4=stroke air=cooledgasoline engine

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 CONTENTS

A. General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Performance Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
G. Setting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
H. Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
I. Standard Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
J. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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 A. GENERAL SPECIFICATIONS
FA76D *Crankshaft:
*Air cooling: Heat treated ductile iron integrated with counter-
Large capacity, curved vane blower casting, integrated balance weights and camshaft drive gear. Induction
with flywheel. Air passes through deep fins to maintain hardened crankpin and main journals.
- optimum operating temperature of engine. *Main bearings:
*Ignition: Durable bush type, lead bronze sintered alloy plain
Magneto with waterproof molded ignition coil and bearings with steel back metal.
dustproof breaker point enclosure. *Valves:
Breaker system standard. (Electronic ignition system Forged 2 1-4N austenitic stainless steel exhaust valve.
available as optional specification.) Forged heat-resisting steel intake valve.
*Lubrication: Splash type. *Valve seats:
"Carburetor: Exhaust; Sintered alloy insert (Co-W-Ni-Cr-Mo) o n an
Pulse pump type; with idle mixture adjustment. iron base.
Float type; anti-erosion aluminum alloy, with idle mix- Intake; Sintered alloy insert (Cu-Mo) on an iron
ture adjustment and fuel shut off valve. base.
*Air cleaner: *Valve guides:
Semi-dry type, washable polyurethane element with Exhaust; .Sintered alloy insert (Cu-P-Sn) on an iron
nylon brush. base.
*Fuel tank: Intake; Directly borne by cylinder/crankcase. Die-
Sheet metal for pulse pump carburetor model. casted hypereutectic aluminum-silicon alloy,
Polyethylene for Float carburetor model. machined.
"Governor: *Valve tappets:
Mechanical fly-weight type, running in crankcase oil. Wear resisting stamp-forged steel, hardened and
*Governor control: ground.
Adjustable speed control. Wire joint and outer wire *Breather:
clamp are optional for remote speed control. Vacuum type, vented through air cleaner to prevent oil
*Cylinder and crankcase: spill.
One piece hypereutectic aluminum-silicon alloy die "Muffler:
casting with plateau honing. Sheet metal painted with heat-resisting paint, effective
*Piston: noise suppression. (Optional parts available.)
Hard-chrome plated aluminum alloy. *Starter:
*Piston rings: Recoil starter with safety cover as standard. (Optional
- Two compression rings including silicon carbide (on an
iron base) plated top ring. One oil control ring.
parts available.)
*Direction of rotation:
*Connecting rod: '~ounterclockwise,viewed from power take-off side.
I-beam cross section, heat treated aluminum alloy, *Finish:
with large bearings. Anti-rust, painted.
Direct Drive, Pulse Pump Carburetor Direct Drive, Float Carburetor
Bore and stroke 52 x 3 6 mm [2.05 x 1.42 in]
Piston displacement 76 cc [4.66 cu. in]
- Compression ratio 6.4 : 1
Maximum output 1.7 HP/4000 rpm [SAE J607al
Maximum torque 0.32 kgml3200 rpm [2.31 ft-lbs/3200 rpm]
Fuel consumption ratio 330 gr/HP, Hr [0.73 IbslHP, Hr]
Fuel tank capacity 1.1 5Q [I .22 Qt US] 1.7Q [1.8 Qt US]
Fuel Regular gasoline
Oil volume: crankcase max. 3 2 0 cc [0.678 Pt US]
Oil volume: crankcase min. 200 cc [0.42 Pt US]
Lubricating oil A.P.I. Grade: SC, SD, S E class
SAE #20 -Winter, SAE #30 - Summer
Oil fill and drain Dual (carb. side and opposite carb.)
Ignition timing Fixed 23" B.T.D.C
Spark plug 1 4 m m NGK BM-6A
Permissible inclination of
engine for continuous Angled forward (carb. side up) 20'
operation without any Angled backward (carb. side down) 20"
lubrication problem. Angled P.T.O. shaft (towards both) 20°
Idle speed set, no load 1 6 0 0 rpm (crankshaft)
Max. speed set, no load 4000 rpm (crankshaft)
Dry weight (S.T.D. set-up) 7.3 kg [16.1 Ibs]

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 FA130D
*Air cooling: balance weights and camshaft drive gear. Induction
Large capacity, curved vane blower casting, integrated hardened crankpin and main journals.
with flywheel. Air passes through deep fins to maintain *Main bearings:
optimum operating temperature of engine. P.T.O. side, ball bearing. Magneto side, lead bronze
*Ignition: sintered alloy plain bearing with steel back metal.
Magneto with waterproof molded ignition coil and *Valves:
dust-proof breaker point enclosure. Forged 21 -4N austenitic sizinless steel exhaust valve.
Breaker system standard. (Electronic ignition system Forged heat-resisting steel intake valve.
available as optional specification.) *Valve seats:
*Lubrication: Exhaust; Sintered alloy insert (Co-W-Ni-Cr-Mo) o n an
Splash type. iron base.
*Carburetor: Intake; Sintered alloy insert (Cu-Mo) on an iron
Pulse pump type, with idle mixture adjustment. base.
*Air cleaner: "Valve guides:
Semi-dry type, washable polyurethane element with Exhaust; Sintered alloy insert (Cu-P-Sn) o n an iron
nylon brush. base.
*Fuel tank: Intake; Directly borne by cylinder/crankcase. Die-
Sheet metal. casted hypereutectic aluminum-silicon alloy,
*Governor: machined.
Mechanical fly-weight ty,pe, running in crankcase oil. *Valve tappets:
"Governor control: Wear resisting stamp-forged steel, hardened and
Adjustable speed control. Remote speed control joint ground.
optional. *Breather:
*Cylinder and crankcase: Vacuum type, vented through air cleaner to prevent oil
One piece hypereutectic aluminum-silicon alloy die- spill.
casting with plateau-honing. "Muffler:
"Piston: Sheet metal painted with heat-resisting paint, effec-
Hard-chrome plated aluminum alloy. tive noise suppression. (Optional parts available.)
*Piston rings: "Starter:
Two compression rings including silicon carbide (on an Recoil starter with safety cover as standard. (Optional
iron base) plated top ring. One oil control ring. parts available)
*Connecting rod: *Direction of rotation:
I-beam cross section, heat treated aluminum alloy, Counterclockwise, viewed from power take-off side.
with large bearings. "Finish:
*Crankshaft: Anti-rust, painted.
Heat treated ductile iron integrated with counter

Direct Drive, Pulse Pump Carburetor Direct Drive, Float Carburetor

Bore and stroke 6 2 x 4 3 mm [2.44 x 1.69 in]
Piston displacement 129 cc [7.92 cu. in]
Compression ratio 6.4 : 1
Maximum output 3.1 HP/4000 rpm [SAE J607al
Maximum Torque 0.62 kgm/3000 rpm [4.48 ft-lbs/3000 rpm]
Fuel consumption ratio 3 10 gr/HP, Hr [0.68 Ibs/HP, Hr]
Fuel tank capacity 2.7Q [2.8 Qt US]
Fuel Regular gasoline
Oil volume: crankcase max. 500 cc [1.06 Pt US]
Oil volume: crankcase min. 3 0 0 cc [0.63 Pt US]
Lubricating oil A.P.I. Grade: SC. SD. SE class
SAE
- - #20 . . ., SAE #30 - Summer
, , - _ -Winter,

Oil fill and drain Dual (carb. side and opposite carb.)
Ignition timing Fixed 23" B.T.D.C.
Spark plug 1 4 m m , NGK BM-6A
Permissible inclination of A --1-2 c
Angled forward2 (carb.
arb. side up)
(-
20'
engine for continuous Angled backward (carb. side down) 20°
operation without any Angled P.T.O. shaftft (towards both) 20" -
lubrication problem.
Idle speed set, no load 1600 rpm (crankshaft)
Max. speed set, no load 4000 rpm (crankshaft)
Dry weight (S.T.D. set up) 10 kg [22 Ibs] 11.5 kg [25 lbs]

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 *Air cooling: balance weights and camshaft drive gear. Induction
Large capacity, curved vane blower casting, integrated hardened crankpin, main journals and output shaft.
with flywheel. Air passes through deep fins to maintain *Main bearings:
optimum correct operating temperature of engine. P.T.O. side, ball bearing. Magneto side, lead bronze
"Ignition: sintered alloy plain bearing with steel back metal.
- Magneto with waterproof molded ignition coil and *Valves:
dustproof breaker point enclosure. Forged 21-4N austenitic stainless steel exhaust valve.
Breaker system standard. (Electronic ignition system Forged heat-resisting steel intake valve.
available as optional specification.) "Valve seats:
*Lubrication: Exhaust; Sintered alloy insert (Co-W-Ni-Cr-Mo) on an
Splash type. iron base.
"Carburetor: Intake; Sintered alloy insert (Cu-Mo) on an iron
Pulse pump type, with idle mixture adjustment. base.
*Air cleaner: *Valve guides:
Semi-dry type, washable polyurethane element with Exhaust; Sintered alloy insert (Cu-P-Sn) on an iron
nylon brush. base.
*Fuel tank: Intake; Directly borne by cylinder/crankcase. Die-
Sheet metal. - casted hypereutectic aluminum-silicon alloy,
*Governor: machined.
Mechanical fly-weight type, running in crankcase oil. *Valve tappets:
*Governor control: Wear resisting stamp-forged steel, hardened and
Adjustable speed control. Remote speed control joint ground.
optional. "Breather:
"Cylinder and crank case: Vacuum type, vented through air cleaner t o prevent oil
One piece hypereutectic aluminum-silicon alloy die- spill.
casting with plateau honing. "Muffler:
*Piston: Sheet metal painted with heat-resisting paint, effective
Hard-chrome plated aluminum alloy. noise suppression. (Optional parts available.)
*Piston rings: *Starter:
Two compression rings including silicon carbide (on an Recoil starter with safety cover as standard. (Optional
iron base) plated t o p ring. One oil control ring. parts available.)
*Connecting rod: *Direction of rotation:
I-beam cross section, heat treated aluminum alloy, Counterclockwise, viewed from power take-off side.
with large bearings. *Finish:
"Crankshaft: ,Anti-rust, painted.
Heat treated ductile iron integrated with counter-

Bore and stroke

Direct Drive, Pulse Pump Carburetor I Direct Drive, Float Carburetor
72 x 51 mm [2.83 x 2.01 in]
Piston displacement 207 cc 112.67 cu. in]
Compression ratio 6.4 : 1
Maximum output 5.2 W / 4 0 0 0 rpm [SAE J607a1
1 Maximum Torque 1.09 kgm/2600 rpm [7.88 ft-lbs/2600 rpm] -~- - - -

Fuel consumption ratio 3 1 0 gr/HP, Hr [0.68 Ibs/HP, Hr]

Fuel tank capacity 2.7Q [2.8 Qt US]
Fuel Regular gasoline
Oil volume: crankcase max. 6 0 0 cc [1.27 Pt US]
Oil volume: crankcase min. 3 50 cc [0.74 Pt US]
Lubricating oil A.P.I. Grade: SC, SD, S E class
SAE #20 - Winter, SAE #30 - Summer
Oil fill and drain Dual (carb. side and opposite carb.)
I Ignition timing I Fixed 23" B.T.D.C. I
1 Spark plug 1 4 m m NGK BM - 6A
Permissible inclination of
engine for continuous Angled forward (carb. side up) 20'
operation without any Angled backward (carb. side down) 20"
L Angled P.T.O. shaft (towards both) 20"
lubrication ~ r o b l e n i .
Idle speed set, no load 1600 rpm (crankshaft)
Max. speed set, no load 4000 rpm (crankshaft)
Dry weight (S.T.D. set up) 1 3 kg [28.7 Ibs] 3

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 B. PERFORMANCE CURVES

gr /Hp Hr
IlbriHp Hrl

R P.M. A T POWER TAKE-OFF SHAFT

R.P M. AT POWER TAKE-OFF SHAFT

Kg-m
Horsepower is measured in accordance with the appropriate
Ifl-lbr) SAE test procedures.
1 1
17.961 Power curves are corrected t o standard conditions of
atmospheric pressure at sea level and temperature of 6 0 " ~
4 and are developed from laboratory test engines equipped
16.511 with standard air cleaner and muffler.
a.
I The Maximum B.H.P. curve represents laboratory test
C engines equipped t o operate at full performance.
+
P
3 Production engines will develop 95% of the Maximum
3 B.H.P. when tested after run-in t o reduce friction and after
clean out of t h e combustion chamber, with valves, carbure-
griHP Hr
tor and ignition system adjusted t o laboratory standards.
1lbrlHP.Hr)
400
Engine power will decrease 3 112% for each 1,00Oft,
( 0 881 above sea level and 1% for each 10°F above standard tem-
2
perature of 60°F. For practical operation B.H.P. load and
10.661 speed should be within the limits shown b y the recom-
mended Maximum B.H.P. Complete details of installations
requiring operation at other than recommended speeds
2000 3000 4000
R.P.M. A T POWER TAKE.OFF SHAFT should be referred t o factory for approval.

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 C. RIMENSlONAL SPECIFICATIONS

Pulse pump model

Float model

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 Pulse pump model

Float model

425 (1694)
t-

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 Pulse pump model

Float model

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 R. CONSTRUCTION
Main Parts

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 Carburetor Construction

-* Pulse Pump Type

(FA76, FA130,FA210) Pulse pump model

/pilot outlet \ slowair-jet

Inlet check valve Outlet check valve Main nozzle

-
*---
Fuel
Air

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 Float Type
(FA76, FA210)

Throttle valve Pilot outlet

Fuel cock Air vent (Gate-type outer vent)

Fioat

-
*---
Fuel
Air

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 Float Type
(FA130)

Pilot outlet

1 Throttle valve

Ir\
\ Choke valve

Fuel cock d-7

-
*---
Fuel
Air

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 E. DISASSEMBLY
1. Draining engine oil 6. Governor arm
Remove drain-plug and drain off engine oil. 6-1. Loosen the governor arm nut.
In general, drain off the oil after the engine has 6-2. Take the governor arm off the governor shaft. .
been stopped and the oil is still warm. and then remove the governor link, link spring
There are two drain plugs, one on the carburetor and governor spring from the governor arm.
side and the other one on the opposite side, either 6-3. Remove the other end of the governor link and
of which can be used for draining the oil. link spring from the carburetor, and remove the
Check for dirt and foreign matter in the oil. If any other end of the governor spring from the speed
foreign matter is found, inspect the following parts control lever.
1 0 rnm spanner.
during disassembly for any wear or damage:
piston. piston rings, cylinder, con-rod, bearings,
crank-pin, crankshaft and camshaft journals.
-EmF_n&-
rr-W -i-

10 m m spanner.
2. Oil-gauge
These is an oil-gauge located o n the carburetor side
al:d on the opposite side. Remove both of them.

3. Output-shaft pulley
If the pulley is o n the output shaft, remove it at this
point
7. Carburetor
4. Air-cleaner e l s e pump model) Remove the carburetor nuts and
R-r,love the air-cleaner from the carburetor. take off the carburetor, two gaskets and insulator.
m Inspect the gasket for any damage, and if neces- Inspect the gaskets for any damage, and if neces-
sary replace it with a new one when reassembling. sary replace them with new ones when reas-
sembling.
5. i;i;el-tank 10 m m spanner.
!,'?rrlse pump model) Remove the fuel-tank from the
buretor and crankcase.
* l n s ~ e c tthe gasket for any damage, and if neces-
5ar.y replace it with a new one when reassembling.

FA76: Screwdriver. 10 rnm spanner.

FA130, FA210: Screwdriver. 13 mm spanner.

(Float model) Remove the inlet pipe from the

cylinder.

8. Speed control plate assembly and breather

cover
Remove the control plate assembly and breather
cover from the crankcase.
(Float model) After removing the center clamp for If the gasket is damaged, replace it with a new one
the fuel pipe except FA76, pull the fuel pipe off the during reassembly.
carburetor and insert a 6 mm dia. bolt in the fuel pipe 10 rnm box spanner.
t o prevent fuel flowing out. Then remove the four
bolts holding the file1 tank in place and remove the
fue! tank from the engine. Also remove the lower
tank bracket from the crankcase.
10 mm spanner. - 1 0 m m box spanner.

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 9. Fan housing 1 1 . Cylinder head and cylinder head cover
Remove the fan housing from the crankcase and 11-1. Take out the sparkplug.
- cylinder head. (It is not necessary to remove the Check the sparkplug gap, and look for any
recoil starter from the fan housing.) burning or carbon build-up on the elec-
For this operation, disconnect the wire going to trodes, and replace the plug with a new one
the stop-switch. if necessary. or clean it and adjust it before
10 mm spanner. re-using it.
11-2. Evenly loosen the cylinder head bolts in the
same order as specified in the assembly instruc-
tion, and remove the cylinder head and cylinder
head cover. Follow the order shown in the
photo.

FA76: 10 mm spanner.
FA130, FA21 0: 13 m,,i spanner.
- sq@€f

10. Flywheel
10-1. Loosen the nut by turning it counter-clockwise
and take it off.
Wedge a'piece of wood against the vanes of
the flywheel to stop it from turning.
FA76: 17 mm box spanner (plug-wrench).
FA130, FA210: 19 mm box spanner (plug-wrench).

Inspect for combustion gas 1e:tk:ipe aild m y

10-2. Use a pulley puller to remove the flywheel. related gasket damage. if there is r.ny sip., of
1 10-3. Pull the cap off the sparkplug. such leakage, take care when reassernb!!in:7, to
10-4. Take off the contact breaker cover and remove tighten the bolts evenly to rhc speiified
the ignition coil. the contact breaker and the torque. Replace the gaskc; if it is dainaged.
condenser. Inspect the combustion chamber for carbon
Take care not t o damage the wires. build-up, and remove any such build-up
Pulley puller prior to reassembly.

12. Muffler
Loosen the nuts and reniove the muffler

- I 8 mm Spanner FA76: 10 rnm spanner

FA130, FA210: 13 mm spanner
._
L,
-;
1

;< -
,J: -..- . 7
.-7-

- 9"
E-9 Screwdriver. -- -

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 13. Valves Take care not to damage the oil seal. Check
13-1. Use screwdrivers to remove the retainers. whether this oil seal has been damaged
Screwdriver. during crankcase removal, and if so replace it
with a new one during reassembly.
Check the governor assembly in the crank-
case cover for any wear or malfunction.
- If the governor gear or governor weight
show any sign of damage, remove the
governor gear assembly from the cover,

-
take out the pin and remove the weight
from the gear. Replace any damaged parts
for reassembly. To remove the governor
gear, grip the gear section firmly and pull
13-2. Remove the valves from the cylinder. it off straight along its shaft.
Screwdriver.

Check that both valves are seating properly.

If necessary, reface the valve seats.
Inspect the valves for any damage, and - Remove the governor sleeve if it is worn
replace any valve that is damaged. Also and replace it for reassembly. Only the
check the stems carefully. sleeve needs to be removed. The photo
Remove any carbon build-up on the valves. shows the assembly after removal.
Remove it by pressing the tip of a -
screwdriver against the arrowed part.
14. Crankcase cover
14-1. Evenly loosen the crankcase cover bolts In the
same order as for assembly, and take out all the
bolts. Loosen the bolts in the order shown in
the photo.
10 m m b o x spanner.

- Do not remove the governor gear except

when necessary. If it is removed even
once, replace it with a new one for
reassembly.
14-2. Use a wooden (or plastic) hammer to gently tap
the crankcase cover loose, and remove it from Check for wear to the governor tip. If it is
the crankcase. Do not try to prise it off by worn, replace with a new one when reas-
force. se~nbling.
Wooden (or plastic) hammer.

I
[/bovernor tip / t I
E-21 4 i

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 15. Camshaft, tappet and governor tip Evenly loosen the t w bolts.
15-1. Remove the camshaft from the crankcase Remove the con-rod cap, splasher and con-
rod lock together

Inspect the cams and journals for any wear,

and replace camshaft if necessary when 17. Crankshaft
reassembling. Using a. wooden (or plastic) hammer to gently tap the
(Refer to Settings Table) end of the crankshaft on the magneto side, remove
Inspect the camshaft bearings for wear. the crankshaft.
(Refer to Settings Table)
15-2. Remove the tappets from the crankcase.

1- -
- A , 3 *
1 Wooden (plastic) hammer.

E-23
After removing the tappets, make sure not
- to mix up the intake and exhaust sides, so
they can be refitted in their original posi-
tions. Carefully ease the con-rod big-end free of the
Check for any damage to tappet stems and crankshaft by tapping it very carefully with the
faces, and replace if necessary when reas- wooden (or plastic) hammer.
sembling. Take care not to damage the oil seal.
15-3. Withdraw the snap-pin and remove the governor With pump shaft models, take care not to lose a
tip. shim o n the side of the crank gear.
Thin nosed plier.

18. Piston (with con-rod)

Withdraw the piston (with con-rod) from the cylinder
by gently tapping the piston crown with a wooden
(or plastic) hammer.
Wooden (plastic) hammer.

16. Con-rod cap (big-end disassembly)

16-1. Bend down the con-rod lock.
16-2. Loosen and remove the con-rod bolts.

Take care not to damage the cylinder.

Check the degree of cylinder wear. (Refer to the
Settings Table for wear limits.)
Align the con-rod cap with the con-rod big-end
FA76. Hammer, Screwdr~ver and check the big-end bearing for damage; that is,

h8.
L

8 mm box spanner ,
look for any scoring on the crankpin. If there is
FA130, F A 2 1 0 Hammer.
Screwdrver
any scoring, a new con-rod and crankshaft should
1 0 mm box spanner f 1 be used for reassembly.
15

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 IF. ASSEMBLY
Crankcase cover
1. Crankshaft bearing (when bearing is replaces) F - -

1-1. lnsert the plain bearing into the crankcase.

L
Bear~ngd r ~ v e r .
v r
F .
,
Oil seal

rr

FA76
Crankcase cover side (PTO side)
1-3. Fit the crankcase and crankcase cover oil seals.
The oil seals should be facing the way shown
Oil seal
. i n the diagrams. The oil seal should be
Crankcase
pressed right in, as shown.

Direction of bearing
instauation
Bearing inset
lmrn
0
Ak
pa II I
2. Governor gear assembly (when this has been
disassembled)
2-1.Fit the governor weight onto the governor gear
with the pin.

Plain bearing ,

Crankcase side
u (Magneto side)

Align the oil groove with the hole in the

plain bearing.
The direction of the plain bearing groove
must be as shown in the photo. F-4 '2
1 -
The bearing should be pressed in 1 m m , If a governor gear has been removed, always
as shown in the dia,oram. use a new one for reassembly.
Push the pins right in so it is against the
1-2. Insert the ball bearing into the crankcase cover. shaped projection (photo, part A) on the
Insert the plain bearing into the crankcase governor gear.

-
cover. 2-2. Fit the governor sleeve. Use a screwdriver to
press the two tongued parts of the sleeve into
Align the oil groove with the hole in the the groove of the governor gear.
plain bearing. Screwdr~ver.
The direction of the plain bearing groove
must be as shown in the photo. L
The bearing should be pressed in 1 mm, L
as shown in the diagram.

2-3.Put the thrust washer on the governor gear

shaft, and then press the governor assembly
well on to the shaft.
Ball

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 3. Governor tip -A-
Put the washer shown in the diagram on the governor Gasket surface ---B
- tip.
Insert the governor tip into the crankcase from the
inside, and clip the snap-pin firmly.
Shim thickness

Snap pin
-
cr
-

4
, .

Shims: t=1.0, t=1.2, t=1.4, t=1.6

. Use one of these four shims.
F-7
5. Piston and con-rod
5-1. Fit the piston rings (the oil ring, second ring
and top ring) in the correct grooves in the
piston in accordance with the following pro-
cedure.

T A Top ring 7/]

=Second ring=
%- Oil ring
Ring mark"RU
4. Crankshaft
~- Insert the crankshaft into the crankcase Take care n o t to put a ring in the i-
goove.
Have the side of each ring marked
facing upwards.
5-2. At this point, fit the snap-ring on just one :i:iz
of the piston.
5-3. Position the con-rod small-end on the pisto11. so
that the "M" mark on the piston and the
"Made In Japan" mark o n the con-rod are on
the same side. Then insert the piston pin and
put the snap-ring on the other end of the pin.
First coat the crankshaft journals, bearings and oil
seal sections with fresh oil.

Take care not t o damage the oil seals.

(Pump shaft model (Shaft Code No. 06 & 07))
No shim adjustment is required on model FA76 in
which both ends of crankshaft are supported by
plain bearings.
RepIace a shim on the end of the crank gear.
However, if the crankshaft o r the crankcase has
been replaced by a new one, measure the axial
play and select the type of shim accordingly. Put a coating of fresh oil on the con-rod
Axial play is not t o exceed 0.3 mm. small-end and bearing before inserting the
Use one of the shims (which are 1.O, 1.2, 1.4 or piston pin.
1.6 mm in thickness) 5-4. Insert the piston/con-rod assembly into the
T o determine shim thickness: Measure A and B, cylinder, so that the "Made In Japan" mark on
then the required thickness "t" is that which the con-rod is on the magneto side of the
- provides engine.
O<A-B-t 5 0 . 3 Before inserting the assembly, arrange the
openings of the piston rings to the positions
shown in the diagram.
17

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 5-7. Bend the con-rod lock washer up against the
bolt heads.
It is very important to make sure this is done -
properly, otherwise the engine may be
irreparably damaged.

T o p ring gap- -. . Top and oil ring gap

,

6. Tappets and camshaft

6-1. Insert the tappets into the tappet guide holes
from the inside of the crankcase. Tappets taken
Give a liberal coating of fresh oil to the from the intake side should be replaced in the
con-rod big end bearing, the outside of the intake side, and the same goes for the exhaust
piston and the inner wall of the cylinder side.
before inserting the assembly into the
cylinder.
5-5. Align the con-rod cap, together with the con-
rod lock washer and splasher, with the con-rod
already 1ocau.d o n the crankpin.
Then insert and finger-tighten the two con-rod
bolts.

First give the tappets a fresh coating of oil.

I t is easier t o have the crankcase lying on
one side until the camshaft has been in-
serted.
6-2. Insert the camshaft into the crankcase, with the
mark ("- ") on the crank gear lined u p with the
In principle a new con-rod lock washer mark on the cam gear.
should be used each time the unit is reas-
sembled.
Make sure the splasher is the right way
around.
5-6. Tighten the con-rod bolts evenly, a little at a
time. FA76 : 8mm box spanner, Torque wrench
FA130 FA210 : 10mm box spanner, Torque wrench

Crank gear Cam gear

Use a torque wrench to tighten finally.

Specified torque Before fitting the camshaft, give a fresh
FA76: 0.7 kg-m coating of oil to the journals, cams and the
FA130, FA210: 1.2 kg-m bearings.
18

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 7. Crankcase cover Bring the piston t o t.d.c. on the compression
In the case of the FA76 float carburetor type, the stroke (that is, with intake and exhaust
- crankcase cover should be fastened together with fuel valves closed), and measure the tappet clear-
pipe clamp at the position 3 shown below. ances to make sure they are within the
Carefully position the gasket on the mounting surface following standard ranges.
of the crankcase. And fit the cover onto the
crankcase with the governor gear in the cover FP 76 FA130, FA210
positioned so as to mesh with the cam gear and then Intake (Cold) 0.10-C 20 0.12-0.18 mm
tighten up the bolts. Exhaust (Cold) 0.10-0 !O 0.1W0.34 m m
10 mm b o x spanner. Torque wrench.
10 mm b o x spanner. Torque wrench. 9. Muffler
Put the muffer onto the e ~ h :1 2 t port with the gasket
and tighten the flange nuts ev.-Ay.

-
FA76: 1 0 mm spanner.
FA130, FA210: 13 mm spanner.
\ m u

- . ye-

Replace the gasket if it is damaged.

It is important t o tighten the bolts evenly and a
little at a time (and in the order shown in the
photo).
Tightening torque: 0.6 kg-m.

8. Valves (checking tappet clearances) 10. Breather cover and control panel assembly
8-1. Insert the valve springs and retainers in the 10-1. Fit the breather cover;'with its gasket, and t3;.
spring chamber. control panel assernbly.
10 mm box wrench. 10 mm b o x wrench.

8-2. Insert the valves in the valve guides.

Before insertion coat the valve stems with fresh F-21 F-22
oil.
8-3. Lever each valve spring up with a screwdriver 10-2. Plug the breather tube into the cover.
and slot the retainer into the valve stem groove.
Screwdr.ivers. 1 1 . Cylinder head
Thickness gauge.
11-1. First arrange the gasket correctly, and put the
cylinder head in position. Then place the
cylinder cover on the cylinder head.

FA76: 10 mm b o x wrench. Torque wrench

FA1 30, FA21 0: 13 mm b o x wrench. Torque wrench.

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 (Float model) Then po lion the upper stay of the
fuel tank on the top, and hand-tighten the head bolts.
Next, carefully tighten the bolts evenly a little at a
time with a box wrench.
Finally, tighten with a torque wrench to the
specified torque.
Specified torque
FA76 0.7 kg-m
FA1 30, FA2 1I.. 2 kg-rn

12-3. Fit the condenser.

In tlie case of the FA76, position of the
condenser is different from other models, as
shown above.

12. Flywheel (adjusting the ignition timing)

Ignition System

12-4. Locate the flywheel key in the crankshaft

keyway.
The flywheel will be fitted and removed
several times after this, but the key should
Stop switch remain in the keyway.
- -
12-5. Positio~i the flywlieel on the crankshaft and -
finger-tighten tlie flywheel nut.

12-6. Move the ignition coil core slightly to adjust the

gap between core and flywheel rim t o 0.5 mm,
using a thickness gauge t o measure. Then
Breaker cam lubricatina felt
tighten up the ignition coil.
Thickness gauge.

12-1. Tighten tlie ignition coil just enough so it can

still be moved slightly.
12-2. Position the contact breaker and fasten its plate
screw just enough to put a light tension on the
plate.
20

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 12-7. Slowly turn the flywheel clockwise until the Use a test-mt ier t o confirm the position at
edge of the flywheel rim is in line with the edge which the points are about t o open.
of the coil core. If the timing is off, repeat steps 12-7
through 12-10.
12-12. Remove the flywheel again, then fit oh the
points cover.

The ignition timing adjustment is made so as

--
to cause ignition at this piston position F -32
I
(crank angle).
Take care the Ire 1s not caught 01 does n o t
12-8. Maintaining the alignment of flywheel and core
stick up.
obtained in 12-7, remove the.flywhee1 nut and
12-13. Fit the flywheel, starter pulley (with screen)
pull the flywheel off. and washer, in that order, and tighten up the
Take care not to rotate the flywheel when
flywheel nut. I
you remove it.
Specified torquc
12-9. Move the contact breaker plate a fraction at at
time, until you confirm the closed points are FA76: 3
FA130, FA210: 6
-- 3.5 kg-m
6.5 kg-m
just about to start to open. Then tighten up the
contact breaker plate screw. Ignition will take Make sure that . h e flywheel key is properly
place at this instant. located in the c- .shaft keyway.
Use a tester to confirm the position at which Use a suitable piece of wood to brace against
the points are about t o open. the flywheel vaces t o stop the flywheel f r o n
Screwdriver. Tester. turning when tightening the nut.
FA76: 17 rnrn b o x spanner. Torque wre..:.:'~.
FA130, FA210: 19 mrn b o x spanner. Torque wrenc!.. .

12-10. Turn the crankshaft clockwise and use a

thickness gauge to measure the widest gap the
points open to. This gap should be 0.3 mm - The rotating screen (optimal) is included in t!le
0.5 mm. photo.
Thickness gauge. 12-14. Screw the sparkplug into the cylinder head,
and push the sparkplug cap (with cable) down
onto the top of the plug.
Position the plug cable along the cylinder
head cover guide.
13. Carburetor and governor (governor adjust-
ment)
13-1. Hook one end of the governor spring o n the
speed control lever and the other end on the
governor arm.

12-11. Fit the flywheel in position again, and finger-

tighten the flywheel nut as before. Then turn
the flywheel slowly clockwise and check that
- the contact breaker points are just starting to
open at that instant when the edge of the
flywheel rim is in line with the edge of the
ignition coil core. (Refer t o F-29)

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 Refer to the photo gor which way t o
position '' zovernor spring.
13-2. Lightly fix ,governor arm o n the governor
tip shaft.

I 10 rnrn spanner. 13-7. (Float model)

For FA76, FA210: Hold gasket, carburetor,
gasket and the air cleaner element case together
and fix them t o the carburetor with two thru-
bolts.
For FA130: Use the governor link and link
spring to link the governor arm t o the car-
buretor (throttle valve).
- Do not carry out steps 13-7 and 13-8 in
reverse order.
13-8. Float model) Put a gasket on the inlet pipe
13-3. (Pulse pump mc d) Position a gasket. insulator flange and fix the carburetor onto the inlet
pipe.
and another gasket, in that order, o n the inlet
port of the cylinder. Next, put a gasket on the carburetor, and fix air
Replace any gasket or insulator that has cleaner element case in place.
been damaged. Tightening the flange nuts evenly and a little
13-4. (Float model) For FA76lFA130: Put a gasket, at a time is especially important here. If the
insulator, and another gasket o n the cylinder nuts are unevenly tightened, it can cause
intake port and fit the inlet pipe to the port. starting difficulties, power drop and flange
For FA130: Put a gasket o n the cylinder intake damage. -
port and fit the inlet pipe t o the port. 13-9. Pull u p the speed control lever t o fully open the
13-5. (Pulse pump model) Use the governor link and throttle valve.
link spring to link the governor arm to the
carburetor (throttle valve).

13-10. Poke a rod of the right size into the governor

tip shaft hole and turn the shaft fully clock-
wise, and with it in this position tightly fix the
Do not carry out steps 13-5 and 13-6 in governor arm onto the governor tip shaft.
reverse order.
13-6. (Pulse pump model) Fix the carburetor onto 10 mm spanner.
the cylinder.

13-9 and 13-10 form the governor adjustment.

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 14. Fan housing (with recoil starter) Replace any d ,naged gasket.
14-1 .Fix the fan housing on the cylinder (crankcase). (Float model) Screw -
fuel tank lower stay to
the crankcase. Fit + fuel tank between the
10 mm spanner. upper and lower tank tays. Tighten the four
' r m fixing bolts with wasf evenly, then connect
- the fuel pipe to the car reto tor.
I

16. Air cleaner

16-1 . (Foam type)
Fit the air cleaner onto the'carburetor.
Replace the gasket if it is damaged.
If the element is dirty:
- Wash it in kerosene, wring it out and dry
Make sure the high tension cable is not it.
caught anywhere in the fan housing. - Soak it in I oil and wring out any
Also make sure there is a grommet on the excess.
wire outlet. - Replace the el, :nt in the case, with the
14-2. Connect the wire going to the stop switch. side marked "IP 3E" to the back.
Element c.

Plate
7

15. Fuel tank

15-1. (Pulse pump model) Position the gasket on the
fuel tank and screw the fuel tank to the
carburetor. Also screw the fuel tank stay to the Element
crankcase.
F A 7 6 : Screwdr~ver.10 mrn spanner.
FA130, FA21 0: Screwdr~ver.1 3 rnrn spanner.

VK5
4

-
I:. Q-

- Check when fitting the case cover that

Evenly tighten the three screws that fasten the edge of the element is not twisted.
.the fuel tank to the carburetor, and at the (Dual element type)
same time tighten the fuel tank stay screw. Fit the air cleaner on to the carburetor.
Replace the gasket if it is damaged.
If the elements are dirty:
- Remove foam element by sliding it over
paper element.
- Wash the elements in liquid detergent and
water.
Rinse until water remains clear. and dry
them.
- Soak the foam element in engine oil, and
squeeze it to remove excessive oil. Don't
soak the paper element in oil.
23

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 Note: Foam elements should be cleaned (Pulse pump model) - Pilot air screw initial
every 2"ours and paper elements setting: FA130, FA210: Unscrew 1% turns
every 100 hours. FA76: Unscrew 1 turn -
Clean them more often if used under (Float model) - Pilot air screw initial setting:
dusty conditions. FA130, FA210: Unscrew 1% turns
FA76: Unscrew 1% turns
Element case
/ Paper element 21-2. Next, unscrew the idling limiter to the point
where it does not reduce engine speed any
more, then place the speed control lever at the
lower end.
Plus pump type
Pilot air screw

16-2. Insert the free end of the breather tube into the
hole in the back of the air cleaner.

Float type
(FA76, FA210)
Throttle stop screw
Pilot air screw

17. Replace the drain plugs.

1.8. Fill with oil up to the specified level.
19. Replace the oil gauges.
20. Fill the fuel tank.
Refer to the Instruction Manual for details concer-
ning 18 and 20. These steps are required for the
following carburetor adjustment, engine speed regula- Float type
tion and trial operation. (FA130)
Pilot air screw Throttle stop screw
21. Carburetor adjustment (idling adjustment)
The carburetor has more effect on engine perform-
ance than any other single unit, and it has been
completely adjusted before leaving the factory. It
should therefore not be dismantled or readjusted by
non-expert users. However, when the carburetor has
been disassembled and reassembled in the dealer's
service shop, one readjustment is necessary. That is
the adjustment of the slow channel mixture (air-fuel
ratio) when the engine is idling. If this adjustment is
incorrect it can cause irregular starting, erratic idling,
engine stoppages and increased fuel consumption.
21-1. To obtain an initial setting, first screw the pilot
airscrew right in, then unscrew it by the speci-
fied amount. 21-3. Start the engine and let it warm up thoroughly. ,
- The soft pilot airscrew taper-section is easily (Float model) For this screw the fuel cock
damaged, so make sure it is only lightly home, then unscrew it 1'A. turns to turn the fuel
screwed in, not tightly. supply on.
24

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 21-4. Gradually unscrew the throttle stop screw until 22- 1. CARBURETOR InLE
the engine speed drops almost to the point of Hold throttle valvefin closed position and adjust
-. stopping. throttle stop screw to 1500 r.p.m.
21-5. Then turn the pilot air screw to bring the engine GOVERNED IDLE
speed up just a fraction; the engine speed will Release the throttle valve. Adjust idling limiter
come up gradually and then suddenly drop. to 1600 r.p.m.
Determine the point where the engine speed is 22-2. MAXIMUM SPEED
highest, and leave the pilot air screw at that Adjust maximum speed limiter to 4000 r.p.m.
setting for the moment.
21-6. Gradually unscrew the throttle stop screw to Idling limiter
reduce the engine speed until it is barely erttnri,,,,,,,,,...
turning over.
21-7. Screw the pilot air screw either way to see if
doing this raises the engine speed at all. If the
engine speed increases even a fraction, repeat
steps 21-4 and 21-5.
When turning the pilot air screw either way no
longer increases, the engine speed, carburetor
adjustment is finished. The pilot air screw open-
ing at this point is its final setting, and will be
I
within t% turns out from the initial setting.

22. Engine speed settings (no-load) It is important to first screw in the speed
The engine has specific maximum and idling speed limiter enough to bring the engine speed well
settings. These settings have been completed in the below the specified maximum, then gradud-
factory. However, the following readjustments are ly unscrew it to slowly bring the speed up to
necessary when the engine has been disassembled and the specified level.
reassembled in the dealer's service shop. Do not let the engine speed exceed the
specified level during this adjustment, evev
for an instant.

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 G. SETTING TABLE
1 Ignition timing ;:
Contact breaker gap (Max.)
23" B.T.D.C.
-
0.3 0.5 rnrn
-
Valve timing
Intake
Open 50" B.T.D.C. 1 48" B.T.D.C. 1 40" B.T.D.C.
At standard Closed 80" A.B.D.C. 1 120" A.B.D.C. 1 117" A.B.D.C.
tappet clearance
when cold (*) Exhaust
Open 77" B.B.D.C. 1 97" B.B.D.C. 1 80" B.B.D.C.
Closed 37' A.T.D.C. 1 57" A.T.D.C. 1 40" A T n r
Intake 0.10 - 0.20 mm 0.12-0.18 mm
Tappet clearances
Exhaust 0.10 - 0.30 mm -
0.10 0.34 mm
Sparkplug gap -
0.6 0.7 mm
Max. oil capacity 3 2 0 cc 500 cc 600 cc
Lubricants
Min. oil capacity 200 cc 300 cc 350 cc
Pulse pump Pilot air screw
model initial setting Unscrew 1 turn Unscrew 1 ?4 turns

Carburetor Fuel cock

opening Unscrew 1!h turns
Float model
Pilot air screw
initial setting Unscrew 1j/4 turns Unscrew 1?4 turns
Carburetor 1500 rpm - 1500 rpm
Engine speed Idling
(no-load) Governed 1600 rpm 1600 rpm 1600 rpm
Max. 4000 rpm
B.T.D.C. : Before Top Dead Center
A.B.D.C. : After Bottom Dead Center
B.B.D.C. : Before Bottom Dead Center
A.T.D.C. : After Top Dead Center

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 H. TORQUE SETTINGS
Item FA76 1. '3 FAG0
Cylinder head bolts 0.7 2 .O 2 .O
Con-rod bolts 0.7 I .? 1.2
Flywheel nut 3.5 -
6.0 6.5 -
6.0 6.5
Drain plug 1.4 1.4 1.4
M8P1.25 1.5 1.5 1.5
General nuts and bolts M6P1.0 0.6 0.6 0.6
M5P0.8 0.35 0.35 0.35

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 Downloaded from www.Manualslib.com manuals search engine
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 If the engine malfunctions, it is first necessary t o check if This section describes typical troubleshooting procedures.
the way the engine is being used is correct. If the engine Do not unnecessarily disaserr'de the carburetor, magneto
malfunctions even if it is being used correctly, it is or engine unless it has been found to be the cause of the
important t o systematically carry out troubleshooting malfunction.
starting with easy items.

Low Power Output

Is
Is the engine over-
heated?
• Oil level t o o low or high

Overload
dust, grass, etc.
- Reduce or top up

Cooling system clogged with - Clean

Reduce load

Carbon deposit in combus- - Clean

tion chamber

Wrong timing Adjust

liormal?
- Replace
Faulty ignition coil - Replace
Faulty high tension cord - Replace
Malfunction of contact - Disassemble and clean or replace
breaker arm
Demagnetized flywheel - Replace

Clean

and muffler

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 Starting Difficulties

Remove spark plug. fit Replace

the plug cap and turn

ing the starter with the

plug touching the en-
gine block and check t o
see if sparks are
produced.

sion cord and the

er~gineblock when t h e
plug cap is removed?

Faulty ignitiontiming Adjust

-c Faulty condenser - Replace

Faulty high tension - Replace

condenser is replaced cord
Mulfunction of con- - Disassemble and clean or
tact breaker arm replace
Demagnetized fly- - Replace
wheel
t
Is conlpression suffi-
cient? ber of times and then
into fuel pipe or filter
and check electrodes.

Remove the plug and pull the

'starter

Worn p Replace i
rings
Piston rings stuck - Clean or replace
Worn cylinder bore - Rebore or replace
Loose cylinder head - Tighten
bolts
Faulty contact of - Relap
valve seat
Wrong valve clearance - Adjust valve clearance
Wrong valve timing - Adjust
Broken valve spring - Replace
Stuck valve - Clean valve and guide

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 Engine Malfunctions at High Speed

LYES
Does engine speed vary don- Clean
siderably when load is
applied? (Pulse pump model)

fuel filter or fuel pipe

Engine Malfunctions at Low Speed
Faulty plug insulation - Replace
plug cap and turn the crank- * Dirty electrodes - Clean
Contaminated o r pitted - Clean, lap or replace
with the plug touching the breaker points
engine block and check t o see Wrong ignition timing . - Adjust
if strong sparks produced. Damaged condenser - Replace

Is smoke coming out 'of the YES Overrich fuel in slow system Turn off pilot air jet by a minor extent
muffler?

Clogged carburetor Disassemble and clean

valve by hand. Does the speed
drop or does the engine stall

Is air sucked in thro~ighcar- YES- e Loose flange nuts -Retighten

buretor flange? Damaged gasket - Replace

Are valve clearances correct? NO- 1 Compression loss

Wrong valve timing
*dust valve clearances

Is alignment of timing gear ---NO Correct alignment of timing gear marks

marks correct?

Engine Hunts

fuel pipe or fuel filter

-- with dust
Problem in fuel system (lack L* Disassembly carburetor and clean
of fuel) carburetor clogged
Pilot air screw t o o far in Adjust

- I Wrong governor setting Adjust

Faulty governor spring Replace
Problem in governor system. * Worn governor fork and
governor weight

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 Excessive Fuel Consumption
P

YES--+ Fuel level in carburetor float - Adjust

chamber too high
Ignition timing retarded - Adjust
Idling too fast - Adjust
Incomplete opening of choke - Open choke

. valve
Pilot air screw too far out - Adjust

O Worn piston/piston rings Replace

Stuck piston Clean or replace
Worn cylinder bore Rebore or replace
Loose cylinder head Tighten
Faulty valve seat contact Lap
Wrong valve clearance Adjust valve clearance
Wrong valve timing Adjust
Broken valve spring Replace
Stuck valve Clean valve and guide

Excessive Oil Consumption

~ 2 0 m p r e s s i o nsufficient? I YES- Plugged oil ring groove

Oil level too high
Clean
Adjust
Faulty valve seat contact
Worn valve stems and valve
guides
Oil leakage along governor
shaft
Oil leakage from oil seal
Oil leakage from side base
mounting surface
Oil leakage from drain plug Retighten or replace gasket

Replace
Stuck piston rings Clean or replace
Worn cylinder bore Rebore or replace

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 KAWASAKI HEAVY INDUSTRIES, LTD.
ENGINE DIVISION

PIN 99924-2002 840201 Printed in Japan

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