
able
of
Contents
MAINTENANCE
TUNE
UP
DIsassembly
32
InspectIOn
RepaIr
33
VALVE
CLEARANCES
6
AdJustmg
Regulator
33
ENGINE
OIL
6
Assembly
33
OIL
FILTER
7
COOLANT
7
COMPRESSION
7
ELECTRICAL
SYSTEM
BATTERY
8
IGNITION
TIMING
8
STARTER
36
DIstributor
Breaker
Pomt
9
Removal
37
Condenser
9
InstallatIOn
37
Spark
Plugs
9
Trouble
Shootmg
37
Carburetor
9
ALTERNATOR
36
Idle
LImIter
Cap
10
Removal
37
Dash
Pot
automatic
transmISSIOn
11
InstallatIOn
37
model
only
11
REGULATOR
39
Carburetor
Return
Sprmg
11
DeSCriptIOn
39
Fuel
Filter
11
Trouble
Shootmg
40
ENGINE
IGNITION
SYSTEM
DESCRIPTION
14
DISTRIBUTOR
44
REMOVAL
14
ConstructIOn
44
INSTALLATION
14
Checkmg
and
Adjustment
44
CLEANING
INSPECTION
14
SP
ARK
PLUGS
46
DISASSEMBL
Y
14
DeSCriptIOn
46
INSPECTION
REPAIR
18
InspectIOn
46
PreparatIOn
18
Cleamng
Regap
47
Cyltnder
Head
18
Valve
Assembly
18
Valve
Spnng
19
Valve
Rocker
Shaft
Rocker
Arm
19
FUEL
SYSTEM
Valve
LIfter
Push
Rod
20
Camshaft
Camshaft
Bearmg
20
FUEL
FILTER
50
Valve
Tlmmg
20
DESCRIPTION
50
Cyltnder
Block
21
REMOVAL
50
PIston
Piston
Pm
Plsto
LRmg
21
INSTALLATION
50
Connectmg
Rod
23
FUEL
PUMP
50
Crankshaft
24
DeSCriptIOn
50
Bushmg
Bearing
24
Testmg
51
Crankshaft
Sprocket
Removal
DIsassembly
52
Camshaft
Sprocket
25
InspectIOn
52
Flywheel
25
Assembly
52
ASSEMBL
Y
25
CARBURETOR
52
PrecautIOn
25
DeSCription
52
Cyltnder
Head
25
Adjustment
53
PIston
ConnectIng
Rod
26
Removal
58
Engme
26
DIsassembly
58
OIL
PUMP
32
Cleanmg
InspectIOn
59
Removal
Engme
m
vehicle
32
Assembly
InstallatIOn
60
I

ainteDaDee
TUDe
up
VAL
VE
CLEARANCES
Valve
clearance
adjustment
should
be
made
while
engme
IS
stationary
To
adjust
proceed
as
follows
Start
engme
and
run
It
until
It
IS
heated
to
operatIng
temperature
or
at
least
more
than
17S
of
engIne
011
temperature
then
stop
engIne
Rotate
crankshaft
to
bnng
No
1
cylInder
In
top
dead
center
on
ItS
compressIOn
stroke
Remove
valve
rocker
cover
to
gaIn
access
to
valve
operatIng
mechamsm
Adjust
valve
clearance
at
follOWing
four
pOints
while
engIne
IS
still
hot
1
Exhaust
valve
of
No
1
cylinder
2
Intake
valve
of
No
1
cylinder
3
Intake
valve
of
No
2
cylinder
5
Exham
t
valve
of
No
3
cylInder
ote
Numbers
in
parenthesis
agree
with
those
10
accompanY1Og
sketch
AgaIn
rotate
crankshaft
one
turn
so
that
No
4
piston
IS
In
top
dead
center
on
ItS
com
pressIOn
stroke
Adjust
follOWIng
valves
4
Exhaust
valve
of
No
2
cylinder
6
Intake
valve
of
No
3
cylinder
7
Intake
valve
of
No
4
cylInder
8
Exhaust
valve
of
No
4
cylinder
Rg
1
AdJustmg
valve
clearance
8
Adjustment
should
ue
made
whIle
engIne
IS
hot
After
all
valves
have
been
adjusted
correctly
tighten
lock
nut
firmly
to
secure
the
adjustment
Checking
and
adjusting
drive
belt
Check
for
a
cracked
or
damaged
V
belt
Replace
If
defective
Adjust
the
belt
tenSIOn
If
necessary
Belt
deflectIOn
when
thumb
pressure
of
220
Ib
IS
applied
midway
between
pulleys
0394
to
o
590
In
ENGINE
OIL
011
capacity
of
engIne
IncludIng
011
filter
Capacity
MaXimum
VB
US
gal
Imp
gal
MInimum
5IB
US
gal
III
Imp
gal
Make
sure
that
engIne
011
IS
not
detenorated
With
cooling
water
or
gasolIne
DraIn
and
refill
the
011
lf
necessary
Notes
a
A
m1lky
011
indlcates
presence
of
cooling
water
Valve
clearance
Hot
Intake
0014
In
Exhaust
Fig
2
AdJustmg
dnve
belt
tension

aintenIDce
une
up
Find
the
cause
for
necessary
corrective
action
b
Oil
with
extremely
low
viscosity
in
dicates
dllutton
with
gasoline
Check
011
level
If
found
below
L
mark
refill
to
H
mark
on
gauge
OIL
FILTER
The
011
filter
IS
of
a
cartndge
type
Check
for
011
leaks
through
gasketed
flange
If
any
leakage
IS
found
retIghten
shghtly
If
nece
sary
replaLe
filter
as
an
assembly
When
mstalhng
an
011
filter
tIghten
by
hand
Note
Do
not
overtighten
011
fIlter
or
oil
leakage
may
result
I
I
Fig
3
Checking
engine
011
level
Oc
OF
I
0
121
20141
30
21
401401
5015BI
I
EGOQl
I
10
20
Fig
4
Protection
concentration
COOLANT
L
L
C
IS
al
ethylene
glycol
base
product
con
tammg
chemical
mhlbltors
to
protect
the
coohng
system
from
rustmg
and
corrosIOn
The
L
I
C
does
not
con
tam
any
glycerme
ethyl
or
methyl
alcohol
It
wIll
not
evaporate
or
bOll
away
and
can
be
used
wIth
either
high
or
low
temperature
thermostat
It
flows
freely
transfers
heat
effiCiently
and
will
not
clog
the
passages
m
the
coohng
system
The
L
L
C
must
not
be
mIxed
wIth
other
products
ThiS
coolant
can
be
used
throughout
the
seasons
of
the
year
Whenever
any
coolant
IS
changed
the
coohng
system
should
be
flushed
and
refilled
wIth
a
new
coolant
Check
the
level
COMPRESSION
Compression
pressure
test
Note
To
test
cylinder
compression
remove
all
spark
plugs
and
hold
tester
fit
Percent
BOllIng
pomt
concen
09
kg
cm2
Freeze
tra
lion
Sea
level
coolmg
sys
protectIon
tern
pressure
30
2210F
2550F
50f
50
2280
F
2610F
31oF
ETO
104
Fig
5
Testing
compressIon
pressure
7

Bogine
Note
Set
the
locate
plate
so
as
the
LOWER
mark
comes
to
the
engine
bot
tom
side
Set
the
maIn
bearIngR
on
theIr
posItIOns
on
the
cylinder
block
Notes
a
The
center
bearmg
No
3
bearmg
is
a
flanged
type
for
thrust
force
b
Two
lOner
bearmgs
No
2
and
No
4
are
of
the
same
type
c
The
front
bearmg
No
1
IS
the
same
type
as
the
rear
bearmg
No
5
d
All
bearings
except
for
No
I
bearing
are
interchangeable
between
upper
and
lower
bearings
Apply
engIne
OIl
to
the
mam
bearIng
surfaces
on
both
sIdes
of
the
cyltnder
block
and
cap
Fig
53
Mam
bearing
caps
Fig
54
Crankshaft
end
play
check
Install
the
crankshaft
Install
the
mam
bearmg
cap
and
tighten
the
bolts
with
specified
torque
Tlghtemng
torque
36
to
43
ft
Ib
Notes
a
Arrange
the
parts
so
that
the
arrow
mark
on
the
bearing
cap
IS
faced
toward
the
front
of
the
engine
b
Prior
to
tightening
the
bearing
cap
bolts
place
the
bearing
cap
at
a
proper
posItIon
by
shlftmg
the
crankshaft
in
the
axial
direction
c
Tighten
the
bearmg
cap
bolts
gradually
in
separatmg
two
to
three
stages
and
out
wardly
from
the
center
bearing
d
After
securing
the
bearing
cap
bolts
ascertam
that
the
crankshaft
can
be
easily
rotated
Make
sure
that
the
crankshaft
end
play
IS
correct
Crankshaft
end
play
o
0020
to
0
0059
In
I
nstalI
the
rear
011
seal
Install
the
flywheel
securely
USIng
the
lock
washers
and
tighten
the
bolts
with
specIfied
torque
Tlghtemng
torque
47
to
54
ft
Ib
Rotate
the
engine
a
quarter
turn
and
mstall
the
piston
rod
assembly
Notes
a
Insert
the
pistons
in
the
corresponding
cyhnders
b
Apply
engine
oil
to
parts
as
required
c
Arrange
pistons
so
that
the
F
mark
on
the
piston
IS
faced
to
the
front
of
the
engine
d
Install
piston
rings
at
18
Y
to
each
other
avoIdIng
to
fit
them
In
the
thrust
and
pIston
pIn
aXial
directIOns
27

BBgiBe
Fig
70
Tlmmg
mark
Fig
71
Dlstnbutor
mstallatlon
Notes
a
Set
the
No
1
piston
to
its
top
dead
center
of
the
compression
stroke
b
Before
installation
return
the
distributor
rotqr
approximately
60
degrees
from
Its
regular
position
Insert
the
assembly
meshing
the
distributor
drive
gear
and
driven
gear
After
installation
the
distributor
rotor
should
come
into
contact
wIth
the
mark
on
the
rotor
cap
fittmg
as
shown
in
the
Figure
Install
the
spark
plugs
and
connect
the
distrIbutor
to
plug
high
tensIOn
lead
wire
Install
the
fuel
hoses
and
tubes
Install
the
clutch
cover
assembly
Install
the
engme
shngers
and
crankcase
ven
tilatIOn
hose
Fig
72
Removal
of
011
pump
TrochoId
Fig
73011
pump
OIL
PUMP
Removal
Engine
in
vehlCIe
Dram
engme
OIl
Remove
the
front
stabilIzer
Remove
the
splash
shield
board
Detach
the
011
pump
body
together
with
drIve
gear
spmdle
Disassembly
PrIor
to
dlsassembhng
check
to
determme
that
the
pump
IS
defective
Take
out
a
total
of
2
bolts
securmg
the
pump
cover
to
the
pump
body
The
outer
and
mner
Dlsmount
the
engme
from
the
workmg
stand
rotors
and
drive
shaft
can
then
be
dlsassem
Install
the
engme
mountmgs
bled
32

lenition
Sptem
IGNITION
SECONDARY
COI
L
COI
L
CAP
BREAKER
POTNT
cr
r
7
W
tc
l
uToRI
8
TO
STARTER
l
J
ROTOR
HEAD
SPARK
PLUG
Fig
19
Igmtlon
system
Circuit
diagram
The
IgmtlOn
CirCUIt
conSIsts
of
the
distributor
IgmtIon
cOli
IgmtIon
sWitch
spark
plugs
hIgh
tensIOn
cable
and
the
battery
Figure
76
shows
IgmtlOn
CirCUIt
DISTRIBUTOR
Construction
The
dIstributor
consists
of
high
tension
voltage
part
SWitch
off
part
centrifugal
ad
vancing
angle
part
vacuum
advance
mechamcal
part
and
drlvmg
part
Figures
77
and
78
show
the
constructIOn
and
exploded
view
Checking
and
Adjustment
Cap
and
rotor
head
must
always
be
kept
clean
to
maintain
good
insulation
durability
since
high
tensIOn
voltage
from
IgmtIon
cOil
IS
Im
posed
on
them
SometImes
inside
of
the
cap
and
rotor
head
IS
covered
wIth
fine
carbon
partIcles
and
dust
Whenever
crack
or
trace
of
leakage
IS
found
on
the
cap
replace
w1th
a
new
one
44
Recommended
the
rotor
head
also
be
replaced
wIth
a
new
one
If
excessively
damaged
When
pomt
surface
IS
roughened
due
to
bur
nlng
polish
with
a
fine
emery
paper
No
500
or
600
or
011
stone
When
the
point
IS
worn
excessively
replace
When
the
POIn
IS
replaced
with
a
new
one
apply
grease
to
the
arm
pivot
receiver
and
cam
surface
For
causes
of
damaged
burnt
point
Improper
pomt
contact
msufficlent
point
gap
and
defective
condenser
are
conSidered
The
standard
pomt
gap
IS
0
0177
to
0
0217
m
When
gap
IS
devIated
from
the
standard
gap
adjust
Turn
the
shaft
to
a
posItIon
where
the
breaker
arm
heel
rides
the
cam
lug
a
posItIon
where
pomt
gap
IS
maxImum
loosen
the
gap
adjusting
screw
apply
a
thIckness
gauge
bet
ween
contacts
and
adjust
to
the
standard
pomt
gap
When
measurmg
breaker
pomt
spring
ten
SIOn
apply
sprmg
tensIOn
gauge
to
the
breaker
pomt
and
posItIon
the
sprmg
tenslOn
gauge
m
right
angle
agamst
the
breaker
arm

Ignition
Sptem
The
standard
breaker
pOint
spring
tensIOn
IS
1
1
to
1
4
lb
Replace
If
devIated
Performance
of
condenser
IS
affected
by
Im
proper
setting
contaminatIOn
and
reductIOn
of
In
ulatlOn
resIstance
Thus
pellOdlcal
checking
I
I
eqlJ
lred
to
maintain
the
outlet
of
lead
wire
clean
and
to
prevent
et
screw
from
loosening
Checking
the
condenser
capacIty
IS
checked
USing
a
capacity
meter
It
may
be
also
checked
condenser
Isolate
resl
tance
USing
a
tester
by
adjusting
ItS
I
ange
to
measure
large
I
eSlstance
value
When
the
condenser
IS
normal
the
tester
pOinter
SWings
1m
gely
and
rapIdly
and
moves
gradually
back
to
the
Infimte
SIde
When
the
pOinter
does
not
stay
stili
or
It
points
Zero
In
reSIstance
replacement
IS
necessary
Fig
82
AdJusllng
POint
gap
Fig
83
Measunng
breaker
POint
spnng
tension
g
SPARK
PLUGS
Description
The
spark
plugs
are
of
the
re
lster
type
haVing
0
551
In
threads
and
0031
to
0035
11i
gap
Note
All
spark
plugs
installed
on
an
engme
must
be
of
the
same
brand
and
number
of
heat
range
Inspection
Remove
spark
plug
wIre
by
pulhng
on
boot
not
on
WIre
Itself
Remove
spark
plugs
Check
electrodes
and
Inner
and
outer
por
celams
of
plugs
noting
the
type
of
depOSits
and
the
degree
of
electrode
erO
lOn
Refer
to
Figure
85
Normal
Brown
to
gl
aYlsh
tan
depoSits
and
shght
electrode
wear
indIcate
correct
spark
@
I
Pnmary
terminal
2
Secondary
terminal
3
Cdp
4
Sprang
5
SIde
core
6
Prrmary
coil
7
Secondary
COIl
8
Insulator
011
9
enter
lore
10
Segment
II
Case
Fig
84
Construction

Icnition
Sptem
Ovcrhc
Jtmg
Norm
Jl
i
r
rJ
I
ttr
I
i
V
Carbon
fould
Fig
85
Spark
plug
Life
plug
heat
range
Carbon
fouled
Dry
fluffy
carbon
depo
lts
on
the
Insulator
and
electrode
were
mostly
caused
by
slow
speed
dnvlng
In
cIty
weak
Ig
nltlOn
too
nch
fuel
mixture
dirty
aIr
cleaner
etc
It
IS
advIsable
to
replace
WIth
plugs
havmg
hotter
heat
range
011
fouled
Wet
black
depoSits
show
excesSive
oIl
entrance
Into
combusllon
chamber
through
worn
rmgs
and
pIstons
or
excessIve
clearance
between
valve
gUIdes
and
stems
If
the
same
condition
remams
after
repair
use
a
hotter
plug
Overheatmg
WhIte
or
hght
gray
msulator
WIth
black
or
gray
brown
spots
and
blUIsh
burnt
electrodes
indIcate
engme
overheatIng
Moreover
th
e
appearance
results
from
in
correct
IgnitIon
tIming
loose
spark
plugs
low
guel
pump
pressure
wrong
selectIOn
of
fuel
a
hotter
plug
etc
It
IS
adVisable
to
replace
WIth
plugs
havmg
colder
heat
range
After
cleaning
dress
electrodes
With
a
small
fine
file
to
flatten
the
surfaces
of
both
center
and
Side
electrodes
In
parallel
Set
spark
plug
gap
to
specification
FIg
86
Settmg
spark
plug
gap
Install
spark
plugs
and
torque
each
plug
to
11
to
15
ft
Ib
Connect
spark
plug
wires
Cleaning
and
Regap
Clean
spark
plugs
In
a
sand
blast
type
cleaner
A
VOId
excessIve
blasting
Clean
and
remove
carbon
or
OXide
depoSits
but
do
not
wear
away
porcelain
If
depos1ts
are
too
stub
born
discard
plugs
After
cleaning
spark
plugs
renew
firing
sur
face
of
electrodes
With
file
mentioned
above
Then
gap
spark
plugs
to
0
030
to
0
035
In
uSing
a
round
wire
feeler
gauge
All
spark
plugs
new
or
used
should
have
the
gap
checked
and
reset
by
bending
ground
electrode
II