Kubota GR1600EC Workshop Manual

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.

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KiSC issued 04, 2006 A

1

GR1600EC, WSM

2

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

KiSC issued 04, 2006 A

GR1600EC, WSM

3

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

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.

4

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KiSC issued 04, 2006 A

GR1600EC, WSM SAFETY INSTRUCTIONS

5

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KiSC issued 04, 2006 A

GR1600EC, WSM SAFETY INSTRUCTIONS

6

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KiSC issued 04, 2006 A

GR1600EC, WSM

SPECIFICATIONS

SPECIFICATIONS

Engine

Model

Maker

Model

Type

Number of cylinders

Bore and stroke

Total displacement

Engine gross power (DIN)

Rated revolution

Battery

Starting system

Lubrication system

Cooling system

Fuel

Capacities

Dimensions

Fuel tank

Engine crankcase (with filter)

Engine coolant (with recovery tank)

Transmission case

Overall length (with grass catcher)

Overall width

Overall height

Wheel base

Tread

Front

Rear

Weight (without mower and grass catcher)

Tires

Front

Rear

Traveling system

Steering

Transmission

Brake

Differential

Traveling speed

Forward

Reverse

PTO system

Clutch

PTO brake

GR1600EC

KUBOTA

Z482-E2-GX

Indirect injection. Vertical, water-cooled, 4-cycle diesel

2

67 x 68 mm (2.64 x 2.68 in.)

479 (29.9 cu.in.)

10.0 kW (13.4 HP)

53.3 r/s [3200 (rpm)]

51R (12 V, 450CCA)

Cell starter (with glow plug)

Forced lubrication by trochoidal pump

Pressurized radiator, forced circulation with water pump

Diesel fuel No.2-D [above -10 (14 )],

Diesel fuel No.1-D [below -10 (14 )]

18 L (4.8 U.S.gals, 4.0 lmp.gals)

1.2 L (1.27 U.S.qts., 1.06 lmp.qts.)

2.15 L (2.27 U.S.qts., 1.89 lmp.qts.)

2.7 L (0.71 U.S.gals., 0.59 lmp.gals.)

2460 mm (96.9 in.)

1110 mm (43.7 in.)

1190 mm (46.9 in.)

1280 mm (50.4 in.)

750 mm (29.5 in.)

800 mm (31.5 in.)

310 kg (684 lbs)

15 x 6.00 - 6, 4PR

20 x 10.00 - 8, 4PR

Manual (Sector gear type)

Hydrostatic transmission

Internal expanding brake

Bevel gear

0.0 to 10.0 km/h (0.0 to 6.2 mph)

0.0 to 5.0 km/h (0.0 to 3.1 mph)

Mechanical wet multi discs

Wet multi discs

NOTE: *Manufacture's estimate

The company reserves the right to change the specifications without notice.

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KiSC issued 04, 2006 A

7

GR1600EC, WSM SPECIFICATIONS

Mower

Model

Cutting width

Cutting height

Adjustment of cutting height

Mounting method

Weight (Approx.)

Dimensions

Total length

Total width

Total height

Discharge direction

Gear box oil

Grass catcher

Model

Container capacity

Weight (Approx.)

NOTE: *Manufacture's estimate

The company reserves the right to change the specifications without notice.

RCK42GR

1067 mm (42.0 in.)

25 to 102 mm (1 to 4 in.)

Dual gauge

Quick joint, Parallel linkage

75 kg (165 lbs)

965 mm (38.0 in.)

1110 mm (43.7 in.)

295 mm (11.6 in.)

Rear

0.33 L (0.35 U.S.qts, 0.29 Imp.qts)

GCK350GR

350 L (92.5 U.S.gals, 77.0 Imp.gals)

40 kg (88.2 lbs)

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8

KiSC issued 04, 2006 A

GR1600EC, WSM

DIMENSIONS

DIMENSIONS

9

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KiSC issued 04, 2006 A

G

GENERAL

KiSC issued 04, 2006 A

CONTENTS

1. IDENTIFICATION ................................................................................................................G-1

2. GENERAL PRECAUTIONS................................................................................................G-2

3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING......................G-3

[1] WIRING..............................................................................................................................G-3

[2] BATTERY ..........................................................................................................................G-5

[3] FUSE .................................................................................................................................G-5

[4] CONNECTOR ....................................................................................................................G-5

[5] HANDLING OF CIRCUIT TESTER.................................................................................G-7

4. LUBRICANTS, FUEL AND COOLANT .............................................................................G-8

5. TIGHTENING TORQUES ...................................................................................................G-9

[1] GENERAL USE SCREWS, BOLTS AND NUTS ..........................................................G-9

[2] METRIC SCREWS, BOLTS AND NUTS .......................................................................G-9

[3] 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

1. IDENTIFICATION

GENERAL

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

(2) Engine Serial Number

(3) Mower 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

(2) Force

(3) Sharp Edge

(4) Axial Force

(5) Rotating Movement

(A) External Snap Ring

(B) Internal Snap Ring

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

(Securely Tighten)

(2) Incorrect

(Loosening Leads to Faulty

Contact)

0000000614E

A Do not let wiring contact dangerous part.

(1) Dangerous Part

(2) Wiring (Incorrect)

(3) Wiring (Correct)

(4) Dangerous Part

0000000615E

A Securely insert grommet.

(1) Grommet (A) Correct

(B) Incorrect

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KiSC issued 04, 2006 A

G-3

GR1600EC, WSM GENERAL

A

Securely clamp, being careful not to damage wiring.

(1) Clamp

*Wind Clamp Spirally

(2) Wire Harness

(3) Clamp

(4) Welding Dent

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

(2) Clamp

(A) Correct

(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

[2] BATTERY

[3] FUSE

[4] CONNECTOR

GENERAL

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

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

A For connector with lock, push lock to separate.

(A) Push

0000000623E

KiSC issued 04, 2006 A

G-5

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

(2) Deformed Terminal

(3) Sandpaper

(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

4. LUBRICANTS, FUEL AND COOLANT

GENERAL

No.

1

2

3

4

5

Fuel tank

Place

Cooling system with recovery tank

Engine crankcase

Transmission case

Mower gear box

No.

6

Place

Engine transmission universal joint

7 King pin

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

[Mower]

16 Spindle shafts

17 Tension arm

18 Mower universal joint

Capacity

18 L

4.8 U.S.gals.

4.0 lmp.gals.

2.15 L

2.27 U.S.qts.

1.89 lmp.qts.

Lubricants, fuel and coolant

No. 2-D diesel fuel

No. 1-D diesel fuel if temperature is below

-10 (14 )

Fresh clean water with anti-freeze

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

2.7 L

0.71 U.S.gals.

0.59 lmp.gals.

0.33 L

0.35 U.S.qts.

0.29 lmp.qts.

KUBOTA UDT or SUPER UDT fluid*

SAE90 gear oil

(API service classification : more than GL-3)

Greasing

No. of greasing points Capacity Type of grease

1

2

2

1

1

Until grease overflows

Moderate amount

Until grease overflows

Moderate amount

SAE multi-purpose type grease

Engine oil

SAE multi-purpose type grease

Engine oil

*KUBOTA original transmission hydraulic fluid.

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KiSC issued 04, 2006 A

G-8

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 7T 9T

SS400, S20C S43C, S48C SCr435, SCM435 Material of bolt

Material of opponent part

Unit

Diameter

Ordinariness ft-lbs

Aluminum ft-lbs

Ordinariness ft-lbs

Aluminum ft-lbs

Ordinariness ft-lbs

M6

(6 mm, 0.24 in.)

M8

(8 mm, 0.31 in.)

M10

(10 mm, 0.39 in.)

M12

(12 mm, 0.47 in.)

M14

(14 mm, 0.55 in.)

M16

(16 mm, 0.63 in.)

M18

(18 mm, 0.71 in.)

M20

(20 mm, 0.79 in.)

246 to

284

334 to

392

108 to

125

167 to

191

39.3 to

45.1

62.8 to

72.5

7.85 to

9.31

17.7 to

20.5

25.0 to

29.0

34.0 to

40.0

11.0 to

12.8

17.0 to

19.5

4.0 to

4.6

6.4 to

7.4

0.80 to

0.95

1.8 to

2.1

181 to

209

246 to

289

79.6 to

92.5

123 to

141

29.0 to

33.2

46.3 to

53.5

5.79 to

6.87

13.1 to

15.1

7.85 to

8.82

16.7 to

19.6

31.4 to

34.3

0.80 to

0.90

1.7 to

2.0

3.2 to

3.5

5.79 to

6.50

12.3 to

14.4

23.2 to

25.3

275 to

318

368 to

431

124 to

147

197 to

225

48.1 to

55.8

77.5 to

90.2

9.81 to

11.2

23.6 to

27.4

28.0 to

32.5

37.5 to

44.0

12.6 to

15.0

20.0 to

23.0

4.9 to

5.7

7.9 to

9.2

1.00 to

1.15

2.4 to

2.8

203 to

235

272 to

318

91.2 to

108

145 to

166

35.5 to

41.2

57.2 to

66.5

7.24 to

8.31

17.4 to

20.2

39.3 to

44.1

62.8 to

72.5

7.85 to

8.82

17.7 to

20.5

4.0 to

4.5

6.4 to

7.4

0.80 to

0.90

1.8 to

2.1

29.0 to

32.5

46.3 to

53.5

5.79 to

6.50

13.1 to

15.1

344 to

402

491 to

568

167 to

196

260 to

304

60.9 to

70.6

103 to

117

12.3 to

14.2

29.5 to

34.3

35.0 to

41.0

50.0 to

58.0

17.0 to

20.0

26.5 to

31.0

6.2 to

7.2

10.5 to

12.0

1.25 to

1.45

3.0 to

3.5

254 to

296

362 to

419

123 to

144

192 to

224

44.9 to

52.0

76.0 to

86.7

9.05 to

10.4

21.7 to

25.3

0000001412E

[2] METRIC SCREWS, BOLTS AND NUTS

Grade

Unit

Nominal

Diameter

M8

M10

M12

M14

M16

23.6 to 27.4

48.1 to 55.8

77.5 to 90.1

124.0 to 147.0

196.0 to 225.0

Property class 8.8

2.4 to 2.8

4.9 to 5.7

7.9 to 9.2

12.6 to 15.0

20.0 to 23.0

ft-lbs

17.4 to 20.2

35.5 to 41.2

57.2 to 66.5

91.2 to 108.0

145.0 to 166.0

29.4 to 34.3

60.8 to 70.5

103.0 to 117.0

167.0 to 196.0

260.0 to 303.0

Property class 10.9

3.0 to 3.5

6.2 to 7.2

10.5 to 12.0

17.0 to 20.0

26.5 to 31.0

ft-lbs

21.7 to 25.3

44.9 to 52.1

76.0 to 86.8

123.0 to 144.0

192.0 to 224.0

0000001413E

KiSC issued 04, 2006 A

G-9

GR1600EC, WSM GENERAL

[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR

UNF THREADS

SAE GR.5

Grade

Unit

Norminal

Diameter

5/16

3/8

1/2

9/16

5/8

23.1 to 27.8

47.5 to 57.0

108.5 to 130.2

149.2 to 179.0

203.4 to 244.1

2.35 to 2.84

4.84 to 5.82

11.07 to 13.29

15.22 to 18.27

20.75 to 24.91

ft-lbs

17.0 to 20.5

35.0 to 42.0

80.0 to 96.0

110.0 to 132.0

150.0 to 180.0

32.5 to 39.3

61.0 to 73.2

149.2 to 179.0

217.0 to 260.4

298.3 to 358.0

SAE GR.8

3.31 to 4.01

6.22 to 7.47

15.22 to 18.27

22.14 to 26.57

30.44 to 36.53

ft-lbs

24.0 to 29.0

45.0 to 54.0

110.0 to 132.0

160.0 to 192.0

220.0 to 264.0

0000001414E

[4] PLUGS

Material of opponent part

Shape Size Ordinariness Aluminum

Tapered screw

Straight screw

R1/8

R1/4

R3/8

R1/2

G1/4

G3/8

G1/2

12.7 to 21.6

24.5 to 44.1

49.0 to 88.3

58.8 to 107.9

24.5 to 34.3

61.8 to 82.4

49.0 to 88.3

1.3 to 2.2

2.5 to 4.5

5.0 to 9.0

6.0 to 11.0

2.5 to 3.5

6.3 to 8.4

5.0 to 9.0

ft-lbs

9.4 to 15.9

18.1 to 32.5

36.2 to 65.1

43.4 to 79.6

18.1 to 25.3

45.6 to 60.8

36.2 to 65.1

12.7 to 19.6

24.5 to 34.3

49.0 to 58.8

58.8 to 78.5

1.3 to 2.0

2.5 to 3.5

5.0 to 6.0

6.0 to 8.0

ft-lbs

9.4 to 15.4

18.1 to 25.4

36.2 to 43.4

43.4 to 57.9

0000001666E

G-10

KiSC issued 04, 2006 A

GR1600EC, WSM

6. MAINTENANCE CHECK LIST

GENERAL

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)

No.

Period

Item

50 100 150 200 250 300 350 400 450 500 550 600

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Engine oil

Engine oil filter

Transmission fluid

Transmission oil filter

Transmission strainer

Front axle pivot

Safety device

Oiling

Greasing

Mower gear box oil

Air cleaner element

Battery condition

Brake

Fan drive belt tension

Fuel filter element

Change

Replace

Change

Replace

Clean

Adjust

Check

-

-

Check

Change

Clean

Replace

Check

Adjust

Adjust

Check

Replace

After since

Important

Reference page every 1 year every

50 hr every

100 hr every

100 hr every

50 hr every

50 hr every

150 hr every

50 hr every

100 hr every

400 hr every

200 hr every

200 hr every

50 hr every

50 hr every

100 hr every

200 hr every

200 hr every

200 hr

*1

G-25

G-28

G-29

G-30

G-30

G-31

G-19

G-21

G-20

G-20

G-27

G-20

G-31

G-23

G-26

G-27

G-26

G-31

KiSC issued 04, 2006 A

G-11

GR1600EC, WSM GENERAL

No.

Period

Item

Indication on hour meter (Hr)

50 100 150 200 250 300 350 400 450 500 550 600

16

17

18

19

20

21

22

23

24

25

Fuel line

Radiator hose and clamp

Radiator core

Radiator

Coolant

Mower gear box oil seal

Fuel system

Fuse

Blade

Mower belt

Check

Replace

Check

Replace

Check

Clean

Change

Replace

Bleed

Replace

Replace

Replace

After since

Important

Reference page every

200 hr every 1 year every 1 year every 2 years every

100 hr every 2 years every

200 hr every 2 years

G-26

G-34

G-30

G-34

G-30

G-32

G-32

G-34

Service as required

G-37

G-35

G-36

G-37

0000009542E

G-12

KiSC issued 04, 2006 A

GR1600EC, WSM

7. CHECK AND MAINTENANCE

GENERAL

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

KiSC issued 04, 2006 A

G-13

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

(2) Oil Level Dipstick

A : Upper Level

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.

Fuel tank capacity

18 L

4.8 U.S.gals.

4.0 Imp.gals.

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

Flash point

Water and

Sediment, volume %

Carbon Residue on, 10 percent

Residuum %

Ash, weight %

Min

52

Max

0.05

Max

0.35

Max

0.01

Min

282

Distillation

Point

Max

338

Sulfur, weight

Max

0.50

(1) Fuel Cap

Kinematics Viscosity cSt or /S at 40

Saybolt Viscosity, SUS at 100

Min

1.9

Max

4.1

Min

32.6

Max

40.1

Copper strip Corrosion

Max

No.3

Cetane Number

Min

40

0000009549E

KiSC issued 04, 2006 A

G-15

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.

Tire Sizes

Recommended Inflation

Pressure

Front

Rear

15 x 6.0-6, 4PR

20 x 10.00-8, 4PR

(2.0

200 kPa

, 29 psi)

(1.4

140 kPa

, 20 psi)

(1) Ground (A) 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

KiSC issued 04, 2006 A

G-17

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

(2) Overflow Pipe

(3) Recovery Tank Cap

(4) Recovery Tank

A : FULL

B : LOW

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

[2] CHECK POINTS OF EVERY 50 HOURS

Checking Safety Device

GENERAL

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

KiSC issued 04, 2006 A

G-19

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

Universal Joint

(2) King Pin (LH, RH)

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

(2) Speed Control Shaft (RH)

(3) Speed Control Shaft (LH)

(4) Seat Adjuster

(5) Throttle Cable

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

(2) Around Pin

(3) Pivot of Mower Link

(4) Pivot of Lift Arm

(5) Front Link

(6) Grass Catcher Hinge

(7) PTO Lever (Fulcrum)

(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

(2) Highest Level

(3) Electrolyte

(4) Vent Well

(5) Separator

0000009562E

KiSC issued 04, 2006 A

G-24

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

12.4

12.2

12.0

11.8

100 % (Full charge)

75 %

50 %

25 %

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

(2) Highest Level

(3) Electrolyte

(4) Vent Well

(5) Separator

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

1.2 L

1.27 U.S.qts

1.06 Imp.qts

(1) Drain Plug

0000009564E

KiSC issued 04, 2006 A

G-25

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) Factory spec.

15 to 25 mm

0.59 to 0.98 in.

(1) Brake Pedal

(2) Lock Nut

(3) Nut

(4) Spring

0000009566E

KiSC issued 04, 2006 A

G-26

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) Factory spec.

7 to 9 mm

0.28 to 0.35 in.

(1) 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).

Mower gear box oil capacity

0.33 L

0.35 U.S.qts

0.29 Imp.qts

(1) Oil Filler Plug (2) Drain Plug

0000009568E

G-27

KiSC issued 04, 2006 A

GR1600EC, WSM

[5] CHECK POINTS OF EVERY 200 HOURS

Replacing Engine Oil Filter Cartridge

GENERAL

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

2.7 L

0.71 U.S.gals

0.59 Imp.gals

(1) Suction Pipe

(2) Bolt

(3) O-ring (Small)

(4) O-ring (Large)

(5) Strainer

(6) Transmission Oil Filter

Cartridge

(7) Dipstick

(A) 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

(2) O-ring (Small)

(3) O-ring (Large)

(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

Cartridge

(2) Screw

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

KiSC issued 04, 2006 A

G-30

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

77.4 to 90.2

7.89 to 9.20

57.1 to 66.5 ft-lbs

Clearance between front axle frame and anti-vibration bolt (A)

Factory spec.

(1) Center Pin Locking Nut

(2) Front Axle Frame

(3) Anti-vibration Bolt

0.3 to 0.5 mm

0.012 to 0.020 in.

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

KiSC issued 04, 2006 A

G-31

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

(2) Recovery Tank

(3) Recovery Tank Cap

A: FULL

B: LOW

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%.

Freezing Point Boiling Point*

Vol %

Anti-freeze

( ) ( )

40

50

-24 (-12)

-37 (-34)

106 (222)

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 G-

26.)

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

KiSC issued 04, 2006 A

G-34

GR1600EC, WSM

[9] OTHERS

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

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) Capacity (A) Protected circuit

(1)

(2)

E/G STOP (a)

IG/M (b)

OPC (c)

15

10

3

Slow blow fuse

40

Engine stop timer relay

Fuel pump, head light, etc.

OPC

Check circuit against wrong battery connection

(1) Fuse Location (2) 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 12V - 24 W

(B) Replacement of the indicator light bulb

1. Open the hood.

2. Turn bad bulb socket to the left. And remove it.

3. Pull bulb from the socket.

4. Push new bulb into the socket.

5. Install the socket.

6. Close the hood.

Indicator light bulb

14.0 rated voltage / 0.27

AMP/2 MSCP

0000009584E

KiSC issued 04, 2006 A

G-35

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

(2) Blade Bolt

(3) Spindle Holder

(4) Blade

(5) 2-cup Washer

(6) Shim

(7) Spindle Guard

(a) New Blade

(b) Worn Blade

(c) Cracked Blade

A : Loosen

B : 30 mm (1.18 in.)

0000009585E

KiSC issued 04, 2006 A

G-36

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 Bracket mounting screw

39.2 to 44.1

4.0 to 4.5

8.8 to 9.9 ft-lbs

(1) Bolt

(2) Bolt, Nut

(3) Belt

(4) Left Hand Shield

(5) Right Hand Shield

(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

KiSC issued 04, 2006 A

G-37

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

(2) L Joint

(3) Adaptor A

(4) Adaptor B

(5) Adaptor C

(6) Adaptor E

(7) Adaptor F

(8) Adaptor G

(9) Adaptor H

(10) Adaptor I

(11) Adaptor J

0000000680E

KiSC issued 04, 2006 A

G-38

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

(2) L Joint

(3) Adaptor K

(4) Adaptor L

(5) Adaptor M

0000001398E

Oil Pressure Tester

Code No : 07916-32032

Application : Use to measure lubricating oil pressure.

(1) Gauge

(2) Cable

(3) Threaded Joint

(4) Adaptor 1

(5) Adaptor 2

(6) Adaptor 3

(7) Adaptor 4

(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)

, 4267

P

Q

N

O

L

M

J

K

H

I

F

G

D

E

B

C

V a b

T

U

R

S

Copper gasket

Flange (Material : Steel)

Hex. nut 27 mm (1.06 in.) across the plat

Retaining nut

PF 1/2

5 mm (0.20 in.)

17 mm dia. (0.67 in.dia.)

8 mm dia. (0.31 in.dia.)

1.0 mm (0.039 in.)

17 mm dia. (0.67 in.dia.)

6.10 to 6.20 mm dia. (0.2402 to 0.2441 in.dia.)

8 mm (0.31 in.)

4 mm (0.16 in.)

11.97 to11.99 mm dia. (0.4713 to 0.4721 in.dia.)

PF 1/2

23 mm (0.91 in.)

17 mm (0.67 in.)

4 mm (0.16 in.)

12.00 to 12.02 mm dia. (0.4724 to 0.4732 in.dia.)

100 mm (3.94 in.)

M12 x P1.5

Adhesive application

Fillet welding on the enter circumference

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.)

J

K

L

C1

C2

C0.3

H

I

F

G

D

E

B

C

9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.)

5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.)

220 mm (8.66 in.)

80 mm (3.15 in.)

40 mm (1.58 in.)

25 mm dia. (0.98 in. dia.)

5 mm (0.197 in.)

6.0 to 6.1 mm dia. (0.236 to 0.240 in. dia.)

18 mm dia. (0.71 in. dia.)

10.6 to 10.7 mm dia. (0.417 to 0.421 in. dia.)

6.9 to 7.1 mm dia. (0.272 to 0.280 in. dia.)

Chamfer 1.0 mm (0.039 in.)

Chamfer 2.0 mm (0.079 in.)

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.)

F

C1

C2

C0.3

a b

D

E

B

C

20 mm (0.79 in.)

100 mm (3.94 in.)

19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)

21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)

25 mm dia. (0.98 in. dia.)

Chamfer 1.0 mm (0.039 in.)

Chamfer 2.0 mm (0.079 in.)

Chamfer 0.3 mm (0.012 in.)

F

C1

C2

C

D

E

C0.3

a b

2. For idle gear bushing

A 150 mm (5.91 in.)

B 23 mm (0.91 in.)

100 mm (3.94 in.)

19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)

21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)

25 mm dia. (0.98 in. dia.)

Chamfer 1.0 mm (0.039 in.)

Chamfer 2.0 mm (0.079 in.)

Chamfer 0.3 mm (0.012 in.)

0000003194E

Flywheel Stopper

Application : Use to loosen and tighten the flywheel screw.

A 200 mm (7.87 in.)

B

C

30 mm (1.18 in.)

20 mm (0.79 in.)

D

E

F

15 mm (0.59 in.)

8 mm (0.31 in.)

10 mm dia. (0.39 in. dia.)

0000000818E

KiSC issued 04, 2006 A

G-43

GR1600EC, WSM GENERAL

Crankshaft Bearing 1 Replacing Tool

Application : Use to press out and press fit the crankshaft bearing 1.

[Press Out]

G

H

E

F

C

D

A

B

135 mm (5.31 in.)

72 mm (2.83 in.)

40 mm radius (1.57 in. radius)

10 mm (0.39 in.)

22 mm (0.87 in.)

20 mm dia. (0.79 in. dia.)

47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)

43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

[Press Fit]

G

H

E

F

C

D

A

B

130 mm (5.12 in.)

72 mm (2.83 in.)

40 mm radius (1.57 in. radius)

9 mm (0.35 in.)

24 mm (0.95 in.)

20 mm dia. (0.79 in. dia.)

68 mm dia. (2.68 in. dia.)

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

(07916-50401)

(4) Threaded Joint

(07916-50341)

(5) Adaptor B (M18 x P1.5)

(07916-50361)

(1) Hydrostatic Transmission

Tester (07916-52040)

(2) Gasket (04714-00200)

(3) Connector 3 (07916-51331)

(4) Vacuum Gauge

(07916-51331)

(5) Pressure Gauge (Low

Pressure) (07916-51301)

(6) Pressure Gauge (High

Pressure) (in Relief Valve Set

Pressure Tester)

(07916-50321)

(7) HN Tube (in Relief Valve Set

Pressure Tester)

(07916-50331)

(6) Adaptor C (PS3/8)

(07916-50371)

(7) Adaptor D (PT1/8)

(07916-50381)

(8) Adaptor E (PS3/8)

(07916-50392)

(9) 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.

(8) Valve Seat Driver

(07916-60841)

(9) Connector 1 (07916-60811)

(10) Connector 2 (07916-60821)

(11) Long Connector

(07916-60831)

(12) Adaptor 1 (07916-52621)

(13) Adaptor 2 with Collar

(07916-52632)

(14) Adaptor 3 with Collar

(07916-52642)

(15) HST Adaptor Set

(07916-53072)

0000000820E

G-45

KiSC issued 04, 2006 A

GR1600EC, WSM

9. TIRES

[1] TIRE PRESSURE

GENERAL

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.

Front

Rear

Tire sizes

15 x 6.00-6, 4PR

20 x 10.00-8, 4PR

Inflation pressure

200 kPa (2.0 , 29 psi)

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.

Front

15 x 6.00 - 6, 4PR

Rear

20 x 10.00 - 8, 4PR

A: 750 mm (29.5 in.) B: 800 mm (31.5 in.)

G-46

0000009546E

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

250 kg (551 lbs)

Rear axle Wr

450 kg (992 lbs)

Total gross weight

600 kg (1323 lbs)

0000009547E

G-47

KiSC issued 04, 2006 A

1

ENGINE

KiSC issued 04, 2006 A

CONTENTS

1. ENGINE BODY .................................................................................................................1-M1

[1] HALF-FLOATING HEAD COVER ..................................................................................1-M1

[2] CLOSED BREATHER.....................................................................................................1-M1

2. LUBRICATING SYSTEM ..................................................................................................1-M2

3. COOLING SYSTEM .........................................................................................................1-M3

4. FUEL SYSTEM .................................................................................................................1-M4

[1] FUEL LINE ......................................................................................................................1-M4

KiSC issued 04, 2006 A

GR1600EC, WSM

1. ENGINE BODY

[1] HALF-FLOATING HEAD COVER

ENGINE

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

(2) Cylinder Head Cover

(3) Breather Valve

(4) Oil Shield

(5) Rubber Packing

0000004857E

1-M1

KiSC issued 04, 2006 A

GR1600EC, WSM

2. LUBRICATING SYSTEM

ENGINE

(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) Relief Valve

(10) 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

KiSC issued 04, 2006 A

1-M2

GR1600EC, WSM

3. COOLING SYSTEM

(1) Radiator

(2) Water Pump

(3) Cooling Fan

(4) Thermostat

(5) Cylinder Head

(6) Cylinder Block

ENGINE

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

KiSC issued 04, 2006 A

1-M3

GR1600EC, WSM

4. FUEL SYSTEM

[1] FUEL LINE

ENGINE

(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. TROUBLESHOOTING....................................................................................................... 1-S1

2. SERVICING SPECIFICATIONS ....................................................................................... 1-S4

3. TIGHTENING TORQUES ................................................................................................. 1-S9

4. CHECKING, DISASSEMBLING AND SERVICING ...................................................... 1-S10

[1] 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

1. TROUBLESHOOTING

ENGINE

Symptom Probable Cause

A Improper valve timing

Solution

Correct or replace timing gear

Reference

Page

Engine Does Not Start A No fuel

A Air in the fuel system

A Water in the fuel system

Replenish fuel

Bleed

G-8

G-37

A Fuel pipe clogged

A Fuel filter clogged

A Excessively high viscosity of fuel or engine oil at low temperature

A Fuel with low cetane number

Clean

Change

Use specified fuel or engine oil

Use specified fuel

A Fuel leak due to loose injection pipe retaining nut

A Incorrect injection timing

A Fuel camshaft worn

A Injection nozzle clogged

A Injection pump malfunctioning

A Seizure of crankshaft, camshaft, piston, cylinder or bearing

A

Compression leak from cylinder

Change fuel and repair or replace fuel system

Tighten retaining nut

Adjust

Replace

Repair or replace

Replace

Repair or replace

G-26, 34

G-26

G-26, 31

G-8

G-8

1-S24

1-S16

1-S38

1-S27

Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

1-S10

1-S29

(Starter Does Not

Run)

A Piston ring and cylinder worn

A

Excessive valve clearance

A

Battery discharged

A

Starter malfunctioning

A

Main switch malfunctioning

A

Safety switches malfunctioning

A

Wiring disconnected

Replace

Adjust

Charge

Repair or replace

Replace

Replace

Connect

1-S49, 55

1-S12

G-24

6-S20

6-S8, 9

6-S12

KiSC issued 04, 2006 A

1-S1

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

A Air cleaner clogged

A Fuel leak due to loose injection pipe retaining nut

A Injection pump malfunctioning

A Incorrect nozzle injection pressure

A Injection nozzle stuck or clogged

A Governor malfunctioning

A Excessive engine oil

Replace

Clean or replace

Tighten retaining nut

Replace

Adjust

Repair or replace

Repair

G-26, 31

G-20

1-S24

1-S27

1-S19

1-S38

Reduce to specified level

G-8, 14

A Piston ring and cylinder worn or stuck

A Incorrect injection timing

A Deficient compression

A Overload

A Low grade fuel used

A Fuel filter clogged

A Air cleaner clogged

A Deficient nozzle injection

Repair or replace

Adjust

Adjust top clearance

Reduce the load

Use specified fuel

Replace

Clean or replace

Repair or replace nozzle

A Incorrect injection timing

A Engine's moving parts seem to be seizing

A Uneven fuel injection

Adjust

Repair or replace

Replace injection pump

A Deficient nozzle injection Repair or replace nozzle

A Compression leak Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

A Piston ring's gap facing the same direction Shift ring gap direction

A Oil ring worn or stuck

A Piston ring groove worn

A Injection pump's plunger worn

Replace

Replace piston

A Valve stem and valve guide worn Replace

A Oil leaking due to defective seals or packing Replace

Replace injection pump

A Deficient nozzle injection Repair or replace nozzle

A Injection pump broken Replace

1-S49, 55

1-S16

1-S11

G-8

G-31

G-20

1-S38

1-S16

1-S27

1-S38

1-S10

1-S32

1-S33

1-S33

1-S26, 40

1-S27

1-S38

1-S27

KiSC issued 04, 2006 A

1-S2

GR1600EC, WSM ENGINE

Symptom

Water Mixed into

Lubricant Oil

Low Oil Pressure

High Oil Pressure

Engine Overheated

Probable Cause Solution

A Head gasket defective

A Cylinder block or cylinder head flawed

A Engine oil insufficient

A Oil strainer clogged

Replace

Replace

Replenish

Clean

A Oil filter clogged

A Relief valve stuck with dirt

Replace

Clean

A Relief valve spring weaken or broken Replace

A Excessive oil clearance of crankshaft bearing Replace

A Excessive oil clearance of crankpin bearing

A Excessive oil clearance of rocker arm

A Oil passage clogged

A Different type of oil

Replace

Replace

Clean

Use specified type of oil

A Oil pump defective

A Different type of oil

Repair or replace

Use specified type of oil

A Relief valve defective

A Engine oil insufficient

Replace

Replenish

A Fan belt broken or tensioned improperly

A Coolant insufficient

Replace or adjust

Replenish

A Radiator net and radiator fin clogged with dust Clean

A Inside of radiator corroded

A Coolant flow route corroded

A Radiator cap defective

A Radiator hose damaged

A Overload running

A

Head gasket defective

A

Incorrect injection timing

A

Unsuitable fuel used

Clean or replace

Clean or replace

Replace

Replace

Reduce the load

Replace

Adjust

Use specified fuel

Reference

Page

1-S25

G-8, 14

G-28

1-S53, 54

1-S52

1-S43

G-8

1-S30

G-8

G-8

G-27, 1-S13

G-8

G-32, 1-S23

G-30

1-S15

G-30

1-S25

1-S16

G-8

0000009504E

KiSC issued 04, 2006 A

1-S3

GR1600EC, WSM

2. SERVICING SPECIFICATIONS

ENGINE BODY

Compression Pressure

Top Clearance

Valve Clearance (Cold)

Cylinder Head Surface

Valve Recessing (Intake and Exhaust)

Valve Stem to Valve Guide

Valve Seat

Valve Face

Valve Spring

Push Rod

Item

Rocker Arm to Rocker Arm Shaft

ENGINE

Variance Among

Cylinder

Flatness

Clearance

Valve Stem

(O.D.)

Valve Guide

(I.D.)

Width

Angle

Angle

Free Length

Tilt

1-S4

Factory Specification

2.84 to 3.24 MPa

29.0 to 33.0

412 to 469 psi

Allowable Limit

2.26 MPa

23.0

327 psi

10 % or less

0.50 to 0.70 mm

0.0197 to 0.0276 in.

0.145 to 0.185 mm

0.00571 to 0.00728 in.

0.05 mm

0.0020 in.

0.30 mm

0.0118 in.

0.10 mm

0.0039 in.

-0.10 to 0.10 mm

-0.0039 to 0.0039 in.

0.030 to 0.057 mm

0.00118 to 0.00224 in.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

2.12 mm

0.0835 in.

0.785 rad

45

0.785 rad

45

31.3 to 31.8 mm

1.232 to 1.252 in.

28.4 mm

1.118 in.

1.2 mm

0.047 in.

54.9 N

5.6 kgf

12.3 lbs

Setting Load

Setting Length

Oil Clearance

Rocker Arm Shaft

(O.D.)

Rocker Arm

(I.D.)

Alignment

64.7 N

6.6 kgf

14.6 lbs

27.0 mm

1.063 in.

0.016 to 0.045 mm

0.00063 to 0.00177 in.

10.473 to 10.484 mm

0.41232 to 0.41276 in.

10.500 to 10.518 mm

0.41339 to 0.41410 in.

0.15 mm

0.0059 in.

0.25 mm

0.0098 in.

KiSC issued 04, 2006 A

GR1600EC, WSM ENGINE

Tappet to Tappet Guide

Timing Gear

Idle Gear

Camshaft

Item

Clearance

Tappet

(O.D.)

Tappet Guide Bore

(I.D.)

Idle Gear to Crank

Gear

(Backlash)

Idle Gear to Cam

Gear

(Backlash)

Idle Gear to

Injection Pump

Gear

(Backlash)

Oil Pump Drive

Gear to Crank Gear

(Backlash)

Side Clearance

Factory Specification

0.016 to 0.052 mm

0.00063 to 0.00205 in.

17.966 to 17.984 mm

0.70732 to 0.70803 in.

18.000 to 18.018 mm

0.70866 to 0.70937 in.

0.043 to 0.124 mm

0.00169 to 0.00488 in.

0.047 to 0.123 mm

0.00185 to 0.00484 in.

0.046 to 0.124 mm

0.00185 to 0.00488 in.

0.041 to 0.123 mm

0.00161 to 0.00484 in.

Side Clearance

0.20 to 0.51 mm

0.0079 to 0.0201 in.

0.15 to 0.31 mm

0.0059 to 0.0122 in.

Alignment

Camshaft Journal to Cylinder Block Bore

Idle Gear Shaft to Idle Gear Bushing

Piston Pin Bore

Cam Height

(Intake and

Exhaust)

Oil Clearance

26.88 mm

1.0583 in.

Camshaft Journal

(O.D.)

Cylinder Block Bore

(I.D.)

Oil Clearance

Idle Gear Shaft

(O.D.)

Idle Gear Bushing

(I.D.)

I.D.

0.050 to 0.091 mm

0.00197 to 0.00358 in.

32.934 to 32.950 mm

1.29661 to 1.29724 in.

33.000 to 33.025 mm

1.29921 to 1.30020 in.

0.020 to 0.084 mm

0.00079 to 0.00331 in.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

20.000 to 20.051 mm

0.78740 to 0.78941 in.

20.000 to 20.013 mm

0.78740 to 0.78791 in.

Allowable Limit

0.10 mm

0.0039 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.80 mm

0.0315 in.

0.50 mm

0.0197 in.

0.01 mm

0.0004 in.

26.83 mm

1.0563 in.

0.15 mm

0.0059 in.

0.10 mm

0.0039 in.

20.05 mm

0.7894 in.

KiSC issued 04, 2006 A

1-S5

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

Connecting Rod

Crankshaft

Oil Clearance

Piston Pin

(O.D.)

Small End Bushing

(I.D.)

Oil Clearance

Small End Bushing

(I.D.)

Top Ring

Second Ring

Oil Ring

Second Ring

(Clearance)

Oil Ring

(Clearance)

Alignment

Factory Specification

0.014 to 0.038 mm

0.00055 to 0.00150 in.

20.002 to 20.011 mm

0.78748 to 0.078783 in.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

0.015 to 0.075 mm

0.00059 to 0.00295 in.

20.026 to 20.077 mm

0.78845 to 0.79043 in.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

0.25 to 0.40 mm

0.0118 to 0.0157 in.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

0.085 to 0.115 mm

0.00335 to 0.00453 in.

0.02 to 0.06 mm

0.0008 to 0.0024 in.

Allowable Limit

0.10 mm

0.0039 in.

0.15 mm

0.0059 in.

Side Clearance

Alignment

0.15 to 0.31 mm

0.0059 to 0.0122 in.

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.05 mm

0.0020 in.

0.50 mm

0.0197 in.

0.02 mm

0.0008 in.

0.15 mm

0.0059 in.

Crankpin to Crankpin Bearing Oil Clearance

Crankpin

(O.D.)

Crankpin Bearing

(I.D.)

Crankshaft Journal to Crankshaft Bearing 1 Oil Clearance

Crankshaft Journal

(O.D.)

Crankshaft Bearing

1

(I.D.)

Crankshaft Journal to Crankshaft Bearing 2

(Flywheel Side)

Oil Clearance

Crankshaft Journal

(O.D.)

Crankshaft Bearing

2

(I.D.)

0.020 to 0.051 mm

0.00079 to 0.00201 in.

33.959 to 33.975 mm

1.33697 to 1.33760 in.

33.995 to 34.010 mm

1.33893 to 1.33898 in.

0.034 to 0.106 mm

0.00134 to 0.00417 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57417 to 1.57638 in.

0.028 to 0.051 mm

0.00110 to 0.00201 in.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.978 to 43.993 mm

1.73142 to 1.73201 in.

0.20 mm

0.0079 in.

0.20 mm

0.0079 in.

KiSC issued 04, 2006 A

1-S6

GR1600EC, WSM ENGINE

Item

Crankshaft Journal to Crankshaft Bearing 3

(Intermediate)

Oil Clearance

Cylinder Liner

Crankshaft Journal

(O.D.)

Crankshaft Bearing

3

(I.D.)

I.D.

Factory Specification

0.028 to 0.051 mm

0.00110 to 0.00201 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.978 to 39.993 mm

1.57394 to 1.57453 in.

Cylinder Liner

(Oversize)

I.D.

67.000 to 67.019 mm

2.63779 to 2.63854 in.

67.250 to 67.269 mm

2.64764 to 2.64839 in.

Allowable Limit

0.20 mm

0.0079 in.

67.169 mm

2.6445 in.

67.419 mm

2.65429 in.

0000009505E

LUBRICATING SYSTEM

Engine Oil Pressure

Oil Pump

Item

At Idle Speed

At Rated Speed

Factory Specification

More than 49 MPa

0.5

7 psi

196 to 441 MPa

2.0 to 4.5

28 to 64 psi

Inter Rotor to Outer

Rotor

(Clearance)

Outer Rotor to

Pump Body

(O.D.)

Inter Rotor to Cover

(I.D.)

0.03 to 0.14 mm

0.0012 to 0.0055 in.

0.07 to 0.15 mm

0.0028 to 0.0059 in.

0.075 to 0.135 mm

0.00295 to 0.00531 in.

Allowable Limit

147 MPa

1.5

21 psi

0000004340E

1-S7

KiSC issued 04, 2006 A

GR1600EC, WSM

COOLING SYSTEM

Fan Belt

Thermostat

Radiator Cap

Radiator

Item

ENGINE

Tension

Valve Opening

Temperature

(At Beginning)

Valve Opening

Temperature

(Opened

Completely)

Pressure Falling

TIme

Water Leakage

Test Pressure

Factory Specification

7 to 9 mm / 98 N

0.28 to 0.35 in. / 98N

(10 kgf, 22 lbs)

80.5 to 83.5

176.9 to 182.3

Allowable Limit

95

203

10 seconds or more

88 59 kPa

13 psi

No leak at specified pressure

157 kPa

1.6

23 psi

0000004343E

FUEL SYSTEM

Injection Pump

Pump Element

Delivery Valve

Fuel Injection Nozzle

Item

Injection Timing

Fuel Tightness

Fuel Tightness

Injection Pressure

Valve Seat

Tightness

Factory Specification

0.31 to 0.33 rad

(18 to 20 ) before T.D.C.

Allowable Limit

13.7 MPa

140

1991 psi

10 seconds

1991 1849 psi

5 seconds

13.73 12.75 MPa

1991 1849 psi

13.73 to 14.71 MPa

140 to 150

1991 to 2134 psi

When the pressure is

12.75 MPa (130 ,

1849 psi), the valve seat must be fuel tightness

0000009506E

KiSC issued 04, 2006 A

1-S8

GR1600EC, WSM

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

Front coupling mounting screw

Engine mounting nut

Air cleaner stay screw

Engine support screw

*Cylinder head cover screw

Injection pipe retaining nut

Overflow pipe retaining nut

Nozzle holder assembly

Glow plug

*Rocker arm braket screw

*Cylinder head screw

*Fan drive pulley screw

*Idle gear shaft mounting screw

*Connecting rod screw

*Flywheel screw

Bearing case cover mounting screw

*Main bearing case screw 2

*Main bearing case screw 1

Nozzle holder

Oil pressure switch

M8 x 1.25

M8 x 1.25

M8 x 1.25

M10 x 1.25

M6 x 1.0

M12 x 1.5

M12 x 1.5

M20 x 1.5

M8 x 1.0

M6 x 1.0

M8 x 1.25

M12 x 1.5

M6 x 1.0

M7 x 0.75

M10 x 1.25

M6 x 1.0

M7 x 1.0

M6 x 1.0

PT1/8

23.5 to 27.4

23.5

23.5 to 27.4

48.1 to 55.9

6.86 to 11.3

24.5 to 34.3

19.6 to 24.5

49.0 to 68.6

7.85 to 14.7

9.8 to 11.3

37.3 to 42.2

98.0 to 107.8

9.8 to 11.3

26.5 to 30.4

53.9 to 58.8

9.8 to 11.3

26.5 to 30.4

12.7 to 15.7

34.3 to 39.2

14.7 to 19.6

2.4 to 2.8

2.4

2.4 to 2.8

4.9 to 5.7

0.7 to 1.15

2.5 to 3.5

2.0 to 2.5

5.0 to 7.0

0.8 to 1.5

1.00 to 1.15

3.8 to 4.3

10.0 to 11.0

1.00 to 1.15

2.7 to 3.1

5.5 to 6.0

1.00 to 1.15

2.7 to 3.1

1.3 to 1.6

3.5 to 4.0

1.5 to 2.0

ENGINE ft-lbs

17.4 to 20.3

17.4

17.4 to 20.3

35.4 to 41.2

5.1 to 8.3

18.1 to 25.3

14.5 to 18.1

36.2 to 50.6

5.8 to 10.8

7.2 to 8.3

27.5 to 31.1

72.3 to 79.5

7.2 to 8.3

19.5 to 22.4

39.8 to 43.4

7.2 to 8.3

19.5 to 22.4

9.4 to 11.6

25.3 to 28.9

10.8 to 14.5

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

KiSC issued 04, 2006 A

1-S9

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

Compression pressure

Allowable limit

2.26 MPa

23.0

327psi

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 Factory spec.

0.50 to 0.70 mm

0.0197 to 0.0276 in.

Tightening torque Cylinder head screw

37.3 to 42.2

3.8 to 4.3

27.5 to 31.1 ft-lbs

(1) 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

Intake valve

Exhaust valve

No.2

7. If the clearance is not within the factory specifications, adjust with the adjusting screw.

Intake and exhaust valve clearance (Cold)

Factory spec.

0.145 to 0.185 mm

0.00571 to 0.00728 in.

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.

A: Gear Case Side (1) Cylinder Head Cover

(2) "1TC" Mark

(3) Alignment Mark

0000009509E

KiSC issued 04, 2006 A

1-S12

GR1600EC, WSM

(2) Lubricating System

(3) Cooling System

ENGINE

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

Factory spec.

More than 49 kPa

0.5

7 psi

Engine oil pressure

At rated speed

Factory spec.

196 to 441 kPa

2.0 to 4.5

28 to 64 psi

Allowable limit

147 kPa

1.5

21 psi

(When reassembling)

A After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.

0000000914E

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) Factory spec.

7 to 9 mm

0.28 to 0.35 in.

(1) Fan Drive Pulley (2) Dynamo Pulley

0000010059E

KiSC issued 04, 2006 A

1-S13

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 Factory spec.

More than 10 seconds for pressure fall from

88 to 59 kPa

(from 0.9 to 0.6 from 13 to 9 psi)

(1) 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

Factory spec.

157 kPa

1.6

23 psi

(1) Radiator Tester (2) Adaptor

0000000924E

1-S15

KiSC issued 04, 2006 A

GR1600EC, WSM

(4) Fuel System

ENGINE

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 Factory spec.

0.31 to 0.33 rad. (18 to 20 ) before T.D.C.

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:

0.20 mm (0.0079 in.)

(5) One-holes:

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

Allowable limit

13.7 MPa

140

1991 psi

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 psi).

, from 1991 to 1849

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

10 seconds

Factory spec.

Fuel tightness of delivery valve

1991 1849 psi

5 seconds

Allowable limit

1991 1849 psi

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. 07909-

31361), 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. 07909-

31361).

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

[2] PREPARATION

(1) Separating Engine

ENGINE

Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester (Code No. 07909-

31361).

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 Factory spec.

No fuel leak at

12.75 MPa

130

1849 psi

0000000935E

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

Capacity (with recovery tank)

2.15 L

2.27 U.S.qts.

1.89 Imp.qts.

(1) Radiator Cap (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 Capacity

1.2 L

1.27 U.S.qts.

1.06 Imp.qts.

(1) Drain Plug

(2) Oil Inlet

(3) Dipstick

A : Upper Level

B : Lower Level

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

KiSC issued 04, 2006 A

1-S21

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

(2) Bonnet Bracket

(3) Side Bonnet

(4) Wire Harness

(5) Connector

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

(2) Muffler

(3) Fuel Hose

(4) Accelerator Wire

(5) Wire Harness

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

Tightening torque

Engine mounting nut

23.5

2.4

17.4 ft-lbs

(1) Radiator Retaining Snap Pin

(2) Front Coupling

(3) Engine Assembly

(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

Tightening torque

Engine support screw

48.1 to 55.9

4.9 to 5.7

35.4 to 41.2 ft-lbs

(1) Radiator

(2) Recovery Tank

(3) Dynamo

(4) Fan Belt

(5) Engine Support RH

(6) Starter

(7) Engine Support LH

(8) Air Cleaner Stay

(9) Cooling Fan

0000009515E

KiSC issued 04, 2006 A

1-S23

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

Cylinder head cover screw

6.86 to 11.3

0.7 to 1.15

5.1 to 8.3 ft-lbs

(1) 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

Injection pipe retaining nut

24.5 to 34.3

2.5 to 3.5

18.1 to 25.3 ft-lbs

(1) Pipe Clamp (2) 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.

Overflow pipe retaining nut

19.6 to 24.5

2.0 to 2.5

14.5 to 18.1 ft-lbs

Tightening torque 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

(2) Nozzle Holder Assembly

(3) Lead

(4) Glow Plug

(5) Copper Gasket

(6) Heat Seal

0000001489E

KiSC issued 04, 2006 A

1-S24

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

(2) Rocker Arm Assembly

(3) Push Rod

(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 Cylinder head screw

37.3 to 42.2

3.8 to 4.3

27.5 to 31.1 ft-lbs

(j) to (a): To Loosen

(a) to (j): To Tighten

(1) O-ring

0000001684E

KiSC issued 04, 2006 A

1-S25

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

(2) Valve Cap

(3) Valve Spring Collet

(4) Valve Spring Retainer

(5) Valve Spring

(6) Valve Stem Seal

(7) Valve

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

(2) Speed Control Plate

(3) Injection Pump

(4) Governor Spring

(5) Governor Lever

(6) Idling Adjusting Spring

(7) Control Rod

(8) Slot (Crankcase Side)

(9) Slot (Fork Lever Side)

(10) 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 Fan drive pulley screw

98.0 to 107.8

10.0 to 11.0

72.3 to 79.5 ft-lbs

(1) Alignment Mark

0000000859E

KiSC issued 04, 2006 A

1-S27

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)

(2) Start Spring

(3) Gear Case

(4) Gear Case Gasket

(5) O-rings

(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

9.8 to 11.3

1.00 to 1.15

7.2 to 8.3 ft-lbs

(1) Idle Gear

(2) Idle Gear Collar

(3) External Snap Ring

(4) 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

KiSC issued 04, 2006 A

1-S29

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

(2) Fuel Camshaft

(3) Injection Pump Gear

(4) Governor Sleeve

(5) Fork Lever 1

(6) Fork Lever 2

(7) Governor Spring

(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

(2) Crankshaft Oil Slinger

(3) O-ring

(4) Crankshaft Collar

(5) Oil Pump

(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

(2) Screw

(3) Oil Strainer

(4) Oil Pan

(5) Oil Pan Mounting Screws

(6) Hole

0000009517E

1-S31

KiSC issued 04, 2006 A

GR1600EC, WSM

(3) Piston and Connecting Rod

ENGINE

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 Connecting rod screw

26.5 to 30.4

2.7 to 3.1

19.5 to 22.4 ft-lbs

(1) Connecting Rod Cap (a) 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) Top Ring Gap

(B) Second Ring Gap

(C) Oil Ring Gap

(D) Piston Pin Hole

(a) 0.785 rad. (45 )

(b) 0.785 rad. (45 )

(c) 1.57 rad. (90 )

0000001686E

KiSC issued 04, 2006 A

1-S32

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

(3) Oil Ring

(4) Piston Pin Snap Ring

(5) Piston

(6) Connecting Rod

(7) Piston Pin

(8) Mark

(9) Fan-Shaped Concave

(10) Expander Joint

(11) Oil Ring Gap

(12) Manufacturer's Mark

0000003201E

1-S33

KiSC issued 04, 2006 A

GR1600EC, WSM

(4) Crankshaft

ENGINE

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 Flywheel screw

53.9 to 58.8

5.5 to 6.0

39.8 to 43.4 ft-lbs

(1) Flywheel Screw

(2) Flywheel

(a) 1TC Mark

(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

Bearing case cover mounting screw

9.8 to 11.3

1.00 to 1.15

7.2 to 8.3 ft-lbs

(1) Bearing Case Cover Mounting

Screw (Inside)

(2) Bearing Case Cover Mounting

Screw (Outside)

(3) Bearing Case Gasket

(4) Bearing Case Cover Gasket

(5)

(6)

Oil Seal

Bearing Case Cover

(a) Top Mark "UP"

(b) Upside

0000001337E

KiSC issued 04, 2006 A

1-S34

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

Main bearing case screw 2

26.5 to 30.4

2.7 to 3.1

19.5 to 22.4 ft-lbs

(1) 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

(4) Crankshaft Bearing 3

(c) Oil Groove

(Upper, with oil groove)

(5) Crankshaft Bearing 3 (Lower)

(6) 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

(5) Water Pump

ENGINE

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

(2) Water Pump Shaft

(3) Water Pump Body

(4) Mechanical Seal

(5) Impeller

0000000926E

1-S37

KiSC issued 04, 2006 A

GR1600EC, WSM

(6) Injection Nozzle

[4] SERVICING

(1) Cylinder Head and Valves

ENGINE

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.

Nozzle holder

34.3 to 39.2

3.5 to 4.0

25.3 to 28.9 ft-lbs

Tightening torque

Overflow pipe retaining nut

Nozzle holder assembly

19.6 to 24.5

2.0 to 2.5

14.5 to 18.1 ft-lbs

49.0 to 68.6

5.0 to 7.0

36.2 to 50.6 ft-lbs

(1) Nozzle Holder

(2) Adjusting Washer

(3) Nozzle Spring

(4) Push Rod

(5) Distance Piece

(6) Nozzle Piece

(7) Nozzle Retaining Nut

0000000936E

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

KiSC issued 04, 2006 A

1-S38

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.

Valve recessing (Intake and Exhaust)

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.

(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.

Allowable limit

0.030 to 0.057 mm

0.00118 to 0.00224 in.

0.10 mm

0.0039 in.

Valve stem O.D.

Valve guide I.D.

Factory spec.

Factory spec.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

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)

Factory spec.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

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 Factory spec.

2.12 mm

0.0835 in.

(1) Correct

(2) Incorrect

(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 Factory spec.

0.785 rad

45

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 Factory spec.

0.785 rad

45

(1) Valve Seat Cutter

(A) Check Contact

(B) Correct Seat Width

(C) Correct Seat Surface

(D) Check Contact

(a) Identical Dimensions

(b) Valve Seat Width

(c) 0.262 rad (15 )

(d) 0.785 rad (45 )

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

KiSC issued 04, 2006 A

1-S42

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.

Free length (A)

Allowable limit

28.4 mm

1.118 in.

Tilt (B) Allowable limit

1.2 mm

0.047 in.

(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.

Setting load / Setting length

Allowable limit

54.9 N / 27.0 mm

5.6 kgf / 27.0 mm

12.3 lbs / 1.063 in.

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.

Allowable limit

0.016 to 0.045 mm

0.00063 to 0.00177 in.

0.15 mm

0.0059 in.

Rocker arm shaft O.D.

Factory spec.

Rocker arm I.D.

Factory spec.

10.473 to 10.484 mm

0.41232 to 0.41276 in.

10.500 to 10.518 mm

0.41339 to 0.41410 in.

0000000884E

KiSC issued 04, 2006 A

1-S43

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.

Allowable limit

0.016 to 0.052 mm

0.00063 to 0.00205 in.

0.10 mm

0.0039 in.

Tappet O.D.

Factory spec.

Tappet guide bore I.D.

Factory spec.

17.966 to 17.984 mm

0.70732 to 0.70803 in.

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.

Backlash between idle gear and crank gear

Allowable limit

0.15 mm

0.0059 in.

Backlash between idle gear and cam gear

Factory spec.

Allowable limit

Backlash between idle gear and injection pump gear

Factory spec.

Allowable limit

0.047 to 0.123 mm

0.00185 to 0.00484 in.

0.15 mm

0.0059 in.

0.046 to 0.124 mm

0.00185 to 0.00488 in.

0.15 mm

0.0059 in.

Backlash between oil punp drive gear and crank gear

Factory spec.

Allowable limit

0.041 to 0.123 mm

0.00161 to 0.00484 in.

0.15 mm

0.0059 in.

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.

0.20 to 0.51 mm

0.0079 to 0.0201 in.

Idle gear side clearance

Factory spec.

Allowable limit

0.80 mm

0.0315 in.

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.

Camshaft side clearance

Factory spec.

Allowable limit

0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.50 mm

0.0197 in.

0000000890E

KiSC issued 04, 2006 A

1-S45

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.

Cam height of intake and exhaust

Factory spec.

Allowable limit

26.88 mm

1.0583 in.

26.83 mm

1.0563 in.

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.

Oil clearance of camshaft journal

Allowable limit

0.15 mm

0.0059 in.

Camshaft journal O.D.

Factory spec.

Camshaft bearing I.D.

(Cylinder block bore

I.D.)

Factory spec.

32.934 to 32.950 mm

1.29661 to 1.29724 in.

33.000 to 33.025 mm

1.29921 to 1.30020 in.

0000000893E

KiSC issued 04, 2006 A

1-S46

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.

Allowable limit

0.020 to 0.084 mm

0.00079 to 0.00331 in.

0.10 mm

0.0039 in.

Idle gear shaft O.D.

Factory spec.

Idle gear bushing I.D.

Factory spec.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

20.000 to 20.051 mm

0.78740 to 0.78941 in.

0000000894E

(3) Piston and Connecting Rod

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

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.

Piston pin bore I.D.

Allowable limit

20.05 mm

0.7894 in.

0000000897E

KiSC issued 04, 2006 A

1-S47

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.

Allowable limit

0.014 to 0.038 mm

0.00055 to 0.00150 in.

0.10 mm

0.0039 in.

Piston pin O.D.

Factory spec.

Small end bushing I.D.

Factory spec.

20.002 to 20.011 mm

0.78748 to 0.78783 in.

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)

Factory spec.

Allowable limit

0.015 to 0.075 mm

0.00059 to 0.00295 in.

0.15 mm

0.0059 in.

Small end bushing I.D.

(Spare parts)

Factory spec.

(1) Seam

(2) Oil Hole

20.026 to 20.077 mm

0.78845 to 0.79043 in.

(A) When removing

(B) When installing

(a) 0.785 rad. (45 )

0000000899E

KiSC issued 04, 2006 A

1-S48

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.

Top ring

Allowable limit

1.20 mm

0.0472 in.

Piston ring gap

Second ring

Oil ring

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.

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.

Factory spec.

0.085 to 0.115 mm

0.00335 to 0.00453 in.

Second ring

Clearance between piston ring and piston ring groove

Allowable limit

0.15 mm

0.0059 in.

Factory spec.

0.02 to 0.06 mm

0.0008 to 0.0024 in.

Oil ring

Allowable limit

0.15 mm

0.0059 in.

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

(4) Crankshaft

ENGINE

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.

Crankshaft side clearance

Allowable limit

0.50 mm

0.0197 in.

(Reference)

A Oversize thrust bearing

Oversize Bearing

0.2 mm

0.008 in.

0.4 mm

0.016 in.

Thrust bearing 1 02

Thrust bearing 2 02

Thrust bearing 1 04

Thrust bearing 2 04

Code Number

15261-23950

15261-23970

15261-23960

15261-23980

Marking

020 OS

020 OS

040 OS

040 OS

A Oversize dimensions of crankshaft journal

Oversize

0.2 mm

0.008 in.

Dimension A

23.40 to 23.45 mm

0.9134 to 0.9154 in.

0.4 mm

0.016 in.

23.80 to 23.85 mm

0.9213 to 0.9232 in.

Dimension B

Dimension C

46.1 to 46.3 mm

1.815 to 1.823 in.

1.8 to 2.2 mm radius

0.071 to 0.087 in. radius

46.3 to 46.5 mm

1.823 to 1.831 in.

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

KiSC issued 04, 2006 A

1-S51

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.

Allowable limit

0.020 to 0.051 mm

0.00079 to 0.00201 in.

0.15 mm

0.0059 in.

Crankpin O.D.

Crankpin bearing I.D.

Factory spec.

Factory spec.

33.959 to 33.975 mm

1.33697 to 1.33760 in.

33.995 to 34.010 mm

1.33893 to 1.33898 in.

(Reference)

A Undersize crankpin bearing

Undersize Bearing

0.2 mm

0.008 in.

0.4 mm

0.016 in.

Crankpin bearing 02

Crankpin bearing 04

Code Number

15861-22970

15861-22980

Marking

020 US

040 US

A Undersize dimensions of crankpin

Undersize

Dimension A

Dimension B

Dimension C

0.2 mm

0.008 in.

2.3 to 2.7 mm radius

0.091 to 0.106 in. radius

4 mm dia.

0.16 in. dia.

33.759 to 33.775 mm dia.

1.32910 to 1.32973 in. dia.

0.4 mm

0.016 in.

2.3 to 2.7 mm radius

0.091 to 0.106 in. radius

4 mm dia.

0.16 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

KiSC issued 04, 2006 A

1-S52

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.

Allowable limit

0.034 to 0.106 mm

0.00134 to 0.00417 in.

0.20 mm

0.0079 in.

Crankshaft journal O.D.

Factory spec.

Crankshaft bearing 1

I.D.

Factory spec.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57417 to 1.57638 in.

(Reference)

A Undersize crankshaft bearing 1

Undersize Bearing

0.2 mm

0.008 in.

0.4 mm

0.016 in.

Crankshaft bearing 1 02

Crankshaft bearing 1 04

Code Number

15861-23910

15861-23920

Marking

020 US

040 US

A Undersize dimensions of crankshaft journal

Undersize

Dimension A

0.2 mm

0.008 in.

1.8 to 2.2 mm radius

0.071 to 0.087 in. radius

0.4 mm

0.016 in.

1.8 to 2.2 mm radius

0.071 to 0.087 in. radius

Dimension B

Dimension C

5 mm dia.

0.20 in. dia.

39.734 to

39.750 mm dia.

1.56433 to

1.56496 in. dia.

5 mm dia.

0.20 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

KiSC issued 04, 2006 A

1-S53

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) Factory spec.

0.0 to 0.3 mm

0.0 to 0.0118 in.

(1) Seam

(2) Crankshaft Bearing 1

(3) Cylinder Block

(A) 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.

Oil clearance between crankshaft journal and crankshaft bearing 2

(Crankshaft bearing 3)

Factory spec.

Allowable limit

0.028 to 0.051 mm

0.00110 to 0.00201 in.

0.20 mm

0.0079 in.

Crankshaft journal O.D.

(Flywheel side)

Factory spec.

Crankshaft bearing 2

I.D.

Factory spec.

Crankshaft journal O.D.

(Intermediate)

Factory spec.

Crankshaft bearing 3

I.D.

Factory spec.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.978 to 43.993 mm

1.73142 to 1.73201 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.978 to 39.993 mm

1.57394 to 1.57453 in.

0000009525E

KiSC issued 04, 2006 A

1-S54

GR1600EC, WSM

(5) Cylinder

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.

0.4 mm

0.016 in.

Crankshaft bearing 2 02

Crankshaft bearing 3 02

Crankshaft bearing 2 04

Crankshaft bearing 3 04

15694-23930

15861-23860

15694-23940

15861-23871

020 US

020 US

040 US

040 US

A Undersize dimensions of crankshaft journal

Undersize

Dimension A

0.2 mm

0.008 in.

1.8 to 2.2 mm radius

0.071 to 0.087 in. radius

0.4 mm

0.016 in.

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

Dimension D

39.734 to 39.750 mm dia.

1.56433 to 1.56496 in. dia.

43.734 to 43.750 mm dia.

1.72181 to 1.72244 in. dia.

39.534 to 39.550 mm dia.

1.55646 to 1.55709 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

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".)

67.000 to 67.019 mm

2.63779 to 2.63854 in.

Cylinder I.D.

Factory spec.

Allowable limit

67.169 mm

2.6445 in.

(A) Top

(B) Middle

(C) Bottom (Skirt)

(a) Right-angled to Piston Pin

(b) Piston Pin Direction

0000009527E

KiSC issued 04, 2006 A

1-S55

GR1600EC, WSM

(6) Oil Pump

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.

Cylinder I.D.

[Oversize]

Allowable limit

67.419 mm

2.65429 in.

Finishing

Horn to 1.2 to 2.0 m Rmax.

(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

Piston ring assembly

16851-21900

16851-21090

025

025

A When the oversize cylinder is worn beyond the allowable limit, replace the cylinder block with a new one.

(1) Cylinder I.D.

[Before Correction]

(2) Cylinder I.D. [Oversize]

0000009528E

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

KiSC issued 04, 2006 A

1-S56

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

1. STRUCTURE

TRANSAXLE

(1) Hydraulic Transmission

Section

(2) Mower PTO Section (3) Differential Gear Section (4) Rear Axle Section

0000009178E

2-M1

KiSC issued 04, 2006 A

GR1600EC, WSM

2. TRAVELLING SYSTEM

[1] HYDROSTATIC TRANSMISSION

(1) Structure

TRANSAXLE

(1) Check Valve

(2) Trunnion Arm

(3) Charge Relief Valve

(4) Charge Pump

(5) Center Section

(6) Cylinder Block (Pump)

(7) Piston Spring

(8) Piston

(9) Spring (Cylinder Block)

(10) Washer

(11) Thrust Ball Bearing

(12) Swashplate

(13) Cradle Bearing

(14) Ball Bearing

(15) Oil Seal

(16) Pump Shaft

(17) Ball Bearing

(18) Oil Seal

(19) Motor Shaft

(20) Thrust Ball Bearing

(21) Cylinder Block (Motor)

(22) By-pass Plug

(23) By-pass Spool

(24) By-pass Spring

(25) Journal Bearing

(26) Oil Seal

(27) Journal Bearing

(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

KiSC issued 04, 2006 A

2-M2

GR1600EC, WSM

(2) Oil Flow

TRANSAXLE

(1) Pump

(2) Charge Pump

(3) Check Valve (Forward)

(4) Filter Cartridge

(5) Motor

(6) By-pass Valve

(7) Lubricating Orifice

(8) Check Valve (Reverse)

(9) Neutral Orifice

(10) 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

(3) Operation

B Neutral

TRANSAXLE

(1) Cylinder Block (Pump)

(2) Swashplate

(3) Piston

(4) Cylinder Block (Motor)

(5) Lubricating Orifice

(6) Check Valve (Forward)

(7) By-pass Valve

(8) Transaxle Case

(9) Oil Strainer

(10) Check Valve (Reverse)

(11) Charge Relief Valve

(12) Filter Cartridge

(13) Charge Pump

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

KiSC issued 04, 2006 A

2-M4

GR1600EC, WSM

B

Forward

TRANSAXLE

(1) Cylinder Block (Pump)

(2) Swashplate

(3) Piston

(4) Cylinder Block (Motor)

(5) Lubricating Orifice

(6) Check Valve (Forward)

(7) By-pass Valve

(8) Transaxle Case

(9) Oil Strainer

(10) Check Valve (Reverse)

(11) Charge Relief Valve

(12) Filter Cartridge

(13) Charge Pump

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

KiSC issued 04, 2006 A

2-M5

GR1600EC, WSM

B

Reverse

TRANSAXLE

(1) Cylinder Block (Pump)

(2) Swashplate

(3) Piston

(4) Cylinder Block (Motor)

(5) Lubricating Orifice

(6) Check Valve (Forward)

(7) By-pass Valve

(8) Transaxle Case

(9) Oil Strainer

(10) Check Valve (Reverse)

(11) Charge Relief Valve

(12) Filter Cartridge

(13) Charge Pump

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

KiSC issued 04, 2006 A

2-M6

GR1600EC, WSM

(4) Charge Pump

(5) By-pass Valve

TRANSAXLE

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

Factory spec.

0.3 to 0.5 MPa

3.1 to 5.1

43.5 to 72.5 psi

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

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

(6) Control Linkage

TRANSAXLE

(1) Speed Change Pedal

(2) Speed Change Rod

(3) Speed Change Plate

(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

KiSC issued 04, 2006 A

2-M8

GR1600EC, WSM

[2] MOWER PTO SYSTEM

(1) Mower PTO Clutch

TRANSAXLE

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

(2) Clutch Lever

(3) Spline Boss

(4) Clutch Disc and Friction

Plate

(5) Clutch Case

(6) 24T Gear

(7) 19T-2 Gear

(8) Spring

(9) Brake Disc and Friction

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

(2) Clutch Lever

(3) Spline Boss

(4) Clutch Disc and Friction

Plate

(5) Clutch Case

(6) 24T Gear

(7) 19T-2 Gear

(8) Spring

(9) Brake Disc and Friction

Plate

(10) Thrust Collar

0000009201E

KiSC issued 04, 2006 A

2-M9

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

(2) Clutch Lever

(3) Spline Boss

(4) Clutch Disc and Friction

Plate

(5) Clutch Case

(6) 24T Gear

(7) 19T-2 Gear

(8) Spring

(9) Brake Disc and Friction

Plate

(10) Thrust Collar

0000009205E

2-M10

KiSC issued 04, 2006 A

CONTENTS

1. TROUBLESHOOTING....................................................................................................... 2-S1

2. SERVICING SPECIFICATIONS ....................................................................................... 2-S4

3. TIGHTENING TORQUES ................................................................................................. 2-S5

4. CHECKING, DISASSEMBLING AND SERVICING ........................................................ 2-S6

[1] CHECKING AND ADJUSTING ...................................................................................... 2-S6

[2] 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

1. TROUBLESHOOTING

TRANSAXLE

Symptom

System Will Not

Operate in Either

Direction

Vibration and Noise

Probable Cause

A HST component parts defective

Solution

Replace HST assembly

Reference

Page

A Oil level is low

A Control linkage defective (Speed change pedal to speed control arm)

A Charge pressure is too low

A Oil filter cartridge clogged

A Check valve defective

A By-pass valve defective

A Charge pump defective

A Charge relief valve defective

Fill oil to proper level

Replace oil filter cartridge

Repair or replace charge relief valve

Replace by-pass valve

G-8, 2-S11

Repair control linkage 2-S7, 15

G-30

Replace charge pump 2-S18

2-S18

Replace check valve 2-S19

2-S19

2-S17, 20

A Oil level is low

A Control linkage defective (Speed change pedal to speed control arm)

A Charge pressure is too low

A Oil filter cartridge clogged

A Check valve defective

A By-pass valve defective

A Charge pump defective

A Charge relief valve defective

Fill oil to proper level

Replace oil filter cartridge

Repair or replace charge relief valve

Replace by-pass valve

G-8, 2-S11

Repair control linkage 2-S7, 15

G-30

Replace charge pump 2-S18

2-S18

Replace check valve 2-S19

2-S19

A HST component parts defective Replace HST assembly

2-S17, 20

2-S1

KiSC issued 04, 2006 A

GR1600EC, WSM TRANSAXLE

Less of Power

Oil Heat Over

Machine Will Not Stop in Neutral Position

System Operates in

One Direction Only

A Oil level is low

A Control linkage defective (Speed change pedal to speed control arm)

A Charge pressure is too low

A Oil filter cartridge clogged

A Check valve defective

A By-pass valve defective

A Charge pump defective

A Charge relief valve defective

Fill oil to proper level

Replace oil filter cartridge

Repair or replace charge relief valve

Replace by-pass valve

G-8, 2-S11

Repair control linkage 2-S7, 15

G-30

Replace charge pump 2-S18

2-S18

Replace check valve 2-S19

2-S19

A HST component parts defective Replace HST assembly

2-S17, 20

A Oil level is low

A Excessive machine load

A Charge pressure is too low

A Oil filter cartridge clogged

Fill oil to proper level

Reduce machine load

Replace oil filter cartridge

G-8, 2-S11

G-30

A Charge pump defective

A Charge relief valve defective

A Control linkage defective (Speed change pedal to speed control arm)

A

Improper adjustment of neutral arm holder shaft

Replace charge pump 2-S18

Repair or replace charge relief valve

Repair control linkage 2-S7, 15

Adjust

2-S18

2-S6

A Control linkage defective (Speed change pedal to speed control arm)

A Check valve defective

Repair control linkage 2-S7, 15

Replace check valve 2-S19

0000010488E

2-S2

KiSC issued 04, 2006 A

GR1600EC, WSM TRANSAXLE

DIFFERENTIAL GEAR SECTION

Symptom Probable Cause Solution

Reference

Page

Excessive or Unusual

Noise at All Time

Noise while Turning

A Improper backlash between 11T bevel gear and 17T-13T gear shaft

A Improper backlash between differential pinion and differential side gear

A Bearing worn

A Insufficient or improper type of transmission fluid used

A Differential pinions or differential side gears worn or damaged

A Bearing worn

Adjust

Adjust

Replace

Replace

Replace

2-S35

2-S34

Replenish or change G-8, 2-S11

2-S28

0000009607E

MOWER PTO SECTION

Symptom

PTO Clutch Slip

Probable Cause Solution

A

Improper length of PTO rod spring

A

PTO rod spring weaken or broken

Adjust

Replace

A

Clutch disc or friction plate excessively worn Replace

PTO Shaft Does Not

Rotate

PTO Clutch Drags

A

PTO clutch malfunctioning

A

Bearing broken

A

Brake plate excessive worn

A

Clutch spring weaken or broken

A

Deformation of plate

Repair or replace

Replace

Replace

Replace

Replace

Reference

Page

2-S13

2-S13

2-S24, 31,

32

2-S23, 24

2-S23

2-S24, 32,

33

2-S24, 32

2-S24

0000009608E

2-S3

KiSC issued 04, 2006 A

GR1600EC, WSM

2. SERVICING SPECIFICATIONS

Item

Charge Relief Valve

(Oil temperature at 50 , 122 )

PTO Clutch Disc

Pressure Plate

Friction Plate 1

Friction Plate 2

Clutch Spring

PTO Brake Disc

Brake Friction Plate 1

Brake Friction Plate 2

Setting Pressure

Thickness

Thickness

Thickness

Thickness

Free Length

Thickness

Thickness

Thickness

Differential Case to Differential Side Gear Clearance

42T Gear to Differential Side Gear

Differential Case

Bore (I.D.)

Differential Side

Gear Boss (O.D.)

Clearance

42T Gear Bore

(I.D.)

Clearance Differential Pinion Gear to Differential

Pinion Shaft

Differential Case

Bore (I.D.)

Differential Side

Gear Boss (O.D.)

Differential Pinion Gear to Differential Side

Gear

Backlash

11T Bevel Gear Shaft to 17T-13T Gear

Shaft

Backlash

TRANSAXLE

Factory Specification

0.3 to 0.5 MPa

3.1 to 5.1

43.5 to 72.5 psi

1.3 to 1.5 mm

0.051 to 0.059 in.

1.55 to 1.65 mm

0.061 to 0.065 in.

1.55 to 1.65 mm

0.061 to 0.065 in.

0.75 to 0.85 mm

0.030 to 0.034 in.

45 mm

1.77 in.

3.3 to 3.5 mm

0.13 to 0.14 in.

1.75 to 1.85 mm

0.069 to 0.073 in.

0.95 to 1.05 mm

0.037 to 0.041 in.

0.040 to 0.082 mm

0.0016 to 0.0032 in.

22.500 to 22.521 mm

0.8858 to 0.8867 in.

22.439 to 22.460 mm

0.8834 to 0.8843 in.

0.040 to 0.082 mm

0.0016 to 0.0032 in.

22.500 to 22.521 mm

0.8858 to 0.8867 in.

0.025 to 0.055 mm

0.00098 to 0.00217 in.

10.000 to 10.015 mm

0.39370 to 0.39429 in.

9.960 to 9.975 mm

0.39212 to 0.39272 in.

0.15 to 0.30 mm

0.0059 to 0.0012 in.

0.10 to 0.30 mm

0.0039 to 0.0012 in.

Allowable Limit

0.17 mm

0.0067 in.

0.25 mm

0.0096 in.

1.2 mm

0.047 in.

1.50 mm

0.059 in.

1.50 mm

0.059 in.

0.70 mm

0.028 in.

42 mm

1.65 in.

3.0 mm

0.118 in.

1.60 mm

0.063 in.

0.80 mm

0.031 in.

0.17 mm

0.0067 in.

0000009610E

KiSC issued 04, 2006 A

2-S4

GR1600EC, WSM

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

Brake plate mounting screw

Universal joint mounting screw

Transaxle mounting screw

Hydrostatic transmission mounting screw

Hydrostatic transmission mounting screw 2

Center section mounting hex. socket head screw

By-pass valve plug

Check valve plug

PTO clutch assembly mounting screw

Beam mounting screw

Transaxle case screw

42T gear mounting screw

34 to 40

9.8 to 11.3

48.1 to 55.8

23.5 to 27.5

17.7 to 20.6

17.7 to 20.6

15.0

30.0

17.7 to 20.6

17.7 to 20.6

7.8 to 8.8

9.8 to 11.3

3.47 to 4.07

1.00 to 1.15

4.9 to 5.7

2.4 to 2.8

1.8 to 2.1

1.8 to 2.1

1.53

3.06

1.8 to 2.1

1.8 to 2.1

0.8 to 0.9

1.00 to 1.15

TRANSAXLE ft-lbs

25.1 to 29.5

7.23 to 8.33

35.5 to 41.2

17.3 to 20.3

13.1 to 15.2

13.1 to 15.2

11.1

22.1

13.1 to 15.2

13.1 to 15.2

5.8 to 6.5

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

(2) Brake Pedal Arm

(3) Pin

(4) Rod End

(5) Speed Change Rod

(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

(2) Lock Nut

(3) Lock Nut

(4) Adjusting Screw

0000009308E

KiSC issued 04, 2006 A

2-S7

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 Factory spec.

0.3 to 0.5 MPa

3.1 to 5.1

43.5 to 72.5 psi

Condition

A Engine Speed : Rated Speed

A Oil Temperature : 50 (122 )

(1) P1 Port (Reverse) (2) P2 Port (Forward)

0000009310E

2-S8

KiSC issued 04, 2006 A

GR1600EC, WSM

[2] PREPARATION

(1) Separating Transaxle

TRANSAXLE

Dismounting Mower

1. See page 7-S6. ("Mower" Section)

Dismounting the Container

0000009311E

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

(2) Grass Container Lock Handle

(3) Handle

(4) Grass Container Lock Rod

(5) Stay

(6) Container Pipe Frame

(7) Lock Arm

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

(2) Connector

(3) Discharge Duct

(4) Connector

(5) Grass Container Full Switch

(6) Switch Cover

(7) Container Base

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 Capacity

2.5 L

0.71 U.S.gals

0.59 Imp.gals

(1) Suction Pipe

(2) Strainer

(3) O-ring

(4) O-ring

(5) Filling Plug with Dipstick

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

KiSC issued 04, 2006 A

2-S11

GR1600EC, WSM TRANSAXLE

Seat

1. Remove two snap pins (2), (4).

2. Remove the seat (1) and seat plate (3).

(1) Seat

(2) Snap Pin

(3) Seat Plate

(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

(2) Fender

(3) Fender Mounting Screw

(4) Step Sheet

(5) Speed Change Pedal

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

KiSC issued 04, 2006 A

2-S12

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) Factory spec.

68 mm

2.68 in.

(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

(2) Nut

(3) Nut

(4) Spring

(5) PTO Arm

(6) Nut

(7) Nut

A : "Disengaged" Position

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

(2) Spring

(3) PTO Lever

(4) Filling Pipe

(5) Beam

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

(2) Brake Rod 1

(3) Lock Nut

(4) Plain Washer

(5) Brake Spring

(6) Brake Rod 2

(7) Brake Plate

0000009325E

KiSC issued 04, 2006 A

2-S14

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

(2) Rue Ring Pin

(3) Speed Control Arm

(4) Speed Change Rod

(5) Lock Nut

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

Transaxle mounting screw

48.1 to 55.8

4.9 to 5.7

35.5 to 41.2 ft-lbs

(1) Transaxle (2) Transaxle Mounting Screw

0000009331E

KiSC issued 04, 2006 A

2-S15

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

(2) Neutral Spring

(3) Cooling Fan

(4) Breather Hose

(5) Suction Pipe 1

(6) Hose

(7) Suction Pipe 2

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

Tightening torque

Hydrostatic transmission mounting screw 2

17.7 to 20.6

1.8 to 2.1

13.1 to 15.2 ft-lbs

(1) Hydrostatic Transmission

Assembly

(2) Hole

(3) Drain Pipe

(4) Hydrostatic Transmission

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

(2) 34T Gear

(3) Bevel Gear Shaft

(4) External Snap Ring

(5) Shim

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

(2) Internal Snap Ring

(3) Oil Seal

(4) O-ring

(5) Spring

(6) Steel Ball

(7) Charge Relief Valve

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

KiSC issued 04, 2006 A

2-S18

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

Center section mounting hex. socket head screw

17.7 to 20.6

1.8 to 2.1

13.1 to 15.2 ft-lbs

(1) Center Section (2) 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

(2) By-pass Spool

(3) O-ring

(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 Check valve plug

30.0

3.06

22.1 ft-lbs

(1) Plug

(2) O-ring

(3) Spring

(4) Check Valve

(5) Ball Check

(6) Spring

(7) O-ring

(8) Plug

0000009345E

KiSC issued 04, 2006 A

2-S19

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

(Pump Side)

(2) Spring

(3) Washer

(4) Thrust Ball Bearing

(5) Cylinder Block Assembly

(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

(2) Swashplate

(3) Pump Shaft

(4) Oil Seal

(5) Internal Snap Ring

(6) Internal Snap Ring

(7) Oil Seal

(8) Internal Snap Ring

(9) External 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

KiSC issued 04, 2006 A

2-S20

GR1600EC, WSM

(2) Transaxle Case

TRANSAXLE

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

(2) Neutral Spring

(3) Cooling Fan

(4) Breather Hose

(5) Suction Pipe 1

(6) Hose

(7) Suction Pipe 2

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

Tightening torque

Hydrostatic transmission mounting screw 2

17.7 to 20.6

1.8 to 2.1

13.1 to 15.2 ft-lbs

(1) Hydrostatic Transmission

Assembly

(2) Hole

(3) Drain Pipe

(4) Hydrostatic Transmission

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

(2) Ball Bearing

(3) Slot

(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

(2) Clutch

(3) Brake Disc and Friction Plate

(4) PTO Shaft

(5) Clutch Case

(6) Thrust Needle Bearing

(7) Collar

(8) Spring

(9) Spline Boss

(10) Clutch Disc and Friction Plate

(11) External Snap Ring

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

(2) Thrust Collar

(3) External Snap Ring

(4) Clutch Lever

(5) PTO Clutch Cover

(6) Ball Bearing

(7) Oil Seal

0000010145E

Beam

1. Remove the beam (1) from the transaxle case.

(When reassembling)

Tightening torque Beam mounting screw

17.7 to 20.6

1.8 to 2.1

13.1 to 15.2 ft-lbs

(1) Beam

0000009350E

KiSC issued 04, 2006 A

2-S25

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)

(2) Transaxle Case Screw

(3) Transaxle Case (Front Side)

F : Front Side

R : Rear 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

(2) Intermediate Shaft

(3) 19T-2 Gear

(4) 17T-13T Gear Shaft

(5) External Snap Ring

(6) Collar

(7) Needle Bearing

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) 11T Gear Shaft (LH)

(2) Rear Differential Gear

Assembly

(3) External Snap Ring

(4) Washer

(5) Drive Shaft

(6) 11T Gear Shaft (RH)

0000009353E

KiSC issued 04, 2006 A

2-S27

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

(2) 42T Gear

(3) Differential Side Gear

(4) Shim

(5) Differential Pinion Gear

(6) Differential Pinion Shaft

(7) Differential Side Gear

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

(2) Oil Seal

(3) Bush

(4) Collar

(5) External Snap Ring

0000009355E

2-S28

KiSC issued 04, 2006 A

GR1600EC, WSM

[4] SERVICING

(1) Hydrostatic Transmission

TRANSAXLE

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

(2) O-ring

(3) Spring

(4) Check Valve

(5) Ball Check

(6) Spring

(7) O-ring

(8) Plug

0000009357E

KiSC issued 04, 2006 A

2-S29

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

(2) O-ring

(3) By-pass Spool

(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

(2) Spring

(3) Piston

(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

KiSC issued 04, 2006 A

2-S30

GR1600EC, WSM

(2) Transaxle Case

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

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.

Thickness of PTO clutch disc

Allowable limit

1.2 mm

0.047 in.

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.

Thickness of pressure plate

Allowable limit

1.50 mm

0.059 in.

Thickness of friction plate 1

Factory spec.

Allowable limit

1.55 to 1.65 mm

0.061 to 0.065 in.

1.50 mm

0.059 in.

Thickness of friction plate 2

Factory spec.

Allowable limit

0.75 to 0.85 mm

0.030 to 0.034 in.

0.70 mm

0.028 in.

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.

Clutch spring free length

Allowable limit

42 mm

1.65 in.

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.

PTO brake disc thickness

Allowable limit

3.00 mm

0.118 in.

0000009362E

KiSC issued 04, 2006 A

2-S32

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.

Thickness of brake friction plate 1

Allowable limit

1.60 mm

0.063 in.

Thickness of brake friction plate 2

Factory spec.

Allowable limit

0.95 to 1.05 mm

0.037 to 0.041 in.

0.80 mm

0.031 in.

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.

Allowable limit

0.040 to 0.082 mm

0.0016 to 0.0032 in.

0.17 mm

0.0067 in.

Clearance between 42T gear and differential side gear

Factory spec.

Allowable limit

0.040 to 0.082 mm

0.0016 to 0.0032 in.

0.17 mm

0.0067 in.

Differential case bore

I.D.

Differential side gear boss O.D.

42T gear bore I.D.

Factory spec.

Factory spec.

Factory spec.

(1)

(2)

42T Gear

Differential Side Gear

22.500 to 22.521 mm

0.8858 to 0.8867 in.

22.439 to 22.460 mm

0.8834 to 0.8843 in.

22.500 to 22.521 mm

0.8858 to 0.8867 in.

(3) Differential Side Gear

(4) Differential Gear Case

0000009364E

KiSC issued 04, 2006 A

2-S33

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.

Clearance between differential pinion gear and differential pinion shaft

Factory spec.

Allowable limit

0.025 to 0.055 mm

0.00098 to 0.00217 in.

0.25 mm

0.0096 in.

Differential pinion gear

I.D.

Differential pinion shaft

O.D.

Factory spec.

Factory spec.

10.000 to 10.015 mm

0.39370 to 0.39429 in.

9.960 to 9.975 mm

0.39212 to 0.39272 in.

(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

Factory spec.

0.15 to 0.30 mm

0.0059 to 0.012 in.

(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

(2) Differential Pinion Gear

(3) Differential Pinion Shaft

(4) Shim

(5) Drive Shaft

(6) Shim

0000009366E

KiSC issued 04, 2006 A

2-S34

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

Factory spec.

0.10 to 0.30 mm

0.0039 to 0.012 in.

(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

Shaft (LH))

(2) 17T-13T Gear Shaft

(3) 11T Bevel Gear Shaft

(4) Shim (for 11T Bevel Gear

Shaft)

(5) Shim (for 17T-13T Gear

Shaft (RH))

0000009367E

2-S35

KiSC issued 04, 2006 A

3

BRAKES

KiSC issued 04, 2006 A

CONTENTS

1. TROUBLESHOOTING....................................................................................................... 3-S1

2. SERVICING SPECIFICATIONS ....................................................................................... 3-S2

3. TIGHTENING TORQUES ................................................................................................. 3-S3

4. CHECKING, DISASSEMBLING AND SERVICING ........................................................ 3-S4

[1] CHECKING AND ADJUSTING ...................................................................................... 3-S4

[2] DISASSEMBLING AND ASSEMBLING......................................................................... 3-S4

(1) Pedal System Component....................................................................................... 3-S4

(2) Brake Assembly....................................................................................................... 3-S8

KiSC issued 04, 2006 A

GR1600EC, WSM

1. TROUBLESHOOTING

Symptom

Insufficient Braking

Force

Brake Drags

Heavy Brakes

Probable Cause

A Brake pedal free travel excessive

A Brake shoe worn

A Brake drum worn

A Grease or oil on brake shoe

A Brake pedal free travel too small

A Brake spring weaken or broken

A Brake pedal rusted

A Brake cam lever rusted

BRAKES

Solution

Adjust

Replace

Replace

Replace

Adjust

Replace

Repair or replace

Replace

Reference

Page

3-S4

3-S8

3-S8

3-S8

3-S4

3-S8

3-S7

3-S8

0000009612E

3-S1

KiSC issued 04, 2006 A

GR1600EC, WSM

2. SERVICING SPECIFICATIONS

Item

Brake Pedal Free Travel

BRAKES

Factory Specification

15 to 25 mm

0.59 to 0.98 in.

Allowable Limit

0000009613E

3-S2

KiSC issued 04, 2006 A

GR1600EC, WSM

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

Steering wheel mounting nut

Drag link locking nut

Steering support mounting screw

Pedal system component mounting nut

20 to 25

74.8 to 81.3

48.1 to 55.8

48.1 to 55.8

2.0 to 2.5

7.62 to 8.29

4.9 to 5.7

4.9 to 5.7

BRAKES ft-lbs

14.8 to 18.4

55.2 to 60.0

35.5 to 41.2

35.5 to 41.2

0000009614E

3-S3

KiSC issued 04, 2006 A

GR1600EC, WSM

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

Brake Pedal Free Travel

BRAKES

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)

Factory spec.

15 to 25 mm

0.59 to 0.98 in.

(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)

Battery

0000009449E

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

KiSC issued 04, 2006 A

3-S4

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

(2) Connector

(3) Discharge Duct

(4) Connector

(5) Grass Container Full Switch

(6) Switch Cover

(7) Container Base

0000009314E

Seat

1. Remove two snap pins (2), (4).

2. Remove the seat (1) and seat plate (3).

(1) Seat

(2) Snap Pin

(3) Seat Plate

(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

(2) Fender

(3) Fender Mounting Screw

(4) Step Sheet

(5) Speed Change Pedal

0000009320E

KiSC issued 04, 2006 A

3-S5

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

Steering wheel mounting nut

20 to 25

2.0 to 2.5

14.8 to 18.4 ft-lbs

(1) Steering Wheel

(2) Panel

(3) Side Bonnet

(4) Hour Meter

(5) Main Switch

(6) Indicator Lamp

(7) Fuse Box

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

Tightening torque

Steering support mounting screw

48.1 to 55.8

4.9 to 5.7

35.5 to 41.2 ft-lbs

(1) Steering Support

(2) Accelerator Wire

(3) Sector Gear

(4) Drag Link

0000009452E

KiSC issued 04, 2006 A

3-S6

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

48.1 to 55.8

4.9 to 5.7

35.5 to 41.2 ft-lbs

(1) Parking Lock Spring

(2) Pedal System Component

Mounting Nut

(3) Pedal System Component

0000009454E

3-S7

KiSC issued 04, 2006 A

GR1600EC, WSM

(2) Brake Assembly

BRAKES

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

(2) Plain Washer

(3) Brake Spring

(4) Brake Assembly

(5) Brake Rod 2

(6) Brake Plate

(7) External Snap Ring

(8) Brake Drum

0000009456E

3-S8

KiSC issued 04, 2006 A

4

FRONT AXLE

KiSC issued 04, 2006 A

CONTENTS

1. TROUBLESHOOTING....................................................................................................... 4-S1

2. SERVICING SPECIFICATIONS ....................................................................................... 4-S2

3. TIGHTENING TORQUES ................................................................................................. 4-S3

4. CHECKING, DISASSEMBLING AND SERVICING ........................................................ 4-S4

[1] CHECKING AND ADJUSTING ...................................................................................... 4-S4

[2] 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

1. TROUBLESHOOTING

Symptom Probable Cause

Front Wheels Wander to Right or Left

A Tire pressure uneven

A Improper toe-in

A Kingpin worn

A Center pin collar worn

A Center pin locking nut loosen

Front Wheels Shimmy A Improper toe-in

A Kingpin worn

A Center pin collar worn

A Steering linkage loosen or worn

FRONT AXLE

Solution

Adjust

Replace tie-rod

Replace front axle assembly

Replace

Tighten

Replace tie-rod

Replace front axle assembly

Replace

Tighten or replace

Reference

Page

4-S4, 6

4-S5

4-S5, 6

4-S5

4-S4, 6

4-S5

4-S5, 6

4-S5

0000009615E

4-S1

KiSC issued 04, 2006 A

GR1600EC, WSM

2. SERVICING SPECIFICATIONS

Item

Front Wheel Alignment

Front Axle Frame to Anti-vibration Bolt

Center Pin to Center Pin Collar

FRONT AXLE

Toe-in

Clearance

Clearance

Center Pin Boss

(I.D.)

Center Pin Collar

(O.D.)

Factory Specification

1 to 10 mm

0.04 to 0.39 in.

0.3 to 0.5 mm

0.012 to 0.020 in.

0.109 to 0.200 mm

0.00430 to 0.00789 in.

25.400 to 25.430 mm

1.00000 to 1.00118 in.

25.230 to 25.291 mm

0.99329 to 0.99570 in.

Allowable Limit

0.210 mm

0.00828 in.

0000009616E

4-S2

KiSC issued 04, 2006 A

GR1600EC, WSM

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

Center pin locking nut

Tie-rod mounting locking nut

77.4 to 90.2

49.9 to 54.2

7.9 to 9.2

5.09 to 5.53

FRONT AXLE ft-lbs

57.2 to 66.5

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) Factory spec.

1 to 10 mm

0.04 to 0.39 in.

(A) Wheel to Wheel Distance at Front

(B) 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

Factory spec.

0.3 to 0.5 mm

0.012 to 0.020 in.

(1) Front Axle Frame

(2) Anti-Vibration Bolt

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

KiSC issued 04, 2006 A

4-S4

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

(2) Bonnet Bracket

(3) Side Bonnet

(4) Wire Harness

(5) Connector

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

(2) Front Axle Assembly

(3) Center Pin Locking Nut

(4) Center Pin Collar

(5) Anti-vibration Bolt

(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

Tie-rod mounting locking nut

49.9 to 54.2

5.09 to 5.53

36.8 to 40.0 ft-lbs

(1) 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.

Allowable limit

0.109 to 0.200 mm

0.00430 to 0.00789 in.

0.210 mm

0.0828 in.

Center pin boss I.D. (A) Factory spec.

Center pin collar O.D.

(B)

Factory spec.

25.400 to 25.430 mm

1.00000 to 1.00118 in.

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. TROUBLESHOOTING....................................................................................................... 5-S1

2. SERVICING SPECIFICATIONS ....................................................................................... 5-S2

3. TIGHTENING TORQUES ................................................................................................. 5-S3

4. CHECKING, DISASSEMBLING AND SERVICING ........................................................ 5-S4

[1] CHECKING AND ADJUSTING ...................................................................................... 5-S4

[2] 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

1. TROUBLESHOOTING

Symptom

Cannot Steer

Hard Steering

Probable Cause

A Steering shaft and sector gear broken

A Steering linkage broken

A Tire pressure uneven

A Improper alignment of front wheels

A Bearing stuck

A Steering shaft and sector gear stuck

STEERING

Solution

Replace

Replace

Adjust

Replace tie-rod

Replace

Replace

Reference

Page

5-S6, 7

5-S6

4-S4, 6

5-S7

5-S7

0000009618E

5-S1

KiSC issued 04, 2006 A

GR1600EC, WSM

2. SERVICING SPECIFICATIONS

Item

Steering Wheel Play

STEERING

Factory Specification

30 to 70 mm

0.79 to 1.18 in.

Allowable Limit

0000009619E

5-S2

KiSC issued 04, 2006 A

GR1600EC, WSM

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

Steering wheel mounting nut

Drag link locking nut

Steering support mounting screw

Sector gear mounting screw

20 to 25

74.8 to 81.3

48.1 to 55.8

48.1 to 55.8

2.0 to 2.5

7.62 to 8.29

4.9 to 5.7

4.9 to 5.7

STEERING ft-lbs

14.8 to 18.4

55.2 to 60.0

35.5 to 41.2

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 Factory spec.

30 to 70 mm

0.79 to 1.18 in.

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

(2) Connector

(3) Discharge Duct

(4) Connector

(5) Grass Container Full Switch

(6) Switch Cover

(7) Container Base

0000009314E

Seat

1. Remove two snap pins (2), (4).

2. Remove the seat (1) and seat plate (3).

(1) Seat

(2) Snap Pin

(3) Seat Plate

(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

(2) Fender

(3) Fender Mounting Screw

(4) Step Sheet

(5) Speed Change Pedal

0000009320E

KiSC issued 04, 2006 A

5-S5

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

Steering wheel mounting nut

20 to 25

2.0 to 2.5

14.8 to 18.4 ft-lbs

(1) Steering Wheel

(2) Panel

(3) Side Bonnet

(4) Hour Meter

(5) Main Switch

(6) Indicator Lamp

(7) Fuse Box

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

Tightening torque

Steering support mounting screw

48.1 to 55.8

4.9 to 5.7

35.5 to 41.2 ft-lbs

(1) Steering Support

(2) Accelerator Wire

(3) Sector Gear

(4) Drag Link

0000009452E

KiSC issued 04, 2006 A

5-S6

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

(2) Steering Shaft

(3) Ball Bearing

(4) Shaft Retainer

(5) Sector Gear Mounting Screw

(6) Sector Bush

(7) Sector Bush

(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. WIRING DIAGRAM...........................................................................................................6-M1

2. STARTING SYSTEM ........................................................................................................6-M3

3. CHARGING SYSTEM.......................................................................................................6-M4

4. LIGHTING SYSTEM .........................................................................................................6-M5

KiSC issued 04, 2006 A

GR1600EC, WSM

1. WIRING DIAGRAM

ELECTRICAL SYSTEM

6-M1

0000009632E

KiSC issued 04, 2006 A

GR1600EC, WSM

Color of Wiring

W......White

R......Red

L......Blue

P.......Pink

B......Black

Br......Brown

Sb......Sky Blue

ELECTRICAL SYSTEM

WR......White / Red

WY......White / Yellow

RB......Red / Black

RW......Red / White

RG......Red / Green

RY......Red / Yellow

BW......Black / White

BR......Black / Red

GW......Green / White

YR......Yellow / Red

YL......Yellow / Blue

LW......Blue / White

0000004213E

6-M2

KiSC issued 04, 2006 A

GR1600EC, WSM

2. STARTING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Body Earth

(3) Starter Motor

(4) Glow Plug

(5) Engine Stop Solenoid

(6) Body Earth

(7) Engine Stop Time Relay

(8) Fuel Feed Pump

(9) Slow Blow Fuse (40 A)

(10) Fuse (15 A)

(11) Seat Switch

(12) Grass Container Open

Switch

(13) Grass Container Open

Relay

(14) Diode (3 A)

(15) Brake Switch

(16) Fuse (3 A)

(17) Fuse (10 A)

(18) Main Switch

(19) Hour Meter

(20) Glow Plug Lamp

(21) PTO Switch

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

KiSC issued 04, 2006 A

6-M3

GR1600EC, WSM

3. CHARGING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Body Earth

(3) Body Earth

(4) Dynamo

(5) Slow Blow Fuse (40 A)

(6) Regulator

(7) Main Switch

(8) Fuse (10 A)

(9) Charge Lamp

(10) 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

4. LIGHTING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Body Earth

(3) Thermo Switch

(4) Oil Switch

(5) Body Earth

(6) Dynamo

(7) Regulator

(8) Slow Blow Fuse (40 A)

(9) Main Switch

(10) Fuse (10 A)

(11) Fuse (3 A)

(12) PTO Switch

(13) Grass Container Full

Switch

(14) Buzzer Relay

(15) Buzzer

(18)

(19)

(20)

(21)

Oil Pressure Lamp

Charge Lamp

Easy Checker

Head Light Switch

(16) Thermo Lamp (22) Head Light

(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

KiSC issued 04, 2006 A

6-M5

CONTENTS

1. TROUBLESHOOTING....................................................................................................... 6-S1

2. SERVICING SPECIFICATIONS ....................................................................................... 6-S4

3. TIGHTENING TORQUES ................................................................................................. 6-S5

4. CHECKING, DISASSEMBLING AND SERVICING ........................................................ 6-S6

[1] 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

1. TROUBLESHOOTING

ELECTRICAL SYSTEM

Symptom

All Electrical

Equipments Do Not

Operate

Fuse Blown

Frequently

Probable Cause Solution

Reference

Page

A Battery discharged or defective

A Battery positive cable disconnected or improperly connected

A Battery negative cable disconnected or improperly connected

A Slow blow fuse blown (40 A)

A Short-circuited

Recharge or replace G-24, 1-S21

Repair or replace

Repair or replace

Replace

Repair or replace

G-35

0000009621E

BATTERY

Battery Discharges

Too Quickly

A Battery defective

A Dynamo defective

A Regulator defective

A Wiring harness disconnected or improperly connected (between battery positive terminal and regulator B terminal)

A Cooling fan belt slipping

Replace

Repair or replace

Replace

Repair or replace

Adjust tension

1-S21

6-S21

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

Engine Does Not Stop

When Main Switch is

Turned OFF

A PTO switch defective

A Grass container open switch defective

A Fuse blown (15 A)

A Wiring harness disconnected or improperly connected (between main switch ACC terminal and engine stop solenoid)

A Engine stop solenoid defective

A Timer relay defective

Engine Does Not Start A Engine stop solenoid defective

A Timer relay defective

Replace

Replace

Replace

Repair or replace

Replace

Replace

Replace

Replace

Reference

Page

A Battery discharged or defective

A Slow blow fuse blown (40 A)

A Wiring harness disconnected or improperly connected (between main switch ST terminal and safety switches, between safety switches and starter motor, between battery positive terminal and starter motor)

A Starter motor defective

A Main switch defective

A Seat switch defective

A Brake switch defective

Recharge or replace

Replace

Repair or replace

Repair or replace

Replace

Replace

Replace

G-24, 1-S21

G-35

6-S20

6-S8, 9

6-S13

6-S12

6-S12

6-S13

G-35

6-S14

6-S15

6-S14

6-S15

0000009623E

CHARGING SYSTEM

Symptom Probable Cause Solution

Charging Lamp Does

Not Light when Main

Switch is Turned ON

Charging Lamp Does

Not Go Off When

Engine is Running

A Fuse blown (15 A)

A Bulb blown

A Wiring harness disconnected or improperly connected (between main switch ACC terminal and regulator connector terminal

(yellow), between regulator connector terminal

(green) and charge lamp)

Replace

Replace

Repair or replace

A Regulator defective

A Dynamo defective

A Regulator defective

Replace

Repair or replace

Replace

Reference

Page

G-35

G-35

6-S21

0000009624E

KiSC issued 04, 2006 A

6-S2

GR1600EC, WSM ELECTRICAL SYSTEM

LIGHTING SYSTEM

Light

Symptom

Head Light Does Not

Glow Plug Lamp Does

Not Light When Main

Switch Is in Pre-heat

Position

Oil Pressure Lamp

Lights Up When

Engine Is Running

Probable Cause Solution

Reference

Page

A Fuse blown (10 A)

A Bulb blown

A Wiring harness disconnected or improperly connected (between main switch ACC terminal and head light switch, between head light switch and head light)

Replace

Replace

Repair or replace

A Battery discharged or defective

A Slow blow fuse blown (40 A)

A Wiring harness disconnected or improperly connected (between main switch G terminal and glow plug lamp, between glow plug lamp and glow plugs)

A Main switch defective

A Bulb blown

A Engine oil pressure too low

A Engine oil insufficient

A Oil pressure switch defective

A Short circuit between oil pressure switch lead and chassis

A Fuse blown (10 A)

Recharge or replace

Replace

Repair or replace

Replace

Replace

Repair engine

Replenish

Replace

Repair

Replace

G-35

G-35

G-24, 1-S21

G-35

6-S8, 9

G-35

G-25

6-S17

G-35 Oil Pressure Lamp

Does Not Light When

Main Switch Is Turned

ON and Engine Is Not

Running

Thermo Lamp Does

Not Light When Main

Switch Is Turned ON and Engine Is Not

Running

A Bulb blown

A Oil pressure switch defective

A Wiring harness disconnected or improperly connected (between main switch ACC terminal and oil pressure lamp, between oil pressure lamp and oil pressure switch)

Replace

Replace

Repair or replace

A Fuse blown (10 A)

A Bulb blown

A Thermo switch defective

A Wiring harness disconnected or improperly connected (between main switch ACC terminal and thermo lamp, between thermo lamp and thermo switch)

Replace

Replace

Replace

Repair or replace

G-35

6-S17

G-35

G-35

6-S18

0000009625E

KiSC issued 04, 2006 A

6-S3

GR1600EC, WSM

2. SERVICING SPECIFICATIONS

Item

Battery

Glow Plug

Head Light Switch

Starter

ELECTRICAL SYSTEM

Voltage

Potential Difference

Resistance

Resistance OFF

Resistance ON

Commutator

(O.D.)

Commutator

(Difference of O.D.)

Mica

(Undercut)

Brush

(Length)

Factory Specification

More than 12 V

Less than 0.1 V

Approx. 0.9

Infinity

0

28.0 mm

1.102 in.

Less than 0.05 mm

0.002 in.

0.50 to 0.80 mm

0.0197 to 0.0315 in.

16.0 mm

0.630 in.

Allowable Limit

27.0 mm

1.063 in.

0.4 mm

0.016 in.

0.20 mm

0.0079 in.

10.5 mm

0.413 in.

0000009626E

6-S4

KiSC issued 04, 2006 A

GR1600EC, WSM

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

Starter (C terminal nut)

Dynamo (stator nut)

5.9 to 11.8

39.2 to 44.1

0.6 to 1.2

4.0 to 4.5

ELECTRICAL SYSTEM ft-lbs

4.3 to 8.7

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 Factory spec.

More than 12 V

(1) Positive Terminal Post (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.

1.230 Sp. Gr.

1.200 Sp. Gr.

1.170 Sp. Gr.

1.140 Sp. Gr.

1.110 Sp. Gr.

100 % Charged

75 % Charged

50 % Charged

25 % Charged

Very Little Useful Capacity

Discharged

At an electrolyte temperature of 20 (68 )

(a) Good

(b) Bad

(c) Bad

0000001142E

KiSC issued 04, 2006 A

6-S7

GR1600EC, WSM

(2) Main Switch

ELECTRICAL SYSTEM

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

Connector B (Red) terminal - chassis

Approx. battery voltage

(1) 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.

Resistance

B terminal - ACC terminal

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

B terminal - ACC terminal

0

(1) G Terminal

(2) ACC Terminal

(3) ST Terminal

(4) B Terminal

0000007173E

KiSC issued 04, 2006 A

6-S9

GR1600EC, WSM

(3) Starter

ELECTRICAL SYSTEM

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

(4) Glow Plug

ELECTRICAL SYSTEM

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.

Main switch key at

"PREHEAT"

Approx. battery voltage

Voltage(Lead terminal - Chassis)

Main switch key at

"START"

Approx. battery voltage

(1) 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

(5) Safety Switch

ELECTRICAL SYSTEM

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.

When plunger is pushed

0

Resistance (between terminal a and b)

When plunger is released

Infinity

Resistance (between terminal c and d)

When plunger is pushed

When plunger is released

0

Infinity

(1) PTO Switch

(2) PTO Lever

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.

When plunger is pushed

0

Resistance (between terminal a and b)

When plunger is released

Infinity

Resistance (between terminal c and d)

When plunger is pushed

When plunger is released

0

Infinity

(1) Brake Switch a to d : Safety Switch Terminal

0000009475E

KiSC issued 04, 2006 A

6-S12

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.

When plunger is pushed

0

Resistance (between switch terminals)

When plunger is released

Infinity

(1) 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.

When plunger is pushed

0

Resistance (between switch terminals)

When plunger is released

Infinity

(1) OPC Switch (Seat Switch)

0000009477E

6-S13

KiSC issued 04, 2006 A

GR1600EC, WSM

(7) Fuel Pump

ELECTRICAL SYSTEM

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

KiSC issued 04, 2006 A

6-S14

GR1600EC, WSM

(9) Time Relay

(10)Charging System

ELECTRICAL SYSTEM

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

Voltage

Connector terminal 3 - chassis

Approx. battery 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

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

KiSC issued 04, 2006 A

6-S15

GR1600EC, WSM

(11)Lighting System

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

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.

OFF Infinity

Resistance

Factory spec.

ON 0

(1) 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.

In normal state 0

Resistance(Switch terminal -Chassis)

At pressure over approx. 4.9 kPa(0.5

, 7 psi)

Infinity

(1) Engine Oil Pressure Switch

0000001186E

6-S17

KiSC issued 04, 2006 A

GR1600EC, WSM

(12)Coolant Temperature Sensor

(13)Grass Container Full Switch

ELECTRICAL SYSTEM

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)

Factory spec.

A certain voltage is indicated

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 Factory spec.

120 to 126

248.0 to 258.8

(1) Thermo Switch (A) ON

(B) OFF

(C) 120 to 126

(248.0 to 258.8 )

(D) 116 or

0000009486E

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.

When switch lever is pushed

0

Resistance (between switch terminals)

When switch lever is released

Infinity

(1) Switch Cover (2) Grass Container Full Switch

0000009487E

KiSC issued 04, 2006 A

6-S18

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

(2) Position Indicator

(3) Wing Nut

(4) Position Change Lever

A : Switch Position

B : Switch Position

0000009489E

KiSC issued 04, 2006 A

6-S19

GR1600EC, WSM

[2] DISASSEMBLING AND ASSEMBLING

(1) Starter

ELECTRICAL SYSTEM

(1) Sleeve Bearing

(2) Bushing

(3) Starter Drive Housing

(4) Drive Lever

(5) Magnet Switch

(6) Yoke

(7) Connecting Lead

(8) Through Bolt

(9) Rear End Frame

(10) Bushing

(11) Brush

(12) Brush Holder

(13) Brush Spring

(14) Brush

(15) Washer

(16) Armature

(17) Overrunning Clutch

1. Disconnect the connecting lead (7).

2. Remove the magnetic switch (5).

3. Remove the rear end frame (9).

4. Remove the brush (11) from brush holder (12).

5. Remove the brush holder (12).

6. Draw out the yoke (6) from the starter drive housing (3).

7. 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

KiSC issued 04, 2006 A

6-S20

GR1600EC, WSM

(2) Dynamo

ELECTRICAL SYSTEM

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 Nut

39.2 to 44.1

4.0 to 4.5

28.9 to 32.5 ft-lbs

(1) Screw

(2) Stator

(3) Nut

(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

(2) Pulley

(3) Rotor

(4) Collar

(5) Bearings

(6) Collar

0000001177E

6-S21

KiSC issued 04, 2006 A

GR1600EC, WSM

[3] SERVICING

(1) Starter

ELECTRICAL SYSTEM

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.

Commutator O.D.

Allowable limit

27.0 mm

1.063 in.

Difference of O.D.'s

Mica undercut

(1) Segment

(2) Undercut

(3) Mica

Factory spec.

Allowable limit

Factory spec.

Allowable limit

Less than 0.05 mm

0.002 in.

0.4 mm

0.016 in.

0.50 to 0.80 mm

0.0197 to 0.0315 in.

0.20 mm

0.0079 in.

(a) Correct

(b) incorrect

0000009491E

KiSC issued 04, 2006 A

6-S22

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.

Brush length (A)

Allowable limit

10.5 mm

0.413 in.

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

1. POWER TRANSMISSION

MOWER

(1) Center Pulley

(2) Output Shaft

(3) 17T Spiral Gear

(4) 18T Spiral Gear

(5) Input Shaft

(6) Outer Pulley

(7) Mower Belt

(8) Universal Joint

(9) Blade Shaft

(10) 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) Output Shaft

(2) Center Pulley (1) Mower Belt (7) Outer Pulley (6) Blade Shaft (9) Blade (10)

0000009588E

7-M1

KiSC issued 04, 2006 A

GR1600EC, WSM

2. LIFTING MECHANISM

MOWER

(1) Lift Link LH

(2) Rear Link LH

(3) Gas Spring

(4) Lift Link Shaft

(5) Mower Lift Lever

(6) Lift Link

(7) Cutting Height Adjusting

Dial

(8) Adjusting Cam

(9) Lift Link RH

(10) Rear Link RH

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

KiSC issued 04, 2006 A

7-M2

CONTENTS

1. TROUBLESHOOTING....................................................................................................... 7-S1

2. SERVICING SPECIFICATIONS ....................................................................................... 7-S2

3. TIGHTENING TORQUES ................................................................................................. 7-S3

4. CHECKING, DISASSEMBLING AND ASSEMBLING .................................................... 7-S4

[1] 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

1. TROUBLESHOOTING

Symptom Probable Cause

Blade Does Not Turn A PTO system malfunctioning

A Mower belt broken

Blade Speed Is Slow A Mower belt loosen

A Grass clogged

A Cup washer flattened out or worn

A Engine rpm too low

Cutting Is Poor

Mower Is Not Lifted

A Mower blade worn or bent

A Mower blade screw loosen

A Cutting height improper

A Ground speed too fast

A Tire pressure uneven

A Anti-scalp rollers not adjusted correctly

A Linkage system broken

MOWER

Solution

Replace mower belt or tension spring

Reference

Page

Check transmission

Replace mower belt 7-S8

7-S8

Remove grass

Replace cup washer 7-S8

Mow at full throttle, check and reset engine rpm

Sharpen or replace mower blade

Retighten mower blade screw

7-S8

7-S8

Adjust cutting height 7-S5

Slow-down

Add air to correct

Adjust anti-scalp rollers

Replace linkage system

7-S4

7-S11

0000009591E

7-S1

KiSC issued 04, 2006 A

GR1600EC, WSM

2. SERVICING SPECIFICATIONS

Item

Left Tip of Blade to Right Tip of Blade

Front Tip of Blade to Rear Tip of Blade

17T Spiral Gear to 18T Spiral Gear

Difference

Difference

Backlash

MOWER

Factory Specification Allowable Limit

Less than 6 mm

0.24 in.

Less than 5 mm

0.20 in.

0.13 to 0.25 mm

0.0051 to 0.0098 in.

0.40 mm

0.157 in.

0000009592E

7-S2

KiSC issued 04, 2006 A

GR1600EC, WSM

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

Mower blade screw

Gear box mounting screw

Gear box bracket mounting screw and nut

Pulley mounting screw (gear box)

Pulley mounting nut (pulley holder)

Pulley holder mounting screw

98 to 118

77.5 to 90.2

48.1 to 55.8

77.5 to 90.2

103 to 118

48.1 to 55.8

10.0 to 12.0

7.9 to 9.2

4.9 to 5.7

7.9 to 9.2

10.5 to 12.0

4.9 to 5.7

MOWER ft-lbs

72.3 to 86.8

57.2 to 66.5

35.5 to 41.2

57.2 to 66.5

76.0 to 87.0

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

Rear wheel

200 kPa, 2.0

140 kPa, 1.4

, 29 psi

, 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

Factory spec.

Less than 6 mm

0.24 in.

(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

[2] PREPARATION

(1) Dismounting Mower

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

Factory spec.

Less than 5 mm

0.20 in.

(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

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

KiSC issued 04, 2006 A

7-S6

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

(2) Rear Link

(3) L-pin

(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 Mower blade screw

98 to 118

10.0 to 12.0

72.3 to 86.8 ft-lbs

(1) Mower Blade Screw

(2) Shim

(3) Cap Washer

(4) Mower Blade

(5) Spindle Holder

(6) Dust Cover

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

Tightening torque

Gear box bracket mounting screw and nut

48.1 to 55.8

4.9 to 5.7

35.5 to 41.2 ft-lbs

(1) Gear Box

(2) Mower Belt

(3) Tension Pulley

(4) Universal Joint

(5) Gear Box Mounting Screw

(6) Gear Box Bracket Mounting

Screw and Nut

0000009602E

KiSC issued 04, 2006 A

7-S8

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.)

Gear box oil capacity

0.33 L

0.35 U.S.qts

0.29 Imp.qts

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

(2) Output Shaft

(3) Pulley

(4) External Snap Ring

(5) Oil Seal

(6) Internal Snap Ring

(7) Ball Bearing

(8) External Snap Ring

(9) Case

(10) Drain Plug

(11) O-ring

(12) 18T Spiral Gear

(13) Ball Bearing

(14) Shim

(15) Case Cover

(16) 17T Spiral Gear

(17) Shim

(18) Ball Bearing

(19) Input Shaft

(20) Ball Bearing

(21) Internal Snap Ring

(22) Oil Seal

0000009603E

KiSC issued 04, 2006 A

7-S9

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).

103 to 118

10.5 to 12.0

76.0 to 87.0 ft-lbs

Tightening torque

Pulley mounting nut

Pulley holder mounting screw

48.1 to 55.8

4.9 to 5.7

35.5 to 41.2 ft-lbs

(1) Blade Shaft

(2) Oil Seal

(3) Ball Bearing

(7) Ball Bearing

(8) Pulley Holder Mounting Nut

(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

(2) Mower Lift Linkage

MOWER

(1) 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

1. Dismount the mower. (See page 7-S6.)

2. Remove the fender. (See page 2-S12.)

3. Set the mower lift lever to "LIFT" position.

4. Unscrew the gas spring mounting nuts (2), (9), and then remove the gas spring (10).

5. Remove the screws (1), (19) and lock nuts (2), (18), and pull out the rue rings (7), (11).

6. Remove the rear link LH (4) and RH (17).

7. Pull out the rue rings (7), (12) and remove the clevis pins (5),

(13).

8. Remove the lift link LH (6) and RH (14).

9. 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

[4] SERVICING

(1) Gear Box

MOWER

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.

Allowable limit

0.13 to 0.25 mm

0.0051 to 0.0098 in.

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

(2) Shim (for 17T Spiral Gear)

(3) 17T Spiral Gear

(4) Output Shaft

(5) Shim (for 18T 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 : [email protected]

KUBOTA Corporation

Printed in Japan 2006. 03, S, EI, EI, e Code No.9Y011-15402

2005. 02, S, EI, EI, e