adjueting sow loarance Leck ut Valve clearance mmm (in.) Model L40AE-L100AE Item. Standard Intake 0.15, Exhaust (0-0.059) 2) The table below shows the proper valve timing. Valve timing Modell | 40AE-L70AE | L75AE-L100AE ea Standard open | bTDC 25" bTDC 20° Intake closed | aBDC 53° aBDC 53° ‘open | bBDC 59° bEDC 53° Exheust! closed| _aTDC 25° aTDC 20° 8. Identification of cylinder head Model L70AE is provided with the cylinder head peculiar to the model, and has an iden- tification stamp accordingly. dentiicaton stamp L70AE:7 a4 4.2 PISTON AND PISTON PIN 4. Piston CAUTION: The intake/exhaust valve recesses are added to the top surface of the piston (applicable to L40AE -L70AE) as a result of a change in the camshaft. When replacing piston, take special care of Interchangeability of parts 1) Checking the piston top and combustion surface Remove carbon build-up on the piston top and combustion surface. Be careful not to scratch the surface. Check the combustion surface for damage. 2) Checking and measureing piston 0.D. (1) Replace the piston if the outer surface and ring groove are damaged exces- sively. (2) Measure piston ©.D. across the piston pin approx. 12 mm (0.47 in.) from the bottom end of the piston. 3) Piston and piston pin To remove piston pin, heat piston to 70— 80°C (158-176°F), before extruding it To reassemble it, repeat the same step.hecking and Servici 2 Piston pin Measure the O.D. of the piston pin. Replace if it wom exceeds the service limit or exces- sively stepped and worn, {Measuring point of piston pin) Piston pin 0.0. mm (in) jo Model LagAE, L43AE L60AE, L70AE L75AE-L100AE Standard 18.992--19.000 20.991-21.000 22.991~23.000 tar (0.7477-0.7480) _ (0.8264-0.8268) (0.9052~0.9055) ae 18.92 20.91 22.91 Service Limk (0.7449) (0.8232) (0.9020) 3. Checking piston pin hole Piston 0.0. mm (in.) 1) Replace the piston if the pin hole is Model Standard Service limit | discolored or damaged. Laoae | 67.965 (2.6758) | 67.60 (2.6646) | 2) Measure the I.D. of the piston pin hole. If LasAE 69.965 (2.7545) | 69.70 (2.7441) it exceeds the service limits, replace the L6OAE 74,965 (2.9514) | 74.70 (2.9410) piston. LTOAE | 77.965 (3.0694) | 77.70 (3.0591) 3) Piston replacement procedure L75AE | 79.965 (2.1482) _| 79.70 (9.1976) Heat the piston to 70~80°C (158~176°F), TSOAE | 69.965 (2.3057) | 83.70 (8.2953) i satets, [L | 83.965 6.3 = align the small end hole with the piston pin TC jooneli 7 eaiiss casaaq) fiasco ara) hole, then, insert the piston pin into the hole. Recommended way of heating Heat the piston in oil. Avoid heating it directly. {Checking piston pin hole) Clearance between Piston and Sleeve _mm (in.) Model Standard | Service limit L40AE- | 0.04-0.06 i LSAE | (0.00157~-0.0026) hi 0.05-0.07 UHOOAE | (©.00197-0.00276) | - Piston pin hole LD. mm (in) Model Standard ‘Service limit T40AE- | 18.985-18.996 19.07 Lasae (0.7474-0.7479) (0.7508) LéOAE- | 20.983-20.996 21.07 L70AE (0.8261~0.8266) (0.8295) L76AE- | 22.963-22.996 23.07 LiooaE | (0.9048-0.9054) (0.9089) 42Checking and Servici Clearance between piston pin hole and pin mm (in) Modal Standard ‘Service limit | 0,004-0.015 a L40AE | (0.0002-0.0006)_| sting LaBAE— | 0.005-0.017 — YP ee LiooAE | _(0.0002-0.0007) 7 T 4, Piston rings Tapered toe 1) Measuring piston rings Measure the thickness and width of the Col expander piston ring. Insert the piston ring into the piston ring groove and measure the clear- ance. (Ring contiguration) Replace the piston ring if it exceeds the service limit. Piston ring tetrng nding Oiring Neco! 7 2 T 8 T 3 z zi2s | 170-1485 | 275-295 | ia7o-ias0 | 26-28 | 9470-0490 ane tansard | (9.1069-0.1141 | (09579-0.086) | (0,1000-0.1161) | (00878-00887) | (01024-01102) | (01988-0.1374 | Service 252 136 275 136 28 336 int (@:0082) (0035) | 1083 (0.0555) (0.0980) (e120) 1 30-02 | iaro-14s5 | 30-32 | 1470-1490 | 2024 | 9470-0490 rane Satee_| oat-0.tee0) | 0.0879-0.0888 | (os t8t-n.taee) | (20579-00587 | (00787-0048 | (1365-01974) "Senice 27 136 277 1.26 +90 336 im (es1090) (09585) (0109) (0.0585) (ores) oxy) sunoee |, 9234 | 1470-1408 | 9294 | 1470-1490 | ares | 3470-3499 ie (0.1260-9 1299) | (00579-00585) | (01360-0,1909) | (01578-00587) | (0.0827-0.0964 | (0.1368-0.1974) Une 287 136 | 287 136 207 336 ime coatos) (09885) ites) (0.0585) (ots) 1829) gerd | 3235 | 1470-1405 | a395 | te70-100 | 2428 | Sa70- m0 sae | (oxa99-0.197@) | (06579-00058 | (01900-0.1978) | (09776-00783) | (0.0945-0.1102 | (01563-01571) tA Senice | 307 136, 307 1.86 237 396 it | 1208) (00885) (ore) (os732) (0.0988) 01820) sundae | 3436 | 1470-1485 | 34-05 | 1a70-1900 | 25-20 | Ga70-9000 (0.1088-0.1417) | (0.6579-0.0505) | (0-1289-0.1417) | (0.6776-0.0789) | (0.0084-0.1141) | (0:1869-0.1571) Le0hE —[Seniee a7 736 ai7 7.36 2a ry int oz) (015535) © (06732) ovr | _ 0.1820) sansa | 3638 | 1a70-1405 | a ‘sro-1e00 | 25-29 | 3970-3300 tious (o.1419-0.1496) | (0.0578-0.0865) | 0-1417-0.1496) | (0.0776-00708) | (0.0964-0.1141) | (01889-0.1571) Sovice 337 736 397 136 247 288 mt (oa3) (015585) (01327) 05732) coxa) (01820) 43Checking and Servicing Piston ring side clearance mm (in.) Model] L40AE- | L7S5AE- item L70AE_| LIQOAE Ring width 18 20 Cinder sleeve tst_ [Ring groove (0.0591) | (0.0787) (Cylinder block ting (0.065-0.095, Side gg [ames | _10.0026-0.0037) fa 0.15 (0.0059) Ring width 15 2.0 ° Pullout ‘on | Ring groove (0.0591) | (0.0787) 4 epton ring 0.03-0.065 7 Side Standard | (0.0012-0.0026) pn OP rising [fTHinse clearance [Limit 0.15 (0.0058) bade if ; Ring width 35 40 ting the pon hea seb raeteos inches ‘oil [Ring groove (0.1378) | (0.1575) Se ring 0.02-0.085 (Measuring of ring end gap) side Standard | (0,0008-0.0022)_ clearance Tit 0.15 (0.0059) Measuring of ring end gap mm (in) Model L40AE-L100AE Item ‘Standard Service lirnit ist | Fn rage [nd 10 Gnd gap SiN9_| (@.0118-0.0177) | (0.0394) Oil 0.15-0.35 ring, (0.0059-0.0138) ‘Measuring the clearance between the piston ring and groove (Side clearance) 2) Measuring piston ring end gap Measure the ring end gap by using a new cylinder, which is free from wear. If meas- uring the clearance in an engine which is in use, measure at the lower part of the cyt inder as this will be most free from wear. Push the ring into the cylinder with the piston top. 3) Cautions when replacing piston rings (1) Use the special-purpose tool to attach or remove the piston ring. Never stretch the piston ting. (2) Carefully clean the ring groove . The end gap of the top ring should face the in- take side. (8) When inserting the ring, the maker should face up.Ghaot (4) Make sure the ring moves smoothly. (5) When inserting the coil expander into the oil ring, make sure the coil expander joint is opposite to the ring end gap. (6) Make sure each piston ring gap is 120° apart. compression ring 45 4.3 CONNECTING ROD 1. Checking the connecting rod 1) Parallelism or distortion of the large and small end holes. Pass the measuring jigs through the large and small end holes of the connecting rod to measure parallelism or distortion. Replace the rod if it is bent beyond the allowable limit. mm (in.) item L40AE-L100AE Paralleliy or distortion 0.05 (0.0020) 2) Side gap of connecting rod Re-attach the connecting rod to the crank pin to make sure the gap in the crankshaft direction is proper. Make sure the thrust surfaces on both ends are not damaged. mm (in) Model or | LAOAE-L1008E [Side gap 0.2-0.4 (0.0079-0.0157)Checking and Servicing ‘Small & large end hole of Connecting rod Model LAOAE, L48AE LGOAE, L70AE L75AE-L100AE Servi Sanice Service tem Standard ‘imi, | __ Standard limit Standard limit ry ya.o12-19.024 | 19.10 | 21.0421.008 | 21.10 | 23.025-29.098 | 29.10 onal ond (0.7485-0.7490) | (0.7520) | (0.8273-0.8279) | (0.8307) | (0.9065-0.9070) _| (0.9084) (Piston pin) | OF 0.015-0.030 ay 0017-0.084 | 0.028-0.044 r= clearance (0.0006-0.0012) (0.0007-0.0013) (0.00%1-0.0017) 10 30.007-30.015 | 30.09 | 96.007-36.015 | 96.09 | 40.000-40.042 | 40.08 Lagoond | (¥-¥ director) | (i.te14-1-1017) | (1.1646) | (1o4176-4.4179)_| (1.4200) | (1.8748-15765) | (1.6780) (Crank pin) [OU 0.025-0.050 0.025-0.050 | 0.083-0.062 clearance (@.0010-0.0020) | — | (0.0010-0.0020) | — | (0.0013-0.0024) | — Material: L40AE-L70AE : Aluminum alloy, stamp forging L7SAE-LI00AE : Carbon steel alloy, stamp forging 2. Checking the crank pin metals 1) Check the contact surface of the crank pin metals for separation, melting seizure, etc. Replace it if it is separated or damaged. od bolt (L7SAE-L10OAE: push bait ype) ‘wast Nut (Check of crank pin metal) her (Only LACAE-L70AE} 2) Measuring clearance between crank pin and crank pin bearing metals. (Use plastigage.) (1) Remove the bearing cap and wipe the oil from the bearing metals and crank pin. (2) Insert a plastigage into the cap on the large end in the crankshaft direction. 8) Attach the connecting rod to the crank pin and tighten the connecting rod to the specified torque. (4) Remove the rod and measure the crushed plastigage with the measuring scale. (Measuring the crank pin metal clearance)Ghecking and Servicing Tightening torque kg-om (lb-t) tom Ot] LAOAE-L70AE | L75AE-LT00AE em | Connecting 180-210 375-425 rod (13.0-18.2) (27.1-30.7) crank pin bearing metals. if it exceeds the service limit. Measuring clearances between crank pins and Line up it using the undersized crank pin metal Clearance between crank pin and metal mm (in) i fae Model) soaE-L70AE | L75AE-L100AE 0.025-0.050 | _0.095-0.062 Standard (0,010-0.0020) | (0.0013-0.0024) Service limit (o.0oa7) (Undersized crank pin metal, Part No.) ie a L40AE, L4gae L6OAE, L70AE L7SAE-LI00AE ‘Standard ~_ | 71250-2360 ~_714350-23600 714850-23600 Under-size 0.25 mm (0.0096 in) 714250-296 714350-23610 | __714650-29610 Under-size 0.50 mm (0.0197 in.) 714250-23620 714350-23620 71465023620 3. Connecting the piston and connecting rod Line up the posi In of the piston top mark and the matching marks on the connecting rod as shown in the illustration. When inserting the piston into the cylinder, position the piston top mark so that it faces the crankcase cover side (gear box). LAQAE~L70AE (Through bot) a fi e 4 LTSAE-L 1000 (Push boi) (Line up the piston and connecting rod) 47Checking and Servicing Piston top mark Piston top marks are stamped, as shown below, depending on specifications [S-spec. or D-spec.] and piston 0.D. (selective fitting with the cylinder block). mm (in) mm (in.) aoe Piston ‘Cylinder block nee ‘S-spec | D-spec Classification of ID 40.015 | k ++0.0080 (0.0006) °F 985 (o.0012) oF '#88 4 49.005 ee ss | ps }————> 5 > 40.020 . eo . (0.0002) a (0.0008) oF more 40.005 | po i 40,020 | : fessthan (0.0002) | ow | on 7 : tess than (9.0908) 0.005 a " 40.010 0.0002) mere en (@.0004) more =0.005 | ” 40,010 lesstnan (002 |g | oy . 7 fess than {3 3008) 0.005 40.005 (0.0006) mre {0.0002) of more d:: standard diameter (Refer to Page 32.) : nominal diameter «The piston is selectivery fitted with the cylinder block as indicated by the arrow mark in the above. (>) «The piston for servicing is supplied in SM or DM irrespective of ILD. of the cylinder blook. (~~)Checking and Servicing 4.4 CRANKSHAFT, MAIN BEARING AND FLYWHEEL 1. Crankshft 1) Stem color check Clean the crankshaft and check for flaws using the color penetrant or by magnatiux rank pin inspector. aed Ball bearing Replace the crankshaft if it is cracked or badly damaged. 2) Measuring the crank pin and journal Check the crank pin and journal for surface wear. If the pin and joural are worn be- yond the allowable limit, replace the padbeata beatsas crankshaft assembly, or grind them and fit them with an undersized bearing metal. Crankshaft mm (in) Mosel HORE, LABAE TBOAE, LORE U7SAELIOORE hem Standard = Standard Seriee | standard | Stet Pin pooes-2008 | 2390 | sovesasoez | aso | sosessesse | 3000 soa 6. Gren toon | crtrray | caiss-tateg, | cata | asroscnsraty | (18700) OW 0.025-0.055 a 0.026-0.055 ~ 0.033-0.062 Giearance| (00010-00020) | — | (o.0010-0.0022) | — 00013-00024 | ‘Jounal | socca-soats | cos | seo0z5c8 | o4ov | s000240018 | soe cox |00. (ererteiy | div | Gaveo-ra7en | ciara) | (1s7ae-t5755) | (i870) bell cy 0.025-0.058 O47. 0.025-0.061 O17 0,025-0.061 0.17, Crank side dearance | (0.0010-0.0023) | (0.0067) (0.0010-0.0024} | (0.0067) {0.0010-0.0024) | (0.0067) journal “ouna’ | $0002-20.015 35007-95018 40,007-40.018 oD. (erecta) | — | daveanaren | — | dsrstcisrs) | Fywhes! [Bearing | 20900-2000 | _ | 34998-28.600 | 39988-40.000 fe | (issoraaern Garsiavo | — | careisra) | | maa) eeozoms | oner-0 an { (0.00008-0.00%0) wooes-0001 | — | @consoooi | — 3) The ball bearing on the flywheel side has been press-fitted onto the crankshaft. (Replace the crankshaft assembly if it is loosened.) 49Checking and Servicis 2. Main bearing metal 1) Checking the metal (metal on the crankcase cover side) Replace the main bearing metal if it is discolored, separated, or damaged in any other way. ‘The main bearing metal has been pressfited into the crankcase cover. Align oil hole in ‘the metal with oil groove as illustrated be- low. CAUTIONS: 1. Mount the metal so that the oil groove faces up. 2. The sinkage should be 1 mm (0.0394 in.) from the thrust surface. Carefully fit the main bearing metal so that the oil groove is on the upper halt. tim ‘Align the oil hole in the bearing metal with the oil groove. (Positioning the main bearing metal) Measure an oil clearance between the main bearing metal and journal. If an olf clearance exceeds the allowable limit, add an undersized bearing metal shown below. (Under-size crank pin metal, Part No.) Model | | tem | Laoag, L4gAc | LODE, L7OAE L75AE-L100AE Standard 114250-02100 14350-02100 114650-02100 Under-size 0.25 mm (0.0098 in.) 14250-02200 | __114350-02200 __114650-02200 Under-size 0.50 mm (0.0197 in) | —_114250-02210 | _—_‘114350-02210 Tt 14650-02210 3. Flywheel 2) Ring gear 1) Timing mark Ring gear has been shrinkage-fitted on the Fuel injection timing mark for measurement are on the periphery of the flywheel. flywheel at approx. 180°C (356°F). ing goar Chamfeting side. a TH TTT hots re to a ar te Te Fywnost ) -spec. engine -speo. engineChecking and Servici 4.5 CAMSHAFT AND TAPPET 1. Camshaft 1) Checking the clearance at the thrust of the camshaft (cylinder block side) Check the clearance at the thrust of the camshaft. The camshaft bearing has been press-fitted into the cylinder block. Main- tain the sinkage between the pressfitted bearing face and the thrust surface of cyl- inder block at 1.4~1.5 mm. 44-15 '0551-0.0767in.) (Cam shaft thrust clearance) 2) Measuring the camshaft and bearing (Crankcase cover side) Measure the |.D. of the ball bearing and 0.D. of the camshaft. Replace to ball bear- ing if it exceeds the wear limit or is badly damaged. Overtap: 50°(40") Exhaust valve closed 592189") Intake valve closed ~ 59°53") Valve timing (valve clearance in cold state: at 0.15mm) Shape of fuel cam (Reverse preventive type) Camshaft mn) Tee] TaDAE, LaRAE TOOAE, L7ORE TrSAE-LIOORE tem sancos | Sin Standard Sevice Standard ome Sg [shan | 14986-15000 1492 vase0-t5000 | 14s2 |_14968-18.000 1492 ee joo. ossorcossos) | (08874) | (Os80%-05906) | casera) | (Ose01-05006) | (05874) TE [econo [gore tec yeore-15094 TEoTeT5.0a 83 lion” | cossre-asets) is (05042-05019) = __| (o5012-05919) - BE for] onieo0ws S016-0.065 ‘o01e2085 : 35 | cearance | (0.0006-00018) = | c.0006-n00t6) — | (e.0c6-2.0018) 7 3 [sem | 24980-24993 | 24.90 " 29.980-29.993. 2380 "34,980-34.993 94.90 SE Se | GSES | ity HEE) | chime | aren | sre Ge. [Gearing | 24900-2500 | 2502 | paa00-0n00 | soca | 34900-86000 | 9502 298 to (6.9638-0.9643) | (09050) | (iseor—isert) | (tata) | (13776-19780) | (1.3787) Ze for | ao2room | (0.020-0.00| 020-0090, a 8 | cearance | (o.0008-00012 | — (0:0008-0.0012) = (0.0008-0.00%2) a 7 “coso-0280 O45 040-0200, 0.45 0.040-0280 04s Trusidearance | oioore-oorro) | @oi77 | (ooote-ooria) | @0177) | (oonr6-no11) | (oor77 51Checking and Servicing 2. Tappet 1) Check the condition of the tappet contact point. The tappet is offset with regard to the cam center and rotated during operation to prevent uneven wear. Replace the tappet if it is badly worn or contacts the cam un- evenly. 2) Check the outer surface of the tappet for wear and damage. Replace if defective. CAUTION: Keep the intake and exhaust tappets separate in disassembling or reassembling them. Tappet mm (in) Model L40AE-L100AE tem ‘Standard Servioe limit Stem 0.0. 6.960-6.980 (0.2740-0.2748) | 6.87 (0.2705) er Exhaust Hole dia. (Cylinder block) 7.000-7.015 (0.2756-0.2762) | 7.06 (0.2780) Oilclearance (0.020-0.055 (0.0008-0.0022) = OD. 23.972-23.993 (0.9438-0.9446) | 23.69 (0.9405) propper iti Purp Hole dia. (Cylinder block) | _24.000-24,033 (0.9449-0.9462) | 24.06 (0.9472) Oil clearance (0.007-0.061 (0.0003-0.0024) i 4.6 TIMING GEARS 1. Checking the timing gears 1) Check each gear and replace those that are damaged or worn. 2) When reassembiing, line up the timing marks ‘on each gear. cam gear ILO pump dive gear (Governor goar mado of resin) (Gear train) 524.7 CRANKCASE COVER Always handle the aluminum packing with care. When the crankcase cover is disassembled, replace the aluminum packing on the crankcase cover if damaged or deformed. Be sure to tighten the crankcase cover to the tightening torques as specified below. The crankcase cover is held in position by two knock pins. Tightening torque ‘kg-om (ib-tt) Model ent L4OAE, L48AE | L60AE-L100AE Crankcase 100-120 200-230 cover 72-87) (145-166) ‘Stiffener bolt 200-230 (14.5-16.6) . Cleaning and checking Clean the cylinder block when the engine is overhauled. Clean out each oil hole and make sure it is not clogged. (Leave plugs in place if they do not need to be replaced. Protect the plugs from oil leaks.) ‘S-spec. engine Plug’ Ol for (Oil hole and blind cover of the crankcase) Crankcase cover_ mm (in) Model | LAOAE, L48AE LEOAE, L70AE L75AE-L100AE Service Service Service ftom ___ Standare | timit Standard limit | __ Standard limit 1D. 34.000-34.025 | 39,000-39.025 44.000-44,025 (1.3386—1.3396) | (1.5354-1.5364) |__| (1.7828-1.7338) | | 5 | Bearing OD. 34,070-34.105 39,070-39.105 | 44,085-44.120 3 2 (Plain) (1.3413-1.3427) |__| (1.6382-1.5396) (1.7356-1.7370) | & § | Fitting 0.045-0.105 0.045-0.105, 0.060-0.120 &3 (0.0018-0.0041) | — | (0.0018-0.0041) | — _ (0.0024-0.0047) |_ Bearing metal |.D. 30 30.13 35 35.13 | 40 40.13, (Plain metal) (1.1811) (1.1862) (1.3780) (1,3831)| (1.8748) | (1.5800) 1D. 51.945-51.905 61.940-61.960 71.935-71.955 si (2.0451-2.0455) | — | (2.4386-2.4994) | — _| (2.8921-2.8929) | — 3 7 7 4 | Ball bearing '51,987-52.000 61.987-62,000 71.987-72.000 é & |0.0. (2.0467-2.0472) | — | (2.4404-2.4409) | —_(2.8341-2.8346) | B | Fitting 0.022-0.055, 0.027-0.080 | 0.032-0.065 {0.0009-0.0022) |__| (0.0011-0.0024) |_ —_| (0.0013-0.0026) | _ —Checking and Servicing ‘The S specification differs from the D specification in the direction in which the Lub. oil filter is ex- tracted, for the purpose of facilitating maintenance of the crank case cover. mm_(in,) ‘S-specification D-specification Lock bot LO flow path bos 208 pu lier extract length | 97 eats)Checking and Servicing 2, Replacing the crankshaft oil seal and 4.8 CYLINDER SLEEVE AND camshaft oil seal CYLINDER BLOCK When replacing oil seal, use special tool. Insert crankshaft oil seal into cranklcase cover untill it is 4 mm (0. end of crankcase. 1. Clinder sleeve 1575 in.) deep from the The cylinder sleeve (FC25S) is cast in the aluminum die-casting cylinder block. Insert camshaft oil seal into crankcase cover Measure the |.D. of the cylinder sleeve. Re- flush with the end of crankcase. When insert- bore the cylinder sleeve if it exceeds the ing crankshaft oil seal into cylinder block, insert allowable limit and use with an oversized it flush with the end of cylinder block. piston. mm (in) 1.25 (0.0098 Oversize piston beled Ccamehalt i soa! Camehatt Extovinaer 1 Fh ie End of crankcase cover Si Crankshat ol al Ccrankehalt ol seal sina 4mm (ousrsin) (Cylinder block and cylinder sleeve) 2. Cylinder block mm (in) Masel L40AE, L4gAE L6OAE, L70AE L75AE-L100AE Service Service| Service Item Standard limit beanie limit Soret, limit LD. 71.9905-72.0095 | __ 79.980-79.996 89.984-90.000 aan (2.8343-2.8350) (3.1488-3.1494) | — | (9.5427-3.5433) | — shaft Ball bearing | 71.987-72.000 | | _79.987-80.000 '89,985-90.000 bearing |0.0. (2.8341-2.8346) (3.1491-3.1496) | — | (8.5427-3.5433) | part Fiting 0.0225-0.0095 |_| 0.009-0.020 0.015-0.016 I {0.00089-0.00037) (0.00035-0.00079)} ~~ _ | {0.00059-0.00063); ~~ Camshaft bearing 20.957-20.978 _ 20.957-20.978 | 20.957-20.978 part ID. (0.8251-0.8259) (0.8251-0.8259) ~ | ©. 8251-0.8259) Pa 55Checking and Servicing Cylinder sleeve LD. mm (in) Moa | __ Standard oe Ger26res) 8086) oe Grasso | eevee bieatad (2908-2.9899) 29888) LT0AE o7e-.0720) (0778) L7SAE isee-3:1508) (1867) LOOAE (@s07t-3.3089) 302 LIO0AE (G886-3.3870) (3.3829) 4.9 LUBRICATION SYSTEM This engine adopts a forced oil lubrication sys- tem driven by a trochoid pump. Lubricating oil is circulated as follows. The rocker arm chamber is lubricated by moisture. LO filter + Trocoid pump -> Crankshaft > Crankpin metal crankcase cover Retet hole WS overer ovine Lopume Ty a Frocoid P= pump = Lo te (G0 mesh, resin) (Lubricating oll route) 1. Lubricating oil pump 1) Measure the clearance between the outer rotor and body (crankcase cover). Replace the pump if the clearance exceeds the al- lowable limit. 2) Measure the clearance between the outer rotor and the inner rotor with a thickness guage. Replace the pump as a set if the clearance exceeds the allowable limit. 3) Installing the lubricating oll pump (1) Insert the lubricating oil pump assembly © from the outside of the crankcase cover. Coat the rotor with oil before in- stalling the cover. (2) Insert the parallel pin@ into the lubri- cating oil pump shaft. (3) Set the weight © on the gear. (4) Insert the spindle into the weight, then push the spindle into the shaft. Once in place, the spindle cannot be removed. Pushin (installation of lubricating oll pump)Checking and Servicing Oil pump mm (in) Model LA0AE-L1004E ttem Standard Service limit ] 28.96-28.98 28.90 | Outer rotor 0.0. (1.1402-1.1409) (1.1978) I 29.100-29.121 29.18 Outer | Housing LD. (Crankcase cover) (1.1457-1.1465) (1.1488) Clearance between housing LD. and 0.420-0.161 oe outer rotor 0.0. (0.0047-0.0068) 7:97-8:00 7.90 (Outer and inner rotor width | (03138-05160) ost | : 8.02-8.05 8.10 en een (0.3157-0.3169) (0.3189) | Glearance between housing and 0.02-0.08 i | inner/outer rotors (0.0008-0.0031) | Clearance between the inner ane outer oor e008) oneee) 57Checking and Servici 4.10 FUEL SYSTEM 1. Fuel injection pump 1) Specifications Model: __YPFE-M Model | tem Laoae | L4sae | L6OAE | L70AE | L7SAE | LOOAE | L1OAE Stamped [Bare engine aos | 45 | 60s _| 7os_| 768 | 90s | 1008 mark [Generator set aop_| 480 | op | 7op | 75D | 90D | 1000 CAUTION: 1. The ID marks for stamped the pump is on the pump mounting flange. 2. None of these fuel injection pumps is inter- changeable. 3. The fuel injection pump for discrete engine differs from the generator in the direction of the fuel inlet pipe. L40AE-L100AE ‘Adjusting Shims Standard 05 thickness (shop assembly) (0.0197) Postion of stamped Fuel pump mounting flange ‘0mm (381 in) I Mi2xt8 Pump body sem ease) Pump mounting flange Control lever —Tappet for fuel injection pump (Configuration of fuel oil pump)Checking and 3) Disassembly and reassembly This is standard fuel injection pump body. Disassemble and reassemble the fuel pump in the direction order of “UP", "DOWN" and “SIDE” from the center of the fuel injection pump body (marked “C’) as illustrated. Delivery valve holder Tightening torque: 200 fem El Reassemble the gasket A and B for the seving delivery seat in the position at the time of disassembly. Datvery valve oon q ZA er fE ee ssuctonpoojont AL] YU TEGT A Gasket —_accoss hole cover sora Tye Sa soso ino ; / : Spring seat (A) | Plunger Lo Bris NOTE: 1 See the position of mark* a Never remove the suction pipe joint from the G pump body during routine disassembly. ii ‘Symbols: 8 = panei Directions of disassembly from the center of fuel pump body (C). Up side | oe 59 Laem « SPtN9 80a! (8) (Fuel pump disassembly and reassembly)Checking and Servicing 2. Fuel injection valve 1) Specifications Model: YDLLA-P Item Specification | | 4QAE/aBAE L6QAE/L70AE L7SAE - LIODAE Mark to identity assembly © AB AN Pear pee ea cece YANMAR YANMAR YANMAR 150? 150P 150P nozzle body 224at 21480 22480 Example: 2) Check ‘Symbol 150P indicates an injection angle of 150°; (1) Carbon deposits symbol 224Al implies 4 nozzle holes which are (Flowering) 0.22 mm in injection hole OPosition of 1 mark. ‘of assembly -& It | H¢7,ammjo.207 ny 216.95 10.667 in) (Structure of injection valve) CAUTION: 1. When replacing fuel injection valve, be sure to check engine model against the identity marks shown above. Any injection vaive is least identifiable in appearance. 2. When removing the fuel injection valve, wrap it in cloth to protect the nozzle tip (injection port). Do not place the nozzle tip directly on the ground. Carbon deposits build up on the nozzle in the form of flowers. Flowering lowers combustion performance significantly. Make sure the nozzle is free from con- tamination. (2) Shape of injection spray Move the lever of the nozzle tester at a speed of approx. 1.2 time/sec. to check the spray pattern. Normal shape of spray 1, The spray should all be at the same angle. (from all four injection ports) 2, The spray should be a fine mist. 3. The spray should be smooth and steady without deviations. (4 nozzles) 3) Cautions when installing fuel injection valve (1) Tighten the fuel injection valve assembly to the specified torque. (2) Clean the sleeve surface. Be sure to re- place the nozzle gasket at the same time. Note: If nozzle gasket stays in cylinder head atter injection valve assembly has been removed from cylinder head, screw M8 or M9 stud bolt (more than 100 mm tong) in nozzle gasket, then pull ‘out stud bolts to remove gasket.Checking and ‘Nozzle spacer Nozzle gasket Fuel valve positioning pin (Fuel injection nozzle) | a Nozzle holder Tightening torque kg-om (Ib-f) ttem Model | LAQAE-L100AE Installing fuel injection valve 100-120 Adjusting shims nut (72-87) Fuel injection nozzle case 400-450 Nozzle positoning pins (2 pes) nut (28:9-92.5) Pree EEE CEE 4) Disassembly and reassembly Lae Nomale sein Remove the case nut, and then all parts of the valve can be disassembled. igen ctaae To disassemble and reassemble the case ara nut, use a 15 mm deep socket wrench, chp S08 Bele The fuel valve positioning pin does not need to be removed in most cases. (} Wj Nozzle valve 5) Adjustment tna The injection starting pressure is 200 kg. To adjust the nozzle injection starting pressure, y remove the nozzle holder and increase or decrease the number of adjusting shims. Adjustment by 0.1 mm results in a change [ff Nozze bees in the injection starting pressure of about 20 kg/om*. Adjusting shims come in the following thick- nesses: 0.1, 0.15, 0.4, 0.5, 0.6, 0.7, and ' 0.8 mm. mm (in.) L40AE-LIQ0AE, ne Case mt ‘Adjusting shim 0.60-0.65 standard thickness (0.0236-0.0256) 61 (Fuel injection valve assembly)Checking and Servicing 3. Fuel filter The fuel filter uses an element of nominal filterable particle diameter of 5 4. During the periodical inspection of this part, check the element for break, separation from the frame to which it should be bonded, stoppage, etc., ‘and if a defection is found, replace it with new ‘one, To detach the fuel filter, first remove the filter cap on fuel tank, then pull out it from the fuel filler port. But pull the filter down-wards for YDG (generator set), YLP, and YDP (pump sel). 4.11 SPEED CONTROL DEVICE The position where governor spring must be in- stalled differs depending on engine model and its rated rpm as shows in the following table and illustrated. Check the spring for position before ascertain- ing the fuel injection limit. Position of Governor Spring Hole Model and Location of governor spring installation hole ‘Application LA0AE=L70AE L75AE~L100AE : 3600 pm | 3000 pm | 9600rpm | 3000 rpm Type of speed control device (60H2) | GOH) (60 Hz) (60 Hz) ‘A. Speed variable, regulator handle revolution’ | fixed type (remote controllable) : | 2b 2-c 3-b | 3-c B Remote control type | © Speed variable, (friction plate type) 1-b 1-6 1-¢ D Constant revolution, lock lever type t-b 2-c 2-6 62No-load max. revolutions set bolt Govern exxing hana (Type A) STOP m ‘Notoad max evolution sei bolt NUS (Type B) aun I] feos fer Lochner 63Checking and Servicing 4.12 ELECTRICAL SYSTEM 1. Wiring Diagrams L4DAE - L100AE ENGINES WIRING DIAGRAM For 12V-15A/12V-3A Charging Generator _ Starter motor.. T2V0.5RW 1 Chargi sgeneralor pases Gose? ow ow oB104 joBto4 catos jcaio4 a ene * Gad GW : Green/White Toma BAMalo, CB\Fomale): Receptacle LA: Eyelet type oe Notes: Node! ‘GPSS Greer 3 nut current * 14.8 - 16A (OC) 2.6~3.3A (DC) § | aidso0 pm ‘ater GENO? _| an antes aa a chracicin 2 atcharging” Silene 10007] er lose 1000 pan] MAT State (Adent temperature 20°C) 3 | sat : aaa) ai3¥) 3 (reat -a0-165°0 | -20-y650 Continaton of Comin assi2 ssni2 Staring moter av cakw ‘aeabo amp (max) = 7 {13600 rpm) vwv-10w | eV ~25W 1. Be sure fo ground both engine and engine-criven machine. 2 Section enclosed wih dotted square is pro-wired at Yanmar factory Section enclosed wih altemate long and Short dash line isthe section incuded in engine packing. For this section, purchaser is expected to: 1) Connect 4P coupler. 2) Secure charge lamp ground (LAY06) wih bolt (M6). Locally procure: 1) Batley, LAOAE, 48AE: 18 ~ 24 AH, LOOAE, 7OAE: 24 ~ 36 AH, L75AE ~ 100AE: 96 - 45 AH 2) Batley, cable; @ & © (AV20), lamp, snitch snd cable (AVI 25). Take off power for tho lamp through the female box terminal (CBi04). Procure the lamp and switch at your specification, 13V ~ 3.0% (engine revolution 3600 rpm, 20°C) 13V ~ 1.18% (engine revolution 1400 rpm, 20°C) LLengih of wiring hamess between key switch and 4P coupler is 700 mm (29.194 in) When inetaling the engine according to the vibration prot specification, use the cable in sufficient length to prevent disconection. . Nee 64Checking and Servicing. L40AE - 100AE ENGINES WIRING DIAGRAM For 12V — 3A Charging Generator Isr} note | fol Terminal: ‘CAiNiale), CB(Female): Receptacle type tA: Eyelet type Notes: T ‘GPa5e7 HF Se 5 26 -33R OO ‘An astrisk (*)Indcatos a charactoristic in § (atisv) ‘warm state (ambient temperature 20°C) 5 alee 1098 3 (@t13v) ? ae fap tuere © | Combination of s2100 regulator (Model) Starting motor 72v-0.8KW 1, Be sure to ground both engine and engine-criven machine. 2. Section enclosed with dotied square Is pre-wired at Yanmar factory. 3. Locally procure: 41), Battery; LAOAE/LABAE: 18-24AH, LECAE/TOAE: 24-96AH, L7SAE~L1O0AE: 98 — 45 AH, 2) Batery cable; @ & © (AV20) 3) Starting switch and 4P couplet.hacking and Servicing L40AE - 100AE ENGINE WIRING DIAGRAM For 12V - 1.7A Charging generator erry (121 peepee cere eT sees For 12V - 1A Charging generator GAY! Greenwnite ? BIW: BlackWhito & Green ie Terminal, ‘CAlMale), CB(Female) : Receptace Mate, caret :Receptacte ype ora rasa? T5-19R(00) | 07-124 (06) ‘aia ai Anat () can carat a ies 1300TpR | ras soo | Mane abot operate 20°) av) sav ~a0-see | -20-s5%0 pai eati7 av caw 4, Be sure to ground both engine and engine-diiven machine. 2. Sedtion enclosed with dotted square Is pre-wired at Yanmar factory 3. Locally procure 1) battery 2) battory cable 2) stating switch and 4) cables. AE Bator: L40AE, 48 18 — 24 AH *L6OAE, 70AE 24 96 AH U75AE™100AE 36 — 45 AH Battery cable: © & © AVEOGhecking and Servicing LAQAE - 100AE ENGINES WIRING DIAGRAM (with air heater and timer) For 12V — 15A/12V - 3A Charging Generator Starter motor. :AE- TOE} 1 207 (SRE~100AE-9)_ ; oq “mer (15880) Ground eatery Seale >| a OM —, ca ; [ i: She Bhs S| | a i ee eee | Bye i avi 25 : ai is : TAOS gl aa8 Red Eye aq Fite White Gav. Grenvtnite Torna g ‘Pattie, ca\Female: Receptacle ype Z CAS pe ‘heater Koy svtch comecons 1. Be sure to ground both engine and engine-diven machine 8 | Rt [m2 [ea] c Z. Section encosed wih doites square fe prowred at Yanmar facoy & Baty: LAQSE/AEAE: SOAM, UEOAEI7ONE” 35AM, L75-100AE" 45Af Frain | O--O- 4, Battery cable (D + @j: AV20 ... <1.3m, AV30 ... <2.3m_ o 5. Starter catlos @) and (© sha have total resitance below S/100 0, provided that terminal or fol | | I | tesiiance shal havo 18/000 1 por connector wie sorwin connector 02 eeitho Sieg opto 67Cher icking and Servici LAQAE — L70AE ENGINES WIRING DIAGRAM Generator for Lighting For 12V-25W/40W (Use lamp only) Lame. 12V-25W tor pose we 1BN-Zaw (or Goce Me erator . Sees eestor Ground For 6V-15W (Use Lamp only) ge a Magneto-generator ee ‘GPasot Cate Notes: 1. Use Lamp only 2. For Recall siaing specifcation engine 3. Color code’ ‘Terminal: CA(Male), CB(Female}: Receptacle type UW: Eyelet typeChecking and Servicing. 2. Starter Motor Type of starter motor Starter motors are roughly divided into the com- mon type (conventional type) and reduction type; they are subdivided into the Bendix type and roller clutch type and multi-plate clutch type.) magnetic shift type (The clutch is available in the 1. Specifications and Performancé depending on pinion engagement mechanisms. The L-A series uses the common type, magnetic shift system starter motor as standard. : TA0AE-SE LAQAE-DE_ | L75AE-SE~LI00AE-SE Engine model ~LIOOAE-SE | -LIO0AE-DE (Optional) Type Conventional Reduction type Model HE __|-sti4—ai3a_ | S114- 4148 S114— 478 | Rating (sec.) 3 € Output (V-KW) Pia ose “12-12 Direction of rotation (viewed from pinion side) | Clockwise _| Counterclockwise Clockwise Weight kg (.) : 36 (7.9) 4402) Clutch system Over running « Engagement systern Magnetic shitt « No. of pinion teeth, EEEEEEEEE 8 © Pinion coming out voltage (V) TAG: Eee No-oad Terminal voltage (V) 5 12 Current (A) 60 (Max) 105 (Max.) ‘Speed (1pm) | 7000 (Min) “4000 (Min.) Loaded Terminal vot { 8 87 characteristics Current (A) EEEEEEEEE oO EEEAEEEEE a Torque kg-mi(ft-lb) «| ~—~=~=«0.82 (2.811850 rpm “| 0.46 (3.23)/1550 rpm _| (Min) (Min) (Min) (Min) Characteristics Curve s fz Zz) 2/8) £503 Sent scours) B| ERE siveae oar (= Mee Se ulsage slsiz i se] todo apd Wel Current (A) Current (A)cking and Servicing 2. Construction The starter motor is composed of three major parts, as follows: 1) Magnetic switch Moves plunger to engage and disengage pinion and, through the engagement lever, ‘opens and closes the main contact (moving contact) to start and stop the starter motor. 2) Motor A continuous current series motor which generates rotational drive power. 24 Conventional type starter motor (Standard electric starter) 3) Pinion Transters driving power from motor to ring gear. An over-running clutch is employed to prevent damage if the engine runs too fast. ‘The overrun clutch is composed of the roller and clutch outer, as illustrated below. The roller is held down the roller in tapered part. ‘The overrun clutch is composed of the roller and clutch outer, as illustrated below. The roller is kept pressed by the roller spring. The clutch outer houses the roller in tapered part. Dust cover Magnetic switch Dust cover Torsion spring Field col Shitover a “ LOver-cunning teh Brush holder ~ Gear case Rear cover bearing meta Pinion stopper Dust cover Gear case bear se bearing Theust = ree Prion ‘Through bot Armatire Rear cover Yoke Over-running clutch Rolr Cover Ciuteh outer 70Ghacking and Servicing 2.2 Reduction type staretr motor (Option for L75AE-SE ~ L100AE-SE) ‘Magnetic switch, Dust cover’ Brush holder Yoke. Armature | Rar cover “Through bolt Packing 1) Construction of the reduction type 71 Starter motor This motor is equipped with reduction gears between the armature and pinion; the re- duction gears increase the torque of the motor before transmitting the torque to the pinion. The pinion and pinion shaft are shifted by the magnetic switch but the clutch assembly remains unmoved. (1) Circumscribed type The armature shaft is equipped with a small gear at the end, which is constantly ‘engaged with a large gear on the circum- ference of the clutch. Thus, the revolu- tion of the armature is transmitted to the pinion through the reduction gears and the clutch assembly. While the engine is being cranked, the motor emits a slightly loud sound because of the built- in reduction gears. This does not mean, of course, a sign of trouble. Torsion spring Housing Shift lever clutch Goar ease inion shatt Pinion Packing Magnetic switca “Torsion spring (2) Internal structure of reduction type Ilustration above shows the internal structure of the reduction type starting motor. This motor is similar to the mag- netic shift type motor, except that it has built-in reduction mechanism as its name implies. In general type of starting motor, the ar- mature is designed to turn at the same rpm as the pinion, However, the reduc- Gear case