Kawasaki Gas Engines

John Deere K Series
Liquid-cooled Engines
COMPONENT
TECHNICAL
MANUAL
John Deere
Lawn & Grounds Care Division
CTM39 (Oct93)
Replaces CTM39 (28JAN91)
Litho in U.S.A
INTRODUCTION
This component technical manual is written for an

experienced technician. It covers recommended repair Safety
procedures, starting with the engine removed from the
machine and on a workbench or engine stand. Some
components may be serviced in the machine.
Determine the repair procedure before removing the Specifications and
engine. Use this manual in conjunction with the Information
machine technical manual. It is a part of a total product
support program. Use the Fundamental Of Service
(FOS) manual as reference for fundamentals of service
and basic theory of operation. Intake, Muffler & Breather
Fuel System & Governor

The manual is organized so that all the information on
a particular system is kept together. The order of
grouping is as follows:
• Table of Contents
Cylinder Head & Valves
• Safety
• Specifications
• Theory of Operation Cylinder Block, Pistons & Rods
• Repair
Note: Depending on the particular section or system

being covered, not all of the above groups may
Camshaft, Crankshaft &
be used. Flywheel
Power Train
Each section will be identified with a symbol rather than Lubrication System
a number. The pages within a section will be
consecutively numbered.
Cooling System
All information, illustrations and specifications in this
manual are based on the latest information available at
the time of publication. The right is reserved to make Electrical System
changes at any time without notice.
Troubleshooting
We appreciate your input on this manual. To help, there
are postage paid post cards included at the back. If you
find any errors or want to comment on the layout of the
manual please fill out one of the cards and mail it back
to us.
Component Analysis
Miscellaneous
COPYRIGHT© 1993
JOHN DEERE HORICON WORKS
Horicon, Wisconsin
All rights reservedl
4/7/95 1-1
SAFETY
HANDLE FLUIDS SAFELY-AVOID HANDLE CHEMICAL PRODUCTS

FIRES SAFELY
• BE PREPARED FOR EMERGENCIES
TS1132 TS1133
TS291 Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with John Deere equipment include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.
TS227
• DISPOSE OF WASTE PROPERLY
When you work around fuel, do not smoke or work near Improperly disposing of waste can threaten the
heaters or other fire hazards. environment and ecology. Potentially harmful waste
used with John Deere equipment include such items as
Store flammable fluids away from fire hazards. Do not oil, fuel, coolant, brake fluid, filters, and batteries. Use
incinerate or puncture pressurized containers. leakproof containers when draining fluids. Do not use
Make sure machine is clean of trash, grease, and food or beverage containers that may mislead
debris. someone into drinking from them. Do not pour waste
onto the ground, down a drain, or into any water
Do not store oily rags; they can ignite and burn source. Inquire on the proper way to recycle or dispose
spontaneously. of waste from your local environmental or recycling
Be prepared if a fire starts. center, or from your John Deere dealer.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
1-2 4/7/95
SAFETY
USE SAFE SERVICE PROCEDURES • WORK IN CLEAN AREA
• Before starting a job

• WEAR PROTECTIVE CLOTHING
1. Clean work area and machine:
Wear close fitting clothing and safety equipment
appropriate for the job. 2. Make sure you have all necessary tools to do your
job.
Prolonged exposure to loud noise can cause
3. Have the right parts on hand.
impairment or loss of hearing. Wear a suitable hearing
protective device such as earmuffs or earplugs to 4. Read all instructions thoroughly; do not attempt
protect against objectionable or uncomfortable loud shortcuts.
noises.
.
• ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
TS206
• WORK IN VENTILATED AREA
TS228
TS220
• SERVICE MACHINES SAFELY
Engine exhaust fumes can cause sickness or death. If
Tie long hair behind your head. Do not wear a necktie, it is necessary to run an engine in an enclosed area,
scarf, loose clothing, or necklace when you work near remove the exhaust fumes from the area with an
machine tools or moving parts. If these items were to exhaust pipe extension.
get caught, severe injury could result.
If you do not have an exhaust pipe extension, open the
Remove rings and other jewelry to prevent electrical doors and get outside air into the area.
shorts and entanglement in moving parts.
• USE PROPER TOOLS

Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards. Use power tools
only to loosen threaded parts and fasteners. For
loosening and tightening hardware, use the correct size
tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches. Use only service parts meeting John Deere
specifications.
4/7/95 1-3
SAFETY
• REMOVE PAINT BEFORE WELDING OR HEATING LIVE WITH SAFETY

Avoid potentially toxic fumes and dust. Hazardous TS231
fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work outside
or in a well ventilated area. Dispose of paint and
solvent properly. Remove paint before welding or
heating: If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator. If you use solvent or
paint stripper, remove stripper with soap and water
before welding. Remove solvent or paint stripper
containers and other flammable material from area.
Allow fumes to disperse at least 15 minutes before
welding or heating.
• AVOID HARMFUL ASBESTOS DUST

Avoid breathing dust that may be generated when
handling components containing asbestos fibers. Before returning machine to customer, make sure
Inhaled asbestos fibers may cause lung cancer. machine is functioning properly, especially the safety
systems. Install all guards and shields.
Components in products that may contain asbestos
fibers are brake pads, brake band and lining
assemblies, clutch plates, and some gaskets. The
asbestos used in these components is usually found in
a resin or sealed in some way. Normal handling is not
hazardous as long as airborne dust containing
asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If not available, apply
a mist of oil or water on the material containing
asbestos. Keep bystanders away from the area.
REPLACE SAFETY SIGNS
TS201
Replace missing or damaged safety signs. See the

machine operator's manual for correct safety sign
placement.
1-4 4/7/95
CONTENTS SPECIFICATIONS & INFORMATION
CONTENTS
Page
SPECIFICATIONS & INFORMATION
BASIC ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ENGINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE MODEL CONFIGURATION CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE SERIAL NUMBER PLATE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CARBURETOR SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TEST & ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 5
REPAIR SPECIFICACATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FD440V/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GASOLINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FD440V/501V/590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INTERNAL ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4/7/95 2 -1
NOTES SPECIFICATIONS & INFORMATION
2-2 4/7/95
BASIC ENGINE SPECIFICATIONS
FD440V FD501V FD590V- FD590V- FD620D FD620D FD620D

ENGINE
AS00 AS00 AS00/02 AS03 AS04/11 ASO2 AS00/01
HORSEPOWER 11.1 kW 12.6kW 13.4 kW 14.9kW (20 13.4 kW 14.9kW 16.4 kW
(15 HP) (17 HP) (18 HP) HP) (18 HP) (20 HP) (22 HP)
CYLINDER 2 2 2 2 2 2 2
CYCLE 4 4 4 4 4 4 4
BORE 67 mm 67 mm 74 mm 74 mm 76 mm 76 mm 76 mm
(2.64 in.) (2.64 in.) (2.90 in.) (2.90 in.) (2.99 in.) (2.99 in. (2.99 in.
STROKE 62 mm 62 mm 68 mm 68 mm 68 mm 68 mm 68 mm
(2.44 in.) (2.44 in.) (2.66 in.) (2.66 in.) (2.66 in.) (2.66 in.) (2.66 in.)
437 cm3 437 cm3 585 cm3 585 cm3 617 cm3 617 cm3 617 cm3
DISPLACEMENT (26.7 cu. (26.7 cu. (35.7 cu. (35.7 cu. (35.7 cu. (35.7 cu. (35.7 cu.
in.) in.) in.) in.) in.) in.) in.)
ENGINE APPLICATIONS
NOTE: Refer to the engine application chart to identify product-model/engine type-model relationship.
Lawn Tractors
Machine Engine Model No.
LX178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD440V - AS00
LX188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD501V - AS00
Lawn And Garden Tractors

285 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS00
285 w/Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS01
320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS00
425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS02
445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS01
Front Mowers
F911 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS00
F725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS03
Golf And Turf Equipment

1800 Utility Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS04
2243 Professional Greensmower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS02
2653 Professional Utility Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS04
6X4 Gator Utility Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS11
4/7/95 2-3
ENGINE MODEL CONFIGURATION

CHANGES
FD440V/FD501V/FD590V:
FD590V
The following is a list of the major differences between
the model configurations of the FD590V-AS00 through
the FD590V-AS03.
• The FD590V-AS00 is the first configuration used and
its first application was in the 285 Lawn and Garden
Tractor.
• FD590V-AS01 was converted to a electronic fuel
injection system. The carburetor was replaced by a
throttle body and a water temperature sensor was
added.
• FD590V-AS02 engine is used in the 2243 Triplex
Professional Greensmower.
• FD590V-AS03 is used in the F725 Front Mower. The
power was increased from 18 to 20 horsepower. To M53952
obtain the higher horsepower the following
components were changed:
• A larger redesigned intake manifold The engine serial number (A) is located on the side of
• The cylinder head induction passage and combustion the cooling air duct.
chamber was redesigned.
• A larger carburetor is used. FD620D:
NOTE: The FD440V, FD501V and FD590V are vertical

shaft engines. The FD620D is a horizontal shaft
engine.
FD620D
The differences in horsepower are due to the following:
• rpm that the engine must run for the application.
• the efficiencies of fuel injection on the FD620 - AS01.
ENGINE SERIAL NUMBER PLATE

LOCATIONS
NOTE: Refer to the engine model designation on the
engine serial number plate to identify repair
information covered in the Component Technical
Manual
M53953
The engine serial number (A) is located on the

crankcase cover.
2-4 4/7/95
TEST & ADJUSTMENT SPECIFICATIONS SPECIFICATIONS & INFORMATION
CARBURETOR SERIAL NUMBER

LOCATIONS
FD440V/FD501V/FD590V: FD620D:
M53957 M53958
The carburetor serial number (A) is located on the top The carburetor serial number (A) is located on the side
of carburetor. of carburetor.
TEST & ADJUSTMENT SPECIFICATIONS

Engine:
Oil pressure sensor activates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 kPa (14.2 psi)
Oil pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 kPa (40 psi)
Oil filter bypass valve opening pressure . . . . . . . . . . . 78.5—117.5 kPa (11.4—17.1 psi)
Cylinder compression pressure (minimum) . . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi)
Maximum compression pressure variation between cylinders . . . . . . . . 138 kPa (20 psi)
Crankcase vacuum (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1 in.) water
Intake and exhaust valve clearance (cold) . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)
Intake and exhaust valve adjustment interval . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hrs.
Valve clearance adjusting nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in)
Fuel/Air System:
Fuel Pump
Minimum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 ml (3.5 oz) in 15 seconds
Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 kPa (1.5 psi)
Carburetor SLOW idle mixture screw initial setting. . . . . . . . . . . . . . . . . . . . . . . . . 1 Turn
Carburetor SLOW idle stop screw setting
. . . . . . . . . . . . . . . 50 rpm less than throttle control arm SLOW idle stop screw setting
Throttle Cable Throttle control arm SLOW idle stop screw setting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1175+25 / -50 rpm
Throttle control arm FAST idle stop screw setting . . . . . . . . . . . . . . . . . . 3650 ± 75 rpm
Air Restriction Indicator
Normal restriction vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . .102—178 mm (4—7 in.)
Maximum restriction vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 mm (15 in.)
Fuel Tank
Check valve opening pressure (maximum) . . . . . . . . . . . . . . . . . . . . . . 3 kPa (0.4 psi)
Cooling System:
Radiator cap
Maximum test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi)
Minimum pressure after 15 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
Opening pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–96 kPa (12–14 psi)
Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 kPa (11 psi)
Thermostat
Begin-to-open temperature . . . . . . . . . . . . . . . . . . . . . . . approximately 63°C (145°F)
Full-open temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 80°C (176°F)
Full-closed temperature . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 63°C (145°F)
4/7/95 2-5
SPECIFICATIONS & INFORMATION REPAIR SPECIFICACATIONS
REPAIR SPECIFICACATIONS
FD440V/501V
Crankcase
Oil Capacity
With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 L (3.59 pt)
Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 L (3.20 pt)
Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)
Fuel System
Carburetor Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.)
Intake Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.)
Fuel Pump Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
CYLINDER HEAD AND VALVES

Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Rocker Arm
Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.)
Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.)
Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.)
Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)
Valves and Springs
Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.)
Minimum Valve Stem O.D.
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.93 mm (0.194 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.92 mm (0.193 in.)
Maximum Valve Guide I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.06 mm (0.199 in.)
Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)
Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . 0.50 - 1.10 mm (0.020 - 0.043 in.)
Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)
Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Cylinder Head
Maximum Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)
Cap Screw Torque In Sequence (Lubricated)
Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.)
FLYWHEEL
Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (66 lb-ft)
CAMSHAFT AND TAPPETS

Camshaft
Minimum End Journals O.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.91 mm (0.548 in.)
Minimum Lobe O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.43 mm (0.962 in.)
Minimum Fuel Pump Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.760 in.)
Maximum Cover Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.05 mm (0.553 in.)
Maximum Crankcase Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 14.07 mm (0.554 in.)
2-6 4/7/95
REPAIR SPECIFICACATIONS SPECIFICATIONS & INFORMATION
PISTON, CONNECTING ROD AND CRANKSHAFT
Piston
Maximum Ring Groove Clearance
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured
Maximum Ring End Gap
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.)
Minimum Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.)
Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.04 mm (0.631 in.)
Distance from bottom of piston skirt
Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.)
Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm (2.6358 - 2.6364 in.)
Piston-to-Cylinder Bore Clearance. . . . . . . . . . 0.015 - 0.150 mm (0.00059 - 0.0059 in.)
Connecting Rod
Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.)
Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.)
End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)
Crankshaft
Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.92 mm (1.178 in.)
Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 30.93 mm (1.218 in.)
Maximum T.I.R. (Total Indicated Runout) . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Plain Bearings
Maximum Crankcase and Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . 30.09 mm (1.185 in.)
CYLINDER BLOCK
Cylinder Bore
Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.98 - 67.00 mm (2.637 - 2.638 in.)
Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.06 mm (2.640 in.)
Rebore Cylinder
Oversize Diameter
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm (2.656 - 2.657 in.)
LUBRICATION SYSTEM
Oil Pump
Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.)
Maximum Rotor Shaft Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.)
Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.592 in.)
Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.)
Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (0.748 in.)
GOVERNOR
Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.)
IGNITION AND CHARGING SYSTEM

See Ignition and Charging Specifications in this Group.
4/7/95 2-7
ELECTRIC STARTER
See this group for continuity checks.
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.)
Maximum No Load Starter Draw . . . . . . . . . . . . . . . . . . . . . 50 amps at 6000 rpm (min)
COOLING SYSTEM
Engine Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 L (2.2 qt)
Thermostat
Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)
Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)
Water Pump
Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.94 mm (0.391 in.)
Maximum Pump and Crankcase Housing Bore I.D. . . . . . . . . . . . . 10.09 mm (0.397 in.)
Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.)
Crankcase Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Over-flow Reservoir
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)
2-8 4/7/95
FD590V
Crankcase
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 L (4.44 pt)
Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)
FUEL SYSTEM
Carburetor Nut Torque
(M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.)
(M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (133 lb-in.)
Intake Manifold
Fuel Pump
Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

Rocker Arm
Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.)
Push Rod
Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)
Valves and Springs
Minimum Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.)
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.)
Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.)
Cylinder Head
Maximum Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)
Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
FLYWHEEL
Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 118 N•m (72 - 87 lb-ft)
4/7/95 2-9
Camshaft
Minimum Lobe O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.23 mm (0.993 in.)
Minimum Fuel Pump Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.760 in.)
Maximum Cover and Crankcase Bearing I.D. . . . . . . . . . . . . . . . . 16.07 mm (0.633 in.)
PISTON, CONNECTING ROD, AND CRANKSHAFT
Piston
Top and Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Oil Ring Not Measured
Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.040 in.)
Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.98 mm (0.668 in.)
Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.)
Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm (2.9108 - 2.9114 in.)
Piston-to-Cylinder Bore Clearance. . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.)
Connecting Rod
Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.)
Crankshaft
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Plain Bearings
Maximum Crankcase and Cover I.D . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)
CYLINDER BLOCK
Cylinder Bore
Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.98 - 74.00 mm (2.915 - 2.916 in.)
Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.07 mm (2.918 in.)
Rebore Cylinder
Oversize Diameter
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46 - 74.48 mm (2.934 - 2.935 in.)
LUBRICATION SYSTEM
Oil Pump
Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.770 in.)
2 - 10 4/7/95
GOVERNOR
Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.)

ELECTRIC STARTER
COOLING SYSTEM
Engine Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.04 L (3.2 qt)
Thermostat
Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)
Water Pump
Over-flow Reservoir
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)
4/7/95 2 - 11
FD620D
Crankcase
Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 L (3.2 pt)
Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)
FUEL SYSTEM
Carburetor Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)
Intake Manifold

Rocker Arm
Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.)
Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.)
Valves and Springs
Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.)
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.)
Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.)
Cylinder Head
Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)
Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
FLYWHEEL
Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N•m (80 lb-ft)
Sheave Half Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)
Camshaft
Minimum Lobe O.D.
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.21 mm (0.993 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.46 mm (1.002 in.)
Maximum Cover and Crankcase Bearing I.D. . . . . . . . . . . . . . . . . 16.07 mm (0.633 in.)
2 - 12 4/7/95
PISTON, CONNECTING, AND RODCRANKSHAFT
Piston
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.)
Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured
Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.98 mm (0.668 in.)
(Area to measure piston O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.)
Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm (2.989 - 2.990 in.)
Piston-to-Cylinder Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.)
Connecting Rod
Crankshaft
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Plain Bearings
Maximum Crankcase Cover I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)
Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.)
CYLINDER BLOCK
Cylinder Bore
Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.98 - 76.00 mm (2.994 - 2.995 in.)
Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.07 mm (2.997 in.)
Rebore Cylinder
Oversize Diameter
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.46 - 76.48 mm (3.012 - 3.013 in.)
LUBRICATION SYSTEM
Oil Pump
Maximum Rotor Shaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.)
Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.592 in.)
Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.770 in.)
GOVERNOR
Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.)

4/7/95 2 - 13
ELECTRIC STARTER
COOLING SYSTEM
Sheeve/Half Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)
Thermostat
Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65°C (148°F)
Water Pump
2 - 14 4/7/95
METRIC TORQUE VALUES SPECIFICATIONS & INFORMATION
METRIC TORQUE VALUES

4.8 8.8 9.8 10.9 12.9
Property
Class
and 4.8 8.8 9.8 10.9 12.9
Head
Markings 4.8 8.8 9.8 10.9 12.9 12.9
Property 5 10 10 12
Class
and
10
10
12
5
Nut 5 10 10 12
Markings
Ts1163
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya
SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
M6 48 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
DO NOT use these values if a different torque value or approximately 50 percent of the dry torque shown in
tightening procedure is given for a specific application. the chart, applied to the nut, not to the bolt head.
Torque values listed are for general use only. Check Tighten toothed or serrated-type lock nuts to the full
tightness of fasteners periodically. torque value.
a
Shear bolts are designed to fail under predetermined “Lubricated” means coated with a lubricant such as
loads. Always replace shear bolts with identical grade. engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without any
Fasteners should be replaced with the same or higher
grade. If higher grade fasteners are used, these should lubrication.
only be tightened to the strength of the original. Make b Grade 2 applies for hex cap screws (not hex bolts) up
sure fasteners threads are clean and that you properly to 152 mm (6-in.) long. Grade 1 applies for hex cap
start thread engagement. This will prevent them from screws over 152 mm (6-in.) long, and for all other types
failing when tightening. of bolts and screws of any length.
Tighten plastic insert or crimped steel-type lock nuts to
4/7/95 2 - 15
SPECIFICATIONS & INFORMATION GASOLINE SPECIFICATIONS
GASOLINE SPECIFICATIONS FUEL STORAGE

Keep fuel in a clean container in a protected area.
c
CAUTION: Water and sediment must bromated before fuel gets to
the engine. Do not use deicers to remove water from
fuel. Do not depend on fuel filters to remove water.
Handle fuel with care, it is highly flammable. DO If possible, install a water separator at the storage tank
NOT refuel machine: outlet.
• Indoors. Always fill fuel tank outdoors.
• While you smoke. IMPORTANT: Keep all dirt, scale, water or other
foreign material out of fuel.
• When machine is near and open flame or
sparks.
If vehicle is either stored or used during the winter, add
• When engine is running. STOP engine. TY6295 John Deere Gasoline Storage Stabilizer or an
• When engine is hot. Allow it to cool. equivalent to the fuel. Follow directions on can.
Help prevent fires:

• Fill fuel tank only to bottom of filler neck.
• Clean oil, grease and dirt from machine.
• Clean up spilled fuel immediately.
• Do not store machine with fuel in tank in a
building where fumes may reach an open
flame or spark.
To prevent fire and explosion caused by static

electric discharge while you fill tank:
• Use approved, non-metal fuel container.
• When using a funnel, MAKE SURE it is
PLASTIC.
• Avoid using a funnel which has a metal screen
or filter.
IMPORTANT: To avoid engine damage:

DO NOT mix oil with gasoline
Use only clean oil and fuel
Use clean approved containers and funnels.
Store oil and fuel in an area protected from dust,
moisture and other contamination.
Unleaded fuel is recommended because it burns

cleaner and leaves less unburned deposits in engine
combustion chamber. Regular leaded gasoline with an
anti-knock index of 87 or higher may be used.Use of
gasohol is acceptable as long as the ethyl alcohol
blend does not exceed 11 percent. Unleaded gasohol
is preferred over leaded gasohol.
Fill fuel tank at end of each day's operation. Fill only to
bottom of filler neck.
2 - 16 4/7/95
LUBRICANT SPECIFICATIONS SPECIFICATIONS & INFORMATION
LUBRICANT SPECIFICATIONS ENGINE COOLANT

Use ethylene glycol base coolant. These coolants
usually have labels stating “For Automobile and Light
ENGINE OIL Duty Service.” These products are also often labeled
Use oil viscosity based on the expected air temperature for use in aluminum engines. Check container label
range during the period between oil changes. before using.
The following oil is preferred:
IMPORTANT: To prevent engine damage, DO NOT
• John Deere PLUS-4® use pure antifreeze or more than 50% antifreeze
in the cooling system. DO NOT mix or add any
other type additives to the cooling system.
Mix approximately 50 percent antifreeze with 50

percent distilled or deionized water. This mixture will
provide freeze protection to -340 F (-37 0 C).
Certain geographical areas may require lower
temperature protection. See the label on your
antifreeze container or consult your John Deere dealer
to obtain the latest information and recommendations.
The recommended antifreeze provides:
• Adequate heat transfer.
• Corrosion-resistant environment within the cooling
system.
• Compatibility with cooling system hose and seal
material.
• Protection during cold and hot weather operations.
SYNTHETIC LUBRICANTS
TS1411 Synthetic lubricants may be used in John Deere
equipment if they meet the applicable performance
requirements (industry classification and/or military
Other oils may be used if they meet one of the specification) as shown in this group.
following: The recommended temperature limits and service or oil
• API Service Classification SG change intervals should be maintained as shown in the
operator’s manual.
• API Service Classification SF
• CCMC Specification G4 Avoid mixing different brands, grades, or types of oil.
Oils meeting Military Specification MIL-L-46167B may Oil manufacturers blend additive in their oils to meet
certain specifications and performance requirements.
be used as arctic oils.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
OIL FILTERS
Filtration of oils is critical to proper lubrication. Always
change filters regularly.
Use filters meeting John Deere performance
specification.
4/7/95 2 - 17
SPECIFICATIONS & INFORMATION COMPONENT LOCATION
COMPONENT LOCATION
FD440V/501V/590V
Radiator Outlet
Hose
Air Cleaner Cover
Oil Pressure
Switch
Oil Dipstick
Oil Filter
Breather
Hose
Drain Plug
Fuel Pump
Control Plate
Ignition Coil
Cylinder Head Water Pump
Spark Plug Lead Rocker Arm Cover M45816
Right-Hand Side Shown
NOTE: Bare block components are similar between engines, some

peripheral components may be different between applications.
2 - 18 4/7/95
COMPONENT LOCATION SPECIFICATIONS & INFORMATION
COMPONENT LOCATION - FD440V/501V/590V - Continued

Radiator Cap
Radiator Screen
Overflow
Hose
Radiator Inlet
Hose
Radiator
Fan Housing
Thermostat Cover
Coolant Temperature
Switch Overflow
Reservoir
Cylinder Head
Rocker Arm Cover
Spark Plug Lead
Ignition Coil
Crankcase
Starter
Regulator/
Rectifier
Starter Solenoid Ignition Module
M45645
Left-Hand Side Shown
4/7/95 2 - 19
SPECIFICATIONS & INFORMATION INTERNAL ENGINE COMPONENTS
INTERNAL ENGINE COMPONENTS
Air Cleaner
Air Cleaner Paper Element
Foam Element
Fan
Valve Seat
Flywheel Intake Valve
Stator Valve Springs
Crankshaft
Valve Cover
Crankshaft
Valve Guide
Gear
Exhaust Valve
Water Pump Gear

Oil Pump
Water Pump Impeller

Camshaft Gear
Oil Screen Camshaft
Governor Gear Governor Flyweights M45646
Side View Cutaway
2 - 20 4/7/95
INTERNAL ENGINE COMPONENTS SPECIFICATIONS & INFORMATION
INTERNAL ENGINE COMPONENTS - Continued

Breather Hose
Carburetor
Rocker Arm Shaft Throttle Control Plate
Rocker Arm Breather Cover
Adjusting Screw
and Lock Nut
Push Rod
Tappet
Camshaft
Piston Pin
Pulsar Coil
Piston Rings
Oil Filter
Piston
Connecting Rod
Starter Motor
Oil Pressure Sensor
Stator
Starter Solenoid
Connecting Rod Cap
Regulator/Rectifier
M45647
Top View Cutaway
4/7/95 2 - 21
SPECIFICATIONS & INFORMATION INTERNAL ENGINE COMPONENTS
ENGINE COMPONENTS - FD620D

Governor
Drive Gear
Coolant Pump Gear
Carburetor
Camshaft Gear Governor Arm
Muffler
Pistons
Fan Belt
Drive
Crankcase
Breather
Chamber
Rocker Arms Connecting

Rod
Push Rods
Valves Oil Filter
Cylinder
Head Outer
Sheave
Halve
Tappets
Camshaft
Flywheel
Crankshaft
Gear
Oil Pump
Gear Crankshaft Cylinder Block
M54274
Cutaway - FD620D
The FD620D engine components are similar to the horizontal shaft engines
except for the orientation of the oil pickup screen.
Differences of the external components consist of an optional fan drive
and a down draft carburetor.
2 - 22 4/7/95
CONTENTS INTAKE, EXHAUST & BREATHER
CONTENTS
Page
INTAKE, EXHAUST & BREATHER
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4/7/95 3-1
INTAKE, EXHAUST & BREATHER AIR CLEANER
AIR CLEANER
FD440V/FD501V/FD590V
IMPORTANT: Carefully remove air cleaner cover and elements.

Inspect inside paper element and intake passage for signs of dust.
If present, replace elements and test engine compression or
inspect for damage.
Do not clean paper element with solvent or compressed air.
Any time air cleaner base is removed, check for free

choke operation during reassembly.
Air Cleaner Cover

Foam Element
Wash with detergent and water,
Replace if stretched or torn.
Oil lightly with engine oil.
Paper Element Squeeze out excess,
Do Not clean. Replace
if oily, dirty or damaged
in any way or direct
light can be seen
through paper.
M53973
FD620D
Mounting Screws (3)

Use medium strength Breather Hose
Thread Lock and Sealer
Tighten evenly.
Foam Element
Wash with detergent and
water, Replace if
stretched or torn.
Oil lightly with engine oil.
Squeeze out excess.
Paper Element
Do Not clean.
Replace if oily, dirty
or damaged in any To Air Filter
way or direct light can Restriction
be seen through Indicator
M57331
3-2 4/7/95
INTAKE MANIFOLD INTAKE, EXHAUST & BREATHER
INTAKE MANIFOLD NOTE: Cracks not visible to the eye may be detected
by coating suspected area with a mixture of
25% kerosene and 75% light engine oil. Wipe
REMOVAL area dry and immediately apply a coat of zinc
oxide dissolved in wood alcohol. If cracks are
1. Remove carburetor and governor control panel. present, the coating will become discolored at
the crack location.
17 N•m
Air Horn (12 lb-ft) INSTALLATION
(If equipped)
1. Before installing manifold, install cylinder heads and
tighten head bolts in sequence to half the rated
Carburetor torque value.
See Fuel System
for repair 2. Install intake manifold and tighten bolts in two steps
to a final torque of 6 N•m (52 lb-in.).
17 N•m 3. Tighten cylinder head bolts to 21 N•m (15 lb-ft.).
Stud
(12 lb-ft)
MUFFLER
Intake Elbow Gasket
Replace
NOTE: Muffler design may vary between applications.
Gasket
Manifold Bolts
6 N•m
(52 lb-in.)
Intake Mainiflod
Intake Gasket
M57355
Side Draft Carburetor Configuation Shown Nut

6-7.5 N•m
(52-69 lb-in.)
IMPORTANT: To prevent warpage, loosen bolts 1/4
turn at a time, in sequence, until all bolts are
loose. Lock Washer
Gasket
Manifold Bolts Replace
Tighten in 3 N•m increments. Stud
Mounting Bolt
Final Torque 6 N•m (52 lb-in.) 14 -19 N•m 6-7.5 N•m
5 1 4 8 (10 -13.5 lb-ft) (52-69 lb-in.)
M46434
• Clean exhaust pipe flanges and install new gasket

before installing muffler.
7 3 2 6 • Use medium strength, Thread Lock and Sealer on
M46862 studs and nuts.
• Loosely tighten flange nuts.
Torquing Sequence
• If equipped with extra supporting brackets, also
loosely tighten mounting bolts.
2. Visually inspect manifold passages for corrosion, • Tighten flange nuts first then mounting bolts.
cracks, porous castings or deposits. Clean or
replace as necessary.
4/7/95 3-3
INTAKE, EXHAUST & BREATHER BREATHER
BREATHER REPAIR
Inspect reed valve for breakage, hairline cracks or
distortion, replace if necessary.
OPERATION
• Inspect the backing plate for damage or a rough
The breather controls crankcase pressure, preventing contact surface, replace if necessary.
oil from being forced out passed the piston rings, oil
• Inspect the valve seating surface for damage, repair
seals and gaskets. The reed valve limits air flow out of
if necessary.
the crankcase caused by piston movement, then blocks
return air flow creating a vacuum in the crankcase. Reed Valve Backing Plate
Seating
Oil ladden air enters the breather chamber where it is Surface
directed through a mase, separating most of the oil
from the air. The oil drains back to the crankcase and
the air vents back the the intake air in the air cleaner.
Air Vent to Intake
M51757
Drain Hole
• breather reed valve tip air gap of 0.2 mm (0.008
Gasket in.).
Reed Valve
Back Plate
Cover
M54277
3-4 4/7/95
CONTENTS FUEL SYSTEM & GOVERNOR
CONTENTS
Page
FUEL SYSTEM & GOVERNOR
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SIDE DRAFT CARBURETOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DOWN DRAFT CARURETOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CLEAN AND REBUILD CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FLOAT LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MECHANICAL FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
THROTTLE BODY REPAIR - FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
THROTTLE BODY REPAIR - FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4/7/95 4-1
NOTES FUEL SYSTEM & GOVERNOR
4-2 4/7/95
CARBURETOR FUEL SYSTEM & GOVERNOR
CARBURETOR
SPECIFICATIONS
Side Draft:
Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)
Intake Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)
Choke & Throttle Plate Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.88 N•m (7.8 lb-in.)
Down Draft:
Throttle Shaft Retaining Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 N•m (17 lb-in.)
Drain Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 N•m (10 lb-in.)
Choke &Throttle Valve Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.88 N•m (7.8 lb-in.)
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 N•m (87 lb-in.)
Main Jet & Main Air Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 N•m (8.9 lb-in.)
Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft)
Carburetor Repair Kits

• Gasket Kit
• Jet Kit
TROUBLESHOOTING
Problem or
Engine is hard to start when cold

Engine speed unstable (surging)
Runs better without air cleaner
Symptom
Engine will not start, plug wet
Spark plug burned white

Spark plug fouled black
Run worse when warm
Black smoky exhaust
Engine is sluggish
Engine overheats
Check or Loss of power
Solution
Mixture too rich ● ● ● ● ● ● ●
Mixture too lean ● ● ● ● ●
Check and clean air cleaner ● ● ● ● ● ●
Clean under engine shrouding ● ● ● ●
Adjust Idle mixture and check engine

● ● ● ● ●
performance.
Choke is not completely open. Adjust. ● ● ● ● ●
Inlet needle and seat leaking ● ● ● ●
Choke is not completely shut. Adjust. ●
Clean Carburetor ● ● ● ● ● ●
4/7/95 4-3
FUEL SYSTEM & GOVERNOR CARBURETOR
THEORY OF OPERATION Choke Operation:
Carburetors operate on the principles that air moving The choke plate restricts most of the air flow though the
through a tube will speed up with a resulting drop in carburetor to provide a very fuel rich mixture for
pressure when it passes through the venturi. The low starting. Because of the restriction and very low
pressure at the venturi allows normal air pressure in pressure area in carburetor throat, fuel is forced though
the float bowl to force fuel through the main jet and up all ports (main and pilot). Air is mixed with the main air
into the carburetor throat where it is atomized by the jet and pilot air jets as previously described. The fuel/
high speed flow of air and carried into the engine. air mixture is richer because there is less air flow
through the venturi.
Float System:
Fuel Shut-off Solenoid:
The float and inlet needle valve controls the inlet of fuel
into the carburetor. It is continually opening and It’s purpose is to help control engine backfire.
closings the inlet needle valve to maintains a constant When the ignition key is turned on, the solenoid
fuel supply and level. retracts a plunger that was plugging the main jet or
Proper level is important because it will effect the ability access passage to the main jet, and allows fuel to enter
of atmospheric pressure to force the transfer of fuel main jet or cavity.
through the passages When the engine is turned off, the fuel shut-off solenoid
releases the plunger, closing off fuel flow. This allows
the engine to starve for fuel, preventing excess fuel that
Pilot System: might have ignited during engine shutdown.
The pilot system meters fuel/air mixture while engine is
idling and running under light load.
At idle, the throttle plate will be nearly closed. Only the
pilot outlet port is uncovered. There is not enough air
volume or velocity to draw fuel through the main circuit.
Fuel flow is metered by the pilot jet. Some air is also
metered by a pilot air jet and allowed to mix with the
pilot fuel for better atomization.Some pilot air jets are
lock into the correct position with a clip and cap
screw.Tis is done to align internal passages. The pilot
jet and pilot air jet are not adjustable.
The pilot mixture air screw only adjusts the mixture out
the pilot outlet and does not effect the transition
ports.Each transition port is uncovered as the throttle
opens, allowing more fuel flow.
Main Jet System:

The main circuit functions when the engine is at partial
to full throttle (throttle plate full open), moderate to
heavy loads. In this condition, air flows very quickly
through the venturi, creating a very low pressure area
at the end of the main nozzle. Air pressure in the bowl
now can push fuel up through the main jet and out the
nozzle. At the same time, air is also drawn through the
main air jet, into a cavity surrounding the main nozzle
called the emulsion tube. Here the fuel is mixed with air
bubbles created by the small holes, Raw fuel and air
begin atomizing.
The main jet and main air jet are not adjustable. Only
the main jet can be removed and replaced by a
different size to compensate for higher or lower altitude
operation. The engine and it’s application determine
the size of the main jet used in each carburetor.
4-4 4/7/95
Side Draft Carburetor with Fuel Shut-off Solenoid
Down Draft Carburetor with Fuel Shut-off Solenoid
4/7/95 4-5
SIDE DRAFT CARBURETOR REPAIR
c CAUTION
Gasoline is extremely flammable. Do not smoke. Always work in a
ventilated area away from open flame or spark producing equipment, this
includes equipment that utilizes pilot lights.
Refer to the illustration and the following notes for disassembly and assembly.
Spring Choke Shaft

Replace Carburetor if worn
Restriction
Throttle Shaft Indicator Fitting
Washer Use Thread Sealant
Replace carburetor
if worn Seal
Intake
Nuts Adapter
Pilot Jet Seal
17 N•m
Note position before 12 lb-ft)
removing
Idle Stop Screw Bushing
Pilot Air Jet
Idle Mixture Screw
No damage to tapered end.
Gasket
Use Thread
Carburetor Body Lock & Sealer
Choke Plate
Use Thread Lock & Sealer
Main Air Jet
Intake Elbow Vent

17 N•m Emulsion Hose
(12 lb-ft) Needle Tube
Replace
Main Jet
Float
Gasket
Gasket
Pin
Drain Screw
Bowl Screw
Intake Manifold
M56705
4-6 4/7/95
DOWN DRAFT CARURETOR REPAIR

Refer to the illustration and the following notes for disassembly and assembly.
Air Horn (If equipped)
O-Ring
Cap Screws Choke Plate

2.9 N•m
(26 lb-in.)
Collars
Choke Shaft
Gasket
Needle Valve
Float
High Altitude Main Jet Float Pin

J
Pilot Jet
Carburetor Body
Fuel Shut-off Solenoid
(If Equipped)
Washer
Main Jet Seal
Springs
Retainer
Drain Screw
2 N•m
Idle Mixture Screw (17 lb-in.)
Low Idle Screw Throttle Shaft
Throttle Plate Spring

M57347
4/7/95 4-7
CLEAN AND REBUILD FLOAT LEVEL ADJUSTMENT

CARBURETOR
There are a n umber of plates or boll plugs on/in the NOTE: Plastic floats are non-adjustable.
carburetor that should not be removed.
• Turn the idle mixture screw in and note the number
of turns required to lightly seat it before removing
it. Float Mating
Tap
Surface
NOTE: If all rubber or plastic parts cannot be removed Air Horn
for cleaning, use a solvent, with a high flash
Needle
point, that will not damage these parts when
cleaning.
• Remove rubber or plastic parts from the carburetor.

Immerse all the carburetor metal parts in a
carburetor cleaning solution.
• Rinse the parts in water and dry with compressed
air, do not use rags or paper to dry parts. Lint can
plug the tiny passages in the carburetor.
• Inspect the carburetor body for damage. Ensure the
sealing surfaces and flanges are smooth and free
of nicks and burrs.
• Turn the idle mixture screw in until lightly seated
and back it out the same number of turns counted
during disassembly.
• Install the choke valve with the metering hole
towards the fuel inlet joint of the carburetor. GOOD REPLACE M57333
• Ensure the float pin extends the same distance on
both sides of the float hinge bracket when
reassembling the carburetor.
1. Hold air horn upside down at eye level with float
• Ensure the throttle and choke valves move freely assembly installed.
and that the shaft bosses are not elongated or
2. Gently support float with a finger and lower it slowly
worn. If shaft bosses have any of these conditions,
until the float arm tab just touches the float valve
replace the carburetor.
needle.
• Inspect the inlet needle for wear or damage. The tip
3. The float lower surface should be parallel with the
should be smooth, without any grooves, scratches
body mating surface.
or tears. If worn or damaged, replace the float
assembly and carburetor body as a set. 4. If necessary, bend float arm tab to adjust float level.
• Inspect the idle mixture screw for wear or damage,
replace it if necessary.
4-8 4/7/95
MECHANICAL FUEL PUMP FUEL SYSTEM & GOVERNOR
MECHANICAL FUEL PUMP REPAIR
THEORY OF OPERATION
Function:
Transfer fuel from the fuel tank to the carburetor.
Theory of Operation:
From Tank Inlet Chamber

Outlet Chamber
Outlet Valve Fuel Pump

To Carburetor
M51693
Inlet Valve
Plunger Disconnect fuel line and remove fuel pump and rod.
Diaphragm
Spring
M49793
Gasket
The fuel pump is a mechanical drive type unit. A cam Push Rod
on the camshaft of the engine moves actuating plunger.
This plunger moves pivot arm which is connected to
diaphragm. A spring is also connected to the Insulator
diaphragm.
As the contact point of the plunger on the cam changes
from the base to the tip during rotation, the plunger
moves outward. This rotates the pivot arm and pulls the Cap Screw
14 -19 N•m
diaphragm downward increasing the volume of the M57334
(10 - 13 lb-ft)
pump chamber. This creates a low pressure area and
fuel is drawn in from the fuel tank past inlet valve.
When the contact point of the plunger changes from
the tip to the base on the plunger moves inward and Inspect pump and insulator for wear or damage.
the pivot arm rotate the opposite direction. This allows Replace as necessary.
the spring to push the diaphragm upward and reduce Check push rod for bend using V-blocks and a dial
the volume in the pump chamber. Fuel is forced out of indicator. Install push rod, insulator and fuel pump.
the pump chamber past outlet valve to the carburetor.
The maximum pressure that the pump can develop
controlled by the strength of the spring. This design Pump Push Rod Specifications
prevents over pressurizing the fuel being delivered the Maximum Bend. . . . . . . . . . . . . . 0.05 mm (0.002 in.)
carburetor.
4/7/95 4-9
FUEL SYSTEM & GOVERNOR GOVERNOR
GOVERNOR
THEORY OF OPERATION
IMPORTANT: Do not remove flyweight assembly or shaft unless damaged.

Removal damages the assembly.
Sleeve
Link and Spring

Flyweight Assembly
Do Not remove unless damaged.
Thrust Inner Flange
Washer
Governor Arm
32.2 - 32.8 mm
Shaft (1.267 - 1.291 in.)
Groove
Oil Seal Governor Shaft

Lips toward
engine.
Press in 1.0 Crankcase Throttle Shaft
mm (0.04
in.) below
crankcase Governor
surfaces. Spring
Clamp Nut
Projections 7.8 N•m
Sleeve (69 lb-in.)
Shaft Arm M57332
Theory of Operation: governor arm.

The governor controls engine speed. Governed engine 4. Turn governor shaft 1/4 turn clockwise to remove
speed is a balance between governor spring tension, shaft.
set by the throttle control, and actual engine speed, 5. Replace shaft seal. Press in to dimensions,
countered by centrifugal force of the governor 6. Install governor shaft by properly positioning it
flyweights. As tension is applied to governor spring, between the two projections on crankcase.
governor arm opens carburetor throttle shaft,
increasing engine rpm. As engine speed increases,
flyweight assembly, driven by the crankshaft, pushes NOTE: Install sleeve into governor and install as an
on governor shaft, rotating governor arm, closing assembly.
throttle shaft, reducing rpm.
7. Push assembly onto shaft until it snaps into place.
REPAIR Check assembly for freedom of movement
8. Install governor arm loose in governor shaft.
1. Remove camshaft
9. Hold top of governor arm counterclockwise to open
2. Use two suitable pry-bars to pry flyweights assembly throttle plate.
from shaft. Do Not damage crankcase sealing
10. Turn governor shaft fully counterclockwise to end of
surfaces. its travel. Check dimension from arm to end of shaft.
3. Unscrew governor arm clamp nut and remove
11. Tighten arm clamp nut.
4 - 10 4/7/95
FUEL INJECTION SYSTEM FUEL SYSTEM & GOVERNOR
FUEL INJECTION SYSTEM all sensors.
NOTE: For more information on fuel injection testing,

THEORY OF OPERATION see the appropriate vehicle technical manual.
The fuel injected engines uses a digital fuel injection
system to control fuel delivery to the injector.
FUEL INJECTOR
Throttle Body Fuel Pressure Regulator
Fuel Injection
Module THEORY OF OPERATION
Function:
Injects fuel into the throttle body at the correct time and
duration.
Throttle
Sensor
Air Temperature Electrical Terminal
Injector Sensor M70805 Solenoid
Fuel Inlet
FD590V Shown Spring Filter Core
The following sensors and circuits monitor engine Valve

operating conditions.
• throttle sensor (FD590V)
• air temperature sensor
• coolant temperature sensor
• starter voltage circuit
Nozzle
• engine speed circuit Fuel Outlet M45335
• battery voltage circuit
• altitude compensation (Optional on FD590V)
These sensors send digital signals to a computer in the Theory of Operation:
fuel injection module. The computer processes these
signals and determines the correct amount of fuel to The fuel injector is a solenoid operated type valve with
inject to match the present engine operating conditions. single point injection. Fuel is injected into the throttle
body when the solenoid is energized by the computer.
A fuel control circuit that consists of a fuel pump and The amount of fuel injected depends on the length of
fuel pump relay are also controlled by the injection time the injector valve is open and on fuel pressure.
module computer to provide the correct fuel delivery.
High pressure fuel from the fuel pump flows through
Fuel system pressure is controlled by the fuel pressure filter to the inlet passage. High pressure fuel also flows
regulator. out the outlet passage to the pressure regulator. The
The FD620D uses a injection system that is similar in pressure regulator maintains the correct fuel pressure
operation to of that of the FD590V with the following needed for injection. When the solenoid is energized,
differences. the solenoid core pulls the valve open against spring
tension. High pressure fuel is injected in the throttle
• There is an additional air pressure sensor to body through the nozzle. After a precise amount of fuel
compensate for altitude. is injected, the computer de-energizes the solenoid.
• The ignition module is combined with the fuel Spring tension closes valve guickly to prevent
injection module so there is only one module. additional leakage.
• All the sensors are used to help adjust engine
timing, unlike the FD590V where only the engine
speed effected timing.
• Throttle sensor is no longer used. Engine speed is
sensed by the pulser
• Only one pulser is used. It controls ignition timing,
injection timing and engine speed. The flywheel
has four tabs that are used by the single pulser.
• This injection system has self-diagnosis that checks
4/7/95 4 - 11
FUEL SYSTEM & GOVERNOR FUEL INJECTOR
REPAIR FUEL PRESSURE REGULATOR
NOTE: See electrical system for electrical tests. THEORY OF OPERATION
IMPORTANT: Do not drive against tip. Plastic cover Function:

can crack and nozzle will be damaged. Do not
drop injector. Maintains a constant differential in pressure between
fuel pressure at the injector and air pressure in the
throttle body.Therefore, the amount of fuel injected is
determined by the opening time of the injector.
O-rings
Replace
Spring
To Throttle Body Spring Chamber
Screen
Clean M48181 Diaphragm Valve Support
Valve
1. Remove injector retainer. Grip end of injector, twist

and pull.
Fuel Chamber
Inlet From
IMPORTANT: Always install new o-rings on
Injector
injector when injector is removed.
2. Replace injector o-rings and clean fuel screen.

3. Lubricate o-rings with clean engine oil.
4. Install injector in the same orientation as removed.
Return to Tank
M44227
The pressure regulator is an overflow type regulator.
The spring chamber is connected to the throttle boby to
insure that they are operating at the same air pressure.
High pressure fuel from the injector flows to the
pressure regulator inlet and fills the fuel chamber. A
hose from the vacuum inlet is connected to the intake
manifold. This allows the air pressure in the spring
chamber and intake manifold to be equal.
When intake manifold vacuum increases, the spring
chamber vacuum also increases and overcomes spring
tension allowing the diaphragm to move upward. With
the valve connected to the diaphragm, the valve moves
upward and allows more fuel to flow out the outlet and
return to the fuel tank. This lowers the fuel pressure. As
intake manifold vacuum decreases, the spring chamber
vacuum decreases and the spring returns the
diaphragm to the original position. The valve restricts
fuel flow to return and fuel pressure increases.
4 - 12 4/7/95
THROTTLE BODY FUEL SYSTEM & GOVERNOR
REPAIR Replace regulator if defective. Install new o-ring on

regulator inlet and install regulator.
IMPORTANT: Relieve fuel pressure before

disconnecting fuel line. NOTE: Valve will not move without maximum fuel
pressure on inlet.
Remove fuel lines, vacuum line and regulator.

THROTTLE BODY
THEORY OF OPERATION
NOTE: The throttle body and fuel pressure regulator

Regulator for both the FD590 and FD620 work under the
same principles.
Function:
Injects and atomizes the fuel into the intake air for the
M57358 proper combustion.
FD590V Fuel Regulator Throttle Body
Regulator
Fuel Inlet Throttle Sensor
Injector
M57359
Fuel Pressure Regulator
FD620D Fuel Regulator
Return to Tank M57361
Test Regulator:
FD590D Throttle Body
Apply vacuum to vaccum port of regulator. Regulator
must hold vaccum.
Operation:
An electric fuel pump, controled by the computer,
supplies fuel to the inlet of the throttle body to the
injector. The fuel pressure regulator holds the fuel
under pressure in the injector. The computer recieves
signals from the throttle sensor and other sensors then
controls the time the injector is open. The injector
injects the atomized into the throat of the throttle body.
Excess fuel not used by the injector flows through the
pressure regulator back to the fuel tank.
O-ring The FD620 has an extra passage in the throttle body
the allows for a means to relieve the fuel pressure in
the fuel lines before any work is done on the system.
M57360
4/7/95 4 - 13
FUEL SYSTEM & GOVERNOR THROTTLE BODY
4. Mark position of throttle sensor before removal. This

Throttle Body Injector Regulator will aid in obtaining approximate idle speed when
reassembled.
5. Remove throttle plate and throttle shaft only if there
is evidence of wear.
Fuel Inlet
NOTE: Some individual components can be replaced
without removing throttle body.
Disassemble throttle body only if necessary.
Such as: fuel leakage, or component
malfunction.
Remove regulator and temperature sensor.
Fuel Return to Tank

Fuel Pressure Relief Plug
M57362
Throttle Body
FD620 Throttle Body
Throttle Sensor
THROTTLE BODY REPAIR - FD590V Throttle Shaft

Remove Throttle Body
Cap Screws
Injector Throttle
Plate
Pressure Regulator
O-Ring
Retainer
Air Temperature Sensor M48180
6. Use thread Lock and Sealer on throttle plate screws.

Return 7. Assemble all parts. Install new O-rings and gaskets.
Stud & Nut (2)
8. Install throttle body and connect governor linkage.
Injector Tighten nuts and air shrouding cap screws.
9. Connect throttle cable and all hoses.
Fuel Inlet
M48179
THROTTLE BODY REPAIR - FD620D
1. Disconnect:
• Fuel inlet hose
• Fuel Return Hose
• Injector
• Breather Hose
• Throttle Cable
Close openings using caps and plugs.
2. Remove cap screws from air shrouding and throttle
body retaining nuts.
3. Disconnect governor linkage as throttle body is
being removed. M57363
4 - 14 4/7/95
THROTTLE BODY FUEL SYSTEM & GOVERNOR
c CAUTION
Relieve fuel pressure before removing any fuel
line or components.
Loosen Fuel Pressure Relief Valve Plug.
Do not remove throttle shaft unless it appears to be worn or damaged.

If throttle shaft is worn, check throttle body bushing. If worn, replace throttle body.
The throttle plate must be perfectly centered in bore when closed. It must also
operate freely when plate screws are tightened.
O-ring Seal Shaft Retainer

Replace if damaged. 2 N•m
(17 lb-in.) Throttle Shaft
Nut Seal
17 N•m Install lips out
(12 lb-ft)
Injector Cover Throttle Plate
Plate Screw
Use Thread Lock
Cover Cap Screws
0.8 N•m
Tighten evenly. (8 lb-in.)
Spring Low Idle
Stop Screw
Injector
Twist and pull to remove. Throttle Body
Clean screen.
Lubricate o-rings with Fuel Regulator
engine oil.
Stud(2) O-rings
Fuel Pressure Relief Plug

15 N•m (133 lb-in.)
Gasket
Replace
M57338
4/7/95 4 - 15
FUEL SYSTEM & GOVERNOR THROTTLE BODY
4 - 16 4/7/95
CONTENTS CYLINDER HEAD & VALVES
CONTENTS
Page
CYLINDER HEAD & VALVES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEAD AND VALVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VALVE, VALVE SEAT AND GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVE SPRING FREE LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PUSH ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4/7/95 5-1
NOTES CYLINDER HEAD & VALVES
5-2 4/7/95
SPECIFICATIONS CYLINDER HEAD & VALVES
SPECIFICATIONS
Cylinder Head
Compression (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi)
Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (.002 in.)
Cap Screw Torque In Sequence
Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.)
Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Spark Plug Torque
FD440V//FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.)
Rocker Arm
Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.)
Push Rod
Maximum Runnout (bend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.03 in.)
Valves and Springs

Valve Clearance
FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (.010 in.)
Spring Free Length
FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.)
Intake
FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.93 mm (0.194 in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.)
Exhaust
FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.92 mm (0.193 in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.)
Maximum Valve Guide I.D.
FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.06 mm (0.199 in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.)
Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . 0.5 -1.10 mm (.020-.043 in.)
Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in.)
Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45o
Minimum Valve Margin
FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.)
Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30o
4/7/95 5-3
CYLINDER HEAD & VALVES CYLINDER HEAD
CYLINDER HEAD CLEANING AND INSPECTION
REMOVAL NOTE: Use tools that will not gouge or damage the
cylinder head.
IMPORTANT: Loosen cylinder head bolts 1/4 turn

at a time, in the sequence shown, to avoid 1. Scrape heads to remove carbon deposits or use a
warping the cylinder head de-carbonizing agent.
Clean head with a suitable solvent and dry with
Mark position of all valve train parts so they can compressed air.
be reinstalled in their original position. 2. Lay a straight edge along the sealing surface of head
and measure warpage with a thickness gauge at
several different points. If warpage exceeds service
limit, repair or replace cylinder head.
3. Check cylinder head for cracks.
2 4. Apply clean engine oil to all contact surfaces and
assemble cylinder head.
3
Special Bolt
M46437
HEAD AND VALVE COMPONENTS
Valve Cover
Gasket Circlip
Replace
Top Retainer Rocker Arm Shaft

Minimum Diameter: 11.95 mm
Cover (0.470 IN.)
Cap Screws Seals
Replace
Keepers
Head Bolts
Springs 21 N•m
Check Free Length (15 lb-ft)
Bottom Retainer
Cylinder Head Exhaust Valve

Warp(max):0.06 mm Head Gasket
(0.002 in.)
Lock Nut Intake Valve
9 N•m
(79 lb-in.) Guide Pin
Rocker Arm
Adjuster Screw Minimum I.D.:12.074 mm
(0.4754 in.)
M57335
5-4 4/7/95
VALVE, VALVE SEAT AND GUIDE CYLINDER HEAD & VALVES
VALVE, VALVE SEAT AND GUIDE • Valve guides are not replaceable. If worn, replace
head.
• If grinding the valve and valve seat is necessary,
INSPECTION follow tool manufacturer’s instructions carefully.
• Lap valves after grinding with lapping compound
and recheck valve seating surface for correct width
A and evenness of seating pattern.
.
45°
45° B Correct Seat

Position
Seat Too High Seat Too Deep
M18615
• If seats are warped or distorted beyond

D M57341 reconditioning, replace cylinder head.
• Check valve seating pattern for correct width and
evenness all the way around.
A - Valve Margin (Min.) • Clean and measure valve stem at three points
FD440V/FD501V . . . . . . . . . . . . . 0.50 mm (0.020 in.) along length of stem.
FD590v/FD620D . . . . . . . . . . . . . . 0.6 mm (0.024 in.)
VALVE SPRING FREE LENGTH
B - Valve Seating Width
. . . . . . . . . . . . . . . . . . . 0.5 - 1.1 mm (0.02 - 0.043 in.) • Inspect valve spring for pitting, rust and burrs.
C - Valve Stem Diameter (Min.)
Intake: FREE LENGTH SPECIFICATIONS (MIN)
FD440V/FD501V . . . . . . . . . . . . . 4.93 mm (0.194 in.) FD440/501V . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.)
FD590V/FD620D . . . . . . . . . . . . . 5.94 mm (0.234 in.)
FD590V/FD620D . . . . . . . . . . . 29.70 mm (1.170 in.))
Exhaust:
FD440V/FD501V . . . . . . . . . . . . . 4.92 mm (0.193 in.)
FD590V/FD620D . . . . . . . . . . . . . 5.92 mm (0.233 in.)
Intake: . . . . . . . . . . . . . . . . . . . 5.945 mm (0.2341 in.)

Exhaust: . . . . . . . . . . . . . . . . . 5.925 mm (0.2332 in.)
D - Guide I.D. (Max.)

FD440V/FD501V . . . . . . . . . . . . . 5.06 mm (0.199 in.)
FD590V/FD620D . . . . . . . . . . . . . 6.05 mm (0.238 in.)
M50036
Valve Stem Run out (Max.) . . . . 0.05 mm (0.002 in.)
4/7/95 5-5
CYLINDER HEAD & VALVES VALVE, VALVE SEAT AND GUIDE
PUSH ROD INSPECTION
Push Rod
Maximum run-out : 0.8 mm
(0.03 in.)
M50044
INSTALLATION
IMPORTANT: Handle head gaskets carefully to

avoid removing the sealing agents from the
surface during handling.
Use a torque wrench when tightening cylinder

head bolts in sequence shown.
NOTE: For easier assembly turn flywheel until cam

lobes are at their lowest position. Install the
push-rods in their original positions. This will
allow head to be installed without compressing
valve springs.
Torque should be applied in 3 N•m (27 lb-in.)

increments.
• Tighten cylinder head bolts to half the required
torque.
• Install manifold before applying a final torque of 21
N•m (186 lb-in.).
• Adjust Valve Clearance.
3
Special Bolt
M46437
5-6 4/7/95
CONTENTS CYLINDER BLOCK, PISTONS & RODS
CONTENTS
Page
CYLINDER BLOCK, PISTONS & RODS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVE PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECT REPLACE CRANKSHAFT PLAIN BEARINGS . . . . . . . . . . . . . . . . . . . 8
REPLACE CRANKSHAFT JOURNAL BUSHING AND SEALS . . . . . . . . . . . . . . . 9
INSPECT BLOCK CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DEGLAZE CYLINDER BORE 10
REBORE CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVE AND INSTALL PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CHECK PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECT PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSPECT CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ASSEMBLE CONNECTING ROD AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . 14
4/7/95 6-1
NOTES CYLINDER BLOCK, PISTONS & RODS
6 -2 4/7/95
SPECIFICATIONS CYLINDER BLOCK, PISTONS & RODS
SPECIFICATIONS
FD440V/FD501V
CYLINDER BLOCK
Cylinder Bore
Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.98 - 67.00 mm (2.637 - 2.638 in.)
Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.06 mm (2.640 in.)
Rebore Cylinder
Oversize Diameter
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm (2.656 - 2.657 in.)
Plain Bearings
Maximum Crankcase and Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . 30.09 mm (1.185 in.)
Piston
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Maximum Ring End Gap
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.)
Minimum Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.)
Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.)
Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm (2.6358 - 2.6364 in.)
Piston-to-Cylinder Bore Clearance. . . . . . . . . . 0.015 - 0.150 mm (0.00059 - 0.0059 in.)
Connecting Rod
Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.)
4/7/95 6-3
CYLINDER BLOCK, PISTONS & RODS SPECIFICATIONS
FD590V
CYLINDER BLOCK
Cylinder Bore
Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.98 - 74.00 mm (2.915 - 2.916 in.)
Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.07 mm (2.918 in.)
Rebore Cylinder
Oversize Diameter
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46±74.48 mm (2.934±2.935 in.)
Plain Bearings
Maximum Crankcase and Cover I.D . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)
Piston
Top and Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Oil Ring Not Measured
Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.98 mm (0.668 in.)
Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.)
Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm (2.9108 - 2.9114 in.)
Piston-to-Cylinder Bore Clearance . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.)
Connecting Rod
6-4 4/7/95
SPECIFICATIONS CYLINDER BLOCK, PISTONS & RODS
FD620D
CYLINDER BLOCK
Cylinder Bore
Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.98 - 76.00 mm (2.994 - 2.995 in.)
Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.07 mm (2.997 in.)
Rebore Cylinder
Oversize Diameter
0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.46 - 76.48 mm (3.012 - 3.013 in.)
Piston
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.)
Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured
Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.98 mm (0.668 in.)
(Area to measure piston O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.)
Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm (2.989 - 2.990 in.)
Piston-to-Cylinder Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.)
Connecting Rod
Plain Bearings
Maximum Crankcase Cover I.D.. . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)
Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.)
4/7/95 6-5
CYLINDER BLOCK, PISTONS & RODS REPAIR
REPAIR
CRANKCASE DISASSEMBLY
1. Drain crankcase.
2. Remove water pump.
NOTE: Crankcase is pinned by oil filter and opposite side.

Do not force cover.
5 7 6
4
3 2
1 4
1 2
5 8
3 6
M53974 M517207
FD440V/FD501V FD590V/FD620D
3. Remove crankcase cover and gasket..
6-6 4/7/95
REPAIR CYLINDER BLOCK, PISTONS & RODS
COMPONENTS
Fan Drive Coupling

15 N•m
(130 lb-in)
Nut
Gasket
Washer FD440/501: 90 N•m (66 lb-ft)
FD590/620: 110 N•m (80 lb-ft)
Flywheel
Stator
Oil Pump Assembly
Breather Assembly Lifters
Oil Pressure Governor

Sensor Flyweight
Seal
Bushing
Oil Filter
Oil Pick-up
Screen
Camshaft
Piston Rings
Cylinder
Block
Crankshaft Crankcase
Seal
Piston
Piston Pin Gear Pin

Crankcase Cap Screws
21 N•m (186 lb-in.)
Crankshaft Gear
Rod Cap
FD440/501V: 12 N•m (106 lb-in.)

FD590/620: 21N•m (186 lb-in. ) M57345
4/7/95 6-7
REMOVE PISTONS INSPECT & REPLACE

CRANKSHAFT PLAIN BEARINGS
Match Marks
Raised Letters
(MADE IN JAPAN)
Flywheel Side
Large Chamfers
M46447
NOTE: Note location of the arrow match mark on the M50072

piston head in relation to “Made in Japan” on
the connecting rod. No. 1 piston is opposite
no.2. Keep parts together as a set. Measure crankshaft bearings in crankcase and
crankcase cover. Replace block, cover or shells, if
equipped, if diameter is greater than specifications.
1. Turn the crankshaft to expose the connecting rod (See this group.)
end caps. Mark the end caps for reassembly in the
same position as removed.
2. Remove carbon and/or ridge from the top of the BEARING I.D. SPECIFICATIONS (MAX)
cylinder bore with a suitable ridge remover and Crankcase and Cover
remove the piston and connecting rod through the FD440/501V . . . . . . . . . . . . . . 30.09 mm (1.185 in.)
top of the cylinder bore. FD590V . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)
FD620D
Crankcase Cover . . . . . . . . . 34.07 mm (1.341 in.)
Crankcase . . . . . . . . . . . . . . 34.11 mm (1.343 in.)
6-8 4/7/95
REPLACE CRANKSHAFT JOURNAL To Design a Bushing Tool

BUSHING AND SEALS
1. Place crankcase on bench with oil seal side up. A
C
M46456
Bushing Tool Dimensions

(A) . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575 in.)
(B) . . . . . . . . . . . . . . . . . . . . . . . . 26 mm (1.024 in.)
M44227 (C) . . . . . . . . . . . . . . . . . . . . . . 33.8 mm (1.331 in.)
3. Remove bearing shell using a bushing, bearing and
Crankcase Seal
seal driver set and press.
2. Remove oil seal. 4. Apply a light coat of oil on outside diameter of new
bearing shell.
5. Install new bearing shell flush with crankcase flange
NOTE: Do not re-use oil seal. Replace with new. surface.
Bushing Tool
Flange Surface
Flange Surface
Spring Loaded
New Bushing Lip
Lip Seal
Dust Lip
High Temperature
Grease
M46445
Support Block
M46455
6. Remove crankshaft oil seal and press in a new seal
with spring loaded lip towards inside of the engine
• The service bushing is to be reinstalled using a and outside edge of seal flush with flange surface.
bushing tool as shown. 7. Pack space between seal lip and dust lip with high
• Coat the bushing and flange surface with a light film temperature grease.
of oil, Press in the new bushing flush with the 8. Install new seal with flange flush with case.
flange surface.
• No finish reaming is required
4/7/95 6-9
INSPECT BLOCK CYLINDERS DEGLAZE CYLINDER BORE

1. Clean and check block for cracks. 1. Deglaze cylinder bore using a rigid hone with a 220
2. Cracks not visible to the eye may be detected by to 300 grit stone.
coating the suspected area with mixture of 25 2. Use hone as instructed by manufacturer to obtain
percent kerosene and 75 percent light engine oil. 45° crosshatch pattern as shown.
3. Wipe area dry and immediately apply coating of zinc
oxide dissolved in wood alcohol. If crack is present,
coating becomes discolored at the defective area. IMPORTANT: Do not use gasoline, kerosene, or
Replace block if any cracks are found. commercial solvents to clean cylinder bores.
Solvents will not remove all abrasives from
cylinder walls.
3. Clean cylinder walls using clean white rags and

water. Continue to clean cylinder until white rags
show no discoloration.
REBORE CYLINDER BLOCK
IMPORTANT: Check stone for wear or damage. Use

correct stone for the job.
M54745
NOTE: The cylinder block can be rebored to use 0.50 (

0.020 ) oversize pistons and rings. Have a
4. Measure cylinder bore parallel with crankshaft and reliable repair shop rebore the block, or use a
right angles to crankshaft at top and bottom of ring drill press and honing tool.
travel.
5. If cylinder bore exceeds wear limit, replace cylinder
block or rebore cylinder.
45° - 60°
NOTE: Before reboring, check availablity of oversize
piston and rings. They must be installed.
CYLINDER BORE SPECIFICATIONS
Standard Wear Limit

FD440V FD501V
. . . . . . . . . . . . . . . . . . . . . . . . . . . 66.98 - 67.00 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . (2.637 - 2.638 in.)
Wear Limit. . . . . . . . . . . . . . . 67.06 mm (2.640 in.)
FD590V
. . . . . . . . . . . . . . . . . . . . . . . . . . . 73.98 - 74.00 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . (2.915 - 2.916 in.) M82412a
Wear Limit . . . . . . . . . . . . . . . 74.07 mm (2.918 in.)
FD620D
. . . . . . . . . . . . . . . . . . . . . . . . . . . 75.98 - 76.00 mm 1. Rebore cylinder with a honing tool to initial and final
. . . . . . . . . . . . . . . . . . . . . . . . . (2.9913 - 2.9921 in.) bore specifications.
Wear Limit . . . . . . . . . . . . . . . 76.07 mm (2.997 in.) 2. Align center of bore to press center. Set the press to
operate from 200±250 rpm.
3. Lower and raise hone until ends extend 20±25 mm
(0.75±1.0 in.) past ends of cylinder.
4. Turn adjusting nut on hone until stones contact
cylinder wall at narrowest point.
6 - 10 4/7/95
5. Coat inside of cylinder with honing oil. Turn hone by

hand. If you cannot turn it, hone is too tight.
First Compression
6. Start drill press. Move hone up and down in cylinder Ring
approximately 20 times per minute to get 40 -60° Second
cross-hatch pattern. Compression
7. Check cylinder diameter regularly during honing. Ring
Stop press before measuring. Remove hone from
cylinder.
Side Rails
CYLINDER INITIAL BORE SPECIFICATIONS
Spacer M80429
Piston Oversize: 0.50 mm (0.020 in.)
FD440V/FD501V
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm
3. Install top compression ring and second ring, if
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.656 -2.657 in. )
equipped, with R or NPR mark facing up. Rings
FD590V should turn freely in grooves.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46 - 74.48 mm 4. Oil ring: Install spacer, then side rails. Put side rail
. . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.934 - 2.935 in. ) end gaps 180° apart.
FD620D
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.46 - 76.48 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . (3.012 - 3.013 in. ) CHECK PISTON RING END GAP
Before installing rings on piston, check end gap in
8. Hone the cylinder an additional 0.028 - 0.030 mm cylinder bore.
(0.0011 - 0.0012 in.) for final bore specifications.
This allows for 0.020 mm (0.0008 in.) shrinkage
when cylinder cools.
IMPORTANT: DO NOT use gasoline or commercial

solvents to clean cylinder bores. Solvents will
not remove metal particles produced during
honing.
9. Clean the cylinder thoroughly using soap, warm

water and clean rags. Continue to clean cylinder
until white rags show no discoloration.
10. Apply oil to cylinder walls.
REMOVE AND INSTALL PISTON M53962

RINGS
1. Remove piston rings with a piston ring expander.
Install each ring squarely in bore approximately 25.4
2. Inspect piston. Clean piston ring grooves. Check mm (1.0 in.) down from top of cylinder.
piston ring end gap.
Check end gap. Replace ring if end gap is more than
specifications.
NOTE: FD590V and FD620D engines are equipped
with a second compression ring. Install ring
with mark facing up END GAP SPECIFICATIONS (MAX)
Compression Rings
FD440V/501/590V . . . . . . . . . . . . 1.00 mm (0.040 in.)
FD620D . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.050 in.)
Oil Rings . . . . . . . . . . . . . . . . . . . . . . . Not Measured
4/7/95 6 - 11
INSPECT PISTON FD440V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NA

FD590V . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
FD620D . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
IMPORTANT: Do not use a caustic cleaning
solution or a wire brush to clean piston. Oil Control Rings:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Meassured
1. Remove all deposits from the piston.
IMPORTANT: Note location of arrow match mark
on piston head in relation to MADE IN JAPAN on
connecting rod. No. 1 piston is opposite of No. 2
piston. Keep parts together as a set.
Arrow
“Made in Japan”
M29916
C-ring
Replace
2. Clean carbon from piston ring grooves with a ring
groove cleaner. If cleaning tool is not available,
break an old ring and use it carefully to clean
groove. Connecting Rod
Piston Pin M50063
3. Check that oil return passages in grooves are open.
4. Inspect piston for scoring or fractures. Replace
piston if damaged.
6. Remove piston pin and connecting rod.
7. Measure piston pin outer diameter and piston pin
NOTE: Inspect clearance visually. Replace piston if bore.
clearance appears excessive.
5. Check ring grooves for wear at several points around

piston. Replace piston if clearance is greater than
specification.
M50064 M80427
PISTON AND PISTON PIN SPECIFICATIONS
Piston Pin O.D. (MIN)

FD440/501V . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.)
FD590V/FD620D . . . . . . . . . . . . 16.98 mm (0.668 in.)
M38102
Piston Pin Bore I.D. (MAX)
RING SIDE CLEARANCE SPECIFICATION (MAX) FD440/501V . . . . . . . . . . . . . . . . 16.04 mm (0.631 in.)
FD590V/FD620D . . . . . . . . . . . . 17.04 mm (0.671 in.)
Top Ring:
FD440V/FD501V/ FD590V . . . . . 0.10 mm (0.004 in.)
FD620D . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Second Ring:
6 - 12 4/7/95
A
Crankshaft Bearing
B
M80248
Piston Pin Bearing
10. Measure piston O.D. (B) perpendicular to piston pin M50066

bore at approximate specified distance (A) from bottom
of piston skirt.
12. Subtract piston O.D. measurement (B) from Measure connecting rod crankshaft bearing and piston
cylinder bore measurement to determine piston-to- pin bearing. Replace connecting rod if either
cylinder bore clearance. measurement is greater than specifications.
13. Replace piston and/or rebore cylinder block if not
within specifications. CONNECTING ROD BEARING I.D.
SPECIFICATIONS (MAX)
Distance (A)
FD440/501V . . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.)
FD590V/FD620D . . . . . . . . . . . . . . 11 mm (0.433 in.) Crankshaft Piston Bearing
FD440/501V
Piston O.D. (B) . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.)
FD440V . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm FD590V/ FD620D
. . . . . . . . . . . . . . . . . . . . . . . . . (2.6358 - 2.6364 in.) . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 IN.)
FD590V . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm
. . . . . . . . . . . . . . . . . . . . . . . . . (2.9108 - 2.9114 in.) Piston Pin Bearing
FD620D . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm
. . . . . . . . . . . . . . . . . . . . . . . . . . . (2.989 - 2.990 in.) FD440/501V
. . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.)
Piston-to-Cylinder Bore Clearance FD590v/FD620D
FD440V . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.150 mm . . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.)
. . . . . . . . . . . . . . . . . . . . . . . . (0.00059 - 0.0059 in.)
FD590V/FD620D . . . . . . . . . . . . . . . 0.030 - 0.170 mm
. . . . . . . . . . . . . . . . . . . . . . . . (0.00118 - 0.0067 in.)
INSPECT CONNECTING ROD

Install connecting rod cap. Tighten to specification.
CAP TORQUE SPECIFICATIONS

FD440/501V . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)
FD590V/FD620D . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Clean and inspect rod. Replace if scored.
4/7/95 6 - 13
ASSEMBLE CONNECTING ROD

AND PISTON
NOTE: With pistons installed, No. 1 piston is

designated by the large chamfer on connecting
rod facing toward flywheel.
No. 2 piston is designated by the large chamfer on

connecting rod facing away from flywheel.
The arrow match mark on both piston heads should
point toward the flywheel.
IMPORTANT: Do not reuse piston pin retaining

rings.
Arrow
“Made in Japan”
C-ring
Replace
Connecting Rod
Piston Pin M50063
IMPORTANT: No. 1 piston, align arrow match mark

(A) on piston head with MADE IN JAPAN (B) on
connecting rod.
No. 2 piston, align arrow match mark on piston
head opposite MADE IN JAPAN on connecting
rod.
6 - 14 4/7/95
CONTENTS CAMSHAFT, CRANKSHAFT & FLYWHEEL
CONTENTS
Page
CAMSHAFT, CRANKSHAFT & FLYWHEEL
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECT CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECT CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVE AND INSTALL TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4/7/95 7-1
NOTES CAMSHAFT, CRANKSHAFT & FLYWHEEL
7-2 4/7/95
SPECIFICATION CAMSHAFT, CRANKSHAFT & FLYWHEEL
SPECIFICATION
Crankshaft - FD440/501V

Maximum T.I.R. (Total Indicated Runout) . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Crankshaft - FD590V/FD620D

Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Block and Crankcase Plain Bearings

Maximum Crankcase Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.)
Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.)
Camshaft
Bearing Journals
FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.91 mm (0.548 in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.91 mm (0.626 in.)
Lobes Journal
FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.43 mm (0.962 in.)
FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.23 mm (0.993 in.)
FD620D
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.21 (0.993 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.46 mm (1.002 in.)
Fuel Pump Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.760 in.)
Connecting Rod Cap Bolt Torque

FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)
FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
4/7/95 7-3
CAMSHAFT, CRANKSHAFT & FLYWHEEL CAMSHAFT
CAMSHAFT CAMSHAFT SPECIFICATIONS (MIN)
Bearing Journals
REMOVAL
FD440/501V . . . . . . . . . . . . . . . . 13.91 mm (0.548 in.)
FD590V/FD620D . . . . . . . . . . . . 15.91 mm (0.626 in.)
IMPORTANT: Align timing marks to prevent
damage to tappets when removing camshaft.
Cam Lobes Journal
FD440/501V . . . . . . . . . . . . . . . . 24.43 mm (0.962 in.)
FD590V . . . . . . . . . . . . . . . . . . . 25.23 mm (0.993 in.)
Timimg Marks FD620D
Intake . . . . . . . . . . . . . . . . . . . . . . . 25.21 (0.993 in.)
Exhaust . . . . . . . . . . . . . . . . . 25.46 mm (1.002 in.)
Fuel Pump Lobe . . . . . . . . . . . . 19.50 mm (0.760 in.)
INSPECT CAMSHAFT BEARINGS

Measure camshaft bearings in cylinder block and
crankcase cover. Replace block or cover if diameter is
greater than specification.
M44227
1. Rotate crankshaft until timing marks (A) align.

2. Remove and inspect camshaft.
INSTALLATION
3. Lubricate journals.
4. Align timing marks and install camshaft.
INSPECT CAMSHAFT
Inspect camshaft for worn or broken teeth and loose
rivets holding gear to camshaft. Replace camshaft if M51723
loose.
Cylinder Block Bearing
Cam Lobes PTO side

Flywheel Side Journal
Journal
Fuel Pump Lobe M51722
M51724
Measure journals cam lobes. Replace camshaft if less
than specifications.
Crankcase Cover Bearing
NOTE: On FD440V and FD590V engines, measure

fuel pump lobe. Not used on FD620D.
7-4 4/7/95
CRANKSHAFT CAMSHAFT, CRANKSHAFT & FLYWHEEL
Camshaft Bearing Specifications (Max) CRANKSHAFT
Cylinder Block Bearing

REMOVAL
FD440V . . . . . . . . . . . . . . . . . . . 14.07 mm (0.554 in.)
FD590V/FD620D . . . . . . . . . . . . 16.07 mm (0.633 in.) 1. Remove camshaft.
Crankcase Cover Bearing
FD440/501V . . . . . . . . . . . . . . 14.05 mm (0.553 in.) IMPORTANT: Mark connecting rod caps so they
FD590V/FD620D . . . . . . . . . . 16.07 mm (0.633 in.) can be reinstalled in the same location.
REMOVE AND INSTALL TAPPETS

1. Remove camshaft.
NOTE: Mark tappets so they can be installed in their

original guides during assembly
Rod Caps
.
M53975
2. Remove connecting rod caps and push pistons to

top of cylinder. Remove crankshaft.
IMPORTANT: A bent crankshaft must be replaced;

it cannot be straightened.
Tappets
INSPECTION
1. Check crankshaft alignment (T.I.R).
• Place crankshaft into an alignment jig. Using dial
indicators, rotate crankshaft slowy.
M53975
2. Remove tappets.Replace if scored.

3. Install tappets in original positions. M80432
Maximum Crankshaft Bend

All. . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
4/7/95 7-5
CAMSHAFT, CRANKSHAFT & FLYWHEEL CRANKSHAFT
2. Clean and inspect crankshaft. Measure crankshaft INSTALLATION

main bearing journals and connecting rod journal.
1. Cover keyway on flywheel end of crankshaft with
tape to prevent seal damage when installing
crankshaft.
2. Put a light film of oil on crankshaft bearing surfaces.
3. Pack grease in oil seals and install crankshaft.
4. Install connecting rod caps and torque.
Connecting Rod Cap Bolt Torque

FD440/501V . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)
FD590V/FD620D . . . . . . . . . . . . . 21 N•m (186 lb-in.)
M51729
NOTE: Under-size connecting rod is not available for

FD440/501V engine. Replace crankshaft if
measurements are less than specifications.
On FD590Vand FD620D engines, connecting

rod journal can be resized to accept under-
sized rod. Have grinding done by a reliable
repair shop. Before sending crankshaft for
grinding, inspect journal radii for cracks.
Crankshaft Specifications (Min)

Main Bearing Journal
FD440/501V . . . . . . . . . . . . . . 29.92 mm (1.178 in.)
FD590V/ FD620D. . . . . . . . . . 33.91 mm (1.335 in.)
Connecting Rod Journal
FD440/501V . . . . . . . . . . . . . . 30.93 mm (1.218 in.)
FD590V/ FD620D. . . . . . . . . . 33.91 mm (1.336 in.))
A
D
B
C
M57348
Resizing Specifications -FD590V/FD620D

A . . . . . . . . . . 33.48 - 33.47 mm (1.3181 - 1.3176 in.)
B . . . . . . . . . . . . . . 2.30 - 2.70 mm (0.090 - 0.110 in.)
C . . . . . . . . . . . . . . . . . . . . . 44.50 mm Max 1.752 in.)
D . . . . . . . . . . 34.00 - 33.95 mm (1.3386 - 1.3366 in.)
7-6 4/7/95
CONTENTS LUBRICATION SYSTEM
CONTENTS
Page
LUBRICATION SYSTEM
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OIL PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DISASSEMBLE AND ASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECT OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4/7/95 8-1
NOTES LUBRICATION SYSTEM
8-2 4/7/95
SPECIFICATIONS LUBRICATION SYSTEM
SPECIFICATIONS
Oil Pump
Minimum Relief Valve Spring Free Length
FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.05 - 21.55 mm (0.829 - 0.848 in.)
FD590VFD/620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.770 in.)
Inner and Outer Rotor Clearence
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)
Pump Housing Depth
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.230 mm (1.6063 in.)
Outer Rotor Thickness (Max.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.830 mm (0.3870)
4/7/95 8-3
LUBRICATION SYSTEM LUBRICATION SYSTEM OPERATION
LUBRICATION SYSTEM OPERATION The filter contains a bypass valve which opens if the
element becomes plugged to insure engine lubrication.
A positive displacement gerotor pump is used to
pressurize the lubrication system. The lubrication An oil pressure switch mounted above the oil filter turns
system is protected by an oil pressure relief valve, low on a warning light if oil pressure is below 28 kPa (4 psi).
oil pressure switch, and a oil filter with bypass. Filtered pressure oil flows through a passage in the oil
sump to the crankshaft main bearing (PTO side).
The oil pump (F) draws oil (B) from the sump through Drilled passages in the crankshaft distribute oil from
screen (G). Pressure oil (A) from the pump flows to the the main bearing to the connecting rod journals, and
oil pressure relief valve (E). If oil pressure exceeds 296 crankshaft main bearing (flywheel side). A drilled
kPa (43 psi), the relief valve opens allowing oil to return passage in the connecting rods allow oil from the
to sump. Relief valve is not adjustable. connecting rod journal to lubricate the piston and
Pressure oil from the relief valve flows to the oil filter . cylinder walls.
COMPONENTS
Water Pump Gear Rocker Arms and Valves
Piston
Tappets
Camshaft
Governor
Gear
Connecting Rod
Oil Pressure Sensor
Crankshaft
Oil Filter
Crankshaft Main Bearings

Oil Pressure Oil Pump
Relief Valve Pick-up Screen
M57349
8-4 4/7/95
OIL PUMP REPAIR LUBRICATION SYSTEM
OIL PUMP REPAIR INSPECT OIL PUMP
DISASSEMBLE AND ASSEMBLE

Gear
Oil Pump Assembly

Cover
Screen Cover
Cover Cap Screws Pin
7.8 N•m (Two used)
(69 lb-in.)
Rotor Shaft
Oil Pressure
Inner Rotor Relief Valve
Spring
Ball
Oil Pick-up Screen

Outer Rotor
M53966
Cover
FD440V Shown
IMPORTANT: Oil pressure relief valve spring and Screen

M53967
ball will be loose when pump cover is removed.
1. Remove oil pump assembly, relief valve spring and

ball.
NOTE: Rotors and rotor shaft are replace as a kit. If
2. Remove, clean or install a new oil pick-up screen. any of the parts show signs of wear or are
scored, replace.
Gear Inner Rotor
Pins
Plate Hole
Outer Rotor
Spring
Ball
M57350
3. Install oil pressure relief valve ball, spring and oil

pump assembly.
IMPORTANT: Fill rotor housing with engine oil for

initial lubrication.
4. Install cover so that hole in cove plate is centered

over relief valve. Tighten cover screws evenly.
4/7/95 8-5
LUBRICATION SYSTEM OIL PUMP REPAIR
Outer Rotor Bearing

Shaft Bearing
M44227
Measure parts per the oil pump specifications. Replace

crankcase if bearing surfaces are worn or scored
greater than specifications. If parts show signs of
premature wear, check condition of pick-up screen and
sealing area around screen.
OIL PUMP SPECIFICATIONS
Rotor Shaft
Minimum Shaft O.D. . . . . . . . . 10.92 mm (0.430 in.)
Maximum Bearing I.D. . . . . . . . 11.07 mm (0.436 in.)
Outer Rotor
Minimum Rotor O.D. . . . . . . . . 40.43 mm (1.592 in.)
Maximum Bearing I.D. . . . . . . . 40.80 mm (1.606 in.)
Thickness (Max.) . . . . . . . . . . . . . 9.830 mm (0.3870)
Inner and Outer Rotor Clearence

Maximum. . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)
Pump Housing Depth

Maximum . . . . . . . . . . . . . 10.230 mm (1.6063 in.)
Spring Free Length Specifications (MIN)

FD440/501V . . . 21.05 - 21.55 mm (0.829 - 0.848 in.)
FD590V/FD620D . . . . . . . . . . . 19.50 mm (0.770 in.)
8-6 4/7/95
CONTENTS COOLING SYSTEM
CONTENTS
Page
COOLING SYSTEM
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TEST THERMOSTAT 8
COOLANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COOLANT PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
COOLING FAN AND BRACKET -FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COOLING FAN DRIVE BELT ADJUSTMENT - FD620D . . . . . . . . . . . . . . . . . . . 10
4/7/95 9-1
NOTES COOLING SYSTEM
9-2 4/7/95
SPECIFICATIONS COOLING SYSTEM
SPECIFICATIONS
Engine Coolant Capacity

FD440/FD501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 L (2.2 qt)
FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.04 L (3.2 qt)
FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 L (1 qt)
Thermostat
FD440/501/590
Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F)
Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)
FD620D
Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65°C (148°F)
Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80°C (176°F)
Water Pump
Over-flow Reservoir
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)
Sheave/Half - FD620D
Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)
4/7/95 9-3
COOLING SYSTEM COOLING SYSTEM OPERATION
COOLING SYSTEM OPERATION When the engine temperature is 82°C (180°F), the
thermostat begins to open and is fully open at 95°C
(203°F). High temperature coolant from the left cylinder
Function: head flows through the thermostat to the radiator. The
radiator is cooled by a radiator fan (E) that is mounted
Remove heat from engine. to the flywheel (G). The radiator fan pulls in air from the
front of the engine and forces the air upward through
the radiator fins. The coolant temperature decreases
as the coolant flows from the radiator inlet to the outlet.
The engine is liquid-cooled and uses a pressurized, fin- With the thermostat open, the water pump draws low
type radiator, water pump, and thermostat to regulate temperature coolant from the radiator through the
engine temperature. The cooling system is protected radiator outlet hose (K) instead of the bypass hose.
by a coolant temperature switch that warns the The low temperature coolant is circulated through the
operator if the engine temperature becomes too high. engine to provide constant cooling.
The water pump is driven off the camshaft gear (H)
A coolant temperature switch (Q) mounted in the left
When the engine temperature is cold, below 82°C cylinder head turns on a warning light if coolant
(180°F), the thermostat (R) is closed. The closed | temperature is above 111°C (232°F).
thermostat stops coolant flow into the radiator(A). Now
The radiator cap (B) maintains a constant pressure of
the water pump (J) must draw coolant from the bypass
88 kPa (13 psi) inside the radiator which actually raises
hose (O) which is between the cylinder head and the
the boiling point of the coolant. The radiator cap
water pump. An impeller (I) forces the low temperature
contains a pressure valve and a vacuum valve. When
coolant (U) through the cylinder block coolant
the coolant is hot and pressure is above 88 kPa (13
passages (N) to the piston coolant passage (L).
Coolant flows around the piston coolant passage, and psi), the pressure valve opens allowing some coolant to
flow to the overflow reservoir. After the engine is
then through the right cylinder head, intake manifold
stopped, the coolant cools and the pressure inside the
(M), and left cylinder head to the bypass hose. The
radiator decreases to a partial vacuum. The vacuum
engine heat is transferred to the coolant and the
opens the vacuum valve and some coolant from the
coolant temperature increases. Since the high
overflow reservoir flows back to the radiator
temperature coolant (T) bypasses the radiator, the
engine warms up to operating temperature quickly.
9-4 4/7/95
COMPONENTS COOLING SYSTEM
COMPONENTS
Radiator
Fan
Radiator Cap
Outlet Hose Inlet Hose
Thermostat
Coolant
Temperature
Switch
Piston Coolant
Passage
Intake Manifold
Cylinder Head
Coolant Passage
Cylinder Block
Coolant Passage Cylindar Block
Coolant Passage
Water Pump Gear Impeller Bypass Hose
High Temperature Coolant Low Temperatire Coolant

M44227
4/7/95 9-5
COOLING SYSTEM REPAIR
REPAIR
FD440V/501V
c CAUTION
Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using
for cleaning purposes. Clear area of bystanders, guard against flying
chips, and wear personal protection equipment including eye protection.
Screen
Clean. Radiator
Clean. Straighten
bent fins.
Over Flow Tube
Reservoir
4 N•m
(31 lb-in.)
Cover
Damper Bushings
Replace if hard
or cracked.
6 N•m Top Half Air Duct
Retaining Clip (53 lb-in,)
Studs*
6 N•m
(53 lb-in,) Return Hose
Bottom Half Air Duct

Outlet Hose
6 N•m
(53 lb-in,)
Fan Extension
Thermostat
Housing
Thermostat
Coolant Pump See Test.
See Pump Repair.
Bypass Hose
M57353
*FD440V: Studs are coated with LOCTITE. To remove studs, install nut and strike stud sharply with a hammer to loosen.
9-6 4/7/95
REPAIR COOLING SYSTEM
FD590V
c CAUTION
Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using for
cleaning purposes. Clear area of bystanders, guard against flying chips, and
wear personal protection equipment including eye protection.
Screen
Dampner Bushing Radiator
Replace if hard or Clean. Straighten
cracked. bent fins
Over Flow Tube
Seal
Bracket
Must sit in groove.
Replace if cracked
or deformed.
Reservoir
6 N•m
(53 lb-in.)
Retaining Clip
15 N•m
(10 lb-ft)
Top Half Air Duct
Fan
6 N•m
Bottom Half Air Duct
(53 lb-in.)
6 N•m
(53 lb-in.) 6 N•m
(53 lb-in.)
Return Hose
O-Ring
Intake Elbow
Thermostat
Fan Extension Housing
Thermostat
M57352
4/7/95 9-7
COOLING SYSTEM COOLANT PUMP
THERMOSTAT TEST THERMOSTAT

Check thermostat using a thermostat tester. Heat
NOTE: FD440/501V: Remove both halves of cooling thermostat in water to check opening temperature.
air duct. Replace, if not according to specifications.
THERMOSTAT SPECIFICATIONS
FD440/501V
Thermostat Housing
Begin Opening . . . . . . . . . . . . . . . . . . . 82°C (180°F)
Fully Open. . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F)
FD620D
Begin Opening . . . . . . . . . . . . . . . . . 65°C (148°F)
Fully Open . . . . . . . . . . . . . . . . . . . . 80°C (176°F)
COOLANT PUMP
M51700 REMOVAL & INSTALLATION

FD590V Shown
Thermostat B
Housing C
Drain Plug
D
M51701
M53946
FD620D Shown
Disconnect hoses and remove pump assembly, noting
position and lenght of cap screws.
TORQUE SPECIFICATIONS
Mounting Cap Screws . . . . . . . . . . 8 N•m (70 lb-in.)
Cap Screw (B)* . . . . . . . . . . . . . 21 N•m (186 lb-in.)
*Cap screw (B) attaches crankcase cover to
crankcase.
9-8 4/7/95
COOLANT PUMP COOLING SYSTEM
COOLANT PUMP REPAIR NOTE: Mechanic seal is sealed into place and will be
difficult to remove.
IMPORTANT: Leakage from water pump will drain When installing impeller assembly to housing,
into engine block and could cause engine coat mating surfaces with clean water.
damage. If there if any doubt of the condition of
water pump, replace it as a complete assembly.
6. Install new mechanical seal.
Pin Oil Seal Shaft

Impeller
Impeller
Mechanical Oil Seal
Seal
Mating
Ring
Machnical
O-Ring
Seal
Housing Pin Coat mating
Shaft surfaces with
M51707 clean coolant
Washer PUMP SPECIFICATIONS (MIN)

Spur Gear M44227 Shaft O.D. (MIN) . . . . . . . . . . . . . 9.94 mm (0.391 in.)
Housing Shaft Bore/ I.D.
1. Remove gear with a puller. (MAX) . . . . . . . . . . . . . . . . . . 10.09 mm (0.397 in.)
2. Remove impeller assembly from shaft. Disassemble
impeller assembly.
3. Measure outside diameter of shaft. If less than
specifications or shows any signs of corrosion,
replace it.
4. Measure pump shaft bore in housing. Replace
housing if greater than specifications.
5. Drive old mechanical seal from housing.
4/7/95 9-9
COOLING SYSTEM COOLANT PUMP
COOLING FAN AND BRACKET -FD620D
Fan
I
Install with ridges on inside
diameter of fan pointing away
from engine.
Pulley
Mountng Flange
Bearing Spacer
Bracket
Belt Tension
Snap Ring 245 - 391 N
(55 - 88 lb)
Bearing 15 N•m
(130 lb-in.)
Outer Fan Drive Sheave

Washers
Nut
Shim(S)
Add to loosen belt.
Remove to tighten. M57354
IMPORTANT: Bearings are a pressed fit. Remove COOLING FAN DRIVE BELT
only if being replaced.
ADJUSTMENT - FD620D
To avoid pinching fan belt between flywheel and Apply approximately (force) pressure between fan and
outer sheave half, rotate flywheel while drive sheave. If deflection is not within 12 - 19 mm
tightening outer sheave half mounting cap (0.472 - 0.748 in.), remove drive sheave and add shims
screws. to loosen belt or remove shims to tighten belt.
c CAUTION
DO NOT heat oil over 182°C (360°F). Oil fumes or
oil can ignite above 193°C (380°F). Use a
thermometer. DO NOT allow a flame or heating
element to come in direct contact with the oil.
Heat the oil in a well-ventilated area.
1. Heat mounting bracket with bearings (E) in hot oil to

remove bearings. Tap bearings from mounting
bracket.
2. Install bearings using a bushing, bearing and seal
driver set and a press.
9 - 10 4/7/95
CONTENTS ELECTRICAL SYSTEM
CONTENTS
Page
ELECTRICAL SYSTEM
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REPLACE STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REPLACE PULSER COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REPLACE IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REPLACE IGNITION MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STARTER SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ANALYZE STARTER CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BENCH TEST SOLENOID SHIFT STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECT STARTER - SOLENOID SHIFT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TEST FEILD WINDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TEST STARTER ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TEST STARTER SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL INJECTION TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL INJECTION AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL INJECTION AIR PRESSURE SENSOR - FD620D . . . . . . . . . . . . . . . . . . . . 9
FUEL INJECTION THROTTLE SENSOR - FD590D . . . . . . . . . . . . . . . . . . . . . . . 9
ALTITUDE COMPENSATION SWITCH
CIRCUIT - OPTIONAL FD590D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4/7/95 10 - 1
NOTES ELECTRICAL SYSTEM
10 - 2 4/7/95
SPECIFICATION ELECTRICAL SYSTEM
SPECIFICATION
CHARGING SYSTEM
Capacity
FD440/501/590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Amps
FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Amps
Stator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 VAC @ 3000 RPM
INJECTOR
FD590D
Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 - 12.9 Ohms
FD620D
Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 Ohms
IGNITION SYSTEM
Pulser Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 - 1.0 VAC
ELECTRIC STARTER
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.)
Maximum No Load Starter Draw

FD440/501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 amps at 6000 rpm (min)
FD590/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 amps at 6000 rpm (min)
4/7/95 10 - 3
ELECTRICAL SYSTEM STATOR OPERATION
STATOR OPERATION 1. Remove:

• cooling air duct or flywheel guard
The charging system is a permanent magnet and
• FD590V: radiator support brackets
stator design.
• FD620D: fan bracket
As the flywheel rotates, a permanent magnet in the
• Remove pulser coil(s)
flywheel induces AC current in the stator windings. This
current flows to the regulator-rectifier where it is • wire ties from wiring harness.
converted to DC current needed to charge the battery. 2. Disconnect wiring harness from ignitor.
3. Install coils.
4. Install fan or radiator brackets.
REPLACE STATOR 5. Connect plug to ignitor.
6. Install new wire ties where needed.
Connector
Clamp
Stator REPLACE IGNITION COILS
M51685
FD590V Stator Shown
1. Remove:
• flywheel
• Wire clamp(s) Wire Leads Coil
• stator wiring lead pins from connector
M52688
• Cut wire tie from wiring harness and remove stator
2. Install stator and connect wiring leads to plug. FD590V Ignition Coil
1. Disconnect plug wire from spark plug lead and

REPLACE PULSER COILS primary wire leads from coil.
2. Remove ignition coil.
NOTE: Pulser coils are mounted in a fixed position. 3. Install ignition coil and connect wiring leads.
Some application only use one pulser coil.
Pulser Coil
M51686
FD590 Pulser Coil
10 - 4 4/7/95
REPLACE IGNITION MODULE ELECTRICAL SYSTEM
REPLACE IGNITION MODULE BENCH TEST SOLENOID SHIFT

STARTER
NOTE: Perform bench test before disassembling

starter motor to determine cause of problem.
Ground
Lead IMPORTANT: Never operate motor longer than 20
seconds. Allow at least two minutes for cooling
and battery recovery before operating again.
Ignition
Overheating, caused by excessive operation,
Module will seriously damage starting motor.
1. Remove starter from engine.

Connectors
M51960
Battery
Terminal
B
S
M Remote
NOTE: Module may not be mounted on engine on Switch
some applications.
Switch Terminal
Note position of ground wire. Module must be
grounded
1. Disconnect connectors and remove ignition module.

2. When installing ignition, put wire lead under cap
screw. _ +
3. Install ignition module and connect plugs. Starter Frame 12V Battery
STARTER SERVICE PARTS KITS

2. Connect battery to starter using heavy duty cables
The following kits are available through your parts and remote starter switch as shown.
catalog:
When switch is activated, starter should engage and
• Brush Kit run.
• Clutch Kit
SPECIFICATIONS
ANALYZE STARTER CONDITION Terminal Voltage (Min) . . . . . . . . . . . . . . . . 11.5 volts
1. The starter overheats because of: Starter Motor RPM (Min) . . . . . . . . . . . . . . 6000 rpm
• Long cranking. Current Draw (Max) . . . . . . . . . . . . . . . . . . . 50 amps
• Armature binding.
2. The starter operates poorly because of: Results:
• Armature binding.
• Dirty or damaged starter drive. • IF SOLENOID CHATTERS; hold-in winding is
• Badly worn brushes or weak brush springs. open-circuited.
• Excessive voltage drop in cranking system.
• Battery or wiring defective. • IF NOTHING HAPPENS; either the solenoid pull-
• Shorts, opens, or grounds in armature. in winding is open-circuited or mechanical parts
are sticking.
NOTE: Starter repair is limited to brushes, end caps, • IF SOLENOID ENGAGES, BUT MOTOR DOES NOT
and starter drive. Fields in starter are RUN; check solenoid switch continuity, brushes,
permanent magnets and are not serviceable. If armature and field windings.
housing or armature is damaged, replace
starter Solenoid cannot be repaired, replace it.
4/7/95 10 - 5
ELECTRICAL SYSTEM INSPECT STARTER - SOLENOID SHIFT TYPE
INSPECT STARTER - SOLENOID SHIFT TYPE
NOTE: Mark body and end cover to aid reassembly.
Armature
Solenoid
Shift Lever
Pinion
Pinion Stopper Half
End Cover
Retaining Clip Retaining Bolt
Pinion Always replace with new
Stopper Half
Brushes
Washer
Front Cover
Insulator
Brush Spring
Brush Holder
Case with
Field Windings M53943
1. Mark body and covers to aid alignment for TEST FEILD WINDINGS
reassembly.
2. Separate pinion stopper halves to remove retaining
clip to remove starter drive. NOTE: Field winding case is a tie point for many
3. Test and inspect starter parts for wear or damage. separate field coils.
4. Replace brushes as a set if length of any one is less It may be difficult to detect one bad coil.
than 6 mm (0.240 in.). If rpm was slow and armature tests are normal,
Brushes must be soldered to field windings replace field coil assembly.
5. Apply very light coat of multipurpose grease to:
• sliding surfaces of armature and solenoid shift lever Replace field coil if not according to specifications.
pivots.
Field Brushes
• armature shaft spline.
Continuity between
• points where shaft contacts cover. brushes and to case
6. Assemble starter. Hook solenoid plunger over shift To Solenoid
fork.
Brush Assembly Tips:

Test For Open
• With front cover facing down in vise, assemble front
cover, armature and body. Starter
• Assemble brush holder over armature. Case
• Install brushes against armature.
• Squeeze springs into place. Armature Brushes
Continuity between
• install insulator and cover.
brushes and solenoid
lead. Open to case.
M57356
10 - 6 4/7/95
TEST STARTER ARMATURE ELECTRICAL SYSTEM
TEST STARTER ARMATURE TEST STARTER SOLENOID
IMPORTANT: Do not clean armature with solvent. NOTE: If bench test indicated solenoid problems, use
Solvent can damage insulation on windings. an ohmmeter or test light to check solenoid.
Use only mineral spirits and a brush.
Switch
Arm Solenoid Body
Solenoid
High Current
Terminal
Terminals
M24861 M51705
1. Locate short circuits by rotating armature on a 1. Test solenoid terminals for continuity. There should
growler while holding a hacksaw blade or steel strip be no continuity.
on armature. The hacksaw blade will vibrate in area 2. Depress switch arm. There should be continuity
of short circuit. when arm is fully depressed.
2. Shorts between bars are sometimes caused by dirt 3. Test for open circuits between terminal and tab
or copper between bars. Inspect for this condition. There should be continuity.
3. If test indicates short circuited windings, clean the 4. Test for open circuits between tabs and body. There
commutator of dust and fillings. Check armature should be continuity.
again. If test still indicates short circuit, replace If solenoid fails any test, it is defective and must be
armature. replaced.
When installing solenoid, hook switch arm over shift
fork, so that when solenoid is activated it will pull shift
fork in.
Test For Grounds Test For Open

M50112, M50113
4. Using an ohmmeter, test each individual armature

windings for grounded or open circuits.
Armature windings are connected in parallel, so each
commutator bar needs to be checked.
• If test either test fails, armature must be replaced
4/7/95 10 - 7
ELECTRICAL SYSTEM TEST STARTER ARMATURE
FUEL INJECTOR TEST FUEL INJECTION AIR

TEMPERATURE SENSOR
NOTE: Also see Fuel Injector in Fuel System and
Governor section. Function
Monitors coolant temperature for computer to
determine the amount of fuel delivery for starting a cold
engine or warm engine operation.
Sensor
Terminals
M48181
Measure resistance across terminal. If out of

specification replace.
Resistance Specification
M44227
at 20° C(68° F). . . . . . . . . . . . . . . . . 11.1 - 12.9 ohms
Connect jumper wire from battery ground to fuel FD590D Air Temperature Sensor
injector terminal. Briefly and repeatedly connect a
positive wire from battery to other injector terminal.
Injector must click each time wire contact is made. No Air Temperature Sensor
click, replace injector.
FUEL INJECTION TEMPERATURE

SENSOR
Function:
Monitors coolant temperature for computer to
determine the amount of fuel delivery for starting a cold
engine or warm engine operation.
M57364
Coolant Temperature Sensor
FD620D Air Temperature Sensor
When changing sensor make sure sensor and groment

are sealed and in place. Sensor is on clean air side of
filter.
M48182
Replace temperature sensor and gasket as needed.

Do not attempt to turn plastic connector. Use a thread
sealer.
10 - 8 4/7/95
TEST STARTER ARMATURE ELECTRICAL SYSTEM
FUEL INJECTION AIR PRESSURE FUEL INJECTION THROTTLE

SENSOR - FD620D SENSOR - FD590D
Function: Function:
The computer uses the signal from this sensor to Mechanically senses throttle shaft position which
determine throttle plate position and engine load. calibrates the fuel injection computer to the throttle
plate position
Air Pressure Sensor
Throttle Sensor
M57336
M57367
Make sure vacuum hose is not pinched, cracked or any

pin holes. Connections must be tight to throttle body Adjustment:
and sensor.
1. Set throttle shaft at slow idle position. Turn slow idle
screw out so throttle plate is completely closed.
2. With sensor connected to vehicle wiring harness,
read voltage of white wire. Adjust sensor until
voltage reads between 0.35 - 0.38 volts.
3. Hold throttle sensor in this position and tighten cap
screws.
4. Open and close throttle plate several times and
recheck voltage. Readjust if necessary.
5. Replace sensor if voltage can not be obtained.
6. Readjust slow idle stop screw.
ALTITUDE COMPENSATION
SWITCH CIRCUIT - OPTIONAL
FD590D
Function:
The altitude compensation switch circuit allows the fuel
injection module computer to adjust the fuel-air mixture
when the unit is operated above 1500 m (4918 ft.). The
unit must be operated above 1500m (4918 ft.) for the
altitude compensation switch to operate.
When the unit is operated below 1500m (4918 ft.), the
altitude compensation switch is closed and provides a
path to ground to energize the circuit. When the unit is
operated above 1500m (4918 ft.), the altitude
compensation switch opens breaking the path to
ground which denergizes the circuit. This leans the
fuel-air mixture for high altitude operation.
4/7/95 10 - 9
ELECTRICAL SYSTEM TEST STARTER ARMATURE
10 - 10 4/7/95
CONTENTS TROUBLESHOOTING
CONTENTS
Page
TROUBLESHOOTING
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PERFORMANCE DAIGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CRANKCASE VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4/7/95 11 - 1
NOTES TROUBLESHOOTING
11 - 2 4/7/95
TROUBLESHOOTING TROUBLESHOOTING
TROUBLESHOOTING
Engine RPM Low Or Engine Stalls

Engine cranks but will not start
Problem or Symptom
Excessive fuel consumption
Excessive oil consumption

Engine misses at high rpm
Engine misses at low rpm

Engine runs erratically
Engine overheats
Check or Solution
Engine backfires
Coolant leakage
Engine knocks
Loss of power
Weak or faulty spark plug
Faulty high tension leads
Faulty ignition Module
Faulty ignition coil
Faulty pulser coil
Contaminated fuel or faulty fuel supply system
Fuel shut-off solenoid not allowing fuel into

main jet
Defective fuel pump
Air being drawn in through a hole in the fuel

line(s)
Fuel shut-off valve closed (Inline valve)
Clogged fuel line or filter
Fuel tank vent line clogged
Vapor lock
Improper use of choke
Air filter restricted
Defective breather valve
Float level too high
Poor compression. Worn piston/piston rings

stuck or not seated. Worn cylinder bore
Cylinder head loose
4/7/95 11 - 3

Problem or Symptom


Engine overheats
Check or Solution
Engine backfires
Coolant leakage
Engine knocks
Loss of power
Worn or burn valves or improper clearance
Worn valve stem(s) or valve guide(s)
Warped cylinder head
Broken valve spring
Defective head gasket
Low oil level
Too much oil in crankcase
Carburetor out of adjustment
Air/fuel passages clogged
Carbon deposits in exhaust pipe/muffler
Carbon deposits in combustion chamber
Lack of coolant
Governor linkage out of adjustment
Faulty governor spring
Governor gear assembly binding or broken
Air being drawn through carburetor or intake

manifold flanges
Incorrect timing gear alignment
Plugged oil ring groove
Oil leakage along governor shaft
Defective oil seal
Drain-back hole in breather chamber plugged
11 - 4 4/7/95

Problem or Symptom


Engine overheats
Check or Solution
Engine backfires
Coolant leakage
Engine knocks
Loss of power
Incorrect oil viscosity
Carburetor flange loose or leaking at gasket
Carburetor body and throttle shaft worn
Intake valve burned or sticking
Excessive engine load
Fan belt slippage
Defective radiator hose or clamp
Broken or missing fan shroud
Defective radiator
Cracked or porous casting
Loose stud bolts and cap screw
Engine overheating
Damaged water pump seals
Improperly installed gasket
Improper or defective radiator cap
Battery weak or discharged
4/7/95 11 - 5
TROUBLESHOOTING DIAGNOSIS
DIAGNOSIS
STARTING MOTOR
Test Conditions:
• Known good battery
Test/Check Point Normal If Not Normal
Engine will Not Crank
1. Starter solenoid Solenoid clicks when key is in start See cranking and neutral start
(Solenoid does not click) position circuits of product technical manual.
Check wire connections at battery
and solenoid switch terminals of
solenoid.
Check solenoid, starter motor and
engine to battery ground.
Faulty solenoid - test and replace
2. Starter motor Starter motor should crank engine Disconnect all external drives.
(Solenoid clicks but starter does Rotate engine by hand to check for
not rotate) seized engine
Check starter solenoid to starter
motor connection
Remove and test starter motor.
3. Starter Motor Engine cranking Worn pinion or ring gear. Replace

(Starter rotates but engine does Incorrect starter alignment or starter
not crank) drive cover broken.
Faulty starter drive clutch. Replace.
Engine Cranks Slow
4. Starter Motor Engine cranking at a minimum of Check solenoid to motor

250 rpm. connection.
Test or repair starter.
Engine seizing. Repair engine.
Starter Does not disengage
5. Starter Drive Disengages when key is returned to Faulty ignition switch. Replace
(Starter motor continues to run) run. Faulty solenoid. Replace
6. Starter Drive Retracts when motor disengages Faulty pinion and ring gear
(Starting motor disengages) Starter shift fork binding
Engine cranking speed good Starts and runs with no performance Continue testing
but will not start complaints
11 - 6 4/7/95
DIAGNOSIS TROUBLESHOOTING
ENGINE
Test Conditions:
• Engine cranking speed above specification
ENGINE WILL NOT START
Conditions:
• Engine cranking
1. Spark plug Hot blue spark Spark: Go to step 5.

Removed and grounded against No sparks between high tension Spark at spark tester but not plug:
block wire and block Faulty spark plug. Replace
Check high tension cap and high
tension lead condition.
Spark plug not wet Plug dry:

No fuel, see carburetor or fuel
injection system test.
No fuel in tank.
Plug Wet: See Carburetion Checks
Conditions:
• Engine not cranking
• Ignition on
2. Ignition coil and spark plug Battery voltage at positive terminal No voltage at Coil:
(Test both coil) of coil. Spark at spark plug when Check engine harness connection.
negative terminal is grounded. No battery voltage at connector, see
product technical manual.
Battery voltage at harness
connector:
Repair or replace engine harness
Voltage at positive terminal of coil
and no spark when negative coil is
grounded:
Test and replace coil.
No spark with engine cranking:
Check ignition module connections
and continue testing.
Condition;
• Engine cranking
• Pulser coil disconnected
3. Pulser Coil(s) connectors 0.1 - 1.0 volts AC output from each No voltage: replace pulser coils
coil. Voltage: check ignition module
connections and ground.
4. Ignition module or fuel Voltage to module See product technical manual.

injection module Replace module with known good
one.
4/7/95 11 - 7
5. Compression Test Compression above 1171 kPa (170 Compression OK: See carbureted
psi). Maximum difference between or fuel injected fuel system
cylinders 97 kPa (14 psi) diagnosis.
Compression low:
Add oil to cylinders and retest.
No Change in Compression:
Check valve adjustment cylinder
head, gasket, valves and valve
springs.
Change in Compression:
Check piston, cylinder and rings
PERFORMANCE DIAGNOSIS
ENGINE HARD TO START
1. Spark plugs Not oil or wet Check the following:

• Spark plugs.
• High tension wire & ignition
coil(s)
• One faulty pulser
• Check air cleaner for plugging or
for intake leaks.
• Compression
See carburetor or fuel injection
system diagnosis.
2. Lubrication system Correct oil level and viscosity Correct oil level
Oil not contaminated with coolant or Change oil and determine cause for
gasoline. contamination.
3. Muffler Little to no smoke. Excessive black smoke:

No sound of restriction. • Check for plugged air cleaner.
• Too much oil in crankcase.
• Defective breather valve.
• Excessive carbon in exhaust
port or muffler.
See carbureted or fuel injection
system diagnosis.
11 - 8 4/7/95
DIAGNOSIS TROUBLESHOOTING
COMPRESSION TEST CRANKCASE VACUUM TEST
REASON: Reason:
To determine the condition of pistons, rings, cylinder To check operation of breather and condition of seals,
walls and valves gaskets, rings, piston and cylinders walls.
Equipment: Equipment:
• JDM59 Compression Gauge • JTO5701 Hose Clamp
• JTO5703 Barb Fitting
• JTO5699 Line
• JTO5698 U-Tube Manometer
Procedure:
1. Park machine on level surface, key switch OFF,
transmission in NEUTRAL, and LOCK park brake.
B
M56385
1. Remove both spark plugs and install compression

gauge. A
2. Ground high tension leads or disconnect positive C
lead from ignition coil.
3. Hold throttle shaft open.
IMPORTANT: DO NOT overheat starting motor M57357

during test. Starter duty is 5 seconds on, 10
seconds off.
2. Put small end of barb fitting (A) into line (B) and
fasten with hose clamp (C).
4. Crank engine for three to five compression strokes.
3. Install large end of barbed fitting into dipstick tube.
5. Record pressure readings for each cylinder.
Compression Specifications
B
Minimum . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi)
Minimum difference between cylinders
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi) D
Results:
• Above specification, adjust valves and check fuel
and intake air systems. Check exhaust for
M56365
restriction.
• Below specification, squirt clean engine oil into
cylinders and repeat test.
• Pressure increases significantly, check piston rings IMPORTANT: DO NOT make connection between
and cylinder walls for wear or damage, manometer (D) and engine line (B) BEFORE
• Pressure does NOT increase after retest, check for engine is running or fluid in manometer could
leaking valves, valve seeats or cylindwer head be drawn into crankcase. DO NOT turn engine
gaskets. OFF until line (B) has been disconnected from
6. Reconnect ignition coils and install spark plugs manometer (D).
4/7/95 11 - 9
4. START and run engine at SLOW idle.

5. Connect line (B) to U-Tube Manometer Kit (D).
6. Run engine at FAST idle.
7. Record crankcase vacuum reading. Manometer E
should show a minimum vacuum of 25 mm (1.0
in.) of water.
8. Run engine at SLOW idle. DO NOT TURN ENGINE
OFF!
9. Disconnect clear tube (B) from manometer.
C D
10. Turn engine OFF.
11. Remove barbed fitting and install dipstick.
M56384
OIL PRESSURE TEST

4. Install JT03349 Connector (C).
5. Connect JT03017 Hose Assembly (D) and JT05577
Reason:
Pressure Gauge Assembly (E).
To determine condition of lubrication system. 6. Crank engine and check oil pressure. No oil
pressure, determine cause before starting engine.
Equipment:
• JT05577 Pressure Gauge Assembly IMPORTANT: If pressure reading is below 69 kPa
• JT03017 Hose Assembly (10 psi), STOP ENGINE IMMEDATELY and
determine cause.
• JT03349 Connector
7. Run engine at FAST idle and check. Minimum oil

Procedure:
pressure 276 kPa (40 psi).
1. Check engine oil level, bring level to full mark.. 8. Run engine at FAST idle until at operating
temperature.
9. Install oil pressure switch and switch wiring lead.
c CAUTION Use John Deere Pipe Sealant with TEFLON
(medium strength), or equivalent, on switch threads.
Engine components are HOT. Be careful not to
touch, especially the exhaust pipe or muffler, Results:
while making adjustments. Wear protective eye
glasses and clothing. If oil pressure is BELOW specifications, inspect or
replace the following:
• Oil pressure relief valve for broken or worn spring
• Oil pressure relief valve for stuck or damaged
valve.
• Worn or damaged oil pump.
B
• Oil pump suction screen or oil passages plugged.
• Excessive wear of connecting rod and main
bearing journals.
A
Results:
If crankcase vacuum is LESS than specification, check
M56383
the following:
• Breather reed valve clearance and condition,
2. Disconnect oil pressure switch wiring lead (A). • Seals and gaskets for leakage,
3. Remove oil pressure switch (B). • Valve cover gasket for leakage,
• Valve and valve seats for wear or damage.
• Head warpage.
• Rings, piston, and cylinder walls for wear or
damage.
11 - 10 4/7/95
CONTENTS COMPONENT ANALYSIS
CONTENTS
Page
COMPONENT ANALYSIS
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
RING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PISTON WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CRANKSHAFT AND CONNECTING ROD WEAR . . . . . . . . . . . . . . . . . 4
4/7/95 12 - 1
NOTES COMPONENT ANALYSIS
12 - 2 4/7/95
ANALYZE VALVES COMPONENT ANALYSIS
ANALYZE VALVES
Lead deposits on the intake valve are caused by
exhaust gas leakage past the valve. This indicates that
the valve is not seating properly. Valve Margin Valve Face
Grind intake valve and reface the seat to correct this
condition.
NOTE: Be sure to reset valve clearance after grinding

valves. M30024
IMPORTANT: Do not run the engine with blower

housing removed.
Lead Deposits
Poor engine cooling due to dirt or obstructions is a
common cause for overheating an engine and the
valves. Remove blower housing and clean the engine
M29934
cooling fins.
Other causes for valves running hot are worn valve
guides or valve springs, incorrect valve clearance, lean
fuel-air mixture and incorrect or overheated spark plug.
Valve stem corrosion is caused by moisture in the Using old or stale gasoline is a common cause for
engine. Moisture in the fuel-air-mixture can condense sticky valves.
inside the engine when the engine is stopped and
This gummy deposit can be seen on the valve. When
cools down.
this condition exists, the carburetor may also contain
Valve corrosion can also occur during storage. Fogging gum deposits and will require a complete cleaning.
or pouring oil in the combustion chamber before
Always use fresh gasoline and drain fuel tank, lines,
storing, helps prevent valve corrosion.
and carburetor before storing machine.
Corroded or pitted valves collect deposits and may
cause sticking valves. Replace badly corroded or pitted
valves.
Gummy (Sticky)
Deposit
Valve Stem M29936

Corrosion
M5563
Exhaust valves are designed to function in
temperatures exceeding 2760°C (5000°F). However,
when operating at high temperatures for long periods of
Exhaust valves are designed to function in time, valve burning may occur. Valves running too hot
temperatures exceeding 2760°C (5000°F). However, will show a dark discoloration of the valve stem into the
when operating at high temperatures for long periods of area protected by the valve guide. Another indication is
time, valve burning may occur. distortion of the valve margin (A) and valve face (B).
Valves running too hot will show a dark discoloration of Valve inserts may also begin to burn away.
the valve stem into the area protected by the valve Other causes for valves running hot are worn valve
guide. Another indication is distortion of the valve guides or valve springs, incorrect valve clearance, lean
margin and valve face. Valve inserts may also begin to fuel-air mixture and incorrect or overheated spark plug.
burn away.
4/7/95 12 - 3
COMPONENT ANALYSIS ANALYZE PISTON RING WEAR
ANALYZE PISTON RING WEAR

Rings of the wrong size or rings having improper end Varnish, Lacquer or Carbon Deposits
gap will not conform to the shape of the cylinder. This
results in high oil consumption and excessive blow-by.
Ring end gaps should be staggered on the piston
during installation. End gaps in alignment can also
cause oil consumption and blow-by.
Light scuffing or scoring of both rings and piston occurs
when unusually high friction and combustion
temperatures approach the melting point of the piston
material.
When this condition exists, it is due to one or more of
the following probable causes:
M29944
• Dirty cooling shroud and cylinder head.
• Lack of cylinder lubrication.
• Improper combustion. Vertical scratches across the piston rings are due to an
• Wrong bearing or piston clearance. abrasive in the engine. Abrasives may be airborne,
• Too much oil in crankcase causing fluid friction. may have been left in the engine during overhaul or
may be loose lead and carbon deposits.
When this condition exists, check for one or more of the
following:
• Damaged, collapsed or improperly installed air
filter.
• Loose connection or damaged gasket between air
cleaner and carburetor.
• Air leak around carburetor-to-cylinder block gasket.
• Air leakage around throttle shaft.
• Failure to properly clean cylinder bore after
reconditioning engine.
M29943
Vertical Scratches
The engine operating at abnormally high temperatures

may cause varnish, lacquer or carbon deposits to form
in the piston grooves making the rings stick. When this
happens, excessive oil consumption and blow-by will
occur.
Engine overheating and ring sticking is usually caused
by one or more of the following:
• Overloading
M29945
• Incorrect ignition timing.
• Lean fuel mixture.
• Dirty cooling fins.
• Incorrect oil. Abrasive particles in engine oil causes scratches on
side rails of oil control ring. Inner spacer wear or
• Low oil supply.
distortion may cause:
• Stale fuel.
• High oil consumption.
• Increased deposits in combustion chamber.
• Sticking compression rings.
Increased oil consumption may be caused by:
• Worn side rails with low tension.
• Worn or distorted inner spacer.
12 - 4 4/7/95
ANALYZE PISTON RING WEAR COMPONENT ANALYSIS
.
Damaged
Area
Side Rails
Spacer M30039
M38101
Check rod and piston alignment when piston shows a

diagonal wear pattern extending across the skirt of the
piston. Contact with the cylinder wall shows on bottom
ANALYZE PISTON WEAR of skirt at left and ring lands on the right.
Detonation, is abnormal combustion causing excessive A cylinder bored at an angle to the crankshaft can also
temperature and pressure in the combustion chamber. give improper ring contact with cylinder causing:
Commonly called carbon knock, spark knock or timing • Rapid piston wear.
knock, detonation occurs as the compressed fuel-air • Uneven piston wear.
mixture ignites spontaneously to interrupt the normal
• Excessive oil consumption.
ignition.
The following is a list of possible causes for detonation:
• Lean fuel mixture.
• Low octane fuel.
• Advanced ignition timing.
• Engine lugging. Diagonal
• Build-up of carbon deposits on piston or cylinder Wear
head, causing excessive compression. Pattern
• Wrong cylinder head or milling of head increasing
compression ratio.
M29948
A broken retaining ring caused the damage shown.

Retaining rings loosen or break due to:
• Rod misalignment.
• Excessive crankshaft end play.
• Crankshaft journal taper.
• Weak retaining rings.
• Incorrectly installed retaining rings.
M29947 Inertia can cause a broken retaining ring to beat out the
piston and cylinder, causing extensive damage.
Pre-ignition is the igniting of the fuel-air mixture prior to

regular ignition spark. Pre-ignition causes internal
shock, resulting in pings, vibration, detonation and
power loss. Severe damage to piston rings and valves
results from pre-ignition.
Check the following for causes of pre-ignition:
• Internal carbon deposits.
• Incorrect spark plug (high heat range).
Damaged
• Broken ceramic in spark plug. Area
• Sharp edges on valves. M29949
4/7/95 12 - 5
COMPONENT ANALYSIS ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR
ANALYZE CRANKSHAFT AND

CONNECTING ROD WEAR
Check connecting rod and cap for damage or unusual
wear patterns.
Lack of lubrication or improper lubrication can cause
the connecting rod and cap to seize the crankshaft.
When the rod and cap seize to the crankshaft, the
connecting rod and piston may both break causing
other internal damage. Inspect block carefully before
rebuilding engine.
Crankshaft and connecting rod damage can result
from:
• Engine run low on oil or without oil.
• Oil not changed regularly.
• Bearing cap installed incorrectly.
12 - 6 4/7/95
INDEX
A D
Air Cleaner Service 3 - 2 Deglaze Cylinder Bores . . . . . . . . . . . . . . . . . . . . 6 - 10
Analyze Crankshaft & Connecting Down Draft Carburetor Repair . . . . . . . . . . . . . . . . 4 - 7
Rod Wear 12 - 6 E
Analyze Piston Ring Wear 12 - 4 Electrical System Specifications . . . . . . . . . . . . . . 10 - 3
Analyze Piston Wear 12 - 5
Engine Applications . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Analyze Starter Condition 10 - 5
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
Analyze Valves 12 - 3
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7
B Engine Oil Specifications . . . . . . . . . . . . . . . . . . . 2 - 17
Basic Engine Specifications 2 - 3 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Breather Operation 3 - 4 F
Breather Repair 3 - 4
FD440/501V Engine Repair Specifications . . . . . . . 2 - 6
Breather Service 3 - 4
FD440V/501V Cooling System Repair . . . . . . . . . . 9 - 6
C FD440V/501V/590V Engine
Camshaft Bearing Inspection 7 - 4 Component Locations . . . . . . . . . . . . . . . 2 - 18
Camshaft Installation 7 - 4 FD440V/FD501V Cylinder Block,
Camshaft Removal 7 - 4 Piston & Rod Specifications . . . . . . . . . . . . 6 - 3
Camshaft Service 7 - 4 FD440V/FD501V/FD590V Engine
Camshaft Specifications 7 - 4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Camshaft, Crankshaft & Flywheel FD590D Altitude Compensation Switch
Specifications 7 - 3 Circuit Operation . . . . . . . . . . . . . . . . . . . 10 - 9
Carburetor Operation 4 - 4 FD590D Fuel INjection Throttle Sensor
Carburetor Serial Number Locations 2 - 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 9
Carburetor Specifications 4 - 3 FD590V Cooling System Repair . . . . . . . . . . . . . . . 9 - 7
Clean and Rebuild Carburetor 4 - 8 FD590V Cylinder Block, Piston & Rod
Component Location 2 - 18 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Compression Test 11 - 9 FD590V Engine Repair Specifications . . . . . . . . . . . 2 - 9
Connecting Rod & Piston Assembly 6 - 14 FD590V Engine Throttle Body Repair . . . . . . . . . . 4 - 14
Connecting Rod Bearing Specifications 6 - 13 FD620D Cooling Fan & Bracket . . . . . . . . . . . . . . 9 - 10
Connecting Rod Inspection 6 - 13 FD620D Cooling Fan Belt Adjustment . . . . . . . . . 9 - 10
Coolant Pump Removal & Installation 9 - 8 FD620D Cylinder Block, Piston & Rod
Coolant Pump Repair 9 - 9 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Coolant Pump Service 9 - 8 FD620D Engine Air Cleaner . . . . . . . . . . . . . . . . . . 3 - 2
Coolant Pump Specifications 9 - 9 FD620D Engine Component Locations . . . . . . . . . 2 - 22
Cooling System Components 9 - 5 FD620D Engine Repair Specifications . . . . . . . . . 2 - 12
Cooling System Operation 9 - 4 FD620D Engine Throttle Body Repair . . . . . . . . . . 4 - 14
Cooling System Repair 9 - 6 FD620D Fuel Injection Air Pressure
Cooling System Specifications 2 - 5, 9 - 3 Sensor Operation . . . . . . . . . . . . . . . . . . . 10 - 9
Crankcase Disassembly 6 - 6 Float Level Adjustment . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Crankcase Vacuum Test 11 - 9 Fuel Injection Air Temperature Sensor
Crankshaft Inspection 7 - 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8
Crankshaft Installation 7 - 6 Fuel Injection System Operation . . . . . . . . . . . . . . 4 - 11
Crankshaft Journal Bushing & Seal Fuel Injection System Service . . . . . . . . . . . . . . . . 4 - 11
Replacement 6 - 9 Fuel Injection Temperature Sensor
Crankshaft Plain Bearings Inspection Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8
& Replacement6 - 8 Fuel Injector Operation . . . . . . . . . . . . . . . . . . . . . 4 - 11
Crankshaft Removal 7 - 5 Fuel Injector Repair . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
Crankshaft Service 7 - 5 Fuel Injector Test . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8
Cylinder Block, Piston & Rod Fuel Pressure Regulator Operation . . . . . . . . . . . 4 - 12
Components 6 - 7 Fuel Pressure Regulator Repair . . . . . . . . . . . . . . 4 - 13
Cylinder Block, Piston & Rod Fuel Pressure Regulator Service . . . . . . . . . . . . . 4 - 12
Specifications 6 - 3 Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
Cylinder Bore Specifications 6 - 10 Fuel System Troubleshooting . . . . . . . . . . . . . . . . . 4 - 3
Cylinder Head & Valve Specifications 5 - 3 Fuel/Air System Specifications . . . . . . . . . . . . . . . . 2 - 5
Cylinder Head Cleaning and Inspection 5 - 4 G
Cylinder Head Removal 5 - 4
Gasoline Specifications . . . . . . . . . . . . . . . . . . . . . 2 - 16
Cylinder Head Service 5 - 4
Governor Operation . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Cylinder Head Specifications 5 - 3 Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Cylinder Initial Rebore Specifications 6 - 11
Governor Service . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Cylinder Inspection6 - 10
4/7/95 INDEX - 1
INDEX
H R
Handling Asbestos . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4 Rebore Cylinder Block . . . . . . . . . . . . . . . . . . . . . . 6 - 10
Head and Valve Components . . . . . . . . . . . . . . . . . 5 - 4 Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Ring End Gap Specifications . . . . . . . . . . . . . . . . . 6 - 11
I Ring Land Side Clearance Specifications . . . . . . . 6 - 12
Rocker Arm Specifications . . . . . . . . . . . . . . . . . . . . 5 - 3
Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . 10 - 4
Ignition Module Replacement . . . . . . . . . . . . . . . . . 10 - 5 S
Intake Manifold Installation . . . . . . . . . . . . . . . . . . . . 3 - 3 Safe Chemical Handling . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Intake Manifold Removal . . . . . . . . . . . . . . . . . . . . . 3 - 3 Safe Fluid Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Intake Manifold Service . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Serial Number Plate Locations . . . . . . . . . . . . . . . . . 2 - 4
Internal Engine Components . . . . . . . . . . . . . . . . . 2 - 20 Side Draft Carburetor Repair . . . . . . . . . . . . . . . . . . 4 - 6
L Solenoid Shift Starter Inspection . . . . . . . . . . . . . . 10 - 6
Starter Armature Test . . . . . . . . . . . . . . . . . . . . . . . 10 - 7
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . 2 - 17
Starter Field Windings Test . . . . . . . . . . . . . . . . . . 10 - 6
Lubrication System Components . . . . . . . . . . . . . . . 8 - 4
Starter Service Parts Kits . . . . . . . . . . . . . . . . . . . . 10 - 5
Lubrication System Operation . . . . . . . . . . . . . . . . . 8 - 4
Starter Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . 10 - 7
Lubrication System Specifications . . . . . . . . . . . . . . 8 - 3
Starting Motor Diagnosis . . . . . . . . . . . . . . . . . . . . 11 - 6
M Stator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
Manual Fuel Pump Repair . . . . . . . . . . . . . . . . . . . . 4 - 9 Stator Replacement . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
Mechanical Fuel Pump Operation . . . . . . . . . . . . . . 4 - 9 Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
Mechanical Fuel Pump Service . . . . . . . . . . . . . . . . 4 - 9 T
Metric Torque Valves . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
Model Configuration Changes . . . . . . . . . . . . . . . . . 2 - 4 Tappet Removal & Installation . . . . . . . . . . . . . . . . .7 - 5
Test & Adjustment Specifications . . . . . . . . . . . . . . . 2 - 5
Muffler Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Thermostat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8
O Thermostat Specifications . . . . . . . . . . . . . . . . . . . . 9 - 8
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17 Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10 Throttle Body Service . . . . . . . . . . . . . . . . . . . . . . 4 - 13
Oil Pump Disassembly & Assembly . . . . . . . . . . . . . 8 - 5 Trhottle Body Operation . . . . . . . . . . . . . . . . . . . . . 4 - 13
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3
Oil Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 V
Oil Pump Specifications . . . . . . . . . . . . . . . . . . . . . . 8 - 6
Valve & Spring Specifications . . . . . . . . . . . . . . . . . 5 - 3
P Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . 5 - 5
Performance Diagnosis . . . . . . . . . . . . . . . . . . . . . 11 - 8 Valve, Valve Seat and Guide Inspection . . . . . . . . . 5 - 5
Piston & Piston Pin Specifications . . . . . . . . . . . . . 6 - 12 Valve, Valve Seat and Guide Service . . . . . . . . . . . 5 - 5
Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
Piston Ring End Gap Check . . . . . . . . . . . . . . . . . . 6 - 11
Piston Rings Removal and Installation . . . . . . . . . . 6 - 11
Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Proper Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Proper Welding Procedures . . . . . . . . . . . . . . . . . . . 1 - 4
Proper Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Pulser Coil Replacement . . . . . . . . . . . . . . . . . . . . 10 - 4
Push Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Push Rod Specifications . . . . . . . . . . . . . . . . . . . . . 5 - 3
INDEX - 2 4/7/95

Kawasaki Gas Engines

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John Deere K Series

This component technical manual is written for an

Fuel System & Governor

Note: Depending on the particular section or system

HANDLE FLUIDS SAFELY-AVOID HANDLE CHEMICAL PRODUCTS

• BE PREPARED FOR EMERGENCIES

TS291 Direct exposure to hazardous chemicals can cause

USE SAFE SERVICE PROCEDURES • WORK IN CLEAN AREA

• Before starting a job

• USE PROPER TOOLS

• REMOVE PAINT BEFORE WELDING OR HEATING LIVE WITH SAFETY

• AVOID HARMFUL ASBESTOS DUST

REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See the

BASIC ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

BASIC ENGINE SPECIFICATIONS

FD440V FD501V FD590V- FD590V- FD620D FD620D FD620D

Lawn And Garden Tractors

Golf And Turf Equipment

ENGINE MODEL CONFIGURATION

NOTE: The FD440V, FD501V and FD590V are vertical

ENGINE SERIAL NUMBER PLATE

The engine serial number (A) is located on the

CARBURETOR SERIAL NUMBER

TEST & ADJUSTMENT SPECIFICATIONS

CYLINDER HEAD AND VALVES

CAMSHAFT AND TAPPETS

PISTON, CONNECTING ROD AND CRANKSHAFT

IGNITION AND CHARGING SYSTEM

CYLINDER HEAD AND VALVES

CAMSHAFT AND TAPPETS

PISTON, CONNECTING ROD, AND CRANKSHAFT

IGNITION AND CHARGING SYSTEM

CYLINDER HEAD AND VALVES

CAMSHAFT AND TAPPETS

PISTON, CONNECTING, AND RODCRANKSHAFT

IGNITION AND CHARGING SYSTEM

METRIC TORQUE VALUES

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya

SIZE Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft

M6 48 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

GASOLINE SPECIFICATIONS FUEL STORAGE

Help prevent fires:

To prevent fire and explosion caused by static

IMPORTANT: To avoid engine damage:

Unleaded fuel is recommended because it burns

LUBRICANT SPECIFICATIONS ENGINE COOLANT

Mix approximately 50 percent antifreeze with 50

Cylinder Head Water Pump

Spark Plug Lead Rocker Arm Cover M45816

Right-Hand Side Shown

NOTE: Bare block components are similar between engines, some

COMPONENT LOCATION - FD440V/501V/590V - Continued

Rocker Arm Cover

Spark Plug Lead

Left-Hand Side Shown

INTERNAL ENGINE COMPONENTS

Flywheel Intake Valve

Stator Valve Springs

Water Pump Gear

Water Pump Impeller