WORKSHOP MANUAL
GR1600EC
KiSC issued 04, 2006 A
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of KUBOTA GR1600EC. It is divided into three parts, "General", "Mechanism" and
"Servicing".
B General
Information on the product identification, the general precautions, maintenance check list, check and maintenance
and special tools are described.
B Mechanism
Information on the construction and function are included. This part should be understood before proceeding with
troubleshooting, disassembling and servicing.
B Servicing
Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting,
disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and
allowable limits.
All information illustrations and specifications contained in this manual are based on the latest product information
available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used have not been specified as one
model.
February 2005
KUBOTA Corporation 2005
0000009635E
KiSC issued 04, 2006 A
GR1600EC, WSM
SAFETY INSTRUCTIONS
This symbol, the industry's "Safety Alert Symbol" is used throughout this manual and on labels on the machine
itself to warn of the possibility of personal injury. Read these instructions carefully.It is essential that you read the
instructions and safety regulations before you attempt to repair or use this unit.
A Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
A Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
A Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
A Indicates that equipment or property damage could result if instructions are not followed.
A Gives helpful information.
0000000752E
BEFORE SERVICING AND REPAIRING
A Read all instructions and safety instructions in this
manual and on your machine safety decals.
A Clean the work area and machine.
A Park the machine on a firm and level ground, and set
the parking brake.
A Lower the implement to the ground.
A Stop the engine, and remove the key
A Disconnect the battery negative cable
A Hang a "DO NOT OPERATE" tag in operator
station.
0000000753E
SAFETY STARTING
A Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
A Do not alter or remove any part of machine safety
system.
A Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
A Never start the engine while standing on ground.
Start the engine only from operator's seat.
0000000754E
1
KiSC issued 04, 2006 A
GR1600EC, WSM
SAFETY INSTRUCTIONS
SAFETY WORKING
A Do not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued.
A Wear close fitting clothing and safety equipment
appropriate to the job.
A Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
A When servicing is performed together by two or
more persons, take care to perform all work safely.
A Do not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
A Do not touch the rotating or hot parts while the
engine is running.
A Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
hot water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
A Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
0000000755E
AVOID FIRES
A Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
A To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
A Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
A Make sure that no fuel has been spilled on the
engine.
0000000756E
2
KiSC issued 04, 2006 A
GR1600EC, WSM
SAFETY INSTRUCTIONS
VENTILATE WORK AREA
A If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains
poisonous carbon monoxide.
0000000757E
PREVENT ACID BURNS
A Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
0000000758E
DISPOSE OF FLUIDS PROPERLY
A Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental
protection
regulations
when
disposing of oil, fuel, coolant, electrolyte and other
harmful waste.
0000000759E
PREPARE FOR EMERGENCIES
A Keep a first aid kit and fire extinguisher handy at all
times.
A Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
0000000760E
3
KiSC issued 04, 2006 A
GR1600EC, WSM
SAFETY INSTRUCTIONS
SAFETY DECALS
The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not
on the machine, replace it. The decal part number is listed in the parts list.
0000009636E
4
KiSC issued 04, 2006 A
GR1600EC, WSM
SAFETY INSTRUCTIONS
0000009633E
5
KiSC issued 04, 2006 A
GR1600EC, WSM
SAFETY INSTRUCTIONS
0000009634E
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KiSC issued 04, 2006 A
GR1600EC, WSM
SPECIFICATIONS
SPECIFICATIONS
Model
GR1600EC
Maker
KUBOTA
Model
Z482-E2-GX
Type
Indirect injection. Vertical, water-cooled, 4-cycle diesel
Number of cylinders
2
Bore and stroke
67 x 68 mm (2.64 x 2.68 in.)
Total displacement
Engine
479
Engine gross power (DIN)
(29.9 cu.in.)
10.0 kW (13.4 HP)
Rated revolution
53.3 r/s [3200
Battery
(rpm)]
51R (12 V, 450CCA)
Starting system
Cell starter (with glow plug)
Lubrication system
Forced lubrication by trochoidal pump
Cooling system
Pressurized radiator, forced circulation with water pump
Diesel fuel No.2-D [above -10
Diesel fuel No.1-D [below -10
Fuel
Fuel tank
(14
(14
)],
)]
18 L (4.8 U.S.gals, 4.0 lmp.gals)
Engine crankcase (with filter)
1.2 L (1.27 U.S.qts., 1.06 lmp.qts.)
Engine coolant (with recovery tank)
2.15 L (2.27 U.S.qts., 1.89 lmp.qts.)
Transmission case
2.7 L (0.71 U.S.gals., 0.59 lmp.gals.)
Capacities
Overall length (with grass catcher)
2460 mm (96.9 in.)
Overall width
1110 mm (43.7 in.)
Overall height
1190 mm (46.9 in.)
Wheel base
1280 mm (50.4 in.)
Dimensions
Front
750 mm (29.5 in.)
Rear
800 mm (31.5 in.)
Tread
Weight (without mower and grass catcher)
310 kg (684 lbs)
Front
15 x 6.00 - 6, 4PR
Rear
20 x 10.00 - 8, 4PR
Tires
Steering
Manual (Sector gear type)
Transmission
Hydrostatic transmission
Brake
Internal expanding brake
Traveling system
Differential
Bevel gear
Forward
0.0 to 10.0 km/h (0.0 to 6.2 mph)
Reverse
0.0 to 5.0 km/h (0.0 to 3.1 mph)
Traveling speed
Clutch
Mechanical wet multi discs
PTO system
PTO brake
Wet multi discs
NOTE: *Manufacture's estimate
The company reserves the right to change the specifications without notice.
0000009637E
7
KiSC issued 04, 2006 A
GR1600EC, WSM
SPECIFICATIONS
Model
RCK42GR
Cutting width
1067 mm (42.0 in.)
Cutting height
25 to 102 mm (1 to 4 in.)
Adjustment of cutting height
Dual gauge
Mounting method
Quick joint, Parallel linkage
Weight (Approx.)
75 kg (165 lbs)
Mower
Dimensions
Total length
965 mm (38.0 in.)
Total width
1110 mm (43.7 in.)
Total height
295 mm (11.6 in.)
Discharge direction
Rear
Gear box oil
0.33 L (0.35 U.S.qts, 0.29 Imp.qts)
Model
GCK350GR
Container capacity
350 L (92.5 U.S.gals, 77.0 Imp.gals)
Grass catcher
Weight (Approx.)
40 kg (88.2 lbs)
NOTE: *Manufacture's estimate
The company reserves the right to change the specifications without notice.
0000009638E
8
KiSC issued 04, 2006 A
GR1600EC, WSM
DIMENSIONS
DIMENSIONS
0000009634E
9
KiSC issued 04, 2006 A
G
GENERAL
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
[1]
[2]
[3]
[4]
[5]
4.
5.
[1]
[2]
[3]
IDENTIFICATION ................................................................................................................G-1
GENERAL PRECAUTIONS................................................................................................G-2
HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING......................G-3
WIRING..............................................................................................................................G-3
BATTERY ..........................................................................................................................G-5
FUSE .................................................................................................................................G-5
CONNECTOR....................................................................................................................G-5
HANDLING OF CIRCUIT TESTER.................................................................................G-7
LUBRICANTS, FUEL AND COOLANT .............................................................................G-8
TIGHTENING TORQUES ...................................................................................................G-9
GENERAL USE SCREWS, BOLTS AND NUTS ..........................................................G-9
METRIC SCREWS, BOLTS AND NUTS .......................................................................G-9
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF
THREADS........................................................................................................................G-10
[4] PLUGS.............................................................................................................................G-10
6. MAINTENANCE CHECK LIST ........................................................................................G-11
7. CHECK AND MAINTENANCE ........................................................................................G-13
[1] DAILY CHECK ................................................................................................................G-13
[2] CHECK POINTS OF EVERY 50 HOURS ...................................................................G-19
[3] CHECK POINTS OF EVERY 100 HOURS .................................................................G-25
[4] CHECK POINT OF EVERY 150 HOURS ...................................................................G-27
[5] CHECK POINTS OF EVERY 200 HOURS .................................................................G-28
[6] CHECK POINT OF EVERY 400 HOURS ...................................................................G-31
[7] CHECK POINTS OF EVERY 1 YEAR ........................................................................G-31
[8] CHECK POINTS OF EVERY 2 YEARS......................................................................G-34
[9] OTHERS ..........................................................................................................................G-35
8. SPECIAL TOOLS .............................................................................................................G-38
[1] SPECIAL TOOLS FOR ENGINE ..................................................................................G-38
[2] SPECIAL TOOLS FOR MACHINE ...............................................................................G-45
9. TIRES ................................................................................................................................G-46
[1] TIRE PRESSURE ...........................................................................................................G-46
[2] TREAD.............................................................................................................................G-46
10. IMPLEMENT LIMITATIONS .............................................................................................G-47
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
1. IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
engine serial number (2), machine serial number (1), mower serial
number (3) and hour meter reading.
(1)
Machine Serial Number
(3)
Mower Serial Number
(2)
Engine Serial Number
(4)
Hour Meter
0000009540E
G-1
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
2. GENERAL PRECAUTIONS
A During disassembly, carefully arrange removed parts in a
clean area to prevent confusion later. Screws, bolts and nuts
should be installed in their original position to prevent
reassembly errors.
A When special tools are required, use KUBOTA genuine
special tools. Special tools which are not frequently used
should be made according to the drawings provided.
A Before disassembling or servicing electrical wires, always
disconnect the ground cable from the battery first.
A Remove oil and dirt from parts before measuring.
A Use only KUBOTA genuine parts for parts replacement to
maintain machine performance and to assure safety.
A Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
See the figure left side.
A When reassembling external snap rings or internal snap rings
, they must be positioned so that sharp edge faces against the
direction from which a force is applied. See the figure left side.
A When inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
A To prevent damage to the hydraulic system, use only specified
fluid or equivalent.
(1)
Grease
(A)
External Snap Ring
(2)
Force
(B)
Internal Snap Ring
(3)
Sharp Edge
(4)
Axial Force
(5)
Rotating Movement
0000000612E
G-2
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING
To ensure safety and prevent damage to the machine and
surrounding equipment, heed the following precautions in
handling electrical parts and wiring.
A Check electrical wiring for damage and loosened
connection every year. To this end, educate the customer
to do his or her own check and at the same time
recommend the dealer to perform periodic check for a fee.
A Do not attempt to modify or remodel any electrical parts
and wiring.
A When removing the battery cables, disconnect the
negative cable first. When installing the battery cables,
connect the positive cable first.
(1)
Negative Terminal
(2)
Positive Terminal
0000000613E
[1] WIRING
A Securely tighten wiring terminals.
(1)
Correct
(2)
(Securely Tighten)
Incorrect
(Loosening Leads to Faulty
Contact)
0000000614E
A Do not let wiring contact dangerous part.
(1)
Dangerous Part
(3)
Wiring (Correct)
(2)
Wiring (Incorrect)
(4)
Dangerous Part
0000000615E
A Securely insert grommet.
(1)
Grommet
(A)
Correct
(B)
Incorrect
0000000616E
G-3
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
A Securely clamp, being careful not to damage wiring.
(1)
(2)
Clamp
(3)
Clamp
*Wind Clamp Spirally
(4)
Welding Dent
Wire Harness
0000000617E
A Clamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag be
required.
(1)
Wiring
(A)
Correct
(2)
Clamp
(B)
Incorrect
0000000618E
A In installing a part, take care not to get wiring caught by it.
(1)
Wiring
(A)
Incorrect
0000000619E
A After installing wiring, check protection of terminals and
clamped condition of wiring, only connect battery.
(1)
Cover
*Securely Install Cover
0000000620E
G-4
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
[2] BATTERY
A Take care not to confuse positive and negative terminal posts.
A When removing battery cables, disconnect negative cable
first. When installing battery cables, check for polarity and
connect positive cable first.
A Do not install any battery with capacity other than is specified
(Ah).
A After connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal
covers on them.
A Do not allow dirt and dust to collect on battery.
A Take care not to let battery liquid spill on your skin and
clothes.
If contaminated, wash it off with water
immediately.
A Before recharging the battery, remove it from the
machine.
A Before recharging, remove cell caps.
A Do recharging in a well-ventilated place where there is no
open flame nearby, as hydrogen gas and oxygen are
formed.
0000000621E
[3] FUSE
A Use fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
A Never use steel or copper wire in place of fuse.
A Do not install working light, radio set, etc. on machine which is
not provided with reserve power supply.
A Do not install accessories if fuse capacity of reserve power
supply is exceeded.
(1)
Fuse
(2)
Fusible Link
0000000622E
[4] CONNECTOR
A For connector with lock, push lock to separate.
(A)
Push
0000000623E
G-5
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
A In separating connectors, do not pull wire harnesses.
A Hold connector bodies to separate.
(A)
Correct
(B)
Incorrect
0000000624E
A Use sandpaper to remove rust from terminals.
A Repair deformed terminal. Make certain there is no terminal
being exposed or displaced.
(1)
Exposed Terminal
(3)
Sandpaper
(2)
Deformed Terminal
(4)
Rust
0000000625E
A Make certain that there is no female connector being too open.
(A)
Correct
(B)
Incorrect
0000000626E
A Make certain plastic cover is large enough to cover whole
connector.
(1)
Cover
(A)
Correct
(B)
Incorrect
0000000627E
G-6
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
[5] HANDLING OF CIRCUIT TESTER
A Use tester correctly following manual provided with tester.
A Check for polarity and range.
0000000628E
G-7
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
4. LUBRICANTS, FUEL AND COOLANT
No.
Place
Capacity
Lubricants, fuel and coolant
1
Fuel tank
18 L
4.8 U.S.gals.
4.0 lmp.gals.
No. 2-D diesel fuel
No. 1-D diesel fuel if temperature is below
-10
(14 )
2
Cooling system with
recovery tank
2.15 L
2.27 U.S.qts.
1.89 lmp.qts.
Fresh clean water with anti-freeze
3
Engine crankcase
1.2 L
1.27 U.S.qts.
1.06 lmp.qts.
Engine oil: API service CD, CE or CF
Below 0
(32 ) : SAE10W, 10W-30 or 10W-40
0 to 25
(32 to 77 ) : SAE20, 10W-30 or 10W-40
Above 25
(77 ) : SAE30, 10W-30 or 10W-40
4
Transmission case
2.7 L
0.71 U.S.gals.
0.59 lmp.gals.
KUBOTA UDT or SUPER UDT fluid*
5
Mower gear box
0.33 L
0.35 U.S.qts.
0.29 lmp.qts.
SAE90 gear oil
(API service classification : more than GL-3)
Greasing
No.
Place
No. of greasing points
6
Engine transmission
universal joint
1
7
King pin
2
8
Center pin
9
Speed control pedal shaft
10
Mower link
11
Seat adjuster
12
Cable
13
PTO lever
14
Hydraulic lift lever
15
Grass catcher hinge
Capacity
Type of grease
Until grease overflows
SAE multi-purpose type
grease
Moderate amount
Engine oil
Until grease overflows
SAE multi-purpose type
grease
Moderate amount
Engine oil
[Mower]
16
Spindle shafts
2
17
Tension arm
1
18
Mower universal joint
1
*KUBOTA original transmission hydraulic fluid.
0000009541E
G-8
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
5. TIGHTENING TORQUES
[1] GENERAL USE SCREWS, BOLTS AND NUTS
Screws, bolt and nuts whose tightening torque are not specified in this Workshop Manual should be tightened
according to the table below.
Indication on top of
bolt
No-grade or 4T
Material of bolt
Material of
opponent part
7T
SS400, S20C
Ordinariness
Unit
S43C, S48C
Aluminum
ft-lbs
Diameter
9T
Ordinariness
ft-lbs
SCr435, SCM435
Aluminum
ft-lbs
Ordinariness
ft-lbs
ft-lbs
M6
(6 mm, 0.24 in.)
7.85
to
9.31
0.80
to
0.95
5.79
to
6.87
7.85
to
8.82
0.80
to
0.90
5.79
to
6.50
9.81
to
11.2
1.00
to
1.15
7.24
to
8.31
7.85
to
8.82
0.80
to
0.90
5.79
to
6.50
12.3
to
14.2
1.25
to
1.45
9.05
to
10.4
M8
(8 mm, 0.31 in.)
17.7
to
20.5
1.8
to
2.1
13.1
to
15.1
16.7
to
19.6
1.7
to
2.0
12.3
to
14.4
23.6
to
27.4
2.4
to
2.8
17.4
to
20.2
17.7
to
20.5
1.8
to
2.1
13.1
to
15.1
29.5
to
34.3
3.0
to
3.5
21.7
to
25.3
M10
(10 mm, 0.39 in.)
39.3
to
45.1
4.0
to
4.6
29.0
to
33.2
31.4
to
34.3
3.2
to
3.5
23.2
to
25.3
48.1
to
55.8
4.9
to
5.7
35.5
to
41.2
39.3
to
44.1
4.0
to
4.5
29.0
to
32.5
60.9
to
70.6
6.2
to
7.2
44.9
to
52.0
M12
(12 mm, 0.47 in.)
62.8
to
72.5
6.4
to
7.4
46.3
to
53.5
77.5
to
90.2
7.9
to
9.2
57.2
to
66.5
62.8
to
72.5
6.4
to
7.4
46.3
to
53.5
103
to
117
10.5
to
12.0
76.0
to
86.7
M14
(14 mm, 0.55 in.)
108
to
125
11.0
to
12.8
79.6
to
92.5
124
to
147
12.6
to
15.0
91.2
to
108
167
to
196
17.0
to
20.0
123
to
144
M16
(16 mm, 0.63 in.)
167
to
191
17.0
to
19.5
123
to
141
197
to
225
20.0
to
23.0
145
to
166
260
to
304
26.5
to
31.0
192
to
224
M18
(18 mm, 0.71 in.)
246
to
284
25.0
to
29.0
181
to
209
275
to
318
28.0
to
32.5
203
to
235
344
to
402
35.0
to
41.0
254
to
296
M20
(20 mm, 0.79 in.)
334
to
392
34.0
to
40.0
246
to
289
368
to
431
37.5
to
44.0
272
to
318
491
to
568
50.0
to
58.0
362
to
419
0000001412E
[2] METRIC SCREWS, BOLTS AND NUTS
Property class 8.8
Property class 10.9
Grade
Unit
Nominal
Diameter
ft-lbs
ft-lbs
M8
23.6 to 27.4
2.4 to 2.8
17.4 to 20.2
29.4 to 34.3
3.0 to 3.5
21.7 to 25.3
M10
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
60.8 to 70.5
6.2 to 7.2
44.9 to 52.1
M12
77.5 to 90.1
7.9 to 9.2
57.2 to 66.5
103.0 to 117.0
10.5 to 12.0
76.0 to 86.8
M14
124.0 to 147.0
12.6 to 15.0
91.2 to 108.0
167.0 to 196.0
17.0 to 20.0
123.0 to 144.0
M16
196.0 to 225.0
20.0 to 23.0
145.0 to 166.0
260.0 to 303.0
26.5 to 31.0
192.0 to 224.0
0000001413E
G-9
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR
UNF THREADS
SAE GR.5
Grade
SAE GR.8
Unit
Norminal
Diameter
ft-lbs
ft-lbs
5/16
23.1 to 27.8
2.35 to 2.84
17.0 to 20.5
32.5 to 39.3
3.31 to 4.01
24.0 to 29.0
3/8
47.5 to 57.0
4.84 to 5.82
35.0 to 42.0
61.0 to 73.2
6.22 to 7.47
45.0 to 54.0
1/2
108.5 to 130.2
11.07 to 13.29
80.0 to 96.0
149.2 to 179.0
15.22 to 18.27
110.0 to 132.0
9/16
149.2 to 179.0
15.22 to 18.27
110.0 to 132.0
217.0 to 260.4
22.14 to 26.57
160.0 to 192.0
5/8
203.4 to 244.1
20.75 to 24.91
150.0 to 180.0
298.3 to 358.0
30.44 to 36.53
220.0 to 264.0
0000001414E
[4] PLUGS
Material of opponent part
Shape
Size
Ordinariness
Aluminum
ft-lbs
Tapered
screw
Straight
screw
ft-lbs
R1/8
12.7 to 21.6
1.3 to 2.2
9.4 to 15.9
12.7 to 19.6
1.3 to 2.0
9.4 to 15.4
R1/4
24.5 to 44.1
2.5 to 4.5
18.1 to 32.5
24.5 to 34.3
2.5 to 3.5
18.1 to 25.4
R3/8
49.0 to 88.3
5.0 to 9.0
36.2 to 65.1
49.0 to 58.8
5.0 to 6.0
36.2 to 43.4
R1/2
58.8 to 107.9
6.0 to 11.0
43.4 to 79.6
58.8 to 78.5
6.0 to 8.0
43.4 to 57.9
G1/4
24.5 to 34.3
2.5 to 3.5
18.1 to 25.3
G3/8
61.8 to 82.4
6.3 to 8.4
45.6 to 60.8
G1/2
49.0 to 88.3
5.0 to 9.0
36.2 to 65.1
0000001666E
G-10
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
6. MAINTENANCE CHECK LIST
A The jobs indicated by
must be done initially.
A *1 : This maintenance should be done daily more often in dusty conditions than in normal conditions.
Suggested cleaning interval is every 100 hours in normal conditions.
Indication on hour meter (Hr)
Period
No.
50
Item
100
150
200
250
300
350
400
450
500
550
600
After
since
Important
Reference
page
1
Engine oil
Change
every
100 hr
G-25
2
Engine oil filter
Replace
every
200 hr
G-28
3
Transmission fluid
Change
every
200 hr
G-29
4
Transmission oil filter
Replace
every
200 hr
G-30
5
Transmission strainer
Clean
every
200 hr
G-30
6
Front axle pivot
Adjust
every
200 hr
G-31
7
Safety device
Check
every
50 hr
G-19
8
Oiling
-
every
50 hr
G-21
9
Greasing
-
every
50 hr
G-20
Check
every
50 hr
G-20
Change
every
150 hr
G-27
Clean
every
50 hr
10
11
Mower gear box oil
*1
G-20
Air cleaner element
Replace
every 1
year
G-31
12
Battery condition
Check
every
50 hr
G-23
13
Brake
Adjust
every
100 hr
G-26
14
Fan drive belt tension
Adjust
every
100 hr
G-27
Check
every
100 hr
G-26
Replace
every
400 hr
G-31
15
Fuel filter element
G-11
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Indication on hour meter (Hr)
Period
No.
50
Item
16
17
100
150
200
250
300
350
400
450
500
550
600
After
since
Important
Reference
page
Check
every
100 hr
G-26
Replace
every 2
years
G-34
Check
every
200 hr
G-30
Replace
every 2
years
G-34
Fuel line
Radiator hose and
clamp
18
Radiator core
Check
every
200 hr
G-30
19
Radiator
Clean
every 1
year
G-32
20
Coolant
Change
every 1
year
G-32
21
Mower gear box oil seal
Replace
every 2
years
G-34
22
Fuel system
Bleed
23
Fuse
Replace
24
Blade
Replace
25
Mower belt
Replace
G-37
Service
as required
G-35
G-36
G-37
0000009542E
G-12
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
7. CHECK AND MAINTENANCE
A Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and
chock the wheels.
0000001417E
[1] DAILY CHECK
To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items
before starting.
Checking
A Check areas where previous trouble was experienced.
A Walk around the machine.
1. Tire pressure, wear and damage
2. Oil and water leak
3. Engine oil level
4. Transmission fluid level
5. Coolant level in the recovery tank
6. Damage of machine body, tightness of all bolts and nuts
7. Radiator screen
8. Panel screen
9. Brake play
10. Fuel level
11. Check air cleaner element
A Mower
1. Oil leak
2. Make sure blade cap screws are tight.
3. Blades for wear or damage.
4. Check all hardware.
5. Make sure all pins are in place.
6. Mower deck cleaning
7. Greasing
A While sitting in the operator's seat,
1. Speed control pedal and brake pedal
2. Brake
A Turning the key switch "ON"
1. Performance of the easy checker light.
A Starting the engine
1. Color of the exhaust fumes
2. Safety start switch, seat safety control and another safety devices.
3. Check for abnormal noise and vibration.
A Others
1. Check the areas where previous troubles were experienced.
0000009543E
G-13
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking Engine Oil Level
A Always stop the engine and remove the key before
checking oil.
1. Check engine oil before starting and 5 minutes or more after
the engine has stopped.
2. Wipe dipstick (2) area clean.
3. To check the oil level, remove the dipstick (2), wipe it clean,
reinsert it, and draw it out again. Check to see that the oil level
is between the two notches.
4. Add new oil to the prescribed level at the oil inlet (1) if
necessary.
5. When using a different brand or viscosity oil from the previous
one, remove all of the old oil and oil filter. Never mix two
different types of oil.
6. Use the proper Engine Oil SAE according to the ambient
temperatures. (See page G-8.)
(1)
Engine Oil Inlet
A:
Upper Level
(2)
Oil Level Dipstick
B:
Lower Level
0000009548E
G-14
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking Amount of Fuel and Refueling
A Handle fuel carefully. If the engine is running, do not fill
the fuel tank. If engine is hot, let engine cool several
minutes before adding fuel.
Do not smoke while filling the fuel tank or servicing the
fuel system. Fill fuel tank only to bottom of filler neck.
Check the fuel level. Take care that the fuel tank does not
become empty.
18 L
4.8 U.S.gals.
4.0 Imp.gals.
Fuel tank capacity
A Use Diesel Fuel Only.
1. Use No.2-D diesel fuel.
2. Use No.1-D diesel fuel if the temperature is below -10
(14
).
3. Always use a strainer when refueling to prevent fuel injection
pump contamination.
A No.2-D is a distillate fuel of lower volatility for engines in
industrial and heavy mobile service.
(SAE J313 JUN87)
Grade of Diesel Fuel Oil according to ASTM D975
Water and
Sediment,
volume %
Carbon Residue
on, 10 percent
Residuum %
Ash, weight %
Min
Max
Max
Max
52
0.05
0.35
0.01
Flash point
Distillation
Temperatures
90%
Point
Kinematics Viscosity
cSt or
/S at 40
Saybolt Viscosity, SUS
at 100
Min
Max
Min
Max
Min
Max
282
338
1.9
4.1
32.6
40.1
(1)
Sulfur, weight
Copper strip Corrosion
Cetane Number
Max
Max
Min
0.50
No.3
40
Fuel Cap
0000009549E
G-15
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking and Cleaning Radiator to Prevent Overheating
A Be sure to stop the engine and remove the key before
cleaning.
Daily or after every 5 hours of operation, check to be sure the
radiator screen (2) and radiator core are clean. Dirt or chaff on the
radiator screen (2) or radiator core decrease cooling
performance.
1. Remove the radiator screen (2) and panel screen (1) and
remove all foreign material.
2. Remove the dust from between the fins and the tube.
3. Tighten the fan drive belt as necessary. For this, refer to
"CHECK POINT EVERY 100 HOURS".
4. If scale forms in the tube, clean with the scale inhibitor or its
equivalent.
5. Each time the panel screen (1) is covered with grass during
operation, rub it off the screen with hand. Check the radiator
screen (2) from time to time if grass accumulates.
6. If the dust or chaff has accumulated inside of the panel,
remove the radiator screen (2) and clean inside completely.
After cleaning, reinstall the radiator screen (2) properly.
A When assembling the panel screen (1), be sure to fit it to
panel with no clearance at the bottom.
(1)
Panel Screen
(2)
Radiator Screen
0000009550E
G-16
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking Tire Pressure
A Do not attempt to mount a tire on a rim. This should be
done by a qualified person with the proper equipment.
A Always maintain the correct tire pressure.
Do not inflate tires above the recommended pressure.
A Inflation pressure in front tires rises quickly when using
compressed air.
A Never operate machine with a loose rim, wheel or axle.
A Whenever bolts are loosened, retighten to specified
torque.
A Check all bolts frequently and keep them tightened.
B Inflation Pressure
Though the inflation pressure is factory-set to the prescribed
level, it naturally drops slowly in the course of time. Thus, check
it every day and inflate as necessary.
Recommended Inflation
Pressure
Tire Sizes
(1)
Front
15 x 6.0-6, 4PR
Rear
20 x 10.00-8, 4PR
Ground
(A)
(2.0
200 kPa
, 29 psi)
(1.4
140 kPa
, 20 psi)
Insufficient
(B)
Normal
(C)
Excessive
0000009551E
Checking Transmission Fluid Level
1. Park the machine on a flat surface, lower the implement to the
ground and shut off engine and remove the key.
2. Raise the operator's seat.
3. To check the oil level, draw out the dipstick (1), wipe it clean,
reinsert it, and draw it out again. Check to see that the oil level
lies between the two notches. If the level is too low, add new
oil to the prescribed level at the oil inlet. (See page G-8.)
A If oil level is low, do not run engine.
(1)
Oil Level Dipstick
A:
Oil level is acceptable within
this range.
0000009552E
G-17
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking Coolant Level
A Do not remove the radiator cap when the engine is hot.
Loosen cap slightly, to the stop, to relieve any excess
pressure before removing cap completely.
Check the coolant level daily both the radiator and the recovery
tank (4) before starting engine.
1. Remove the radiator cap (1) and check to see that the coolant
level is just below the fill port.
2. Check to see that the coolant level is between the "FULL" and
"LOW" marks of recovery tank (4).
3. When the coolant level drops due to evaporation, add water
only up to just below the fill port of the radiator and the full level
of the recovery tank (4).
In case of leakage, add coolant and water in the specified
mixing ratio up to the full level. (See page G-32.)
A If the radiator cap has to be removed, follow the caution
above and securely retighten the cap.
A Use clean, distilled coolant and water to fill the radiator
and recovery tank.
(1)
Radiator Cap
A:
FULL
(2)
Overflow Pipe
B:
LOW
(3)
Recovery Tank Cap
(4)
Recovery Tank
0000009553E
Greasing
A Be sure to stop the engine and remove the key before
greasing.
(1)
Spindle Shaft
(2)
Tension Arm
(3)
Mower Universal Joint (Apply
grease on the spline shaft)
0000009554E
G-18
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
[2] CHECK POINTS OF EVERY 50 HOURS
Checking Safety Device
A Do not allow anyone near the machine while testing.
A If the machine does not pass one of the following tests, do
not operate the machine.
1. Check the following tests before operating the mower. Sit on
the operator's seat for all tests.
B Safety Start Control 1
1. Depress the brake pedal fully.
2. Engage the PTO lever.
3. Turn the key switch to the "START" position.
4. The engine should not crank.
B Safety Start Control 2
1. Disengage the PTO lever.
2. Release the brake pedal.
3. Turn the key to the "START" position.
4. The engine should not crank.
B Seat Safety Control 1
1. Run the engine at half throttle.
2. Engage the PTO lever.
3. Stand up. (Do not get off the machine.)
4. Engine should shut off.
B Seat Safety Control 2
1. Run the engine at half throttle.
2. Disengage the PTO lever.
3. Release the brake pedal.
4. Stand up. (Do not get off the machine.)
5. Engine should shut off.
B PTO Safety Control 1
1. Dismount the grass container from the platform.
2. Run the engine at half throttle.
3. Engage the PTO lever.
4. Engine should shut off.
B PTO Safety Control 2
1. Run the engine at half throttle.
2. Engage the PTO lever.
3. Dump the grass from grass container.
4. Engine should shut off.
0000009555E
G-19
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Cleaning Air Cleaner Element
1. The air cleaner uses a dry element, never apply oil.
2. Do not touch the filter element except where cleaning is
required.
To clean the element, use clean and dry
compressed air on the inside of the element. Air pressure
should not exceed 205 kPa (2.1
, 30 psi).
A Operating in dusty conditions requires more frequent
maintenance.
A Align the arrow marks when reinstalling the air cleaner
cover.
(1)
Air Cleaner Cover
(2)
Air Cleaner Element
0000001434E
Checking Mower Gear Box Oil Level
A Always stop the engine and remove the key before
checking oil.
1. Park the machine on a flat surface and lower the mower to the
ground.
To check the oil level, loosen filler plug (1) bolt and check to
see that the oil level is just below the oil filler plug (1) port.
If the level is too low, add new oil to the prescribed level at the
oil inlet. (See page G-8.)
(1)
Oil Filler Plug
0000009556E
Lubricating All Grease Nipple
1. Apply a grease to the following locations as figures.
A Be sure to stop the engine and remove the key before
greasing.
(1)
Engine Transmission
(2)
King Pin (LH, RH)
Universal Joint
0000009557E
G-20
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Oiling
1. Apply oil to the following location as figures.
A Be sure to stop the engine and remove the key before
oiling.
(1)
Mower Universal Joint
(4)
Seat Adjuster
(2)
Speed Control Shaft (RH)
(5)
Throttle Cable
(3)
Speed Control Shaft (LH)
0000009558E
G-21
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Oiling (Continued)
1. Apply oil to the following location as figures.
A Be sure to stop the engine and remove the key before
oiling.
(1)
Around Hole of Mower Link
(5)
(2)
Around Pin
(6)
Front Link
Grass Catcher Hinge
(3)
Pivot of Mower Link
(7)
PTO Lever (Fulcrum)
(4)
Pivot of Lift Arm
(8)
Link Fulcrum
0000009559E
G-22
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking Battery Condition
A To avoid the possibility of battery explosion:
For the refillable type battery, follow the instructions
below.
A Do not use or charge the refillable type battery if the fluid
level is below the LOWER (lower limit level) mark.
Otherwise, the battery component parts may prematurely
deteriorate, which may shorten the battery's service life or
cause an explosion. Check the fluid level regularly and
add distilled water as required so that the fluid level is
between the UPPER and LOWER levels.
A Never remove the vent plugs while the engine is running.
A Keep electrolyte away from eyes, hands and clothes. If
you are spattered with it, wash it away completely with
water immediately and get medical attention.
A Wear eye protection and rubber gloves when working
around battery.
1. Mishandling the battery shortens the service life and adds to
maintenance costs.
2. The original battery is maintenance free type battery, but need
some servicing. If the battery is weak, the engine is difficult to
start and the lights become dim. It is important to check the
battery periodically.
(1)
Battery
0000009560E
G-23
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
B Battery Charging
A When the battery is being activated, hydrogen and
oxygen gases in the battery are extremely explosive.
Keep open sparks and flames away from the battery at all
times, especially when charging the battery.
A When charging the battery, ensure the vent caps are
securely in place (if equipped).
A When disconnecting the cable from the battery, start with
the negative terminal first.
When connecting the cable to the battery, start with the
positive terminal first.
A Never check battery charge by placing a metal object
across the posts.
Use a voltmeter or hydrometer
(For accessible maintainable type batteries with removable
vent caps.)
1. Make sure each electrolyte (3) level is to the bottom of vent
wells (4), if necessary add distilled water in a well-ventilated
area.
2. The water in the electrolyte (3) evaporates during recharging.
Liquid shortage damages the battery. Excessive liquid spills
over and damages the machine.
3. To slow charge the battery, connect the battery positive
terminal to the charger positive terminal and the negative to
the negative, then recharge in the standard fashion.
4. A boost charge is only for emergencies. It will partially charges
the battery at a high rate and in a short time.
When using a boost-charged battery, it is necessary to
recharge the battery as early as possible.
Failure to do this will shorten the battery's service life.
5. When the specific gravity of electrolyte (3) become between
1.27 and 1.29 charge has completed.
6. When exchanging an old battery into new one, use battery of
equal specification shown in "SPECIFICATIONS".
(1)
Lowest Level
(4)
Vent Well
(2)
Highest Level
(5)
Separator
(3)
Electrolyte
0000009562E
G-24
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
B Battery Charging (Continued)
(For non-accessible maintenance-free type batteries.)
Maintenance-free, non-accessible batteries are designed to
eliminate the need to add water. Yet the volume of electrolyte (3)
above plates may eventually become depleted due to abnormal
conditions such as high heat or improper regulator setting. Use a
voltmeter to check the state of charge. (See reference chart
below to determine if charging is necessary.)
Battery voltage
Reference state of charge
12.6
100 % (Full charge)
12.4
75 %
12.2
50 %
12.0
25 %
11.8
0%
B Direction for Storage
1. When storing the machine for long periods of time, remove the
battery from machine, adjust the electrolyte (3) to the proper
level and store in a dry place out of direct sunlight.
2. The battery self-discharges while it is stored.
Recharge it once every three months in hot seasons and once
every six months in cold seasons.
(1)
Lowest Level
(4)
Vent Well
(2)
Highest Level
(5)
Separator
(3)
Electrolyte
0000009563E
[3] CHECK POINTS OF EVERY 100 HOURS
Changing Engine Oil
A Be sure to stop the engine and remove the key before
changing the oil.
A Allow engine to cool down sufficiently; oil can be hot and
may cause burns.
1. To change the used oil, remove the drain plug (1) at the bottom
of the engine and drain the oil completely. The used oil can be
drained out more easily if the engine is warm.
2. Fill with the new oil up to the upper notch on the dipstick.
3. To check the oil level. Remove the dipstick, wipe it clean,
insert it and draw it out again. Check to see the oil level is
between the two marks.
Engine oil capacity
(1)
1.2 L
1.27 U.S.qts
1.06 Imp.qts
Drain Plug
0000009564E
G-25
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking Fuel Line and Fuel Filter
A Be sure to stop the engine and remove the key when
attempting to make the following checks and changes.
A Never fail to check the fuel lines periodically. The fuel
lines are subject to wear and aging. Fuel may leak out
onto the running engine, causing a fire.
The fuel line connections should be checked annually or every
100 service hours, whichever comes first.
1. The fuel line (2) is made of rubber and ages regardless of
service period.
2. If the fuel line (2) and clamps (1) are found to be damaged or
deteriorated, replace them.
3. Check fuel filter (3), if it is clogged by debris or contaminated
with water, replace it.
A When the fuel line is disconnected for maintenance or
repair, close both ends of the fuel line with a piece of
clean cloth or paper to prevent dust and dirt from
entering. In addition, particular care must be take not to
admit dust and dirt into the fuel pump. Entrance of even
a small amount of dust or dirt cause premature wear and
malfunction of the fuel pump and injector components.
(1)
Pipe Clamp
(2)
Fuel Line
(3)
Fuel Filter
0000009565E
Checking Brake
A When making adjustments, park the machine on a flat
area, block wheels, stop the engine and remove the key.
1. Correct play ranges from 15 to 25 mm (0.59 to 0.98 in.). If it is
not correct, loosen the lock nut (2) and turn the nut (3) in the
desired direction until the proper play is achieved. After
adjustment, retighten lock nut securely.
Play (A)
15 to 25 mm
0.59 to 0.98 in.
Factory spec.
(1)
Brake Pedal
(3)
Nut
(2)
Lock Nut
(4)
Spring
0000009566E
G-26
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking Fan Drive Belt Tension
A Be sure to stop the engine and remove the key before
checking belt tension.
1. Measure the deflection (A), depressing the belt halfway
between the fan drive pulley (1) and dynamo pulley (2) at
specified force (98 N, 10 kgf, 22 lbs).
2. If the measurement is not within the factory specifications,
loosen the dynamo mounting screws and relocate the dynamo
to adjust.
Deflection (A)
(1)
7 to 9 mm
0.28 to 0.35 in.
Factory spec.
Fan Drive Pulley
(2)
Dynamo Pulley
0000010059E
[4] CHECK POINT OF EVERY 150 HOURS
Changing Mower Gear Box Oil
A Be sure to stop the engine and remove the key before
changing the oil.
1. To drain the used oil, remove the oil filler plug (1) at the mower
gear box, tilt the mower deck and drain the oil completely into
the oil pan.
2. Fill with the new oil.
(See page G-8.)
3. After filling, reinstall the oil filler plug (1).
0.33 L
0.35 U.S.qts
0.29 Imp.qts
Mower gear box oil capacity
(1)
Oil Filler Plug
(2)
Drain Plug
0000009568E
G-27
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
[5] CHECK POINTS OF EVERY 200 HOURS
Replacing Engine Oil Filter Cartridge
A Be sure to stop the engine and remove the key before
changing the oil filter cartridge.
A Allow engine to cool down sufficiently, oil can be hot and
may cause burns.
1. The oil filter cartridge (1) must be changed every 200 service
hours.
2. Apply a slight coat of oil onto the rubber gasket of new
cartridge.
3. Tighten the filter quickly until it contacts the mounting surface.
Tighten filter by hand an additional 1/2 turn only.
4. After the cartridge has been replaced, the engine oil level
normally lowers a little. Add engine oil to proper level. Check
for oil leaks around filter gasket.
A To prevent serious damage to the engine, element of
recommended type must be used. Use only a genuine
KUBOTA filter or its equivalent.
(1)
Engine Oil Filter Cartridge
0000009569E
G-28
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Changing Transmission Fluid
A Be sure to stop the engine and remove the key before
changing or checking the oil.
A Allow transmission case to cool down sufficiently; oil can
be hot and may cause burns.
The fluid in the transmission case is also used for the
hydrostatic drive system.
1. To drain the transmission oil, place oil pan underneath the
transmission case and remove the suction pipe (1) at the
bottom of the transmission case.
2. After draining, disassemble and clean the strainer (5) and
change the oil filter cartridge (6). After reassembling, fill with
UDT or SUPER UDT hydrostatic transmission fluid, or its
equivalent.
3. Remove the oil plug and fill with the new oil.
4. After running the engine for a few minutes, stop it and check
the oil level again; add oil to the prescribed level.
A Operate only at low rpm immediately after changing the
transmission fluid and filter cartridge.
Keep the engine at medium speed for a few minutes to
insure proper lubrication of all parts so that there is no
damage to transmission.
Transmission fluid capacity
(1)
Suction Pipe
2.7 L
0.71 U.S.gals
0.59 Imp.gals
(6)
Transmission Oil Filter
Dipstick
(2)
Bolt
(3)
O-ring (Small)
(7)
Cartridge
(4)
O-ring (Large)
(A)
(5)
Strainer
Oil level is acceptable within
this range
0000009570E
G-29
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Cleaning Transmission Strainer
When changing the transmission fluid, disassemble and rinse
the strainer with nonflammable solvent to completely clean off
filings.
Check O-rings (2), (3), replace if damaged, cracked or
hardened.
When reassembling be careful not to damage the parts.
A Since the fine filings in the oil can damage the precision
component parts of the hydraulic system, the end of the
suction line is provided with an oil strainer.
(1)
Suction Pipe
(3)
O-ring (Large)
(2)
O-ring (Small)
(4)
Strainer
0000009571E
Replacing Transmission Oil Filter Cartridge
A Be sure to stop the engine before changing the oil filter
cartridge.
A Allow transmission case to cool down sufficiently; oil can
be hot and may cause burns.
1. The transmission oil filter cartridge (1) must be changed every
300 service hours.
2. Remove the grass container and clean the area indicated.
3. Remove the oil filter cartridge (1) with the filter wrench.
4. Lightly tighten the screw (2) by using a screwdriver.
5. Apply a slight coat of oil onto the cartridge gasket.
6. Tighten the filter quickly until it contacts the mounting surface.
Tighten filter by hand an additional 1/2 turn only.
7. Assemble the cover and mount the grass container.
8. After the new cartridge has been replaced, the transmission
fluid level normally lowers a little. Add fluid to proper level.
Check for oil leaks around filter gasket.
A To prevent serious damage to hydraulic system, the
replacement filter must be a highly efficient, 10
filter.
Use only a genuine KUBOTA filter or its equivalent.
(1)
Transmission Oil Filter
(2)
Screw
Cartridge
0000009572E
Checking Radiator Hose and Hose Clamp
Check to see if radiator hoses are properly fixed every 200
hours of operation or six months, whichever comes first.
1. If hose clamps are loose or water leaks, tighten bands
securely.
2. Replace hoses (2) and tighten hose clamps securely, if
radiator hoses (2) are swollen, hardened or cracked.
(1)
Radiator Core
(2)
Radiator Hose
0000009573E
G-30
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Adjusting Front Axle Pivot
1. Jack up the front of machine.
2. Tighten the center pin locking nut (1) with specified torque.
3. Measure the clearance between the front axle frame (2) and
anti-vibration bolt (3).
4. If the measurement exceeds the factory specification, adjust
the anti-vibration bolt.
Tightening torque
Center pin locking nut
Clearance between
front axle frame and
anti-vibration bolt (A)
0.3 to 0.5 mm
0.012 to 0.020 in.
Factory spec.
(1)
Center Pin Locking Nut
(2)
Front Axle Frame
(3)
Anti-vibration Bolt
77.4 to 90.2
7.89 to 9.20
57.1 to 66.5 ft-lbs
A:
Clearance
0000009574E
[6] CHECK POINT OF EVERY 400 HOURS
Replacing Fuel Filter
1. Disconnect the fuel hoses and loosen the filter band to replace
the fuel filter (3).
A If the fuel line is removed, be sure to properly bleed the
fuel system. (See page G-37.)
(1)
Pipe Clamps
(2)
Fuel Line
(3)
Fuel Filter
0000009575E
[7] CHECK POINTS OF EVERY 1 YEAR
Replacing Air Cleaner Element
1. Change the element once a year.
0000009576E
G-31
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Flushing Cooling System and Changing Coolant
A Do not remove the radiator cap when the engine is hot.
Then loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
1. Stop the engine and let cool down.
2. To drain the coolant, remove the clamp and the hose, and
remove the radiator cap. The radiator cap must be removed
to completely drain the coolant.
3. After all coolant is drained, install the hose with the clamp.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the
coolant level is just below the fill port on the radiator. Install
the radiator cap securely.
7. Fill with coolant up to "FULL" mark on the recovery tank.
8. Start and operate the engine for a few minutes.
9. Stop the engine and let cool. Check coolant level of recovery
tank (2) and add coolant if necessary.
A Do not start engine without coolant.
A Use clean, fresh water and anti-freeze to fill the radiator
and recovery tank.
A When the anti-freeze is mixed with water, the anti-freeze
mixing ratio must be less than 50 %.
A Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
A Refer to "LUBRICANTS, FUEL AND COOLANT" (See
page G-8.)
Coolant capacity (with recovery tank)
1.9 L
2.0 U.S.qts
1.7 Imp.qts
(1)
Clamp
A:
FULL
(2)
Recovery Tank
B:
LOW
(3)
Recovery Tank Cap
0000009577E
G-32
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Flushing Cooling System and Changing Coolant (Continued)
B Anti-Freeze
A When using anti-freeze, put on some protection such as
rubber gloves (Anti-freeze contains poison.).
A If should drink anti-freeze, throw up at once and take
medical attention.
A When anti-freeze comes in contact with the skin or
clothing, wash it off immediately.
A Do not mix different types of anti-freeze. The mixture can
produce chemical reaction causing harmful substances.
A Anti-freeze is extremely flammable and explosive under
certain conditions. Keep fire and children away from antifreeze.
A When draining fluids from the engine, place some
container underneath the engine body.
A Do not pour waste onto the grounds, down a drain, or into
any water source.
A Also, observe the relevant environmental protection
regulations when disposing of anti-freeze.
If it freezes, coolant can damage the cylinders and radiator. If
the ambient temperature falls below 0
or before a long-term
storage, let out coolant completely, or mix fresh water with longlife coolant and fill the radiator and reserve tank with the mixture.
1. Long-life coolant (hereafter LLC) comes in several types. Use
ethylene glycol (EG) type for this engine.
2. Before employing LLC-mixed coolant, fill the radiator with
fresh water and empty it again. Repeat this procedure 2 or 3
times to clean up the inside.
3. Mixing the LLC
Put the LLC in coolant in the percentage (%) for a target
temperature. When mixing, stir it up well, and then fill into the
radiator.
4. The procedure for the mixing of water and anti-freeze differs
according to the make of the anti-freeze and the ambient
temperature. Refer to SAE J1034 standard, more specifically
also to SAE J814c.
0000009578E
G-33
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Flushing Cooling System and Changing Coolant (Continued)
A When the anti-freeze is mixed with water, the anti-freeze
mixing ratio must be less than 50%.
Vol %
Anti-freeze
Freezing Point
Boiling Point*
(
(
40
-24 (-12)
106 (222)
50
-37 (-34)
108 (115)
)
)
*At 0.1013 MPa (760 mmHg) pressure (atmospheric). A higher
boiling point is obtained by using a radiator pressure cap which
permits the development of pressure within the cooling system.
1. Adding the LLC
(1) Add only water if the mixture reduces in amount by
evaporation.
(2) If there is a mixture leak, add the LLC the same
manufacture and type in the same mixture percentage.
*Never add any long-life coolant of different manufacture.
(Different brands may have different additive components, and
the engine may fail to perform as specified.)
2. When the LLC is mixed, do not employ any radiator cleaning
agent. The LLC contains anti-corrosive agent. If mixed with
the cleaning agent, sludge may build up, adversely affecting
the engine parts.
3. Kubota's genuine long-life coolant has a service life of 2 years.
Be sure to change the coolant every 2 years.
A The above data represent industry standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
A When the coolant level drops due to evaporation, add
water only to keep the anti-freeze mixing ratio less than
50%. In case of leakage, add anti-freeze and water in the
specified mixing ratio before filling in to the radiator.
0000009579E
[8] CHECK POINTS OF EVERY 2 YEARS
Replacing Fuel Lines
1. Replace the fuel line.
Refer to "Checking Fuel Lines and Fuel Filter". (See page G26.)
0000009580E
Replacing Radiator Hose
1. Replace hoses and clap bands every 2 years or earlier if
checked and found that hoses are swollen, hardened or
cracked.
0000009581E
G-34
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Replacing Mower Gear Box Oil Seals
1. Replace the mower gear box oil seals.
Refer to "Disassembling Gear Box".
(See page 7-S9.)
0000009582E
[9] OTHERS
Replacing Fuses
1. Open the hood.
2. Remove the blown fuse.
3. Place a new 3 A or 10 A or 15 A or 30 A or 40 A fuse in position.
A Never "jump" the fuse with wire or foil, or install a larger
capacity fuse than is recommended.
B Protected circuit
Fuse No. (ID Label)
Protected circuit
E/G STOP (a)
15
Engine stop timer relay
IG/M (b)
10
Fuel pump, head light, etc.
OPC (c)
3
OPC
(1)
Slow blow fuse
40
(2)
(1)
Capacity (A)
Fuse Location
(2)
Check circuit against wrong
battery connection
Slow Blow Fuse
0000009583E
Replacing Bulbs
(A) Replacement of the head light bulb
1. Open the hood.
2. Turn bulb socket to remove socket from head light housing.
3. Push bulb down and turn one quarter turn to remove bulb from
the socket.
4. Install new bulb to the socket.
5. Install the socket in housing.
6. Close the hood.
Head light bulb
1.
2.
3.
4.
5.
6.
12V - 24 W
(B) Replacement of the indicator light bulb
Open the hood.
Turn bad bulb socket to the left. And remove it.
Pull bulb from the socket.
Push new bulb into the socket.
Install the socket.
Close the hood.
Indicator light bulb
14.0 rated voltage / 0.27
AMP/2 MSCP
0000009584E
G-35
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Checking and Replacing Mower Blade
A Be sure to stop the engine and remove the key.
A Blades may be sharp. When you handle blades, wear
heavy gloves or wrap end of blade with a rag.
B Checking Blade
1. The blade cutting edges should be kept sharp at all times.
Sharpen the cutting edges, if they resemble blade (b).
Replace the blades if they appear similar to blade (c).
B Replacing Blade
1. Remove the mower deck from the machine and turn it over to
expose the blades (4).
2. Wedge a block of wood (1) between the blade (4) and mower
housing as illustrated.
3. The blade bolt (2) has right hand threads, turn
counterclockwise to loosen.
The blade bolt (2) has left hand threads, turn clockwise to
loosen.
A Use the proper size box or socket wrench to tighten or
loosen the blade mounting bolt.
4. To sharpen the blades yourself, clamp the blade securely in a
vise.
Use a large mill file and file along the original bevel until sharp.
5. To check the blade for balance, place a small rod though the
centre hole. If the blade is not balanced, file the heavy side of
the blade until balance is achieved.
6. To attach blades (4), be sure to install the 2 cup washers (5)
between the blade (4) and bolt (2) head.
Tightening torque
Blade mounting bolt
98.0 to 117.6
10.0 to 12.0
72.3 to 86.8 ft-lbs
(1)
Block
(a)
New Blade
(2)
Blade Bolt
(b)
Worn Blade
(3)
Spindle Holder
(c)
Cracked Blade
(4)
Blade
(5)
2-cup Washer
A:
Loosen
(6)
Shim
B:
30 mm (1.18 in.)
(7)
Spindle Guard
0000009585E
G-36
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Replacing Mower Belt
1. Remove the mower deck from the machine.
2. Remove the left and right hand shield (4), (6) from the mower
deck.
3. Clean around the pulleys to remove the belt (3) from the
pulleys. Slip the belt (3) over the top of the left side pulley.
4. Remove the both brackets which mounts the gear box to the
mower deck.
5. To install a new belt, reverse the above procedure.
Tightening torque
(1)
Bolt
Bracket mounting screw
(4)
39.2 to 44.1
4.0 to 4.5
8.8 to 9.9 ft-lbs
Left Hand Shield
(2)
Bolt, Nut
(5)
Right Hand Shield
(3)
Belt
(6)
Mower Gear Box
0000009586E
Bleeding Fuel System
Air must be removed:
1. When the fuel filter or lines are removed.
2. When tank is completely empty.
3. After the machine has not been used for a long period of time.
Bleeding procedure is as follows:
1. Fill the fuel tank with fuel.
2. Start the engine and run for about 30 seconds, and then stop
the engine.
0000009587E
G-37
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
8. SPECIAL TOOLS
[1] SPECIAL TOOLS FOR ENGINE
Special Use Puller Set
Code No :
07916-09032
Application : Use exclusively for pulling out bearing, gears and
other parts with ease.
0000000677E
Piston Ring Compressor
Code No :
07909-32111
Application : Use exclusively for pushing in the piston with
piston rings into the cylinder.
0000000678E
Piston Ring Tool
Code No :
07909-32121
Application : Use exclusively for removing or installing the
piston ring with ease.
0000000679E
Diesel Engine Compression Tester
Code No :
07909-30208 (Assembly) 07909-31251 (G)
07909-30934 (A to F)
07909-31271 (I)
07909-31211 (E and F)
07909-31281 (J)
07909-31231 (H)
Application : Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1)
Gauge
(7)
Adaptor F
(2)
L Joint
(8)
Adaptor G
(3)
Adaptor A
(9)
Adaptor H
(4)
Adaptor B
(10)
Adaptor I
(5)
Adaptor C
(11)
Adaptor J
(6)
Adaptor E
0000000680E
G-38
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Diesel Engine Compression Tester (for Glow Plug)
Code No :
07909-39081 (Assembly) 07909-31301 (L)
07909-31291 (K)
07909-31311 (M)
Application : Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1)
Gauge
(4)
Adaptor L
(2)
L Joint
(5)
Adaptor M
(3)
Adaptor K
0000001398E
Oil Pressure Tester
Code No :
07916-32032
Application : Use to measure lubricating oil pressure.
(1)
Gauge
(5)
(2)
Cable
(6)
Adaptor 2
Adaptor 3
(3)
Threaded Joint
(7)
Adaptor 4
(4)
Adaptor 1
(8)
Adaptor 5
0000000681E
Valve Seat Cutter
Code No :
07909-33102
Application : Use to reseat valves.
Angle :
0.785 rad (45 )
0.262 rad (15 )
Diameter :
28.6 mm (1.126 in.)
38.0 mm (1.496 in.)
31.6 mm (1.244 in.)
41.3 mm (1.626 in.)
35.0 mm (1.378 in.)
50.8 mm (2.000 in.)
0000000682E
Radiator Tester
Code No :
07909-31551
Application : Use to check of radiator cap pressure, and leaks
from cooling system.
Remarks : Adaptor (1) BANZAI Code No. RCT-2A-30S.
0000000815E
G-39
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Connecting Rod Alignment Tool
Code No :
07909-31661
Application : Use to check the connecting rod alignment.
Applicable : Connecting rod big end I.D.
range
30 to 75 mm (1.18 to 2.95 in.) dia.
Connecting rod length
65 to 300 mm (2.56 to 11.81 in.)
0000000684E
Nozzle Tester
Code No :
07909-31361
Application : Use to check the fuel injection pressure and spray
pattern of nozzle.
Measuring : 0 to 50 MPa
range
(0 to 500
, 0 to 7000 psi)
0000000685E
Plastigage
Code No :
07909-30241
Application : Use to check the oil clearance between
crankshaft and bearing, etc..
Measuring : Green.....0.025 to 0.076 mm (0.001 to 0.003 in.)
range
Red.........0.051 to 0.152 mm (0.002 to 0.006 in.)
Blue.........0.102 to 0.229 mm (0.004 to 0.009 in.)
0000000686E
Red Check
Code No :
07909-31371
Application : Use to check cracks on cylinder head, cylinder
block, etc..
0000000687E
G-40
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Injection Pump Pressure Tester
Application : Use to check fuel tightness of injection pumps.
A
Pressure gauge full scale : More than 29.4 MPa (300
psi)
B
Copper gasket
C
Flange (Material : Steel)
D
Hex. nut 27 mm (1.06 in.) across the plat
E
Retaining nut
F
PF 1/2
G
5 mm (0.20 in.)
H
17 mm dia. (0.67 in.dia.)
I
8 mm dia. (0.31 in.dia.)
J
1.0 mm (0.039 in.)
K
17 mm dia. (0.67 in.dia.)
L
6.10 to 6.20 mm dia. (0.2402 to 0.2441 in.dia.)
M
8 mm (0.31 in.)
N
4 mm (0.16 in.)
O
11.97 to11.99 mm dia. (0.4713 to 0.4721 in.dia.)
P
PF 1/2
Q
23 mm (0.91 in.)
R
17 mm (0.67 in.)
S
4 mm (0.16 in.)
T
12.00 to 12.02 mm dia. (0.4724 to 0.4732 in.dia.)
U
100 mm (3.94 in.)
V
M12 x P1.5
a
Adhesive application
b
Fillet welding on the enter circumference
, 4267
0000001341E
G-41
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Valve Guide Replacing Tool
Application : Use to press out and press fit the valve guide.
A
20 mm dia. (0.79 in. dia.)
B
9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.)
C
5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.)
D
220 mm (8.66 in.)
E
80 mm (3.15 in.)
F
40 mm (1.58 in.)
G
25 mm dia. (0.98 in. dia.)
H
5 mm (0.197 in.)
I
6.0 to 6.1 mm dia. (0.236 to 0.240 in. dia.)
J
18 mm dia. (0.71 in. dia.)
K
10.6 to 10.7 mm dia. (0.417 to 0.421 in. dia.)
L
6.9 to 7.1 mm dia. (0.272 to 0.280 in. dia.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
C0.3
Chamfer 0.3 mm (0.012 in.)
0000000816E
G-42
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Bushing Replacing Tools
Application : Use to press out and to press fit the bushing.
1. For small end bushing
A
145 mm (5.71 in.)
B
20 mm (0.79 in.)
C
100 mm (3.94 in.)
D
19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
E
21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
F
25 mm dia. (0.98 in. dia.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
C0.3
Chamfer 0.3 mm (0.012 in.)
a
6.3
(248
.)
b
6.3
(248
.)
2. For idle gear bushing
A
150 mm (5.91 in.)
B
23 mm (0.91 in.)
C
100 mm (3.94 in.)
D
19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
E
21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
F
25 mm dia. (0.98 in. dia.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
C0.3
Chamfer 0.3 mm (0.012 in.)
a
6.3
(248
.)
b
6.3
(248
.)
0000003194E
Flywheel Stopper
Application : Use to loosen and tighten the flywheel screw.
A
200 mm (7.87 in.)
B
30 mm (1.18 in.)
C
20 mm (0.79 in.)
D
15 mm (0.59 in.)
E
8 mm (0.31 in.)
F
10 mm dia. (0.39 in. dia.)
0000000818E
G-43
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
Crankshaft Bearing 1 Replacing Tool
Application : Use to press out and press fit the crankshaft
bearing 1.
[Press Out]
A
135 mm (5.31 in.)
B
72 mm (2.83 in.)
C
40 mm radius (1.57 in. radius)
D
10 mm (0.39 in.)
E
22 mm (0.87 in.)
F
20 mm dia. (0.79 in. dia.)
G
47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)
H
43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)
[Press Fit]
A
130 mm (5.12 in.)
B
72 mm (2.83 in.)
C
40 mm radius (1.57 in. radius)
D
9 mm (0.35 in.)
E
24 mm (0.95 in.)
F
20 mm dia. (0.79 in. dia.)
G
68 mm dia. (2.68 in. dia.)
H
39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)
00000009544E
G-44
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
[2] SPECIAL TOOLS FOR MACHINE
Relief Valve Pressure Tester
Code No :
07916-50045
Application : This allows easy measurement of relief set
pressure.
(1)
Gauge (07916-50322)
(2)
Cable (07916-50331)
(3)
Threaded Joint
(6)
(07916-50371)
(7)
(07916-50401)
(4)
Threaded Joint
Adaptor B (M18 x P1.5)
Adaptor D (PT1/8)
(07916-50381)
(8)
(07916-50341)
(5)
Adaptor C (PS3/8)
Adaptor E (PS3/8)
(07916-50392)
(9)
(07916-50361)
Adaptor F (PF1/2)
(07916-62601)
(10)
Adaptor 58 (PT1/4)
(07916-52391)
0000000705E
Hydrostatic Transmission Tester and HST Adaptor Set
Code No :
07916-52040 (Hydrostatic Transmission Tester)
07916-53072 (HST Adaptor Set)
Application : This allows easy measurement of hydrostatic
transmission pressure.
(1)
Hydrostatic Transmission
(8)
Tester (07916-52040)
Valve Seat Driver
(07916-60841)
(2)
Gasket (04714-00200)
(9)
Connector 1 (07916-60811)
(3)
Connector 3 (07916-51331)
(10)
Connector 2 (07916-60821)
(4)
Vacuum Gauge
(11)
Long Connector
(07916-51331)
(5)
(6)
(07916-60831)
Pressure Gauge (Low
(12)
Adaptor 1 (07916-52621)
Pressure) (07916-51301)
(13)
Adaptor 2 with Collar
(14)
Adaptor 3 with Collar
(15)
HST Adaptor Set
Pressure Gauge (High
Pressure) (in Relief Valve Set
(07916-52632)
Pressure Tester)
(07916-50321)
(7)
HN Tube (in Relief Valve Set
(07916-52642)
(07916-53072)
Pressure Tester)
(07916-50331)
0000000820E
G-45
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
9. TIRES
[1] TIRE PRESSURE
A Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper
equipment.
A Always maintain the correct tire pressure.
Do not inflate tires above the recommended pressure as shown below.
A Do not use tires larger than specified.
Tire sizes
Inflation pressure
Front
15 x 6.00-6, 4PR
200 kPa (2.0
, 29 psi)
Rear
20 x 10.00-8, 4PR
140 kPa (1.4
, 20 psi)
Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time.
Thus, check it everyday and inflate as necessary.
0000009545E
[2] TREAD
The tread can not be adjusted.
A Do not turn discs to obtain wider tread.
A Always attach tires as shown in the drawing.
A If not attached as illustrated, transmission parts may be damaged.
A Use the tapered bolts for wheels with beveled or tapered holes.
A:
Front
Rear
15 x 6.00 - 6, 4PR
20 x 10.00 - 8, 4PR
750 mm (29.5 in.)
B:
800 mm (31.5 in.)
0000009546E
G-46
KiSC issued 04, 2006 A
GR1600EC, WSM
GENERAL
10. IMPLEMENT LIMITATIONS
The KUBOTA Machine has been thoroughly tested for proper performance with implements sold or approved by
KUBOTA. Use of implements which are not sold or approved by KUBOTA and which exceed the maximum
specifications listed below, or which are otherwise unfit for use with the KUBOTA Machine may result in malfunctions
or failures of the machine, damage to other property and injury to the operator or others. [Any malfunctions or failures
of the machine resulting from use with improper implements are not covered by the warranty.]
Maximum axle loading weight
Front axle Wf
Rear axle Wr
Total gross weight
250 kg (551 lbs)
450 kg (992 lbs)
600 kg (1323 lbs)
0000009547E
G-47
KiSC issued 04, 2006 A
1
ENGINE
KiSC issued 04, 2006 A
CONTENTS
1.
[1]
[2]
2.
3.
4.
[1]
ENGINE BODY .................................................................................................................1-M1
HALF-FLOATING HEAD COVER ..................................................................................1-M1
CLOSED BREATHER.....................................................................................................1-M1
LUBRICATING SYSTEM ..................................................................................................1-M2
COOLING SYSTEM .........................................................................................................1-M3
FUEL SYSTEM.................................................................................................................1-M4
FUEL LINE ......................................................................................................................1-M4
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
1. ENGINE BODY
[1] HALF-FLOATING HEAD COVER
The rubber packing is fitting in to maintain the head
cover 0.5 mm (0.02 in.) or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1)
Cylinder Head Cover
(2)
Rubber Packing
0000004839E
[2] CLOSED BREATHER
Closed breather system has been adopted to prevent
the release of blowby gas into the atmosphere.
After its oil content is filtered by oil shield (4), the
blowby gas is fed back to the intake manifold through
breather valve (3) to be used for re-combustion.
(1)
Breather Hose
(4)
Oil Shield
(2)
Cylinder Head Cover
(5)
Rubber Packing
(3)
Breather Valve
0000004857E
1-M1
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
2. LUBRICATING SYSTEM
(1)
Rocker Arm
(2)
Oil Pressure Switch
(3)
Rocker Arm Shaft
(4)
Valve
(5)
Idle Gear
(6)
Crankshaft
(7)
Oil Pump
(8)
Oil Strainer
(9)
(10)
Relief Valve
Push Rod
(11)
Tappet
(12)
Camshaft
(13)
Piston
(14)
Connecting Rod
(15)
Oil Filter Cartridge
This engine's lubricating system consists of oil strainer (8), oil pump (7), relief valve (9), oil filter cartridge (15) and
oil pressure switch (2).
The oil pump sucks lubricating oil from the oil pan through the oil strainer and the oil flows down to the filter
cartridge, where it is further filtered. Then the oil is forced to crankshaft (6), connecting rods (14), idle gear (5),
camshaft (12) and rocker arm shaft (3) to lubricate each part.
Some part of oil, splashed by the crankshaft or leaking and dropping from gaps of each part, lubricates these parts:
piston (13), cylinders, small ends or connecting rods, tappets (11), push rods (10), inlet and exhaust valves (4) and
timing gears.
0000000937E
1-M2
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
3. COOLING SYSTEM
(1)
Radiator
(2)
Water Pump
(3)
Cooling Fan
(4)
Thermostat
(5)
Cylinder Head
(6)
Cylinder Block
The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).
The coolant is cooled through the radiator core, and the cooling fan (3) set behind the radiator (1) pushes cooling
air through the radiator core to improve cooling.
The water pump receives water from the radiator or from the cylinder head and force it into the cylinder block.
The thermostat opens or closes according to the water temperature. When the water temperature is high, the
thermostat opens to allow the water to flow from the cylinder head to the radiator. When the water temperature is
low, the thermostat close to flow the water only to the water pump.
0000000938E
1-M3
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
4. FUEL SYSTEM
[1] FUEL LINE
(1)
Injection Nozzle
(2)
Fuel Overflow Pipe
(3)
Fuel Tank
(4)
Fuel Filter
(5)
Fuel Feed Pump
(6)
Fuel Filter
(7)
Injection Pump
(8)
Injection Pipe
Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (7) after impurities
such as dirt, water, etc. are removed.
The fuel pressurized by the injection pump to the opening pressure (13.73 to 14.71 MPa, 140 to 150
, 1990
to 2133 psi), of the injection nozzle (1) is injected into the combustion chamber.
Part of the fuel fed to the injection nozzle (1) lubricates the moving parts of the needle valve inside the nozzle, then
returns to the fuel tank through the fuel overflow pipe (2) from the upper part of the nozzle holder.
0000000939E
1-M4
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
4.
[1]
TROUBLESHOOTING....................................................................................................... 1-S1
SERVICING SPECIFICATIONS ....................................................................................... 1-S4
TIGHTENING TORQUES ................................................................................................. 1-S9
CHECKING, DISASSEMBLING AND SERVICING ...................................................... 1-S10
CHECKING AND ADJUSTING .................................................................................... 1-S10
(1) Engine Body .......................................................................................................... 1-S10
(2) Lubricating System ................................................................................................ 1-S13
(3) Cooling System ..................................................................................................... 1-S13
(4) Fuel System........................................................................................................... 1-S16
[2] PREPARATION ............................................................................................................. 1-S20
(1) Separating Engine ................................................................................................. 1-S20
[3] DISASSEMBLING AND ASSEMBLING....................................................................... 1-S23
(1) Cylinder Head and Valves ..................................................................................... 1-S23
(2) Timing Gear, Camshaft and Fuel Camshaft .......................................................... 1-S27
(3) Piston and Connecting Rod................................................................................... 1-S32
(4) Crankshaft ............................................................................................................. 1-S34
(5) Water Pump........................................................................................................... 1-S37
(6) Injection Nozzle ..................................................................................................... 1-S38
[4] SERVICING ................................................................................................................... 1-S38
(1) Cylinder Head and Valves ..................................................................................... 1-S38
(2) Timing Gear, Camshaft and Fuel Camshaft .......................................................... 1-S45
(3) Piston and Connecting Rod................................................................................... 1-S47
(4) Crankshaft ............................................................................................................. 1-S51
(5) Cylinder ................................................................................................................. 1-S55
(6) Oil Pump................................................................................................................ 1-S56
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
1. TROUBLESHOOTING
Symptom
Probable Cause
Engine Does Not Start A No fuel
Solution
Reference
Page
Replenish fuel
G-8
A Air in the fuel system
Bleed
G-37
A Water in the fuel system
Change fuel and
repair or replace fuel
system
G-26, 34
A Fuel pipe clogged
Clean
G-26
A Fuel filter clogged
Change
G-26, 31
A Excessively high viscosity of fuel or engine oil Use specified fuel
or engine oil
at low temperature
G-8
A Fuel with low cetane number
G-8
Use specified
fuel
A Fuel leak due to loose injection pipe retaining Tighten retaining nut
nut
1-S24
A Incorrect injection timing
Adjust
1-S16
A Fuel camshaft worn
Replace
A Injection nozzle clogged
Repair or replace
1-S38
A Injection pump malfunctioning
Replace
1-S27
A Seizure of crankshaft, camshaft, piston, Repair or replace
cylinder or bearing
(Starter Does Not
Run)
A Compression leak from cylinder
Replace head gasket,
tighten cylinder head
screw, glow plug and
nozzle holder
1-S10
A Improper valve timing
Correct or replace
timing gear
1-S29
A Piston ring and cylinder worn
Replace
1-S49, 55
A Excessive valve clearance
Adjust
1-S12
A Battery discharged
Charge
G-24
A Starter malfunctioning
Repair or replace
6-S20
A Main switch malfunctioning
Replace
6-S8, 9
A Safety switches malfunctioning
Replace
6-S12
A Wiring disconnected
Connect
1-S1
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Symptom
Engine Revolution Is
Not Smooth
Either White or Blue
Exhaust Gas Is
Observed
Either Black or Dark
Gray Exhaust Gas Is
Observed
Deficient Output
Excessive Lubricant
Oil Consumption
Fuel Mixed into
Lubricant Oil
Probable Cause
Solution
Reference
Page
A Fuel filter clogged or dirty
Replace
G-26, 31
A Air cleaner clogged
Clean or replace
G-20
A Fuel leak due to loose injection pipe retaining Tighten retaining nut
nut
1-S24
A Injection pump malfunctioning
Replace
1-S27
A Incorrect nozzle injection pressure
Adjust
1-S19
A Injection nozzle stuck or clogged
Repair or replace
1-S38
A Governor malfunctioning
Repair
A Excessive engine oil
Reduce to specified
level
G-8, 14
A Piston ring and cylinder worn or stuck
Repair or replace
1-S49, 55
A Incorrect injection timing
Adjust
1-S16
A Deficient compression
Adjust top clearance
1-S11
A Overload
Reduce the load
A Low grade fuel used
Use specified fuel
G-8
A Fuel filter clogged
Replace
G-31
A Air cleaner clogged
Clean or replace
G-20
A Deficient nozzle injection
Repair or replace
nozzle
1-S38
A Incorrect injection timing
Adjust
1-S16
A Engine's moving parts seem to be seizing
Repair or replace
A Uneven fuel injection
Replace injection
pump
1-S27
A Deficient nozzle injection
Repair or replace
nozzle
1-S38
A Compression leak
Replace head gasket, 1-S10
tighten cylinder head
screw, glow plug and
nozzle holder
A Piston ring's gap facing the same direction
Shift ring gap
direction
1-S32
A Oil ring worn or stuck
Replace
1-S33
A Piston ring groove worn
Replace piston
1-S33
A Valve stem and valve guide worn
Replace
1-S26, 40
A Oil leaking due to defective seals or packing
Replace
A Injection pump's plunger worn
Replace injection
pump
1-S27
A Deficient nozzle injection
Repair or replace
nozzle
1-S38
A Injection pump broken
Replace
1-S27
1-S2
KiSC issued 04, 2006 A
GR1600EC, WSM
Symptom
ENGINE
Probable Cause
Solution
Reference
Page
Water Mixed into
Lubricant Oil
A Head gasket defective
Replace
A Cylinder block or cylinder head flawed
Replace
Low Oil Pressure
A Engine oil insufficient
Replenish
A Oil strainer clogged
Clean
A Oil filter clogged
Replace
A Relief valve stuck with dirt
Clean
A Relief valve spring weaken or broken
Replace
A Excessive oil clearance of crankshaft bearing
Replace
1-S53, 54
A Excessive oil clearance of crankpin bearing
Replace
1-S52
A Excessive oil clearance of rocker arm
Replace
1-S43
A Oil passage clogged
Clean
A Different type of oil
Use specified type of
oil
G-8
A Oil pump defective
Repair or replace
1-S30
A Different type of oil
Use specified type of
oil
G-8
A Relief valve defective
Replace
A Engine oil insufficient
Replenish
G-8
A Fan belt broken or tensioned improperly
Replace or adjust
G-27, 1-S13
A Coolant insufficient
Replenish
G-8
High Oil Pressure
Engine Overheated
1-S25
G-8, 14
G-28
A Radiator net and radiator fin clogged with dust Clean
A Inside of radiator corroded
Clean or replace
G-32, 1-S23
A Coolant flow route corroded
Clean or replace
G-30
A Radiator cap defective
Replace
1-S15
A Radiator hose damaged
Replace
G-30
A Overload running
Reduce the load
A Head gasket defective
Replace
1-S25
A Incorrect injection timing
Adjust
1-S16
A Unsuitable fuel used
Use specified fuel
G-8
0000009504E
1-S3
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item
Factory Specification
Compression Pressure
2.84 to 3.24 MPa
29.0 to 33.0
412 to 469 psi
Variance Among
Cylinder
Top Clearance
Valve Seat
10 % or less
0.145 to 0.185 mm
0.00571 to 0.00728 in.
Flatness
0.05 mm
0.0020 in.
Valve Recessing (Intake and Exhaust)
Valve Stem to Valve Guide
-0.10 to 0.10 mm
-0.0039 to 0.0039 in.
0.30 mm
0.0118 in.
Clearance
0.030 to 0.057 mm
0.00118 to 0.00224 in.
0.10 mm
0.0039 in.
Valve Stem
(O.D.)
5.968 to 5.980 mm
0.23496 to 0.23543 in.
Valve Guide
(I.D.)
6.010 to 6.025 mm
0.23661 to 0.23720 in.
Width
2.12 mm
0.0835 in.
Angle
0.785 rad
45
Valve Face
Angle
0.785 rad
45
Valve Spring
Free Length
31.3 to 31.8 mm
1.232 to 1.252 in.
Tilt
Rocker Arm to Rocker Arm Shaft
Push Rod
2.26 MPa
23.0
327 psi
0.50 to 0.70 mm
0.0197 to 0.0276 in.
Valve Clearance (Cold)
Cylinder Head Surface
Allowable Limit
28.4 mm
1.118 in.
1.2 mm
0.047 in.
Setting Load
64.7 N
6.6 kgf
14.6 lbs
Setting Length
27.0 mm
1.063 in.
Oil Clearance
0.016 to 0.045 mm
0.00063 to 0.00177 in.
Rocker Arm Shaft
(O.D.)
10.473 to 10.484 mm
0.41232 to 0.41276 in.
Rocker Arm
(I.D.)
10.500 to 10.518 mm
0.41339 to 0.41410 in.
Alignment
1-S4
54.9 N
5.6 kgf
12.3 lbs
0.15 mm
0.0059 in.
0.25 mm
0.0098 in.
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Item
Tappet to Tappet Guide
Timing Gear
Factory Specification
Allowable Limit
Clearance
0.016 to 0.052 mm
0.00063 to 0.00205 in.
0.10 mm
0.0039 in.
Tappet
(O.D.)
17.966 to 17.984 mm
0.70732 to 0.70803 in.
Tappet Guide Bore
(I.D.)
18.000 to 18.018 mm
0.70866 to 0.70937 in.
Idle Gear to Crank
Gear
(Backlash)
0.043 to 0.124 mm
0.00169 to 0.00488 in.
0.15 mm
0.0059 in.
Idle Gear to Cam
Gear
(Backlash)
0.047 to 0.123 mm
0.00185 to 0.00484 in.
0.15 mm
0.0059 in.
Idle Gear to
Injection Pump
Gear
(Backlash)
0.046 to 0.124 mm
0.00185 to 0.00488 in.
0.15 mm
0.0059 in.
Oil Pump Drive
Gear to Crank Gear
(Backlash)
0.041 to 0.123 mm
0.00161 to 0.00484 in.
0.15 mm
0.0059 in.
Idle Gear
Side Clearance
0.20 to 0.51 mm
0.0079 to 0.0201 in.
0.80 mm
0.0315 in.
Camshaft
Side Clearance
0.15 to 0.31 mm
0.0059 to 0.0122 in.
0.50 mm
0.0197 in.
Alignment
Cam Height
(Intake and
Exhaust)
Camshaft Journal to Cylinder Block Bore
Idle Gear Shaft to Idle Gear Bushing
Piston Pin Bore
0.01 mm
0.0004 in.
26.88 mm
1.0583 in.
26.83 mm
1.0563 in.
Oil Clearance
0.050 to 0.091 mm
0.00197 to 0.00358 in.
0.15 mm
0.0059 in.
Camshaft Journal
(O.D.)
32.934 to 32.950 mm
1.29661 to 1.29724 in.
Cylinder Block Bore
(I.D.)
33.000 to 33.025 mm
1.29921 to 1.30020 in.
Oil Clearance
0.020 to 0.084 mm
0.00079 to 0.00331 in.
Idle Gear Shaft
(O.D.)
19.967 to 19.980 mm
0.78610 to 0.78661 in.
Idle Gear Bushing
(I.D.)
20.000 to 20.051 mm
0.78740 to 0.78941 in.
I.D.
20.000 to 20.013 mm
0.78740 to 0.78791 in.
1-S5
0.10 mm
0.0039 in.
20.05 mm
0.7894 in.
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Item
Piston Pin to Small End Bushing
Piston Pin to Small End Bushing
(Spare Parts)
Piston Ring Gap
Piston Pin to Piston Ring Groove
Factory Specification
Allowable Limit
Oil Clearance
0.014 to 0.038 mm
0.00055 to 0.00150 in.
0.10 mm
0.0039 in.
Piston Pin
(O.D.)
20.002 to 20.011 mm
0.78748 to 0.078783 in.
Small End Bushing
(I.D.)
20.025 to 20.040 mm
0.78839 to 0.78897 in.
Oil Clearance
0.015 to 0.075 mm
0.00059 to 0.00295 in.
Small End Bushing
(I.D.)
20.026 to 20.077 mm
0.78845 to 0.79043 in.
Top Ring
0.15 to 0.30 mm
0.0059 to 0.0118 in.
1.20 mm
0.0472 in.
Second Ring
0.25 to 0.40 mm
0.0118 to 0.0157 in.
1.20 mm
0.0472 in.
Oil Ring
0.15 to 0.30 mm
0.0059 to 0.0118 in.
1.20 mm
0.0472 in.
Second Ring
(Clearance)
0.085 to 0.115 mm
0.00335 to 0.00453 in.
0.15 mm
0.0059 in.
Oil Ring
(Clearance)
0.02 to 0.06 mm
0.0008 to 0.0024 in.
0.15 mm
0.0059 in.
Connecting Rod
Alignment
Crankshaft
Side Clearance
0.05 mm
0.0020 in.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Alignment
Crankpin to Crankpin Bearing
0.020 to 0.051 mm
0.00079 to 0.00201 in.
Crankpin
(O.D.)
33.959 to 33.975 mm
1.33697 to 1.33760 in.
Crankpin Bearing
(I.D.)
33.995 to 34.010 mm
1.33893 to 1.33898 in.
0.034 to 0.106 mm
0.00134 to 0.00417 in.
Crankshaft Journal
(O.D.)
39.934 to 39.950 mm
1.57221 to 1.57284 in.
Crankshaft Bearing
1
(I.D.)
39.984 to 40.040 mm
1.57417 to 1.57638 in.
Oil Clearance
0.028 to 0.051 mm
0.00110 to 0.00201 in.
Crankshaft Journal
(O.D.)
43.934 to 43.950 mm
1.72968 to 1.73031 in.
Crankshaft Bearing
2
(I.D.)
43.978 to 43.993 mm
1.73142 to 1.73201 in.
1-S6
0.50 mm
0.0197 in.
0.02 mm
0.0008 in.
Oil Clearance
Crankshaft Journal to Crankshaft Bearing 1 Oil Clearance
Crankshaft Journal to Crankshaft Bearing 2
(Flywheel Side)
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.20 mm
0.0079 in.
0.20 mm
0.0079 in.
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Item
Crankshaft Journal to Crankshaft Bearing 3
(Intermediate)
Factory Specification
Allowable Limit
Oil Clearance
0.028 to 0.051 mm
0.00110 to 0.00201 in.
0.20 mm
0.0079 in.
Crankshaft Journal
(O.D.)
39.934 to 39.950 mm
1.57221 to 1.57284 in.
Crankshaft Bearing
3
(I.D.)
39.978 to 39.993 mm
1.57394 to 1.57453 in.
Cylinder Liner
I.D.
67.000 to 67.019 mm
2.63779 to 2.63854 in.
67.169 mm
2.6445 in.
Cylinder Liner
(Oversize)
I.D.
67.250 to 67.269 mm
2.64764 to 2.64839 in.
67.419 mm
2.65429 in.
0000009505E
LUBRICATING SYSTEM
Item
Engine Oil Pressure
Oil Pump
Factory Specification
At Idle Speed
More than 49 MPa
0.5
7 psi
At Rated Speed
196 to 441 MPa
2.0 to 4.5
28 to 64 psi
Inter Rotor to Outer
Rotor
(Clearance)
0.03 to 0.14 mm
0.0012 to 0.0055 in.
Outer Rotor to
Pump Body
(O.D.)
0.07 to 0.15 mm
0.0028 to 0.0059 in.
Inter Rotor to Cover
(I.D.)
Allowable Limit
147 MPa
1.5
21 psi
0.075 to 0.135 mm
0.00295 to 0.00531 in.
0000004340E
1-S7
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
COOLING SYSTEM
Item
Factory Specification
Fan Belt
Tension
Thermostat
Valve Opening
Temperature
(At Beginning)
80.5 to 83.5
176.9 to 182.3
Valve Opening
Temperature
(Opened
Completely)
95
203
Allowable Limit
7 to 9 mm / 98 N
0.28 to 0.35 in. / 98N
(10 kgf, 22 lbs)
Radiator Cap
Pressure Falling
TIme
10 seconds or more
88
59 kPa
0.9
0.6
13
9 psi
Radiator
Water Leakage
Test Pressure
No leak at specified
pressure
157 kPa
1.6
23 psi
0000004343E
FUEL SYSTEM
Item
Factory Specification
Injection Pump
Injection Timing
Pump Element
Fuel Tightness
Delivery Valve
Fuel Tightness
10 seconds
13.73
12.75 MPa
140
130
1991
1849 psi
Fuel Injection Nozzle
Injection Pressure
13.73 to 14.71 MPa
140 to 150
1991 to 2134 psi
Valve Seat
Tightness
Allowable Limit
0.31 to 0.33 rad
(18 to 20 )
before T.D.C.
13.7 MPa
140
1991 psi
5 seconds
13.73 12.75 MPa
140
130
1991
1849 psi
When the pressure is
12.75 MPa (130
,
1849 psi), the valve seat
must be fuel tightness
0000009506E
1-S8
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
3. TIGHTENING TORQUES
Tightening torques of screws and nuts on the table below are especially specified.
(For general use screws and nuts : See page G-9.)
Item
Size x Pitch
ft-lbs
Front coupling mounting screw
M8 x 1.25
23.5 to 27.4
2.4 to 2.8
17.4 to 20.3
Engine mounting nut
M8 x 1.25
23.5
2.4
17.4
Air cleaner stay screw
M8 x 1.25
23.5 to 27.4
2.4 to 2.8
17.4 to 20.3
Engine support screw
M10 x 1.25
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2
*Cylinder head cover screw
M6 x 1.0
6.86 to 11.3
0.7 to 1.15
5.1 to 8.3
Injection pipe retaining nut
M12 x 1.5
24.5 to 34.3
2.5 to 3.5
18.1 to 25.3
Overflow pipe retaining nut
M12 x 1.5
19.6 to 24.5
2.0 to 2.5
14.5 to 18.1
Nozzle holder assembly
M20 x 1.5
49.0 to 68.6
5.0 to 7.0
36.2 to 50.6
Glow plug
M8 x 1.0
7.85 to 14.7
0.8 to 1.5
5.8 to 10.8
*Rocker arm braket screw
M6 x 1.0
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3
*Cylinder head screw
M8 x 1.25
37.3 to 42.2
3.8 to 4.3
27.5 to 31.1
*Fan drive pulley screw
M12 x 1.5
98.0 to 107.8
10.0 to 11.0
72.3 to 79.5
*Idle gear shaft mounting screw
M6 x 1.0
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3
*Connecting rod screw
M7 x 0.75
26.5 to 30.4
2.7 to 3.1
19.5 to 22.4
*Flywheel screw
M10 x 1.25
53.9 to 58.8
5.5 to 6.0
39.8 to 43.4
Bearing case cover mounting screw
M6 x 1.0
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3
*Main bearing case screw 2
M7 x 1.0
26.5 to 30.4
2.7 to 3.1
19.5 to 22.4
*Main bearing case screw 1
M6 x 1.0
12.7 to 15.7
1.3 to 1.6
9.4 to 11.6
34.3 to 39.2
3.5 to 4.0
25.3 to 28.9
14.7 to 19.6
1.5 to 2.0
10.8 to 14.5
Nozzle holder
Oil pressure switch
PT1/8
A In removing and applying the screws and nuts marked with "*", a pneumatic wrench or similar
pneumatic tool, if employed, must be used with enough care not to get them seized.
A For "*" marked screws and nuts on the table, apply engine oil to their threads and seats before
tightening.
A The letter "M" in Size x Pitch means that the screw or nut dimension stands for metric. The size is the
nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two
threads.
0000009507E
1-S9
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. Run the engine until it is warmed up.
2. Stop the engine.
3. Disconnect the 2P connector from the fuel pump.
4. Remove the air cleaner, the muffler and all injection nozzles.
5. Disconnect the accelerator wire.
6. Engage the parking brake.
7. Set a compression tester (Code No. 07909-30208) with the
adaptor (Adaptor H, Code No. 07909-31231) to the nozzle
hole.
8. While cranking the engine with the starter, measure the
compression pressure.
9. Repeat steps 7 and 8 for each cylinder.
10. If the measurement is below the allowable limit, apply a small
amount of oil to the cylinder wall through the nozzle hole and
measure the compression pressure again.
11. If the compression pressure is still less than the allowable limit,
check the top clearance, valve clearance and cylinder head.
12. If the compression pressure increases after applying oil, check
the cylinder wall and piston rings.
A Check the compression pressure with the specified valve
clearance.
A Always use a fully charged battery for performing this
test.
A Variances in cylinder compression values should be
under 10 %.
Factory spec.
2.84 to 3.24 MPa
29.0 to 33.0
412 to 469 psi
Allowable limit
2.26 MPa
23.0
327psi
Compression pressure
0000009508E
1-S10
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Top Clearance
1. Remove the cylinder head. (Do not attempt to remove the
cylinder head gasket.).
2. Move the piston up, and stick a strip of fuse [1.5 mm dia.
(0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the
piston head at three positions with grease so as to avoid the
intake and exhaust valves and the combustion chamber ports.
3. Lower the piston, and install the cylinder head and tighten the
cylinder head screws to the specified torque.
4. Turn the flywheel until the piston exceeds its top dead center.
5. Remove the cylinder head, and measure the thickness of the
squeezed fuses.
6. If the measurement is not within the factory specifications,
check the oil clearance between the crankpin and crankpin
bearing and between the piston pin and small end bushing.
A After checking the top clearance, be sure to assemble the
cylinder head with a new cylinder head gasket.
Top clearance
Tightening torque
(1)
Factory spec.
Cylinder head screw
0.50 to 0.70 mm
0.0197 to 0.0276 in.
37.3 to 42.2
3.8 to 4.3
27.5 to 31.1 ft-lbs
Fuse
0000000844E
1-S11
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Valve Clearance
A The valve clearance must be checked and adjusted when
engine is cold.
1. Remove the cylinder head cover (1) and the glow plugs.
2. Align the "1TC" mark (2) on the flywheel and alignment mark
(3) on the rear end plate so that the No. 1 piston comes to the
compression top dead center.
3. Check the following valve clearance marked with " " using a
thickness gauge.
[When No.1 piston is at the compression top dead center
position]
Cylinder No.
No.1
No.2
Intake valve
Exhaust valve
4. If the clearance is not within the factory specifications, adjust
with the adjusting screw.
5. Then turn the flywheel 6.28 rad. (360 ), and align the "1TC"
mark (2) on the flywheel and alignment mark (3) on the rear
end plate so that the No.1 piston comes to the overlap
position.
6. Check the following valve clearance marked with " " using a
thickness gauge.
[When No.1 piston is at the overlap position]
Cylinder No.
No.1
No.2
Intake valve
Exhaust valve
7. If the clearance is not within the factory specifications, adjust
with the adjusting screw.
Intake and exhaust
valve clearance (Cold)
0.145 to 0.185 mm
0.00571 to 0.00728 in.
Factory spec.
A The sequence of cylinder numbers is given as No.1 and
No.2 starting from the gear case side.
A After adjusting the valve clearance, secure the adjusting
screw with the lock nut.
(1)
Cylinder Head Cover
(2)
"1TC" Mark
(3)
Alignment Mark
A:
Gear Case Side
0000009509E
1-S12
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(2) Lubricating System
Engine Oil Pressure
1. Remove the engine oil pressure switch, and set an oil
pressure tester (Code No.: 07916-32032).
2. Start the engine. After warming up, measure the oil pressure
of both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
A Engine oil insufficient.
A Oil pump defective
A Oil strainer clogged
A Oil filter cartridge clogged
A Oil gallery clogged
A Excessive oil clearance
A Foreign matter in the relief valve
At idle
speed
Engine oil pressure
Factory
spec.
More than 49 kPa
0.5
7 psi
Factory
spec.
196 to 441 kPa
2.0 to 4.5
28 to 64 psi
Allowable
limit
147 kPa
1.5
21 psi
At rated
speed
(When reassembling)
A After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
0000000914E
(3) Cooling System
Checking Fan Drive Belt Tension
A Be sure to stop the engine and remove the key before
checking belt tension.
1. Measure the deflection (A), depressing the belt halfway
between the fan drive pulley (1) and dynamo pulley (2) at
specified force (98 N, 10 kgf, 22 lbs).
2. If the measurement is not within the factory specifications,
loosen the dynamo mounting screws and relocate the dynamo
to adjust.
Deflection (A)
(1)
Fan Drive Pulley
7 to 9 mm
0.28 to 0.35 in.
Factory spec.
(2)
Dynamo Pulley
0000010059E
1-S13
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Fan Belt Damage and Wear
1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A)
Good
(B)
Bad
0000000920E
Thermostat Valve Opening Temperature
1. Suspend the thermostat in the water by a string with its end
inserted between the valve and seat.
2. Heating the water gradually, read the temperature when the
valve opens and leaves the string.
3. Continue heating and read the temperature when the valve
opens approx. 6 mm (0.236 in.).
4. If the measurement is not within the factory specifications,
replace the thermostat.
Thermostat's valve
opening temperature
Factory spec.
80.5 to 83.5
176.9 to 182.3
Temperature at which
thermostat completely
opens
Factory spec.
95
203
0000004389E
1-S14
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
A When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water may gush out, scalding nearby people.
0000000922E
Radiator Cap Air Leakage
1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No.:
RCT-2A-30S) on the radiator cap.
2. Apply the specified pressure (88 kPa, 0.9
, 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.6
, 9 psi).
3. If the measurement is less than the factory specification,
replace the radiator cap.
Pressure falling time
(1)
More than 10 seconds for
pressure fall from
88 to 59 kPa
(from 0.9 to 0.6
from 13 to 9 psi)
Factory spec.
Radiator Tester
(2)
Adaptor
0000000923E
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester (1) (Code No. 07909-31551) and an
adaptor (2) (BANZAI Code No.: RCT-2A-30S) and raise the
water pressure to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pinhole, repair with the radiator
cement. When water leak is excessive, replace the radiator.
Radiator water leakage
test pressure
(1)
Radiator Tester
157 kPa
1.6
23 psi
Factory spec.
(2)
Adaptor
0000000924E
1-S15
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(4) Fuel System
Injection Timing
1. Remove the injection pipes.
2. Remove the engine stop solenoid.
3. Turn the flywheel counterclockwise (facing the flywheel) until
fuel flows from the delivery valve holder.
4. Continue to turn the flywheel slowly, and stop it as soon as the
fuel level at the tip of the delivery valve holder begins to
increase.
5. Check to see if the timing angle lines on the flywheel is aligned
with the alignment mark (2).
6. If the injection timing is out of adjustment, readjust the timing
with shims.
Injection timing
0.31 to 0.33 rad. (18 to 20 )
before T.D.C.
Factory spec.
A The sealant is applied to both sides of the shim (soft metal
gasket shim). The liquid gasket is not required for
assembling.
A Shims are available in thickness of 0.20 mm (0.0079 in.),
0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine
these shims for adjustments.
A Addition or reduction of shim (0.05 mm, 0.0020 in.) delays
or advances the injection timing by approx. 0.0087 rad.
(0.5 ).
A In disassembling and replacing the injection pump, be
sure to use the same number of new shims with the same
thickness.
A Refer to figure below to check the thickness of the shims.
(1)
Timing Line
(2)
Alignment Mark
(3)
Shim (Soft Metal Gasket Shim)
(4)
Two-holes:
(5)
One-holes:
0.20 mm (0.0079 in.)
0.25 mm (0.0098 in.)
(6)
Without hole:
0.30 mm (0.0118 in.)
0000009510E
1-S16
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Fuel Tightness of Pump Element
1. Remove the engine stop solenoid.
2. Remove the injection pipes and glow plugs.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (1) jetted with the proper injection
pressure to the injection pump pressure tester (2). (Refer to
the figure.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
Fuel tightness of pump
element
13.7 MPa
140
1991 psi
Allowable limit
A Never try to disassemble the injection pump assembly.
For repairs, you are strongly requested to contact a
Kubota-authorized pump service shop.
(1)
Injection Nozzle
(2)
Injection Pump Pressure Tester
(3)
Protection Cover for Jetted Fuel
0000004218E
1-S17
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Fuel Tightness of Delivery Valve
1. Remove the engine stop solenoid.
2. Remove the injection pipes and glow plugs.
3. Set a pressure tester to the fuel injection pump.
4. Install the injection nozzle (1) jetted with the proper injection
pressure to the injection pump pressure tester (2).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle.
After that, turn the flywheel by the hand and raise the pressure
to approx. 13.73 MPa (140
, 1991 psi).
7. Now turn the flywheel back about half a turn (to keep the
plunger free). Maintain the flywheel at this position and clock
the time taken for the pressure to drop from 13.73 to 12.75
MPa (from 140 to 130
, from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73
to 12.75 MPa (from 140 to 130
, from 1991 to 1849
psi).
9. If the measurement is less than allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
Factory spec.
10 seconds
13.73
12.75 MPa
140
130
1991
1849 psi
Allowable limit
5 seconds
13.73
12.75 MPa
140
130
1991
1849 psi
Fuel tightness of
delivery valve
A Never try to disassemble the injection pump assembly.
For repairs, you are strongly requested to contact a
Kubota-authorized pump service shop.
(1)
Injection Nozzle
(2)
Injection Pump Pressure Tester
(3)
Protection Cover for Jetted Fuel
0000001361E
1-S18
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
A Check the injection pressure and condition after confirming that there is nobody standing in the
direction the fume goes.
A If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood
poisoning may be caused.
0000000932E
Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester (Code No. 0790931361), and check the nozzle spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.
(a)
Good
(b)
Bad
0000004118E
Fuel Injection Pressure
1. Set the injection nozzle to a nozzle tester (Code No. 0790931361).
2. Slowly move the tester handle to measure the pressure at
which fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the adjusting washer (1) in the nozzle holder to adjust
it.
Fuel injection pressure
Factory spec.
13.73 to 14.71 MPa
140 to 150
1991 to 2134 psi
(Reference)
A Pressure variation with 0.01 mm (0.0004 in.) difference of
adjusting washer thickness.
Approx. 235 kPa (2.3
, 34 psi)
(1)
Adjusting Washer
0000000934E
1-S19
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Valve Seat Tightness
1. Set the injection nozzle to a nozzle tester (Code No. 0790931361).
2. Raise the fuel pressure, and keep at 12.75 MPa (130
,
1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.
Valve seat tightness
No fuel leak at
12.75 MPa
130
1849 psi
Factory spec.
0000000935E
[2] PREPARATION
(1) Separating Engine
Draining Coolant
A Never open the radiator cap while operating or
immediately after stopping. Otherwise, hot water will
spout out from the radiator. Wait for more than ten
minutes to cool the radiator, before opening the cap.
1. Open the radiator drain plug (2), and remove radiator cap (1)
to completely drain the coolant.
2. After all coolant is drained, close the drain plug (2).
Coolant
(1)
Radiator Cap
2.15 L
2.27 U.S.qts.
1.89 Imp.qts.
Capacity (with
recovery tank)
(2)
Drain Plug
0000009511E
1-S20
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Draining Engine Oil
1. Start and warm up the engine for approx. 5 minutes
2. Place an oil pan underneath the engine.
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug (1).
(When refilling)
A Fill the engine oil up to the upper line on the dipstick (3).
A Never mix two different type of oil.
A Use the proper SAE Engine Oil according to ambient
temperature.
Refer to "LUBRICANTS, FUEL AND COOLANT" (See
page G-8.)
Engine Oil
1.2 L
1.27 U.S.qts.
1.06 Imp.qts.
Capacity
(1)
Drain Plug
A:
Upper Level
(2)
Oil Inlet
B:
Lower Level
(3)
Dipstick
0000009512E
Battery
A When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Open the bonnet.
2. Disconnect the negative cable (1) from the battery.
3. Disconnect the positive cable (2) from the battery and remove
the battery (3).
(1)
Negative Cable
(2)
Positive Cable
(3)
Battery
0000009318E
1-S21
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Bonnet and Side Bonnet
1. Disconnect the connectors (5) from the head light.
2. Remove the wire harness (4) from the bonnet.
3. Remove the bonnet (1) with bonnet bracket (2).
4. Remove the side bonnet (3).
(1)
Bonnet
(4)
Wire Harness
(2)
Bonnet Bracket
(5)
Connector
(3)
Side Bonnet
0000009461E
Air Cleaner, Muffler, Fuel Hose and Wire Harness
1. Remove the air cleaner (1) and muffler (2).
2. Disconnect the fuel hoses (3).
3. Disconnect the accelerator wire (4).
4. Disconnect the wire harness (5).
(1)
Air Cleaner
(4)
Accelerator Wire
(2)
Muffler
(5)
Wire Harness
(3)
Fuel Hose
0000009513E
1-S22
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Engine Assembly
1. Remove the radiator retaining snap pins (1).
2. Disconnect the front coupling (2).
3. Separate the engine assembly (3) with radiator from the frame
(4).
(When reassembling)
Front coupling mounting
screw
23.5 to 27.4
2.4 to 2.8
17.4 to 20.3 ft-lbs
Engine mounting nut
23.5
2.4
17.4 ft-lbs
Tightening torque
(1)
Radiator Retaining Snap Pin
(3)
Engine Assembly
(2)
Front Coupling
(4)
Frame
0000009514E
[3] DISASSEMBLING AND ASSEMBLING
(1) Cylinder Head and Valves
Dynamo, Fan Belt and Radiator
1. Disconnect the radiator hoses and separate the radiator (1)
with recovery tank (2) from engine assembly.
2. Remove the cooling fan (9) and fan pulley.
3. Remove the dynamo (3) and fan belt (4).
4. Remove the starter (6).
5. Disconnect the air cleaner stay (8) and engine stop solenoid.
6. Remove the wire bracket.
7. Remove the engine support LH (7) and RH (5).
(When reassembling)
A Check to see that there are no cracks on the belt surface.
A After reassembling the fan belt, be sure to adjust the fan
belt tension.
Air cleaner stay screw
23.5 to 27.4
2.4 to 2.8
17.4 to 20.3 ft-lbs
Engine support screw
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2 ft-lbs
Tightening torque
(1)
Radiator
(6)
Starter
(2)
Recovery Tank
(7)
Engine Support LH
(3)
Dynamo
(8)
Air Cleaner Stay
(4)
Fan Belt
(9)
Cooling Fan
(5)
Engine Support RH
0000009515E
1-S23
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Cylinder Head Cover
1. Remove the head cover screws (1).
2. Remove the cylinder head cover (2).
(When reassembling)
A Check to see if the cylinder head cover gasket is not defective.
Tightening torque
(1)
6.86 to 11.3
0.7 to 1.15
5.1 to 8.3 ft-lbs
Cylinder head cover
screw
Head Cover Screws
(2)
Cylinder Head Cover
0000001488E
Injection Pipes
1. Loosen the screw on the pipe clamp (1).
2. Detach the injection pipes (2).
(When reassembling)
A Sent compressed air into the pipes to blow out dust. Then,
reassemble the pipes in the reverse order.
Tightening torque
(1)
Injection pipe retaining
nut
Pipe Clamp
(2)
24.5 to 34.3
2.5 to 3.5
18.1 to 25.3 ft-lbs
Injection Pipe
0000001490E
Nozzle Holder Assembly and Glow Plug
1. Remove the overflow pipe (1).
2. Remove the nozzle holder assemblies (2).
3. Remove the copper gasket (5) and the heat seal (6).
4. Remove the lead (3) from the glow plugs (4).
5. Remove the glow plugs (4).
(When reassembling)
A Replace the copper gasket and heat seal with new one.
Tightening torque
Overflow pipe retaining
nut
19.6 to 24.5
2.0 to 2.5
14.5 to 18.1 ft-lbs
Nozzle holder assembly
49.0 to 68.6
5.0 to 7.0
36.2 to 50.6 ft-lbs
Glow plug
7.85 to 14.7
0.8 to 1.5
5.8 to 10.8 ft-lbs
(1)
Overflow Pipe
(4)
Glow Plug
(2)
Nozzle Holder Assembly
(5)
Copper Gasket
(3)
Lead
(6)
Heat Seal
0000001489E
1-S24
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Rocker Arm and Push Rod
1. Remove the rocker arm bracket screws (1).
2. Detach the rocker arm assembly (2).
3. Remove the push rods (3).
(When reassembling)
A When putting the push rods (3) onto the tappets (4), check to
see if their ends are properly engaged with the dimples.
A After installing the rocker arm, be sure to adjust the valve
clearance.
Tightening torque
Rocker arm bracket
screw
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3 ft-lbs
(1)
Rocker Arm Bracket screws
(3)
Push Rod
(2)
Rocker Arm Assembly
(4)
Tappet
0000001491E
Cylinder Head
1. Loosen the pipe clamp, and remove the water return pipe.
2. Remove the cylinder head screw in the order of (j) to (a).
3. Lift up the cylinder head to detach.
4. Remove the cylinder head gasket and O-ring (1).
(When reassembling)
A Replace the cylinder head gasket with a new one.
A Securely fit the O-ring (1) to the pipe pin.
A Tighten the cylinder head screws after applying sufficient oil.
A Tighten the cylinder head screws diagonal sequence starting
from the centre.
A Tighten them uniformly, or the head may deform in the long
run.
A Retighten the cylinder head screws after running the engine
for 30 minutes.
Tightening torque
(j) to (a): To Loosen
Cylinder head screw
(1)
37.3 to 42.2
3.8 to 4.3
27.5 to 31.1 ft-lbs
O-ring
(a) to (j): To Tighten
0000001684E
1-S25
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
A Visually check the contact between tappets and cams for
proper rotation. If defect is found, replace tappets.
A Before installing the tappets, apply engine oil thinly around
them.
A Do not change the combination of tappet and tappet
guide.
(1)
Tappet
0000000854E
Valves
1. Remove the valve caps (2).
2. Remove the valve spring collet (3), pushing the valve spring
retainer (4) by valve spring replacer (1).
3. Remove the valve spring retainer (4), valve spring (5) and
valve stem seal (6).
4. Remove the valve (7).
(When reassembling)
A Wash the valve stem seal and valve guide hole, and apply
engine oil sufficiently.
A After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
A Do not change the combination of valve and valve guide.
(1)
Valve Spring Replacer
(5)
Valve Spring
(2)
Valve Cap
(6)
Valve Stem Seal
(3)
Valve Spring Collet
(7)
Valve
(4)
Valve Spring Retainer
0000000855E
1-S26
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(2) Timing Gear, Camshaft and Fuel Camshaft
Injection Pump and Speed Control Plate
1. Remove the socket head screws and nuts, and remove the
injection pump (3).
2. Remove the screws and separate the speed control plate (2),
taking care not to damage the governor spring (4).
3. Disconnect the governor spring (4) and remove the speed
control plate (2).
(When reassembling)
A Hook the governor spring (4) to the governor lever (5) first and
install the speed control plate (2).
A Be sure to place the copper washers underneath two screws
(1). (Two screws (1) in the upper of the speed control plate
(2).)
A Position the slot (9) on the fork lever just under the slot (8) on
the crankcase.
A Insert the injection pump (3) so that the control rod (7) should
be pushed by the idling adjusting spring (6) at its end and the
pin (10) on the rod engages with the slot (9) on the fork lever
(as shown in the figure).
A The sealant is applied to both sides of the soft metal
gasket shim. The liquid gasket is not required for
assembling.
A Addition or reduction of shim (0.05 mm, 0.0020 in.) delays
or advances the injection timing by approx. 0.0087 rad.
(0.5 )
A In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
(1)
Screws and Copper Washers
(6)
Idling Adjusting Spring
(2)
Speed Control Plate
(7)
Control Rod
(3)
Injection Pump
(8)
Slot (Crankcase Side)
(4)
Governor Spring
(9)
(5)
Governor Lever
(10)
Slot (Fork Lever Side)
Pin
0000000858E
Fan Drive Pulley
1. Secure the flywheel to keep it from turning.
2. Remove the fan drive pulley screw.
3. Draw out the fan drive pulley with a puller.
(When reassembling)
A Install the pulley to the crankshaft, aligning the mark (1) on
them.
A Apply engine oil to the fan drive pulley retaining screws. And
tighten them.
Tightening torque
(1)
Fan drive pulley screw
98.0 to 107.8
10.0 to 11.0
72.3 to 79.5 ft-lbs
Alignment Mark
0000000859E
1-S27
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Gear Case
1. Remove the screw (1) of inside the gear case and outside
screws (6).
2. Disconnect the start spring (2) from the fork lever 1.
3. Remove the gear case (3).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) to both
sides of the gear case gasket (4).
A Be sure to set three O-rings (5) inside the gear case.
(1)
Screw (Inside)
(4)
(2)
Start Spring
(5)
Gear Case Gasket
O-rings
(3)
Gear Case
(6)
Screw
0000004067E
1-S28
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Idle Gear
1. Remove the external snap ring (3), the collar (2) and the idle
gear (1).
2. Remove the idle gear shaft mounting screws (4).
3. Remove the idle gear shaft (5).
(When reassembling)
A Apply engine oil to the idle gear shaft mounting screw (4). And
tighten them.
A Install the idle gear, aligning the mark (6) on the gears referring
to the photo.
Tightening torque
Idle gear shaft mounting
screw
(1)
Idle Gear
(2)
Idle Gear Collar
(3)
External Snap Ring
(4)
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3 ft-lbs
Idle Gear Shaft Mounting
Screw
(5)
Idle Gear Shaft
(6)
Alignment Mark
0000001330E
Camshaft
1. Remove the camshaft mounting screws (1) and draw out the
camshaft with gear (2) on it.
(When reassembling)
A When install the camshaft, apply engine oil to the camshaft
journals.
A Apply engine oil to the camshaft mounting screws. And
tighten them.
(1)
Camshaft Mounting Screw
(2)
Camshaft Gear
0000001331E
1-S29
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Fuel Camshaft
1. Remove the retaining plate (1).
2. Remove the fork lever holder mounting screws (8), then draw
out the injection pump gear (3) and fuel camshaft (2) with the
governor fork assembly.
(When reassembling)
A Hook the governor spring (7) to the fork lever 2 (6) as shown
in the figure before installing the fork lever assembly to the
crankcase.
(1)
Retaining Plate
(5)
Fork Lever 1
(2)
Fuel Camshaft
(6)
Fork Lever 2
(3)
Injection Pump Gear
(7)
Governor Spring
(4)
Governor Sleeve
(8)
Fork Lever Holder Mounting
Screw
0000001332E
Oil Pump and Crankshaft Gear
1. Remove the oil pump gear (6).
2. Remove the oil pump (5).
3. Remove the collar (4), O-ring (3) and crankshaft oil slinger (2).
4. Remove the crankhshaft gear (1).
(When reassembling)
A Install the collar (4) after aligning the marks on the gears. (See
the figure at "Idle Gear".)
(1)
Crankshaft Gear
(4)
Crankshaft Collar
(2)
Crankshaft Oil Slinger
(5)
Oil Pump
(3)
O-ring
(6)
Oil Pump Gear
0000009516E
1-S30
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Oil Pan and Oil Strainer
1. Remove the oil pan mounting screws (5).
2. Remove the oil pan (4) by lightly tapping the rim of the pan with
a wooden hammer.
3. Remove the oil strainer (3).
(When reassembling)
A After cleaning the oil strainer, check to see that the filter mesh
in clean, and install it.
A Visually check the O-ring (1), apply engine oil, and install it.
A Securely fit the O-ring to the oil strainer.
A To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order from the center.
A Using the hole (6) numbered "2", install the oil strainer by
mounting screw.
A Scrape off the old adhesive completely. Wipe the sealing
surface clean using waste cloth soaked with gasoline.
Now apply new adhesive 3 to 5 mm (0.12 to 0.20 in.) thick
all over the contact surface. Apply the adhesive also on
the center of the flange as well as on the inner wall of each
bolt hole.
A Cut the nozzle of the "liquid gasket" (Three Bond 1207D or
equivalent) container at its second notch. Apply "liquid
gasket" about 5 mm (0.20 in.) thick.
Within 20 minutes after the application of fluid sealant,
reassemble the components. Wait then for about 30
minutes, and pour oil in the crankcase.
(1)
O-ring
(4)
(2)
Screw
(5)
Oil Pan
Oil Pan Mounting Screws
(3)
Oil Strainer
(6)
Hole
0000009517E
1-S31
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(3) Piston and Connecting Rod
Connecting Rods
1. Remove the connecting rod caps (1).
(When reassembling)
A Align the marks (a) with each other. (Face the marks toward
the injection pump.).
A Apply engine oil to the connecting rod screws and lightly screw
it in by hand, then tighten it to the specified torque.
If the connecting rod screw won't be screwed in smoothly,
clean the threads.
If the connecting rod screw is still hard to screw in, replace it.
Tightening torque
(1)
Connecting rod screw
Connecting Rod Cap
(a)
26.5 to 30.4
2.7 to 3.1
19.5 to 22.4 ft-lbs
Mark
0000000865E
Pistons
1. Turn the flywheel and bring the piston to top dead centre.
2. Draw out the piston upward by lightly tapping it from the
bottom of the crankcase with the grip of a hammer.
3. Draw out the other piston in the same method as above.
(When reassembling)
A Before inserting the piston into the cylinder, apply enough
engine oil to the piston.
A When inserting the piston into the cylinder, face the mark on
the connecting rod to the injection pump.
A Do not change the combination of cylinder and piston.
Make sure of the position of each piston by marking. For
example, mark "1" on the No.1 piston.
A When installing the piston into the cylinder, place the
gaps of all the piston rings as shown in the figure.
A Carefully insert the pistons using a piston ring
compressor (1). Otherwise, their chrome-plated section
may be scratched, causing trouble inside the cylinder.
(1)
Piston Ring Compressor
(a)
0.785 rad. (45 )
(A)
Top Ring Gap
(b)
0.785 rad. (45 )
(B)
Second Ring Gap
(c)
1.57 rad. (90 )
(C)
Oil Ring Gap
(D)
Piston Pin Hole
0000001686E
1-S32
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Piston Ring and Connecting Rod
1. Remove the piston rings using a piston ring tool (Code No.
07909-32121).
2. Remove the piston pin (7), and separate the connecting rod
(6) from the piston (5).
(When reassembling)
A When installing the ring, assemble the rings so that the
manufacturer's mark (12) near the gap faces the top of the
piston.
A When installing the oil ring onto the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).
A Apply engine oil to the piston pin.
A When installing the connecting rod to the piston, immerse the
piston in 80
(176
) oil for 10 to 15 minutes and insert the
piston pin to the piston.
A When installing the connecting rod to the piston, align the
mark (8) on the connecting rod to the fan-shaped concave (9).
A Mark the same number on the connecting rod and the
piston so as not to change the combination.
(1)
Top Ring
(2)
Second Ring
(9)
(10)
Fan-Shaped Concave
Expander Joint
(3)
Oil Ring
(11)
Oil Ring Gap
(4)
Piston Pin Snap Ring
(12)
Manufacturer's Mark
(5)
Piston
(6)
Connecting Rod
(7)
Piston Pin
(8)
Mark
0000003201E
1-S33
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(4) Crankshaft
Flywheel
1. Secure the flywheel to keep it from turning using a flywheel
stopper. (Refer to "SPECIAL TOOLS".)
2. Remove all flywheel screws (1) and then remove the flywheel
(2).
(When reassembling)
A Set the No. 1 crankpin at the top dead center (T.D.C.).
A Align the "1TC" mark (a) on the outer surface of the flywheel
horizontally with the alignment mark (b) on the rear end plate.
A Apply engine oil to the threads and the undercut surface of the
flywheel screw and fit the screw.
Tightening torque
53.9 to 58.8
5.5 to 6.0
39.8 to 43.4 ft-lbs
Flywheel screw
(1)
Flywheel Screw
(a)
1TC Mark
(2)
Flywheel
(b)
Alignment Mark
0000009518E
Bearing Case Cover
1. Remove the bearing case cover mounting screws. First,
remove inside screws (1) and then outside screws (2).
2. Remove the bearing case cover (6).
(When reassembling)
A Fit the bearing case gasket (3) and the bearing case cover
gasket (4) with correct directions.
A Install the bearing case cover (6) to position the casting mark
"UP" (a) on it upward.
A Apply engine oil to the oil seal (5) lip and take care that it is not
rolled when installing.
A Tighten the bearing case cover mounting screws with even
force on the diagonal line.
Tightening torque
(1)
(2)
Bearing case cover
mounting screw
9.8 to 11.3
1.00 to 1.15
7.2 to 8.3 ft-lbs
Bearing Case Cover Mounting
(5)
Oil Seal
Screw (Inside)
(6)
Bearing Case Cover
Bearing Case Cover Mounting
Screw (Outside)
(a)
Top Mark "UP"
(3)
Bearing Case Gasket
(b)
Upside
(4)
Bearing Case Cover Gasket
0000001337E
1-S34
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Crankshaft Assembly
1. Remove the main bearing case screw 2 (1).
2. Pull out the crankshaft assembly.
(When reassembling)
A Clean the oil passage of the crankshaft with compressed air.
A Apply oil to the main bearing case screw 2 (1).
A Install the crankshaft assembly, aligning the screw hole of
main bearing case with the screw hole of crankcase.
Tightening torque
(1)
Main bearing case
screw 2
26.5 to 30.4
2.7 to 3.1
19.5 to 22.4 ft-lbs
Main Bearing Case Screw 2
0000000871E
1-S35
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Main Bearing Case Assembly
1. Remove the two main bearing case screws 1 (1), and remove
the main bearing case assembly 1 (2), being careful with
crankshaft bearing 3 (4), (5).
2. Remove the main bearing case assembly (3) as above. Keep
in mind, however, that the thrust bearing (8) is installed in the
main bearing case assembly (3).
(When reassembling)
A Clean the oil passage in the main bearing cases.
A Apply clean engine oil on the bearings.
A Install the main bearing case assemblies in original positions.
Since diameters of main bearing cases vary, install them in
order to marking (b) from the gear case side. (Refer to the
figure.)
A Match the alignment numbers (a) on the main bearing case
assembly 1.
A Do the same for the main bearing case assembly (3) too.
A When installing the main bearing case 1, face the mark
"FLYWHEEL" to the flywheel.
A Install the thrust bearing (8) with its oil groove facing outward.
A Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 to the specified
torque.
Tightening torque
Main bearing case
screw 1
12.7 to 15.7
1.3 to 1.6
9.4 to 11.6 ft-lbs
(1)
Main Bearing Case Screw 1
(a)
Alignment Number
(2)
Main Bearing Case Assembly 1
(b)
Marking
(3)
Main Bearing Case Assembly
(c)
Oil Groove
(4)
Crankshaft Bearing 3
(Upper, with oil groove)
(5)
(6)
Crankshaft Bearing 3 (Lower)
Crankshaft Bearing 2
(Upper, with oil groove)
(7)
Crankshaft Bearing 2 (Lower)
(8)
Thrust Bearing
0000009519E
1-S36
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(5) Water Pump
Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove
the thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) only at
the thermostat cover side of the gasket (2).
(1)
Thermostat Cover
(2)
Thermostat Cover Gasket
(3)
Thermostat Assembly
0000000925E
Water Pump Assembly
1. Loosen the dynamo mounting screws, and remove the fan
belt.
2. Remove the fan and fan pulley.
3. Remove the water pump assembly from the gear case cover.
4. Remove the water pump flange (1).
5. Press out the water pump shaft (2) with the impeller (5) on it.
6. Remove the impeller from the water pump shaft.
7. Remove the mechanical seal (4).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) to the
both sides of gasket.
A Replace the mechanical seal with new one.
(1)
Water Pump Flange
(4)
Mechanical Seal
(2)
Water Pump Shaft
(5)
Impeller
(3)
Water Pump Body
0000000926E
1-S37
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(6) Injection Nozzle
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
A Assemble the nozzle in clean fuel oil.
A Install the push rod (4), noting its direction.
A After assembling the nozzle, be sure to adjust the fuel injection
pressure.
Tightening torque
Nozzle holder
34.3 to 39.2
3.5 to 4.0
25.3 to 28.9 ft-lbs
Overflow pipe retaining
nut
19.6 to 24.5
2.0 to 2.5
14.5 to 18.1 ft-lbs
Nozzle holder assembly
49.0 to 68.6
5.0 to 7.0
36.2 to 50.6 ft-lbs
(1)
Nozzle Holder
(5)
Distance Piece
(2)
Adjusting Washer
(6)
Nozzle Piece
(3)
Nozzle Spring
(7)
Nozzle Retaining Nut
(4)
Push Rod
0000000936E
[4] SERVICING
(1) Cylinder Head and Valves
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head's four sides and two
diagonals as shown in the figure.
3. Measure the clearance with a thickness gauge.
4. If the measurement exceeds the allowable limit, correct it with
a surface grinder.
A Do not place the straightedge on the combustion
chamber.
A Be sure to check the valve recessing after correcting.
Cylinder head surface
flatness
Allowable limit
0.05 mm
0.0020 in.
0000000874E
1-S38
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Cylinder Head Flaw
1. Prepare an air spray red check (Code No. 07909-31371).
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
(1)
Red Permetive Liquid
(2)
Detergent
(3)
White Developer
0000000875E
Valve Recessing
1. Clean the cylinder head surface, valve face and valve seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
5. If it still exceeds the allowable limit after replacing the valve,
replace the cylinder head.
Factory spec.
0.10 (protrusion) to
0.10 (recessing) mm
0.0039 (protrusion) to
0.0039 (recessing) in.
Allowable limit
0.30 (recessing) mm
0.0118 (recessing) in.
Valve recessing (Intake
and Exhaust)
(1)
Cylinder Head Surface
(A)
Recessing
(B)
Protrusion
0000001343E
1-S39
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Clearance between Valve Stem and Valve Guide
1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. with a small hole gauge, and
calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the
valves. If it still exceeds the allowable limit, replace the valve
guide.
Clearance between
valve stem and valve
guide
Factory spec.
0.030 to 0.057 mm
0.00118 to 0.00224 in.
Allowable limit
0.10 mm
0.0039 in.
Valve stem O.D.
Factory spec.
5.968 to 5.980 mm
0.23496 to 0.23543 in.
Valve guide I.D.
Factory spec.
6.010 to 6.025 mm
0.23661 to 0.23720 in.
0000000877E
Replacing Valve Guide
(When removing)
1. Press out the used valve guide using a valve guide replacing
tool.
(When installing)
1. Clean a new valve guide and valve guide bore, and apply
engine oil to them.
2. Press in a new valve guide using a valve guide replacing tool.
3. Ream precisely the I.D. of the valve guide to the specified
dimension.
Valve guide I.D. (Intake
and Exhaust)
6.010 to 6.025 mm
0.23661 to 0.23720 in.
Factory spec.
A Do not hit the valve guide with a hammer during
replacement.
(A)
When removing
(B)
When installing
0000000878E
1-S40
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Valve Seating
1. Coat the valve face lightly with prussian blue and put the valve
on its seat to check the contact.
2. If the valve does not seat all the way around the valve seat or
the valve contact is less than 70 %, correct the valve seating
as follows.
3. If the valve contact does not comply with the reference value,
replace the valve or correct the contact of valve seating.
Valve seat width
(1)
Correct
(2)
Incorrect
2.12 mm
0.0835 in.
Factory spec.
(3)
Incorrect
0000000879E
1-S41
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Correcting Valve and Valve Seat
A Before correcting the valve and seat, check the valve
stem and the I.D. of valve guide section, and repair them
if necessary.
A After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
Valve face angle
0.785 rad
45
Factory spec.
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 0.785 rad (45 ) valve
seat cutter (Code No. 07909-33102).
2. Fitting the valve, check the contact position of the valve face
and seat surface with prussian blue. (Visual check) [ If the
valve has been used for a long period, the seat tends to come
in contact with the upper side of the valve face.]
3. Grind the upper surface of the seat with a 0.262 rad (15 )
valve seat cutter until the valve seat touches to the center of
the valve face (so that (a) equals (b) as shown in the figure)
4. Grind the seat with a 0.785 rad (45 ) valve seat cutter again,
and visually recheck the contact between the valve and seat.
5. Repeat steps 3 and 4 until the correct contact is achieved.
6. Continue lapping until the seated rate becomes more than 70
% of the total contact area.
Valve seat angle
0.785 rad
45
Factory spec.
(1)
Valve Seat Cutter
(a)
Identical Dimensions
(A)
Check Contact
(b)
Valve Seat Width
(B)
Correct Seat Width
(c)
0.262 rad (15 )
(C)
Correct Seat Surface
(d)
0.785 rad (45 )
(D)
Check Contact
0000003400E
Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its
seat with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply
oil, then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
A When valve lapping is performed, be sure to check the
valve recessing and adjust the valve clearance after
assembling the valve.
0000000881E
1-S42
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Free Length and Tilt of Valve Spring
1. Measure the free length (A) of valve spring with vernier
calipers. If the measurement is less than the allowable limit,
replace it.
2. Put the valve spring on a surface plate, place a square on the
side of the valve spring.
3. Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt (B).
If the measurement exceeds the allowable limit, replace it.
4. Check the entire surface of the valve spring for scratches.
If there is any defect, replace it.
Factory spec.
31.3 to 31.8 mm
1.232 to 1.252 in.
Allowable limit
28.4 mm
1.118 in.
Allowable limit
1.2 mm
0.047 in.
Free length (A)
Tilt (B)
(A)
Free Length
(B)
Tilt
0000001676E
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
Factory spec.
64.7 N / 27.0 mm
6.6 kgf / 27.0 mm
14.6 lbs / 1.063 in.
Allowable limit
54.9 N / 27.0 mm
5.6 kgf / 27.0 mm
12.3 lbs / 1.063 in.
Setting load / Setting
length
0000000883E
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1. Measure the rocker arm shaft O.D. with an outside
micrometer.
2. Measure the rocker arm I.D. with an inside micrometer, and
then calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
rocker arm and measure the oil clearance again. If it still
exceeds the allowable limit, replace also the rocker arm shaft.
Oil clearance between
rocker arm and rocker
arm shaft
Factory spec.
0.016 to 0.045 mm
0.00063 to 0.00177 in.
Allowable limit
0.15 mm
0.0059 in.
Rocker arm shaft O.D.
Factory spec.
10.473 to 10.484 mm
0.41232 to 0.41276 in.
Rocker arm I.D.
Factory spec.
10.500 to 10.518 mm
0.41339 to 0.41410 in.
0000000884E
1-S43
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Push Rod Alignment
1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the
push rod.
Push rod alignment
Allowable limit
0.25 mm
0.0098 in.
0000000885E
Oil Clearance between Tappet and Tappet Guide Bore
1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder
gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
Oil clearance between
tappet and tappet guide
bore
Factory spec.
0.016 to 0.052 mm
0.00063 to 0.00205 in.
Allowable limit
0.10 mm
0.0039 in.
Tappet O.D.
Factory spec.
17.966 to 17.984 mm
0.70732 to 0.70803 in.
Tappet guide bore I.D.
Factory spec.
18.000 to 18.018 mm
0.70866 to 0.70937 in.
0000000886E
1-S44
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(2) Timing Gear, Camshaft and Fuel Camshaft
Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating
gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance is not proper, replace the gear.
Factory spec.
0.043 to 0.124 mm
0.00169 to 0.00488 in.
Allowable limit
0.15 mm
0.0059 in.
Factory spec.
0.047 to 0.123 mm
0.00185 to 0.00484 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between idle
gear and injection pump
gear
Factory spec.
0.046 to 0.124 mm
0.00185 to 0.00488 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between oil
punp drive gear and
crank gear
Factory spec.
0.041 to 0.123 mm
0.00161 to 0.00484 in.
Allowable limit
0.15 mm
0.0059 in.
Backlash between idle
gear and crank gear
Backlash between idle
gear and cam gear
0000000888E
Idle Gear Side Clearance
1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear to the
front and rear.
3. If the measurement exceeds the allowable limit, replace the
idle gear collar.
Factory spec.
0.20 to 0.51 mm
0.0079 to 0.0201 in.
Allowable limit
0.80 mm
0.0315 in.
Idle gear side clearance
0000000889E
Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear to the
front and rear.
3. If the measurement exceeds the allowable limit, replace the
camshaft stopper.
Factory spec.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Allowable limit
0.50 mm
0.0197 in.
Camshaft side
clearance
0000000890E
1-S45
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Camshaft Alignment
1. Support the camshaft with V blocks on the surface plate at
both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
4. If the measurement exceeds the allowable limit, replace the
camshaft.
Camshaft alignment
Allowable limit
0.01 mm
0.0004 in.
0000000891E
Cam Height
1. Measure the height of the cam at its highest point with an
outside micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
Factory spec.
26.88 mm
1.0583 in.
Allowable limit
26.83 mm
1.0563 in.
Cam height of intake
and exhaust
0000000892E
Oil Clearance of Camshaft Journal
1. Measure the camshaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block bore I.D. for camshaft with a
cylinder gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
camshaft.
Factory spec.
0.050 to 0.091 mm
0.00197 to 0.00358 in.
Allowable limit
0.15 mm
0.0059 in.
Camshaft journal O.D.
Factory spec.
32.934 to 32.950 mm
1.29661 to 1.29724 in.
Camshaft bearing I.D.
(Cylinder block bore
I.D.)
Factory spec.
33.000 to 33.025 mm
1.29921 to 1.30020 in.
Oil clearance of
camshaft journal
0000000893E
1-S46
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushing I.D. with an inside micrometer,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
bushing.
4. If it still exceeds the allowable limit, replace the idle gear shaft.
Oil clearance between
idle gear shaft and idle
gear bushing
Factory spec.
0.020 to 0.084 mm
0.00079 to 0.00331 in.
Allowable limit
0.10 mm
0.0039 in.
Idle gear shaft O.D.
Factory spec.
19.967 to 19.980 mm
0.78610 to 0.78661 in.
Idle gear bushing I.D.
Factory spec.
20.000 to 20.051 mm
0.78740 to 0.78941 in.
0000000894E
Replacing Idle Gear Bushing
(When removing)
1. Press out the used idle gear bushing using an idle gear
bushing replacing tool.
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing
tool, until it is flush with the end of the idle gear.
(A)
When removing
(B)
When installing
0000000895E
(3) Piston and Connecting Rod
Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
2. If the measurement exceeds the allowable limit, replace the
piston.
Factory spec.
20.000 to 20.013 mm
0.78740 to 0.78791 in.
Allowable limit
20.05 mm
0.7894 in.
Piston pin bore I.D.
0000000897E
1-S47
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Oil Clearance between Piston Pin and Small End Bushing
1. Measure the piston pin O.D. where it contacts the bushing with
an outside micrometer.
2. Measure the small end bushing I.D. with an inside micrometer,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
bushing. If it still exceeds the allowable limit, replace the
piston pin.
Oil clearance between
piston pin and small end
bushing
Factory spec.
0.014 to 0.038 mm
0.00055 to 0.00150 in.
Allowable limit
0.10 mm
0.0039 in.
Piston pin O.D.
Factory spec.
20.002 to 20.011 mm
0.78748 to 0.78783 in.
Small end bushing I.D.
Factory spec.
20.025 to 20.040 mm
0.78839 to 0.78897 in.
0000000898E
Replacing Small End Bushing
(When removing)
1. Press out the used bushing using a small end bushing
replacing tool.
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil
to them.
2. Insert a new bushing onto the tool and press-fit it with a press
so that the seam (1) of bushing positions as shown in the
figure, until it is flush with the connecting rod.
3. Drill a hole to the bushing with aligning the oil hole (2) of
connecting rod. (Refer to the figure.)
A Be sure to chamfer the oil hole circumference with an oil
stone.
Oil clearance between
piston pin and small end
bushing (Spare parts)
Small end bushing I.D.
(Spare parts)
Factory spec.
0.015 to 0.075 mm
0.00059 to 0.00295 in.
Allowable limit
0.15 mm
0.0059 in.
Factory spec.
20.026 to 20.077 mm
0.78845 to 0.79043 in.
(1)
Seam
(A)
When removing
(2)
Oil Hole
(B)
When installing
(a)
0.785 rad. (45 )
0000000899E
1-S48
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Piston Ring Gap
1. Insert the piston ring into the lower part of the cylinder (the
least worn out part) with piston.
2. Measure the ring gap with a thickness gauge.
3. If the measurement exceeds the allowable limit, replace the
piston ring.
Factory
spec.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
Allowable
limit
1.20 mm
0.0472 in.
Factory
spec.
0.30 to 0.45 mm
0.0118 to 0.0177 in.
Allowable
limit
1.20 mm
0.0472 in.
Factory
spec.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
Allowable
limit
1.20 mm
0.0472 in.
Top ring
Piston ring gap
Second
ring
Oil ring
0000009520E
Clearance between Piston Ring and Piston Ring Groove
1. Clean the rings and the ring grooves, and install each ring in
its groove.
2. Measure the clearance between the ring and the groove with
a thickness gauge.
3. If the clearance exceeds the allowable limit, replace the piston
ring.
4. If the clearance still exceeds the allowable limit with new ring,
replace the piston.
Second
ring
Clearance between
piston ring and piston
ring groove
Factory
spec.
0.085 to 0.115 mm
0.00335 to 0.00453 in.
Allowable
limit
0.15 mm
0.0059 in.
Factory
spec.
0.02 to 0.06 mm
0.0008 to 0.0024 in.
Allowable
limit
0.15 mm
0.0059 in.
Oil ring
0000009521E
1-S49
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Connecting Rod Alignment
1. Remove the crankpin bearing, and install the connecting rod
cap.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod alignment tool
(Code No. 07909-31661).
4. Put a gauge over the piston pin, and move it against the face
plate.
5. If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the face
plate.
6. If the measurement exceeds the allowable limit, replace the
connecting rod.
Space between gauge
pin face plate
Allowable limit
0.05 mm
0.0020 in.
0000000902E
1-S50
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
(4) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the
front and rear.
3. If the measurement exceeds the allowable limit, replace the
thrust bearings.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the
table and figure.
Factory spec.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Allowable limit
0.50 mm
0.0197 in.
Crankshaft side
clearance
(Reference)
A Oversize thrust bearing
Oversize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Thrust bearing 1 02
15261-23950
020 OS
Thrust bearing 2 02
15261-23970
020 OS
0.4 mm
0.016 in.
Thrust bearing 1 04
15261-23960
040 OS
Thrust bearing 2 04
15261-23980
040 OS
A Oversize dimensions of crankshaft journal
Oversize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
23.40 to 23.45 mm
0.9134 to 0.9154 in.
23.80 to 23.85 mm
0.9213 to 0.9232 in.
Dimension B
46.1 to 46.3 mm
1.815 to 1.823 in.
46.3 to 46.5 mm
1.823 to 1.831 in.
Dimension C
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
(0.8-S)
The crankshaft journal must be fine-finished to higher than
0000000904E
Crankshaft Alignment
1. Support the crankshaft with V blocks on the surface plate at
both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the crankshaft alignment.
4. If the measurement exceeds the allowable limit, replace the
crankshaft.
Crankshaft alignment
Allowable limit
0.02 mm
0.0008 in.
0000000905E
1-S51
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Oil Clearance between Crankpin and Crankpin Bearing
1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage (Code No.: 07909-30241) on the
centre of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get
the oil clearance.
5. If the oil clearance exceeds the allowable limit, replace the
crankpin bearing.
6. If the same size bearing is useless because of the crankpin
wear, replace it with an undersize one referring to the table
and figure.
A Never insert the plastigage into the crankpin oil hole.
A Be sure not to move the crankshaft while the connecting
rod screws are tightened.
Oil clearance between
crankpin and crankpin
bearing
Factory spec.
0.020 to 0.051 mm
0.00079 to 0.00201 in.
Allowable limit
0.15 mm
0.0059 in.
Crankpin O.D.
Factory spec.
33.959 to 33.975 mm
1.33697 to 1.33760 in.
Crankpin bearing I.D.
Factory spec.
33.995 to 34.010 mm
1.33893 to 1.33898 in.
(Reference)
A Undersize crankpin bearing
Undersize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Crankpin bearing 02
15861-22970
020 US
0.4 mm
0.016 in.
Crankpin bearing 04
15861-22980
040 US
A Undersize dimensions of crankpin
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
2.3 to 2.7 mm radius
0.091 to 0.106 in. radius
2.3 to 2.7 mm radius
0.091 to 0.106 in. radius
Dimension B
4 mm dia.
0.16 in. dia.
4 mm dia.
0.16 in. dia.
Dimension C
33.759 to 33.775 mm dia.
1.32910 to 1.32973 in. dia.
33.559 to 33.575 mm dia.
1.32112 to 1.32185 in. dia.
(0.8-S)
The crankpin must be fine-finished to higher than
0000001689E
1-S52
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 1
1. Measure the O.D. of the crankshaft front journal with an
outside micrometer.
2. Measure the I.D. of the crankshaft bearing 1 with an inside
micrometer, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
crankshaft bearing 1.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an undersize one referring to the
table and figure.
Oil clearance between
crankshaft journal and
crankshaft bearing 1
Factory spec.
0.034 to 0.106 mm
0.00134 to 0.00417 in.
Allowable limit
0.20 mm
0.0079 in.
Crankshaft journal O.D.
Factory spec.
39.934 to 39.950 mm
1.57221 to 1.57284 in.
Crankshaft bearing 1
I.D.
Factory spec.
39.984 to 40.040 mm
1.57417 to 1.57638 in.
(Reference)
A Undersize crankshaft bearing 1
Undersize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Crankshaft bearing 1 02
15861-23910
020 US
0.4 mm
0.016 in.
Crankshaft bearing 1 04
15861-23920
040 US
A Undersize dimensions of crankshaft journal
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
Dimension B
5 mm dia.
0.20 in. dia.
5 mm dia.
0.20 in. dia.
Dimension C
39.734 to
39.750 mm dia.
1.56433 to
1.56496 in. dia.
39.534 to
39.550 mm dia.
1.55646 to
1.55709 in. dia.
(0.8-S)
The crankpin must be fine-finished to higher than
0000009522E
1-S53
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (Refer to "SPECIAL TOOLS".)
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
2. Using a crankshaft bearing 1 replacing tool, press in a new
bearing 1 (2) so that its seam (1) directs toward the exhaust
manifold side. (See figure.)
Dimension (A)
0.0 to 0.3 mm
0.0 to 0.0118 in.
Factory spec.
(1)
Seam
(2)
Crankshaft Bearing 1
(A)
(3)
Cylinder Block
Dimension
0000009524E
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 (Crankshaft Bearing 3)
1. Put a strip of plastigage (Code No. 07909-30241) on the
center of the journal.
2. Install the bearing case and tighten the bearing case screws 1
to the specified torque, and remove the bearing case again.
3. Measure the amount of the flattening with the scale, and get
the oil clearance.
4. If the oil clearance exceeds the allowable limit, replace the
crankshaft bearing 2 (crankshaft bearing 3).
5. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an undersize one referring to the
table and figure.
A Be sure not to move the crankshaft while the bearing case
screws are tightened.
Factory spec.
0.028 to 0.051 mm
0.00110 to 0.00201 in.
Allowable limit
0.20 mm
0.0079 in.
Crankshaft journal O.D.
(Flywheel side)
Factory spec.
43.934 to 43.950 mm
1.72968 to 1.73031 in.
Crankshaft bearing 2
I.D.
Factory spec.
43.978 to 43.993 mm
1.73142 to 1.73201 in.
Crankshaft journal O.D.
(Intermediate)
Factory spec.
39.934 to 39.950 mm
1.57221 to 1.57284 in.
Crankshaft bearing 3
I.D.
Factory spec.
39.978 to 39.993 mm
1.57394 to 1.57453 in.
Oil clearance between
crankshaft journal and
crankshaft bearing 2
(Crankshaft bearing 3)
0000009525E
1-S54
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 (Crankshaft Bearing 3) (Continued)
(Reference)
A Undersize crankshaft bearing 2 and 3
Undersize
Bearing
Code Number
Marking
0.2 mm
0.008 in.
Crankshaft bearing 2 02
15694-23930
020 US
Crankshaft bearing 3 02
15861-23860
020 US
0.4 mm
0.016 in.
Crankshaft bearing 2 04
15694-23940
040 US
Crankshaft bearing 3 04
15861-23871
040 US
A Undersize dimensions of crankshaft journal
Undersize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
1.8 to 2.2 mm radius
0.071 to 0.087 in. radius
Dimension B
3 mm dia.
0.12 in. dia.
3 mm dia.
0.12 in. dia.
Dimension C
39.734 to 39.750 mm dia.
1.56433 to 1.56496 in. dia.
39.534 to 39.550 mm dia.
1.55646 to 1.55709 in. dia.
Dimension D
43.734 to 43.750 mm dia.
1.72181 to 1.72244 in. dia.
43.534 to 43.550 mm dia.
1.71394 to 1.7147 in. dia.
(0.8-S)
The crankpin must be fine-finished to higher than
0000009526E
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.'s.
2. Get the difference (Maximum wear) between the maximum
and the minimum I.D.'s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to "Correcting Cylinder".)
4. Visually check the cylinder wall for scratches. If deep
scratches are found, the cylinder should be bored. (Refer to
"Correcting Cylinder".)
Factory spec.
67.000 to 67.019 mm
2.63779 to 2.63854 in.
Allowable limit
67.169 mm
2.6445 in.
Cylinder I.D.
(A)
Top
(a)
Right-angled to Piston Pin
(B)
Middle
(b)
Piston Pin Direction
(C)
Bottom (Skirt)
0000009527E
1-S55
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Correcting Cylinder
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
Factory spec.
67.250 to 67.269 mm
2.64764 to 2.64839 in.
Allowable limit
67.419 mm
2.65429 in.
Cylinder I.D.
[Oversize]
Horn to 1.2 to 2.0 m Rmax.
Finishing
(0.000047 to 0.000079 in. Rmax.)
2. Replace the piston and piston rings with oversize ones.
Oversize
Part Name
Code Number
Marking
0.25 mm
0.0098 in.
Piston
16851-21900
025
Piston ring assembly
16851-21090
025
A When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1)
Cylinder I.D.
(2)
Cylinder I.D. [Oversize]
[Before Correction]
0000009528E
(6) Oil Pump
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and
the outer rotor with a thickness gauge.
2. If the clearance exceeds the factory specifications, replace the
oil pump rotor assembly.
Rotor lobe clearance
Factory spec.
0.03 to 0.14 mm
0.0012 to 0.0055 in.
0000000915E
Clearance between Outer Rotor and Pump Body
1. Measure the clearance between the outer rotor and the pump
body with a thickness gauge.
2. If the clearance exceeds the factory specifications, replace the
oil pump rotor assembly.
Clearance between
outer rotor and pump
body
Factory spec.
0.07 to 0.15 mm
0.0028 to 0.0059 in.
0000000916E
1-S56
KiSC issued 04, 2006 A
GR1600EC, WSM
ENGINE
Clearance between Rotor and Cover
1. Put a strip of plastigage (Code No. 07909-30241) onto the
rotor face with grease.
2. Install the cover and tighten the screws.
3. Remove the cover carefully, and measure the amount of the
flattening with the scale and get the clearance.
4. If the clearance exceeds the factory specifications, replace the
oil pump rotor assembly.
Clearance between
rotor and cover
Factory spec.
0.075 to 0.135 mm
0.00295 to 0.00531 in.
0000000918E
1-S57
KiSC issued 04, 2006 A
2
TRANSMISSION
KiSC issued 04, 2006 A
CONTENTS
1. STRUCTURE.....................................................................................................................2-M1
2. TRAVELLING SYSTEM....................................................................................................2-M2
[1] HYDROSTATIC TRANSMISSION ..................................................................................2-M2
(1) Structure ..................................................................................................................2-M2
(2) Oil Flow....................................................................................................................2-M3
(3) Operation.................................................................................................................2-M4
(4) Charge Pump ..........................................................................................................2-M7
(5) By-pass Valve..........................................................................................................2-M7
(6) Control Linkage .......................................................................................................2-M8
[2] MOWER PTO SYSTEM.................................................................................................2-M9
(1) Mower PTO Clutch ..................................................................................................2-M9
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
1. STRUCTURE
(1)
Hydraulic Transmission
(2)
Mower PTO Section
(3)
Differential Gear Section
(4)
Rear Axle Section
Section
0000009178E
2-M1
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
2. TRAVELLING SYSTEM
[1] HYDROSTATIC TRANSMISSION
(1) Structure
(1)
Check Valve
(8)
Piston
(15) Oil Seal
(22)
By-pass Plug
(2)
Trunnion Arm
(9)
Spring (Cylinder Block)
(16) Pump Shaft
(23)
By-pass Spool
(3)
Charge Relief Valve
(10)
Washer
(17)
(24)
By-pass Spring
(4)
Charge Pump
(11)
Thrust Ball Bearing
(18) Oil Seal
Ball Bearing
(25)
Journal Bearing
(5)
Center Section
(12)
Swashplate
(19)
Motor Shaft
(26)
Oil Seal
(6)
Cylinder Block (Pump)
(13)
Cradle Bearing
(20)
Thrust Ball Bearing
(27)
Journal Bearing
(7)
Piston Spring
(14)
Ball Bearing
(21)
Cylinder Block (Motor)
(28)
Oil Seal
Hydrostatic Transmission (HST) consists of a variable displacement piston pump, a fixed displacement piston
motor, two check valves (1) and a by-pass valve.
The pump and motor have five pistons (8) in their own cylinder block (6), (21).
The discharge rate of the HST is 10
/rev. (0.61 cu. in./rev.).
With the speed change pedal connecting to the trunnion arm (2) in HST via a link mechanism, the speed change
pedal permits simple operation of this machine, starting, stopping and accelerating or decelerating.
0000009179E
2-M2
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
(2) Oil Flow
(1)
Pump
(4)
Filter Cartridge
(7) Lubricating Orifice
(2)
Charge Pump
(5)
Motor
(8)
(3)
Check Valve (Forward)
(6)
By-pass Valve
Check Valve (Reverse)
(9)
(10)
Neutral Orifice
Charge Relief Valve
The closed oil-hydraulic loop connects between the pump (1) and the motor (5) in HST.
Oil from the transaxle flows through the filter cartridge (4). Then the oil passed through the filter cartridge (4) is
routed to HST as charge oil by the charge pump (2) and charge relief valve (10).
Overflow oil from the HST housing flows back to the transaxle.
0000009181E
2-M3
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
(3) Operation
B Neutral
(1)
Cylinder Block (Pump)
(5)
Lubricating Orifice
(8)
Transaxle Case
(11)
Charge Relief Valve
(2)
Swashplate
(6)
Check Valve (Forward)
(9)
Oil Strainer
(12)
Filter Cartridge
(3)
Piston
(7)
By-pass Valve
Check Valve (Reverse)
(13)
Charge Pump
(4)
Cylinder Block (Motor)
(10)
Engine revolution rotates the pump shaft via the universal joint.
Being engaged with each other, the pump shaft and the cylinder block (1) in the pump rotate together.
With the speed control pedal in the neutral position, the swashplate (2) in the pump is at right angles to the pump
pistons.
The pump pistons rotate with the pump cylinder block (1) without reciprocating motion.
At this time, since the pump pistons do not generate pressure, no pressure is transmitted to the motor pistons, thus
causing neither rotation of the motor cylinder block (4) nor that of the motor shaft engaged with it.
Thus the machine is stationary.
0000009183E
2-M4
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
B Forward
(1)
Cylinder Block (Pump)
(5)
Lubricating Orifice
(8)
Transaxle Case
(11)
Charge Relief Valve
(2)
Swashplate
(6)
Check Valve (Forward)
(9)
Oil Strainer
(12)
Filter Cartridge
(3)
Piston
(7)
By-pass Valve
Check Valve (Reverse)
(13)
Charge Pump
(4)
Cylinder Block (Motor)
(10)
Stepping on the speed control pedal to the forward position inclines the HST trunnion arm, causing the pump
swashplate (2) to incline as shown in the figure.
The pump pistons rotate with the pump cylinder block (1) while reciprocating.
At this time, the pump pistons generate pressure by reciprocating motion. The pressure generated is transmitted
to the motor pistons (Port B - Port D).
Pressure from the port D thrusts the motor pistons to the surface of the inclined thrust ball bearing, causing them
to slide on the inclined surface.
This causes the motor cylinder block (4) and the motor shaft engaged with it to rotate.
This causes the machine to move forward. The inclination of the pump swashplate (2) determines the motor shaft
speed.
0000009194E
2-M5
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
B Reverse
(1)
Cylinder Block (Pump)
(5)
Lubricating Orifice
(8)
Transaxle Case
(11)
Charge Relief Valve
(2)
Swashplate
(6)
Check Valve (Forward)
(9)
Oil Strainer
(12)
Filter Cartridge
(3)
Piston
(7)
By-pass Valve
Check Valve (Reverse)
(13)
Charge Pump
(4)
Cylinder Block (Motor)
(10)
Stepping on the speed control pedal to the reverse position inclines the HST trunnion arm in the direction opposite
to that at moving forward, causing the pump swashplate (2) to incline as shown in the figure.
The pump pistons rotate with the pump cylinder block (1) while reciprocating.
At this time, the pump pistons generate pressure by reciprocating motion. The pressure generated is transmitted
to the motor pistons (Port A - Port C).
Pressure from the port C thrusts the motor pistons to the surface of the inclined thrust ball bearing, causing them
to slide on the inclined surface.
This causes the motor cylinder block (4) and the motor shaft engaged with it to rotate.
This causes the machine to move reverse. The inclination of the pump swashplate (2) determines the motor shaft
speed.
0000009195E
2-M6
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
(4) Charge Pump
The charge pump revolves in combination with pump
shaft to draw oil from the transaxle case, and feed oil to
the charge circuit.
The charge pump is necessary to make up for
leakage from the pump and motor, preventing system.
Charge relief
pressure
0.3 to 0.5 MPa
3.1 to 5.1
43.5 to 72.5 psi
Factory spec.
Condition
A Engine Speed : Rated speed
A Oil Temperature : 50
(122
(1)
Internal Snap Ring
(2)
Oil Seal
(3)
O-ring
(4)
Charge Pump Housing
(5)
)
Spring (Charge Relief
Valve)
(6) Steel Ball (Charge Relief
Valve)
0000009196E
(5) By-pass Valve
Normally, when the engine is stopped, the pump shaft
and pump cylinder block engaged with it do not rotate.
Thus, the motor shaft does not rotate.
However, pressing the by-pass valve in the center
section permits moving the machine with human power
while the engine is stopped. The following paragraphs
describe this mechanism:
Pressing the by-pass valve connects the forward and
reverse loops in the center section. This allows oil to
flow between the forward and reverse loops through the
by-pass valve to rotate only the motor cylinder block.
This means that pressing the by-pass valve while the
engine is stopped, that is, while the pump shaft is not
rotating, permits rotating the motor shaft engaged with
the motor cylinder block.
(1)
By-pass Spring
(2)
By-pass Spool
(3)
By-pass Plug
0000009198E
2-M7
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
(6) Control Linkage
(1)
Speed Change Pedal
(3)
Speed Change Plate
(2)
Speed Change Rod
(4)
Neutral Arm
(5)
Neutral Spring
(6)
Speed Control Arm
The speed change pedal (1) and the trunnion arm of variable swashplate are linked with the speed change rod (2),
speed change plate (3) and the speed control arm (6). As the front of the pedal is depressed, the swashplate rotates
and forward travelling speed increases. Depressing the rear end increases reverse speed.
The speed control arm (6) is returned to neutral position by the neutral arm (4) and the tension of neutral spring (5).
At the same time, the swashplate is returned to neutral, when the pedal is released.
0000009561E
2-M8
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
[2] MOWER PTO SYSTEM
(1) Mower PTO Clutch
The mower PTO clutch is equipped with mechanical
independent clutches of wet multi-plates type.
The PTO shaft (1) is engaged with the spline boss (3).
The clutch case (5) is engaged with the 24T gear (6).
Normally, spring (8) tension pushes the spline boss
(3) in the PTO clutch toward the front side of the
machine, which creates clearance between clutch disc
and friction plate (4), causing no friction.
Thus, no driving power is transmitted between spline
boss (3) and clutch case (5), that is, no driving power is
transmitted to the PTO shaft (1).
(1)
PTO Shaft
(6)
(2)
Clutch Lever
(7)
19T-2 Gear
(3)
Spline Boss
(8)
Spring
(4)
Clutch Disc and Friction
(9)
Brake Disc and Friction
Plate
(5)
Clutch Case
24T Gear
Plate
(10)
Thrust Collar
0000009200E
B PTO "Engaged"
When the PTO lever is set at the "Engaged" position,
the clutch lever (2) connected to the PTO lever via a link
mechanism rotates to the rear side of the machine.
The clutch lever pushes the spline boss (3) toward the
rear side of the machine via the thrust collar (10), which
eliminates the clearance between the clutch disc and
friction plate (4), causing friction necessary to transmit
driving power.
This allows driving power to be transmitted as follows:
19T-2 Gear (7)
24T Gear (6)
Clutch Case (5)
Spline Boss (3)
PTO Shaft (1)
(1)
PTO Shaft
(6)
(2)
Clutch Lever
(7)
19T-2 Gear
(3)
Spline Boss
(8)
Spring
(4)
Clutch Disc and Friction
(9)
Brake Disc and Friction
Plate
(5)
Clutch Case
24T Gear
Plate
(10)
Thrust Collar
0000009201E
2-M9
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
B PTO "Disengaged"
When the PTO lever is set at the "Disengaged"
position, the clutch lever (2) connected to the PTO lever
via a link mechanism rotates to the front side of the
machine.
Spring (8) tension pushes the spline boss (3) toward
the front side of the machine, which creates clearance
between the clutch disc and friction plate (4), causing no
friction.
This eliminates the clearance between brake discs
and friction plate (9), causing friction.
Driving power to the PTO shaft (1) is thus shut off and
brake engages to prevent the PTO shaft (1) from freespinning.
(1)
PTO Shaft
(6)
(2)
Clutch Lever
(7)
19T-2 Gear
(3)
Spline Boss
(8)
Spring
Clutch Disc and Friction
(9)
(4)
Plate
(5)
Clutch Case
24T Gear
Brake Disc and Friction
Plate
(10)
Thrust Collar
0000009205E
2-M10
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
4.
[1]
[2]
TROUBLESHOOTING....................................................................................................... 2-S1
SERVICING SPECIFICATIONS ....................................................................................... 2-S4
TIGHTENING TORQUES ................................................................................................. 2-S5
CHECKING, DISASSEMBLING AND SERVICING ........................................................ 2-S6
CHECKING AND ADJUSTING ...................................................................................... 2-S6
PREPARATION ............................................................................................................... 2-S9
(1) Separating Transaxle .............................................................................................. 2-S9
[3] DISASSEMBLING AND ASSEMBLING....................................................................... 2-S16
(1) Hydrostatic Transmission ...................................................................................... 2-S16
(2) Transaxle Case ..................................................................................................... 2-S21
[4] SERVICING ................................................................................................................... 2-S29
(1) Hydrostatic Transmission ...................................................................................... 2-S29
(2) Transaxle Case ..................................................................................................... 2-S31
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
1. TROUBLESHOOTING
Symptom
System Will Not
Operate in Either
Direction
Probable Cause
A Oil level is low
Solution
Fill oil to proper level
G-8, 2-S11
A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15
to speed control arm)
A Charge pressure is A Oil filter
too low
clogged
A Charge
defective
cartridge Replace oil filter
cartridge
G-30
pump Replace charge pump 2-S18
A Charge relief valve Repair or replace
charge relief valve
defective
Vibration and Noise
Reference
Page
2-S18
A Check valve defective
Replace check valve
2-S19
A By-pass valve defective
Replace by-pass
valve
2-S19
A HST component parts defective
Replace HST
assembly
2-S17, 20
A Oil level is low
Fill oil to proper level
G-8, 2-S11
A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15
to speed control arm)
A Charge pressure is A Oil filter
too low
clogged
A Charge
defective
cartridge Replace oil filter
cartridge
G-30
pump Replace charge pump 2-S18
A Charge relief valve Repair or replace
charge relief valve
defective
2-S18
A Check valve defective
Replace check valve
2-S19
A By-pass valve defective
Replace by-pass
valve
2-S19
A HST component parts defective
Replace HST
assembly
2-S17, 20
2-S1
KiSC issued 04, 2006 A
GR1600EC, WSM
Less of Power
TRANSAXLE
A Oil level is low
Fill oil to proper level
G-8, 2-S11
A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15
to speed control arm)
A Charge pressure is A Oil filter
too low
clogged
A Charge
defective
cartridge Replace oil filter
cartridge
pump Replace charge pump 2-S18
A Charge relief valve Repair or replace
charge relief valve
defective
Oil Heat Over
Replace check valve
2-S19
A By-pass valve defective
Replace by-pass
valve
2-S19
A HST component parts defective
Replace HST
assembly
2-S17, 20
A Oil level is low
Fill oil to proper level
G-8, 2-S11
A Excessive machine load
Reduce machine load
A Charge
defective
cartridge Replace oil filter
cartridge
G-30
pump Replace charge pump 2-S18
A Charge relief valve Repair or replace
charge relief valve
defective
2-S18
A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15
to speed control arm)
A Improper adjustment of neutral arm holder Adjust
shaft
System Operates in
One Direction Only
2-S18
A Check valve defective
A Charge pressure is A Oil filter
too low
clogged
Machine Will Not Stop
in Neutral Position
G-30
2-S6
A Control linkage defective (Speed change pedal Repair control linkage 2-S7, 15
to speed control arm)
A Check valve defective
Replace check valve
2-S19
0000010488E
2-S2
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
DIFFERENTIAL GEAR SECTION
Symptom
Excessive or Unusual
Noise at All Time
Probable Cause
Reference
Page
A Improper backlash between 11T bevel gear Adjust
and 17T-13T gear shaft
2-S35
A Improper backlash between differential pinion Adjust
and differential side gear
2-S34
A Bearing worn
Noise while Turning
Solution
Replace
A Insufficient or improper type of transmission Replenish or change
fluid used
G-8, 2-S11
A Differential pinions or differential side gears Replace
worn or damaged
2-S28
A Bearing worn
Replace
0000009607E
MOWER PTO SECTION
Symptom
Probable Cause
Solution
Reference
Page
A Improper length of PTO rod spring
Adjust
2-S13
A PTO rod spring weaken or broken
Replace
2-S13
A Clutch disc or friction plate excessively worn
Replace
2-S24, 31,
32
PTO Shaft Does Not
Rotate
A PTO clutch malfunctioning
Repair or replace
2-S23, 24
A Bearing broken
Replace
2-S23
PTO Clutch Drags
A Brake plate excessive worn
Replace
2-S24, 32,
33
A Clutch spring weaken or broken
Replace
2-S24, 32
A Deformation of plate
Replace
2-S24
PTO Clutch Slip
0000009608E
2-S3
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
2. SERVICING SPECIFICATIONS
Item
Charge Relief Valve
(Oil temperature at 50
Factory Specification
Allowable Limit
Setting Pressure
0.3 to 0.5 MPa
3.1 to 5.1
43.5 to 72.5 psi
PTO Clutch Disc
Thickness
1.3 to 1.5 mm
0.051 to 0.059 in.
1.2 mm
0.047 in.
Pressure Plate
Thickness
1.55 to 1.65 mm
0.061 to 0.065 in.
1.50 mm
0.059 in.
Friction Plate 1
Thickness
1.55 to 1.65 mm
0.061 to 0.065 in.
1.50 mm
0.059 in.
Friction Plate 2
Thickness
0.75 to 0.85 mm
0.030 to 0.034 in.
0.70 mm
0.028 in.
Clutch Spring
Free Length
45 mm
1.77 in.
42 mm
1.65 in.
PTO Brake Disc
Thickness
3.3 to 3.5 mm
0.13 to 0.14 in.
3.0 mm
0.118 in.
Brake Friction Plate 1
Thickness
1.75 to 1.85 mm
0.069 to 0.073 in.
1.60 mm
0.063 in.
Brake Friction Plate 2
Thickness
0.95 to 1.05 mm
0.037 to 0.041 in.
0.80 mm
0.031 in.
Differential Case to Differential Side Gear
Clearance
0.040 to 0.082 mm
0.0016 to 0.0032 in.
0.17 mm
0.0067 in.
, 122
)
42T Gear to Differential Side Gear
Differential Pinion Gear to Differential
Pinion Shaft
Differential Case
Bore (I.D.)
22.500 to 22.521 mm
0.8858 to 0.8867 in.
Differential Side
Gear Boss (O.D.)
22.439 to 22.460 mm
0.8834 to 0.8843 in.
Clearance
0.040 to 0.082 mm
0.0016 to 0.0032 in.
42T Gear Bore
(I.D.)
22.500 to 22.521 mm
0.8858 to 0.8867 in.
Clearance
0.025 to 0.055 mm
0.00098 to 0.00217 in.
Differential Case
Bore (I.D.)
10.000 to 10.015 mm
0.39370 to 0.39429 in.
Differential Side
Gear Boss (O.D.)
9.960 to 9.975 mm
0.39212 to 0.39272 in.
Differential Pinion Gear to Differential Side
Gear
Backlash
0.15 to 0.30 mm
0.0059 to 0.0012 in.
11T Bevel Gear Shaft to 17T-13T Gear
Shaft
Backlash
0.10 to 0.30 mm
0.0039 to 0.0012 in.
0.17 mm
0.0067 in.
0.25 mm
0.0096 in.
0000009610E
2-S4
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-9)
Item
ft-lbs
Brake plate mounting screw
34 to 40
3.47 to 4.07
25.1 to 29.5
Universal joint mounting screw
9.8 to 11.3
1.00 to 1.15
7.23 to 8.33
Transaxle mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Hydrostatic transmission mounting screw
23.5 to 27.5
2.4 to 2.8
17.3 to 20.3
Hydrostatic transmission mounting screw 2
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
Center section mounting hex. socket head screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
By-pass valve plug
15.0
1.53
11.1
Check valve plug
30.0
3.06
22.1
PTO clutch assembly mounting screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
Beam mounting screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2
Transaxle case screw
7.8 to 8.8
0.8 to 0.9
5.8 to 6.5
42T gear mounting screw
9.8 to 11.3
1.00 to 1.15
7.23 to 8.33
0000009611E
2-S5
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Adjustment of HST Neutral Position
1. Block the front wheels with stoppers, and lift up the rear of
machine with a jack.
2. Remove the left rear wheel.
3. Start the engine, and set at approx. 1500 to 3000
(rpm).
4. Loosen the holder shaft mounting screw (3).
5. Rotate the holder shaft (2) counterclockwise so that the rear
wheels turn forward.
6. Then rotate it clockwise until the rear wheels stop completely.
7. Put a mark on the neutral arm (1). (Position B)
8. Rotate the holder shaft (2) clockwise so that the rear wheels
turn in reverse.
9. Then rotate it counterclockwise until the rear wheels stop
completely.
10. Put a mark on the neutral arm (1). (Position A)
11. Set the holder shaft (2) where it is right in the center between
position A and B and tighten the holder shaft mounting screw
(3) firmly.
This means the hydrostatic transaxle is fully in neutral.
(Position C)
A Use buddy system in adjusting the neutral position.
A One of you should sit on the operator's seat, adjust the
engine rpm and step on the speed change pedal. The
other should adjust the neutral position.
(1)
Neutral Arm
(2)
Holder Shaft
(3)
Holder Shaft Mounting Screw
0000009304E
2-S6
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Speed Change Pedal Restriction
A This adjustment should be performed after completing
the adjustment of neutral.
1. Set the speed change pedal (1) to "NEUTRAL" position, and
apply the parking brake.
2. Check that the pin (3) of speed change pedal lock with the
brake pedal arm (2).
3. If it is improper, adjust the length (A) with the rod end (4) on
speed change rod.
4. Then adjust the length (B) with adjusting nut (6) on speed
change rod (5).
(Reference)
A Length A : 5 mm (0.2 in.)
A Length B : 17 to 23 mm (0.67 to 0.91 in.)
(1)
Speed Change Pedal
(4)
Rod End
(2)
Brake Pedal Arm
(5)
Speed Change Rod
(3)
Pin
(6)
Adjusting Nut
0000009305E
Adjusting Maximum Speed
A This adjustment should be performed after completing
the adjustment of neutral.
[Forward]
1. Loose the lock nut (2) of adjusting screw.
2. Adjust the length (A) with the adjusting screw (1).
(Reference)
A Length (A) : 10 to 12 mm (0.40 to 0.47 in.)
A Traveling speed : 9.0 to 10.0 km/h (5.6 to 6.2 mph)
[Reverse]
1. Loose the lock nut (3) of adjusting screw.
2. Adjust the length (B) with the adjusting screw (4).
(Reference)
A Length (B) : 12 to 15 mm (0.47 to 0.59 in.)
A Traveling speed : 4.0 to 5.0 km/h (2.5 to 3.1 mph)
(1)
Adjusting Screw
(3)
Lock Nut
(2)
Lock Nut
(4)
Adjusting Screw
0000009308E
2-S7
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Charge Relief Pressure
A When checking, park the machine on level ground, apply
the parking brake.
A This checking should be performed after completing the
adjustment of neutral.
1. Remove the hexagon socket head plug (9/16-18 UNF) from
P1 (1) or P2 (2).
2. Install the adaptor, thread joint, cable and pressure gauge.
3. Start the engine and run engine speed at rated speed.
4. Read the pressure gauge to measure the charge relief
pressure.
5. If the measurement is not within the factory specification,
check the charge pump and charge relief valve.
Charge relief pressure
Condition
A Engine Speed : Rated Speed
A Oil Temperature : 50
(122
(1)
P1 Port (Reverse)
0.3 to 0.5 MPa
3.1 to 5.1
43.5 to 72.5 psi
Factory spec.
)
(2)
P2 Port (Forward)
0000009310E
2-S8
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
[2] PREPARATION
(1) Separating Transaxle
Dismounting Mower
1. See page 7-S6. ("Mower" Section)
0000009311E
Dismounting the Container
A Park the machine on a firm and level ground.
A Stop the engine, and remove the key.
1. Grip the grass container lock handle (2) with the handle (3).
Ground the grass container (1) as shown in the figure.
2. Pull the grass container lock rod (4) and hold it to hook the
stopper pin.
3. Dismount the grass container (1).
(When reassembling)
A Pull the grass container lock rod (4) and hold it to hook the
stopper.
A Put the container pipe frame (6) on the stay (5).
A Release the grass container lock rod (4) so that the lock arm
(7) holds the container pipe frame (6).
A Grip the grass container lock handle (2) with the handle (3).
And turn the container (1) around the container pipe frame (6)
that held by the lock arm (7).
A Release the grass container lock handle (2).
(1)
Grass Container
(5)
Stay
(2)
Grass Container Lock Handle
(6)
Container Pipe Frame
(3)
Handle
(7)
Lock Arm
(4)
Grass Container Lock Rod
0000009312E
2-S9
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Container Base
1. Disconnect the couplers (1) from the relays.
2. Disconnect the connectors (2).
3. Open the switch cover (6). And disconnect the connector (4)
from the grass container full switch (5).
4. Remove the discharge duct (3).
5. Remove the container base (7).
(1)
Coupler
(5)
Grass Container Full Switch
(2)
Connector
(6)
Switch Cover
(3)
Discharge Duct
(7)
Container Base
(4)
Connector
0000009314E
2-S10
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Draining Transmission Fluid
1. Place an oil pan under the transaxle.
2. Remove the suction pipe (1) at the bottom of the transaxle.
3. Remove the strainer (2) to completely drain the transmission
fluid.
4. After draining, clean the strainer (2) and reinstall the strainer
(2) and suction pipe (1).
(When refilling)
A Remove the filling plug with the dipstick (5).
A Fill new oil from the filling port up to the upper notch on
dipstick.
A After running the engine for few minutes, stop the engine and
check the oil level again, if low, add oil to prescribed level.
A Use the KUBOTA UDT or SUPER UDT fluid. Use of other
oils may damage the transmission or hydraulic system.
Refer to "LUBRICANTS, FUEL AND COOLANT" (See
page G-8).
A Never work the machine immediately after changing the
transmission oil. Keeping the engine at medium speed
for a few minutes to prevents damage to the transmission.
A Do not mix different blands oil together.
Transmission fluid
(1)
2.5 L
0.71 U.S.gals
0.59 Imp.gals
Capacity
Suction Pipe
(4)
O-ring
(2)
Strainer
(5)
Filling Plug with Dipstick
(3)
O-ring
0000009315E
Battery
A When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Open the bonnet.
2. Disconnect the negative cable (1) from the battery.
3. Disconnect the positive cable (2) from the battery and remove
the battery (3).
(1)
Negative Cable
(2)
Positive Cable
(3)
Battery
0000009318E
2-S11
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Seat
1. Remove two snap pins (2), (4).
2. Remove the seat (1) and seat plate (3).
(1)
Seat
(3)
Seat Plate
(2)
Snap Pin
(4)
Snap Pin
0000009319E
Fender
1. Remove the speed change pedal (5).
2. Peel the step sheet (4) halfway.
3. Remove the fuel cap (1).
4. Remove the fender (2).
(1)
Fuel Cap
(4)
Step Sheet
(2)
Fender
(5)
Speed Change Pedal
(3)
Fender Mounting Screw
0000009320E
Seat Base
1. Loose the seat base mounting screws 1 (1).
2. Remove the seat base mounting screws 2 (3).
3. Slide the seat base (2) and remove it.
(1)
Seat Base Mounting Screw 1
(2)
Seat Base
(3)
Seat Base Mounting Screw 2
0000009321E
Fuel Tank
1. Drain the fuel.
2. Disconnect the fuel hoses.
3. Remove the fuel tank (1).
(1)
Fuel Tank
0000009323E
2-S12
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
PTO Rod Spring
1. Remove the two nuts (2) (3) and spring (4).
(When reassembling)
1. Assemble a fuel tank, a seat base and a fender.
2. Setting the PTO lever at "Disengaged" position and lifting the
PTO arm (5) slightly by hands directly, the upper side of PTO
arm (5) and lower nut (6) on the upper side of PTO rod (1)
make contact, and there is no play between them. Keeping
this position, be sure to tighten the two nuts (6) (7) on the
upper side of this PTO rod (1).
3. Assembly temporarily the spring (4) and two nuts (2) (3) to the
PTO rod (1). After this, set the PTO lever at "Engaged"
position, and then be sure to tighten two nuts (2) (3) on the
lower side of PTO rod (1) so that the spring length (L2)
reaches the specified value.
(When reassembling)
A After completing above assembling / adjustment, repeat
the motion several times to set the PTO lever at
"Disengaged" and "Engaged" position. Then, finally set
the PTO lever at "Engaged" position. Be sure to check
that the upper side of PTO arm (5) and the lower sides of
two nuts (6) (7) on the upper side of PTO rod (1) are
making no contact.
Spring length (L2)
68 mm
2.68 in.
Factory spec.
(Reference)
A Length (L1) : 115 to 118 mm (4.53 to 4.64 in.)
A Length (L3) : 38 to 40 mm (1.50 to 1.57 in.)
(1)
PTO Rod
(6)
Nut
(2)
Nut
(7)
Nut
(3)
Nut
(4)
Spring
A:
"Disengaged" Position
(5)
PTO Arm
B:
"Engaged" Position
0000010654E
2-S13
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Beam
1. Disconnect the connector from the PTO switch (1).
2. Remove the spring (2) from the PTO lever (3).
3. Remove the PTO rod
4. Remove the filling pipe (4).
5. Remove the beam (5).
(1)
PTO Switch
(4)
Filling Pipe
(2)
Spring
(5)
Beam
(3)
PTO Lever
0000009324E
Brake Rod
1. Remove the split pin (1), and disconnect the brake rod 1 (2)
and the pedal system.
2. Remove the lock nut (3), plain washers (4) and brake spring
(5).
3. Remove the brake plate (7).
4. Remove the brake rod 2 (6) and brake rod 1 (2).
(When reassembling)
A After assembling the brake rod 1, 2 (2), (6) and brake
spring (5), be sure to adjust the brake pedal free travel
(see page G-26).
Tightening torque
Brake plate mounting
screw
35 to 40
3.47 to 4.07
25.1 to 29.5 ft-lbs
(1)
Split Pin
(5)
Brake Spring
(2)
Brake Rod 1
(6)
Brake Rod 2
(3)
Lock Nut
(7)
Brake Plate
(4)
Plain Washer
0000009325E
2-S14
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Speed Control Plate
1. Remove the rue ring pin (2), and disconnect the speed change
plate (1) and speed control arm (3).
2. Separate the speed change plate (1) and speed change rod
(4).
A After assembling the speed change plate (1) and speed
change rod (4), be sure to adjust the speed change pedal
restriction (see page 2-S7).
(1)
Speed Change Plate
(4)
Speed Change Rod
(2)
Rue Ring Pin
(5)
Lock Nut
(3)
Speed Control Arm
0000009328E
Universal Joint and Rear Wheel
1. Remove the universal joint mounting screw (1).
2. Disconnect the universal joint (2).
3. Block the front wheels with stopper, and lift up the frame.
4. Remove the retaining ring (3) and remove the rear wheel (4).
(When reassembling)
A Apply grease to the splines of the universal joint.
Tightening torque
Universal joint mounting
screw
9.8 to 11.3
1.00 to 1.15
7.23 to 8.33 ft-lbs
(1)
Universal Joint Mounting Screw
(3)
Retaining Ring
(2)
Universal Joint
(4)
Rear Wheel
0000009330E
Separating Transmission
1. Remove the transaxle mounting screws (2).
2. Separate the transaxle (1) from the frame.
(When reassembling)
Tightening torque
(1)
Transaxle
Transaxle mounting
screw
(2)
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2 ft-lbs
Transaxle Mounting Screw
0000009331E
2-S15
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
[3] DISASSEMBLING AND ASSEMBLING
(1) Hydrostatic Transmission
Speed Control Arm, Neutral Spring, Cooling Fan and Others
1. Remove the neutral spring (2).
2. Remove the speed control arm (1).
3. Remove the cooling fan (3).
4. Remove the breather hoses (4).
5. Remove the suction pipe 1, 2 (5), (7) and hose (6).
(1)
Speed Control Arm
(5)
Suction Pipe 1
(2)
Neutral Spring
(6)
Hose
(3)
Cooling Fan
(7)
Suction Pipe 2
(4)
Breather Hose
0000009333E
Neutral Arm Holder and Filter Bracket
1. Remove the neutral arm holder (2) with neutral arm (1).
2. Remove the filter bracket (3).
(1)
Neutral Arm
(2)
Neutral Arm Holder
(3)
Filter Bracket
0000009334E
2-S16
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Brake Assembly
1. Remove the brake assembly (1).
2. Remove the external snap ring (2). And pull out the brake
drum (3).
(1)
Brake Assembly
(2)
External Snap Ring
(3)
Brake Drum
0000009335E
Hydrostatic Transmission Assembly
1. Remove the hydrostatic transmission assembly (1).
A When reassembling the hydrostatic transmission
assembly, insert the drain pipe (3) in the hole (2) surely so
as not to drop out it.
Hydrostatic
transmission mounting
screw
23.5 to 27.5
2.4 to 2.8
17.3 to 20.3 ft-lbs
Hydrostatic
transmission mounting
screw 2
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2 ft-lbs
Tightening torque
(1)
(2)
Hydrostatic Transmission
(3)
Drain Pipe
Assembly
(4)
Hydrostatic Transmission
Hole
Mounting Screw 2
0000009336E
2-S17
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
15T Gear, 34T Gear and Bevel Gear Shaft
1. Remove the external snap ring (4). And pull out the 15T gear
(1) and 34T gear (2).
2. Remove the bevel gear shaft (3).
(1)
15T Gear
(4)
External Snap Ring
(2)
34T Gear
(5)
Shim
(3)
Bevel Gear Shaft
0000009338E
Charge Pump Housing and Charge Relief Valve
1. Remove the charge pump housing (1).
2. Remove the spring (5) and the steel ball (6).
3. Remove the O-ring (4) from the charge pump housing (1).
4. Remove the internal snap ring (2) and the oil seal (3).
A When removing the oil seal (3), take care not to damage
the charge pump housing (1).
A Take care not to damage the O-ring (4).
(1)
Charge Pump Housing
(5)
Spring
(2)
Internal Snap Ring
(6)
Steel Ball
(3)
Oil Seal
(7)
Charge Relief Valve
(4)
O-ring
0000009340E
Gerotor
1. Remove the gerotor (1).
2. Draw out the drive pin (2) on the pump shaft (3).
(When reassembling)
A Apply clean transmission oil to the both side of gerotors.
(1)
Gerotor
(2)
Drive Pin
(3)
Pump Shaft
0000009341E
2-S18
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Center Section
1. Remove the center section mounting hex. socket head
screws.
2. Tap the center section (1) with soft hammer and separate the
center section (1) from the HST housing (2).
(When reassembling)
A Cover the splines of each shaft with thin tape to protect the
sealing lip of the oil seals.
A Place a new gasket on the HST housing.
A Take care not to damage the surface of cylinder blocks,
pistons and center section.
Tightening torque
(1)
Center section
mounting hex. socket
head screw
Center Section
(2)
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2 ft-lbs
HST Housing
0000009342E
By-pass Valve
1. Remove the plug (4) and draw out the the by-pass spool (2)
and spring (1).
(When reassembling)
A Take care not to damage the O-ring (3) on the plug (4).
Tightening torque
By-pass valve plug
15.0
1.53
11.1 ft-lbs
(1)
Spring
(3)
O-ring
(2)
By-pass Spool
(4)
Plug
0000009343E
Check Valve
1. Remove the plugs (1), (8).
2. Draw out the springs (3), (6).
3. Draw out the check valve (4) and ball check (5).
(When reassembling)
A Take care not to damage the O-rings (2), (7) on the plugs (1),
(8).
Tightening torque
30.0
3.06
22.1 ft-lbs
Check valve plug
(1)
Plug
(5)
Ball Check
(2)
O-ring
(6)
Spring
(3)
Spring
(7)
O-ring
(4)
Check Valve
(8)
Plug
0000009345E
2-S19
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Cylinder Block Assembly and Thrust Ball Bearing
1. Remove the cylinder block assembly (pump side) (1), spring
(2) and washer (3).
2. Remove the cylinder block assembly (motor side) (5).
3. Remove the thrust ball bearing (4).
(When reassembling)
A Apply clean transmission oil to thrust ball bearing, cylinder
block and piston.
A Take care not to damage the surface of cylinder blocks
and pistons.
(1)
Cylinder Block Assembly
(4)
Thrust Ball Bearing
(Pump Side)
(5)
Cylinder Block Assembly
(2)
Spring
(3)
Washer
(Motor Side)
0000009346E
Swashplate, Pump Shaft and Motor Shaft
1. Remove the swashplate (2) and thrust ball bearing (1) from the
HST housing.
2. Remove the internal snap ring (5), and tap out the pump shaft
(3) and oil seal (4).
3. Remove the internal snap ring (6) and the oil seal (7).
4. Remove the internal snap ring (8), and tap out the motor shaft
(10).
A When removing the oil seal (7), take care not to damage
the HST housing.
(When reassembling)
A Apply clean transmission oil to thrust ball bearing (1).
(1)
Thrust Ball Bearing
(6)
Internal Snap Ring
(2)
Swashplate
(7)
Oil Seal
(3)
Pump Shaft
(8)
Internal Snap Ring
(4)
Oil Seal
(9)
External Snap Ring
(5)
Internal Snap Ring
(10)
Motor Shaft
0000009347E
Cradle Bearing, Slot Guide and Trunnion Arm
1. Remove the slot guide (2) and trunnion arm (3).
2. Remove the cradle bearings (1) from the HST housing.
(When reassembling)
A Apply clean transmission oil to the cradle bearings (1) and
trunnion arm.
A Fasten down the cradle bearing to the HST housing.
(1)
Cradle Bearing
(2)
Slot Guide
(3)
Trunnion Arm
0000009640E
2-S20
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
(2) Transaxle Case
Speed Control Arm, Neutral Spring, Cooling Fan and Others
1. Remove the neutral spring (2).
2. Remove the speed control arm (1).
3. Remove the cooling fan (3).
4. Remove the breather hoses (4).
5. Remove the suction pipe 1, 2 (5), (7) and hose (6).
(1)
Speed Control Arm
(5)
Suction Pipe 1
(2)
Neutral Spring
(6)
Hose
(3)
Cooling Fan
(7)
Suction Pipe 2
(4)
Breather Hose
0000009333E
Neutral Arm Holder and Filter Bracket
1. Remove the neutral arm holder (2) with neutral arm (1).
2. Remove the filter bracket (3).
(1)
Neutral Arm
(2)
Neutral Arm Holder
(3)
Filter Bracket
0000009334E
2-S21
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Brake Assembly
1. Remove the brake assembly (1).
2. Remove the external snap ring (2). And pull out the brake
drum (3).
(1)
Brake Assembly
(2)
External Snap Ring
(3)
Brake Drum
0000009335E
Hydrostatic Transmission Assembly
1. Remove the hydrostatic transmission assembly (1).
A When reassembling the hydrostatic transmission
assembly, insert the drain pipe (3) in the hole (2) surely so
as not to drop out it.
Hydrostatic
transmission mounting
screw
23.5 to 27.5
2.4 to 2.8
17.3 to 20.3 ft-lbs
Hydrostatic
transmission mounting
screw 2
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2 ft-lbs
Tightening torque
(1)
(2)
Hydrostatic Transmission
(3)
Drain Pipe
Assembly
(4)
Hydrostatic Transmission
Hole
Mounting Screw 2
0000009336E
2-S22
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
PTO Clutch Assembly
1. Remove the PTO clutch assembly (1) and the ball bearing (2)
from the transaxle case.
(When reassembling)
A Install the ball bearing (2) with the sealed face inside.
A Align the tangs (4) of PTO brake friction plate with the slots (3)
of transaxle case.
Tightening torque
PTO clutch assembly
mounting screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2 ft-lbs
(1)
PTO Clutch Assembly
(3)
Slot
(2)
Ball Bearing
(4)
Tang
0000009348E
2-S23
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Disassembling PTO Clutch Assembly
1. Remove the 24T gear (1), clutch (2), brake disc and friction
plate (3) from PTO shaft (4).
2. While pressing the clutch (2), turn the clutch case (5)
clockwise. Then, separate the clutch case (5) and the spline
boss (9) with clutch disc and friction plate (10).
3. Then remove the thrust needle bearing (6), collar (7) and
spring (8).
4. Remove the external snap ring (11), clutch disc and friction
plate (10) from the spline boss.
(1)
24T Gear
(7)
Collar
(2)
Clutch
(8)
Spring
(3)
Brake Disc and Friction Plate
(9)
Spline Boss
(4)
PTO Shaft
(10)
Clutch Disc and Friction Plate
(5)
Clutch Case
(11)
External Snap Ring
(6)
Thrust Needle Bearing
0000010144E
2-S24
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Disassembling PTO Clutch Assembly (Continued)
1. Pull out the PTO shaft (1) from PTO clutch cover (5) until
external snap ring (3) touches clutch lever (4).
2. Tap out the PTO shaft (1) while opening the external snap ring
(3) with external snap ring pliers.
3. Remove the thrust collar (2) from PTO shaft (1).
4. Remove the ball bearing (6) and oil seal (7) from the PTO
clutch cover (5).
(1)
PTO Shaft
(5)
(2)
Thrust Collar
(6)
PTO Clutch Cover
Ball Bearing
(3)
External Snap Ring
(7)
Oil Seal
(4)
Clutch Lever
0000010145E
Beam
1. Remove the beam (1) from the transaxle case.
(When reassembling)
Tightening torque
(1)
Beam mounting screw
17.7 to 20.6
1.8 to 2.1
13.1 to 15.2 ft-lbs
Beam
0000009350E
2-S25
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Transaxle Case
1. Remove the transaxle case screws (2).
2. Separate the rear side of transaxle case (1).
(When reassembling)
A Apply liquid gasket (Three Bond 1208D or equivalent) to joint
face of the transaxle case.
A Install the transaxle case screws (2) in the direction
shown in figure.
A Tighten all screws by your hand. Then, tighten the screws
located at the circled positions first with tightening
torques.
Next, tighten the remaining screws with
tightening torque.
Tightening torque
Transaxle case screw
7.8 to 8.8
0.8 to 0.9
5.8 to 6.5 ft-lbs
(1)
Transaxle Case (Rear Side)
F:
(2)
Transaxle Case Screw
R:
Front Side
Rear Side
(3)
Transaxle Case (Front Side)
A:
Screws Which Tightened
First with Tightening Torque
0000009351E
2-S26
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Input Shaft, 19T-2 Gear and 17T-13T Gear Shaft
1. Remove the input shaft (1).
2. Remove the intermediate shaft (2) and 19T-2 gear (3) with
collars (6) and needle bearing (7).
3. Remove the 17T-13T gear shaft (4).
A Install the two external snap rings (5) on intermediate
shaft (2) by shifting each mating portion by 180 degrees.
(1)
Input Shaft
(5)
External Snap Ring
(2)
Intermediate Shaft
(6)
Collar
(3)
19T-2 Gear
(7)
Needle Bearing
(4)
17T-13T Gear Shaft
0000009352E
Rear Differential Gear, Drive Shaft and 11T Gear Shaft (RH, LH)
1. Remove the rear differential gear assembly (2), 11T gear
shafts (1), (6) and drive shaft (5).
2. Remove the external snap ring (3) and washer (4) from drive
shaft (5).
(1)
(2)
(3)
11T Gear Shaft (LH)
(4)
Washer
Rear Differential Gear
(5)
Drive Shaft
Assembly
(6)
11T Gear Shaft (RH)
External Snap Ring
0000009353E
2-S27
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Rear Differential Gear Assembly
1. Remove the 42T gear mounting screws (1).
2. Remove the 42T gear (2) and differential side gear (3).
3. Remove the differential pinion shaft (6).
4. Remove the differential pinion gears (5), differential side gear
(7) and shims (4).
A Arrange the parts to know their original position.
(When reassembling)
A Apply molybdenum disulfide (Three Bond 1901 or equivalent)
to the inner circumferential surface of differential pinion gears
(5), differential side gears (3), (7) and shims (4).
Tightening torque
42T gear mounting
screw
9.8 to 11.3
1.00 to 1.15
7.23 to 8.33 ft-lbs
(1)
42T Gear Mounting Screw
(5)
Differential Pinion Gear
(2)
42T Gear
(6)
Differential Pinion Shaft
(3)
Differential Side Gear
(7)
Differential Side Gear
(4)
Shim
0000009354E
Rear Axle
1. Remove the rear axle (1).
2. Remove the oil seal (2), bush (3), collar (4) and external snap
ring (5).
(1)
Rear Axle
(4)
Collar
(2)
Oil Seal
(5)
External Snap Ring
(3)
Bush
0000009355E
2-S28
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
[4] SERVICING
(1) Hydrostatic Transmission
Charge Pump
1. Check the charge pump housing (1) and gerotor assembly (2)
for scratches and wear.
2. If scratch or worn, replace the charge pump assembly.
(1)
Charge Pump Housing
(2)
Gerotor Assembly
0000009356E
Center Section
1. Check the surfaces (1) of center section for scratches or wear.
2. If deep scratch or excessive wear is found, replace the
hydrostatic transmission assembly.
(1)
Surface
0000009641E
Check Valve
1. Check the ball check (5) and check valve (4) for scratches and
damage.
2. Check the springs (3), (6) for breakage and wear.
3. If anything unusual, replace the check valve assembly.
(1)
Plug
(5)
Ball Check
(2)
O-ring
(6)
Spring
(3)
Spring
(7)
O-ring
(4)
Check Valve
(8)
Plug
0000009357E
2-S29
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
By-pass Valve
1. Check the by-pass spool (3) and spring (4).
2. If defects are found, replace them.
(1)
Plug
(3)
By-pass Spool
(2)
O-ring
(4)
Spring
0000009358E
Cylinder Block Assembly
1. Check the cylinder blocks (4) and pistons (3) for scratches and
wear.
2. If scratch or worn, replace the cylinder block assembly.
3. Check that the piston (3) and spring (2) are in each cylinder
bore.
4. Check the pistons for their free movement in the cylinder block
bores.
5. If the piston or the cylinder block is scored, replace the cylinder
block assembly.
6. Check the polished face (1) of cylinder block for scoring.
7. If scored, replace the cylinder block assembly.
A Do not interchange pistons between pump and motor
cylinder block. Pistons and cylinder blocks are matched.
(1)
Polished Face
(3)
Piston
(2)
Spring
(4)
Cylinder Block
0000001015E
Thrust Ball Bearing
1. Check the thrust ball bearing (1) for scratches and excessive
wear.
2. If the thrust ball bearing (1) is worn, replace it.
(1)
Thrust Ball Bearing
0000001016E
Pump Shaft
1. Check the seal surface (1), the bearing surface (2) and the ball
bearing (3).
2. If the shaft is rough or grooved, replace it.
3. If the ball bearing is worn, replace it.
(1)
Seal Surface
(2)
Bearing Surface
(3)
Ball Bearing
0000004178E
2-S30
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Bushing and Oil Seal
1. Check the oil seals (1) for damage.
2. Check the bushings (2) for wear.
3. If the oil seals and bushings are worn or damaged, replace
them.
(1)
Oil Seal
(2)
Bushing
0000001018E
(2) Transaxle Case
Checking Bearing
1. Hold the inner race, and push and pull the outer race in all
directions to check for wear and roughness.
2. Apply transmission fluid to the bearing, and hold the inner
race. Then, turn the outer race to check rotation.
3. If there is any defect, replace it.
0000001019E
PTO Clutch Disc Wear
1. Measure the thickness of PTO clutch disc with vernier
calipers.
2. If the thickness is less than the allowable limit, replace it.
Factory spec.
1.3 to 1.5 mm
0.051 to 0.059 in.
Allowable limit
1.2 mm
0.047 in.
Thickness of PTO clutch
disc
0000009359E
2-S31
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Pressure Plate and Friction Plate Wear
1. Measure the thickness of pressure plate and friction plate 1, 2
with vernier calipers.
2. If the thickness is less than the allowable limit, replace it.
Factory spec.
1.55 to 1.65 mm
0.061 to 0.065 in.
Allowable limit
1.50 mm
0.059 in.
Factory spec.
1.55 to 1.65 mm
0.061 to 0.065 in.
Allowable limit
1.50 mm
0.059 in.
Factory spec.
0.75 to 0.85 mm
0.030 to 0.034 in.
Allowable limit
0.70 mm
0.028 in.
Thickness of pressure
plate
Thickness of friction
plate 1
Thickness of friction
plate 2
0000009360E
Clutch Spring Free Length
1. Measure the free length of spring with vernier calipers.
2. If the measurement is less than the allowable limit, replace it.
Factory spec.
45 mm
1.77 in.
Allowable limit
42 mm
1.65 in.
Clutch spring free length
0000009361E
PTO Brake Disc Wear
1. Measure the thickness of PTO brake disc with a vernier
caliper.
2. If the thickness is less than the allowable limit, replace it.
Factory spec.
3.3 to 3.5 mm
0.13 to 0.14 in.
Allowable limit
3.00 mm
0.118 in.
PTO brake disc
thickness
0000009362E
2-S32
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Friction Plate Wear
1. Measure the thickness of brake friction plate 1, 2 with vernier
calipers.
2. If the thickness is less than the allowable limit, replace it.
Factory spec.
1.75 to 1.85 mm
0.069 to 0.073 in.
Allowable limit
1.60 mm
0.063 in.
Factory spec.
0.95 to 1.05 mm
0.037 to 0.041 in.
Allowable limit
0.80 mm
0.031 in.
Thickness of brake
friction plate 1
Thickness of brake
friction plate 2
0000009363E
Clearance between Differential Gear Case and Differential Side
Gear
1. Measure the differential gear case (4) bore I.D..
2. Measure the differential side gear (3) boss O.D., and calculate
the clearance.
3. Measure the 42T gear (1) bore I.D..
4. Measure the differential side gear (2) boss O.D., and calculate
the clearance.
5. If the clearance exceeds the allowable limit, replace faulty
parts.
Clearance between
differential case and
differential side gear
Factory spec.
0.040 to 0.082 mm
0.0016 to 0.0032 in.
Allowable limit
0.17 mm
0.0067 in.
Clearance between 42T
gear and differential
side gear
Factory spec.
0.040 to 0.082 mm
0.0016 to 0.0032 in.
Allowable limit
0.17 mm
0.0067 in.
Differential case bore
I.D.
Factory spec.
22.500 to 22.521 mm
0.8858 to 0.8867 in.
Differential side gear
boss O.D.
Factory spec.
22.439 to 22.460 mm
0.8834 to 0.8843 in.
42T gear bore I.D.
Factory spec.
22.500 to 22.521 mm
0.8858 to 0.8867 in.
(1)
42T Gear
(3)
Differential Side Gear
(2)
Differential Side Gear
(4)
Differential Gear Case
0000009364E
2-S33
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Clearance between Differential Pinion Gear and Differential
Pinion Shaft
1. Measure the differential pinion gear (1) I.D..
2. Measure the differential pinion shaft (2) O.D., and calculate
the clearance.
3. If the clearance exceeds the allowable limit, replace faulty
parts.
Factory spec.
0.025 to 0.055 mm
0.00098 to 0.00217 in.
Allowable limit
0.25 mm
0.0096 in.
Differential pinion gear
I.D.
Factory spec.
10.000 to 10.015 mm
0.39370 to 0.39429 in.
Differential pinion shaft
O.D.
Factory spec.
9.960 to 9.975 mm
0.39212 to 0.39272 in.
Clearance between
differential pinion gear
and differential pinion
shaft
(1)
Differential Pinion Gear
(2)
Differential Pinion Shaft
0000009365E
Backlash between Differential Pinion Gear and Differential Side
Gear
1. Stick a strip of fuse the three spots on the differential pinion
gear (2) with grease.
2. Reassemble the differential gear assembly.
3. Fix the differential gear assembly, and install the drive shaft
(5).
4. Turn the drive shaft (5).
5. Remove the differential pinion gear (2) from the differential
gear assembly, and measure the thickness of the fuses with
an outside micrometer.
6. If the backlash is not within the factory specifications, adjust
with shims (4), (6).
Backlash between
differential pinion gear
and differential side
gear
0.15 to 0.30 mm
0.0059 to 0.012 in.
Factory spec.
(Reference)
A Thickness of adjusting shims
For differential pinion gear : 2.3 mm (0.091 in.)
2.5 mm (0.098 in.)
2.7 mm (0.106 in.)
2.9 mm (0.11 in.)
A Tooth contact : More than 35 %
(1)
Differential Side Gear
(4)
Shim
(2)
Differential Pinion Gear
(5)
Drive Shaft
(3)
Differential Pinion Shaft
(6)
Shim
0000009366E
2-S34
KiSC issued 04, 2006 A
GR1600EC, WSM
TRANSAXLE
Backlash between 11T Bevel Gear Shaft and 17T-13T Gear Shaft
1. Stick a strip of fuse the three spots on the 11T bevel gear shaft
(3) with grease.
2. Reassemble the hydrostatic transmission and transaxle case.
3. Fix the transaxle case, and push the by-pass valve.
4. Turn the motor shaft.
5. Remove the 11T bevel gear shaft (3), and measure the
thickness of the fuses with an outside micrometer.
Backlash between 11T
bevel gear shaft and
17T-13T gear shaft
0.10 to 0.30 mm
0.0039 to 0.012 in.
Factory spec.
(Reference)
A Thickness of adjusting shims
For 11T bevel gear shaft (4) : 0.2 mm (0.008 in.)
0.3 mm (0.012 in.)
0.5 mm (0.020 in.)
For 17T-13T gear shaft (LH) (1) : 0.2 mm (0.008 in.)
0.3 mm (0.012 in.)
0.5 mm (0.020 in.)
For 17T-13T gear shaft (RH) (5) : 0.2 mm (0.008 in.)
0.3 mm (0.012 in.)
0.5 mm (0.020 in.)
A Tooth contact : More than 35 %
(1)
Shim (for 17T-13T Gear
(4)
Shim (for 11T Bevel Gear
(5)
Shim (for 17T-13T Gear
Shaft (LH))
(2)
17T-13T Gear Shaft
(3)
11T Bevel Gear Shaft
Shaft)
Shaft (RH))
0000009367E
2-S35
KiSC issued 04, 2006 A
3
BRAKES
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
4.
[1]
[2]
TROUBLESHOOTING....................................................................................................... 3-S1
SERVICING SPECIFICATIONS ....................................................................................... 3-S2
TIGHTENING TORQUES ................................................................................................. 3-S3
CHECKING, DISASSEMBLING AND SERVICING ........................................................ 3-S4
CHECKING AND ADJUSTING ...................................................................................... 3-S4
DISASSEMBLING AND ASSEMBLING......................................................................... 3-S4
(1) Pedal System Component....................................................................................... 3-S4
(2) Brake Assembly....................................................................................................... 3-S8
KiSC issued 04, 2006 A
GR1600EC, WSM
BRAKES
1. TROUBLESHOOTING
Symptom
Insufficient Braking
Force
Brake Drags
Heavy Brakes
Probable Cause
Solution
Reference
Page
A Brake pedal free travel excessive
Adjust
3-S4
A Brake shoe worn
Replace
3-S8
A Brake drum worn
Replace
3-S8
A Grease or oil on brake shoe
Replace
3-S8
A Brake pedal free travel too small
Adjust
3-S4
A Brake spring weaken or broken
Replace
3-S8
A Brake pedal rusted
Repair or replace
3-S7
A Brake cam lever rusted
Replace
3-S8
0000009612E
3-S1
KiSC issued 04, 2006 A
GR1600EC, WSM
BRAKES
2. SERVICING SPECIFICATIONS
Item
Brake Pedal
Factory Specification
Free Travel
Allowable Limit
15 to 25 mm
0.59 to 0.98 in.
0000009613E
3-S2
KiSC issued 04, 2006 A
GR1600EC, WSM
BRAKES
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-9)
Item
ft-lbs
Steering wheel mounting nut
20 to 25
2.0 to 2.5
14.8 to 18.4
Drag link locking nut
74.8 to 81.3
7.62 to 8.29
55.2 to 60.0
Steering support mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Pedal system component mounting nut
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
0000009614E
3-S3
KiSC issued 04, 2006 A
GR1600EC, WSM
BRAKES
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Brake Pedal Free Travel
A Stop the engine, remove the key, and chock the wheels
before checking brake pedal.
1. Release the parking brake.
2. Loosen the lock nut (1).
3. Adjust the brake spring (2) length (A) so that the brake pedal
free travel (B) is from 15 to 25 mm (0.59 to 0.98 in.).
4. Retighten the lock nut (1).
Brake pedal free travel
(B)
15 to 25 mm
0.59 to 0.98 in.
Factory spec.
(Reference)
A Brake spring length (A) : 73 to 74 mm (2.87 to 2.91 in.)
(1)
Lock Nut
(2)
Brake Spring
0000009448E
[2] DISASSEMBLING AND ASSEMBLING
(1) Pedal System Component
Dismounting Mower
1. See page 7-S6. ("Mower" Section)
0000009311E
Dismounting Container
1. See page 2-S9. ("Transaxle" Section)
0000009449E
Battery
A When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Open the bonnet.
2. Disconnect the negative cable (1) from the battery.
3. Disconnect the positive cable (2) from the battery and remove
the battery (3).
(1)
Negative Cable
(2)
Positive Cable
(3)
Battery
0000009318E
3-S4
KiSC issued 04, 2006 A
GR1600EC, WSM
BRAKES
Container Base
1. Disconnect the couplers (1) from the relays.
2. Disconnect the connectors (2).
3. Open the switch cover (6). And disconnect the connector (4)
from the grass container full switch (5).
4. Remove the discharge duct (3).
5. Remove the container base (7).
(1)
Coupler
(5)
Grass Container Full Switch
(2)
Connector
(6)
Switch Cover
(3)
Discharge Duct
(7)
Container Base
(4)
Connector
0000009314E
Seat
1. Remove two snap pins (2), (4).
2. Remove the seat (1) and seat plate (3).
(1)
Seat
(3)
Seat Plate
(2)
Snap Pin
(4)
Snap Pin
0000009319E
Fender
1. Remove the speed change pedal (5).
2. Peel the step sheet (4) halfway.
3. Remove the fuel cap (1).
4. Remove the fender (2).
(1)
Fuel Cap
(4)
Step Sheet
(2)
Fender
(5)
Speed Change Pedal
(3)
Fender Mounting Screw
0000009320E
3-S5
KiSC issued 04, 2006 A
GR1600EC, WSM
BRAKES
Steering Wheel, Side Bonnet and Panel
1. Remove the steering wheel (1).
2. Remove the side bonnet (3).
3. Remove the accelerator lever grip.
4. Disconnect the connectors for hour meter (4), main switch (5)
and light switch.
5. Remove the indicator lamps (6).
6. Remove the fuse box (7) from the steering support.
7. Remove the panel (2).
(When reassembling)
Tightening torque
20 to 25
2.0 to 2.5
14.8 to 18.4 ft-lbs
Steering wheel
mounting nut
(1)
Steering Wheel
(5)
(2)
Panel
(6)
Main Switch
Indicator Lamp
(3)
Side Bonnet
(7)
Fuse Box
(4)
Hour Meter
0000009450E
Separating Engine
1. See page 1-S20. ("Engine" Section)
0000009451E
Steering Support Assembly
1. Disconnect the drag link (4) from the sector gear (3).
2. Disconnect the connectors for the timer relay, regulator and
buzzer unit.
3. Disconnect the accelerator wire (2).
4. Separate the steering support assembly (1).
(When reassembling)
Drag link locking nut
74.8 to 81.3
7.62 to 8.29
55.2 to 60.0 ft-lbs
Steering support
mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2 ft-lbs
Tightening torque
(1)
Steering Support
(3)
Sector Gear
(2)
Accelerator Wire
(4)
Drag Link
0000009452E
3-S6
KiSC issued 04, 2006 A
GR1600EC, WSM
BRAKES
Brake Rod and Speed Change Rod
1. Disconnect the brake rod 1 (1) from the pedal system
component.
2. Disconnect the speed change rod (2) from the pedal system
component.
(1)
Brake Rod 1
(2)
Speed Change Rod
0000009453E
Pedal System Component
1. Remove the parking lock spring (1).
2. Remove the pedal system component mounting nuts (2).
3. Separate the pedal system component (3) from frame.
(When reassembling)
Tightening torque
Pedal system
component mounting
nut
(1)
Parking Lock Spring
(2)
Pedal System Component
(3)
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2 ft-lbs
Pedal System Component
Mounting Nut
0000009454E
3-S7
KiSC issued 04, 2006 A
GR1600EC, WSM
BRAKES
(2) Brake Assembly
Brake Assembly
1. Remove the lock nut (1), plain washers (2) and brake spring
(3).
2. Remove the brake plate (6).
3. Remove the brake rod 2 (5).
4. Remove the brake assembly (4).
5. Remove the external snap ring (7).
6. Pull out the brake drum (8).
(When reassembling)
A Apply liquid gasket (Three Bond 1208D or equivalent) to joint
face of the brake assembly.
A After assembling the brake assembly, be sure to adjust
the brake pedal free travel (see page G-26).
(1)
Lock Nut
(5)
Brake Rod 2
(2)
Plain Washer
(6)
Brake Plate
(3)
Brake Spring
(7)
External Snap Ring
(4)
Brake Assembly
(8)
Brake Drum
0000009456E
3-S8
KiSC issued 04, 2006 A
4
FRONT AXLE
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
4.
[1]
[2]
TROUBLESHOOTING....................................................................................................... 4-S1
SERVICING SPECIFICATIONS ....................................................................................... 4-S2
TIGHTENING TORQUES ................................................................................................. 4-S3
CHECKING, DISASSEMBLING AND SERVICING ........................................................ 4-S4
CHECKING AND ADJUSTING ...................................................................................... 4-S4
PREPARATION ............................................................................................................... 4-S4
(1) Separating Front Axle Assembly ............................................................................. 4-S4
[3] DISASSEMBLING AND ASSEMBLING......................................................................... 4-S6
(1) Front Axle Assembly................................................................................................ 4-S6
[4] SERVICING ..................................................................................................................... 4-S6
KiSC issued 04, 2006 A
GR1600EC, WSM
FRONT AXLE
1. TROUBLESHOOTING
Symptom
Front Wheels Wander
to Right or Left
Probable Cause
Solution
Reference
Page
A Tire pressure uneven
Adjust
A Improper toe-in
Replace tie-rod
4-S4, 6
A Kingpin worn
Replace front axle
assembly
4-S5
A Center pin collar worn
Replace
4-S5, 6
A Center pin locking nut loosen
Tighten
4-S5
Replace tie-rod
4-S4, 6
A Kingpin worn
Replace front axle
assembly
4-S5
A Center pin collar worn
Replace
4-S5, 6
A Steering linkage loosen or worn
Tighten or replace
4-S5
Front Wheels Shimmy A Improper toe-in
0000009615E
4-S1
KiSC issued 04, 2006 A
GR1600EC, WSM
FRONT AXLE
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Front Wheel Alignment
Toe-in
Front Axle Frame to Anti-vibration Bolt
Clearance
0.3 to 0.5 mm
0.012 to 0.020 in.
Center Pin to Center Pin Collar
Clearance
0.109 to 0.200 mm
0.00430 to 0.00789 in.
Center Pin Boss
(I.D.)
25.400 to 25.430 mm
1.00000 to 1.00118 in.
Center Pin Collar
(O.D.)
25.230 to 25.291 mm
0.99329 to 0.99570 in.
Allowable Limit
1 to 10 mm
0.04 to 0.39 in.
0.210 mm
0.00828 in.
0000009616E
4-S2
KiSC issued 04, 2006 A
GR1600EC, WSM
FRONT AXLE
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-9)
Item
ft-lbs
Center pin locking nut
77.4 to 90.2
7.9 to 9.2
57.2 to 66.5
Tie-rod mounting locking nut
49.9 to 54.2
5.09 to 5.53
36.8 to 40.0
0000009617E
4-S3
KiSC issued 04, 2006 A
GR1600EC, WSM
FRONT AXLE
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Toe-in
1. Inflate the tires to the specified pressure.
2. Turn the front wheels straight ahead.
3. Measure the toe-in (B-A).
4. If the measurement is not within the factory specifications,
replace the tie-rod.
Toe-in (B-A)
(A)
1 to 10 mm
0.04 to 0.39 in.
Factory spec.
Wheel to Wheel Distance
(B)
at Front
Wheel to Wheel Distance
at Rear
(C)
Front
0000009459E
Anti-Vibration Bolt
1. Jack up the front of machine.
2. Measure the clearance between the front axle frame (1) and
anti-vibration bolt (2).
3. If the measurement exceeds the factory specification, adjust
the anti-vibration bolt.
Clearance between
front axle frame and
anti-vibration bolt
(1)
Front Axle Frame
(2)
Anti-Vibration Bolt
0.3 to 0.5 mm
0.012 to 0.020 in.
Factory spec.
A:
Clearance
0000009460E
[2] PREPARATION
(1) Separating Front Axle Assembly
Dismounting Mower
1. See page 7-S6. ("Mower" Section)
0000009311E
Battery
A When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Open the bonnet.
2. Disconnect the negative cable (1) from the battery.
3. Disconnect the positive cable (2) from the battery and remove
the battery (3).
(1)
Negative Cable
(2)
Positive Cable
(3)
Battery
0000009318E
4-S4
KiSC issued 04, 2006 A
GR1600EC, WSM
FRONT AXLE
Bonnet and Side Bonnet
1. Disconnect the connectors (5) from the head light.
2. Remove the wire harness (4) from the bonnet.
3. Remove the bonnet (1) with bonnet bracket (2).
4. Remove the side bonnet (3).
(1)
Bonnet
(4)
Wire Harness
(2)
Bonnet Bracket
(5)
Connector
(3)
Side Bonnet
0000009461E
Separating Front Axle Assembly
1. Disconnect the drag link (1) from the front axle assembly (2).
2. Support the front of frame with jacks.
3. Remove the front wheels.
4. Loose the anti-vibration bolts (5).
5. Remove the center pin locking nut (3), and draw out the center
pin bolt (6).
6. Separate the front axle assembly (2).
(When reassembling)
A Apply grease to the outer side of center pin collar (4).
Tightening torque
Center pin locking nut
77.4 to 90.2
7.9 to 9.2
57.2 to 66.5 ft-lbs
(1)
Drag Link
(4)
(2)
Front Axle Assembly
(5)
Center Pin Collar
Anti-vibration Bolt
(3)
Center Pin Locking Nut
(6)
Center Pin Bolt
0000009462E
4-S5
KiSC issued 04, 2006 A
GR1600EC, WSM
FRONT AXLE
[3] DISASSEMBLING AND ASSEMBLING
(1) Front Axle Assembly
Tie-rod
1. Remove the tie-rod mounting locking nut (1).
2. Remove the tie-rod (2).
(When reassembling)
Tightening torque
(1)
49.9 to 54.2
5.09 to 5.53
36.8 to 40.0 ft-lbs
Tie-rod mounting
locking nut
Tie-rod Mounting Locking Nut
(2)
Tie-rod
0000009463E
[4] SERVICING
Clearance between Center Pin Boss and Center Pin Collar
1. Measure the center pin boss (2) I.D. with a cylinder gauge.
2. Measure the center pin collar (3) O.D. with an outside
micrometer and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace them.
Clearance between
center pin boss and
center pin collar
Factory spec.
0.109 to 0.200 mm
0.00430 to 0.00789 in.
Allowable limit
0.210 mm
0.0828 in.
Center pin boss I.D. (A)
Factory spec.
25.400 to 25.430 mm
1.00000 to 1.00118 in.
Center pin collar O.D.
(B)
Factory spec.
25.230 to 25.291 mm
0.99329 to 0.99570 in.
(1)
Front Axle Frame
(2)
Center Pin Boss
(3)
Center Pin Collar
0000009464E
4-S6
KiSC issued 04, 2006 A
5
STEERING
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
4.
[1]
[2]
TROUBLESHOOTING....................................................................................................... 5-S1
SERVICING SPECIFICATIONS ....................................................................................... 5-S2
TIGHTENING TORQUES ................................................................................................. 5-S3
CHECKING, DISASSEMBLING AND SERVICING ........................................................ 5-S4
CHECKING AND ADJUSTING ...................................................................................... 5-S4
PREPARATION ............................................................................................................... 5-S4
(1) Separating Steering Support Assembly................................................................... 5-S4
[3] DISASSEMBLING AND ASSEMBLING......................................................................... 5-S7
(1) Steering Support Assembly ..................................................................................... 5-S7
[4] SERVICING ..................................................................................................................... 5-S7
KiSC issued 04, 2006 A
GR1600EC, WSM
STEERING
1. TROUBLESHOOTING
Symptom
Cannot Steer
Hard Steering
Probable Cause
Solution
Reference
Page
A Steering shaft and sector gear broken
Replace
5-S6, 7
A Steering linkage broken
Replace
5-S6
A Tire pressure uneven
Adjust
A Improper alignment of front wheels
Replace tie-rod
4-S4, 6
A Bearing stuck
Replace
5-S7
A Steering shaft and sector gear stuck
Replace
5-S7
0000009618E
5-S1
KiSC issued 04, 2006 A
GR1600EC, WSM
STEERING
2. SERVICING SPECIFICATIONS
Item
Steering Wheel
Factory Specification
Play
Allowable Limit
30 to 70 mm
0.79 to 1.18 in.
0000009619E
5-S2
KiSC issued 04, 2006 A
GR1600EC, WSM
STEERING
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-9)
Item
ft-lbs
Steering wheel mounting nut
20 to 25
2.0 to 2.5
14.8 to 18.4
Drag link locking nut
74.8 to 81.3
7.62 to 8.29
55.2 to 60.0
Steering support mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Sector gear mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
0000009620E
5-S3
KiSC issued 04, 2006 A
GR1600EC, WSM
STEERING
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Steering Wheel Play
1. Turn the front wheels straight ahead.
2. Rotate the steering wheel lightly by hand, and measure the
play.
3. If the measurement exceeds the factory specifications,
replace the steering shaft and sector gear.
Steering wheel play
30 to 70 mm
0.79 to 1.18 in.
Factory spec.
0000009465E
[2] PREPARATION
(1) Separating Steering Support Assembly
Dismounting Mower
1. See page 7-S6. ("Mower" Section)
0000009311E
Dismounting Container
1. See page 2-S9. ("Transaxle" Section)
0000009449E
Battery
A When disconnecting the battery cables, disconnect the
negative cable from the battery first. When connecting,
connect the positive cable to the battery first.
1. Open the bonnet.
2. Disconnect the negative cable (1) from the battery.
3. Disconnect the positive cable (2) from the battery and remove
the battery (3).
(1)
Negative Cable
(2)
Positive Cable
(3)
Battery
0000009318E
5-S4
KiSC issued 04, 2006 A
GR1600EC, WSM
STEERING
Container Base
1. Disconnect the couplers (1) from the relays.
2. Disconnect the connectors (2).
3. Open the switch cover (6). And disconnect the connector (4)
from the grass container full switch (5).
4. Remove the discharge duct (3).
5. Remove the container base (7).
(1)
Coupler
(5)
Grass Container Full Switch
(2)
Connector
(6)
Switch Cover
(3)
Discharge Duct
(7)
Container Base
(4)
Connector
0000009314E
Seat
1. Remove two snap pins (2), (4).
2. Remove the seat (1) and seat plate (3).
(1)
Seat
(3)
Seat Plate
(2)
Snap Pin
(4)
Snap Pin
0000009319E
Fender
1. Remove the speed change pedal (5).
2. Peel the step sheet (4) halfway.
3. Remove the fuel cap (1).
4. Remove the fender (2).
(1)
Fuel Cap
(4)
Step Sheet
(2)
Fender
(5)
Speed Change Pedal
(3)
Fender Mounting Screw
0000009320E
5-S5
KiSC issued 04, 2006 A
GR1600EC, WSM
STEERING
Steering Wheel, Side Bonnet and Panel
1. Remove the steering wheel (1).
2. Remove the side bonnet (3).
3. Remove the accelerator lever grip.
4. Disconnect the connectors for hour meter (4), main switch (5)
and light switch.
5. Remove the indicator lamps (6).
6. Remove the fuse box (7) from the steering support.
7. Remove the panel (2).
(When reassembling)
Tightening torque
20 to 25
2.0 to 2.5
14.8 to 18.4 ft-lbs
Steering wheel
mounting nut
(1)
Steering Wheel
(5)
(2)
Panel
(6)
Main Switch
Indicator Lamp
(3)
Side Bonnet
(7)
Fuse Box
(4)
Hour Meter
0000009450E
Separating Engine
1. See page 1-S20. ("Engine" Section)
0000009451E
Steering Support Assembly
1. Disconnect the drag link (4) from the sector gear (3).
2. Disconnect the connectors for the timer relay, regulator and
buzzer unit.
3. Disconnect the accelerator wire (2).
4. Separate the steering support assembly (1).
(When reassembling)
Drag link locking nut
74.8 to 81.3
7.62 to 8.29
55.2 to 60.0 ft-lbs
Steering support
mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2 ft-lbs
Tightening torque
(1)
Steering Support
(3)
Sector Gear
(2)
Accelerator Wire
(4)
Drag Link
0000009452E
5-S6
KiSC issued 04, 2006 A
GR1600EC, WSM
STEERING
[3] DISASSEMBLING AND ASSEMBLING
(1) Steering Support Assembly
Steering Shaft and Sector Gear
1. Remove the shaft retainer (4).
2. Remove the sector gear mounting screw (5), and remove the
sector gear (8).
3. Remove the steering bearing (1) and ball bearing (3).
4. Pull out the steering shaft (2).
(When reassembling)
A Apply to grease to the sector gear teeth.
A Apply to grease to the pinion teeth of steering shaft.
A Apply to grease to the sector bushes (6), (7).
A Apply to grease to the steering bearing.
A Adjust the clearance between the shaft retainer and the pinion
gear of steering shaft.
(Reference)
A Length (L) : 1 mm (0.040 in.)
Tightening torque
Sector gear mounting
screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2 ft-lbs
(1)
Steering Bearing
(5)
Sector Gear Mounting Screw
(2)
Steering Shaft
(6)
Sector Bush
(3)
Ball Bearing
(7)
Sector Bush
(4)
Shaft Retainer
(8)
Sector Gear
0000009467E
[4] SERVICING
Steering Support Bushing Wear
1. Visually inspect the sector bushes (1) for signs of wear or
damage.
2. If defect are found, replace the sector bush (1).
(1)
Sector Bush
0000009468E
5-S7
KiSC issued 04, 2006 A
6
ELECTRICAL SYSTEM
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
4.
WIRING DIAGRAM...........................................................................................................6-M1
STARTING SYSTEM ........................................................................................................6-M3
CHARGING SYSTEM.......................................................................................................6-M4
LIGHTING SYSTEM .........................................................................................................6-M5
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
1. WIRING DIAGRAM
0000009632E
6-M1
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Color of Wiring
W......White
WR......White / Red
BW......Black / White
R......Red
WY......White / Yellow
BR......Black / Red
L......Blue
RB......Red / Black
GW......Green / White
P.......Pink
RW......Red / White
YR......Yellow / Red
B......Black
RG......Red / Green
YL......Yellow / Blue
Br......Brown
RY......Red / Yellow
LW......Blue / White
Sb......Sky Blue
0000004213E
6-M2
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
2. STARTING SYSTEM
(1)
Battery
(7)
Engine Stop Time Relay
(2)
Body Earth
(8)
Fuel Feed Pump
(3)
Starter Motor
(4)
Glow Plug
(10)
Fuse (15 A)
(5)
Engine Stop Solenoid
(11)
Seat Switch
(6)
Body Earth
(9)
Slow Blow Fuse (40 A)
(12)
Grass Container Open
(16)
Fuse (3 A)
Switch
(17)
Fuse (10 A)
Grass Container Open
(18)
Main Switch
Relay
(19)
Hour Meter
(14) Diode (3 A)
(20)
Glow Plug Lamp
(15) Brake Switch
(21)
PTO Switch
(13)
When the main switch is turned to the PREHEAT position, the terminal BAT is connected to the terminals GLOW
and ON. The glow plugs become red-hot, and the glow plug (preheat indicator) lamp also lights on while preheating.
When the main switch is then turned to the START position with the brake switch on and PTO switch on, the
terminal BAT is connected to the terminals START and ON. Consequently, battery current flows to the starter motor
and start the engine.
The main switch automatically returns to the ON position, the terminal BAT is connected only to the terminal ON,
thereby causing the starting circuit to be opened, stopping the starter motor.
When the main switch turned from the ON position to the OFF position, the engine stop solenoid moves the fuel
injection pump control rack to the "No Fuel Injection" position and stop the engine.
This machine equipped the operator presence control (OPC) system which automatically stops the engine when
operator stands from the seat while shifting the PTO lever.
The engine of this machine also stops automatically when the grass container is opened or is dismounted while
shifting the PTO lever.
0000009628E
6-M3
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
3. CHARGING SYSTEM
(1)
Battery
(4)
Dynamo
(7)
Main Switch
(9)
(2)
Body Earth
(5)
Slow Blow Fuse (40 A)
(8) Fuse (10 A)
(10)
(3)
Body Earth
(6)
Regulator
Charge Lamp
Hour Meter
The charging system supplies electric power for various electrical devices and also charges the battery while the
engine runs.
It consists of a dynamo (4) and a regulator (6).
0000009629E
6-M4
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
4. LIGHTING SYSTEM
(1)
Battery
(7)
Regulator
(13)
Grass Container Full
(2)
Body Earth
(8)
Slow Blow Fuse (40 A)
(3)
Thermo Switch
(9)
(4)
Oil Switch
(5)
Body Earth
(6)
Dynamo
(18)
Oil Pressure Lamp
Switch
(19)
Charge Lamp
Main Switch
(14)
Buzzer Relay
(20)
Easy Checker
(10)
Fuse (10 A)
(15)
Buzzer
(21)
Head Light Switch
(11)
Fuse (3 A)
(16)
Thermo Lamp
(22)
Head Light
(12)
PTO Switch
(17)
Grass Container Full Lamp
(23)
Hour Meter
The lighting system consists of main switch, head light switch, head lights, etc..
The grass container full lamp in the easy checker lights when the grass container is filled while shifting the PTO
lever. And the buzzer rings.
0000009630E
6-M5
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
4.
[1]
TROUBLESHOOTING....................................................................................................... 6-S1
SERVICING SPECIFICATIONS ....................................................................................... 6-S4
TIGHTENING TORQUES ................................................................................................. 6-S5
CHECKING, DISASSEMBLING AND SERVICING ........................................................ 6-S6
CHECKING AND ADJUSTING ...................................................................................... 6-S6
(1) Battery ..................................................................................................................... 6-S6
(2) Main Switch ............................................................................................................. 6-S8
(3) Starter.................................................................................................................... 6-S10
(4) Glow Plug .............................................................................................................. 6-S11
(5) Safety Switch......................................................................................................... 6-S12
(6) Operator Presence Control (OPC) Switch............................................................. 6-S13
(7) Fuel Pump ............................................................................................................. 6-S14
(8) Engine Stop Solenoid ............................................................................................ 6-S14
(9) Time Relay ............................................................................................................ 6-S15
(10) Charging System ................................................................................................... 6-S15
(11) Lighting System ..................................................................................................... 6-S16
(12) Coolant Temperature Sensor ................................................................................ 6-S18
(13) Grass Container Full Switch .................................................................................. 6-S18
[2] DISASSEMBLING AND ASSEMBLING....................................................................... 6-S20
(1) Starter.................................................................................................................... 6-S20
(2) Dynamo ................................................................................................................. 6-S21
[3] SERVICING ................................................................................................................... 6-S22
(1) Starter.................................................................................................................... 6-S22
(2) Dynamo ................................................................................................................. 6-S24
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
1. TROUBLESHOOTING
Symptom
All Electrical
Equipments Do Not
Operate
Fuse Blown
Frequently
Probable Cause
A Battery discharged or defective
Solution
Recharge or replace
A Battery positive cable
improperly connected
disconnected
or Repair or replace
A Battery negative cable
improperly connected
disconnected
or Repair or replace
A Slow blow fuse blown (40 A)
Replace
A Short-circuited
Repair or replace
Reference
Page
G-24, 1-S21
G-35
0000009621E
BATTERY
Battery Discharges
Too Quickly
A Battery defective
Replace
1-S21
A Dynamo defective
Repair or replace
6-S21
A Regulator defective
Replace
A Wiring harness disconnected or improperly Repair or replace
connected (between battery positive terminal
and regulator B terminal)
A Cooling fan belt slipping
Adjust tension
G-27
0000009622E
6-S1
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
STARTING SYSTEM
Symptom
Starter Motor Does
Not Operate
Probable Cause
Solution
Reference
Page
A Battery discharged or defective
Recharge or replace
G-24, 1-S21
A Slow blow fuse blown (40 A)
Replace
G-35
A Wiring harness disconnected or improperly Repair or replace
connected (between main switch ST terminal
and safety switches, between safety switches
and starter motor, between battery positive
terminal and starter motor)
Engine Does Not Stop
When Main Switch is
Turned OFF
A Starter motor defective
Repair or replace
6-S20
A Main switch defective
Replace
6-S8, 9
A Seat switch defective
Replace
6-S13
A Brake switch defective
Replace
6-S12
A PTO switch defective
Replace
6-S12
A Grass container open switch defective
Replace
6-S13
A Fuse blown (15 A)
Replace
G-35
A Wiring harness disconnected or improperly Repair or replace
connected (between main switch ACC
terminal and engine stop solenoid)
A Engine stop solenoid defective
Replace
6-S14
A Timer relay defective
Replace
6-S15
Replace
6-S14
Replace
6-S15
Engine Does Not Start A Engine stop solenoid defective
A Timer relay defective
0000009623E
CHARGING SYSTEM
Symptom
Charging Lamp Does
Not Light when Main
Switch is Turned ON
Probable Cause
Solution
Reference
Page
A Fuse blown (15 A)
Replace
G-35
A Bulb blown
Replace
G-35
A Wiring harness disconnected or improperly Repair or replace
connected (between main switch ACC
terminal and regulator connector terminal
(yellow), between regulator connector terminal
(green) and charge lamp)
Charging Lamp Does
Not Go Off When
Engine is Running
A Regulator defective
Replace
A Dynamo defective
Repair or replace
A Regulator defective
Replace
6-S21
0000009624E
6-S2
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
LIGHTING SYSTEM
Symptom
Head Light Does Not
Light
Probable Cause
Solution
Reference
Page
A Fuse blown (10 A)
Replace
G-35
A Bulb blown
Replace
G-35
A Wiring harness disconnected or improperly Repair or replace
connected (between main switch ACC
terminal and head light switch, between head
light switch and head light)
Glow Plug Lamp Does
Not Light When Main
Switch Is in Pre-heat
Position
Oil Pressure Lamp
Lights Up When
Engine Is Running
A Battery discharged or defective
Recharge or replace
G-24, 1-S21
A Slow blow fuse blown (40 A)
Replace
G-35
A Wiring harness disconnected or improperly Repair or replace
connected (between main switch G terminal
and glow plug lamp, between glow plug lamp
and glow plugs)
A Main switch defective
Replace
6-S8, 9
A Bulb blown
Replace
G-35
A Engine oil pressure too low
Repair engine
A Engine oil insufficient
Replenish
G-25
A Oil pressure switch defective
Replace
6-S17
A Short circuit between oil pressure switch lead Repair
and chassis
Oil Pressure Lamp
Does Not Light When
Main Switch Is Turned
ON and Engine Is Not
Running
A Fuse blown (10 A)
Replace
G-35
A Bulb blown
Replace
G-35
A Oil pressure switch defective
Replace
6-S17
Thermo Lamp Does
Not Light When Main
Switch Is Turned ON
and Engine Is Not
Running
A Fuse blown (10 A)
Replace
G-35
A Bulb blown
Replace
G-35
A Thermo switch defective
Replace
6-S18
A Wiring harness disconnected or improperly Repair or replace
connected (between main switch ACC
terminal and oil pressure lamp, between oil
pressure lamp and oil pressure switch)
A Wiring harness disconnected or improperly Repair or replace
connected (between main switch ACC
terminal and thermo lamp, between thermo
lamp and thermo switch)
0000009625E
6-S3
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
2. SERVICING SPECIFICATIONS
Item
Battery
Factory Specification
Voltage
More than 12 V
Potential Difference
Less than 0.1 V
Glow Plug
Resistance
Head Light Switch
Resistance OFF
Resistance ON
Starter
Commutator
(O.D.)
Allowable Limit
Approx. 0.9
Infinity
0
28.0 mm
1.102 in.
27.0 mm
1.063 in.
Commutator
(Difference of O.D.)
Less than 0.05 mm
0.002 in.
0.4 mm
0.016 in.
Mica
(Undercut)
0.50 to 0.80 mm
0.0197 to 0.0315 in.
0.20 mm
0.0079 in.
16.0 mm
0.630 in.
10.5 mm
0.413 in.
Brush
(Length)
0000009626E
6-S4
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-9)
Item
ft-lbs
Starter (C terminal nut)
5.9 to 11.8
0.6 to 1.2
4.3 to 8.7
Dynamo (stator nut)
39.2 to 44.1
4.0 to 4.5
28.9 to 32.5
0000009627E
6-S5
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Battery
Battery Voltage
1. Stop the engine and turn the main switch off.
2. Connect the COM (-) lead of the voltmeter to the battery's
negative terminal post (2) and the (+) lead to the positive
terminal post (1), and measure the battery voltage.
3. If the battery voltage is less than the factory specification,
check the battery specific gravity and recharge the battery.
Battery voltage
(1)
Factory spec.
Positive Terminal Post
More than 12 V
(2)
Negative Terminal Post
0000009469E
Battery Terminal Connection
1. Turn the main switch on, and turn on the head light.
2. Measure the voltage with a voltmeter across the battery's
positive terminal post and the cable terminal, and the voltage
across the battery's negative terminal post and the chassis.
3. If the measurement exceeds the factory specification, clean
the battery terminal posts and cable clamps, and tighten them
firmly.
Potential difference
Factory spec.
Less than 0.1 V
0000001141E
6-S6
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Battery Specific Gravity
1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more
than 0.05, replace the battery.
A Hold the hydrometer tube vertical without removing it
from the electrolyte.
A Do not suck too much electrolyte into the tube.
A Allow the float to move freely and hold the hydrometer at
eye level.
A The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
A Specific gravity slightly varies with temperature. To be exact,
the specific gravity decreases by 0.0007 with an increase of
1
(0.0004 with an increase of 1 ) in temperature, and
increases by 0.0007 with a decreases of 1
(0.0004 with a
decrease of 1 ).
Therefore, using 20
(68 ) as a reference, the specific
gravity reading must be corrected by the following formula :
-Specific gravity at 20
= Measured value + 0.0007 x
(electrolyte temperature - 20 )
-Specific gravity at 68
= Measured value + 0.0004 x
(electrolyte temperature - 68 )
Specific Gravity
State of Charge
1.260 Sp. Gr.
100 % Charged
1.230 Sp. Gr.
75 % Charged
1.200 Sp. Gr.
50 % Charged
1.170 Sp. Gr.
25 % Charged
1.140 Sp. Gr.
Very Little Useful Capacity
1.110 Sp. Gr.
Discharged
At an electrolyte temperature of 20
(a)
Good
(b)
Bad
(68
)
(c)
Bad
0000001142E
6-S7
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
(2) Main Switch
Main Switch
1. Open the bonnet.
2. Disconnect the 4P connector and remove the main switch (1).
3. Perform the following checks.
(1)
Main Switch
0000009471E
Connector Voltage
1. Measure the voltage with a voltmeter across the connector B
(red) terminal and chassis.
2. If the voltage differs from the battery voltage (11 to 14 V), the
wiring harness is faulty.
Voltage
(1)
Connector B (Red)
terminal - chassis
Approx. battery voltage
Connector
0000007172E
6-S8
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Main Switch Continuity
1) Main Switch Key at OFF Position
1. Set the main switch OFF position.
2. Measure the resistance with an ohmmeter across the B
terminal and the ACC terminal, B terminal and ST terminal, B
terminal and G terminal.
3. If infinity is not indicated, the contacts of the main switch are
faulty.
B terminal - ACC terminal
Resistance
B terminal - ST terminal
Infinity
B terminal - G terminal
2) Main Switch Key at ON Position
1. Set the main switch ON position.
2. Measure the resistance with an ohmmeter across the B
terminal and the ACC terminal.
3. If 0 ohm is not indicated, the B - ACC contact of the main
switch are faulty.
Resistance
B terminal - ACC terminal
0
3) Main Switch Key at PREHEAT Position
1. Set and hold the main switch key at the PREHEAT position.
2. Measure the resistance with an ohmmeter across the B
terminal and the G terminal, and measure the resistance
across the B terminal and the ACC terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
B terminal - G terminal
Resistance
0
B terminal - ACC terminal
4) Main Switch Key at START Position
1. Set and hold the main switch key at the START position.
2. Measure the resistance with an ohmmeter across the B
terminal and the G terminal, across the B terminal and the ST
terminal, and across the B terminal and the ACC terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
B terminal - G terminal
Resistance
B terminal - ST terminal
0
B terminal - ACC terminal
(1)
G Terminal
(3)
ST Terminal
(2)
ACC Terminal
(4)
B Terminal
0000007173E
6-S9
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
(3) Starter
Motor Test
A Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable and the leads from the
starter.
3. Remove the starter from the engine.
4. Disconnect the connecting lead (2) from the starter C terminal
(1).
5. Connect a jumper lead from the connecting lead (2) to the
battery positive terminal post.
6. Connect a jumper lead momentarily between the starter motor
housing and the battery negative terminal post.
7. If the motor does not run, check the motor.
(1)
C Terminal
(2)
Connecting Lead
0000005097E
Starter Magnet Switch Test (Pull-in, Holding Coils)
A Preparate a 6 V battery for the test, and each test should
be carried out for 3 to 5 seconds.
1) Checking Pull-in Coil
1. Connect jumper lead from the battery's negative terminal post
to the C terminal.
2. The plunger should be attracted strongly when a jumper lead
is connected from the battery positive terminal to the S
terminal.
2) Checking Holding Coil
1. Connect jumper leads from the battery's negative terminal
post to the body and the battery's positive terminal post to the
S terminal.
2. Push the plunger in by hand and release it. Then, the plunger
should remain being attracted.
0000005505E
6-S10
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
(4) Glow Plug
Lead Terminal Voltage
1. Disconnect the wiring lead (1) from the glow plug (2) after
turning the main switch off.
2. Turn the main switch key to the "PREHEAT" position, and
measure the voltage between the lead terminal and the
chassis.
3. Turn the main switch key to the "START" position, and
measure the voltage with a voltmeter between the lead
terminal and the chassis.
4. If the voltage at either position differs from the battery voltage,
the wiring harness or main switch is faulty.
Voltage(Lead
terminal - Chassis)
(1)
Main switch key at
"PREHEAT"
Approx. battery voltage
Main switch key at
"START"
Approx. battery voltage
Wiring Lead (Positive)
(2)
Glow Plug
0000007174E
Glow Plug Continuity
1. Disconnect the lead from the glow plugs.
2. Measure the resistance with an ohmmeter between the glow
plug terminal and the chassis.
3. If 0 ohm is indicated, the screw at the tip of the glow plug and
the housing are short-circuited.
4. If the factory specification is not indicated, the glow plug is
faulty.
Glow plug resistance
Factory spec.
Approx. 0.9
0000001152E
6-S11
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
(5) Safety Switch
PTO Switch
1. Remove the battery.
2. Remove the fender.
3. Disconnect the connector from the PTO switch (1).
4. Measure the resistance with an ohmmeter between the
terminals.
5. If the PTO switch is defective, replace it.
Resistance (between
terminal a and b)
Resistance (between
terminal c and d)
(1)
PTO Switch
(2)
PTO Lever
When plunger is
pushed
0
When plunger is
released
Infinity
When plunger is
pushed
0
When plunger is
released
Infinity
a to d : Safety Switch Terminal
0000009474E
Brake Switch
1. Remove the battery.
2. Remove the fender.
3. Disconnect the connector from the brake switch (1).
4. Measure the resistance with an ohmmeter between the
terminals.
5. If the brake switch is defective, replace it.
Resistance (between
terminal a and b)
Resistance (between
terminal c and d)
(1)
Brake Switch
When plunger is
pushed
0
When plunger is
released
Infinity
When plunger is
pushed
0
When plunger is
released
Infinity
a to d : Safety Switch Terminal
0000009475E
6-S12
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Grass Container Open Switch
1. Remove the battery.
2. Dismount the grass container.
3. Disconnect the safety switch (1) lead.
4. Measure the resistance with an ohmmeter between the saety
switch terminals.
5. If the safety switch is defective, replace it.
Resistance (between
switch terminals)
(1)
When plunger is
pushed
0
When plunger is
released
Infinity
Safety Switch for Grass
Container
0000009476E
(6) Operator Presence Control (OPC) Switch
OPC Switch (Seat Switch)
1. Remove the battery.
2. Remove the OPC switch (1).
3. Measure the resistance with an ohmmeter between the OPC
switch terminals.
4. If the OPC switch is defective, replace it.
Resistance (between
switch terminals)
(1)
When plunger is
pushed
0
When plunger is
released
Infinity
OPC Switch (Seat Switch)
0000009477E
6-S13
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
(7) Fuel Pump
Connector Voltage
1. Disconnect the 2P connector from the fuel pump.
2. Turn the main switch key to the "ON" position, and measure
the voltage with a voltmeter between the connector terminals.
3. If the voltage differs from the battery voltage, the wiring
harness or main switch is faulty.
Voltage
Between connector
terminals
Approx. battery voltage
0000001160E
Fuel Pump Continuity
1. Disconnect the 2P connector from the fuel pump.
2. Check the continuity between the connector terminals with an
ohmmeter.
3. If it does not conduct, the fuel pump is faulty.
0000001161E
(8) Engine Stop Solenoid
Engine Stop Solenoid Test
1. Disconnect the 1P connector from the engine stop solenoid.
2. Remove the engine stop solenoid from the engine.
3. Connect the jumper leads from the battery positive terminal to
the 1P connector, and from the battery negative terminal to the
engine stop solenoid body.
4. If the solenoid plunger is not attracted, the engine stop
solenoid is faulty.
(1)
Battery (12 V)
0000001163E
6-S14
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
(9) Time Relay
Timer Relay Connector Voltage
1. Disconnect the connector from the timer relay after turning the
main switch off.
2. Measure the voltage with a voltmeter across the connector
terminal 4 and chassis.
3. Turn the main switch on, and measure the voltage across the
connector terminal 3 and chassis.
4. If these voltages differ from the battery voltage, the wiring
harness or main switch is faulty.
Connector
terminal 4 - chassis
Approx. battery voltage
Connector
terminal 3 - chassis
Approx. battery voltage
Voltage
(1)
Timer Relay
0000009482E
Test of Timer Relay
1. Remove the timer relay from the machine.
2. Connect jumper leads across the battery positive terminal and
the timer relay terminal 3, and across the battery positive
terminal and the timer relay terminal 4.
3. Connect jumper leads across the battery negative terminal
and the timer relay terminal 2, and across the battery negative
terminal and the bulb terminal.
4. Connect jumper lead across the timer relay terminal 1 and the
bulb terminal.
5. The bulb lights up when disconnecting a jumper lead from the
terminal 3 arid goes off 6 to 13 seconds late, the timer relay is
proper.
(1)
Timer Relay
(2)
Load (Lamp)
(3)
Battery (12V)
0000009483E
(10)Charging System
No-load Dynamo Output
1. Disconnect the lead wires from the dynamo.
2. Start the engine and operate the dynamo at the rated speed.
3. Measure the output voltage with a volt meter.
4. If the measurement is not within the specified values, replace
the dynamo.
No-load output
Factory spec.
AC 20 V or more
0000009484E
6-S15
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Regulating Voltage
1. Complete the charging circuit with a fully charged battery and
run the engine speed at the rated speed.
2. Measure the battery voltage with a volt meter.
3. If the measurement is not within the specified values, replace
the regulator.
Regulating voltage
Factory spec.
14 to 15 V
0000009485E
(11)Lighting System
Head Light Switch Continuity
1. Disconnect the wiring leads from head light switch and remove
it.
2. Measure the resistance with an ohmmeter across the head
light switch terminals in each position.
3. If the resistance differs from the factory specifications, the
head light switch is faulty.
Resistance
(1)
Factory
spec.
OFF
Infinity
ON
0
Head Light Switch
0000007184E
6-S16
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Engine Oil Pressure Lamp
1. Disconnect the lead from the engine oil pressure switch after
turning the main switch OFF.
2. Turn the main switch ON and connect a jumper lead from the
lead to the chassis.
3. If the engine oil pressure indicator lamp does not light, the
wiring harness is faulty.
(1)
Engine Oil Pressure Switch
(a)
From Oil Pressure Lamp
0000001185E
Engine Oil Pressure Switch Continuity
1. Measure the resistance with an ohmmeter across the switch
terminal and the chassis.
2. If 0 ohm is not indicated in the normal state, the switch is faulty.
3. If infinity is not indicated at pressure over 4.9 kPa (0.5
,
7 psi), the switch is faulty.
Resistance(Switch
terminal -Chassis)
(1)
In normal state
0
At pressure over
approx. 4.9 kPa(0.5
, 7 psi)
Infinity
Engine Oil Pressure Switch
0000001186E
6-S17
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
(12)Coolant Temperature Sensor
Coolant Temperature Sensor
1) Connector Voltage
1. Disconnect the 1P connector from the thermo switch (1).
2. Turn the main switch key to the "ON" position, and measure
the voltage with a voltmeter between the connector terminal
and the chassis.
3. If a certain voltage is not indicated, the wiring harness is faulty.
Voltage (Connector
terminal - Chassis)
A certain voltage is
indicated
Factory spec.
2) Thermo Switch Continuity
1. Disconnect the 1P connector, and remove the thermo switch.
2. Using an ohmmeter, check for continuity between the switch
terminal and the chassis.
3. If infinity is indicated at temperature over factory
specifications, the switch is faulty.
Working temperature
(1)
Thermo Switch
120 to 126
248.0 to 258.8
Factory spec.
(A)
ON
(B)
OFF
(C)
120 to 126
(248.0 to 258.8
(D)
116
(240.8
)
) or more
0000009486E
(13)Grass Container Full Switch
Grass Container Full Switch Continuity
1. Remove the battery.
2. Dismount the grass container.
3. Open the switch cover (1).
4. Disconnect the grass container full switch (2) lead.
5. measure the resistance with an ohmmeter between the grass
container full switch terminals.
6. If the grass container full switch is defective, replace it.
Resistance (between
switch terminals)
(1)
Switch Cover
When switch lever is
pushed
0
When switch lever is
released
Infinity
(2)
Grass Container Full Switch
0000009487E
6-S18
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Buzzer
1. Remove the air intake net.
2. Disconnect the lead from buzzer (1).
3. Connect the jumper lead between the battery positive terminal
and terminal 1 of connector.
4. Connect the jumper lead between the battery negative
terminal and terminal 2 of connector.
5. If the buzzer does not whistle, replace it.
(1)
Buzzer
1:
Terminal 1
2:
Terminal 2
0000009488E
Adjusting Grass Container Full Switch
A Before mowing, adjust the grass container full switch
position according to the grass condition.
1. Dismount the grass container (see page 2-S9).
2. Open the switch cover (1).
3. Loose the wing nut (3) and align the position indicator (2) with
switch position "A".
4. Set the position change lever (4) up.
5. Close the switch cover and remount the grass container, and
start mowing.
6. If the discharge duct is plugged, align the position indicator (2)
with switch position "B".
7. If the grass container is not filled much, set the position change
lever (4) down.
(1)
Switch Cover
A:
Switch Position
(2)
Position Indicator
B:
Switch Position
(3)
Wing Nut
(4)
Position Change Lever
0000009489E
6-S19
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
[2] DISASSEMBLING AND ASSEMBLING
(1) Starter
(1)
Sleeve Bearing
(2)
Bushing
(3)
Starter Drive Housing
(4)
Drive Lever
(5)
Magnet Switch
(6)
Yoke
(7)
Connecting Lead
(8)
Through Bolt
(9)
1.
2.
3.
4.
5.
6.
7.
Rear End Frame
(10)
Bushing
(11)
Brush
(12)
Brush Holder
(13)
Brush Spring
(14)
Brush
(15)
Washer
(16)
Armature
(17)
Overrunning Clutch
Disconnect the connecting lead (7).
Remove the magnetic switch (5).
Remove the rear end frame (9).
Remove the brush (11) from brush holder (12).
Remove the brush holder (12).
Draw out the yoke (6) from the starter drive housing (3).
Draw out the armature (16) with the drive lever (4).
A Do not damage to the brush and commutator.
(When reassembling)
A Apply grease to spline teeth of the armature, bushing, pinion gear of the overrunning clutch and armature shaft.
Tightening torque
C Terminal Nut
5.9 to 11.8
0.6 to 1.2
4.3 to 8.7 ft-lbs
0000009490E
6-S20
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
(2) Dynamo
Stator
1. Remove the nut (3) and separate the stator comp. (4).
2. Unscrew the screws (1) and remove the stator (2).
(When reassembling)
Tightening torque
39.2 to 44.1
4.0 to 4.5
28.9 to 32.5 ft-lbs
Nut
(1)
Screw
(3)
Nut
(2)
Stator
(4)
Stator Comp.
0000001176E
Rotor
1. Tap out the shaft (1) from the rotor (3).
(When reassembling)
A Take care the direction of the collar (4), the flat side should
face to the pulley (2) side
(1)
Shaft
(4)
Collar
(2)
Pulley
(5)
Bearings
(3)
Rotor
(6)
Collar
0000001177E
6-S21
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
[3] SERVICING
(1) Starter
Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking
direction.
4. If the pinion slips or does not rotate in the both directions,
replace the overrunning clutch assembly.
0000001168E
Commutator and Mica
1. Check the contact face of the commutator for wear, and grind
the commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.'s exceeds the allowable limit,
correct the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a
saw blade and chamfer the segment edges.
Factory spec.
28.0 mm
1.102 in.
Allowable limit
27.0 mm
1.063 in.
Factory spec.
Less than 0.05 mm
0.002 in.
Allowable limit
0.4 mm
0.016 in.
Factory spec.
0.50 to 0.80 mm
0.0197 to 0.0315 in.
Allowable limit
0.20 mm
0.0079 in.
Commutator O.D.
Difference of O.D.'s
Mica undercut
(1)
Segment
(a)
Correct
(2)
Undercut
(b)
incorrect
(3)
Mica
0000009491E
6-S22
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with
emery paper.
2. Measure the brush length (A) with vernier calipers.
3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
Factory spec.
16.0 mm
0.630 in.
Allowable limit
10.5 mm
0.413 in.
Brush length (A)
0000009492E
Brush Holder
1. Check the continuity across the brush holder and the holder
support with an ohmmeter.
2. If it conducts, replace the brush holder.
0000001171E
Armature Coil
1. Check the continuity across the commutator and armature coil
core with an ohmmeter.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator
with an ohmmeter.
4. If it does not conduct, replace the armature.
0000001172E
6-S23
KiSC issued 04, 2006 A
GR1600EC, WSM
ELECTRICAL SYSTEM
Field Coil
1. Check the continuity across the lead (1) and brush (2) with an
ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
ohmmeter.
4. If it conducts, replace the yoke assembly.
(1)
Lead
(2)
Brush
(3)
Yoke
0000001173E
(2) Dynamo
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
0000001178E
6-S24
KiSC issued 04, 2006 A
7
MOWER
KiSC issued 04, 2006 A
CONTENTS
1. POWER TRANSMISSION................................................................................................7-M1
2. LIFTING MECHANISM .....................................................................................................7-M2
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
1. POWER TRANSMISSION
(1)
Center Pulley
(4)
18T Spiral Gear
(7) Mower Belt
(2)
Output Shaft
(5)
Input Shaft
(8)
(3)
17T Spiral Gear
(6)
Outer Pulley
Universal Joint
(9)
(10)
Blade Shaft
Blade
The power is transmitted from transmission case to blades as follows.
PTO Shaft
Universal Joint (8)
Input Shaft (5)
18T Spiral Gear (4)
17T Spiral Gear (3)
(2)
Center Pulley (1)
Mower Belt (7)
Outer Pulley (6)
Blade Shaft (9)
Blade (10)
Output Shaft
0000009588E
7-M1
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
2. LIFTING MECHANISM
(1)
Lift Link LH
(4)
Lift Link Shaft
(2)
Rear Link LH
(5)
Mower Lift Lever
(3)
Gas Spring
(6)
Lift Link
(7)
Cutting Height Adjusting
Dial
(9)
(10)
Lift Link RH
Rear Link RH
(8) Adjusting Cam
The rear link RH (10) and mower lift lever (5) are linked with lift link RH (9) and lift link (6). The rear link LH (2) and
mower lift lever (5) are linked with lift link LH (1), lift link shaft (4) and lift link (6).
As the mower lift lever (5) moves to "LIFT" position, the lift link (6) and lift link RH (9) are raised and the lift link
shaft (4) is rotated to raise the lift link LH (1). As a result, the rear link RH (10) and LH (2) are lifted. The gas spring
(3) connected with lift link shaft (4) assists lifting of mower.
The cutting height adjusting dial (7) adjusts cutting height of mower by rotating the adjusting cam. The position of
rear link RH (10) and LH (2) are adjusted by cutting height fine turning bolt on lift link (6) and lift link LH (1).
0000009590E
7-M2
KiSC issued 04, 2006 A
CONTENTS
1.
2.
3.
4.
[1]
TROUBLESHOOTING....................................................................................................... 7-S1
SERVICING SPECIFICATIONS ....................................................................................... 7-S2
TIGHTENING TORQUES ................................................................................................. 7-S3
CHECKING, DISASSEMBLING AND ASSEMBLING .................................................... 7-S4
CHECKING AND ADJUSTING ...................................................................................... 7-S4
(1) Adjusting Anti-scalp Rollers..................................................................................... 7-S4
(2) Adjusting Left and Right Cutting Height................................................................... 7-S5
[2] PREPARATION ............................................................................................................... 7-S6
(1) Dismounting Mower................................................................................................. 7-S6
[3] DISASSEMBLING AND ASSEMBLING......................................................................... 7-S8
(1) Mower...................................................................................................................... 7-S8
(2) Mower Lift Linkage ................................................................................................ 7-S11
[4] SERVICING ................................................................................................................... 7-S12
(1) Gear Box ............................................................................................................... 7-S12
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
1. TROUBLESHOOTING
Symptom
Blade Does Not Turn
Blade Speed Is Slow
Cutting Is Poor
Mower Is Not Lifted
Probable Cause
Solution
Reference
Page
A PTO system malfunctioning
Check transmission
A Mower belt broken
Replace mower belt
7-S8
A Mower belt loosen
Replace mower belt
or tension spring
7-S8
A Grass clogged
Remove grass
A Cup washer flattened out or worn
Replace cup washer
A Engine rpm too low
Mow at full throttle,
check and reset
engine rpm
A Mower blade worn or bent
Sharpen or replace
mower blade
7-S8
A Mower blade screw loosen
Retighten mower
blade screw
7-S8
A Cutting height improper
Adjust cutting height
7-S5
A Ground speed too fast
Slow-down
A Tire pressure uneven
Add air to correct
A Anti-scalp rollers not adjusted correctly
Adjust anti-scalp
rollers
7-S4
A Linkage system broken
Replace linkage
system
7-S11
7-S8
0000009591E
7-S1
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Left Tip of Blade to Right Tip of Blade
Difference
Less than 6 mm
0.24 in.
Front Tip of Blade to Rear Tip of Blade
Difference
Less than 5 mm
0.20 in.
17T Spiral Gear to 18T Spiral Gear
Backlash
0.13 to 0.25 mm
0.0051 to 0.0098 in.
Allowable Limit
0.40 mm
0.157 in.
0000009592E
7-S2
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-9)
Item
ft-lbs
Mower blade screw
98 to 118
10.0 to 12.0
72.3 to 86.8
Gear box mounting screw
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5
Gear box bracket mounting screw and nut
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Pulley mounting screw (gear box)
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5
Pulley mounting nut (pulley holder)
103 to 118
10.5 to 12.0
76.0 to 87.0
Pulley holder mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
0000009593E
7-S3
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
4. CHECKING, DISASSEMBLING AND ASSEMBLING
[1] CHECKING AND ADJUSTING
(1) Adjusting Anti-scalp Rollers
Adjusting Anti-scalp Rollers
A The flattest cut can be achieved by having the anti-scalp
rollers adjusted off the ground.
Check anti-scalp roller adjustments each time the mower
deck cutting height is changed.
It is recommended that all the anti-scalp rollers be kept off
the ground to minimize scuffing.
1. Check the machine wheel pressure.
Inflate wheels to the correct pressure. (See table below.)
Inflation Pressure
Front wheel
200 kPa, 2.0
, 29 psi
Rear wheel
140 kPa, 1.4
, 20 psi
2. Start the engine.
3. Raise up the mower deck to the transport position.
(Also the top end of the lift.)
4. Turn the cutting height control dial to adjust height.
5. Lower the mower deck.
B Front side anti-scalp roller
6. Adjust height H of the rear side anti-scalp roller to one of four
positions to approximately 19 mm (0.75 in.) between rollers
and ground. Adjust both side rollers to the same height.
7. Install the roller with attaching hardware.
B Rear side anti-scalp roller
8. Adjust height H of the front side anti-scalp roller to one of
seven positions to approximately 19 mm (0.75 in.) between
rollers and ground. Adjust both side rollers to the same height.
9. Install the roller with attaching hardware.
H:
Height 19 mm (0.75 in.)
0000009594E
7-S4
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
(2) Adjusting Left and Right Cutting Height
Adjusting Left and Right Cutting Height
1. Park the machine on level surface.
2. Wheel pressure must be correct.
3. Raise up the mower deck to the transport position. (Also the
top end.)
4. Turn the cutting height control dial (1) to the "3" position.
5. Place 51 mm (2 in.) height wood blocks under each side of the
mower deck.
Anti-scalp rollers must not rest on the wood block.
6. Lower the mower deck.
7. Adjust the left side equally.
8. Measure the heights of blade L and R from the ground surface
and calculate the difference.
9. If the difference between left tip and right tip of blade is not
within the factory specification, adjust the length of cutting
height fine tuning bolt (2).
Difference (L) - (R)
between left tip and right
tip of blade
Less than 6 mm
0.24 in.
Factory spec.
(Reference)
A Length of cutting height fine tuning bolt (H) :
16 to 20 mm (0.63 to 0.79 in.)
(1)
Cutting Height Control Dial
(2)
Cutting Height Fine Tuning Bolt
(3)
Lock Nut
(L)
Left Blade Measurement
Position
(R)
Right Blade Measurement
Position
A : Blade Height
0000009595E
7-S5
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
Adjusting Parallel Linkage
1. Park the machine on a level surface.
2. Wheel pressure must be correct.
3. Adjust the cutting height so that blade is level.
4. Position mower blade in the Front-to-Rear position.
5. Measure the height of blade X and Y from the ground surface
and calculate the difference.
6. If the difference between front tip and rear tip of blade is not
within the factory specification, adjust the length "L" of front
link with lock nut (1).
Difference (X - Y)
between front tip and
rear tip of blade
Less than 5 mm
0.20 in.
Factory spec.
(Reference)
A L : 26 to 28 mm (1.0 to 1.1 in.)
(1)
Lock Nut
X:
Height of Blade Tip (Front)
Y:
Height of Blade Tip (Rear)
0000009596E
[2] PREPARATION
(1) Dismounting Mower
Cutting Height Adjusting Dial
1. Park the machine on level ground, and stop the engine.
2. Set the cutting height adjusting dial (1) to "1" position.
3. Set the front anti-scalp rollers at the top position.
4. Lower the mower lift lever (2) and lock in the lower position.
(1)
Cutting Height Adjusting Dial
(2)
Mower Link Lever
0000009597E
Front Link
1. Pull the lever fulcrum fixing pin (2) and turn it counterclockwise
to lock.
2. Push down the link fixing lever (1).
3. Remove the front link (3) from the mower deck.
(When reassembling)
A When attach the front link, make sure the length of the front
link.
(1)
Link Fixing Lever
(2)
Lever Fulcrum Fixing Pin
(3)
Front Link
0000009598E
7-S6
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
Rear Link and Universal Joint
1. Disconnect the rotate plate rod (1).
2. Disconnect the rear link (2) from the mower deck, pulling the
L-pins (3).
3. Disconnect the universal joint (4) from the PTO shaft.
4. Raise the mower lift lever and lock in the raised position.
(When reassembling)
A Apply grease to the spline of PTO shaft.
A Slide the universal joint back and front to make sure the
universal joint is locked securely.
A When attach the rear links, make sure the length of the rear
links.
(1)
Rotate Plate Rod
(3)
L-pin
(2)
Rear Link
(4)
Universal Joint
0000009599E
Dismounting Mower
1. Turn the front wheel to the right.
2. Pull out the mower deck to the left.
0000009600E
7-S7
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
[3] DISASSEMBLING AND ASSEMBLING
(1) Mower
Mower Blades (Left Blade and Right Blades)
1. Turn over the mower.
2. Unscrew the mower blade screw (1), and remove the shim (2),
two cup washers (3), mower blade (4) and dust cover (6).
A To remove the blade securely, wedge a block of wood
between one blade and the mower deck in such position
that it will hold the blade safely while loosing or tightening
the blade screw.
(When reassembling)
A Be sure to assemble the two cup washers between the mower
blade and the mower blade screw.
A Make sure the cup washer is not flattened out or worn,
causing blade to slip easily.
Replace two cup washers if either is damaged.
Tightening torque
98 to 118
10.0 to 12.0
72.3 to 86.8 ft-lbs
Mower blade screw
(1)
Mower Blade Screw
(5)
Spindle Holder
(2)
Shim
(6)
Dust Cover
(3)
Cap Washer
(4)
Mower Blade
A:
Loosen
0000009601E
Gear Box and Mower Belt
1. Remove the left and right belt covers from the mower deck.
2. Disconnect the universal joint (4) from the gear box (1).
3. Clean around the gear box (1).
4. Remove the mower belt (2) from the tension pulley (3).
5. Remove the gear box mounting screws (5) and gear box
bracket mounting screws and nuts (6).
6. Remove the gear box (1) and mower belt (2).
Gear box mounting
screw
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5 ft-lbs
Gear box bracket
mounting screw and nut
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2 ft-lbs
Tightening torque
(1)
Gear Box
(5)
Gear Box Mounting Screw
(2)
Mower Belt
(6)
Gear Box Bracket Mounting
(3)
Tension Pulley
(4)
Universal Joint
Screw and Nut
0000009602E
7-S8
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
Disassembling Gear Box
1. Unscrew the drain plug (10), and drain the gear box oil.
2. Unscrew the pulley mounting screw (1), and remove the pulley
(3).
3. Remove the case cover (15).
4. Remove the shim (14) and 18T spiral gear (12) with ball
bearing (13).
5. Remove the 17T spiral gear (16) and shim (17).
6. Remove the oil seal (22) and internal snap ring (21).
7. Draw out the input shaft (19) with two ball bearing (18), (20).
8. Remove the oil seal (5) and internal snap ring (6).
9. Draw out the output shaft (2) with the ball bearing (7).
10. Remove two external snap rings (4), (8) on the output shaft (2)
to remove the ball bearing (7).
(When reassembling)
A Replace the oil seals (5), (22) with new ones.
A Apply grease to the splines of input shaft and of output shaft.
A Use the specified gear box oil.
A Refer to "LUBRICANTS, FUEL AND COOLANT". (See
page G-8.)
0.33 L
0.35 U.S.qts
0.29 Imp.qts
Gear box oil capacity
Tightening torque
Pulley mounting screw
77.5 to 90.2
7.9 to 9.2
57.2 to 66.5 ft-lbs
(1)
Pulley Mounting Screw
(12)
(2)
Output Shaft
(13)
Ball Bearing
(3)
Pulley
(14)
Shim
(4)
External Snap Ring
(15)
Case Cover
(5)
Oil Seal
(16)
17T Spiral Gear
(6)
Internal Snap Ring
(17)
Shim
(7)
Ball Bearing
(18)
Ball Bearing
(8)
External Snap Ring
(19)
Input Shaft
Ball Bearing
(9)
18T Spiral Gear
Case
(20)
(10)
Drain Plug
(21)
Internal Snap Ring
(11)
O-ring
(22)
Oil Seal
0000009603E
7-S9
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
Disassembling Pulley Holder
1. Remove the grease nipple (12).
2. Unscrew the pulley mounting nut (11), and remove the pulley
(10).
3. Tap out the blade shaft (1).
4. Remove the pulley holder (6) from the mower deck.
5. Remove the oil seal (2), (9).
6. Remove the ball bearings (3), (7) and collar (4).
Pulley mounting nut
103 to 118
10.5 to 12.0
76.0 to 87.0 ft-lbs
Pulley holder mounting
screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2 ft-lbs
Tightening torque
(1)
Blade Shaft
(7)
(2)
Oil Seal
(8)
Ball Bearing
Pulley Holder Mounting Nut
(3)
Ball Bearing
(9)
Oil Seal
(4)
Collar
(10)
Pulley
(5)
Pulley Holder Mounting Screw
(11)
Pulley Mounting Nut
(6)
Pulley Holder
(12)
Grease Nipple
0000009604E
7-S10
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
(2) Mower Lift Linkage
(1)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Screw
(2)
Gas Spring Mounting Nut
(3)
Lock Nut
(4)
Rear Link LH
(5)
Clevis Pin
(6)
Lift Link LH
(7)
Rue Ring
(8)
Rue Ring
(9)
Gas Spring Mounting Nut
(10)
Gas Spring
(11)
Rue Ring
(12)
Rue Ring
(13)
Clevis Pin
(14)
Lift Link RH
(15)
Lift Link
(16)
Cotter Pin
(17)
Rear Link RH
(18)
Lock Nut
(19)
Screw
Dismount the mower. (See page 7-S6.)
Remove the fender. (See page 2-S12.)
Set the mower lift lever to "LIFT" position.
Unscrew the gas spring mounting nuts (2), (9), and then
remove the gas spring (10).
Remove the screws (1), (19) and lock nuts (2), (18), and pull
out the rue rings (7), (11).
Remove the rear link LH (4) and RH (17).
Pull out the rue rings (7), (12) and remove the clevis pins (5),
(13).
Remove the lift link LH (6) and RH (14).
Pull out the cotter pin (16), and remove the lift link (15) from
the mower lift lever.
0000009605E
7-S11
KiSC issued 04, 2006 A
GR1600EC, WSM
MOWER
[4] SERVICING
(1) Gear Box
Backlash between 17T Spiral Gear and 18T Spiral Gear
1. Remove the 18T spiral gear (6) from gear box.
2. Stick the strip of fuse the 18T spiral gear (6) with grease.
3. Reassemble the gear box.
4. Turn the input shaft (1).
5. Take out the fuses, and measure the thickness of fuses with
an outside micrometer. (Backlash equal thickness of fuse)
6. If the backlash exceeds the allowable limit, adjust with shims
(2), (5).
Backlash between 17T
spiral gear and 18T
spiral gear
Factory spec.
0.13 to 0.25 mm
0.0051 to 0.0098 in.
Allowable limit
0.40 mm
0.0157 in.
(Reference)
A Thickness of adjusting shims
for 17T spiral gear (2) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
for 18T spiral gear (5) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
(1)
Input Shaft
(4)
Output Shaft
(2)
Shim (for 17T Spiral Gear)
(5)
Shim (for 18T Spiral Gear)
(3)
17T Spiral Gear
(6)
18T Spiral Gear
0000009606E
7-S12
KiSC issued 04, 2006 A
EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX
: (81)72-245-2484
E-mail : ksos-pub@kubota.co.jp
KUBOTA Corporation
Printed in Japan 2006. 03, S, EI, EI, e
2005. 02, S, EI, EI, e
Code No.9Y011-15402