EX40 EFI Engine

Service, Repair, and

Rebuild Manual

Manual Number 105062943

Edition Code 0114A00000
 CONTENTS

Section Title Page

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. GENERAL DESCRIPTION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . . 2
3. DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1 PREPARATIONS AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3 DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-4 REASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5. IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7. OIL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9. ELECTRIC FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10. STANDARD REPAIR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10-1 STANDARD DIMENSIONS AND LIMITS OF USE . . . . . . . . . . . . . . . . . . . 49
10-2 SERVICE DATA (The following are only for your reference.) . . . . . . . . . . . 54
10-3 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-4 AIR GAP AND CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11.PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1. SPECIFICATIONS
Model EX40D
Air-Cooled, 4-Cycle, Slant Single-Cylinder,
Type
Horizontal P.T.O. Shaft, OHC Gasoline Engine

Bore & Stroke mm (in.) 89 × 65 (3.50 × 2.56)

Piston Displacement ml (cu.in.) 404 (24.65)

Compression Ratio 8.3

Maximum Output kW(HP)/r.p.m. per SAE J 1940 10.4 (14)/3600

N・m / r.p.m. 27/2400

Maximum Torque (kgf・m / r.p.m.) (2.8/2400)
(ft・lb. / r.p.m.) (19.91/2400)

Direction of Rotation Counterclockwise as viewed from the P.T.O. shaft side

Cooling System Forced air cooling system

Lubrication System Splash lubrication system

Automobile engine oil ; Grade SE or higher (SG,SH or SJ in recomended)

Lubricant SAE 10W-30-----Under ordinary atmospheric temperatures
SAE 5W-30-------In cold areas

Capacity of Lubricant L 1.2 (1.3 qt.)

Fuel system Throttle body single point injection

Fuel type Automobile unleaded gasoline

Fuel Supply System Regulated pressure with electric fuel pump type

Ignition System Flywheel magneto digital C.D.I.

Spark Plug NGK BR-6HS

Starting System Starter / Generator

Governor System None (Vehicle speed control)

Dry Weight kg (lb.) Approx. 24.4 (53.6)

Dimensions (L x W x H) mm (in.) 351 x 451 x 340 (13.8 x 17.8 x 13.4)

*Specifications are subject to change without notice.

- 1-
2. GENERAL DESCRIPTION OF ENGINE COMPONENTS
2-1 CYLINDER AND CRANKCASE
The cylinder and crankcase are aluminum die-casting
as a single piece. A special cast iron cylinder liner is
molded into the aluminum die-casting.
The crankcase has a mounting surface on the output
shaft side to which the main bearing cover is attached.
The cylinder is inclined to the right at an angle of 25
25°
degrees from the horizontal as viewed from the output
shaft side.
Fig.2-1
2-2 MAIN BEARING COVER
The main bearing cover is an aluminum die-casting,
which is mounted on the output shaft side of the
crankcase. By removing the main bearing cover, the
inside of the engine can be inspected with ease.
Pilots and bosses are machined into the cover
to facilitate the direct coupling of the engine with
machines such as generators and pumps.
Oil gauges (fillers) are on both sides of the cover for
easy maintenance. Fig.2-2

2-3 CRANKSHAFT
The crankshaft is forged carbon steel, and the crank
pin is high-frequency inductionhardened.
The crank sprocket used to drive the chain and the
gear used to drive the governor gear are pressed into
the output end of the shaft.

Fig.2-3
2-4 CONNECTING ROD AND PISTON
The connecting rod is a specially heat-treated
aluminum alloy die-casting. Its large and small ends
function as bearings. A splasher built into the
connecting rod lubricates by splashing engine oil.
The piston is an aluminum alloy casting with grooves
for mounting one compression ring and one oil ring.

Fig.2-4

- 2-
2-5 PISTON RINGS
The piston rings are made of special cast iron. The profile of the top ring is a tapered face.
The oil ring is designed for better sealing and less oil consumption, in combination with 3 pieces.

BARREL
1
TOP
1
RING
2 TAPER

3 2 SECOND
TAPER
RING

OIL THREE-PIECE
3 CONSTRUCTION
RING

Fig.2-5

2-6 CAMSHAFT
The camshaft and the sprocket are made of special
sintered alloy. They are constructed as a single
piece. The camshaft is provided with intake and
exhaust cam, and the decompression release lever is
mounted on the sprocket shaft end side.

Fig.2-6

2-7 VALVE ARRANGEMENT

This engine has a chain-driven overhead cam and
EXHAUST VALVE INTAKE VALVE
overhead valve construction, with a single cam which
has individual profile for intake and exhaust to
perform high output.

Fig.2-7

- 3-
2-8 CYLINDER HEAD
The cylinder head is on aluminum die-casting with a
dome-shaped combustion chamber. The intake and
exhaust ports are arranged in a cross direction to
improve combustion efficiency.

Fig.2-8

2-9 COOLING SYSTEM

The engine uses a forced air-cooling system in which a synthetic resin cooling fan (which is separate from the
flywheel), reduce noise and forces cooling air into the cylinder and cylinder head.
Baffles are provided to guide the flow of cooling air.

2-10 LUBRICATION SYSTEM

The rotating parts, sliding parts and valves of the engine are lubricated with oil in the crankcase.
The oil is splashed onto the parts by the oil splasher on the connecting rod.

2-11 TIMING CHAIN

Timing chain system is adopted and designed for
TIMING CHAIN
lubricating for the upper portion of cylinder head.
The timing chain is engaged between the sprocket
portion of integrated camshaft in the cylinder head and
the crankshaft gear sprocket.
OIL SPLASHER
The sprocket teeth in particular shape are adopted to
enhance the durability and to realize low noise level.

Fig.2-9

- 4-
2-12 IGNITION SYSTEM
The ignition system is a flywheel magneto digital FLYWHEEL

C.D.I. system. The magneto consists of a flywheel

and ignition coil. The flywheel (cooling fan is
separete from the flywheel) is directly mounted on
the crankshaft and the ignition coil is directly
mounted on the crankcase.

IGNITION COIL
FAN

Fig.2-10

2-13 BALANCER
Unbalanced inertia force is cancelled by the balancer
which rotates at the same speed as the crankshaft to
effectively reduce vibration.

Fig.2-11

- 5-
3. DISASSEMBLY AND REASSEMBLY
3-1 PREPARATIONS AND PRECAUTIONS
(1) W
 hen disassembling the engine, memorize the location of each part so that you can reassemble the engine
correctly. If necessary, attach identification tags with the required assembly information to the parts.
(2) Store groups of parts in separate boxes. This will make reassembly easier.
(3) To prevent parts from being mislaid, keep each group provisionally assembled after removing the parts
from the engine.
(4) Handle the disassembled parts with the utmost care. Clean them with cleaning oil if necessary.
(5) Use the correct tools in the correct way when disassembling and reassembling the engine.

3-2 SPECIAL TOOLS

Tool name Use

Commercially available product Flywheel puller For pulling off the flywheel

Commercially available product Chain wrench For locking the flywheel

FLYWHEEL PULLER

675$3:5(1&+

Fig.3-1

- 6-
3-3 DISASSEMBLY PROCEDURE

Step Parts to remove Remarks and procedures Fasteners

Drain the engine oill Remove a drain plug (M14 x 12mm) located on both 14 mm spanner
sides of the case.
1 Take care not to lose the gaskets.
* To discharge oil quickly, remove the oil guage(M22).

Remove oil filler Remove oil filler from crankcase. M8 Bolt : 1 pc.
2

GASKET

STEP 1

GASKET

DRAIN PLUG

Fig.3-2

- 7-
Step Parts to remove Remarks and procedures Fasteners
Blower housing (1) Remove the blower housing (synthetic resin) from 10 mm box spanner
3 the crankcase. M6 x 16 mm : 5 pcs.

M6 x 16 BOLT : 5 pcs.

BLOWER HOUSING

STEP 3

Fig.3-3

- 8-
Step Parts to remove Remarks and procedures Fasteners
Throttle body, Insulator Remove the carburetor from the cylinder head.
4 Remove the insulator & operation bracket.

ADAPTER
(AIR INTAKE)
GASKET

INSULATOR
GASKET

THROTTLE BODY

GASKET STEP 4

Fig.3-4

- 9-
Step Parts to remove Remarks and procedures Fasteners
Ignition coil Remove the spark plug cap from the spark plug and 10 mm box spanner
5 remove the ignition coil from the crankcase. M6 x 25 mm：2 pcs.

Washer Remove the starting pulley and cooling Blower from the 24 mm box spanner or
Cooling Blower flywheel.Fit a box wrench or a socket wrench on the socket wrench
flywheel nut and loosen the nut by knocking the wrench M18 nut
sharply with a hammer. (See Fig. 3-6)
NOTE:
6 1. Do not insert a screwdriver or other object between the
flywheel blades which is a synthetic resin, otherwise the
risk of damaging the blades might be occurred.
2. Knock the wrench with a hammer in a counter clockwise
direction.

Flywheel Remove the flywheel from the crankshaft. Leave the nut Flywheel puller
temporarily to prevent the flywheel from dropping out. Fit
the flywheel puller as shown in Figure 3-7 and remove
7 the flywheel from the crankshaft by rotating the bolt at the
center in a clockwise direction.
(Knock the center bolt with a hammer sometimes)

ATTACH NUT
TEMPORARILY
FLYWHEEL PULLER

Fig.3-6 Fig.3-7
COOLING BLOWER WASHER
M6 x 8 BOLT : 1 pc. STEP 7
M18 NUT : 1 pc.
FLYWHEEL
STEP 6
CLAMP
M6 x 25 BOLT and
WASHER : 2 pcs.
WIRE : 1 pc.

STEP 5

IGNITION COIL

Fig.3-5

- 10 -
Step Parts to remove Remarks and procedures Fasteners
Baffle 1 (Case) Remove the Baffle 1 from the crankcase. 12 mm box spanner
8 M8 x 12 mm : 1 pc.

BAFFLE 1 M8 x 12
(CASE) BOLT : 1 pc.

STEP 8

Fig.3-8

- 11 -
Step Parts to remove Remarks and procedures Fasteners
Wire clamp Disconnect the wire clamp. 10 mm box spanner
M6 x 10 mm : 1 pc.
NOTE:
Disconnect the wire clamp in this step, also an engine
9 which has the oil sensor.
However, please make sure do not damaged (cut off)
the oil sensor wire after disassembly procedure.

Spark plug Remove the spark plug from the cylinder head. 21 mm plug wrench
10

WIRE CLAMP
M6 x 10 TAPPING BOLT : 1 pc.

STEP 9

STEP 10

SPARK PLUG

OIL SENSOR

WIRE CLAMP

VIEW A M6 x 10 TAPPING BOLT : 1 pc.

Fig.3-9

- 12 -
Step Parts to remove Remarks and procedures Fasteners
Rocker cover (1) Remove the rocker cover from the cylinder head. 10 mm box spanner
(2) Remove the gasket (rocker cover). M6 x 12mm : 4 pcs.
11

Rocker arm Remove the pin (rocker arm) and the rocker arm from
12 the cylinder head at the compression top dead center.
(See Fig. 3-12)

The position of compression top dead center

Punch marks
ROCKER ARM
(EXHAUST VALVE SIDE)

PIN
(ROCKER ARM)

ROCKER ARM
(INTAKE VALVE SIDE)

Fig.3-11 Fig.3-12

STEP 12 ROCKER ARM

(EXHAUST VALVE SIDE)

PIN
(ROCKER ARM)
ROCKER ARM
(INTAKE VALVE SIDE)

VIEW A

GASKET(ROCKER COVER)

STEP 11
ROCKER COVER

Fig.3-10 M6 x 12 BOLT : 4 pcs.

- 13 -
Step Parts to remove Remarks and procedures Fasteners
Main bearing cover Remove the flange bolts of main bearing cover from 12 mm box spanner
the crankcase. M8 x 38mm : 8 pcs.
Remove the main bearing cover while tapping gently
13 around the cover using a plastic hammer or similar
tool. (See Fig. 3-14)
Be careful not to damage the oil gauge or oil seal or
not to lose the pipe knocks.

Fig.3-14

M8 x 38 BOLT : 8 pcs.

PIPE KNOCK

STEP 13

MAIN BEARING COVER

Fig.3-13

- 14 -
Step Parts to remove Remarks and procedures Fasteners
Tensioner, Camshaft (1) Remove the tensioner. (See Fig. 3-16) 10mm box spanner or
Do not lose the pin (tensioner). spanner
(2) Remove the retaining bolt of pin (camshaft) from M6 x 12mm : 1 pc.
the cylinder head. (See Fig. 3-17)
14 (3) Remove the pin (camshaft), taking care not to Pliers
scratch the O-ring.
(4) Remove the chain from the camshaft sprocket and
then take out the camshaft. (See Fig. 3-18)
(5) Remove the chain from the crankshaft.

PIN (CAMSHAFT)

M6 x 12 BOLT : 1 pc.
Bolt used to prevent the
PIN (TENSIONER) pin (camshaft) from coming out

Fig.3-16 Fig.3-17

CHAIN

CAMSHAFT

Fig.3-18

CHAIN
CAMSHAFT

SPRING STEP 14 CHAIN

(TENSIONER)
M6 x 12 BOLT : 1 pc.
PIN Bolt used to prevent the
(CAMSHAFT) pin (camshaft) from coming out

TENSIONER

PIN STEP 14
(TENSIONER)
Fig.3-15

- 15 -
Step Parts to remove Remarks and procedures Fasteners
Cylinder head, (1) Remove the cylinder head from the crankcase. 12 mm box spanner
Chain guide (2) Remove the cylinder head gasket from the cylinder head. M10 × 75mm : 4 pcs.
Take care not to lose the dowel pin. M8 × 35mm : 2 pcs.
15 (3) Remove the chain guide from the top side of the
crankcase.
(If the chain guide is removed from the inner side of the
crankcase, it might be damaged.)

Intake and exhaust (1) Remove the collet valve from the spring retainer.
valves (See Fig. 3-20)
16
(2) Remove the intake valve and the exhaust valve.

Fig.3-20

SPRING RETAINER
COLLET VALVE
VALVE SPRING

STEM SEAL
DOWEL PIN

GASKET STEP 15 RETAINER PLATE

(EXHAUST ONLY)
INTAKE
VALVE
PUSH
M10 x 75 BOLT : 4 pcs.

VALVE SPRING
EXHAUST
VALVE
STEP 16
COLLET VALVE
STEM SEAL
DOWEL PIN

CYLINDER HEAD SPRING RETAINER

CHAIN GUIDE
M8 x 35 BOLT : 2 pcs.

Fig.3-19

- 16 -
Step Parts to remove Remarks and procedures Fasteners
Connecting rod and piston (1) Scrape off any carbon from the cylinder and the 12 mm box spanner
piston head, then remove the connecting rod bolt. M8 x 40mm : 2 pcs.
(2) Remove the connecting rod cap.
17 (3) Rotate the crankshaft until the piston comes to its
top position. Push the connecting rod and remove
the piston from the upper part of the cylinder.

Piston and piston rings (1) Remove the piston clips (2 pcs.). Take out the
piston pin and then remove the piston from the
connecting rod small end, taking care not to
damage the connecting rod small end.
18
(2) Remove the piston rings from the piston by
spreading them at the gap. Take special care not to
damage the rings when doing this.

STEP 17
M8 x 40 CONNECTING ROD BOLT : 2 pcs.

CONNECTING ROD CAP PISTON RING

CONNECTING ROD CLIP

PISTON
PISTON PIN STEP 18
CLIP

Fig.3-21

- 17 -
Step Parts to remove Remarks and procedures Fasteners
Crankshaft (1) Remove the woodruff key (for the flywheel
magneto).
(2) Remove the crankshaft from the crankcase Plastic hammer
19 by tapping its magneto side end with a plastic
hammer, taking care not to damage the oil seal.
(See Fig. 3-23)

Oil sensor
(1) Remove the clamp. M6 x 10mm : 1 pc.
20 (See Fig. 3-24)
(2) Remove the oil sensor from the crankcase. M6 x 16mm : 2 pcs.

OIL SENSOR WIRE CLAMP

Fig.3-23 Fig.3-24
M6 x 10 TAPPING BOLT : 1 pc.

WIRE CLAMP

CRANKCASE

M6 x 16 BOLT and
WASHER : 2 pcs.
WOODRUFF KEY

OIL SENSOR

STEP 20

STEP 19

CRANKSHAFT Fig.3-22

- 18 -
3-4 REASSEMBLY PROCEDURE
3-4-1 NOTES ON REASSEMBLY
(1) Clean the each parts carefully, taking special care with the piston, cylinder, crankshaft, connecting rod
and bearings.
(2) Scrape off any carbon deposits on the cylinder head and the piston head. Be particularly careful when
removing carbon from the piston ring grooves.
(3) Inspect the oil seals for any damage to the lip. Replace them if damaged. Apply oil to the lip before
reassembly.
(4) Replace all the gaskets with new ones.
(5) Replace the keys, pins, bolts and nuts with new ones, if necessary.
(6) Tighten nuts and bolts to the specified torque settings.
(7) When reassembling the engine, apply oil to all moving parts.
(8) Check clearances and end plays and adjust, if necessary.
(9) When mounting any major part during reassembly of the engine, rotate it with your hand to check for
any jamming or abnormal noise.

3-4-2 ASSEMBLY STEPS AND PRECAUTIONS

(1) OIL SENSOR
(a) Mount the oil sensor and fix the wire with the
OIL SENSOR
clamp.

Tightening torque
8.0 - 10.0 N・m
(80 - 100 kgf・cm) WIRE CLAMP
(5.8 - 7.2 ft・lb.)

NOTE : M6 x 10 TAPPING BOLT : 1 pc.

Make sure to not damaged (cut off) the oil
Fig.3-25
sensor wire after assembly procedure.

(2) CRANKSHAFT
(a) Wrap the key-way portion of the crankshaft with CRANKSHAFT

polyvinyl tape and insert the crankshaft into the

crankcase, taking care not to damage the oil
seal lip.

(b) Insert the woodruff key (for the flywheel magneto).

NOTE: Do not insert the woodruff key before
inserting the crankshaft into the
crankcase. POLYVINYL TAPE

Fig.3-26

- 19 -
(3) PISTON AND PISTON RINGS OPEN ENDS OF PISTON RING
(a) Install each piston ring in the correct groove of
the piston by widening it enough to slide it over
the piston.
NOTE: Be careful not to twist the rings too
much, as they may be damaged. Install
the oil ring first, followed by the top ring.
When installing the piston ring, make
sure that the "R" mark is face up.
(See Fig. 3-29)
Fig.3-27

BARREL
1
TOP
1
RING
2 TAPER

3 2 SECOND
TAPER
RING

OIL THREE-PIECE
3 CONSTRUCTION
RING

Fig.3-28

MARK "R" or "1R"

Fig.3-29

- 20 -
(4) PISTON AND CONNECTING ROD
The piston is attached to the connecting rod by
the piston pin.
When assembling the piston and connecting
rod, make sure to align the mark on the piston
head with the ‘MAG’ mark on the connecting

MAG
When assembling the
rod. piston and connecting
rod, make sure to align
the mark on the piston
NOTE 1: B
 efore assembling the connecting rod, head with the ‘MAG’ mark
on the connecting rod.
apply oil to its small end.
NOTE 2: B
 e sure to insert the clips in the two Fig.3-30

ends of the piston pin and check the clips for

any play.

(5) CONNECTING ROD PISTON RING GUIDE

(a) Install the piston and connecting rod assembly CONNECTING ROD

into the cylinder by holding the piston rings

with the ring guide, with the ‘MAG’ mark on
the connecting rod on the flywheel side. (If you
do not have a ring guide, hold the piston rings G
MA
with the fingers and tap the upper part of the
piston with a piece of wood.)
"MAG" MARK
NOTE 1: Apply oil to the piston rings, the large
end of the connecting rod and cylinder
before installing the connecting rod into FLYWHEEL SIDE

the cylinder. Fig.3-31

NOTE 2: The piston ring gaps should be

positioned around the piston at 90-degree SECOND RING

intervals.
(See Fig. 3-32) OIL RING

TOP RING

Fig.3-32

- 21 -
(b) Rotate the crankshaft down to the bottom dead
center and lightly tap the piston head until the
large end of the connecting rod touches the
crank pin.

(c) T
 o mount the connecting rod, line up the matching
marks and fit the clinch portions firmly together. ALIGNMENT
ALIGNMENT MARKS
MARKS
M8 bolt (12mm box wrench)
Tightening torque
22.5 - 27.5 N・m
(225 - 275 kgf・cm)
(16.3 - 19.9 ft・lb.) Fig.3-33

(d) Check for free movement of the connecting rod

by turning the crankshaft slowly.

(6) INTAKE AND EXHAUST VALVES

Take the following points into account when
mounting the intake and exhaust valves on the
cylinder head.

NOTE 1: Replace the valve with a new one if

it shows signs of wear.
(Refer to the “STANDARD REPAIR
TABLES” on page 49 and 50.)

NOTE 2: Carefully scrape off any carbon Fig.3-34

deposits on the combustion chamber. Apply
COLLET VALVE
oil to the valve stems before mounting the SPRING RETAINER
intake and exhaust valves. Insert the VALVE SPRING
STEM SEAL
valves in the cylinder head and place it on
CYLINDER HEAD
a level workbench. Next, mount the valve RETAINER PLATE
(EXHAUST ONLY)
springs, the spring retainers and collet INTAKE VALVE
valves. (Mount the stem seal on the intake
STEM SEAL
valve guide.)

EXHAUST VALVE

VALVE COLLET
SPRING VALVE
SPRING
RETAINER

Fig.3-35

- 22 -
(7) CHAIN GUIDE
Mount the chain guide to the crankcase.
CHAIN GUIDE

Models EX40
mounting positions

Fig.3-36 Fig.3-37

(8) CYLINDER HEAD

Inspect and repair any scratches on mounting surface and replace head gasket to new one before installing.
Tightening Torque
1st step 2nd step
1 4 1 4
Cylinder head bolts Remarks
6

5
3 3
2 2

29.0 - 31.0 N・m

(290 - 310 kgf・cm) Re-use
M10 × 75 mm : ①,②,③,④, (21.0 - 22.4 ft・lb.)
flange bolt : 4 pcs.
17.0 - 19.0 N・m 37.0 - 39.0 N・m When replace to new cylinder
(14mm box wrench)
(170 - 190 kgf・cm) (370 - 390 kgf・cm)
(26.7 - 28.2 ft・lb.) head and flange bolts
(12.3 - 13.7 ft・lb.)
M8 × 35 mm : ⑤,⑥
As for ⑤ and ⑥ , only 1st step
flange bolt : 2 pcs. -
(12mm box wrench) tightening.

Tighten the cylinder head bolts in diagonal order. DOWEL PIN

M10 x 75 BOLT : 4 pcs.
(1) Re-use (Oil the screw thread) GASKET
● Tighten all bolts (6pcs) by 18 ± 1 N・m primary,
and then tighten longer ones (M10 × 75mm
flange bolt: 4pcs) by 30 ± 1 N・m.

(2) When replace to new cylinder head and flange

bolts (Oil the screw thread)
● Tighten all bolts (6pcs) by 18 ± 1 N・m primary, CYLINDER HEAD
and then tighten longer ones (M10 × 75mm M8 x 35 BOLT : 2 pcs.

flange bolt: 4pcs) by 38 ± 1 N・m. Fig.3-38

- 23 -
(9) SETTING THE TIMING CHAIN
(a) Align the timing mark on the crankshaft sprocket with the mark plate of the timing chain.
(b) Align the timing mark on the camshaft sprocket with the mark plate of the opposite end of the timing chain.
Number of oval steel link : 112
CHAIN GUIDE FITTING POSITION MARK PLATE
The mark plate does not
have a camshaft side or
crankshaft sprocket side.

TIMING MARK

ROLL PIN
CRANKSHAFT SPROCKET
CAMSHAFT SPROCKET
TIMING MARK

TIMING MARK
MARK PLATE for BALANCER GEAR
TIMING MARK for CHAIN

Fig.3-39

(10) MOUNTING THE CAMSHAFT ON THE CYLINDER HEAD

Mount the camshaft on the cylinder head by inserting the pin (camshaft) through the head.
Fix the bolt to prevent the pin (camshaft) from coming out.

PIN (CAMSHAFT)

CHAIN
M6 x 12 BOLT : 1 pc.
Bolt used to prevent the
CAMSHAFT pin (camshaft) from coming out

CHAIN
CAMSHAFT

SPRING CHAIN
(TENSIONER)

PIN M6 x 12 BOLT : 1 pc.

(CAMSHAFT) Bolt used to prevent the
pin (camshaft) from coming out

TENSIONER
PIN Fig.3-40
(TENSIONER)

- 24 -
(11) MOUNTING THE TENSIONER
PIN
(TENSIONER)

SPRING
(TENSIONER) PIN (TENSIONER)
TENSIONER

Fig.3-41 Fig.3-42

(12) BALANCER SHAFT TIMING MARK for

BALANCER GEAR
Mount the balancer shaft on the crankcase,
align the timing marks on the balancer gear BALANCER
GEAR
and the crankshaft gear.

NOTE: Incorrect alignment of the timing

marks can result in malfunction of the
engine, leading to damage due to
interference of the parts.
TIMING MARK for CHAIN

Fig.3-43

- 25 -
(13) MAIN BEARING COVER
Apply oil to the bearing and the oil seal lip when mounting the main bearing cover. Also apply sealant
(Three Bond “1215”) to the surface of the crankcase. To avoid damaging the oil seal lip, wrap the
crankshaft key-way portion with polyvinyl tape before mounting the main bearing cover.

Tightening torque
22.0 - 24.0 N・m
(220 - 240 kgf・cm)
(16.2 - 17.7 ft・lb.)

M8 x 38 mm : 8 pcs.
(12mm box wrench)

SEALANT
(Three bond͆1215͇)

MAIN BEARING COVER

Fig.3-44

- 26 -
 (14) Pass the pin (rocker arm) through the rocker
arm and mount them on the cylinder head.

NOTE 1: C
 onduct this job at the compression ROCKER ARM
(EXHAUST VALVE SIDE)
top dead center.
(The position of two punch marks on
cam sprocket is in parallel with the PIN
(ROCKER ARM)
cylinder head surface at a time.)
Punch marks
NOTE 2: M
 ake sure that the piston is at the
compression top dead center by ROCKER ARM
checking mutual position between the (INTAKE VALVE SIDE)

flywheel and the ignition coil or by The position of compression top dead center

checking that the key way is at the

Fig.3-45
top. (See each Fig.3-46)

(15) VALVE CLEARANCE ADJUSTMENT

Temporarily fit the flywheel.
Rotate the crankshaft up to the compression
top dead center and insert the thickness gauge
between the valve and the adjusting screw of
rocker arm to measure the clearance.

[Adjustment method]
Loosen the nut on the adjustment screw and turn
Temporarily
the screw to adjust the valve clearance. When fit the nut

the valve clearance is correct, tighten the nut. Fig.3-46

Valve clearance (when the engine is cold)

THICKNESS GAUGE NUT (9mm spanner)
Intake valve side +0.03
0.12 0 mm
+0.0012 ADJUSTMENT
Exhaust valve side (0.0047 0 in.) SCREW
ROCKER ARM
(EXHAUST
Tightening torque VALVE SIDE)
5.0 - 7.0 N・m
(50 - 70 kgf・cm)
(3.6 - 5.1 ft・lb.)

NOTE: After adjusting the valve clearances, rotate the

ROCKER ARM
crankshaft and check again that the intake and (INTAKE VALVE SIDE)
exhaust valve clearance are correct.
Fig.3-47

- 27 -
(16) ROCKER COVER
Replace the gasket with a new one, and mount SPARK PLUG
GASKET
the rocker cover. (ROCKER COVER)

M6 × 12 mm flange bolt : 4 pcs.

Tightening torque
5.0 - 7.0 N・m
(50 - 70 kgf・cm)
(3.6 - 5.1 ft・lb.)

ROCKER COVER
M6 x 12 BOLT : 4 pcs.

Fig.3-48

(17) SPARK PLUG

Remove any carbon deposits from the spark plug
and inspect the electrode for damage before
mounting. Replace with a new one, if necessary.
Spark plug : NGK BR-6HS (21 mm plug wrench)

0.6 - 0.7 mm
Electrode gap (0.024 - 0.028 in.)

Tightening torque
New spark plug Re-tightening torque
12.0 - 15.0 N・m 23.0 - 27.0 N・m
(120 - 150 kgf・cm) (230 - 270 kgf・cm)
(8.7 - 10.8 ft・lb.) (16.6 - 19.5 ft・lb.)

(18) BAFFLE 1 (CASE) PROJECTION

The projection (upper) on the baffle 1 with the
BAFFLE 1 (CASE)
crankcase and mount it (under) with the bolt.

M8 x 12 BOLT : 1 pc.
M8 × 12 mm bolt : 1 pc.

Fig.3-49

- 28 -
(19) FLYWHEEL, COOLING BLOWER
and STARTING PULLEY
NOTE: When mounting the flywheel, be sure to
COOLING
wipe off any oil on the tapered portion
BLOWER
of the crankshaft and flywheel.

a) Mount the flywheel on the crankshaft.

b) Install cooling blower and starting pulley to

WASHER
the crankshaft.
Fig.3-50

c) Tighten crankshaft nut with a strap wrench

STRAP WRENCH
adopted as shown in the illustration.

Tightening torque
100.0 - 120.0 N・m
(1000 - 1200 kgf・cm)
(72.3 - 86.8 ft・lb.)

M18 Nut : 1 pc. (24mm box wrench)

(20) IGNITION COIL Fig.3-51

When mounting the ignition coil, insert a THICKNESS

GAUGE
thickness gauge between the ignition coil
and the flywheel to check the air gap.

0.3 - 0.5 mm
Air gap (0.012 - 0.020 in.)

Tightening torque
7.0 - 9.0 N・m
(70 - 90 kgf・cm) IGNITION COIL
(5.1 - 6.5 ft・lb.) Fig.3-52

M6 × 25 mm bolt and washer : 2 pcs.

WIRE 1 M6 x 8 BOLT : 1 pc.

Make sure to put in the wire 1 to the notch on NOTCH

the crankcase, and tighten it with the clamp.
(M6×8 mm bolt : 1 pc.)
CLAMP

Fig.3-53

- 29 -
(21) BAFFLE2, RECOIL BRACKET, BLOWER HOUSING, RECOIL STARTER and STOP SWITCH
(1) Mount the stop switch to the blower housing. (M4 × 12 mm screw and washer : 2 pcs.)
*Tighten the wire 2 (ground) with the stop switch. (See Detail C)
(2) Mount the blower housing on the crankcase.（M6 × 16 mm bolt : 5 pcs.）
*Tighten the wire 2 (ground) with the blower housing. (See View D)

M6 x 15 BOLT : 5 pcs.

BLOWER HOUSING

Fig.3-54

(22) WIRING
Refer to the wiring diagram (See page 48 and 49) for wiring details.

- 30 -
(23) MUFFLER
(1) Mount the muffler and the gasket on the
cylinder head.

NOTE : B
 e sure to remove any tape or cloth
used to cover the exhaust port
when the engine was disassembled. to MUFFLER

GASKET
(Attention to the direction of bulge forming) GASKET
(Attention to the
Bulge forming direction of bulge
MUFFLER SIDE forming)

CYLINDER SIDE

Take utmost care not to cut your hand

with the muffler gasket

M8 × 12 mm Bolt : 1 pc.
Fig.3-55
M8 Nut : 2 pcs.

Tightening torque
(Recommend)
18.0 - 22.0 N・m
(180 - 220 kgf・cm)
(13.0 - 16.2 ft・lb.)

(24) EXTERNAL INSPECTION

Reassembly is completed. Check that the wiring is correct and that there are no loose nuts and bolts or
any other faults visible on the outside of the engine.

(25) FILLING WITH ENGINE OIL

Use the automobile engine oil of API service class SE or higher grade.
The amount of oil, refer to the table below.

Model
EX40
Engine oil volume
1.2L
(maximum)

- 31 -
4. ENGINE OIL
Using engine oil of the correct grade and viscosity greatly lengthens engine life and improves
performance. Too much or too little oil can also result in serious problems, including engine damage.

4-1 CLASSIFICATION BY OIL GRADE

API (American Petroleum Institute)
Classification SA SB SC SD SE SF SG SH SJ

Grades suited for Robin Engine: SE or higher (SG,SH or SJ in recomended)

4-2 CLASSIFICATION BY OIL VISCOSITY

SAE (Society of Automotive Engineers)

5W
10W
20W
Single grade
#20
#30
#40

10W-30
Multigrade
10W-40
Ambient
temperature

Be sure to use automobile engine oil of the viscosity shown in the table above, depending on environmental
air temperature.
When the air temperature falls below –20℃ or rises above 40℃, be sure to choose engine oil of appropriate
viscosity and grade, according to the prevailing conditions.

*Care must be taken when using multi-grade engine oil, because the oil consumption rate tends to increase
when the air temperature is high.

4-3 ADDING AND CHANGING ENGINE OIL

○ Engine oil inspection and filling up . . . Every time you use the engine
(add engine oil up to the designated maximum level)

○ Engine oil change . . . . . . . . . . . . . . . First time . . . . . . . . . . After 20 hours’ use

Thereafter . . . . . . . . . . Every 200 hours’ use

- 32 -
5. IGNITION SYSTEM
The ignition system is controlled by the digital CDI, and the ignition timing is variable according to engine
speed. The flywheel (cooling fan is separate from the flywheel) is directly mounted on the crankshaft and the
ignition coil is directly mounted on the crankcase.

6. WIRING DIAGRAM

Fig.6-1

- 33 -
7. OIL SENSOR
7-1 SPECIFICATIONS
Float type
Type
(with lead switch incorporated)

Resistance
100 M ohms or over
(at FULL oil level)

Operating OIL SENSOR

-30 to +180 degree Celsius
Temperature

Fig.7-1
7-2 CONSTRUCTION AND OPERATION
The oil sensor is composed of the float,
permanent magnet incorporated into the float
and the lead switch.
In accordance with the oil level, the float moves
FLOAT
up and down.
When the oil level is upper level, the float
moves up.
PERMANENT MAGNET

LEAD SWITCH

Fig.7-2

When the oil level is lower level, the float moves

down.
The permanent magnet is close to the lead
switch, and the lead switch is activated by the
magnetic force.

MAGNETIC FORCE

NOTE : W
 ith regards to the wiring diagram, Fig.7-3
please refer to the section 9-3 (page49).

- 34 -
8. TROUBLESHOOTING
The following three conditions must be fulfilled for satisfactory engine start.

(1) The cylinder filled with a proper fuel-air mixture.

(2) Good compression in the cylinder.
(3) Good spark, properly timed, to ignite the mixture.

The engine cannot be started unless these three conditions are met.

There are also other factors which make engine start difficult, e.g., a heavy load on the engine when it is
about to start at low speed, and a high back pressure due to a long exhaust pipe.

The most common causes of engine troubles are given below:

- 35 -
8-1 STARTING DIFFICULTIES

Phenomenon Possible causes Remedy

1) Battery discharged Charge battery

2) Poor connection between battery and starter motor Clean or repair
1. Low engine
speed at 3) Poor connection between battery and ground Clean or repair
starting
4) Electric starter faulty Repair or replace
Replace with recommended
5) Improper engine oil engine oil
Spark plug
* Improper spark plug gap Adjust
* No insulation Replace
2. Ignition * Carbon deposits Clean
system Ignition coil Check with failure diagnosis system
malfunction
* No insulation or discontinuity Replace
* Poor connection or discontinuity of ignition code Repair or replace
Improper air gap between ignition coil and flywheel Adjust
1) No fuel in fuel tank Refill
2) Fuel pump clogged Clean or replace
3) Fuel hose clogged or pinched Clean or replace
4) Air mixing into fuel lines Check and adjust connecting portion
5) Improper gasoline or water infiltration Replace
3. Fuel system 6) Throttle body
malfunction * Poor connection or discontinuity of throttle body (ECU). Repair or replace.
Check with failure diagnosis system
* Clogged or damaged Clean or replace
* Improper operation of throttle valve Check and adjust or replace
7) Poor connection of fuel pump wiring Check with failure diagnosis system
8) Improper pulsation damper Replace
Check with failure diagnosis system
9) Improper temperature sensor and replace
1) Insufficient tightening of cylinder head bolts Check and retighten
2) Wear of piston, piston ring and/or cylinder Repair or replace
3) Improper contact of valve and seat Repair
4) Valve seizure Repair
4. Engine core
components 5) Improper valve clearance Adjust
malfunction
Retighten intake manifold bolts or
6) Intake manifold gasket leakage replace gasket
Retighten cleaner adapter flange
7) Throttle body gasket leakage nut or replace gasket
8) Insufficient tightening of spark plug Retighten

- 36 -
8-2 INSUFFICIENT OUTPUT

Phenomenon Possible causes Remedy

1) Loosen spark plug Retighten or replace gasket

2) Cylinder head gasket leakage Retighten or replace gasket

3) Piston ring(s) seizure or wear Replace

1. Low 4) Piston or cylinder wear Repair or replace
compression
5) Incorrect valve and seat contact Repair or replace

6) Valve stem seizure Repair or replace

7) Improper valve clearance Adjust

1) Spark plug faulty Replace

2) Ignition coil faulty Replace

2. Ignition system
malfunction
3) Improper air gap between ignition coil and flywheel Adjust

4) Magneto demagnetization Replace

1) Throttle body clogged Check and replace

2) Improper fuel pump operation Check and replace

3) Fuel strainer or fuel hose clogged Clean or replace

3. Fuel system
malfunction
4) Air mixing into fuel lines Check and adjust connecting portion

5) Improper gasoline or water infiltration Replace

6) Improper pulsation damper operation Replace

1) Air cleaner clogged Clean or replace

4. Low intake air
volume
2) Throttle valve faulty Repair or replace

8-3 OVERHEAT

Phenomenon Possible causes Remedy

1) Cooling air flow obstructed at inlet or cylinder baffle portion Clean

2) Improper engine oil Replace
Check and replace throttle body,
3) Lean air/fuel mixture
Overheating and pulsation damper
4) Excessive back pressure of exhaust system Check, clean or replace
5) Over-load Change to rated load
6) Loosen or missing spark plug cap Check and connect properly

- 37 -
8-4 ROUGH IDLING

Phenomenon Possible causes Remedy

1) Low idling speed Adjust

1. Throttle body
2) Throttle body slow system passage clogged Check, clean and replace

2. Intake system 1) Air mixing from connecting portion of air intake system Check, tighten or replace gasket

3. Cylinder head 1) Cylinder head gasket faulty (blow-by) Replace

1) Improper valve clearance Adjust

4. Valve system 2) Leakage from valve seat Adjust valve seat contact

3) Excessive clearance between valve stem and guide Replace

5. Ignition system 1) Weak ignition spark Check and replace spark plug

8-5 HIGH ENGINE OIL CONSUMPTION

Phenomenon Possible causes Remedy

1) Loosen drain plug Tighten

2) Drain plug gasket damaged Replace

3) Incorrect oil filter fitting Repair

1. Oil leakage
4) Loosen main bearing cover bolts Tighten

5) Main bearing cover gasket damaged Replace

6) Crankshaft oil seal damaged Replace

1) Piston oil ring faulty Replace

2) Piston rings seizure, wear or poor contact Replace

3) Excessive wear of piston and cylinder Replace

2. Oil dilution
4) Excessive wear of valve stem Replace

5) High oil level Adjust oil level

6) Breather faulty Repair or replace

- 38 -
8-6 HIGH FUEL CONSUMPTION

Phenomenon Possible causes Remedy

1) Throttle body faulty Check or replace

1. Fuel system 2) Pulsation damper faulty Check or replace

3) Fuel pump faulty Check or replace

1) Low compression Check or repair

2. Engine core
components Check and adjust load and/or
2) Over cooling engine speed

8-7 DETONATION

Phenomenon Possible causes Remedy

Check with failure diagnosis

1) Poor connection of ignition system wirings
1. Ignition system system and connect properly
malfunction
2) Improper or damaged spark plug Clean or replace

1) Lean or rich air/fuel mixture Check or replace throttle body

2) Throttle body damaged Check or replace throttle body

2. Fuel system
malfunction 3) Fuel lines clogged or damaged Clean or replace

Connect properly or replace

4) Air mixing from connecting portion of air intake system
gasket

1) Carbon deposit in combustion chamber Remove and clean

3. Cylinder head
2) Cylinder head gasket faulty (blow-by) Replace

1) Improper valve clearance Adjust

2) Valve heat deterioration Replace

4. Valve system
3) Valve spring deterioration Replace

4) Improper valve timing Adjust

- 39 -
8-9 ENGINE MISFIRE

Phenomenon Possible causes Remedy

1) Improper spark plug gap or damaged electrode Cealn, adjust or replace

2) Ignition coil faulty Replace

1. Ignition system Check with failure diagnosis
3) Damaged ignition system wirings system and replace
Check with failure diagnosis
4) Poor connection of ignition system wirings system and connect properly

1) Lean or rich air/fuel mixture Check and replace throttle body

2) Clogged throttle body Check and replace

2. Fuel system 3) Throttle body faulty Check and replace

4) Fuel pump faulty Check and replace

5) Improper gasoline or water infiltration Replace

1) Valve heat deterioration or improper valve adjustment Adjust or replace

3. Engine core
componets 2) Valve spring deterioration Replace

3) Low compression Check, adjust or replace

- 40 -
9. ELECTRIC FUEL INJECTION SYSTEM
This engine is equipped with Electronic Fuel Injection system (FI system) Integrated with ECU (Engine
Control Unit).
The Fl system consists of throttle body, ECU, MAP (Manifold Absolute Pressure) sensor, injector, engine
case temperature sensor, electric fuel pump.
The fuel system is calibrated after careful testing for optimum all-round performance (including starting,
acceleration, fuel consumption, output power characteristics).
The throttle body monitors air and engine temperature at start up and performs the choke function
automatically.
While the engine is in operation, the throttle body monitors engine speed, manifold absolute pressure, and
engine temperature to ensure proper engine performance.
Failure diagnosis is made by the diagnosis lamp on the panel.

Fuel Pump Fuel Tank

ECU
Spark Plug

MAP Sensor Injector

Intake Boost
Throttle Body

Ignition Coil Fuel

Engine Case Electrical Signal
Temperature Sensor Air P-ressure

Fig.9-1

- 41 -
9-1 FUNCTIONS AND CONSTRUCTION
9-1-1 FUEL INJECTOR
Fuel is metered by the fuel injector that is actuated electronically by ECU.

The fuel is injected into the throttle bore and mixed with air from the air cleaner.

9-1-2 ENGINE CONTROL UNIT (ECU)

The ECU (engine control unit) on bottom of the throttle body is powered by DC battery. The ECU
monitors engine conditions such as engine speed, air pressure, and engine temperature.

With these inputs, the ECU actuates the fuel injector to ensure the fuel/air mixture is of optimum
concentration and is fed into the combustion chamber of the engine at the correct timing. When engine
speed reached to 4,400 rpm, the ECU cuts fuel to prevent over speed.

The ECU also controls the low oil sensor system and monitors voltage of DC battery, and each wiring
whether disconnecting or electrical short circuit.

9-1-3 CHOKE SYSTEM

The throttle body monitors air pressure and engine temperature at start up and performs the choke
function automatically.

The choke system automatically adjusts for easier start of the engine in all weather conditions.

9-2 FUEL SYSTEM TESTING AND DIAGNOSIS

Most fuel system malfunctions occur when the fuel/air ratio of the mixture is not correct.

This is usually caused by clogged fuel filters, air passages, fuel passages, or by variations in the fuel
level.

To get the best possible performance from the throttle body, make sure that the fuel feed and air feed
passages are free so air and fuel can flow freely through them.

The procedure for inspecting the fuel system is described below.

Run all system tests with a full tank of fresh, clean fuel.

- 42 -
9-3 EFI SYSTEM
9-3-1 CHECKING ECU CONNECTOR
1. Disconnect the connector, and check their terminals ECU
for contamination and deformation.
2. Check to see that cable is not broken or terminals
are not shelled off.
3. If any damaged parts are found, repair or replace
them.

NOTE ;
When replacing the ECU, the throttle body also
needs to be replaced.
Fig.9-2

IMPORTANT ;
Connect connectors surely after checking.

PIN ASSIGNMENT OF ECU CONNECTOR

110 111 112 113 114 115 116 117 118 10 11 12 13 14 15 16 17 18

101 102 103 104 105 106 107 108 109 1 2 3 4 5 6 7 8 9
JAPAN AVIATION ELECTRONIC INDUSTRY JAPAN AVIATION ELECTRONIC INDUSTRY
PARTS No.MX23A18NFG PARTS No.MX23A18NF1
COLOR : GRAY COLOR : BLACK
101 INJECTOR CONTROL 1 FUEL PUMP
102 N.C. 2 N.C.
103 N.C. 3 IGNITION GND
104 N.C. 4 N.C.
105 N.C. 5 N.C.
106 ENGINE TEMP. SENSOR 6 N.C.
107 N.C. 7 OIL SENSOR SWITCH
108 N.C. 8 K-LINE
109 IGNITION SIGNAL 9 BATT. +12V
110 INJECTOR (VB+) 10 POWER GND
111 N.C. 11 DIAGNOSIS LAMP
112 N.C. 12 ACCELERATOR PEDAL SWITCH
113 M.A.P. SENSOR 13 N.C.
114 N.C. 14 N.C.
115 SENSOR GND (ENG.TEMP.) 15 N.C.
116 5V ref. 16 N.C.
117 SENSOR GND(M.A.P.) 17 N.C.
118 N.C. 18 SYSTEM GND

- 43 -
9-3-2 ECU CONNECTOR VOLTAGE
(Main Circuit)
1. Turn on the main switch. (Do not start engine.)
ECU
2. Measure the voltage between terminal 9 (+)and
terminal 10 (-).
3. It is OK if the voltage equals to the battery voltage.
(Sensor Voltage)
1. Turn on the main switch. (Do not start engine.)
2. Measure the voltage between terminal 116 (+)and Black Connector Gray Connector
terminal 117 (-). 1 9 101 109
9
3. It is OK if the voltage is approx. 5 V.

Terminal 9 to 10 Approx. battery voltage 10 116 117 118

Voltage 10 8 110 118
Terminal 116 to 117 Approx. 5 V
ECU connector of wire harness ECU connector of wire harness
attached with no tape side attached with gray tape

Fig.9-3

9-3-3 WIRING HARNESS OF ENGINE CASE

TEMPERATURE SENSOR
Connector (harness side)
1. Disconnect the engine case temperature sensor
connector (2P).
2. Check the state of the harness and if it is abnormal,
replace it.
3. Turn the key switch to the ON position.
4. Measure the voltage between the terminals of the
connector with voltage range of circuit tester.
5. When the measurements are the table value below, Engine Case Temperature Sensor
the ECU is normal.
The engine case temperature sensor is damaged, Terminal 1 (+) Terminal 2 (-)
then replace it.
6. When the measurements are out of the table value
below, the ECU is failure, then replace it.
Connector (harness side)
Wiring harness
Terminal 1- Terminal 2 5V
voltage Fig.9-4

- 44 -
 Connector (harness side)

9-3-4 ENGINE CASE TEMPERATURE SENSOR

1. Disconnect the connector from the engine case
temperature sensor.
2. Measure the resistance with an ohmmeter across
the terminal 1 and 2 of engine case temperature Engine Case Temperature Sensor
sensor
3. If the measurement is not indicated, the sensor is Terminal 1 (+) Terminal 2 (-)
faulty.

Resistance
Approx. 10 kΩ
(Sensor terminal 1 - Reference value
at 25°C (77°F) Connector (harness side)
terminal 2)

Fig.9-5

9-3-5 INJECTOR
1. Disconnect the connector of injector (2P).
2. Measure the resistance between the terminals of the Injector
injector with resistance range of circuit tester.
3. If the measurement is not within factory
specification, replace the injector.

Factory Approx.
Injector resistance
specification 11.5 to 12.5 Ω

4. Check the state of the harness and if it is abnormal, Terminal 1 (-)

replace it. Terminal 2 (+)
101 109
5. Turn the key switch to the ON position. 101

6. Measure the voltage between the terminal 2 of

injector connector and body earth with voltage range
110 118
of circuit tester (harness side).
Gray Connector Injector connector
7. Measure the resistance between the terminal 1 of (harness side)
injector connector and ECU terminal 101 with resistance
Fig.9-6
range of circuit tester (harness side).
8. When the measurements are the table value below the ECU is normal. The injector is damaged, then
replace it.
9. When the measurements are out of the table value below, the ECU is damaged, then replace it.

NOTE ;
• The injector can not be replaced separately.
• When the injector is in failure, replace throttle body.
• When replacing the throttle body, the ECU also needs to be replaced.

Harness voltage Terminal 1- Body earth Approx. 5 V

Harness resistance Terminal 2- ECU terminal 101 0Ω

- 45 -
9-3-6 MAP SENSOR
1. Connect the connector of MAP sensor (3P).
2. Turn the key switch to the ON position. Map sensor
3. Measure the voltage between the terminal 3 and
body earth with voltage range of circuit tester.
4. If the measurement is not within factory
specification, replace the throttle body with ECU or
wiring harness.
5. Check .the state of the harness and if it is abnormal,
replace it. Terminal 1 (GND)
Terminal 3 (+)
6. Turn the key switch to the OFF position. 101 109
109

7. Disconnect the connector of MAP sensor (3P).

8. Turn the key switch to the ON position.
110 118 Terminal 2 (signal)
9. Measure the resistance between the terminal 1 Sensor connector
and ECU terminal 117 earth with resistance range Gray Connector (harness side)

of circuit tester (harness side).

Fig.9-7
10. Measure the resistance between the terminal 2
and ECU terminal 113 with resistance range of circuit tester (harness side).
11. Measure the resistance between the terminal 3 and ECU terminal 116 earth with resistance range of
circuit tester (harness side).
12. When the measurements are the table value below the wiring harness is normal.
The MAP sensor is damaged, then replace it.
13. When the measurements are ot.it of table value below, the wiring harness is damaged, then replace it.

NOTE ;
• The MAP sensor can not be replaced separately.
• When the injector or MAP sensor is in failure, replace throttle body.
• When replacing the throttle body, the ECU also needs to be replaced.

Harness voltage Terminal 3- Body earth Approx. 5 V

Terminal 1-ECU terminal 117 0Ω

Harness resistance Terminal 2-ECU terminal 113 0Ω

Terrninal 3-ECU terminal 116 0Ω

- 46 -
9-3-7 IGNITION COIL Ignition coil

NOTE ;
• When the diagnosis lamp is flashing, check the
procedures below in order.
• If the result is within factory specification, there is
a problem with ECU. Replace the ECU and throttle
body.

1. Measure the resistance between the terminal C and

terminal B of the primary coil with resistance range
of circuit tester at 20°C (68°F). Circuit tester
2. Measure the resistance between the terminal C and
terminal A of the secondary coil with resistance
range of circuit tester at 20°C (68 °F).
3. If the measurements are not within factory
specification, replace the ignition coil.
Terminal B
Primary coil
6.0 to 15Ω
(Terminal C- Terminal B)
Ignition coil Factory Terminal C
resistance specitication
Secondary coil Terminal A
5.0 to 12 kΩ
(Terminal C- Terminal A)

Fig.9-8
4. Check the state of the harness and if it is abnormal,
replace it.

- 47 -
9-4 FAILURE DIAGNOSIS MODE TABLE
This engine has the failure diagnosis system to know that low voltage of DC battery and each wiring whether
disconnecting or electrical short circuit.
The ECU monitors engine various conditions for the system when turn the key to the “RUN”(ON) position.

DISPLAY MODE (WHEN IGNITION SWITCH ON)

DISPLAY MODE CONDITION LAMP CONTROL

BLINK CODE NO FAILURE STEP1. LAMP ON TWO SECONDS

STEP2. LAMP OFF FOUR SECONDS
STEP3. LAMP OFF

DETECT FAILURE STEP1 AND 2 IS SAME AS "NO FAILURE"

STEP3. DISPLAY BLINK CODE
IF MORE THAN ONE FAILURE OCCURED,
BLINK CODE WILL BE DISPLAYED IN ORDER
(FROM 21 TO 51) FOLLOWED BY A PAUSE.

DISPLAY MODE (AFTER IGNITION SWITCH ON)

DISPLAY MODE CONDITION LAMP CONTROL

BLINK CODE NO FAILURE STEP1. LAMP OFF

DETECT FAILURE STEP1. LAMP OFF FOUR SECONDS

STEP2. DISPLAY BLINK CODE
IF MORE THAN ONE FAILURE OCCURED,
BLINK CODE WILL BE DISPLAYED IN ORDER
(FROM 21 TO 51) FOLLOWED BY A PAUSE.

CODE 22

BLINK CODE FAILURE DESCRIPTION

21 BATTERY VOLTAGE LOW

22 MAP SENSOR OPEN CONNECTION OR SHORTED CONNECTION
23 TEMP SENSOR OPEN CONNECTION OR SHORTED CONNECTION
31 FUEL PUMP OPEN CONNECTION
41 INJECTOR OPEN CONNECTION
51 IGNITION PULSE OPEN CONNECTION

- 48 -
10. STANDARD REPAIR TABLES
“STD” in the following table is the parts dimension from the brand new engine or the spare parts.
Whereas, “Limit” shows the maximum allowance for the parts to be used on the engine.
If the measurement exceeds beyond the “Limit”, the part needs to be replaced and/or repaired.

10-1 STANDARD DIMENSIONS AND LIMITS OF USE Unit: mm (in.)

ITEM STD Limit
CYLINDER HEAD
* Flatness

0.05 0.1
(0.002) (0.004)

* Intake/exhaust valve seat

contact width

Intake 0.7 - 1.0

-
Exhaust (0.0276 - 0.0394)

* Intake/exhaust valve guide inner diameter

Intake 6.035 - 6.053

-
Exhaust (0.2376 - 0.2383)

* Rocker arm pin outer diameter

D1 D2
Pin outer diameter 7.970 - 7.980 7.9
D1, D2 (0.3138 - 0.3142) (0.3110)

* Rocker arm pin support inner diameter

D3 D4

Support inner diameter 8.00 - 8.018 8.05

D3, D4 (0.3150 - 0.3157) (0.3169)

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 Unit: mm (in.)

ITEM STD Limit

CYLINDER
* Inner diameter To be rebored when the
89.000 - 89.022 difference between max.
Standard
(3.5039 - 3.5040) and min. of diameter
reached to 0.1 (0.004).

89.250 - 89.272
First reboring Ditto
(3.5138 - 3.5147)

89.500 - 89.522
Second reboring Ditto
(3.5236 - 3.5245)

* Roundness after reboring

Less than 0.01

(0.0004)

* Cylindricity after reboring

Less than 0.015

(0.0006)

PISTON
* Outer diameter at skirt in thrust direction

88.980 - 89.000 88.89

Standard
(3.5032 - 3.5039) (3.4996)

Oversize 89.230 - 89.250 89.14

+0.25 (3.5130 - 3.5138) (3.5095)

Oversize 89.480 - 89.500 89.39

+0.50 (3.5228 - 3.5236) (3.5193)

- 50 -
 Unit: mm (in.)

ITEM STD Limit

PISTON
* Ring groove side clearance
0.050 - 0.090 0.15
Top
(0.0020 - 0.0035) (0.0059)

Oil ring 0.030 - 0.125

-
(three-piece) (0.0012 - 0.0049)

* Piston pin hole

20.989 - 21.022 21.045

(0.8263 - 0.8276) (0.82854)

* Piston pin outer diameter

20.992 - 21.000 20.960

(0.8265 - 0.8268) (0.8252)

* Clearance between piston and cylinder at skirt

0.065 - 0.107 0.25

(0.0026 - 0.0042) (0.0098)

* Piston ring end gap

0.10 - 0.25 1.5

Top
(0.0039 - 0.0098) (0.0591)

Oil ring 0.15 - 0.55 1.5

(three-piece) (0.0059 - 0.0217) (0.0591)

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 Unit: mm (in.)

ITEM STD Limit

CONNECTING ROD
* Large end inner diameter

38.000 - 38.016 38.1

(1.4961 - 1.4967) (1.5000)

* Clearance between large end and crank pin

0.030 - 0.060 0.2

(0.0012 - 0.0024) (0.0079)

* Small end inner diameter

21.010 - 21.023 21.08

(0.8272 - 0.8277) (0.8299)

* Clearance between small end and piston pin

0.010 - 0.032 0.12

(0.0004 - 0.0013) (0.0047)

* Large end side clearance

0.100 - 0.780 1.0

(0.0039 - 0.0307) (0.0394)

CRANKSHAFT
* Crank pin outer diameter

37.956 - 37.970 37.85

(1.49433 - 1.4949) (1.4902)

* Journal outer diameter

34.986 - 34.997
D1
(1.3774 - 1.3778)
D1 D2

34.986 - 34.997
D2
(1.3774 - 1.3778)

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 Unit: mm (in.)

ITEM STD Limit

CAMSHAFT
* Cam peak height (intake and exhaust) 35.658 - 35.758 35.61
Intake
(1.4039 - 1.4078) (1.4020)
EXHAUST
Cam peak
height
INTAKE
39.408 - 39.508 39.36
Exhaust
(1.5515 - 1.5554) (1.5496)

Cam inner diameter 10.0 - 10.036 10.05

D1,D2 (0.3937 - 0.3951) (0.3957)

* Cam sprocket inner diameter

* Pin (cam sprocket) outer diameter

Pin outer diameter 9.953 - 9.975 9.95

D1 D2 D3 D4
D3,D4 (0.3919 - 0.3927) (0.3917)

INTAKE/EXHAUST VALVES
* Valve stem outer diameter
5.970 - 5.985 5.85
Intake
(0.2350 - 0.2356) (0.2303)

5.970 - 5.985 5.85

Exhaust
(0.2350 - 0.2356) (0.2303)

* Clearance between valve stem and valve guide

0.050 - 0.083 0.3
Intake
(0.0197 - 0.0033) (0.0118)

0.050 - 0.083 0.3

Exhaust
(0.0197 - 0.0033) (0.0118)

* Valve clearance (in cold state)

0.12 - 0.15 0.25
Intake
(0.0047 - 0.0059) (0.0098)

0.12 - 0.15 0.25

Exhaust
(0.0047 - 0.0059) (0.0098)

- 53 -
 Unit: mm (in.)

ITEM STD Limit

VALVE SPRING FREE LENGTH

36.5
(1.4370)

VALVE SEAT ANGLE (INTAKE AND EXHAUST)

* Valve cutter angle (a)
* Valve contact width (b)

a: 90°
Intake
b: 0.7 - 1.0 2.0
Exhaust
(0.0276 - 0.0394) (0.0787)

CHAIN LENGTH

160N (16kgf.)
F

L 346.20 349.0
(13.6299) (13.7402)

10-2 SERVICE DATA (The following are only for your reference.)
EX40
Compression pressure (Mpa / 500 rpm) 1.15 Mpa
Capacity (L) 1.2
Lubricant Effective Capacity (mL) 600
Consumption (mL/Hr) 7~11

Above numbers may change under each operating conditions

- 54 -
10-3 TIGHTENING TORQUE

Tightening Torque
ITEM
N・m kgf・cm ft・lb

Re-use 29.0 - 31.0 290 - 310 21.0 - 22.4

M10×75 flange bolt When replace to new

Cylinder head bolts cylinder head and 37.0 - 39.0 370 - 390 26.7 - 28.2
flange bolts

M8×35 flange bolt 17.0 - 19.0 170 - 190 12.3 - 13.7

Connecting rod cap bolts 22.5 - 27.5 225 - 275 16.3 - 19.9

Flywheel nut 100.0 - 120.0 1000 - 1200 72.3 - 86.8

Main bearing cover bolts 22.0 - 24.0 220 - 240 16.2 - 17.7

New 12.0 - 15.0 120 - 150 8.7 - 10.8

Spark plug
Re-tightening 23.0 - 27.0 230 - 270 16.6 - 19.5

Muffler nut 18.0 - 22.0 180 - 220 13.0 - 16.2

Ignition coil 7.0 - 9.0 70 - 90 5.1 - 6.5

Oil sensor 8.0 - 10.0 80 - 100 5.8 - 7.2

10-4 AIR GAP AND CLEARANCE

Clearance
ITEM
mm in.

Valve clearance (Intake, Exhaust) 0.12 - 0.15 0.0047 - 0.0059

Air gap (Ignition and flywheel) 0.3 - 0.5 0.012 - 0.020

Electrode gap (Spark plug) 0.6 - 0.7 0.024 - 0.028

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11.PERIODIC MAINTENANCE
18-1 PERIODIC MAINTENANCE SCHEDULE TABLE
Every Every Every Every Every
Maintenance Items 8 hours 50 hours 200 hours 500 1000
(Daily) (Weekly) (Monthly) hours hours

Clean engine and check bolts and nuts ● (Daily)

Check and refill engine oil ● (Refill daily up to upper level)

Change engine oil (*Note : 1) ● (Initial 20 hours) ● (Every 200 hours)

Replace engine oil filter (*Note 1) ● (Initial 20 hours) ●

Clean spark plug ●

Clean air cleaner ●

Clean spark arrester (Optional part) ● (Every 100 hours)

Replace air cleaner element ●

Clean fuel strainer ●

Clean and adjust spark plug and electrodes ●

Replace spark plug ●

Remove carbon from cylinder head ●

Clean throttle body ●

Check and adjust valve clearance ●

Overhaul engine (*Note : 2) ●

*Note : 1. Initial oil change and oil filter replacement should be performed after 100 hours of operation.
Thereafter change oil every 200 hours and replace oil filter 200 hours.
Before changing oil, check for a suitable way to dispose of old oil.
Do not pour it down into sewage drains, onto garden soil or into open streams.
Your local zoning or environmental regulations will give you more detailed instructions
on proper disposal.

*Note : 2. As to the procedures, please refer to the Service Manual or consult your nearest service dealer.

*Note : 3. More frequent oil changing, oil filter replacement and air cleaner service on replacement
may be necessary depending on operating conditions.
This would include dusty environment, high ambient temperature, heavy engine loading.

- 56 -
18-2 ENGINE STORAGE
(1) Carry out the maintenance jobs described in step 18-1 above.
(2) To prevent rust in the cylinder bore, inject 5cc oil through the spark plug hole, run motor 1~2 seconds and
then put back the spark plug.
(3) Clean the exterior of the engine with an oiled cloth. Place a plastic cover or similar over the engine,
and store the engine in a dry place.

- 57 -
NOTES
Club Car, LLC Web www.clubcar.com
P.O. Box 204658 Phone 1.706.863.3000
Augusta, GA 30917-4658 1.800.ClubCar
USA Int’l +1 706.863.3000
Fax 1.706.863.5808