3
ISEKI LAWN MOWERS
TABLE OF CONTENTS
FOREWARD ................................................................ 2
TABLE OF CONTENTS............................................... 3
CHAPTER 1. INTRODUCTION ................................... 5
1. GENERAL INFORMATION ..................................... 5
a. Model name and identification numbers ......... 5
b. Chassis number .............................................. 5
c. Engine model name and serial number .......... 5
2. SPECIFICATIONS ................................................. 6
3. EXTERIOR VIEW AND DIMENSIONS ................... 7
4. PERIODIC INSPECTION TABLE............................ 8
5. FILLING DIAGRAM................................................. 9
CHAPTER 2. DISASSEMBLY OF MAJOR COMPO-
NENTS ....................................................................... 10
I. GENERAL PRECAUTIONS FOR SEPARATION
AND REINSTALLATION ....................................... 10
1. BEFORE OPERATION ......................................... 10
2. PRECAUTIONS TO BE FOLLOWED WHEN
INSTALLING COMMON PARTS ........................... 10
a. Roller or ball bearings ................................... 10
b. Oil seals ........................................................ 10
c. O-rings ...........................................................11
d. Snap-rings .....................................................11
e. Spring (roll) pins.............................................11
f. Cotter pins .....................................................11
g. Bolts and nuts ................................................11
h. After installation, each grease fitting should be
filled with grease. .......................................... 12
i. Other precautions ......................................... 12
II. BEFORE STARTING DISASSEMBLY .................. 12
1. REMOVAL OF THE MOWER DESK ..................... 12
2. REMOVAL AND REINSTALLATION OF MAJOR
FUNCTIONAL COMPONENTS ............................ 13
2.1. REMOVAL AND REINSTALLATION OF
ENGINE ........................................................ 13
REMOVAL..................................................... 13
REINSTALLATION ........................................ 16
2.2. REMOVAL AND REINSTALLATION OF
FENDERAND STEP ..................................... 17
REMOVAL OF FENDER ............................... 17
REMOVAL OF STEP .................................... 17
REINSTALLATION ........................................ 18
2.3. REMOVAL AND REINSTALLATION OF
TRANSMISSION CASE................................ 18
REMOVAL..................................................... 18
REINSTALLATION ........................................ 19
CHAPTER 3. ENGINE ............................................... 20
1. INSPECTION OF ENGINE OIL ............................ 21
2. INSPECTION OF FAN BELT ................................ 21
3. INSPECTION AND ADJUSTMENT OF VALVE
CLEARANCES...................................................... 22
4. INSPECTION AND ADJUSTMENT OF NOZZLE
OPENING PRESSURE AND INJECTION TIMING
...................................................................... 22
4.1. Adjustment of the valve opening pressure of
the injection nozzles ..................................... 22
4.2. Inspection of oil tightness of valve seats ...... 23
4.3. Spraying condition of injection nozzle........... 23
4.4. Inspection and adjustment of injection timing
...................................................................... 23
5. COMPRESSION AND UNLOADED IDLING.............
SPEEDS ............................................................... 25
5.1. Inspection of compression ............................ 25
5.2. Inspection and adjustment of the idling
speeds .......................................................... 25
6. INSPECTION OF WATER PUMP ......................... 25
6.1. Inspection of the pump and pulley ................ 25
6.2. Inspection of the bearing unit........................ 26
7. INSPECTION OF THERMOSTAT ......................... 26
III. ENGINE BODY ..................................................... 26
III.1. CYLINDER HEAD.............................................. 26
1. REMOVAL OF THE CYLINDER HEAD................. 27
2. DISASSEMBLY ..................................................... 28
3. INSPECTION ........................................................ 28
4. DISASSEMBLY AND INSPECTION OF THE
ROCKER ARM SHAFT ......................................... 31
5. INSPECTION OF THE PUSH RODS.................... 32
6. INSTALLATION OF THE CYLINDER HEAD......... 32
III.2. GEAR CASE ...................................................... 34
1. EXPLODED VIEW ................................................ 34
2. REMOVAL OF THE GEAR CASE......................... 34
3. RE-INSTALLATION OF THE GEAR CASE........... 35
III.3. CYLINDER BLOCK ........................................... 36
1. EXPLODED VIEWS .............................................. 36
2. DISASSEMBLY OF THE CYLINDER BLOCK ...... 37
3. INSPECTION OF CYLINDER BLOCK, CRANK-
SHAFT, CAMSHAFT, AND TAPPETS ................... 38
4. INSPECTION OF PISTONS AND CONNECTING
RODS.................................................................... 43
5. ASSEMBLY OF PISTON AND CONNECTING ROD
...................................................................... 45
6. INSTALLATION OF CRANKSHAFT...................... 46
7. INSTALLATION OF PISTON/CONNECTING-ROD
ASSEMBLIES ....................................................... 47
8. INSTALLATION OF REAR OIL SEAL ................... 48
9. INSTALLATION OF STRAINER AND OIL PAN..... 48
10.INSTALLATION OF REAR PLATE AND FLYWHEEL
...................................................................... 49
11.INSTALLATION OF FRONT PLATE AND GEARS
...................................................................... 49
CHAPTER 4. TRANSMISSION & RELATED PARTS
......................................................................... 52
1. DRIVE TRAIN DIAGRAM...................................... 52
2. TRANSMISSION................................................... 52
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