4.5-7.0bcgb Technical Man PDF

SERVICE MANUAL
BCGB G.-...~
PUBLICATION NO.44898
JUNE 2000
1ST EDITION
WESTERBEKE CORPORA TION· 150 JOHN HANCOCK ROAD

MYLES STANDISH INDUSTRIAL PARK· TAUNTON MA 02780
WEBSITE: www.WESTERBEKE.COM
m
N~A Member National MariM Manufacturers Association
••••
Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed
and may void warranty.
Engines & Generators

A WARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
- Dizziness - Throbbing in Temples
-Nausea - Muscular Twitching
-Headache - Vomiting
- Weakness and Sleepiness -Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,

GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
This WARNING DECAL is provided by

WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleeping quarters of your vessel.
They are inexpensive and easily
obtainable at your local marine store.
SAFETY INSTRUCTIONS
INTRODUCTION PREVENT BURNS - FIRE
Read this safety 11UZRual carefully. Most accidents are
caused by failure to follow fundamental rules and precau- A WARNING: Fire can cause injury 01 death!
tions. Know when dangerous conditions exist and take the
necessary precautions to protect yourself, your personne~ • Prevent flash fires. Do not smoke or permit flames or
and your TIUlChinery. sparks to occur near the carburetor, fuel line, filter, fuel
The following safety instructions are in complitmce with pump, or other potential sources of spilled fuel or fuel
the American Boat and Yacht Council (ABYC) standards. vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
PREVENT ELECTRIC SHOCK • Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
A WARNING: Do not touch AC electrical connectlons • Do not operate with the air cleaner/silencer removed.
while engine is mnnlng, 01 when connected to shore Backfire can cause severe injury or death.
power. Lethal voltage is present at these connections! • Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
• Do not operate this machinery without electrical engine/generator clean and free of debris to minimize the
enclosures and covers in place. chances of fire. Wipe up all spilled fuel and engine oil.
• Shut off electrical power before accessing electrical • Be aware - diesel fuel will bum.
equipment
• Use insulated mats whenever working on electrical PREVENT BURNS - EXPLOSION
equipment
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment
A WARNING: Explosions from fuel vapOIS can cause
Injury 01 death!
• Remove wristwatch and all jewelry when working on
electrical equipment • Follow re-fueling safety instructions. Keep the vessel's
• Do not connect utility shore power to vessel's AC hatches closed when fueling. Open and ventilate cabin
circuits, except through a ship-ta-shore double throw after fueling. Check below for fumes/vapor before run-
transfer switch. Damage to vessel's AC generator may ning the blower. Run the blower for four minutes before
result if this procedure is not followed. starting your engine.
• Electrical shock results from handling a charged capaci- • All fuel vapors are highly explosive. Use extreme care
tor. Discharge capacitor by shorting terminals together. when handling and storing fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
PREVENT BURNS - HOT ENGINE out of the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
A WARNING: Do not touch hot engine parts 01 • Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
exhaust system components. A mnnlng engine gets spill. DO NOT allow any smoking, open flames, or other
very hot! sources of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
• Always check the engine coolant level at the coolant fuel system.
recovery tank.
• Do not alter or modify the fuel system.
IA WARNING: - . . " _1D/tII11lf_

•
•
Be sure all fuel supplies have a positive shutoff valve.
Be certain fuel line fittings are adequately tightened and
free of leaks.
• In case of an engine overheat, allow the engine to cool • Make sure a fire extinguisher is installed nearby and is
before touching the engine or checking the coolant. properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
i
SAFETY INSTRUCTIONS
ACCIDENTAL STARTING TOXIC EXHAUST GASES
A WARNING: Accidental starting can cause Injury A WARNING: carbon mDnDxlde (CO) Is a deadly gas!
or death!
• Ensure that the exhaust system is adequate to expel gases
• Disconnect the battery cables before servicing the engine!
discharged from the engine. Check the exhaust system
generator. Remove the negative lead first and reconnect
regularly for leaks and make sure the exhaust manifolds
it last
are securely attached and no warping exists. Pay close
• Make certain all personnel are clear of the engine before attention to the manifold, water injection elbow, and
starting. exhaust pipe nipple.
• Make certain all covers, guards, and hatches are re- • Be sure the unit and its surroundings are well ventilated.
installed before starting the engine.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
BAmRY EXPLOSION builder or dealer for installati~n of approved detectors.
• For additional infonnation refer to ABYC T-22 (educa-
A WARNING: Battery explosion can cause Injury tional infonnation on Carbon Monoxide).
or death!
• Do not smoke or allow an open flame near the battery A WARNING: carbon mDnDxlde (CO) Is an Invisible
being serviced. Lead acid batteries emit hydrogen, a Ddorless gas. InhalatlDn produces flu-like symptDms,
highly explosive gas. which can be ignited by electrical nausea Df death!
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur- • Do not use copper tubing in diesel exhaust systems. Diesel
ing servicing. fumes can rapidly destroy copper tubing in exhaust sys-
• Never connect the negative (-) battery cable to the posi- tems. Exhaust sulfur causes rapid deterioration of copper
tive (+) connection terminal of the starter solenoid. Do tubing resulting in exhaust/water leakage.
not test the battery condition by shorting the terminals • Do not install exhaust outlet where exhaust can be drawn
together. Sparks could ignite battery gases or fuel vapors. through portholes, vents, or air conditioners. If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline, water could
accumulation of explosive gases. To avoid sparks, do not enter the exhaust discharge outlet and close or restrict the
disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft.
is being charged.
• Although diesel engine exhaust gases are not as toxic as
• Avoid contacting the terminals with tools, etc., to prevent exhaust fumes from gasoline engines, carbon monoxide
burns or sparks that could cause an explosion. Remove gas is present in diesel exhaust fumes. Some of the symp-
wristwatch, rings, and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning
the battery. are:
• Always tum the battery charger off before disconnecting Vomiting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery. Dizziness
Throbbing in temples
BATTERY ACID Muscular twitching
Intense headache
A WARNING: Sulfuric acid In batteries can cause Weakness and sleepiness
severe Injury or death!
AVOID MOVING PARTS
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which is destructive.
A WARNING: RDtatlng parts can cause Injury
If it comes in contact with your skin, wash it off at once Dr death!
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps. • Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to make
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
ii
SAFETY INSTRUCTIONS
• Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBUCATIONS FOR
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that INSTALLING DIESEL ENGINES
could be caught in moving parts. Read the following ABYC, NFPA and USCG publications
• Make sure all attaching hardware is properly tightened. for safety codes and standards. Follow their recommenda-
Keep protective shields and guards in their respective tions when installing your engine.
places at all times. ABYC (American Boat and Yacht Council)
• Do not check fluid levels or the drive belt's tension while "Safety Standards for Small Craft"
the engine is operating. Order from:
• stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running; hair and clothing can easily 15 East 26th Street
be caught in these rotating parts. New York, NY 10010
NFPA (National Fire Protection Association)
HAZARDOUS NOISE "Fire Protection Standard for Motor Craft"
Order from:
A WARNING: High noise levels can caUSll hearing National Fire Protection Association
loss! 11 Tracy Drive
Avon Industrial Park
• Never operate an engine without its muffler installed. Avon, MA 02322
• Do not run an engine with the air intake (silencer) USCG (United States Coast Guard)
removed. "USCG 33CFR183"
• Do not run engines for long periods with their enclosures Order from:
open.
U.S. Government Printing Office
Washington, D.C. 20404
A WARNING: Do not wode on machinery when you are
mentally Of physically Incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTAllAnONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).
iii
INSTALLATION
When installing UNIVERSAL engines and generators it is important that strict atten-
tion be paid to the following information:
CODES AND REGULATIONS

Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. TIris hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, instaU a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer for proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and

diesel, engines and generators, is available from your UNIVERSAL
dealer.
iv
TABLE OF CONTENTS
PARTS IDENTIFICATION .........................................2 EXHAUST MANIFOLD/HEAT EXCHANGER .......... 36

TESTING FOR OVERHAUL ......................................3 RAW WATER PUMP ...........................................37
TESTING OIL PRESSURE/COMPRESSION .......... .4 REBUILDING THE CARBURETOR .......................39
ENGINE TROUBLESHOOTING [CHART} ............... 5 STARTER MOTOR ...............................................42
ASSEMBLY INFORMATION ...................................7 ENGINE ADJUSTMENTS ...................................... .45
Sealants and Lubricants ....................................7 Engine Speed Hertz Adjustment ..................... .45
Bolts and Fasteners ...........................................7 Spark Plugs .....................................................46
GENERATOR/ENGINE DISASSEMBLY ...................8 Valve Clearance Adjustment ........................... .47
Ignition Timing ................................................47
ENGINE DISASSEMBLY ........................................9
COMPONENT TESTING ...................................... .48
TIMING BELT DISASSEMBLY ............................... 11
WIRING DIAGRAM [ENGINE} ............................ .49
TIMING BELT ........................................................13
WIRING SCHEMATIC [ENGINE}. .........................50
CYLINDER HEAD AND VALVES .......................... 15
WIRING SCHEMATIC [REMOTE PANEL} ............ 51
CAMSHAFT AND ROCKER ARMS ....................... 19
SERVICE DATA/STANDARDS AND LIMITS ......... 52
PISTON AND CONNECTING RODS ......................21
HARDWARE TORQUES .......................................54
FRONT CASE/COUNTERBALANCE SHAFT
AND OIL PAN ......................................................26 STANDARD HARDWARE ...................................55
SEALANTS AND LUBRICANTS .......................... 55
FRONT CASE/COUNTERBALANCE SHAFT
SPECIFICATIONS ...............................................56
AND OIL PUMP ..................................................28
SPECIAL TOOLS - ENGINE ................................57
FRONT CASE/OIL PUMP AND OIL PAN .............. 29 BC GENERATOR ELECTRICAL TESTING ..... 58 - 71
CRANKSHAFT/BEARINGS AND OIL SEAL .......... 30 SPECIAL TOOLS - GENERATOR ...........................72
CYLINDER BLOCK INSPECTION AND ENGINE GENERATOR TROUBLESHOOTING
PISTON CLEARANCE ..........................................33 [CHART] .............................................................73
DISTRIBUTOR ....................................................34 METRIC CONVERSIONS DATA ........................... 75
COOLANT CIRCULATING PUMP ......................... 35 METRIC CONVERSIONS [CHART]. .....................76
INDEX ...............................................................77
1
BCGB PARI'S lOERllflCATlON
GOVERNOR A\R \NTAKE

COOLANT PRESSURE CAP
ENG\NE Oil F\LL
REMOTE PANEL
CONNECT\ON
WATER \NJECTED
EXHAUST ELBOW
MAN\FOLD _ _-+__\\.-U~~ C\RCUlT BREAKER
GENERATOR
BACKEND
. COOLANTDRA\N
GASDENSER
REAR
FLEX\BLE MOUNT
LEFT SlOE
CARBURETOR
RIGHT SlOE ENG\NE O\L F\LL
HOURMETER
RAW WATER
\NJECT\ON
(SYPHON BREAK
CONNECtiON)
CONTROL
SWITCHES
8 AMP FUSE
25 AMP CiRCUiT
BREAKER
START MOTOR
OCGROUND FUELUFT PUMP

STUD
HEAT EXCHANGER fRONT
lY'!I~seKI=-
~ng;nes & Generators
2
TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD ENGINE OVERHAUL
Cause of Low Compression The following sections contain detailed information
Generally, the time at which an engine should be overhauled relating to the major components and systems of the engine.
is determined by various conditions such as lowered engine Included are disassembly and inspection instructions for the
power output, decreased compression pressure, and increased guidance of suitable equipped and staffed marine engine ser-
fuel and oil consumption. The lowered engine power output vice and rebuilding facilities. The necessary procedures
is not necessarily due to trouble with the engine itself, but is should be undertaken only by such facilities.
sometimes caused by improper oil, clogged filters or a faulty Additional detailed information and specifications are
carburetor. provided in other sections of this manual, covering the
The decrease in compression pressure is caused by many fac- generator, alternator, starter motor, engine adjustments,
tors. It is, therefore, necessary to determine a cause or causes cooling pumps, etc.
on the basis of data produced by periodic inspection and
maintenance. Oil analysis on a seasonal basis is a good DISASSEMBLY
means of monitoring engine internal wear. When caused by 1. Before disassembly and cleaning, carefully check for
worn cylinders or piston rings, the following symptoms will defects which cannot be found after disassembly and
occur: cleaning.
1 Low engine power output 2. Clean the engine exterior.
2 Increased fuel consumption 3. Perform disassembly in a proper order using proper tools.
3 Increased oil consumption Keep disassembled parts in order. Apply oil when neces-
4 Hard engine starting " sary. Take special care to keep the fuel system parts from "
5 Noisy engine operation intrusion of dust and dirt.
SERIAL NUMBER LOCATION~~ ~

These symptoms often appear together. Symptoms 2 and 4
can result also from improper fuel regulation or a faulty car- The engine serial
buretor. They are caused also by defective electrical devices FiIl in the information l";~0~Ob').. ~~\ '!umber is str;zmped
such as the battery, starter or spark plugs. Therefore it is below for referenc~_ ~/ 3-:> II znto the engme block.
desirable to judge the optimum engine overhaul time by the 0~ f"'~ ~ ~I
lowered compression pressure caused by worn cylinders and '~ ~
!~I(
pistons plus increased oil consumption. Satisfactory combus-
tion is obtained only under sufficient compression pressure.
If an engine lacks compression pressure, incomplete combus- I 1
tion of fuel will take place even if other parts of the engine
are operating properly. To determine the period of engine
overhaul, it is important to measure the engine compression
pressure regularly. At the same time, the engine speed at
~~==~~~~
The I engine\1 model
number and "serial
number are printed
which the measurement of compression pressure is made on a decal on the
should be checked because the compression pressure varies engine manifold.
with engine rpm. The engine rpm can be measured at the
front end of the crankshaft. The generator serial
number is stamped
NOTE: To test engine compression see the ENGINE on the top of the
ADJUSTMENT section of this manual. generator housing.
OVERHAUL CONDITIONS
Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress of wear
of these parts.
When decrease of compression pressure reaches the repair
limit, the engine must be overhauled. An additional decal
is located on the top
The engine requires overhaul when oil consumption is high, of the generator
blowby evident, and compression values are at minimum or housing.
below. Engine compression should be 178 psi (1260 Kpa) at
400 rpm With a limit 137 psi (860 Kpa). Pressure should not
differ by more than 14 psi (100 Kpa) between cylinders. See
ENGINE COMPRESSION in this manual.
3
TESTING OIL PRESSURE I ENGINE COMPRESSION
NOTE: WESTERBEKE recommends that the following engine
adjustments be performed by a competent engine mechanic.
The information below is provided to assist the mechanic.
TESTING OIL PRESSURE ENGINE COMPRESSION TEST

To test the oil pressure, remove the hex head plug from the 1. To check the engine's compression pressure, warm up the
oil manifold and install a mechanical oil pressure gauge in its engine then shut it down.
place. After warming up the engine, set the engine speed at 2. Remove the three spark plug caps and remove the three
1800 rpm and read the oil pressure gauge. spark plugs.
Oil Pressure Between 3D and 40 psi at 1800/1500 rpm.
3. Install a compression adapter and gauge in the spark plug
Note: A newly started (cold) engine may have an oil pres- hole.
sure up to 70 or 80 psi. A warmed engine can have an oil
pressure as low as. 30 psi. Oil pressure will vary depending 4. Close off the raw water intake seacock.
on the load placed on the generator. 5. Crank the engine with the start motor and unplug the
ignition coil and allow the compression gauge to reach a
maximum reading and record.
6. Measure the compression pressure for all the cylinders.
Ensure that compression pressure differential for each
OIL GALLERY cylinder is within the specified unit.
Compression pressure should not differ by more than 14 psi (100 Kpa).
7. If a cylinder's compression or pressure differential is
below the limit, add a small amount of engine oil through
the spark plug hole and repeat steps 4 and 5.
(a) If additional of oil causes an increase of pressure, the
piston ring and/or cylinder wall may be worn or damaged.
(b) If additional oil does not increase compression pressure
suspect poor valve contact, valve seizure, or valve wear.
8. Reinstall three plugs and ignition wires.
9. Open the raw water thru seacock.
COMPRESSION PRESSURE
LOW OIL PRESSURE 178 PSI [1260Kpa] AT 400 RPM
The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3
+ 0.1 kglcm2). A gradual loss of oil pressure usually indicates
worn bearings.
COMPRESSION
GAUGE
(TYPICAL)
ADAPTER
4
BeGB GENERATOR TROUBLESHOOTING
The following troubleshooting chart describes certain This chart may be of assistance in determining the need for
problems relating to engine service, the probable causes of an engine overhaul. For back-end troubleshoting, refer to the
these problems, and the recommendations to overcome BC GENERATOR ELECTRICAL TESTING section in this
these problems. manual.
Problem Probable Cause VerificationJRemedy

HARD STARTING
OR FAILURE TO START 1. High exhaust pressure. 1. Install a larger diameter exhaust.
2. Timing belt. 2. Inspect timing belt-replace.
3. AC generator overload. 3. Remove loads before starting.
4. Check valve at fuel supply. 4. Repair or replace ..
5. Defective starter. 5. Repair or replace starter.
6. Faulty fuel regulator. 6. Replace regulator.
7. Raw water in cylinders. 7. Failure of exhaust system or syphon break. Clear cylinders-
Engine may need overhaul.
SMOKY EXHAUST WHITISH, PURPLE OR BLUE SMOKE

1. Excessive engine oil. 1. Correct oil level.
2. Excessive rise of oil into combustion chamber. 2. Engine overhaul.
a. Poor piston contact. a. Check standard.
b. Seized piston ring. b. Replace or clean.
c. Excessive piston-to-cylinder clearance. c. Replace or correct.
d. Worn valve stem and valve guide. d. Replace.
e. Low engine oil viscosity. e. Replace.
f. Excessive oil pressure. r. Correct.
g. Piston rings are worn or unseated. g. Engine overhaul.
3. Insufficient compression. 3. See LOW COMPRESSION; HARD STARTING.
BLACKISH OR DARK GRAY

1. Poor compression. 1. See LOW COMPRESSION.
2. Improper valve clearance. 2. Valve adjustment.
3. Insufficient intake air (air cleaner clogged). 3. Replace air cleaner.
4. Improper fuel. 4. Replace with proper fuel.
EXCESSIVE OIL OIL LEAKAGE

CONSUMPTION 1. Defective oil seals. 1. Replace oil seals.
2. Broken gear case gasket. 2. Replace gasket.
3. Loose gear case attaching bolts. 3. Retighten bolts.
4. Loose drain plug. 4. Retighten plug.
5. Loose oil pipe connector. 5. Retighten oil connections.
6. Broken rocker cover gasket. 6. Replace gasket.
7. Loose rocker cover attaching bolts. 7. Retighten attaching bolts.
OIL LEVEL RISING

1. Dead cylinder. 1. Check compression.
2. Displaced or twisted connecting rod. 2. Replace connecting rod.
3. Worn piston ring. 3. Replace ring.
ENGINE BACKFIRES,
MISFIRES 1. Incorrect valve clearances. 1. Adjust valves and clearances.
2. Valves are out of adjustment. 2. Adjust valves and clearances.
,,,,,,,,,WESTERBEKE
I Engines & Generators
5·
BCGB ENGINE TROUBLESHOOTING
PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY
ABNORMAL SOUND CRANKSHAFT AND MAIN BEARING
OR NOISE 1. Badly worn bearing. 1. Replace bearing and grind crankshaft.
2. Badly worn crankshaft. 2. Grind crankshaft.
3. Melted bearing. 3. Replace bearing and check lubrication system.
CONNECTING ROD AND CONNECTING ROD BEARING

1. Worn connecting rod big end bearing. 1. Replace bearing.
2. Worn crankpin. 2. Grind crankshaft.
3. Bent connecting rod. 3. Correct bend or replace.
PISTON, PISTON PIN, AND PISTON RING

1. Worn cylinder. 1. Rebore cylinder to oversize and replace piston.
2. Worn piston pin. 2. Replace piston.
. 3. Piston seized. 3. Replace piston and rebore cylinder.
4. Piston seized and ring worn or damaged. 4. Replace piston and rings.
VALVE MECHANISM
1. Worn camshaft. 1. Replace.
2. Excessive valve clearance. 2. Adjust.
3. Worn timing gear. 3. Replace.
4. Worn fan pulley bearing. 4. Replace.
LOW COMPRESSION MAIN ENGINE TROUBLES

1. Incorrect valve clearance. 1. Adjust valve clearance.
2. Inadequate contact of valve seat. 2. Lap valve.
3. Valve stem seized. 3. Replace valve and valve guide.
4. Broken valve spring. 4. Replace valve spring.
5. Compression leaks through cylinder head gasket 5. Replace gasket.
6. Piston ring seized. 6. Replace piston and piston ring.
7. Worn piston ring and cylinder, 7. Overhaul engine.
S. Worn engine bearings. S. Overhaul engine.
EXCESSIVE FUEL
CONSUMPTION 1. Noisy knocking. 1. See KNOCKING.
2. Smoky exhaust. 2. See SMOKY EXHAUST.
3. Moving parts nearly seized or excessively worn. 3. Repair or replace.
4. Poor compression. 4. See LOW COMPRESSION; HARD STARTING.
5. Improper valve timing. 5. Adjust.
6. Improper valve clearance. 6. Adjust.
INSUFFICIENT INTAKE AIR

1. Air intake obstructed. 1. Remove obstruction.
NOZZLE TROUBLES
1. Seized nozzle. 1. Replace.
2. Worn nozzle. 2. Replace.
KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE

1. Main engine troubles.
a.Overheated cylinder. a. See OVERHEATING; LOW OUTPUT.
b.Carbon deposits in cylinder. b. Clean.
KNOCKING WITH DARK SMOKE
1. Poor compression. 1. See LOW COMPRESSION; HARD STARTING.
LOW OIL PRESSURE 1. Worn Bearings. 1. Engine overhaul replace bearings.
2. Relief valve malfunction. 2. Overhaul oil pump.
3. Clogged oil cooler/filter. 3. Repair and replace.
4. Diesel dilution of the oil. 4. Injection pump repair.
6
ENGINE ASSEMBLY
GENERAL INFORMATION When installing gaskets that seal around water (coolant)
• Be careful not to mix bolts and nuts. Metric and S.A.E. passages, coat both sides with WHITE SILICONE GREASE.
bolts are used on various engine assemblies. Do not use sealant when installing a new gasket.
• During assembly, recheck clearances and insure that parts
HIGH-COPPER ADHESIVE SPRAYS are useful for hold-
are being assembled in their proper order and facing in the
ing a gasket in position during assembly.
correct direction in relation to the engine block, such as,
pistons, piston rings, bearings and bearing caps. Specialized gasket sealers such as HYLOMAR work well in
• Apply lubricating oil to moving parts during assembly. applications requiring non-hardening properties. HYLOMAR
Insure that moving parts, when assembled on the engine, is particularly effective on copper cylinder-head gaskets and
rotate or slide and are not subject to binding or resists fuel, oil , and water.
excessive tension. NOTE: TAPE SEALANTS should be used on pipe plugs and
• If there are mating marks scribed during disassembly, fitting that connect water coolant passages.
reference them correctly for assembly.
• Use new gaskets, lockwashers, O-rings, packings and seals. Bolts and Fasteners
• Tighten the bolts and nuts on important parts of the engine Lightly oil head bolts and other fasteners as you assemble
to specified torques using a reliable torque wrench. them. Bolts and other plugs that penetrate the water jacket
• When required, use liquid sealants when required on nuts, should be sealed with PERMA1EX #2 or HIGH TACK.
bolts and gaskets. Refrain from using tape sealants.
When assembling the flywheel, coat the bolt threads with
• Most gaskets and many bolt washers are asymmetrical, LOCTITE blue.
make certain they are positioned properly.
LITHIUM based grease is waterproof, ideal for water pump
Torquing Hardware bearings and stuffing boxes.
Antiseize compounds and thread locking adhesives such as
Prevent mechanical damage by running fasteners down in
LOCTITE protect threaded components yet allow them to
three steps-I/2, 213, and III torque. Exceptions are torque-to-
come apart when necessary. LOCKTITE offers levels of
yield bolts and rocker arm shaft fasteners. The former are
locking according to the job.
torqued as indicated. The latter-rocker shaft fasteners-should be
brought down in very small increments, working from the Heavily oil all sliding and reciprocating components, always
center bolts out. Gaskets, especially head gaskets, might be use clean engine oil.
damaged during assembly, they should be positioned with great
care. See TORQUE SPECIFICATIONS thru out this manual.
Sealants and Lubricants

Oil based PERMATEX #2 and its HIGH TACK equivalent are
excellent all purpose sealers. They are effective in just about
any joint in contact with coolant, raw water, oil, or fuel. A light
coating of oil or LIQUID 1EFLON can be used on rubber
gaskets and o-rings.
LOCTlTE hydraulic red sealant should be used on oil adapter
hoses and the oil filter assembly.
Coat both surfaces of the oil pan gasket with high temp RED
SILICONE SEALER.
7
GENERATOR I ENGINE DISASSEMBLY
DESCRIPTION Unfasten the generator from its mounting rails or the
mounting rails from the platform and remove the generator
The engine component of the BCGB generator is not as
from the boat.
bulky or heavy as most engines [approv. 7Slbs] so it can be
disassembled and repaired on a sturdy work bench. Make Once the generator is securely mounted on a work bench,
certain however that the engine is securely fastened so it can drain the engine oil and coolant.
not topple off the bench and that the bench also is secure and Remove the starter motor. Disconnect and remove the wiring
can not tip over. harness, be certain to tag all the wiring connections as you
Set the generator breakers and panel switches in the off posi- separate them.
tion. Disconnect the AC wiring connections at the terminal Separate the generator back-end from the engine by
block/circuit breaker and unplug the harness at the control removing the 3 bolts (one is the engine ground), one stud and
panel. Disconnect the battery cable connections and the one allen flat head that fasten the engine back-plate to the
engine ground cables. housing. Once the housing is removed, the remaining
Close off the raw water seacock and disconnect the raw generator components can be disassembled from the engine
water components. Separate the exhaust hose at the water back-plate.
injection elbow and disconnect the fuel supply and return NOTE: For servicing and testing of the back end [generator],
lines. refer to the GENERATOR section in this manual.
A CAUTION: Make certain the fuel lines are closed

off and drained. Clean up all fuel and oil spills and
properly dispose of the rags.
ASSEMBLY
BOLTS
y
'iJ'",I[,\.\.\.\.\.'/
'~ \\'-\.\.\:
~,/\~ /
III
~~/
YWHEEL
j
\i GENERATOR BACK-END
~ 1
ARMATURE
GENERATOR BACK-END
SEE SPECIAL TOOLS FOR
DISASSEMBLING THE
GENERATOR COMPONENTS.
8
ENGINE DISASSEMBLY
INTRODUCTION 5. Disconnect and drain the oil hoses. Remove, clean, and
inspect the oil gallery/filter assembly.
The following text describes the disassembly, inspection,
repair, and reassembly of the engine when preforming a
complete engine overhaul.
This manual also includes a breakdown of sub assemblies, OIL FILTER
engine adjustments, generator information and all related COMPONENTS
technical data.
NOTE: The cylinder head, rocker arms and valves can be
inspected and adjusted with the engine in the boat. TIming belt
adjustment and replacement can also be accomplished without
removing the engine.
Suggested Sequence of Disassembly
1. Remove the heat exchanger and set it aside for servicing.
See HEAT EXCHANGER in this manual. cj),~\1.
2. Remove the starter motor. The starter motor should be
OIL FILTER
cleaned, inspected, and repainted. Refer to STARTER
MOTOR.
3. Disconnect the exhaust temperature switch and disassemble
the exhaust elbow and manifold from the engine. Set this 6. Loosen the belt guard thumb screws and remove the belt
assembly aside for servicing. Refer to EXHAUST SYSTEM guard sections and their gaskets.
in this manual. 7. Disconnect the linkage arm between the governor and the
Remove the water temperature. switch and sender and carburetor at the ball joint and remove the carburetor.
disassemble the thermostat assembly. When servicing the carburetor, refer to the
CARBURETOR SECTION in this manual.
S. Release the governor belt and remove the governor
assembly and belt. See GOVERNOR MAINTENANCE.
GOVERNOR - -__...c"A
GOVERNOR AND
GOVERNOR BELT
COOlANT
PUMP
ASSEMBLY
THERMOSTAT ASSEMBLY
"-
~
~COVER GUARD
THUMB SCREW
9
ENGINE DISASSEMBLY
9. Remove the gasdenser and the connecting fuel lines from 11. Detach and remove the ignition wires, the distributor, and
the fiont of the engine and remove the fuel lift pump. the spark plugs.
Refer to DISTRIBUTOR DISASSEMBLY in this manual.
See ENGINE ADJUSTMENTS for information on ignition
wires and spark plugs.
INSPECT HOSES
DISTRIBUTOR
COMPONENTS
FUEL UFT PUMP & GASDENSER
10. Loosen the raw water pump, remove the drive belt and
then remove the raw water pump.
Remove the engines coolant pump. For servicing, refer to
COOLANT PUMP.
IGNITION WIRES
10
TIMING BELT DISASSEMBLY
1 o/EAR COVER
NUMBERS INDICATE THE i
SUGGESTED ORDER OF
DISASSEMBLY
TORQUE 7 - 9 FT-LBS
10-12Nm
TORQUE 7 - 9 Ft-Lbs
\
10-12Nm
1 TIMING BELT
COVER A
6 TIMING BELT
TENSIONER
3~CCESS COVER~
12 CRANKSHAFT 13 CRANKSHAFT 10 FLANGE NUT

BOLT SPROCKET TORQUE 36 - 40 FT-LBS TIMING BELT ADJUSTMENT,
TORQUE 98 - 105 FT-LBS [50-56Nm] INSPECTION AND REPLACEMENT
135-145 Nm TIMING BELT CAN BE PERFORMED WITH
COVER C ENGINE IN THE BOAT
-----~L6 In [65 mm]

INSTRUCTIONS FOR INSPECTING AND REPLACING ---"'"""""~
THE TIMING BELT
WES1ERBEKE requires as normal maintenance, replacing
the timing belt after 1000 engine operating hours. The timing ROD 0.31 In [8 mm]
belt should always be replaced during an engine overhaul.
The adjustments, inspection, and replacement procedures
may be performed without removing the generator from the
boat THE TIMING BELT PART NUMBER IS #043036
Timing Belt Removal
1. Turn the crankshaft clockwise to align the timing mark on 3. Loosen the timing belt tensioner nut.
the camshaft sprocket and timing belt rear cover. 4. Move the timing belt tensioner toward the water pump,
NOTE: Always tum the crankshaft clockwise. and temporarily tighten the nut to hold the tensioner in
that position.
TIMING MARK.--=~.//;.J
2. Remove the plug on the left surface of the cylinder block

and insert a rod with a diameter of 0.31 in (8 mm) to lock
the counterbalance shaft.
NOTE: Be sure to use an inserting rod with a diameter of
0.31 in (8 mm).
I
CRANKSHAFT
SPROCKET
11
TIMING BELT DISASSEMBLY
5. Remove the timing belt. Crankshaft Bolt Removal
NOTE: lfthe timing belt is to be reused, draw an arrow on
1. Lock the crankshaft in position.
the belt to indicate the direction of rotation (clockwise) ..
NOTE: Do not tum the crankshaft.
2. Remove the crankshaft bolt.
Timing Belt Inspection

Replace the belt if any of the following conditions exist:
• Hardening of the back rubber, leaves no indent when
pressed with fingernail (back side is glossy).
• Cracks on rubber back.
• Cracks or peeling of canvas.
• Cracks on tooth bottom.
Camshaft Sprocket Removal • Cracks on belt
1. Remove the camshaft sprocket bolt without turning the • Abnormal wear of belt sides. The sides are normal if they
camshaft. are sharp as if cut by a knife.
• Abnormal wear on teeth.
• Tooth missing and canvas fiber exposed.
CRACKS ON EDGE
SPROCKET BOLT HARDENING
ROUNDED EDGES
Oil Pump Sprock~ Flange Nut Removal FLUFFY STRANDS
1. Remove the plug from the left side of the cylinder block.
~
2. Insert an 0.31 in (8 mm) diameter round bar to lock the
counterbalance shaft.
3. Remove the oil pump sprocket flange nut.
CRACKS ON UNDERSIZE
CRACKS ON TOP
TOOTH MISSING
Tensioner Inspection CANVAS EXPOSED
1. Replace the tensioner if the pulley binds, rattles or is noisy

when turned.
OIL PUMP SPROCKET
12
ENGINE TIMING BELT
Flange Installation Tensioner Spring/Timing Tensioner Installation
1. Mount the flange so that its side shown by the heavy 1. Install the tensioner spring and timing belt tensioner.
arrow in the illustration faces toward the sprocket. 2. Hook the tensioner spring onto the bend of the timing belt
FLANGE tensioner bracket and the stopper pin on the cylinder block.
3. Move the timing belt tensioner as close as possible to the
-~ A-Z=i water pump; temporarily tighten the tensioner nut.
WASHER
CRANKSHAFT SPROCKET
Crankshaft Bolt Installation

1. Lock the crankshaft.
NOTE: Do not tum the crankshaft.
2. Tighten the crankshaft bolt to the specified torque.
Oil Pump Sprocket Flange Nut Installation

1. Insert the round bar into the plug hole in the left side of
the cylinder block to keep the counterbalance shaft from Timing Belt Installation
turning. 1. Align the triangular marking on the camshaft sprocket
2. Install the oil pump sprocket. with a marking on the timing belt rear cover.
3. Tighten the nut to the specified torque. 2. Align the notch in the crankshaft sprocket flange with the
D
marking on the front case.
.-4 3. Align the triangular marking on the oil pump sprocket
with the marking on the front case, and then insert a 2.56 in.
(65 mm.) or longer, 0.31 in (Smm.) diameter round bar into
the plug hole in the left side of the cylinder block.
MARK ON TIMING
BELT REAR COVER_~
TRIANGLE MARK ON
CAMSHAFT SPROCKET
Camshaft Sprocket Bolt Installation
1. Tighten the bolt to the specified torque.
CAMSHAFT BOLT TORQUE 58 - 72 Ft-Ibs (80 -100 Nm) TIMING BELT
~"d.~:t=~'=='--" TRIANGLE MARK .

NOTCH IN CRANKSHAFT
SPROCKET MARK ON FRONT CASE
'SPROCKET BOLT
13
ENGINE TIMING BELT
At this time, check that the moveable range of teeth on the 8. Tum the crankshaft clockwise by nine camshaft sprocket
oil pump sprocket is according to specifications. teeth (81°) to align the timing mark on the camshaft
STANDARD VALUE: 4to 5 teeth in forward direction. sprocket with the tensioner set mark on the timing belt
1 to 2 teeth in reverse direction. rear cover.
A CAUTION: This operation is perfonned to give a

proper tension to the timing belt, so do not tum the
crankshaft counterclockwise and push the belt to
check the tension.
TENSIONER SET MARK
REVERSE
4. If the movable range of the teeth on the oil pump sprocket

exceeds the specified range, correct as follows:
a. Pull out the round bar from the plug hole in the left
side of the cylinder block.
b. Tum the oil pump sprocket one tum at a time until the 9. Make sure that the timing belt teeth are engaged with the
round bar can again be inserted. camshaft sprocket teeth along the portion of the sprocket
shown by the curved arrow in the illustration below. Then
c. Check that the movable range of the oil pump sprocket
tighten the tensioner nut.
is in the specified value.
lO.Pull the timing belt in the center of the tension side
5. Set the timing belt over the crankshaft sprocket and then
toward the sealing gasket line for the belt cover, as illus-
over the oil pump sprocket and camshaft sprocket, in that
trated. Make sure that the clearance between the back of
order.
the belt and the sealing line is the standard value.
NOTE: Ensure that the tension side of the timing belt is not STANDARD VALUE: O.47in. (12mm)
slack. Keep the round bar inserted until the timing belt has
been placed. After this step, be sure to remove the round bar.
SEALING GASKET
6. Apply counterclockwise force to the camshaft sprocket to LINE
make the belt taut on the tension side, and make sure that
all timing marks are lined up.
0.47 In [12 mml
CAMSHAFT SPROCKET
TENSION SIDE
1l.Pull out the rod from the plug hole on the left surface of
the cylinder block and apply the specified sealant. Then
tighten the plug to the specified torque.
Specified sealant value: 3M AID Part No. 8660 or
7. Loosen the temperorarily tightened tensioner nut on the equivalent.
water pump side 1 or 2 turns, and tension the belt making T[GHTENING TORQUE: 11-16 H.lbs. (15-22 Nm)
use of the spring force.
14
CYLINDER HEAD AND VALVES
4 CYLINDER HEAD
TORQUE 43 - 51 FT-LBS
50-70Nm
~-----'14
NUMBERS INDICATE THE

SUGGESTED ORDER OF
9 VALVE
SEAL
DISASSEMBLY
oVALVE
1
HEAD
5 7
19 VALVE GUIDE
¢:::l
ENGINE
FRONT
2 8 6
CYLINDER HEAD BOLTS

LOOSENIN~ SEQUENCE
REMOVING THE CYLINDER HEAD

FROM THE CYLINDER BLOCK
Disassemble the cover bolts as shown above, taking care not
to lose the washer and insert Remove the rocker cover and
rocker cover gasket
Loosen each of the cylinder head bolts, a little at a time so
as to avoid the possibility of distorting the cylinder. Repeat
several times until the bolts are unfastened. Follow the
sequence shown in the diagram.
Remove the cylinder head and the cylinder head gasket
15
Use pliers to remove the valve stem seals. Do not reuse the VALVE ASSEMBLY INSPECTION
stem seals.
Valve StemNalve Seat
If the valve stem is bent or worn, replace the valve. Check
contact between the valve and valve seat by applying a thin
coat of Prussion Blue (or Redhead) on the valve seat contact
face, then insert the valve into the valve guide and press-fit
the valve on the valve seat. Do not rotate the valve.
Check if the valve seat contact face contacts the center posi-
tion 0f the valve contact face. If it is not correct concentric,
correct the valve seat. If the margin is out of the limit, replace
the valve.
THICKNESS OF VALVE HEAD MARGIN
Standard Limit
CYLINDER HEAD INSPECTION Intake D.D39in (1.Dmm) D.D2Din (D.5D8mm)
----r--
Exhaust D.D51in (1.3mm) D.D31in (D.787mm)
Before cleaning check the cylinder head for water leaks,
cracks and other possible damage.
Clean by completely removing the oil, scaling, carbon and CONTACT WITH
VALVE SEAT
sealant. After flushing the oil passage, blow air thru to ensure [to be at cenler
that no portion of the oil passage is clogged. of seall
VALVE
To check the cylinder head bottom surface for flatness and LENGTH
VALVE HEAD
distortion, as indicated in the diagram, use a straight edge THICKNESS [MARGIN]
and a feeler gauge. If distortion exceeds the limit correct
by grinding. .L
VALVE LENGTH: Intake 3.6Din (1DD.6mm)
Exhaust 3.968in (100.8mm)
VALVE SEAT WIDTH OF CONTACT
Standard D.D35in - D.051 (D.9 -1.3mm)
Valve Spring
Measure the free height of the valve spring and replace the
spring if it is out of limit.
VALVE SPRING FREE LENGTH
Standard 1.823in (46.3mm) _ _ _ _ Limit 1.783in (45.3 mm)
CYLINDER HEAD FLATNESS

Standard O.020in (O.05mm) Limit D.D79 (D.2mm)
CYLINDER HEAD GRINDING LIMIT
D.D79in (D.2mm)
Total resurfacing depth of cylinder head and block Also check the spring for squareness and if it exceeds the
CYLINDER HEAD HEIGHT (NEW) limit replace the spring.
4.287 - 4.295in (1D8.9 -1D9.1mm) VALVE SPRING SQUARE NESS
Standard less than 2°_ _ _ _ _ _ Limit 4°
A CAUTION: No more than 0.079in (O.2mm) of Refer to the StandardslLimits chart for additional
stock may be removed from the cylinder head and
cylinder block mating surfaces in total.
See the STANDARDS AND UMITS CHART for cylinder

head rework dimensions of the valve seat hole.
./, 11
1____"",0-=···
~
TESTING SQUARENESS/ANGLE
16
Valve Stem and Guides
Measure the clearance between the valve guide and the valve
stem and , if the clearance exceeds the limit, replace the
valve guide or valve, or replace both.
VALVE STEM
SEAL INSTALLER
lr VALVE STEM
SEAL
Valve Springs
MEASURING VALVE
STEM DIAMETER Install the valve spring with it's enamel coated side toward
the rocker arm side.
F"r~---l)PRIIIG RETAINER
VALVE STEM SEAL TO VALVE GUIDE CLEARANCE

Standard Intake 0.0008 - 0.0020in (0.7 - 0.05mm) ENAMEL
COATED
Exhaust 0.020 - 0.0033in (0.50 - 0.085mm) SIDE
Limit Intake 0.0039in (0.10mm)
Exhaust 0.0059in !0.15mm)
VALVE STEM OUTER DIAMETER
Standard Intake 0.2585 - 0.2591 in (6.565 - 6.580mm) NG SEAT
Exhaust 0.2571 - 0.2579in (6.330 - 6.550mm)
Use the valve spring compressor to compress the valve
Valve Seat Reconditioning
Before correcting the valve seat, check for clearance
;::; :~.the valve ~ompre~d' remove the
between the valve guide and the valve. replace the valve
guide if necessary.
To recondition, use a valve and seat cutter and a pilot or a
seat grinder, repair so that the seat width and seat angle are
the specified configuration.
After correction, the valve and the valve seat should be
lapped with lapping compound.
REMOVING
RETAINER
LOCKS
VALVE SEAT CONTACT WIDTH
.035 - .051 in [0.9 -1.3 mmJ
Cylinder Head Gasket
Clean the residue of gasket and oil from the gasket mounting
surface of the cylinder block and the cylinder head.
Place a new cylinder head gasket on the cylinder block
facing its identification mark upward.
INSTALLATION
Valve Stem Seal
Install the valve spring seat, then using the valve stem seal
installer, install a new stem seal to the valve guide.
Do not use the old valve stem seal.
NOTE: Use the installer tool to insert the stem seal, improper
installation can cause oil to leak into the cylinder.
CYLINDER HEAD GASKET
17
Cylinder Head Bolts
Tighten the cylinder head bolts in the order shown in the dia-
gram using a stepped-up tightening torque. INTAKE SIDE
1. Temporarily tighten the bolts in numerical order to 14- 2
22ft-Ibs (20 - 30 Nm).
2. TIghten the bolts again in numerical order to 29 - 36ft-Ibs
(40- 50Nm).
3. TIghten the bolts in numerical order to the specified
torque. ENGINE FRONT
CYLINDER HEAD TORQUE 43 -51ft-lbs (60 - 70Nm)
Rocker Cover
Install the rocker cover using a new gasket (slightly coat both EXHAUST SIDE
sides with clean oil). Gradually tighten the cover bolts to the
specified torque making certain the cover gasket is positioned CYLINDER HEAD BOLTS
properly. TIGHTENING SEQUENCE
ROCKER COVER BOLT TORQUE (6mm BOLT)
2.9 - 5.2 ft-Ibs (4 - 7Nm)
18
CAMSHAFT AND ROCKER ARMS
TORQUE 21 - 25 Ft-Lbs 2! - 35 Nm ~
21-35Nm ---, iii
SUGGESTED ORDER OF
DISASSEMBLY
10 ROCKER ARM
EXHAUST
®
1 :~~~~:::;B~~CKER TORQUE 6_7FT_LBs~9WAVE
;AS~HER
8-10Nm .~
8ROCKERAR
INTAKE
5 ROCKER A R M · • '"'
INTAKE ~ \6
WAVE WASHER )
3W
' 'WASHE. ~
, 1V~
<- ') \1 =;;::Ii

2 ~~R ARM 4~~:8~TARM
12 CAMSHAFT
OILSEAL ~
. ~
INSPECTING THE CAMSHAFT CAMSHAFT HEIGHT STANDARD UMIT
1. Visually inspection the camshaft for cracks and damage. Intake #1 1.3815in (35.09mm) 1.3618in (34.59mm)
#2 1.3807in (35.01mm) 1.3610in (34.57mm)
If necessary, replace the camshaft. #3 1.3803in (35.06mm) 1.3606in (34.56mm)
NOTE: If the dmnage is slight, you may be able to correct the Exhaust #1 1.3839in (35.15mm) 1.3642in (34.65mm)
camshaft with an oil soaked fine emery grindstone. Take #2 1.3831in (35.13mm) 1.3634in (34.63mm)
special care to not damage the original cam form. #3 1.3854in (35.19mm) 1.3657in (34.69mm)
2. Inspect the camshaft journal and, if wearing exceeds the
limit, replace the camshaft.
CAMSHAFT JOURNAL DIAMETER
STANDARD 1.6118 -1.6124in (40.940· 40.955mm)
CHECK JOURNAL BEARINGS

FOR WEAR DAMAGE C:C-~O·
HEIGHT
~-
MEASURING
CAMSHAFT HEIGHT
4. Inspect the clearance between the camshaft journal and

the camshaft support bore as follows:
a. Measure the camshaft journal diameter and the
Camshaft camshaft support bore.
NOTE: If the Journal is seized. also check the cylinder head!
b. Calculate the clearance and replace the camshaft or
3. Measure the cam height and, if it is less than the limit, cylinder head if the clearance exceeds the limit.
replace the camshaft. BEARING OIL CLEARANCE
STANDARD 0.0018· 0.0033in (.045 . 0.085mm)
19
CAMSHAFT AND ROCKER ARMS
Rocker Arm 3. Measure the end play of the camshaft by inserting a
Check each component part of the rocker arm assembly and feeler gauge in the gap between the rear of the thrust
carefully inspect the individual rockers where the arrows plate and the new front camshaft journal.
indicate.
VALVE Standard 0.236 - 0.05511n (0.06 - 0.14mm)
limit 0.1181n (o.3mm)
ROCKER ARM
INSPECTION
Inspecting Clearance Rocker Arm And Shaft

Check the clearance between the rocker arm and shaft and, if
it exceeds the limit, replace the rocker arm or shaft.
ROCKER ARM CLEARANCE (ROCKER ARM TO SHAFT)
4. Using the oil seal installer tool, install the front oil seal in
Standard 0.0005 - o.ooHln (0.012 - o.o43mm) the cylinder head.
limit 0.0041n (0.1mm)
Rocker Shaft
1. Inspect the rocker shaft where the rocker arms sit for
water and damage. Replace the shaft if worn.
2. Measure the shaft length and the shaft outer diameter
(O.D.). If the shaft fails to meet the standards, replace
the shaft.
ROCKER SHAFT LENGTH Standard 9.1341n (232mm)
ROCKER SHAFT 0.0. Standard 16.985 -16.988In (0.6687 - 0.6693mm)
~ ~~II Or] 5. Install the rocker annIrockershaft assembly. Install the

rocker shaft so the portion shown in the diagram is
OIL HOLES
I OIL HOLES located on the front.
BOLT HOLE
INSTALLATION
1. Apply a coating of engine oil to the camshaft journals
and cams and insert the camshaft through the rear of the FRONT
cylinder head.
2. Install the camshaft thrust plate as shown in the diagram BOTTOM VIEW OIL HOLE
tighten the bolts to the specified torque.
THRUST PLATE BOLTTORQUE 7 - 9ft-lbs (10 -12Nm) 6. Tighten the rocker arm shaft bolts (4 bolts) uniformly and
then to the specified torque.
TORQUE
BOLT ROCKER ARM SHAFT BOLT TORQUE 21 - 25ft-lbs (29 - 35 Nm)
20
PISTONS AND CONNECTING RODS
#1 PISTON RING
gOILRING #2 PISTON RING

ARROW
FRONT MARK
STOPPER
NOTCH CYUNDER
NUMBER
II
6 BEARING

SUGGESTED ORDER OF
DISASSEMBLY
REMOVING THE CONNECTING RODS/PISTONS

Turn the engine over and remove the connecting rod bearing
caps and the connecting rod bearings, note the markings on
the bearing cap and keep the disassembled parts (connecting
rod, rod cap, piston, etc. classified by cylinder. If the marks
are worn away be certain to remark them.
~
GUIDEB
PINSmlNG
Disassemble the Pistons BASE SPECIAL ---'.
TOOL
Using the ring remover, remove the piston rings. While
removing the piston rings, note the order they are removed
and which side of the ring faces the piston crown.
Remove the Piston Pins
Insert the special tool, push the rod, and guide B into the
piston pin then set the piston and connecting rod assembly
on the pin setting base. Make certain that the front (arrow)
stamped on the piston top surface faces upwards. Using a
press, drive out the piston pin.
NOTE: Keep the disassembled piston, piston pin and
connecting rod in order according to the cylinder number.
21
PISTON PIN INSPECTION Check the piston ring for damage, wear, seizure and bends
replacing the rings if anything unusual is noted. Always
Reinsert the piston pin into the piston hole with your thumb.
replace the piston rings when installing a new piston.
You should feel a slight resistance, if the bore is misaligned
the pin will click or bind as it enters. Try the pin from both
sides. Replace the piston if the pin can be too easily inserted
or if there is excessive play.
FEELER GAUG E
NOTE: The piston pin and piston are replaced as an assembly.
Measure the outside diameter of the piston pin.
PISTON PIN 0.0.0.6300 - 0.6302io (16.001 -16.007mm)
RING SIDE
ClEARANCE
Check the clearance between the piston ring and the ring
Pistons groove, if it exceeds the limit, replace the rings, the piston
Check the piston surfaces for wear, seizure, cracks and or both.
streaking. If any damage is evident, replace the piston. PISTON RING SIDE CLEARANCE
Inspect the oil return hole in the oil ring groove and the oil Staodard Limit
hole in the piston boss. Clean the piston if these are clogged. No.1 riog 0.0012 - 0.0028io (0.03 - 0.07mm) 0.0047io (0.12mm)
Check the piston pin hole for signs of seizure or damage. No.2 riog 0.0008 - 0.0024io (0.02 - 0.06mm) 0.0039io (0.10mm)
Replace the piston if damage is evident Measure the piston
diameter at 90° (perpendicular) to the pin bore axis. Connecting Rod Bearing
Visually check the surface of the bearing. Replace those
PISTON 0.0.2.5579 - 2.5591io (64.97 - 65.00mm) which are lopsided, streaked or seized. When streaks or
If the piston diameter is less then the standard replace seizure are excessive, check the crankshaft. If damage is
the piston. discovered on the crankshaft, either replace it or reuse after
undersize machining. If the connecting rod bearing indicates
NOTE: The piston and piston pin are replaced as an assembly. severe thermal damage, replace the bearing.
Piston Rings Measure the inner diameter of the connecting rod bearing
and the outer diameter of the crankshaft pin. If the gap (oil
Insert the piston ring into the cylinder bore placing it against
clearance) exceeds the limit, replace the bearing, and, if nec-
the top of the piston head and pressing it in. When it marks a
essary, the crankshaft...or undersize machine the crankshaft
right angle, measure the piston ring gap with a feeler gauge.
and replace the bearings with an appropriate undersize type.
When the gap is too large, replace the piston ring.
CONNECTING ROD BEARING OIL CLEARANCE
PISTON RING GROOVE
Staodard Limit
staodard
0.009 - 0.0020io (0.022 - 0.052mm) 0.004io (0.1mm)
No.1 0.0480 - 0.048810 (1.22 - 1.24mm)
No 2 0.0476 - O.0484io (1.21 -1.23mm)
Oil 0.1108 - 0.1116io (2.815 - 2.835mm)
PISTON RING END GAP CONNECTING ROD Y~''''''''' .....
staodard Limit
No.1 0.0059 - 0.0118io (0.15 - 0.30mm) 0.810 (0.0315mm)
No.2 0.0138 - 0.0197io (0.35 - 0.50mm) 0.8io (0.0315mm)
Oil 0.008 - 0.028io (0.2 - 0.7mm) 1.0io (0.0394mm)
PISTON
PISTON RING GAP
22
NOTE: See Crankshaft/Bearing section for measuring the oil Oil Ring
clearance with a Plastigauge.
Assemble the oil ring spacer into the piston ring groove.
Use a rod aligner to check the connecting rod for bend and Then, after assembling the upper side rail, assemble the
twist. lower side rail.
CONNECTING ROD BEND LIMIT 0.004in (O.OSmm)
NOTE: There is no difference between the upper and lower
m
side rails or the spacers. W~-j/
//,
~~,......-
SIDE RAIL
'-----~
SPACER
The chart below identifies the color coding on new spacer

and side rails according to size.
SPACER AND SIDE RAIL CODING
SIZE Color Identification
S.T.D.
0.0098in (O.2Smm) Oversize Two Blue Lines
CONNECTING ROD TWIST LIMIT 0.004in (0.1mm) 0.0197in (O.SOmm) Oversize One Red Line
CONNECTING ROD BIG END TO CRANKSHAFT SIDE CLEARANCE 0.029Sin (0.7Smm) Oversize Two red lines
Standard 0.0039 - 0.0098in (0.10 - 0.2Smm) 0.D394in (1.00mm) Oversize One Yellow Line
CONNECTING ROD CENTER LENGTH Install the three-piece oil ring in the piston. Then, make
Standard 4.0138 - 4.0178in (101.9S -102.0Smm) certain the side rails move smoothly in both directions. The
side rail my be easily installed by pushing it in with your
finger after fitting the one end over the piston groove. Do not
ASSEMBLY use an expander ring on the oil ring.
Piston Connecting Rod, Piston
Using the special tool (pin setting base) assemble the END OF SIDE RAIL
piston and connecting rod and press-in the piston pin. First,
install the piston pin into the special tool,
PUSH
ROD
FRONT MARK
Piston Rings
Use a piston ring expander and install the piston rings with
GUIDE A the marker and size marks facing up toward the piston top.
Notice the difference in shapes between No.1 and No.2 ring.
Set up the piston and connecting rod on the piston pin setting
base. Make sure that the front marks are facing up. Apply
engine oil to the outer circumference of the piston pin and 1--_ _. , / - " PlSTDO ROG
insert the pin, Guide A and the push rod (assembled) into the
piston and connecting rod.
Using a press, load the push rod top end and press-fit the
piston pin in the connecting rod. The piston pin is press
~~#2PISTONRING
fitted in the specified position by press-fini:ng the Guide A
bottom end surface until it is seated on the bottom surface of
the base. If the press-fitting load is out of the specification,
replace the pin (piston assembly) or connecting rod, or both.
PISTON PIN PRESS-FITTING LOAD 1102 - 33071bs (SOOO -1S00Nm)
23
Installing the Piston Assembly
Apply an ample amount of oil to the outside surfaces of the
piston and the piston rings. Position the piston rings and oil NO.3
ring (side rail spacer) end gaps as shown. NO.2
SIDE RAIL ~ ~ 1 NO;1
~
+!/
r-----NO.1 ARM
FRONT
~ /) CRANKSHAFT PIN DIAMETER

iI2 SPACER ~ -:;::::> ""SIDE RAIL Identification marks
(1) /1\
Journal Diameter
1.4171 - 1.4173in (35.995 - 36.000mm)
Insert the piston and connecting rod assembly into the (2) G 1.4167 - 1.4171 in (35.985 - 38.995mm)
(3) C 1.4165 -1.4167in (35.980 - 35.985mm)
cylinder, working from the arrow mark on the piston top
toward the camshaft spcocket side.
CONNECTING ROD BIG END INNER DIAMETER
Identification Marks Big End Inner Diameter
o 1.5354 -1.5356in (39.000 - 39.005mm)
1.5356 -1.5360in (39.005 - 39.015mm)
I
II 1.5360 - 1.5362in (39.015 - 39.020mm)
FRONT
ARROW CONNECTING ROD BEARING THICKNESS
MARK Identification Color Bearing Thickness
Securely pressing the piston ring with the ring band, insert Brown 0.0586 - 0.0588in (1.488 -1.493mm)
0.0588 - 0.0590in (1.493 -1.498mm)
the piston and connecting rod assembly into the cylinder. Blue 0.0590 - 0.0592in (1.498 -1.503mm)
Keep in mind that the piston ring may be damaged if hit too
strongly.
CONNECTING ROD BEARING SELECTION TABLE
LUBRICATE WITH OIL
PISTON RING Crankshaft Pin Connecting Rod Bearing
BAND INSTALLER Identification Marks Identification Marks
(1) //\ I Brown
n Brown
m
(2) G I
rr
Brown
lIT Blue
(3) [ I
]I Blue
lIT Blue
Crankshaft/Bearing Assembly
When the bearings are to be replaced, select the appropriate FRONT CAGE
0
~....., ,,_
IDENTIFICATION
COLOR
bearings for assembly according to the identification marks

for the crankshaft and the connecting rod.
IDENTIFICATION
MARK
CRANKSHAFT
CONNECTING ROD
STOPPER
NOTCH CYLINDER
NUMBER
24
Installing the Connecting Rod Bearing Caps
Since the connecting rod cap bolts and nuts are torqued
using the plastic area tightening method, the bolts should be
examined before reuse. If the bolt threads are "necked
down", the bolt should be replaced.
Necking can be checked by running a nut with fingers to the
full length of the bolt threads. If the nut does not run
smoothly, the bolt should be replaced.
Before installation of each nut, apply clean engine oil to the
thread portion and bearing surface of the nut
Install each nut to the bolt and tighten it with your fingers.
Then tighten the nuts alternately to install the cap properly.
Tighten the nuts to the proper torque.
CAP NUT TIGHTENING TORQUE 11+90' turn (15Nm +90' tum)
A CAUTION: If the cylinder head has been installed

before installing the connecting rod cap nut, remove
the spatk plugs.
Make a paint mark on the head of each nut. Make a paint

mark on the bolt end at the position 90° to 100° from the
paint mark made on the nut in the direction of the tightening
nut.
Give a 90° to 100° turn to the nut and make sure that the
paint mark on the nut and that on the bolt are in alignment.
If the nut is turned less than 90°, proper fastening
performance may not be expected. When tightening the nut,
rum it sufficiently.
If the nut is overtightend (exceeding 100°), loosen-the nut
completely and then retighten it by repeating the tightening
procedure.
25
FRONT CASE I COUNTERBALANCE SHAFT AND OIL PAN
GASKET
ENGINE BLOCK
15
10 FRONT CASE
'-1
TORGUE 6 - 7 R-Lbs

SUGGESTED ORDER OF
DISASSEMBLY
COOLANT DRAIN
OIL SCREEN ASSEMBLY
5 OIL PUMP COVER
CONFIGURATION
OF FRONT CASE
ASSEMBLY
1 OIL DRAIN ASSEMBLY
OIL PAN REMOVAL 2. Remove the oil pump cover and gasket. Discard
Remove the oil drain hose assembly. Remove the oil pan the gasket.
bolts and then use the special tool to break the pan seal. 3. Remove the oil pump driven gear tightening flange bolts
. to release the counterbalance shaft.
4. Remove the counterbalance shaft. Drive it from the front.
OIL PAN GASKET TOOL
COUNTERBALANCE SHAFT REMOVAL

1. Remove the plug on the cylinder block and insert an
O.32in (Smm) rod into the hole to lock the
FLANGE BOLT
counterbalance shaft. OIL PUMP DRIVEN
GEAR
26
FRONT CASE I COUNTERBALANCE SHAFT AND OIL PUMP
4. Using a special tool drive the counterbalance shaft front FRONT CASE· INSPECTION
bearing from the cylinder block. Check the front case for cracks or other damage also inspect
the oil holes. If the oil holes are clogged, use compressed air
or solvent to clean them out.
EARING REMOVER TOOL
5. Use the same tool and drive the counterbalance shaft rear
CRANKSHAFT
bearing from the cylinder block. FRONT OIL
SEAL
CRANKSHAFT FRONT OIL SEAL· INSPECTION

Check the oil seal for wear and damage. Inspect the oil seal
lip for hardening. If there any signs of wear, replace the seal.
OIL PUMP ASSEMBLY· INSPECTION COUNTERBALANCE SHAFT

Fit the oil pump gear into the cylinder block, then, using a
feeler gauge, check the clearance with the body at the points
indicated in the diagram below.
DRIVEN GEAR BODY CLEARANCE STANDARD
A. 0.0161 - 0.0266in (0.410 - 0.675mm)
B. 0.0051 - 0.0069in (0.130 - 0.175mm)
DRIVE GEAR BODY CLEARANCE STANDARD
C. 0.0173 - 0.0276in (0.44 - 0.70mm)
D. 0.0059 - O.077in (0.150 - 0.195mm)
DRIVEN GEAR SIDE CLEARANCE .0024 - 0.0047in (0.06 - 0.12mm) COUNTERBALANCE SHAFT· INSPECTION
DRIVE GEAR SIDE CLEARANCE 0.0027 - 0.0051 in (0.07 - 0.13mm)
Inspect the oil holes for clogging and clean if necessary.
Using a straight edge, check the side clearance at the point Inspect the shaft journal for seizure, damage and its contact
indicated in the illustration with a feeler gauge. with the bearing. Check the counterbalance shaft oil
There should be no uneven wear on the contact surfaces of clearance. Replace the counterbalance shaft if it fails to meet
the cylinder block or on the pump gear side of the pump the standards.
COUNTERBALANCE SHAFT STANDARDS
Front Journal Diameter 0.7869 - 0.7B74in (19.987 - 20.000mm)
DRIVEN
Rear Journal Diameter 1.7317 -1.7322in (43.984 - 44.000mm)
~~~ANCE.~.Ar GEAR Front Journal Oil Clearance 0.0014 - 0.0027in (0.035 - 0.068mm)
Rear Journal Oil Clearance 0.0014 - 0.0028in (0.035 - 0.071mm)
ot1---DRIVE
GEAR
27
FRONT CASE I COUNTERBALANCE SHAFT AND OIL PUMP
INSTALLATION Crankshaft Oil Seal
Counterbalance Rear Bearing 1.
1. Install the special tool guide pins (bearing Installer) in the
tapered hole of the cylinder block as shown.
. \ t)r---, (
OIL HOLE ~ ~ J 0.. r
\ '- "::J
~\ BEARING
2. Mate the ratchet ball of the bearing in the oil hole of the Front Case Assembly
rear bearing and install the bearing in the bearing Install the front case assembly through the gasket and tighten
installer. the bolts to the specified torque.
3. Apply clean engine oil to the outer circumference of the FRONT CASE BOLTS TORQUE 6 - 7ft.Jbs. (8 -10 Nm)
bearing and the bearing hole in the cylinder block. There are two different length front case bolts. Make certain
4. they are positioned properly. See the diagram.
NOTE: When installing the front case assembly, apply oil to
the inner circumference of the oil seal lip. When installing
the front case assembly take care not to damage the oil
GUIDE PIN - __.v seal lip on the stepped up portion of the front end of
the crankshaft.
A
A BOLT • 18mm (.71 in)
B BOLT· 30mm (1.18 in)
A_-.r.-
\ B
B
Counterbalance Front Bearing
1. Apply engine oil to the bearing outer circumference and Oil Pump Driven Gear
the bearing hole in the cylinder block.
1. Apply an ample amount of clean engine oil to the oil
2. Press-in the front bearing using the installer tool. pump driven gear and insert it so that the timing mark is
positioned as shown.
2. Using the same hole on the side of the cylinder block,
FRONT BEARING reinsert the 8mm rod to lock the counterbalance shaft.
INSTALLATION Then tighten the flange bolt to the specified torque.
SETTING THE
DRIVEN GEAR
TIMING
MARK
DRIVEN GEAR FLANGE BOLT TORQUE 25 - 29ft.lbs. (34· 40Nm)
28
FRONT CASE lOlL PUMP AND OIL PAN
DRIVE GEAR
OIL PUMP ASSEMBLY
TIMING MARKS
Oil Pump Cover Gasket

Fit a new oil pump cover gasket into the groove in the oil FRONT CASE CONFIGURATION
pump cover. The flat side of the gasket is positioned against
the pump cover. Oil Pan
Remove the old gasket and sealant from the oil pan and
cylinder block with a scraper, wire brush, solvent, etc. Make
certain all residue is removed.
Oil Pump Seal

Press the seal into the oil pump cover flush with the surface
using the seal installer tool.
OIL PAN
INSTAUING THE
OIL PUMP SEAL
29
CRANKSHAFT I BEARINGS AND OIL SEAL
1 OIL SEAL
CASE BOLT
ITORQUE 1 - 9 Ft-Lbs
/10-12Nm
SUGGESTED ORDER OF
DISASSEMBLY
CYLINDER BLOCK
\\ ~~_ _- - - . THRUST BEARING

8 CRANKSHAFT BEARING: (UPPER)
INSPECT THE JOURNALS
FOR UNEVEN·WEAR.
CHECK FOR CRACKS, BENDS,
AND CLOGGED OIL HOLES.
~
~ TORQUE 98 - 105 FT-LBS
[135 - 145 Nm]
9 CRANKSHAFT

[135 - 145 Nm]
_--"A?~.~
MAIN BEARING BOLT

[50-56 Nm]
~-+-_ _ _ _ _"f'BEARING CAP BOLT
CRANKSHAFT INSPECTION
1. Check the journals and pins for damage, seizure and
cracks. Check the joumalscontact surface for uneven
wear and replace if badly damaged.
2. Measure the outside diameter of the journal and the
inside dianieter of the main bearing. If the clearance (oil MEASURING
clearance) exceeds the limit, replace the main bearing and II DIRECTION
also the crankshaft, if necessary. Otherwise, fabricate an
undersized crankshaft and replace the main bearing with
an undersized one_
MEASURING THE
CRANKSHAFT 0.0.
Standard Limit AND BEARING 1.0.
0.0008 - 0.0018in (0.021 - O_045mm) .004in (0_1mm)
MEASURING POSITION
3_ When grinding the crankshaft to under-size, take note of

the "R" dimensions of the fillets of the journal and pin
area.
¢-w
30
CRANKSHAFT, BEARING AND OIL SEAL
R - 0.059 IN {1.5MMJ
CRANKSHAFT BEARINGS SPECIFICATIONS
Upper and Lower
When the bearings are to be replaced, select the correct ones
and install them in positions according to the identification
marks stamped on the crankshaft and the top surface of the
cylinder block.
CRANKSHAFT JOURNAL DIAMETER
R - 0.059 IN [1.5MMJ Identification Marks Journal Diameter
1 1.5746 -1.5748 in (39.994 - 4O.ooomm)
2 1.5743 -1.5746 in (39.988 - 39.994mm)
3 1.5741 -1.5743 in (39.982 - 39.988mm)
MEASURE THE CRANKSHAFT OIL CLEARANCE /NO.4

The crankshaft oil measured by using a plastic gauge /NO.3
as follows: _NO.2· ....
---""-.J
-NO.1
1. The oil and grease and other foreign matters form the
crankshaft journal and bearing inner surface. ~NO.2ARM
2. Install the crankshaft. CAMSHAFT JOURNAL
CRANKSHAFT BEARING THICKNESS
3. Cut the plastic gauge to the same length as the width of
Identification Colors Bearing Thickness
the bearing and place it on the journal in parrallel with its
brown· 0.0783 - 0.0784 in (1.988 -1.991mm)
axis.
0.0784 - 0.0785 in (1.991 - 1.994mm)
4. Gently place the main bearing cap over it and tighten the blue 0.0785 - 0.0786 in 11.994 -1.997mm)
bolts to the specified torque. yellow 0.0786 - 0.0787 in 1.997 - 2.ooomm)
green 0.0787 - 0.0789 in 2.000 - 2.oo3mm)
5. Remove the bolts and gently remove the main bearing .
cap. Measure the width of the smashed plastic gauge
(at its widest section) by using the scale printed on the
plastic gauge.
o o
"iIf''''N..-
CYLINDER BLOCK
0000
zzzz
MAIN BEARING BOLT
TORQUE 36 - 40 FT-LBS CYLINDER BLOCK BEARING DIAMETER
[50-56Nm] ~
Identification Marks Bearing Inner Diameter
o ·1.7323 -1.7325 in 144.000 - 44.oo6mm)
I 1_7325 -1.7328 in 44.006 - 44.o12mm)
n: 1.7328 -1.7330 in 44.012 - 44_o18mm)
SCALE
BEARING
IDENTIFICATION
PLASTIGAUGF MARKS
INSPECTING THE CRANKSHAFT REAR OIL SEAL CRANKSHAFT BEARING SELECTION CHART
Crankshaft Journal Crankshaft Bearing Cylinder Block Bearing
1. Inspect the oil clearance lip for wear or damage. Check Identification Marks Identification Marks Identification Marks
the rubber portion for deterioration and hardening.
1 brown 0
Replace the seal if at all suspect. I
2. Check the oil case for cracks and damage. If here is blue 1I
damage, replace the case. 2 0
blue I
yellow ][
3 blue 0
yellow I
green 1I
31
CRANKSHAFTI BEARING AND OIL SEAL
MEASURING END PLAY
Push the crankshaft to the rear. Then, insert a feeler gauge in
the gap between the crankshaft journal side surface and the
thrust bearing end surface to measure the end play.
CRANKSHAFT END PLAY 1.5740 -1.5748 in (0.05 - 0.025mm)
CRANKSHAFT BEARINGS
CRANKSHAFT REAR OIL SEAL

INSTALLING THE THRUST BEARINGS 1. Apply engine oil to the rear cover and to the oil seal.
1. Apply a coat of oil to the thrust beating and install so that 2. Press the oil seal into the seal case using the special tool.
the oil groove faces outward as illustrated.
3. Install the oil seal case into the cylinder block through the
gasket. (If there is no gasket, coat with sealant.) The
entire circumference of the oil seal lip should be coated
with clean engine oil.
2. Install the bearing cap paying careful attention to the cap OIL SEAL CASE
number and the arrow mark. Apply oil to the bolt
threads.
3. Tighten the bearing cap to the specified torque.
BEARING CAP BOLT TORQUE 36 - 40 ft-Ibs (50 - 55Nm)
NOTE: Make certain the lips of the oil seal are not turned up.
OIL CASE BOLT TORQUE: 7 - 9 A-Ibs (10 -12Nm)
32
CYLINDER BLOCK INSPECTION AND PISTON CLEARANCE

SUGGESTED ORDER OF
1"1 SEALING CAPS (35)
DISASSEMBLY
2DDWEL--_
6 STIJIlS "01· n/ 8 KNOCK BUSHINGS 6 X 9~

.
CRINDER BLOCK INSPECTION
1. Before inspecting, clean the cylinder block to ensure that
the water and oil holes are not plugged. If clogged, clear
with compressed air.
2. Check for cracks and damage. Use a flaw detecting com-
pound as needed. Replace the block if defective.
3. Inspect the mating surface. Using a straight edge and
feeler gauge measure the flatness of the top surface.
Grind or replace if the limit is exceeded.
BORING THE CRINDER
1. Select an oversize piston based on the cylinder with the
FLATNESS STANDARD VALUE: 0.0020 in (0.05 mm)
maximum bore and maximum damage depth.
LIMIT: 0.004 in (0.1 mm)
2. Using the outer diameter (at the specified measurement
4. Inspect the cylinder bore. Using a cylinder gauge, mea- point) of the selected oversize piston, calculate the boring
sure the bore at six places (as shown in the diagram). dimension.
Calculate the difference between the max. and min. val-
Boring dimension =
ues. If worn or damaged, rebore or replace the cylinder. (Piston 0.0.) + (piston clearance) - (honing margin: 0.0008in (0.02mm))
CYLINDRICITY STANDARD VALUE: 0.0004 in (0.01 mm) or less OVERSIZE PISTON OUTSIDE DIAMETER AND CYLINDER
CYLINDER BORE: 2.5591 - 2.5602 in (65.00 - 65.03 mm) (INNER DIAMETER FINISH DIMENSION (REF))
Size Mark Piston Dia. Cylinder Inner Dia.
0.250.S. 25 2.5677 - 2.5689in 2.5693 - 2.5697in
UPPER (65.22 - 65.25mm) (65.26 - 65.27mm)
0.500.S. 50 2.5776 - 2.5787in 2.5791 - 2.5795in
~f+------l~~ CENTER (65.47 - 65.50mm) (65.51 - 65.52mm)
0.750.S. 75 2.5874 - 2.58861n 2.5890 - 2.5894in
(65.72 - 65.75mm) (65.76 - 65.77mm)
LOWER
MEASURING 1.000.S. 100 2.5972 - 2.5984in 2.5988 - 2.59921n
DIRECTION MEASURING POSITION (65.97 - 66.00m) (66.01 - 66.02mm)
CHECKING THE PISTON CLEARANCE 3. Bore the cylinder to obtain the calculated dimensions.
Calculate the difference between the minimum cylinder bore 4. Hone to finish the cylinder inner diameter.
in the thrust direction and the piston outer diameter shown in S. Check again for cylindricity and piston clearance .
. the illustration. If the difference exceeds the specified range,
replace the piston or cylinder blo,?k, or rebore the cylinder.
PISTON TO CYLINDER CLEARANCE STANDARD:
0.0008 - 0.0016 in (0.0 - 0.04 mm)
33
DISTRIBUTOR
3 COVER
ASSEMBLY
2 ROTOR
VACUUM
CONTROL
CHECK THE DISTRIBUTER
CAP FOR CRACKS, WEAR
AND EVIDENCE OF ARCHING
OR BURNING, IF ANY OF
THESE CONDITIONS EXIST,
REPLACE THE DISTRIBUTER CAP.
1 O-RING
11 HOUSING
ASSEMBLY

SUGGESTED ORDER OF
DISASSEMBLY
10 BREAKER
PLATE
READ WIRE SET
6 IGNITER
TESTING THE PICK UP COIL

STANDARD RESISTANCE VALUE: 420 - 540 K.Q
Check that when a screwdriver is passed near the iron core

of the pick-Up assembly the needle of the tester deflects. Adjust the point 'gap of the pick-up assembly between the
rotor and the pick-up.
STANDARD GAP: 0.35mm TO 0.40mm
INSPECTING SPARK PLUGS

Check the plugs for carbon build-up and burning. Check the
plug gap.
SPARK PLUG GAP: 0.028 - 0.031 in (0.7 - 0.8 mm)
34
COOLANT CIRCULATING PUMp·
REMOVING THE COOLANT PUMP
1. Loosen the belt guards thumbscrews and remove the
engine's belt guard from its brackets at the front of the COOLANT PUMP
engine.
2. Ease the belt tension by releasing the raw water pump and
remove the engine drive belt [on carburetor models it will
be necessary to remove the governor belt].
3. Unscrew the five bolts that hold the pump to the engine
and remove the coolant pump and its gasket. Note that the
pulley is an integral part of the pump assembly.
~
LOCKNUT
GASKET
USE HI- TACK SEALANT
COOLANT PUMP PULLEY
ASSEMBLY
FLANGE?
/L1fi.~~~~THE PULLEY IS PART OF THE PUMP
REPAIR
If the pump does not pass inspection, replace the entire pump
assembly which includes the pulley.
~~MPBDDY
THREE BOLTS
INSPECTION 0.24 X 1.38 IN
TWO BOLTS
0.24 X 0.71 IN
Carefully check the pump body and impeller for cracks and (96 X35 mm) (6 X18 mm)
damage. Inspect the weep holes for signs of water leakage
and rust that would indicate a faulty seal. The pulley should
tum the shaft (and impeller) smoothly, without noise or INSTALLATION
sluggish rotation.
When reinstalling the pump use a new gasket. There are five
The pulley edges should be smooth and undamaged and the bolts in two sizes that fasten the pump in place, make certain
locknut should be drawn up tight. they are positioned properly. See the diagram above. Use
sealant when assembling the new gasket.
CIRCULATING PUMP BOLT TORQUE 6·7 ft - Ibs (8 -10 Nm)
35
EXHAUST MANIFOLD I HEAT EXCHANGER
EXHAUST MANIFOLD HEAT EXCHANGER
The exhaust manifold, which was disassembled from the The heat exchanger should be inspected and serviced during
cylinder head, should be inspected before reassembly. an engine overhaul.
1. Disconnect the hoses and remove the hose fittings,
INSTALL NEW GASKETS petcock, drain plugs and zinc anode. Also, remove the
end fittings and gaskets.
2. Inspect the tube (casing) for wear and dents, if at all
suspect replace the heat exchanger.
3. Clean out any zinc debris and pressure test the coolant
and raw water passages.
4.. When reassembling, install new gaskets and a-rings.
Apply some lubricant to the new gaskets and to the
petcocks and fittings as you install them.
5. Install a new zinc anode.
MANIFOLD ASSEMBLY
NOTE: All of the above can be accomplished by sending the
heat exchanger to a heat exchanger/radiator service shop.
They will also service transmission and engine oil coolers.
6. Repaint the assembled heat exchanger with
1. Remove the exhaust elbow from the manifold. Scrape off WES1ERBEKE heat resistant spray
and discard the old gasket. Inspect the exhaust elbow for
corrosion and damage, replace if necessary.
2. If the exhaust elbow passes inspection, remove the high
temperature sensor and clean and re-paint the elbow with
WES1ERBEKE heat resistant enamel.
3. Carefully inspect the exhaust manifold, remove the hose INSPECT HOSES
connections noting the location of each for proper
alignment at reassembly. Oean the exterior and interior
manifold. If the manifold can be reused, repaint with
WES1ERBEKE heat resistant enamel.
ASSEMBLY
HEAT EXCHANGER
1. If the manifold was removed as an assembly and left ASSEMBLY
intact, it can be replaced on the cylinder head in the SERVICE 80TH ENDS
reverse order of rem<?val. Install a new gasket.
MANIFOLD MOUNTING BOLTS TORQUE 12 -17 ft-Ib (16 - 23 Nm)
2. Attach the hose connections to the manifold and the
exhaust elbow. Once the engine has been re-installed and
running, carefully check these assemblies and hose
connections for leaks.
REPLACE GASKET
HEAT EXCHANGER ASSEMBLY
Reinstall the heat exchanger. Tighten down the holdown
brackets and once the engine is running, check the heat
exchanger and hose connections for leaks.
36
RAW WATER PUMP
Inspect the pump before disassembly, if the drive shaft is 4. Remove the wear plate and the O-ring.
frozen or rotates with excessive play or roughness, replace S. Remove the cam screw, washer, and cam.
the entire pump.
6. Remove the bearing assembly, releasing the shaft,
NOTE: Since rebuilding a pump from individually purchased bearing and seal assembly. This will allow the bearings
parts would almost match the cost of a new pump, and seals to be disassembled for inspection.
WESTERBEKE recommends purchasing a new pump and
using the old pump for spares. NOTE: It may be necessary to use a drift and arbor press
to press the bearing and seal assembly from the shaft.
PUMP OVERHAUL 7. Inspect all parts and replace those showing wear or erosion.
The pump, as removed from the engine, will have hose
S. Use the illustration to assist in reassembling the raw
attachment nipples threaded into its inlet and outlet port.
water pump.
They may be left in place or removed if ~ey interfere. ~i~
the pump disassembly. Note the port locauon and posluonmg a. Apply a small amount of petroleum jelly to the seal's
if removed. inner race and to the impeller shaft at reassembly.
1. Loosen the set screw with an allen wrench and remove b. When positioning the cam in the housing use a small
the water pump pulley from the shaft. amount of Permatex #1 on the inner cam surface and
cam screw heads; remove any excess from the impeller
2. Remove the four cover screws, the cover plate and the
housing.
cover plate gasket.
. c. Apply a light film of silicon or petroleum jelly to the
NOTE: Replacement of the cover plate gasket is inner surface of the housing for the impeller
recommended; however; it you are going to reuse it, keep 9. When the pump is assembled, reposition and tighten the
the gasket well lubricated until the pump is reassembled. hose nipples. Assemble the pump to the engine and attach
If it's allowed to dry, the gasket will shrink and not be the hoses and the belt.
reusable.
3. Pull out the impeller with long nose pliers or pry out with
a pair of screwdrivers.
''''---CIlIVER PLATE
RAW WATER PUMP COMPONENTS
37
THERMOSTAT ASSEMBLY I FUEL PUMP
COOLANT RECOVERY TANK FUEL PUMP
Flush out the recovery tank and the hose that connects to the This solid state lift pump requires no maintenance. To test: sim-
pressure cap assembly. Use a pipe cleaner or compressed air ulate a start, the pump should produce a clicking sound indicat-
to clear the passage where the hose connects to the casting. ing the piston in the pump is working. If no clicking is heard,
Also clear the by-pass hose fittings. Replace the plastic tank check that 12 volts are present at the pump connection and the
and hose if it fails to pass inspection. pump is grounded. If it fails to work, replace the pump.
PRESSURE CAP GASOENSER
Check the manifold pressure cap. Open the valve by pulling

it and make sure it closes when released. Make certain the
upper and lower seals are in good condition. If any doubt,
replace the cap.
FUEL LIFT PUMP
GASDENSER
THERMOSTAT
The gasdenser cools the fuel to prevent vapor lock, there is no
1. Inspect the thermostat housing and housing gasket. Apply
mai.ntenance required except making certain the fuel fittings
some sealant to the gasket when reassembling.
are tight and secure.
2. Install a new thermostat and gasket (the old thermostat
can become a spare). When installing the new thermostat
and gasket, apply a thin coat of sealant to both sides of
the gasket.
3. A thermostat can be checked for proper operation by
placing it in a pan of cold water and then raising the tem-
perature of the water to a boil. The thermostat should
open noticeably (with travel on the order of 114 - 112 in
0.0098 - 0.0197niin) and be fully opened when the water
is boiling.
THERMOSTAT ASSEMBLY
THERMOSTAT
CLEAN OUT THE

COOLANT RECOVERY
TANK AND CONNECTING
HOSE
38
REBUILDING THE CARBURETOR
CLEAN THE AIR SCREEN

WITH KEROSENE
CARBURETOR
COVER
VALVE
THROmE CONTROL
LEVER
DISASSEMBLY, INSPECTION, AND ASSEMBLY

1. Release the flame arrester clamp and remove the flame
arrester. Disconnect the electric choke wire, the vacuum
hose attached to the manifold, the fuel supply line, and
the throttle control linkage (not shown).
2. Remove the two nuts holding the carburetor to the
manifold and lift the carburetor from the manifold.
5. In the carburetor top cover, gently punch out the float
3. Disconnect the vacuum hose. Remove the cotter pin from
retaining pin in the opposite direction of the split side of
the electric choke control lever and remove the electric
the pivot bracket and remove the float. Make certain you
choke assembly.
catch the needle valve that hangs from the float retaining
4. Remove the four cover screws and washers. Lift the hook under the float pivot arm. Place the needle valve
carburetor top cover straight up and away from the aside.
carburetor base.
6. Remove the main body gasket.
39
REBUILDING THE CARBURETOR
7. Shake the float. If you hear any sand like particles COPPER WA:iHtll~
§i"'i""C~IVI'R SCREW
moving inside, replace the float.
8. Use a lOmm wrench and remove the needle valve seat.
Make certain the seats aluminum gasket is also removed REPLACE THE
FOUR Vl'Jt.)ncn.)-_..u~
CARBURETOR TOP COVER
9. Screw in a new seat and gasket.
10. Replace the main body gasket. Do not use any gasket
sealer on the main body gasket.
11. Gently place the needle valve in the needle valve seat.
Re-install the float and the float retaining pin so that the
needle valves wire retaining loop hooks onto the floats
retaining hook.
12. Check the float level distance from the housing mating
surface with the housing held vertically.
DISTANCE FROM THE MAmNG SURFACE 3/16 in (4.76mm)
FLOAT RETAINING
NEEDLE VALVE SEAT HOOK
WIRE
,RETAINING
LOOP
CARBURETOR ""'.......,..,
BASE
FLOAT
18. Replace the idle mixture screw's O-ring, the rotary

throttle shaft valve and the shaft valve spring.
19. Remove the fuel filter plug and replace the fuel filter
element.
.3/16 IN [(4.76mm]
13. On the carburetor base, remove the retaining screw to the

accelerator pump nozzle, the ~ozzle, and the two copper
washers that fit above and below the nozzle.
14. Replace the two copper washers and reinstall the acceler-
ator pump nozzle. Snug down the nozzles retaining
screw. Do not overtighten the screw.
NOTE: With the carburetor disassembly, clean and inspect
all the components, replace any damaged or worn parts.
15. Place the carburetor top cover straight down on the car-
buretor base. Replace the four washers with new ones
and hand tighten the four cover screws in the order
shown. Do not overtighten. IDLE MIXTURE SCREW
16. Re-assemble the electric choke to the carburetor and FUEL
replace the two choke assembly retaining screws and PLUG
their washers. Re-attach the electric choke control lever #.1'_- FUEL SHUT-OFF SOLENOID
and insert the cotter pin.
20. Make certain all the carburetor screws are properly

tightened. Fasten the assembled carburetor on the intake
manifold using new gaskets (use sealant). Replace the
two nuts and washers and tighten the carburetor to the
manifold.
CARBURETOR TO MANIFOLD TORQUE 12 -14 ft-Ibs (16 - 23 Nm)
40
-
I:IEBUILDING THE CARBURETOR I CARBURETOR ADJUSTMENTS
21. Reconnect the throttle control linkage, the fuel supply CHOKE SOLENOID
line, the vacuum hose, and the electric choke wire.
The choke solenoid is a 12 volt DC operated unit that func-
22. Replace the flame arrester on the carburetor and tighten tions to close the choke plate in the carburetor when the ON
the flame arrester clamp. switch is depressed during engine start-up.
The choke solenoid de-energizes once the engine starts and
CARBURETOR ADJUSTMENT the ON switch is released. Some unstable running may be
Basic Jet Adjustment is performed with the generator operat- present when the engine starts cold but should smooth out as
ing. Screw the jet slowly in until it seats, then back it out the engine reaches operating temperature.
1112 to 2 turns. This jet adjustment can be made in the 3600 Keep' this solenoid dry and periodically lubricate the linkage
rpm range to improve engine performance. between the solenoid and the choke lever.
NOTE: An idle mixture jet adjusted too far off its seat can
induce a sooty exhaust discharge at engine start-up and shut-
down.
NOTE: At idle speed, oil pressure will be lower than the rating
of the oil pressure switch. Jump this switch to prevent engine
shutdown at idle speed.
Run Mixture Jet is presized at the factory and is not
adjustable.
~ ~~,
41
STARTER MOTOR
4. Return test:. With a battery connected to the solenoid ter-
minal M (-) and to the starter body, manually pull out the
pinion fully. The pinion must return to its original position
ATTRACTION TEST when released from holding by hand.
3. Holding test. With a battery connected to the solenoid ter-

minal S (+) and to the starter body, manually pull out the
pinion fully. The pinion must remain at that position even
when released from holding with your hand.
RETURN TEST
HOLDING TEST
STARTER DISASSEMBLY 7. Pull out the reduction gear lever and lever spring from the
front bracket.
1. Disconnect the wire from the solenoid terminal M (-).
8. On the pinion side, pry the snap ring out, and pull out the
2. Loosen the two screws fastening the solenoid. Remove
pinion and pinion shaft.
the solenoid assembly.
9. At each end of the armature, remove the ball bearing with
3. Remove the two long through bolts and two screws
a bearing puller. It is impossible to replace the ball bearing
fastening the brush holder. Remove the rear bracket.
press-fitted ih the front bracket. If that bearing has worn
4. With the brushes pulled away from the armature, off, replace the front bracket assembly.
remove the yoke .and brush holder assembly. Then pull
the armature out. TERMINALM
~~\"'~~
SOLENOID
S. Remove the cover, pry the snap ring out, and remove the
washer.
6. Unscrew the bolts and remove the center bracket. At the
same time, the washers for the pinion shaft end play
adjustment will come off.
INSPECT FOR
BRUSH HOLDER
WEAR & CHIPPING
STARTER
MOTOR
SNAPRING----~, _ ~-
,~
:.----------rr;;;ECT FOR
, ,~ ff-. ,
('fgj~ .....
lMR;~G~-
j PUlY & NOISE \~
'''-----
NOTE: ---"
inspect, clean and replace
if necessary brush, commuter,
solenoid, armature, etc. See the
\YOKE---.... j following pages.
I
~
\ .......
42
STARTER MOTOR
STARTER INSPECTION
Solenoid
Inspect the solenoid for continuity between terminals S and
M and between terminals S and body. No continuity should
be found between S an9 M. Continuity should be found
between S and the body and M and the body.
, Brush and Brush Holder Inspection

1. Check the brushes. If worn out beyond the service limit,
replace the brushes.
Brush Height
, Standard 17 mm (0.669 in)
iiinit6 ,;;;" (O.i36 in) , ,---~""4~1
COmNUllY CHECK
BRUSHES
Inspecting The Annature
1. Check the armature with a growler tester. If it's short
circuited. replace the armature. Also check for insulation 2. Check the brush spring .tension. A weak or defective
between the communicator and its shaft. If poorly spring will cause excessive brush wear; replace the springs
insulated, replace the armature. if suspect. .
ARMATURE BRUSH HOLDER

CHECK ASSEMBLY~ QIo2'~_"""
ARMATURE'--H~
3. Check for insulation between the positive brush holder

2. Measure the commutator 0.0. and the depth of undercut and holder base. If poorly insulated, replace the holder
Repair or replace it if the service limit is exce¢ed. Also assembly. Also check the brush holders for proper staking.
check the commutator outside surface for dirtiness and
roughness. If rough. polish the commutator with fine
crocus cloth.
Commutar O.D. Standard

Standard: 38.7 mm (1.523 in)
E'V>.~~,Service limit: -1.0 mm (-0.039 in)
COMMUTATOR 0.0.
j"""'WES7EllBEKE
I Engines & Generators
43
STARTER MOTOR
Field Coil Inspection 2. Greasing. Whenever the starter has been overhauled,
apply grease to the following parts:
1. Check for insulation between one end (brush) of the
coil and yoke. a. Armature shaft gear and reduction gear.
2. Check for continuity between both ends (brushes) b. All bearings.
of the coil c. Bearing shaft washers and snap rings.
3. Check the poles and coil for tightness. d. Bearing sleeves.
e. Pinion.
f., Sliding portion of lever.
MULTIMETER
A CAUTION: Never smear the starter fitting surface,

tenninals, brushes, or commutator with grease.
3. After reassembly, check by conducting a no-load test

again.
GEAR
FIELD COIL TEST
STARTER ADJUSTMENT AND REASSEMBLY SNAP RING

+
A CAUTION: Before installing, thoroughly clean the
starter Bange and mounting surfaces, remove all oil,
'old paint, and rust. Starter perfonnance largely
depends on the quality of the wiring. Use wire of suffi· PINION SHAFT END PLAY
cient size and grade between the battery and starter
and fully tighten to the tenninal.
Reassemble the starter assembly in the reverse order of

disassembly, making sure of the following:
1. Pinion shaft end play adjustment. Set the end play (thrust
gap) to between 0.5 to 2 mm by inserting an adjusting
washer between the center bracket and the reduction gear.
a. Fit the pinion shaft, reduction gear washer and snap
ring to the center bracket.
b. Measure end play by moving the pinion shaft in the
axial direction. If the end play exceeds 0.5 mm,
increase the number of adjusting washers inserted.
44
ENGINE ADJUSTMENTS
NOTE: WESTERBEKE recommends that the following
engine adjustments be performed by a competent engine
,mechanic. The information below is provided to assist the
mechanic.
ENGINE SPEED (HERTZ) ADJUSTMENT Governor Maintenance
Governor 1. Periodically lubricate the linkage arm attaching points at
The belt-driven, mechanically operated governor maintains the governor arm and throttle lever. Use a graphite
the engine's rpm under various load conditions. Engine speed lubricant or equivalent.
determines the hertz and voltage output of the generator. NOTE: Free movement of this linkage arm is important for
Governor Adiusbnents proper governor/throttle operation.
Operate the generator to bring the unit up to operating tem- 2. Governor oil capacity - 3 ounces 10/30 engine oil.
perature before adjusting the governor. NOTE: Do not overfill the governor.
NOTE: If the governor is severely out of adjustment, manually 3. Change the governor oil every 250 hours of operation.
adjust the linkage at no-load to obtain a safe output voltage
To change the oil, remove the governor from the engine,
before proceeding with the adjustment.
remove the oil fill and the fill level plug, and drain all the
There are three adjusting points on the governor (see illustra- oil. Reinstall on the engine and fill with 3 ounces of I 0/30
tion). engine oil. Replace the plugs.
1. Increase/Decrease Speed Adjustment. This adjusting bolt 4. Periodically adjust the governor belt tension (see DRIVE
sets the no-load speed of the engine. (The linkage arm BELTS ADJUSTMENT). Since belts stretch slightly, this
between the governor arm and throttle lever should be stretching will, to some degree, affect the govenor's
adjusted to hold the throttle full open when the engine is action.
not running.) Make sure this linkage moves freely and
that the ball joint connectors are properly lubricated. Use TORQUING THE CYLINDER HEAD BOLTS
graphite lube for this purpose. Disconnect the ball joint After the initial break-in period (approximately 50 hours), the
and apply graphite lube to the inside of the joint. cylinder head bolts should be re-torqued.
2. Hunting/Regulation Adjustment. If the variation in Tighten the cylinder head bolts according to the sequence
engine speed between no-load and full-load is too great, shown. Make sure the engine is cold when this is done, and
adjust this eye bolt to draw the spring closer to the lever loosen one head bolt one-half turn and then tighten it
hub. The increase/decrease speed bolt may need to be between 43 - 51 lb-ft (60 - 70 Nm). Then proceed to the next
adjusted as well. head bolt in the sequence. Tighten the RS (rocker cover stud)
If the governor surges under load, adjust this eye bolt to securely.
move the spring away from the lever hub (check speed 6 4 2 7
adjustment).
3. Bumper Screw Adjustment. This screw is used to remove
a no-load surge ONLY. NEVER turn the bumper screw
into the governor so far that it increases the no-load speed.
FRONTOF~
ENGINE ' - r - '
LINKAGE ARM GOVERNOR
L FILL
INCREASEf[IECFIEA~;E
SPEED ADJUSTMENT
(UNDER)
45
ENGINE ADJUSTMENTS
SPARK PLUGS DRIVE BELT ADJUSTMENT

The spark plugs should be cleaned and regapped after the The drive belt must be properly tensioned. Excessive drive
first 50 hour break-in period, then inspected every 250 hours belt tension can cause rapid wear of the belt and reduce the
thereafter and replaced as needed. service life of the fresh water pump's bearing. A slack belt or
the presence of oil on the belt can cause belt slipping,
resulting in high operating temperatures.
A WARNING: 00 not remove the spark plugs while The BCOB generator has two drive belts, one drives the
the engine is hot. Allow the engine to cool before governor and alternator and the other drives the raw water
removing them. pump. The tension adjustment procedure for both belts is as
follows:
Spark plug gap: 0.031 +1- 0.0002 in. (0.8 - 0.05 mm). 1. Remove the belt guard.
Spark plug torque: 10 -15 Ib-ft (1.5 - 2.31 kg-m). 2. To adjust the governor drive belt, loosen the two governor
mounting bolts.
NOTE: Loctite Anti-Seize applied to the threaded portion of
the spark plugs will retard corrosion, making future removal To adjust the raw water pump/fresh water pump drive
of the spark plugs easier. belt, loosen the two raw water pump mounting bolts.
3. With the belt(s) loose, inspect for wear, cracks and frayed
GAP edges, and replace if necessary.
4. To loosen or tighten the governor drive belt, slide the
INSPECT FOR governor in or out as required, then retighten its mounting
INSPECT FOR
DAMAGE bolts.
WEAR & CARBON
To loosen or tighten the raw water pump/fresh water
pump drive belt, slide the raw water pump in or out as
required, then retighten its mounting bolts.
INSPECTING 5. The drive belts are properly adjusted if it can be deflected
THE SPARK no less than 3/8 inch (lDmm) and no more than 1/2 inch
PLUGS CHECK FOR (12mm) as the belt is depressed with the thumb at the
DETERIORATION midpoint between the two pulleys on the longest span of
AND DAMAGE the belt.
NOTE: Maintain a 22 lb pressure to the belt's outer face
for proper belt operation. Spare belts should always be
carried on board
A WARNING: Never attempt to check or adjust a

drive belt's tension while the engine is in operation.
6. Operate the generator for about 5 minutes, then shut down

the generator and recheck the belt(s) tension.
7. Replace the belt guard.
46
ENGINE ADJUSTMENTS
adjustments be performed by a competent engine mechanic.
The information below is provided to assist the mechanic.
VALVE CLEARANCE ADJUSTMENT IGNITION TIMING

NOTE: Retorque the cylinder head bolts before adjusting the 1. Attach a timing light to the #1 spark plug and mark the
engine's valves (see TORQUING THE CYUNDER HEAD front timing pointer to indicate 1'5°. Locate the timing
BOLTS). mark on the crankshaft pulley and mark it with white
1. Remove the rocker cover and gasket. chalk or a crayon.
2. Rotate the crankshaft in the normal direction of rotation, 2. Start the engine and warm it up to its normal operating
placing the No. 1 piston at the top of its compression temperature. Make sure the generator is operating without
stroke with the exhaust and intake valves completely a load on it.
closed. Adjust the intake and exhaust valves for No. 1
cylinder, the exhaust valve for No.2 cylinder, and the 3. Using the timing light, align the timing mark in the front
crankshaft pulley so it is just slightly before the fITSt tim-
intake valve for No.3 cylinder (see chart).
ing pointer. Do this by loosening and slowly rotating the
3. Rotate the crankshaft 180° in its normal direction of distributor body. Use the following timing specifications:
rotation. Locate the piston in No. 1 cylinder at the top of
Timing Specifications: 15' ± .5° BTDC at 1800 rpm
its exhaust stroke. Adjust the intake valve for No.2
(no load on generator)
cylinder and the exhaust valve for No.3 cylinder (see
chart).
IGNITION TIMING
CYLINDER #
CRANK ANGLE
1 2 3
When No. 1 piston is set at top of IN
compression stroke
EX
•• • •
When No. 1 piston is positioned IN
at top of exhaust stroke •
EX
•
4•• Replace the rocker cover along with a new rocker cover
gasket.. CHOKE SOLENOID
Rocker cover torque: 2.9-5.1 Ib-n (4 - 7 Nm) The choke solenoid is a 12 volt DC 9perated unit that func-
tions to close the choke plate in the carburetor when the ON
switch is depressed during engine start-up.
The choke solenoid de-energises once the engine starts and
the ON switch is released. Some unstable running may be
present when the engine starts cold but should smooth out as
the engine reaches operating temperature.
Keep this solenoid dry and periodically lubricate the linkage
VALVE between the solenoid and the choke lever.
CLEARANCE
Valve Clearance: Intake 0.20mm (.008 inches)

Exhaust 0.30mm (.0012 inches) CHOKE
SOLENOID
47
COMPONENT TESTING
testing adjustments be performed by a competent technician.
GENERAL
TAP THE GROUND
All DC voltage measurements are made to the engine battery CONNECTION TO
negative ground point unless specified otherwise. In making THE TERMINAL.
test measurements, make sure that a good ground for the RELAY SHOULD
___~ "CLICK" ON.
meter is established, preferably the point where the negative
battery is connected to the engine. Battery positive voltage is
indicated as B+ and should measure no less than 11.5 volts.
AC voltage measurements should be made with a true
RMS AC meter to insure measurement accuracy.
TO B(+)
ENGINE.GROUND
TESTING THE RELAY
TERMINALS
GROUND AND B(+)

. CONNECTIONS
RELAYS
The relays used in the control system have coils which are
polarized by the fact that they have internal free wheeling
suppression diodes across them. Relay coil terminal 86 must
be maintained (+), terminal 85(-). The relay coil is rated 12V
DC, and the coil resistance is typically 85 ohms. With B+ on
terminal 86, direct grounding of terminal 85 is permissible TESTING COIL RESISTANCE
for testing purposes.
RELAYS
RELAY
TERMINALS
REMOVE THIS
RELAY CONNECTOR
48
4.SKW /7 .OKW BeGB GENERATOR
WIRING DIAGRAM #43864
OIICE
IIlLSaI
rMTTBn' IZ
-~
VDC
I
$Cl!II:lII
~
=
I ~~
,~
MIX. CL PIIESS
I
~L
1
sma! Il1O
, I
CL PIIESS
RItCH II1II
~
.
~I!F--+----'
T i l l VIO/lIMT
114 RED/VIO
114 RED
114 RED
IIC REHIHT
lIS ORG II"i ~ =

o;?
liS ,"T
IIC BLI
IIC RFOIVIO
I j
I
I ~I
49
4.SKW /7 .OKW BeGB GENERATOR
WIRING SCHEMATIC #43864
j
rl
L.. I
12 VOC
I 8A HERY
SWITCH STARTER
SOLENOID STARTER
r--,
.-------------------~------~~~------~
rt
I(
L..
l 20 AMP
ICIRCUIT
I BREAKER
Ki
FUEL PUMP
... FI
FUEL SOL.
F2
l, ..
STOP SW
r I CHltNC) HOUR METER
L.. I I
I
I
I KZ
.--+______~~ ~L-------------------------+_--~
L.. _ _ _ _ _ ,
I
CHOKE SOL.
115402 DIODE TI
STUT
"
ON KI-START
:!~C~
1 ~~~L_~~~~~L~_-c~~~--------------+---------~--+--+--------~~~~
CKTZtNO)
EXHAUST OVEUPEED
TEMP saUl DOn DIODE
SWITCH TI IN400Z
OIL
PitESS.
SWITCH
WATER
TEMP
SWITCH
AUX. Oil
PlESS. SWITCH
, __..1:2L J!L _[il....Ii~

!MtI C!IIEIlII
.rAJ
50
REMOTE PANEL WIRING
SCHEMATIC #043912
REMOTE PANEL
r-------------------------------.
1 . 1
i BlK STA RT / STOP SW NI---+'_.....::#,-,-1...:..4-=B:..::L..:.;.K_ _ _ _-,
,
RED RED
I, LED CKT I L--------i~--K~ #14 WHT/RED
I. ...
I- ON SW WHITE *14 YEL/RED
I
I
WHITE *14 WHT
I f- I WHITE *14 RED/VIO

I ~ : I ,
I' L_ -: I
L ______________ .:_. ____________,i
I
VIEWED FROM
MATING END
51
SERVICE DATA I STJ'NDARDS AND LIMITS • BCGB ENGINEiGENERJ'TOR
Component Specified Value I Standard Repair Limit Component Specified Value I Standard Repair Limit
inches(mm) inches(mm) inches(mm) inches(mm)
FRONT CASE/COUNTERBALANCE SHAFT VALVES
Valve Guide Service Size 0.05, 0.25, 0.50 oversize
Oil Pump Side Clearance
Driven Gear..........................0.0024-0.0047 (0.06-0.12) Valve Seat Width of
Drive Gear. ...........................0.0027 -0.0051 (0.07.0.13) Seat Contact ...............................035-.051 (0.9-1.3)
Counterbalance Shaft Front Joumal Diameter Valve Seat Angle ..............................300/44°/65°
................................0.7869-0.7874 (19.987-20.000)
Valve Seat Sink ............................................................................0.008 (0.2)
Counterbalance Shaft Rear Joumal Diameter
· . ..............................1.7317-1.7322 (43.984-44.000) Valve Spring Free Length ................1.823 (46.3) ......................1.783 (45.3)
Counterbalance Shaft Front Joumal Oil Clearance Valve Spring
· ...............................0.0014 - 0.0027 (0.035 - 0.068) Load/Installed Height
IbsJin (Nlmm) ...........................4611.48 (210137.7)
Counterbalance Shaft Rear Joumal Oil Clearance Squareness ......................................Iess than 2° ..............................40
· ...............................0.0014 - 0.0028 (0.035 - 0.071)
TIMING BELT
CYLINDER BLOCK
....................................................47 (12)
Cxlinder Bore 2.5591-2.5602 (65.00-65.03)
ROCKER ARM
Out-of-Roundness and
Taper of Cylinder Bore 0.0004 (less than 0.05) Camshaft Height
No.1 (Intake) ..........................1.3815 (35.09) ..................1.3618 (34.59)
Gasket Surface Flatness 0.0020 (less than 0.05) 0.0039 (0.1) No.2 (Intake) ..........................1.3807 (35.07) ..................1.3610 (34.57)
CYLINDER HEAD No.3 (Intake) ..........................1.3803 (35.06) .................. 1.3606 (34.56)
Flatness of Gasket Surface ...0..0019 (Less than 0.05) ............0.0079 (0.2) No.1 (Exhaust) .......................1.3839 (35.15) .................. 1.3642 (34.65)
No.2 (Exhaust) .......................1.3831 (35.13) ..................1.3634 (34.63)
Overall Height......................4.287-4.295 (108.9-109.1)
No.3 (Exhaust) ......................1.3854 (35.190) ................1.3657 (34.69)
Cylinder Head oversize rework dimension of valve seat hole
Intake 0.3 0.S...... 1.2323 - 1.2333 (31.300 - 3.325) Camshaft Joumal
Intake 0.6 0.S..... 1.2441 -1.2451 (31.600 - 31.625) Diameter ..........................1.6118-1.6124(40.940-40.955)
Exhaust 0.3 O.S....1.1535 - 1.1544 (29.300 - 29.321) Bearing Oil Clearance ..........0.0018.o.0033 (.45-0.085)
Exhaust 0.6 O.S....1.1653 - 1.1662 (29.600 - 29.621)
End Play ....................................0024-.0055 (.06-.14) ................. 118 (.03)
Cylinder Head rework of valve guide hole (both intake and exhaust)
Rocker Shaft Length ........................9.134 (232)
0.05 O.S..................0.4744 - 0.4751 (12.050 - 12.068)
0.25 O.S.........•........0.4823 - 0.4830 (12.250 - 12.268) Rocker Ann Shaft
0.50 O.S..................0.4921 - 0.4928 (12.500 - 12.518) Outer Diameter .......0.6687 - 0.6692 (16.985 - 16.998)
Clearance...................0.0005 - 0.0017 (0.012 - 0.043) ......0.004 (0.1)
Intake Valve Seat Angle .........................45°
PISTON AND CONNECTING ROD
Exhaust Valve Seat Angle ......................30°
Piston Outer Diameter ......2.5579-2.5591 (64.97-65.00)
Intake Valve Seat Width ..................0.079 (2.0) ........................0.004 (0.1)
Piston to Cylinder Clearance
Exhaust Valve Seat Width ...............0.079 (2.0) ........................0.004 (0.1) ..................................0.0008 - 0.0016 (0.02 - 0.04)
Valve Clearance ......................................... Pistcm Ring Grove Width
Exhaust... ...................................0.D12 (0.30) No.1 .............................0.0480 - 0.0488 (1.22 - 1.24)
Intake .....................................:...0.008 (0.20) No.2 .............................0.0476 - 0.0484 (1.21 -1.23)
Valve Head Thickness (margin) Oil ..............................0.1108 - 0.1116 (2.815 - 2.835
(Intake) .........................................039 (1.0) ...........................020 (.5) Piston Service Size ...............0.25, 0.50, 0.75, 1.00 OS
(Exhaust) ......................................051 (1.3) .............................031 (8)
Piston Ring End Gap
Valve Length No.1 .............................0.0059 - 0.0118 (0.15 - 0.30) ........0.0315 (0.8)
(Intake) .....................................3.960 (100.6) No.2 .............................0.0138 - 0.0197 (0.35 - 0.50) ........0.0315 (0.8)
(Exhaust) ..................................3.968 (100.8) Oil ....................................0.008 - 0.028 (0.2 - 0.7) ............0.0394 (1.0)
Valve Stem 0.0. Piston Side Clearance
Intake .......................:0.2585 - 0.2591 (6.565 - 6.580) No.1 .............................0.0012 - 0.0028 (0.03 - 0.07) ......0.0047 (0.12)
Exhaust... ...................0.2571 - 0.2579 (6.530 - 6.550) No.2 .....................•.......0.0008 - 0.0024 (0.02 - 0.06) ......0.0039 (0.10)
Stem to Guide Clearance Piston Pin 0.0..............0.6300 - 0.6302 (16.001 - 16.007)
Intake ......................... 0.0008 - 0.0020 (0.02 - 0.05) ......0.0039 (0.10)
Exhaust ...................0.0020 - 0.0033 (0.0050 - 0.0085) ..0.0059 (0.15) Piston Pin Press-in Load Ibs(N)
...................................1102 - 3307 (5000 - 15000)
Valve Guide Length
(Intake) .........................................1.73 (44)
(Exhaust) ...................................1.949 (49.5) End Play ............................0.0059 - 0.0118 (0.15 - 0.28)
52
SERVICE DATA / STANDARDS AND LIMITS • BCGB ENGINE/GENERATOR
Component Specified Value I Standard Repair Limit Component Specified Value I Standard Repair limit
inches(mm) inches(mm) inches(mm) inches(mm)
PISTON AND CONNECTING ROD CRANKSHAFT, BEARING
Piston Pin Press-in temperature Crankshaft End Play ..........0.0020 - 0.0098 (0.05 - 0.25) ..................
· ........................................ordinary temperature
Crankshaft Journal O.D...1.5740 -1.5748 (39.98 - 40.0)
Connecting Rod Center length
· ..............................4.0138 4.0178 (101.95 - 102.05) Crankshaft Pin 0.D.........1.4165 -1.4173 (35.98 - 36.00)
Parallelism between Big End and Small End Cylindericity of Journal and Pin
· ...............................................0.004 (0.05) · .................................... Less than 0.0002 (0.005)
Connecting Rod Twist... ...................O.OO4 (0.1) Concentricity of Journal and Pin
Connecting Rod Big End to Crankshaft Side Clearance · .................................... Less than 0.0006 (0.015)
..................................0.0039 - 0.0098 (0.10 - 0.25) ..........0.16 (0.4) Oil Clearance of Journal
· ...............................0.0008 - 0.0018 (0.021 - 0.045) ......0.0039 (0.1)
Oil Clearance of Pin ........0.0009 - 0.0020 (0.022 - 0.052)
Undersize rework dimension of Journal
0.25 U.S..................1.5644 - 1.5650 (39.735 - 39.750)
0.50 U.S..................1.5545 -1.5551 (39.485 - 39.500)
0.75 U.S.................1.5447 -1.54539 (39.235 - 39.250)
Undersize rework of dimension of pin
0.25 U.S..................1.4069 - 1.4075 (35.735 - 39.750)
0.50 U.S..................1.3970 - 1\3976 (35.485 - 35.500)
0.75 U.S..................1.3872 - 1.3878 (35.235 - 35.250)
53
ENGINE HARDWARE TORQUES
Timing Belt Nm ft.lbs. Front Case, Counterbalance Shaft Nm ft.lbs.
Crankshaft bolt 135-145 98-105 Front case bolts 8-10 6-7
liming belt cover bolts 10-12 7-9 Oil pump cover bolts 8-10 6-7
Camshaft sprocket bolts 80-100 58-72 Oil pan bolts 10-12 7-9
Oil pump sprocket nuts SO-57 36-41 Oil drain plug 35-45 25-33
liming tensioner nuts 22-30 16-22 Oil screen bolts 15-22 11-16
liming belt rear cover bolts 10-12 7-9 Oil pump driven gear bolt 34-40 25-29
Rocker Anns and Rocker Shaft Rear cover bolts 10-12 7-9
Rocker cover shaft 29-35 21-25 Piston and Connecting Rod
Camshaft thrust plate bolt 10-12 7-9 Connecting rod cap nut 15 + 900 turn 11 +900 turn
Rocker arm adjust nut 8-10 6-7 Crankshaft, Bearing
Cylinder Head, Valve Oil seal case bolts 10-12 7-9
Cylinder head bolt (cold engine) 60-70 43-51 Bearing cap bolts 50-55 36-40
Spark plug 15.2 10.8 Cylinder Block
Rocket cover 12-13 9-10 Taper plug 1/16 8-12 6-9
Miscellaneous Taper plug 1/8 15-22 11-16
Coolant temperature sender 12-18 9-13 Water drain plug 35-45 25-33
Coolant temperature Switch 12-18 9-13 Taper plug 1/4 NPT 35-45 25-33
Generator mounts 34-47 23-34 Oil pressu re switch 12-18 9-13
Exhaust manifold 16-23 12-17 Oil pressure sender 12-18 9-13
Thermostat housing 8-11 6-8 Water Pump
Carburetor to manifold 16-23 12-17 Water pump 8-10 6-7
54
STANDARD HARDWARE
BOLT HEAD MARKINGS
Metric bolt class numbers identify bolts by their strength with 10.9 the
strongest
NOTES: 1. Use the torque values listed below when specific torque values are not available.
2. These torques are based on clean, dry threads. Reduce torque by 10% when engine oil is used.
3. Reduce torques by 30% or more, when threading capscrews into aluminum.
STANDARD BOLT &NUT TORQUE SPECIFICATIONS METRIC BOLT &NUT TORQUE SPECIFICATIONS
SAE Grade 5 SAE Grade 6-7 SAEGradeB
Capsrew Body Size Torque Torque Torque Bolt Grade 4.6 Grade 4.B Grade B.B - 9.B Grade 10.9
(Inches) - (Thread) A-Lb(Nm) Ft-Lb(Nm) A-Lb(Nm) Dla. Wrench Size A-Lb(Nm) Ft-Lb (Nm) Ft-Lb (Nm) A-Lb(Nm)
1/4 - 20 8 (11) 10 (14) 12 (16)
-28 10 (14) 14 (19) M3 5.5mm 0.3 (0.5) 0.5 (0.7) 1 (1.3) 1.5 (2)
M4 7mm 0.8 (1.1) 1 (1.5) 2 (3) 3 (4.5)
5/16 -18 17 (23) 19 (26) 24(33) M5 8mm 1.5 (2.5 2 (3) 4.5 (6) 6.5 (9)
-24 19 (26) 27 (37)
318 -16 31 (42) 34(46) 44 (60) M8 10mm 3 (4) 4 (5.5) 7.5 (10) 11 (15)
-24 35 (47) 49(66) M9 13mm 7 (9.5) 10 (13) 18 (25) 35 (26)
7/16-14 49 (66) 55 (75) 70 (95) M10 16mm 14 (19) 18 (25) 37 (50) 55 (75)
-20 55 (75) 78 (106)
112 -13 75 (102) 85 (115) 105 (142) M12 18mm 26 (35) 33 (45) 63 (85) 97 (130)
- 20 85 (115) 120 (163) M14 21 mm 37 (50) 55 (75) 103 (140) 151 (205)
M16 24mm 59 (BO) 85 (115) 159 (215) 232 (315)
9/16 -12 110 (149) 120 (163) 155 (210)
-18 120 (163) 170 (231)
M18 27mm 81 (110) 118 (160) 225 (305) 321 (435)
518 -11 150 (203) 167 (226) 210 (285) M20 30mm 118 (160) 166 (225) 321 (435) 457 (620)
-18 170 (231) 240 (325) M22 33mm 159 (215) 225 (305) 435 (590) 620 (840)
314 -10 270 (366) 2BO (380) 375 (508)
-16 295 (400) 42!"(569) M24 36mm 203 (275) 288 (390) 553 (750) 789 (1070)
M27 41 mm 295 (400) 417 (565) 811 (1100) 1154 (1565)
718- 9 395 (536) 440 (597) 605 (820) M30 46mm 402 (545) 568 (770) 1103 (1495) 1571 (2130)
-14 435 (590) 675 (915)
1- 8 590 {800) 660 (895) 910 (1234) M33 51 mm 546 (740) 774 (1050) 1500 (2035) 2139 (2900)
-14 660 (895) 990 (1342) M36 55mm 700 (950) 992 (1345) 1925 (2610) 2744 (3720)
SEALANTS &LUBRICANTS
GASmsJSEAlANTS Use LIQUID TEFLON for sealing pipe plugs and fillings that connect coolant
passages. Do not use tape sealants!
Oil based PERMATEX #2 and it's HIGH TACK equivalent are excellent all
purpose sealers. They are effective in just about any joint in contact with BOLTS & FASTENERS/ASSEMBUES
coolant, raw water, oil or fuel.
Ughtly oil head bolts and other fasteners as you assemble them. Bolts and
A light coating of OIL or LIQUID TEFLON can be used on rubber gaskets plugs that penetrate the water jacket should be sealed with PERMATEX #2 or
and O-rings. HIGH TACK
LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil When assembling the flywheel, coat the bolt threads with LOCTITE blue.
filter assembly.
Anti-seize com pounds and thread locking adhesives such as LOCTITE protect
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer. threaded components yet allows them to came apart when necessary.
When installing gaskets that seal around water (coolant) passages, coat both LOCTITE offers levels of locking according to the job.
sides with WHITE SILICONE grease. LITHIUM based grease is waterproof, ideal for water pump bearings and stuff-
High-copper ADHESIVE SPRAYS are useful for holding gaskets in position during boxes.
ing assembly. Heavily oil all sliding and reciprocating components when assembling. Always
Specialized gasket sealers such as HYLOMAR work well in applications requir- use clean engine oil!
ing non-hardening properties. HYLOMAR is particlarly effective on
copper cylinder-head gaskets as it resists fuel, oil and water.
55
BCGB ENGINE/GENERATOR SPECIFICATIONS
ENGINE SPECIFICATIONS
Engine Type 3 cylinder, 4 cycle, overhead camshaft
w/counterbalance shaft, carbureted,
water cooled gasoline engine
Bore and Stroke 2.56 x 2.61 in. (65 mm x 66.3 mm) General Fresh water-cooled block through raw
water-cooled heat exchanger circuit
Total Displacement . 40.3 cubic inches (.66 liter)
Fresh Water Pump Centrifugal type, metal impeller
Bearings Four main bearings
belt-d riven
Combustion Chamber Semi-spherical
Raw Water Pump Positive displacement, rubber impeller
Compression ratio 9.8-1
Cooling Water Capacity 3.5 qts. (3.4 liters)
Firing Order 1-3-2
LUBRICATION SYSTEM
Direction of Rotation Counterclockwise viewed from the back
end Type Forced lubrication by gear pump
Inclination 25° continuous, all directions Oil Filter Fuel flow, paper element spin-on
30° temporary, all directions disposals
Governor Mechanical Oil Capacity 2.7 qts. (2.6 liters)
FUEL SYSTEM Oil Grade API specification SJ class
Fuel Pump Electric fuel pump AC GENERATOR SPECIFICATIONS

Fuel Unleaded 89 octane or higher gasoline Type Brushless, four pole capacitor, regulated
Distributor Breakerless distributor Rating
Spark Plugs 14mm 4.5KW 120/240 volts, 37.5/18.7 amps, 60 Hz,
single phase, 4 wire, 1.0 power factor
Ignition Coil 12 volt
3.8KW 230 volts, 13 amps, 50 Hz, single phase,
Flame Arrester Metal screen type 4 wire, 1.0 power factor
Carburetor Single-barrel downdraft type
7.0KW 120/240 volts, 58.3/29.2 amps, 60 Hz,
ELECTRICAL SYSTEM
single phase, 4 wire, 1.0 power factor
Start Motor 12 volt reduction gear w/solenoid 5.0KW 230 volts, 13 amps, 50 Hz, single phase,
4 wire, 1.0 power factor
Starting Battery 12 volt negative ground
Battery Capacity 300 cold cranking amps (CCA)(min) TUNE-UP SPECIFICATIONS
Battery Charging Integral electric, 17 amps Spark Plug Gap 0.031 ± 0.002 inches (0.8 ± 0.05mm)
AIR REQUIREMENTS Spark Plug Torque 10.8 - 15.2 Ib-ft

Valve Clearances Intake valves: 0.20 mm (0.008 in)
Generator Cooling 225-250 CFM
Exhaust valves: 0.30 mm (.012 in)
(6.3-7.0cmm)
Cylinder Head 60 - 70 Nm 43-51 ft-Ibs
Engine Combustion 42 CFM (1.2 cmm)
(all models) Bolt Torque see TORQUING THE CYLINDER HEAD
BOLTSunderENGINEADJUST~ENTS
Engine Cooling 100 CFM (2.8 cmm)
56
SPECIAL TOOLS • ENGINE
NOTE: Tht:se special tools are available from
your local Mitsubishi Automotive Dealer
CAMSHAFT OIL SEAL INSTALLER VALVE STEM SEAL INSTALLER

MD 999569 MD 998302
OIL PAN GASKET CUTTER

PISTON PIN SETTING BASE For removing the oil pan to
Used to pull-out and press in break the oil pan seal.
the piston pin. MD 998727
MD 999583
CRANKSHAFT REAR OIL SEAL INSTALLER

MD 998376 BEARING REMOVER
For pulling out the front and
rear bearings (counterbalance shaft).
MD 999593
PUSH ROD AND PIN SET GUIDE
Used to pUll-out and press in
the piston pin.
MD 999584
FRONT BEARING INSTALLER

(Counterbalance shaft).
MD 999591
PIN For supporting the sprocket

when the camshaft sprocket is
loosened or tightened.
MD 998715
INSTALLER FOR THE REAR OIL SEAL
(Counterbalance shaft).
MD 999592
END YOKE HOLDER

For supporting the sprocket CRANKSHAFT FRONT OIL SEAL INSTALLER
when the camshaft sprocket is MD 999570
loosened or tightened.
MD990767
OIL PUMP OIL SEAL INSTALLER
VALVE SPRING COMPRESSOR

MD 999597
57
BC GENERATOR ELECTRICAL TESTING
The following field tests should be performed by a qualified technician.
Proper safety precautions must be followed as most of these tests are
executed with the generator operating or connected to ships power.
AC voltage is lethal.
If generator problems persist, contact your Westerbeke dealer.
58
BC GENERATOR ELECTRICAL TESTING
DESCRIPTION GENERATOR TROUBLESHOOTING CHART
The BC generator is a brushless, self-excited generator which A, B, C, & D refer to the components of the INTERNAL WIRING
requires only the driving force of the engine to produce an DIAGRAM and their test procedures in the following pages.
AC output. The stator houses two sets of windings; the main NOTE: This fault finding chart is compiled assuming the engine
stator windings and the exciter windings. When the generator is operating at the correct speed/hem
is started, residual magnetism in the four rotating poles
induces a voltage in the stator which then generates an even FAULT CAUSE TEST/CORRECTION
larger voltage in the exciter windings. This mutual build up No AC Output Shorted stator B
of voltage in the four rotating poles and in the exciter wind- Open stator B
ings quickly reaches the saturation point of the capacitor(s)
Shorted diodes [two] . A
and a regulated energy field is then maintained in the stator.
At the same time, this regulated field produces a steady volt- Residual Voltage Faulty capacitor C
age in the stator windings which can then be drawn off the 4-6 VAC (Hot N) Open exciter B
generator's AC terminals to operate AC equipment. The at no-load
Shorted exciter B
generator is a single-phase, reconnectable 120 volt AC
two-wire or 115 volt AC two-wire or 230 volt AC two-wire,
Engine speed [hertz]
is too low Adjust*
at 50 hertz.
The generator's data plate gives the voltage, current and
Electrical connections Inspect wiring
frequency rating of the generator. An AC wiring decal is
are faulty connections
affixed to the inside of the louvered cover at the generator High AC Output Incorrect voltage tap
end. A diagram of the various AC voltage connections is at No-Load on capacitor C
provided on the decal. An Integral Controller (IC) is mounted Incorrect capacitor C
inside the generator and supplies a continuous DC charge to Incorrect hertz tap
the generators. starting battery when the generator is running. on capacitor C
INTRODUCTION TO TROUBLESHOOTING Engine speed [hertz]
is too high Adjust*
The following test procedures can be used to troubleshoot
WES'IERBEKE'S 4 POLE SINGLE AND DUAL CAPACI- Low AC Output Faulty- rotor winding A
TOR BRUSHLESS GENERATORS. Due to the simplicity 60-106V Faulty diode A
of the generator, troubleshooting is relatively easy.
Faulty capacitor B
Field testing and repairing can be accomplished with basic
tools and repair parts which should include the following:
Voltage Drop Faulty diode A
A quality multimeter [multitester] capable of reading Under Load
less than one ohm and with a specific diode testing (or at No-Load) Faulty capaCitor C
function. Engine speed [hertz]
Basic electrical tools including cutters, soldering iron, is too low Adjust*
wire strapper/crimper, terminals connectors, etc. No Battery Charge Faulty bridge rectifier 0
Repair parts such as diodes, fuses, bridge rectifier, etc. Low Battery Charge
Faulty integral controller 0
Blown fuse B
PRELIMINARY CHECKING .
Faulty winding B
Before electrical testing check for proper engine
speedlhertz adjustment. Low engine speed will cause low High Voltage Engine speed [hertz]
AC voltage output, high engine speed-high AC output. Output when Load is too high Adjust*
is applied
Refer to WES'IERBEKE'S operators manual or service
manual for engine speedlhertz adjustment or for other Unstable Voltage Electrical connections Inspect wiring
possible engine related problems. are faulty, loose connections
Before testing, get a clear explanation of the problem that Noisy Operation Faulty support bearing Inspect rear
exists, be certain it relates to generator components. bearing * *
Generator rotor
connection to engine Check rotor
A WARNING: AC and DC circuits often share the same is loose security**
distributor panel. Be certain to unplug AC power cords * Refer to the GENERATORS OPERATOR MANUAL
and shutdown DC/AC inverters. Simply switching off ** Refer to the GENERATORS SERVICE MANUAL
circuit breakers will not do the job since it will still
leave hot wires on the supply side of the panel.
:59
INTERNAL WIRING SCHEMATIC
DC BAnERY CHARGING CIRCUIT
FUSE - INTEGRAL CONTROLLER y'" ______________________ .,
WINDING: NO TIME DELA
Pn#43634 30A . .
D •
A• ROTOR WINDINGS/DIODE
250V MDA-30. B • STATOR WINDINGS
!':ifI ill----- -~-:-7--------------

r-------" ,
I I
C • EXCITER WINDING(S)/CAPACITOR(S)
~.~. j
D • BATTERY CHARGING CIRCUIT
BALLAST RESISTER
[EARLY MODELS)
~I~~ ~
~-- ----)-~f.]-:
-------;-
••
J
r------- ------------------------,
: 30A ~ D DCCHARGE :
CONNEr:T FOR THE,

REQUIRED FREQUENCY
· k~ C60 .
I 8; '
I
.~ I
r--------,·
I
I
I GND
I
I
:
I
AND OUTPUTVOLTA~£ L~50;
.... -~rACIT~R:t -
WINDING RESISTANCE VALUES IN OHMS
J
1 Ai1I tl------:]----:;~~~J
b
fil
MODa- SINGLE A ROTOR 3.Bn
CAPACITOR 8 STATOR O.6n l I MAKE CERTAIN A REPLACEMENT
c EXCITER 1.gn I ! CAPACITOR HAS THE CORRECT PART
D CHARGER O.14n I I NUMBER. CHECK THE BODY OF THE
I , CAPACITOR FOR THE RATING AND
MODEL- DUAL A ROTOR 4. on I 1 I I PART NUMBER.
~----- --?: -~l-~l-~~~~=t.cy

CAPACITOR 8 STATOR OAn
c EXCITER 2.2n
D CHARGER O.14n
IVIODEL- DUAL
EXCITER CIRCUIT
A
8
ROTOR
STATOR
4. on
O.3n lZOHz 'lll l11 .llA~D OUTPUT VOLTAGE
c
D
EXCITER
CHARGER
2.2n
O.GBn
:50Hz____________________
~
~r-J C ~I 60,..__ 50Hz:J
ACTERMINAL BOARD CONNECTIONS NOTE: When changing from 60Hz to

50Hz. make certain the ground wire is
WITH CIRCUIT BREAKER [CURRENT MODELS] properly repositioned according to
N N Ll l1 . these diagrams.
@ @ ® @ II
120V/60Hz 115V/50Hz 230V/50Hz
JUMPER
L1
REQUIRED
N L1
• •
L1 N
Eng/nes & Generators
60
LOW VOLTAGE - ROTATING FIELD AUXILIARY WINDINGS TESTS
TESTING THE DIODES
A WARNING: Some of the following tests require the If a distinct difference is noted in the ohm value, carefully
generator to be running, make certain the front pulley unsolder the lead on the top of the diode and remove the
cover and timing belt covetS are in place. diode from its isolated heat sink using a thin walled, deep
well 7/16 in (11 mm) socket.
To check the diode, unsolder the connection from the top of
ROTATING FIELD/AUXILIARY WINDINGS the diode. Place one ohmmeter lead on the connection at the
top of the diode and the other ohmmeter lead to the diode's
r------------------, base: Then reverse the. position of the ohmmeter leads.
• A. :
I~~I
f..-Q~1
L _.__ ._____ ... _____ .____ ..:1
Description
Two sets of windings are found in the rotor assembly. An AC
voltage is produced in two groups of windings as the rotor
turns at rated rpm. The AC voltage passes through each of
the two diodes mounted on the isolated fixture just before the
rotor carrier bearing. The AC sine wave is changed to a DC
and this DC voltage is passed through the two groups of TESTING THE DIODES
rotating field windings producing a DC field around these
windings. This field affects the AC winding of the two main
stator groups inducing an AC voltage in these windings that A low resistance should be found with the leads in one
is available at the AC terminal block connections. direction, and infinite resistance (blocking) in the other
direction. .
Testing The Windings Thru the Diodes DIODES 8 - 9.5 OHMS (APPROXIMATELY) USING A 260 SIMPSON
To check the resistance values, rotate the engine's crankshaft ANALOG METER.
to position the diode(s) on the generator's shaft at 12 o'clock.
To make a quick check of these windings, presume the NOTE: Different meter models may show different ohm
diode is OK and place one of the ohmmeter's leads on the values. but should read the same for both diodes.
connection at the top of the diode and the other lead at the DIODE RATING: 1600 AMPS 26 AMPS
connection at the base of the diode. Compare readings with The diode's rating is far in excess of the circuit's requirements.
the figures below. Most likely a diode failure will result from an overs peed or
STANDARD RESISTANCE VALUES load surge.
ROTATING FIELD I AUXILIARY WINDINGS
Single CapaCitor 3.8 Ohms
Dual Capacitor 4.0 Ohms A CAUTION: [ON SOLDERING} When soldering, use a
large enough soldering iron to get the job done quickly.
Excessive heat will damage the diodes.
Also make certain no soldering splashes onto the
windings as it will melt the insulation.
61
LOW VOLTAGE • ROTATING FIELD AUXILIARY WINDINGS TESTS
Testing the Rotor Field Auxiliary Windings Testing Continuity
With the diode removed, both leads for the first group of Check that no continuity exists between either of the wind-
rotating field/auxiliary windings will be isolated with no ing leads and the generator shaft. If continuity is found,
interference from a possibly faulty diode. there is a short in the windings.
Check the resistance value of the rotating windings by Repeat the above tests on the second set of windings on
placing the ohmmeter's probes across the two exposed the opposite side.
leads.
ROTOR WINDINGS RESISTANCE VALUES
Single Capacitor 3.8 ohms
Dual Capacitor 4.0.ohms
Dual Exciter Circuit 4.0 ohms
TESTING THE WINDING LEADS
TESTING FOR
CONTINUITY
[TEST BOTH LEADS]
62
RESIDUAL VOLTAGE - EXCITER CIRCUIT TESTS
SINGLE CAPACITOR
c DUAL EXCITER
t.::~-~ CI--...J
~J DUAL CAPACITOR
TESTING THE EXCITER WINDINGS
AC voltage can be measured across the capacitor(s) while the
generator is operating. 1bis voltage may be as high as 400 to
500 volts AC. 1bis voltage buildup is ~ccomplished as the
exciter windings charge the capacitor(s) and the capacitor(s) MEASURING
.discharge back into the exciter windings. 1bis AC voltage ACVOLTAGE
reading is taken between the #60 Hertz connector and the # GENERATOR
connection plugged into the capacitor(s) while the generator RUNNING
is operating at its rated Hertz (60.5 - 61.5 for gasoline.models
and 61.5 - 62.0 for diesel models). This flow of saturating
AC in the exciter windings produces a phase-imbalance type
of field that effects the auxiliary windings: a beneficial result
that produces good motor starting characteristics for this type
of generator.
63
NO VOLTAGE OUTPUT - MAIN STATOR WINDINGS TESTS
NOTE: The studs on the AC terminaL board are identified by
the six red wire that attach to them. These wires are num-
bered 1 thru 6. There are no numbers on the terminaL block.
B
TESTING RESIDUAL VOLTAGE

EXCITING THE GENERATOR Test for residual voltage between terminal #1 and terminal
The generator may be excited using 12 volts DC taken #3. Then test between terminal #4 and #6 (shown above).
from the engine's starting battery. This voltage is applied RESIDUAL VOLTAGE 2 -3 VOLTS AC
across the #50 and #9 leads of the exciter circuit windings
(unplugged) with any other numbered leads unplugged Correct readings will indicate the stator windings are okay.
Check the exciter windings.
from the capacitors. The generator's reaction during
flashing will help determine its fault.
NORMAL VOLTAGE OUTPUT RANGE DURING 12 VOLT EXCITA·
TION
Single Capacitor 22 - 26 VAC
Dual Capacitor 24 -28 VAC
Dual Exciter 12 ·14 VAC
o A slight rise in the output voltage with the loading of
the engine and/or a growling noise from the generator
end will indicate a fault in the main stator windings.
o No rise or a very slight rise in the output voltage will
indicate a fault in the exciter windings.
o Normal output voltage as specified above, check
exciter circuit.
TESTING THE MAIN STATOR WINDINGS

Test the main stator windings at the AC terminal board by
first removing all the AC output leads, the ground
connection, and the brass interconnects. This will isolate
the six leads on the terminal· board which make up the two
stator groups.
CHECK RESISTANCE
GROUP 1· Test the resistance value between the #1 terminal
and the #3 terminal.
GROUP 2 • Test the resistance value between the #4 terminal
and the #6 terminal.
RESISTANCE VALUES
Single Capacitor 0.6 ohms
Dual Capacitor 0.5 ohms
BCA Model 0.3 ohms
Dual Exciter Circuit 0.5 ohms
TESTING MAIN STATOR

WINDINGS
[60 Hz CONFIGURATION SHOWN]
64.
NO VOLTAGE OUTPUT • MAIN STATOR WINDINGS TESTS
Testing Continuity
There should not be any continuity between these two wind-
ing groups. Test between terminal #3 and tenninal #6. If con-
tinuity exists, there is a short in the windings.
There also should be no continuity between the terminals and
the generator case (ground).
MAIN STATOR
WINDING LEADS
TESTING CONTINUITY
TESTING CONTINUITY EACH TERMINAL TO
BETWEEN THE TWO CASE GROUND
WINDING GROUPS
65
EXCITER CIRCUIT CAPACITOR{S) TESTS
Measuring Resistance TESTING THE CAPACITORS
To measure the resistance of the exciter winding locate the
#9 and the #50 Hertz capacitor connections.
NOTE: Three numbered capacitor connections exist: #7, #8,
and #9; and two Hem connections #50 and #60.
Unplug any other connections from the capacitor noting
their position on the capacitor. Place one probe of the mul-
timeter on plug connection #9 and the other probe on the
50 Hertz lead. Measure the resistance value of the exciter
windings and compare to the figures below.
NOTE: Lower residual voltage along with a lower winding
A WARNING: Capacitors must be discharged before
resistance will confinn a faulty winding. handling as they store electricity and can pack a poten-
tially lethal charge even when disconnected from their
EXCITER WINDINGS RESISTANCE power source.
SingllfCapacitor Dual Capacitor Dual Exciter BCA Model
1.9 ohms 2.2 ohms 1.3 ohms 1.5 ohms
Discharge the capacitor by a bridging the terminals with an
insulated screwdriver.
Connect a multitester (highest ohm scale) to the capacitor ter-
minals. The meter should go to zero ohms and slowly return
to high. Discharge the capacitor again and reverse the leads,
CHECKING FOR
CONTINUITY BETWEEN the same results should be obtained.
LEAD 50Hz & LEAD
19 TO CASE GROUND _ lithe meter goes down and stays at zero ohms, the capacitor
.,;:'"
... , ... -\...;,...~,
is faulty (shorted) .
If the meter fails to go down to zero, the capacitor is faulty
,i~~'"''
.. -;~"
(open circuited) .
I ,
Indications of a defective capacitor:
,'
/ (
o Infinite resistance, or no rise in resistance

/ (shorted capacitor)
II
I o Infinite resistance (open capacitor)
CHECKING FOR
CONTINUITY BETWEEN
LEAD 50Hz AND LEAD 19
, TO THE AC TERMINAL LEADS
I' MEASURING
CAPACITOR
RESISTANCE
Checking Continuity
Check to make sure there is no continuity to the
ground/generator case from either of the two leads. Also
check that no continuity exists between either the #50
Hertz plug or the #9 plug and any of the main stator
winding leads on the AC output. If continuity is found
here, a fault exists between these two winding groups.
An AC voltage is induced in these windings by the CAPACITOR RATINGS
rotating field. Checking the residual voltage output from Single Capacitor Models 25.0 MFD Pn#035985
this winding can determine the condition of the winding Dual Capacitor Models 31.5 MFD Pn#035978
when troubleshooting. Test between leads #50 and #9 with Dual Exciter Models 18.0 MFD Pn#039556
leads lifted off the capacitor(s).
RESIDUAL VOLTAGE: NOTE: The older single capacitor models have 25.0 microfarad
Single CapaCitor Model: 10 -14 Volts AC from each winding capacitors. New models now have 31.5 microfarad capacitors.
Dual Exciter Model: 7 - 9 Volts AC from each winding Dual exciter models have a 18.0 MFD capacity.
Dual CapaCitor Model: 14 -16 Volts AC from each winding The capacitor rating is marked on the housing of the capacitor.
66
BATTERY CHARGING CIRCUIT I BRIDGE RECTIFIER
TESTING THE BATTERY CHARGING CIRCUIT
NOTE: The battery charging circuit is totally separate from the

A C output of the generator: The generator output affects the
circuits output, but not the reverse.
Normal AC voltage running to the rectifier (while the
engine is operating at 1800 rpm) is measured across the
two AC connections on the bridge rectifier (shown below).
AC VOLTAGE TO THE BRIDGE RECTIFIER (APPROXIMATELY): ALSO TEST THESE TWO LEADS
TO THE AC TERMINAL BLOCK
No-load off the generator 16.0 volts AC STUDS TO VERIFY NO CONTINUllY
Full-load off the generator 17.5 volts AC
TESTING THE BRIDGE RECTIFIER
1. Set your multimeter's scale on RX1 (+DC) and set the
needle to zero.
2. Connect the (+) positive lead from the mu~timeter to point
#4. Taking the multimeter's negative (-) probe, momentarily
touch points #1, #2, #3, and #5. The multimeter should
MEASURING DC
; VOLTAGE BETWEEN .'• register no deflection for any of the points touched.
I
. (+) AND (-) LEADS .,:.'
,
:II .*-.,,;*..'.~
;..
... 3. Remove the positive (+) probe from point #4 and connect
the negative (-) probe, momentarily touch points #1, #2,
I .' ••
and #3. The multimeter's needle should deflect when each
II
'1 .i:.
Ii ~:p;.~
..
I' .. ..
point is touched.
·1 "
4. Leaving the negative multimeter (-) probe on point #4,
'\ iii
l: touch point #5 with the positive probe. No deflection should
"
\\ take place.
S. Place the positive (+) probe on point #1 and the negative
probe (-) on point #3. The multimeter again should not
register any deflection (no deflection indicates infinite
Normal DC voltage running out of the rectifier (in volts
DC) is measured across the two DC connections of the resistance). Reverse these connections and the multimeter
bridge rectifier, that is + and - as illustrated. snould again register no deflection.
DC VOLTAGE FROM THE BRIDGE RECTIFIER (APPROXIMATELY):
No-load off the generator 17.0 volts DC
Full-load off the generator 18.5 volts DC #2
Lift the two AC wire leads off the bridge rectifier and
measure the resistance between these two leads. It should
measure 0.14 ohm. No continuity should exist between
these two leads and the ground or the main stator windings. BRIDGE
RECTIFIER
RESISTANCE BETWEEN AC LEADS 0.14 OHMS #5
/
MOUNTING HOLE' #3
RESISTANCE BETWEEN DUAL EXCITERS 0.08 OHMS
67
INTEGRAL CONTROLLER
I~VOLlADJ. POl. BATTERY CHARGING

The generator supplies a continuous 17 amp charge from its
battery charger to the starting battery.
+ - GND The DC Circuit on the BCGB functions to start, operate and

stop the generator's engine. The circuit is best understood by
reviewing the DC WIring Diagram and WIring Schematic.
BLACK The engine's DC wiring is designed with three simple basic
...cc
c
circuits: start, run and stop .
cc YELLOW
...
c
<.:I
The engine has a 12 volt DC electrical control circuit that is
shown on the WIring Diagrams. Refer to these diagrams
...
z:
cc INTEGRAL CONTROLLER when troubleshooting or when servicing the DC electrical
c
B+ GROUND system or the engine.
INTEGRAL CONTROLLER (I.C.)

The Integral Controller (I.e.) is an encapsulated, solid-state
unit that supplies a DC charging voltage to the generator's
starting battery while the generator is operating.
Charging Voltage: 13.0 -14.0 volts DC
Charging Amperage: 0 - 10 amps DC [Early Models]
Charging Amperage: 0 - 17 amps DC [Current Models]
A separate group of stator windings supplies AC voltage to a
bridge rectifier which converts the AC current to supply the
I.e. unit. The I.e. unit senses the needs of the starting battery
and supplies a DC charge when one is needed. If you suspect
that the I.C. unit is faulty (that is, if the battery's charge is
low), check the charging circuit and it's components as
described in the following steps. Check all connections for
cleanliness and tightness including the ground before replac-
ing the I.e. unit.
NOTE: When the generator is jiFSt started, the l. C. unit will
produce a low charging rate. This charging rate will rise as
the generator is operated.
The Integral Controller is mounted inside the generator hous-
ing in the 12:00 position. There is a voltage output adjust-
ment on the controller that will allow a DC voltage output
adjustment of ± 2 volts.
68
INTEGRAL CONTROLLER I NO-LOAD VOLTAGE ADJUSTMENT
TESTING THE INTEGRAL CONTROLLER
To test the battery charger, put a multimeter between the A WARNING: Capacitors must be discharged before
positive (+) and negative (-) leads to the battery. It should handling as they store electricity and can pack a poten-
indicate 13.5V to 14V with the engine running. If only the tial/y lethal charge even when disconnected from their
battery voltage is indicated, check that the battery charger
power source.
terminal connections are tight. With the unit running, test
between the (+) and (-) terminals for·13.5V to 14V. If no
charge is indicated, replace the charger. NOTE: Simply cross the capacitor's two terminals with an insu-
lated (plastic hmulle) screwdriver. This will discharge any
GROUND excess electricity.
. CONNECTION INTEGRAL CONTROLLER
BRIDGE
'" RECTIFIER A WARNING: Do not attempt to make a no-load
voltage adjustment while the generator is operating.
The capaCitor can produce a 400-500 volt charge.
Touching any wiring can produce a severe electrical
shock. In addition, attempting to make a no-load volt-
age adjustment while the generator is operating could
cause your fingers to be caught in the generator's rotor.
5. There are three plugs grouped for the right capacitor

terminal, #7, #8, and #9. If the generator's no-load voltage
is low, then disconnect the lower numbered plug and
connect the plug with the next higher number. If the
generator's no-load voltage is high, then disconnect the
A 30 amp fuse protects the windings from a failure of the higher numbered plug and connect the plug with the next
bridge rectifier or integral controller (high amperage or a lower number. Note that the plug presently connected to
short) this terminal may be anyone of the three plugs available.
SINGLE AND DUAL CAPACITOR NO-LOAD VOLTAGE 6. If the generator's no-load voltage cannot be adjusted
ADJUSTMENT because the voltage needs to be increased and the highest
numbered plug is already connected to the right terminal,
1. Remove the louvered metal plate, at the back of the
generator, covering t1>.e AC terminal connections and or the voltage needs to be lowered and the lowest numbered
plug is connected, refer to HERTZ ADJUSTMENT in the
the capacitor(s).
operators manual.
2. Start the generator and allow it to run for approximately
five minutes so the engine can warm up. Make sure the
generator is operating without any equipment drawing AC
current from the generator (that is, shut off all electrical
appliances). Make sure the engine's speed (Hertz) is
correct. Adjust the governor as needed to obtain the
correct engine speed before proceeding.
3. Refer to the AC 1ERMINAL BOARD CONNECTIONS
DIAGRAM for the correct configuration then check the N N
::I: ::I:
generator's no-load voltage by measuring the voltage
across the neutral lead and the hot lead with a voltmeter. '"
It>
'"
...
Make sure you record this reading. The generator's no-

load voltage is 115 - 124 volts at 60.5 - 61.5 Hertz. If the
voltage output is higher or lower than specified, proceed.
4. Shut off the generator. Make sure the correct Hertz lead
(60 Hertz #6, or 50 Hertz #5) is plugged into the THE CONNECTIONS
SHOWN DEMONSTRATE
capacitor(s). HOW THESE ADJUSTMENTS
c DUAL CAPACITOR CAN BE MADE
50Hz 60Hz 117 118

NO-LOAD VOLTAGE ADJUSTMENT DUAL EXCITER
DUAL EXCITER CIRCUIT MODEL NOTE: When changing Hertz produced by the generator; an
These generators have dual Hertz and no-load voltage adjust- engine speed adjustment at the governor must be made.
ment connectors at each capacitor. There are five connectors The AC output connections on the terminal blocks must be
available for each capacitor. Two connectors are for Hertz selected for the voltage and Hertz to be produced The
selection, 60 Hertz or 50 Hertz, and three connectors, #7, #8, Hertz plug connection at the capacitor must be changed for
and #9, are for no-load voltage adjustment. 50 Hertz (#5) or 60 Hertz (#6). The frame ground wire
must be moved when changing from 115 volts, 50 Hertz to
When making Hertz change or no-load voltage adjustments 230 volts, 50 Hertz. Refer to the AC TERMINAL BOARD
proceed as follows: CONNECTIONS.
1. Shut the generator down. 3. On later model BC generators, a 50HzJ60Hz connection
2. Select the appropriate Hertz connection to plug into each is provided for the DC battery circuit. When changing
capacitor #60, 60 Hertz, 1800 RPM or #50 Hertz, 1500 hertz, connect the proper lead (50Hz or 60Hz) to the
RPM. The three other connectors at each capacitor, #7, bridge rectifier.
#8, and #9, will have an effect on the no-load voltage
produced by the generator. One connector from each
group can be plugged into each capacitor. No-load voltage
will increase or decrease approximately 8 - 10 volts
between connectors used in any pair combination to
. achieve the prescribed no-load voltage.
C
BATTERY CIRCUIT
CONNECTIONS 50/60Hz
[CURRENT MODELS]
50Hz 60Hz #7 #8 #9
~r--1
A WARNING: Make certain the insulating covers on I
,
",
I
the unused leads are in 'place and are NOT in contact

AC CONNECTION
with each other or in contact with the generator's
housing.
70
Be GENERATORS PARTS IDENTIFICATION
B C GENERATORS . /"
ELECTRICAL COMPONENTS
[DUAL EXCITER SHOWN]
/"-
/' ".r ..............
, ~",;:" .
' /~
,,
.....
CAPACITOR
TERMINAL BOARD
TO CIRCUIT
BREAKER
CURRENT MODEL
B C GENERATORS
ELECTRICAL COMPONENTS
[SINGLE CAPACITOR SHOWN]
/' /., '; ",", ....!NTEGRAL CONTROLLER
/' ~"'".;, ...........
~.... ,.1
I
,)
30 AMP FUSE
71
SPECIAL TOOLS • GENERATOR
FIELD FABRICATED TOOLS Lifting Eye Tool
These drawings provide a means by which simple tools can be This tool allows a mechanic to safely remove the generator
made to assist in the removal of the generator end from the end from the engine by attaching this Generator End Lifting
engine and in the replacement of the generator end on the engine. Eye to the four screw holes located under the control panel. To
A local machine shop should be able to fabricate these tools at a use this Lifting Eye, remove the generator's control panel and
modest price, but first check with your local WES1ERBEKE screw the Lifting Eye to the generator end.
dealer to see if these tools are on hand for loan.
Housing Puller Tool

This tool allows the bearing in the generator housing to be
~
gently pushed straight off the housing without any twisting. If
a nut of the same specifications as that of the tapped hole in
the pilot tool were to be welded on the end of the eye bolt, this
tool would be able to pull the bearing back into place without 2-1/2"
(63.5 mm)
any twisting. Please refer to these drawings before the genera-
tor end is removed. 4 HOLES
1/2-13 UNC Store-bought 1/4"
HOUSING PULLER TOOL (6 mm)
(FIELD FABRICATED) eye bolt with tapered tip.
-'-
/
3.346" (85 mm)

4"
(101.~
45°
mm)=---1 Taper /'
~'\ /~/"'
\
/
J Disk Alignment Tool
. Center lifting eye on
baseplate and weld securely.
Dia B.C.
This tool allows a mechaI).ic to safely remove and install the
r-~4--,~ 1 r---~~-- ___ generator drive disks by aligning the disks with the Drive Plate
)?{ £;
2."
/ ---- Guide Pin. The Pin screws into the flywheel and acts as a
guide. Also the pin helps to support some of the rotor and the
drive plate's weight while removing or replacing these parts.
Weld a 1/2-13 UNC Hex Nut to
one side of this center hole.
ammmmmm 5
1/2" (12.7 mm) Dia.
Drill Typ. 4 holes Material: Cold-rolled Steel Material: One M8 bolt with the hex head machined off and a
screwdriver slot cut in the machined end.
Pilot Tool
Screwed into the end of the rotor shaft, this tool can be
used to pull the stator assembly away from the engine
without damaging the stator windings. This tool can be
used at reassembly.
to(~---8"----~~
(203.2 mm)
I ROUNO TIP
'6:.~~f§Pc~1 =----12-" ---l-I ~---~I

15.5 mm Drill ~-<-----(304.8 mm)--------_~-
1-1/4" (31.75 mm) Deep
M18 x 1.5 Pitch
Tap 1" (25.4 mm) Deep
PROPER USE OF HOUSING PULLER
Material: Aluminum
72
ENGINE/GENERATOR TROUBLESHOOTING
OPERATING PROCEDURES
The following chart is repeated from the operators manual. Before restarting the engine, the cause of the problem
The problems described do not relate to problems should be determined and corrected.
consistent with an engine overhaul. This chart is included The tables that follow suggest a troubleshooting procedure
only as a convenience to the operator or service technician. based upon certain engine problem indicators and the most
ENGINE TROUBLESHOOTING likely causes of the problem.
If the engine stops while running for no apparent reason When troubleshooting indicates an electrical problem refer
and the remote control panel indicator lamp is flashing, this to the WIRING DIAGRAMS in this manual, these diagrams
indicates that an engine operating fault has occurred as a may reveal other possible causes of the problem which are
result of one or more of the following conditions: not listed below.
1. Low oil pressure
2. High engine water temperature
3. High exhaust temperature
4. Low battery voltage
PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE

Engine does not 1. Voltage drop at starter solenoid Engine hunts. 1. Throttle plate is binding.
crank. terminal. 2. Low battery voltage.
2. Engine 20A circuit breaker has 3. Generator is overloaded.
tripped. 4. Dirty fuel filter.
3. Battery is low or dead. s. Damaged vacuum hose.
4. Loose battery connections. 6. Cracked distributor cap.
s. Faulty wire connection. 7. Faulty high tension wires.
6. Faulty start switch. S. Faulty fuel pump.
7. Faulty starter solenoid. 9. High exhaust back-pressure.
S. High exhaust back-pressure. 10. Valves are out of adjustment.
9. Sea water filled cylinders.
Engine cranks but 1. Out of fuel.
Engine starts, runs 1. Fuel line restriction. fails to start. 2. Fuel pump inoperative.
but does not come 2. Dirty fuel filter.
up to speed. 3. Engine is flooded.
3. Throttle plate binding. a. Carburetor float needle valve
4. Faulty fuel pump. is open or damaged. Clean or
S. AC generator overload. replace the needle valve.
6. High exhaust pressure. b. Float in carburetor is leaking.
Repair or replace float.
Engine starts, runs 1. Faulty shutdown switch,
. and then shuts (oil pressure, water or exhaust c. Float chamber gasket damaged
down. temperature). or securing screws are loose.
Replace gasket and/or tighten
2. High engine water or exhaust
screws.
temperature.
4. High tension wires grounding
3. Dirty fuel filters.
(wet system).
4. Mechanical check valve at the
fuel supply faulty.
s. Faulty ignition coil
S. Low oil level in sump.
6. Faulty distributor.
7. Faulty wire connection.
6. Faulty fuel pump.
S. Worn or faulty spark plugs.
7. High exhaust back pressure.
9. Faulty run relay (K2).
10. Timing belt.
11. No engine compression.
12. Faulty idle adjustment.
13. High exhaust back pressure.
73
ENGINE/GENERATOR TROUBLESHOOTING
OPERATING PROCEDURES
PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE
Engine misfires. 1. Poor quality fuel. No DC charge to the 1. Faulty connections to
2. Incorrect timing. starting battery. battery voltage regulator.
3. Dirty flame arrester. 2. Faulty battery voltage regulator.
4. Dirty throttle body. 3. Faulty bridge rectifier.
5. Throttle plate is binding. 4. Faulty generator charger
6. Cracked distributor cap. windings.
7. Faulty high tension wires. Alternator excitation 1. Low engine speed, check RPM'S.
8. Spark plugs are worn. failure 2. Faulty condenser, check/replace.
9. High exhaust back-pressure. 3. Faulty windings, check resistance
10. Valve clearances are incorrect.
High no-load 1. High engine speed, adjust RPM'S.
Engine backfires. 1. Spark plug wires are connected voltage 2. Faulty condenser, check/replace.
wrong.
Low no-load 1. Low engine speed, adjust RPM'S.
2. Incorrect timing. voltage 2. Faulty rotary diodes, check/replace.
3. Engine is flooded.
3. Breakdown in windings, check
4. Dirty flame arrester. resistance.
5. Cracked distributor cap. 4. Faulty condenser, check/replace.
6. High exhaust back-pressure.
Proper no-load 1. Low loaded speed, regulate RPM.
Engine overheats. 1. Coolant loss (pressure test but low loaded 2. Load too heavy, reduce load.
cooling system). voltage. 3. Short circuit in rotary diodes,
2. Faulty raw water pump impeller. check/replace.
3. Belts are loose or broken.
Proper no-load 1. RPM too high, regulate RPM.
4. Raw water pump worn. but high loaded
5. High exhaust back-pressure. voltage.
6. Faulty thermostat.
Unstable 1. Loose contacts, check connections.
Black exhaust smoke 1. Dirty flame arrester. voltage. 2. Uneven rotation, check for uniform
discharge from the 2. Faulty vacuum hose ..
engine. Noisy generator 1. Broken bearings, replace.
3. Faulty carburetor. backend. 2. Poor couplings, check/repair.
High oil pressure. 1. Dirty oil or wrong SAE type oil
in the engine.
2. Relief valve is stuck.
74
STANDARD AND METRIC CONVERSION DATA
LENGTH-DISTANCE
Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
Feet (ft) x .305 = Meters (m) x 3.281 = Feet
Miles x 1.609 = Kilometers (km) x .0621 = Miles
VOLUME
Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 =in 3
Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt
Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt
Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal
Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .833 = IMP qt
Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 = IMP gal
Fluid Ounces x 29.573 = Milliliters x .034 = Ounces
US Pints (US pt) x .473 = Liters(L) x 2.113 = Pints
US Quarts (US qt) x .946 = Liters (L) x 1.057 = Quarts
US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons
MASS-WEIGHT
Ounces (oz) x 28.35 = Grams (g) x .035 = Ounces
Pounds (Ib) x .454 = Kilograms (kg) x 2.205 = Pounds
PRESSURE
Pounds Per Sq In (psi) x 6.895 = Kilopascals (kPa) x .145 = psi
Inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
Inches of Water (H20) x .07355 = Inches of Mercury x 13.783 = H20
Inches of Water (H20) x .03613 = psi x 27.684 = H20
Inches of Water (H20) x .248 = Kilopascals (kPa) x 4.026 = H20
TORQUE
Pounds-Force Inches (in-Ib) x .113 = Newton Meters (Nm) x 8.85 =in-Ib
Pounds-Force Feet (ft-Ib) x 1.356 = Newton Meters (Nm) x .738 = ft-Ib
VELOCITY
Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH
POWER
Horsepower (Hp) x .745 = Kilowatts (Kw) x 1.34 = MPH
FUEL CONSUMPTION
Miles Per Hour IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
Kilometers Per Liter (Km/L) x 2.352 = IMP MPG
Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (Km/L)
Kilometers Per Liter (Km/L) x 2.352 = US MPG
TEMPERATURE
Degree Fahrenheit (OF) = (OC X 1.8) + 32
Degree Celsius (OC) = (OF - 32) x .56
75
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 25.40 15 381.00 1 0.0394 15 0.5906
2 50.80 20 508.00 2 0.0787 20 0.7874
3 76.20 25 635.00 3 0.1181 25 0.9843
4 101.60 30 762.00 4 0.1575 30 1.1811
5 127.00 35 889.00 5 0.1969 35 1.3780
10 254.00 40 1016.00 10 0.3937 40 1.5748
10 MILLIMETERS =1 CENTIMETER, 100 CENTIMETERS =1 METER =39.37 INCHES (3.3 FEET)
INCHES TO METERS METERS TO INCHES
Inches Meters Inches Meters Meters Inches Meters Inches
1 0.0254 7 0.1778 0.1 3.937 0.7 27.559
2 0.0508 8 0.2032 0.2 7.874 0.8 31.496
3 0.0762 9 0.2286 0.3 11.811 0.9 35.433
4 0.1016 10 0.2540 0.4 15.748 1.0 39.370
5 0.1270 11 0.2794 0.5 19.685 1.1 43.307
6 0.1524 12 0.3048 0.6 23.622 1.2 47.244
TO CONVERT METERS TO CENTIMETERS, MOVE DECIMAL POINT TWO PLACES TO THE RIGHT
YARDS TO METERS METERS TO YARDS

Yards Meters Yards Meters Meters Yards Meters Yards
1 0.91440 6 5.48640 1 1.09361 6 6.56168
2 1.82880 7 6.40080 2 2.18723 7 7.65529
3 2.74320 8 7.31520 3 3.28084 8 8.74891
4 3.65760 9 8.22960 4 4.37445 9 9.84252
5 4.57200 10 9.14400 5 5.46807 10 10.93614
MOVE DECIMAL POINT FOR HIGHER VALUES - e.g. 6,000 METERS = 6,561.68 YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS

Ib kg Ib kg kg Ib kg Ib
1 0.454 6 2.722 1 2.205 6 13.228
2 0.907 7 3.175 2 4.409 7 15.432
3 1.361 8 3.629 3 6.614 8 17.637
4 1.814 9 4.082 4 8.818 9 19.842
5 2.268 10 4.536 5 11.023 10 22.046
GALLONS TO LITERS LITERS TO GALLONS

Gallons Liters Gallons Liters Liters Gallons Liters Gallons
1 3.79 10 37.86 1 0.26 60 15.66
2 7.57 20 75.71 2 0.53 90 23.77
3 11.36 30 113.57 5 1.32 120 31.32
4 15.14 40 151.42 10 2.64 150 39.62
5 18.93 50 189.28 20 5.28 180 47.54
PINTS TO LITERS LITERS TO PINTS

Pints Liters Pints Liters Liters Pints Liters Pints
1 0.47 6 2.84 1 2.11 6 12.68
2 0.95 7 3.31 2 4.23 7 14.79
3 1.42 8 3.79 3 6.34 8 16.91
4 1.89 9 4.26 4 8.45 9 19.02
5 2.37 10 4.73 5 10.57 10 21.13
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 of
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 °C
76
INDEX
AC Terminal Board Connections .................60 Parts Identification - BC Generator .............71
Bridge Rectifier ...........................67 Parts Identification - Engine/Generator ...........2
Camshaft and Rocker Arms ..................19 Pistons and Connecting Rods .................21
Capacitor Rating - Generator .................60 Raw Water Pump .........................37
Carburetor ...............................38 Relays - Testing .......................... .48
Choke Solenoid .......................... .47 Residual Voltage - Generator .................63
Compression Testing ...................... .4 Resistance Values - Generator ................67
Connecting Rod Bearing Caps ................25 Sealants and Lubricants ..................... .7
Coolant Circulating Pump ....................35 Serial Number Location ......................3
Counterbalance Shaft Inspection ..............27 Service Data .............................52
Crankshaft and Connecting Rods ..............24 Spark Plug Inspection ...................34,46
Crankshaft Inspection .......................30 Special Tools - Engine ......................57
Crankshaft Rear Oil Seal .....................32 Special Tools - Generator ....................72
Crankshaft/Bearing and Oil Seal ...............30 Specifications - BCGB ......................56
Cylinder Block Head and Valves ............... 15 Standards and Limits ......................52
Cylinder Block Inspection ....................33 Standard Hardware Torques ..................55
Cylinder Block Inspection and Piston Clearance ... 33 Starter Motor ............................ .42
Cylinder Head Bolts ........................18 Starter Motor Adjustment ................... .45
Cylinder Head Inspection ....................16 Starter Motor Inspection ................... .43
DC Charging Circuit - Generator ............... 67 Testing Engine Compression ................. .4
Disassembly Engine ........................9 Testing for Overhaul .........................3
Disassembly Engine/Generator ................8 Testing Oil Pressure ....................... .4
Distributor ...............................34 Thermostat ..............................38
Drive Belt Adjustment ...................... .46 Timing Belt Disassembly .....................11
Electrical Testing • Generator ................58 Timing Belt Inspection ......................12
Engine Disassembly ........................9 Timing Belt Installation ......................13
Engine Assembly Data .......................7 Troubleshooting - Generator [Chart] ............59
Engine Hardware Torques ....................54 Troubleshooting [Chart] ...................5, 73
Exhaust Manifold ..........................36 Valve Assembly Inspection ...................16
Front Case Inspection .......................27 Valve Clearance Adjustment ................. .47
Front Case/Counterbalance Shaft and Oil Pan ..... 26 Voltage Adjustments - Generator ...........69, 70
Front Case/Counterbalance Shaft and Oil Pump .... 27 Wiring· Remote Panel .....................51
Fuel Pump ...............................38 Wiring Diagram ......................... .49
Gasdenser ..............................38 Wiring Schematic .........................50
Generator Field Testing .....................58 Wiring Schematic - Generator Internal ..........60
Generator Troubleshooting [Chart] ..........39, 73 Troubleshooting Charts
Governor Maintenance ..................... .45 Engine .................................5
Heat Exchanger .......................... .36 Generator .............................59
Ignition Timing ........................... .47 Engine/Generator ........................73
Limits and Standards ......................52 Wiring Schematics/Diagrams
Metric Conversion Data .....................75 AC Terminal Board .......................60
Metric Conversion [Chart] ...................76 Generator Internal .......................60
Oil Pan Assembly ..........................29 Engine ............................... .49
Oil Pressure - Low ......................... .4 Remote Panel ..........................51
Oil Pressure - Testing ....................... .4 Engine/Generator ........................60
Oil Pressure Pump Inspection/Assembly ......... 27
77
1028WM/DW6/2000

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SERVICE MANUAL

WESTERBEKE CORPORA TION· 150 JOHN HANCOCK ROAD

Engines & Generators

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,

This WARNING DECAL is provided by

IA WARNING: - . . " _1D/tII11lf_

Engines & Generators

Engines & Generators

Engines & Generators

CODES AND REGULATIONS

A detailed 40 page Marine Installation Manual covering gasoline and

Engines & Generators

PARTS IDENTIFICATION .........................................2 EXHAUST MANIFOLD/HEAT EXCHANGER .......... 36

Engines & Generators

GOVERNOR A\R \NTAKE

ENG\NE Oil F\LL

MAN\FOLD _ _-+__\\.-U~~ C\RCUlT BREAKER

OCGROUND FUELUFT PUMP

HEAT EXCHANGER fRONT

SERIAL NUMBER LOCATION~~ ~

Engines & Generators

TESTING OIL PRESSURE ENGINE COMPRESSION TEST

Engines & Generators

Problem Probable Cause VerificationJRemedy

SMOKY EXHAUST WHITISH, PURPLE OR BLUE SMOKE

BLACKISH OR DARK GRAY

EXCESSIVE OIL OIL LEAKAGE

OIL LEVEL RISING

CONNECTING ROD AND CONNECTING ROD BEARING

PISTON, PISTON PIN, AND PISTON RING

LOW COMPRESSION MAIN ENGINE TROUBLES

INSUFFICIENT INTAKE AIR

KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE

Engines & Generators

Sealants and Lubricants

Engines & Generators

A CAUTION: Make certain the fuel lines are closed

Engines & Generators

Engines & Generators

FUEL UFT PUMP & GASDENSER

Engines & Generators

12 CRANKSHAFT 13 CRANKSHAFT 10 FLANGE NUT

-----~L6 In [65 mm]

2. Remove the plug on the left surface of the cylinder block

Timing Belt Inspection

SPROCKET BOLT HARDENING

1. Replace the tensioner if the pulley binds, rattles or is noisy

Engines & Generators

-~ A-Z=i water pump; temporarily tighten the tensioner nut.

Crankshaft Bolt Installation

Oil Pump Sprocket Flange Nut Installation

~"d.~:t=~'=='--" TRIANGLE MARK .

Engines & Generators

A CAUTION: This operation is perfonned to give a

TENSIONER SET MARK

4. If the movable range of the teeth on the oil pump sprocket

Engines & Generators

NUMBERS INDICATE THE

CYLINDER HEAD BOLTS