Yanmar L90AE - Troubleshooting Engine Problems; Starter Motor Failure Troubleshooting

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General Safety5
Serial Number Location6
Service Rules6
Contents7
Specifications9
Cross Sectional Views13
Longitudinal Sectional View14
Camshaft PTO Plan View15
Crankshaft PTO Plan View15
Service Standards16
Intake/Exhaust Valve Seats Service Standards16
Intake/Exhaust Valves & Valve Guides Service Standards16
Valve Springs Service Standards16
Intake/Exhaust Valve Rocker-Arm, Rocker Shaft and Push Rods Service Standards17
Valve Clearance Service Standards17
Valve Opening/Closing Timing Service Standards18
Piston Service Standards18
Piston Pin Service Standards19
Piston and Rings Service Standards19
Piston Ring Service Standards19
Connecting Rod Service Standards20
Crankshaft and Main Bearing Service Standards21
Camshaft Service Standards22
Tappet Service Standards22
Crankcase Cover Service Standards23
Cylinder Block Service Standards24
Oil Pump (Trochoid Pump) Service Standards25
Disassembly and Reassembly26
Tools26
Meters, Instruments and Service Accessories28
Instruments30
Tightening Torques31
Maintenance Schedule32
Disassembly Procedures33
Removing the Fuel Tank33
Removing the Exhaust Silencer33
Removing the Air Cleaner33
Removing the Cooling Fan Case/Starter Pulley/Air Intake Bend34
Removing the Valve Rocker Arm Assembly34
Fuel Injection Valve Disassembly34
Removing the Cylinder Head35
Removing the Fuel Pump35
Removing the Crankcase Cover35
Removing the Camshaft35
Removing the Balancer Shaft36
Removing the Piston and Connecting Rod Assembly36
Removing the Flywheel36
Removing the Crankshaft36
Reassembly Procedures37
Installing the Crankshaft37
Installing the Flywheel37
Installing the Piston and Connecting Rod37
Installing the Camshaft, Balancer Shaft38
Fuel Injection Pump Reassembly38
Installing Crankcase Cover38
Attaching the Crankcase Cover and Tightening Three Orders39
Installing the Cylinder Head39
Inserting the Push Rods39
Valve Rocker Arm Assembly39
Installing the Valve Rocker Arm Cover40
Installing the Fuel Injection Valve40
Installing the Intake Bend40
Installing the Cooling Fan Case40
Installing the Air Cleaner41
Installing the Starting Motor41
Installing the Fuel Tank41
Recoil Starter - Disassembling Procedures42
Recoil Starter - Assembling Procedures43
Recoil Starter - Checks after Reassembly44
Checking and Servicing45
Cylinder Head Checking and Servicing45
Combustion Surfaces Servicing45
Intake and Exhaust Valve Seats, Valve Guides Servicing45
In/Ex Valve Guide and Valve Stem Table46
Valve Spring Servicing47
Measuring the Top Clearance47
Intake and Exhaust Valve Rocker Arms and Push Rods Servicing48
Piston Servicing49
Adjusting the Valve Clearance49
Identification of Cylinder Head49
Piston Pin Servicing50
Checking Piston Pin Hole50
Piston O.D. Table50
Clearance between Piston and Sleeve Table/Piston Pin Hole I.D. Table50
Piston Rings Servicing51
Clearance between Piston Pin Hole and Pin Table51
Piston Ring Side Clearance52
Measuring the Clearance between the Piston Ring and Groove (Side Clearance)52
Measuring of Ring End Gap52
Checking the Connecting Rod53
Small and Large End Hole of Connecting Rod Table54
Checking the Crank Pin Metals54
Connecting the Piston and Connecting Rod55
Clearance between Crank Pin and Metal Table55
Tightening Torque Table55
Undersized Crank Pin Metal, Part No. Table55
Piston Top Mark56
Crankshaft Servicing57
Main Bearing Metal Servicing58
Flywheel Servicing58
Camshaft Servicing59
Checking the Timing Gears60
Tappet Servicing60
Crankcase Cover Servicing61
Replacing the Crankshaft Oil Seal and Camshaft Oil Seal63
Cylinder Sleeve and Cylinder Block Servicing63
Lubrication System Servicing64
Cylinder Sleeve I.D. Table64
Lubricating Oil Pump64
Fuel System Servicing66
Fuel Injection Pump66
Fuel Pump Mounting Flange66
Configuration of Fuel Oil Pump66
Fuel Pump Disassembly and Reassembly67
Fuel Injection Valve68
Fuel Injection Nozzle Diagram69
Fuel Injection Valve Assembly69
Speed Control Device Servicing70
Position of Governor Spring Hole70
Fuel Filter Servicing70
Electrical System Servicing72
L40AE - L100AE Engines Wiring Diagram (for 12V-15A/125V-3A Charging Generator)72
L40AE - L100AE Engines Wiring Diagram (for 12V - 3A Charging Generator)73
L40AE - L100AE Engines Wiring Diagram (for 12V - 1.7A Charging Generator)74
L40AE - L100AE Engines Wiring Diagram (for 12V - 1A Charging Generator)74
L40AE - L100AE Engines Wiring Diagram (with Air Heater and Timer, for 12V - 15A/12V - 3A Charging Generator)75
L40AE - L70AE Engines Wiring Diagram, (Generator for Lighting) for 12V-25W/40W (Use Lamp Only)76
For 6V-15W (Use Lamp Only)76
Starter Motor Servicing77
Starter Motor Specifications and Performance77
Characteristics Curve77
Starter Motor Construction78
Conventional Type Sterter Motor (Standard Electric Starter) Diagram78
Over-Running Clutch Diagram78
Reduction Type Starter Motor (Option for L75AE-SE - L100AE-SE)79
Reduction Type Starter Motor Operation81
Reduction Type Starter Motor Disassembly82
Reduction Type Disassembly83
Magnetic Switch Removal84
Dust Cover and Shift Lever Removal84
Clutch Assembly/Disassembly84
Reduction Type Starter Motor Inspection85
Armature Inspection85
Field Coil Inspection86
Magnetic Switch Inspection86
Pinion/Brush Inspection87
Brush Dimensions88
Reduction Type Starter Motor Adjustment and Performance Test89
Reduction Type Starter Motor Reassembly Precautions90
Reduction Type Starter Motor Characteristics Test90
Reduction Type Starter Motor Maintenance Standards91
Generator (Dynamo), Regulator and Rectifier Servicing/Specifications92
Dynamo Construction93
Generator Check93
Inspection of Dynamo/Regulator (Combination)94
Inspection of Discrete Regulator (Simplified Inspection)95
Inspection of Rectifier96
Air Heater Servicing97
Battery Servicing98
Battery Capacity and Battery Cables98
Battery Inspection99
Battery Charging100
Adjustment101
Adjustment of Fuel Injection Timing101
Bleeding Air from Tuel System101
Fuel Injection Volume Limitation102
Adjusting the Clearance on Intake/Exhaust Valve Head102
Adjusting the Valve Head Clearance102
Troubleshooting103
No Fuel Injection Sound103
Low Compression Pressure105
Recoil too Heavy107
Failure of Starter Motor (Starter)108
Insufficiently Charged Battery110
Normal Fuel Injection and Compression and Light Recoil, but Engine Is Still Hard to Start111
Unexpected Reverse Rotation at Startup112
Reverse Rotation of Engine112
Racing113
Uneven Rotation114
Output Drops115
Sudden Stops During Operation116
Abnormal Exhaust Color117
Black/Bluish-White Exhaust118
Test Run119
Before Starting119
Operation121
Stopping121
Helical Inserting Part for Repair122
Procedure for Using Helical Insert Part123
Difference between Parts under Spec. S and D125
Details of Special Tools128
Flywheel Tightening Handle129
Flywheel Extractor129

Yanmar L90AE - Troubleshooting Engine Problems; Starter Motor Failure Troubleshooting

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