Suzuki K6A-YH6 Engine Technical Repair Manual

Suzuki K6A-YH6 Engine Technical/Repair Manual WARNING: If incorrectly used this machine can cause severe injury. Those who use and maintain this machine should be trained in its proper use, warned of its dangers and should read the entire manual before attempting to set up, operate, adjust or service the machine. ! ©2007 Jacobsen, A Textron Company. All rights reserved. When Performance Matters. ™

3 Foreword General This manual provides detailed information and procedures to safely repair and maintain the following: Suzuki K6A-YH6 gasoline engine This manual is intended to introduce and guide the user through the latest factory-approved troubleshooting and repair techniques and practices. Before you attempt to troubleshoot or make repairs, you must be familiar with the operation of this engine. Refer to the operator’s manual and parts manual for specific information on these topics. THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON ENGINES MANUFACTURED UP TO THE TIME OF PUBLICATION. JACOBSEN RESERVES THE RIGHT TO CHANGE ANY OF THIS INFORMATION WITHOUT NOTICE. CALIFORNIA Proposition 65 Warning ! WARNING Trademark Acknowledgement Jacobsen acknowledges the following trademarks for company names or products mentioned within this publication: Jacobsen® is a registered trademark of Textron Inc. Suzuki® is a registered trademark of the American Suzuki Motors Corporation ThreeBond™ is a trademark of the ThreeBond Co., Ltd. Plastigage® is a registered trademark of AE Clevite Inc. Certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

4 FOREWORD How to Use This Manual This manual is designed to provide multiple ways to locate and access repair information. Read each section in entirety before beginning a procedure. Proper understanding of machine operation and components is the key to successful diagnostics and repair. Make use of special information features with in this manual in order to be better prepared to perform repairs. Always follow manual procedures and safety guidelines. Never take shortcuts. Table of Contents Major machine components or topics of interest are separated into specific chapters. Each manual lists these chapters in a main Table of Contents. Chapter Table of Contents Each chapter begins with a detailed Table of Contents related to the specific machine component or system. Use the Chapter Table of Contents to find specific component or procedural information. Index An alphabetical Index is located at the back of the manual. Use the Index to find specific components and related procedures. Required Tools and Materials Some procedures will require the use of specific tools and/or materials. These tools and/or materials will be listed for reference, prior to beginning a procedure. Specifications Specifications are listed at the point of use with in the procedure. Quick Reference Specifications A list of all machine specifications can be found in Chapter 2 Specifications and General Information. This is a list of all specifications from each chapter, combined and listed in one place for easy reference. Warnings and Cautions Warning and Caution indicators are located throughout the manual at specific points of interest. These notices are given to prevent personal injury, death and/or equipment damage. Always heed these notices, and practice common sense when performing any maintenance or repair procedure. Notes Special notes are given in order to draw attention to detailed instructions. These notes are intended to give further important information regarding the machine and/or a step in a procedure. Troubleshooting Troubleshooting charts are provided in chapter 6 to aid in the diagnostic process. Use these suggestions to aid in identifying a potential mechanical or machine adjustment problem. Copyright 2007 Textron Inc. “All rights reserved, including the right to reproduce this material or portions thereof in any form.”

2 3 4 5 6 7 8 Table of Contents 5 1 Safety Specifications and General Information Maintenance Theory of Operation Test and Adjustments Diagnostic Troubleshooting Repair Tools and Materials

1-1 Chapter 1 1 Safety Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Prepare for the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Keep Work Area Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Keep Work Area Well Ventilated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Use Proper Eye and Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Use Lifting Equipment Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Use Compressed Air and Air Tools Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Handle Fuel Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Store Volatile and Hazardous Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Handle Chemical Products Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Service Electrical Components Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Dispose of Waste Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-2 SAFETY 1 Page Intentionally Blank

SAFETY 1-3 1 Introduction Safety is the most important element of any repair procedure. Knowledge of the procedure to be performed and safe work habits are essential to preventing death, personal injury, or property damage. Use the following statements as a common-sense guide to proper work and tool-use habits. Prepare for the Job Preparation is essential to complete a procedure in a safe and efficient manner. • Wear proper clothing. Loose or baggy clothing could become tangled in moving parts. • Use eye/face protection. Always use proper eye/face protection to protect your eyes from flying debris or chemical splatters. • Wear protective footwear. Wear safety shoes (steel-toe) to protect your feet from falling objects. • Use gloves when handling parts. Parts may have sharp edges or may be hot. • Remove jewelry prior to servicing electrical systems. • Prepare proper tools and equipment. Always use the correct tool for the job. Improper or homemade tools can cause injury or machine damage. • Prepare needed parts and materials. Gather the needed parts and materials before beginning the procedure. • Allow machine to cool. Many components can get hot during operation. Be sure to allow enough time for components to cool before beginning service. • Prepare proper work-space lighting. A well-lit work area can make the job easier. • Follow procedures and safety warnings. Service procedures are written to be as safe and efficient as possible. Never take shortcuts. • Be prepared for emergencies. Accidents can happen, even under the best conditions. Fire extinguishers and first aid kits should be well maintained and easily accessible. Safety Notices Throughout this manual, the following key safety words will be used to alert the reader of potential hazards. Become familiar with these words and their meaning. Take all precautions to avoid the hazards described. ! DANGER ! WARNING ! CAUTION NOTICE Keep Work Area Clean A clean, organized, well lit work area is important to promote safe working conditions. • Keep floor clean of debris and clear of parts and tools. • Clean up any spilled fuel, oil, and/or chemicals immediately. • Store all air hoses and electrical cords properly when not in use. This safety alert symbol is used to alert you to potential hazards. Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury and property damage. It may also be used to alert against unsafe practices. Indicates a potentially hazardous situation which, if not avoided, MAY result in property damage. It may also be used to alert against unsafe practices. !

1-4 SAFETY 1 Keep Work Area Well Ventilated ! WARNING Certain test and adjustment procedures require the engine to be running. Be sure work area is well ventilated; never run the engine in an enclosed area. Use Proper Eye and Face Protection ! WARNING Always wear eye protection while in a shop environment. • Safety Glasses: Safety glasses offer a minimum level of protection from flying debris. • Face Shields: Face shields are often used along with safety glasses to offer a higher level of protection when sparks and flying debris are present. • Vented Goggles: Goggles offer side protection not offered by safety glasses alone. • Unvented Goggles: Unvented goggles offer protection from chemical splashes and vapors. Use Lifting Equipment Safely ! WARNING • Always use a lifting device with a lifting capacity greater than the weight of the item being lifted. • Secure the load to the lifting device using cables, chains, or slings rated to handle the load being lifted. Fasteners being used to connect lifting devices must be strong enough to handle the load. Also be sure the mounting point of load is strong enough to handle the load. • When using a lifting device, always connect the load so it is balanced. • Always use a lifting device on a hard, level surface. • Lower the lifting device to the lowest point before moving. Move the load slowly. • Always support the load as soon as possible; never leave a load suspended in mid-air. Use Compressed Air and Air Tools Safely ! WARNING • Compressed air is a useful tool when used in a safe manner. • Always use eye and ear protection while using compressed air and air tools. • When using air tools, do not exceed the air pressure rating for the tool. • When using an impact wrench, always use approved impact sockets. Never use standard sockets on an impact wrench. • Disconnect the air supply before changing air tool attachments. • Never point air nozzles or air tools at another person. • Always maintain air tools properly. Never operate the engine without proper ventilation; exhaust fumes can be fatal if inhaled. Always use approved personal protection equipment. Avoid workplace hazards by wearing properly maintained, approved eye and face protection. Failure to use appropriate protection equipment may result in death or serious injury. Always check the lifting capacity and condition of hoists, slings, cables, or chains before use. Using underrated or worn lifting components can result in death or serious injury. Always wear approved eye and ear protection while using compressed air. Misuse of compressed air could result in death or serious injury. • When using air nozzles, air pressure should not exceed 30 psi (206.8 kPa). • Never direct air nozzles or tools at a person. • Never point air nozzles directly at skin.

SAFETY 1-5 1 Handle Fuel Safely Handle fuel with care—it is highly flammable. ! WARNING Store fuel according to local, state, or federal ordinances and recommendations from your fuel supplier. Never overfill or allow the tank to become empty. Use clean, fresh fuel. Do not fill above the fuel filler neck. Store Volatile and Hazardous Materials Safely Store volatile materials (gasoline, diesel fuel, oil, etc.) in approved containers that are clearly marked. Containers should be stored in an approved safety cabinet away from possible sources of ignition. Storage areas and cabinets should be well ventilated to prevent the possible build-up of fumes. Handle Chemical Products Safely ! WARNING Routine service often requires the use of various chemical products, including lubricants and cleaning solutions. Many of these chemicals are flammable and can pose health risks if not handled properly. • Never mix chemicals. Mixing chemicals can produce toxic or explosive results. • Follow the manufacture’s recommendations for safe usage and handling of the product. • Various materials may pose a health hazard if used incorrectly. A Material Safety Data Sheet (MSDS) contains important information regarding proper handling and health hazards, as well as emergency response procedures. Contact the chemical manufacturer to obtain an MSDS for the chemical product. Service Electrical Components Safely ! WARNING • Disconnect the battery negative (–) cable before removing or installing electrical components. Always connect the battery negative (–) cable last. • Certain test and adjustment procedures must be performed with the battery connected. Use care to prevent arcing when working on live circuits or components. Arcing can cause component damage and could ignite flammable materials. • Never remove the fuel cap from the fuel tank, or add fuel, when the engine is running or while the engine is hot. • Do not smoke when handling fuel. Never fill or drain the fuel tank indoors. • Do not spill fuel. Clean spilled fuel immediately. • Never handle or store fuel containers near an open flame or any device that may create sparks and ignite the fuel or fuel vapors. • Be sure to reinstall and tighten fuel cap securely. • Use an approved container; the spout must fit inside the fuel filler neck. Avoid using cans and funnels to transfer fuel. Exposure to chemical products could result in serious injury. Handle chemical products with care. Refer to the chemical manufacturer’s Material Safety Data Sheet (MSDS) for information regarding health hazards, safe handling, and emergency response procedures. Always disconnect the negative terminal first and positive terminal last. Connect positive terminal first and negative terminal last. Use care when testing live circuits to prevent arcing. Arcing could result in death or serious injury.

1-6 SAFETY 1 Dispose of Waste Materials Safely Routine service can produce waste products such as used oil, grease, and used batteries. If not handled properly, these materials can pose a threat to the environment. Collect fluids in well-marked, approved storage containers. Some waste fluids can react with certain types of plastics. Make sure the fluid to be stored is compatible with the storage container. Never use food or beverage containers to store waste fluids. IMPORTANT • Dispose of waste fluids properly at approved local recycling centers. If recycling facilities are not available, contact your local community for the correct disposal procedure for waste fluids. • Dispose of old batteries properly. Battery electrolyte contains sulfuric acid and other hazardous materials. Never place an old battery in the trash. Batteries must be disposed of in a manner consistent with EPA and/or local regulations. Never dispose of waste fluids by pouring on the ground, down sewer drains, or into any body of water.

Suzuki K6A-YH6 Engine Technical Repair Manual

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