Rev2 3.0bpmg Technical Man

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SERVICE MANUAL
3.0 BPMG and 3.0 BCG
60 and 50 HERTZ SINGLE PHASE
GASOLI
REVISION 3
l..,,_, 'WES12RBEKE
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APRIL2018
WESTERBEKE CORPORATION• 150 JOHN HANCOCK ROAD

MYLES STANDISH INDVSTRIAL PARK• TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
_.,,..,,
§Jf',d'fMember National Marine Manufacturers Association
AwARNING
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
•Dizziness • Throbbing in Temples
•Nausea • Muscular Twitching
•Headache •Vomiting
• Weakness and Sleepiness •Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,

GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
UJJfil it lu!s 'Hen inspected and repaired.
A WARNING DECAL Is provided by

WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
.WARN ING living/sleeping quarters of your vessel.
·. They are inexpensive and ea5ily
~~~~oE obtainable at your local marine store.
~~
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
and other reproductive harm.
TABLE OF CONTENTS
Parts Identification ... :.........................................2

Testing for Overhaul ····························~··············.3
Troubleshooting.Guide ........................ :.............. .4
Disassembly Procedures .....................................6
Sealants and Lubricants .....................................7
Torque Specifications ..................... ,...................9
Speci.al Tools ...................................................... 11
Service Standards/Repair Limits ...................... 12
Engine Disassembly ........................................... 15
Inspection and Measurement ...........................20
Engine Assembly ...............................................27
Oil Pump .............................................................32
Lubrication System ............................................32
Fuel System .......................................................33
Fuel Filter/Fuel Pump ........................................33
Starter Motor .....................................................34
Carburetor ..........................................................35
Raw Water Pump ...............................................36
Engine Tuning ....................................................38
Engine Adjustments...........................................39
Compression Test ........................................ 39
Water Pump Belt.. ....................................... .39
Ignition Timing ............................................ 39
Oil Pressure Test.. ....................................... .40
Spark Plugs .................................................. 41
Thermostat ...................................................41
Choke Solenoid ........................................... 41
Valve Clearance .......................................... .42
Timing Belt Replacement/Adjustment.. ..... .43
Electronic Governor ...........................................44
Wiring Diagram ..................................................45
Specifications ....................................................46
AC Generator .....................................................47
BC Winding Resistance .....................................48
BCG Internal Wiring Diagram ........................... .48
By passing the Overspeed Board ..................... .48
BCGJBPMG Troubleshooting Chart ................... .49
Flushing the Cooling System ............................ 50
English to Metric Chart.. ...................................51
Standard Metric Conversion Data ..................... 52
lndex...................................................................53
Engines & Generators
1
PARTS IDENTIFICATION
IGNITION COIL
ENGINE SERIAL NUMBER THERMOSTAT
MAGNETIC PICK-UP
16tllTJON CONTROL
MODULE
SERVICE SIDE
GENERATOR UHAUST
TECHNICAL
--'TEMPERATURE
!SWITCH
DATA LABEL
---._,OIL FILTER
SIPHON BREAK
'CONNECTION
START/STO.,.,..,..
SWITCH COOLANT PRESSURE C,l\P
WATER INJECTED
EXHAUST ELBOW
CIRCUIT BREAKER 2bA FUSE
BATTERY CHARGING
WATER (COOLANT)
TEMPERATURE
SWlfCH
r;-~--- OIL DRAIN
HOSE
----HEAT
FRESHWATER EXCHANGER
(COOLANT) MODEL
SERVICE SIDE
RAW WATER PUMP

COOLANT
PUMP
10A FUSE
ENGIN.E SERIAL\
NUMBER
GENERATOR
BATTERY --=--'t---1
VOLTAGE
REGULATOR
IGNITION COIL
EXHAUST ACTUATOR
CONNECTION
TO MUFFLER
LEFT SIDE
EXHAUST
ISOLATOR MOUNT
ARBURETOR
FUEL PUMP
. JL SUMP
DRIP PAN
WESTERBEKE
2
TESTING FOR OVERHAUL
HOW TO DETERMINE ENGINE OVERHAUL PERIOD OVERHAUL CONDITIONS
Cause of Low Compression Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Generally, the time at which an engine should be overhauled Thereafter, it decreases gradually with the progress of wear
is detennined by various conditions such as lowered engine of these parts.
power output, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output When decrease of compression pressure reaches the repair
is not necessarily due to trouble with the engine itself, but is limit, the engine must be overhauled.
sometimes caused by improper oil, clogged filters or a faulty
carburetor. The engine requires overhaul when oil consumption is high,
blowby evident, and compression values are at minimum or .
The decrease in compression pressure is caused by many fac- below. ···
tors. It is, therefore, necessary to determine a cause or causes
on the basis of data produced by periodic inspection and
maintenance. Oil analysis on a seasonal basis is a good
means of monitoring engine internal wear. When caused by
worn cylinders or piston rings, the following symptoms will
occur:
1 Low engine power output
2 Increased fuel consumption
3 Increased oil consumption
4 Hard engine starting
5 Noisy engine operation
These symptoms often appear together. Symptoms 2 and 4
can result also from improper fuel regulation or a faulty car-
buretor. They are caused also by defective electrical devices
such as the battery, starter or spark plugs. Therefore it is
desirable to judge the optimum engine overhaul time by the
lowered compression pressure caused by wont cylinders and
pistons plus increased oil consumption. Satisfactory combus-
tion is obtained·only under sufficient compression pressure.
If an engine lacks compression pressure, incomplete combus-
tion of fuel will take place even if other parts of the engine
are operating properly. To determine the period of engine
overhaul, it is important to measure the engine compression
pressure regularly. At the same time, the engine speed at
which the measurement of compression pressure is made
should be checked because the compression pressure varies
with engine rpm. The engine rpm can be measured at the
front end of the crankshaft.
NOTE: To test engine compression see the ENGINE
ADJUSTMENT section of this manual.
3
TROUBLESHOOTING GUIDE 3.0 KW BPMG
When toubleshooting indicates an electrical problem, see the
ELECTRICAL SYSTEM WIRING DIAGRAM, as this may The following troubleshooting tables are based upon certain
reveal other possible causes of the problem which are not listed engine problem indicators and the most likely causes of the
below. problems
PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE
Engine does not 1. Voltage drop at starter solenoid

crank. terminal. Engine misfires. 1. Poor quality fuel.
2. Main 10 amp fuse blown. 2. Faulty ignition control module.
4. Battery is low or dead. 3. Dirty flame arrester.
5. Loose battery connections. 4. Faulty ignition wires.
6. Faulty wire connection. 5. Spark plugs are worn.
7. Faulty start switch. 6. Binding actuator linkage.
8 Faulty pc board 7. High exhaust back-pressure.
9. Faulty starter solenoid 8. Valve clearance'S are incorrect.
10. Water ftlled cylinders. 9. Valve clearances are incorrect.
Engine starts, runs 1. Faulty shutdown switch,( oil pressure, Engine backfires. 1. Faulty ignition control module.
and then shuts or exhaust temperature). 2. Incorrect timing.
down. 2. Faulty overspeed switch. 3. Engine is flooded. See Engine is
3. Dirty fuel/water separator filter. flooded under Engfne cranks but
4. Clogged fuel line. fails to start
5. Low oil level in sump. 4. Dirty flame arrester.
6. Faulty fuel pump. 5. Faulty ignition coil.
7. No fuel 6. High exhaust back-pressure.
8. Clogged fuel filter Engine overheats. 1. Blockage in cooling water flow: inspect
Engine starts, runs 1. Faulty mag-pickup sensor. the raw water intake, intake strainer,
but does not come 2. Electronic governor controller faulty, pump impellers, and look for broken or
up to speed. 3. Fuel pump. seperated hoses.
4. Fuel supply to engine restricted. 2. Belts may be loose or broken.
5. Actuator linkage binding. 3. Obstructed by-pass hose.
6. Actuator or electrical connections Low oil pressure. 1. Low oil level.
faulty.
2. Wrong SAE type oil in the engine.
1. Air intake restricted.
3. Oil diluted with fuel.
8. Exhaust restricted.
4. Relief valve is stuck.
Engine cranks but 1. Out of fuel.
5. Faulty oil pump.
fails to start. 2. Engine is flooded.
6. Faulty engine bearings.
(Engine will crank 3. Faulty carburetor. (See Carburetor page)
7. Boat heeled over too much.
for 15 seconds) 4. Faulty choke solenoid
8. Faulty oil filter.
5. Faulty ignition coil.
High oil pressure. 1. Dirty oil or wrong SAE type oil in the
6. Bad spark plugs
engine.
Engine hunts. 1. Controller gain adjustment needed.
2. Relief valve ;s stuck.
2. Faulty fuel pump.
3. Faulty PC board. No DC charge to the 1. Faulty connections to
starting battery. battery charging control.
4. Improper drive belt tension.
2. 20 amp fuse blown/faulty.
5. Low DC battery voltage.
3. Faulty voltage regulator.
6. High exhaust back pressure.
4. Faulty magneto.
1. Dirty fuel filter
8. Generator overload.
9. Valves need adjustment.
4
TROUBLESHOOTING GUIDE 3.0 KW BPMG
PROBLEM PROBABLE CAUSE
Blue Exhaust Smoke Discharge 1. Lube oil is diluted.

from the Engine 2. High lube oil level.
3. Crankcase breather hose is clogged.
4. Valves are worn or adjusted incorrectly.
5. Piston rings are worn or unseated.
Black exhaust smoke Discharge 1. Dirty flame arrester.
from the Engine 2. Faulty carburetor.
3. Idle mixture jet too rich.
4. Accelerator diaphragm leaking.
5. Valves are worn or incorrectly adjusted.
6. Piston rings are worn or unseated.
Poor performance 1. Contaminates in carburetor.
at generator speed 2. Faulty fuel pump/contaminated.
3. Electronic governor controller needs
adjustment.
Starter stays energized 1. Faulty MPU suspected. Check MPU.
after start 2. Faulty starter solenoid.
Unit starts and runs 1. Check MPU signal. 1.5 - 2.0 VAG cranking.
at idle speed 2. Faulty overspeed board.
Note: MPU voltages to PC board:

Cranking: 1.5 - 2.0 VAC
Running: 4.0 - 5.0 VAC
(2200 rpm)
5
DISASSEMBLY I ASSEMBLY PROCEDURES
DISASSEMBLY
• Before disassembly and cleaning, carefully check for Surface Preparation
defects which cannot be found after disassembly and Thoroughly removes all substances deposited on the gasket
cleaning. application surfaces using a gasket scraper or wire brush.
• Drain water, fuel and oil before disassembly. Check to ensure that the surfaces to which the silicone gasket
• Clean or wash the engine exterior. is to be applied is flat. make sure that there are no oils,
greases and foreign substances deposited on the application
• Do not remove or disassemble the parts that require no
surfaces. Do not forget to remove the old sealant that
disassembly.
remains in the bolt holes.
• Perform disassembly in a proper order using proper tools.
Keep disassembled parts in order. Apply oil when GASKET INFORMATION
necessary. Take special care to keep the fuel system parts
from intrusion of dust and dirt. The engine has several areas where form-in-place RTV
silicone gaskets are used such as LOCTITE 598 or GE
• Parts must be restored to their respective components from RTV 100. To ensure that the gasket fully serves its purpose,
which they were removed at disassembly. This means that all
it is necessary to observe some precaution when applying the
parts must be set aside separately in groups, each marked for
gasket. Bead size, continuity and locatiO\ are very important.
its component, so that the same combination or set can be
Too thin a bead could cause leaks and too thick a bead could
reproduced at assembly.
be squeezed out of location causing blocking or narrowing of
• Pay attention to marks on assemblies, components and the fluid feed lines. To eliminate the possibility of leaks from
parts for their positions or directions. Put on marks, if a joint, it is necessary to apply the gasket evenly without a
necessary, to aid assembly.. . break while observing the correct bead size.
• Carefully check each part or component for any sign of The gasket material used in the engine is a room temperature
faulty condition during removal or cleaning. The part will vulcanization (RTV) type and is supplied in a 14oz (400
tell you how it acted or what was abnormal about it more gram) applicator/tube. The RTV hardens as it reacts with the
accurately during removal or cleaning. moisture in the atmospheric air and can be used for sealing
.both engine oil and coolax;it assemblies.
The parts assembled with the silicone can be easily
disassembled without use of a special method. In some case
however, the sealant between the joined surfaces may have ·
to be broken by lightly striking with a mallet or similar tool.
A flat and thin gasket scraper may be lightly hammered
in between the joined surfaces. In this case, care must be
taken to prevent damage to the joined surfaces. For removal
of the oil pan, use a special "oil pan remover".
ASSEMBLY
• Wash all parts, except for oil seals, 0-rings, rubber sheets,
etc., with cleaning solvent and dry them with pressure air.
• Always use tools that are in good condition and be sure
you understand how to use them before performing any
job.
• Use only good quality lubricants. Be sure to apply a coat ·
of oil, grease or sealant to parts as specified..
• Be sure to use a torque wrench to tighten parts for which
torques ·are specified.
• When the engine is assembled, new gaskets and 0-rings
must be installed.
6
APPLICATION OF SEALANTS AND LUBRICANTS·
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1342 13738 1741 12078 518 017 ~-64 5900
Cylinder liner
• Inside wall
Piston
• Ring groove, Periphery
Piston ring
• Periphery
Piston pin
• Periphery
Connecting rod
• Inside big and small ends
Metal {Cylinder block, crank case)

• Both sides
Crank shaft (thrust place)

• Sliding surfaces
Crank shaft oil seal

• Lips
Crank case cylinder mating surface

• Joint part
Valve (IN, EX)

• Shaft, Stem head
Valve stem seal (IN, EX)

• Lips
Retainer
• Complete
Valve spring seat

• Complete
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Valve spring
• Complete
•
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::ci Camshaft Bearing, cam
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c Camshaft oil seal
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c • Lips
w Cam pulley bolt

• Thread
Rocker arm
• Bearing, Slipper
Rocker arm shaft

•. Shaft, side
Tappet adjust screw

• Complete
Washer (rocker arm, t=0.5)'

• Complete
Washer (rocker arm, t=2.5)

• Complete
Spring drocker arm, free length 30
mm an 51 mmj_ • Complete
Fuel pump
• Periphery of 0-ring, end of
..Q!ur!.Q..er
2ml at Suction port and
Oil pump
• discharge port , Boss part
0-ring
(81.5-10.7) •
Oil pump 0-ring {"1.5 - 8.5)
•
(81.5 - 15.5)
•
Oil pressure switch
• Thread
7
APPLICATION OF SEALANTS AND LUBRICANTS
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1342 137.lB 1741 1207B 516 G17 KS-64 5900
Oil filter
• Seal
Oil filter bolt

• Thread
Plunger ass'y
• Inside (Pour 1ml)
~1.
Filter cap, 0-ring

• Periphery
Solenoid switch
• Terminal
Spark plug cap • Spark plug insertion part
.:x.
(.)
0 • High tention cord
::0
Q) Starter motor • Termini;i.I
c:
·ai
c: • Spread at pinion part slightly
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Starter case
• Bolt and screw for Reef
• Friction plate, reel shaft part,

Spiral spring, rachet
Starter seal rubber

•
Engine oil
• Oil; at oil change 1OOOml
at overhaul 1200ml
Oilpan gasket
•
Bolt (upper pump case)
• Thread
Upper pump case

• Impeller sliding surfaces
Joint part for water pipe guide
E_ngines_.& G.enerators
8
TORQUE SPECIFICATIONS
Tightening Torque
Item Thread size Bolt or Nut
N-m kg-m lb-:-ft
MS x 1.25 Bolt 2S-30 2.S-3.0 20-22
Cylinder Block - Cylinder Head
MS X 1.0 Bolt S-10 O.S-1.0 5.S-7.2
Ms x 1.25 Bolt 23-25 2.3-2.5 17-1S

Cylinder Block - Crank Case
M6 x 1.0 Bolt S-10 0.8-1.0 5.S-7.2
Connecting Rod M7 x 1.0 Bolt 11-13 1.1-1.3 S.0-9.4
Tappet Lock Nut MS X0.75 Nut S-8 O.S-0.8 4.4-5.8
Flywheel Cup M1S x 1.5 Nut 70-90 7-9 51-65
Drive fTimlng) Pulley M2S x 1.0 Nut 34-3S· 3.4!1·3.6 25-26

Engine
Driven (Camshaft) Pulley M6x1.0 Bolt 10-12 1.0-1.2 5.S-S.7
Plunger Assembly M16 x 1.5 - 19-21 1.9-2.1 12-15
Oil Filter M20 x 1.5 - 18 1.S 13
Oil Pressure Switch PT1/S - 7-9 0.7-0.9

'
5-6
Cylinder Head Cover M6x1.0 Bolt 8-10 0.8-1.0 5.S-7.2
Inlet Manifold M6 x 1.0 Bolt S-10 0.8-1.0 5.8-7.2
Spark Plug M12 x 1.25 - 15-20 1.5-2.0 11-15
Engine Assembly MB x 1.25 Bolt 29-31 2.9-3.1 21-22 '

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9
REQUIRED TOOLS
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1. Straight-point screwdriver (200 mrri) 10. T-bar universal wrench (10 mm)
- do. - (150 mm) - do. - (12 mm)
- do. - (100 mm) - do. - (13 mm)
2. Phillips screwdriver (20,0 mm) 11 . Plastic hammer
- do. - (150 mm) 12. Hammer
- do. - (100 mm) 13. L-shape hexagon wrench (8 mm)
3. Set of wrenches (6 pieces) - do. -, (10 mm)
4. Box wrenches (10 x 13) 14. Box wrench (16 mm)
- do. - (17 x 21) 15. Socket wrench (16 mm)
- do. - (21 x 23) 16. Torque wrench (100 N - m)
5. Adjustable wrench (300 mm) - do. - (12 N - m)
6. Pliers - do. - (5 N - m)
7. Needle-nose pliers Pre-setting type box torque wrench
8. Snap ring pliers (10 mm, 7N - m) .... for the tappetlock nut
9. T-bar, socket wrench (1O mm) 17. Socket wrench set
- do. - (12 mm)
- do. - (13 mm)
- do. - (17 mm)

. ·10
USING SPECIAL TOOLS
5. How to Use Special Tools 2. Piston pin tool
1. Flywheel cup puller After removing the piston pin clip, insert the tip of
CD When disassembling the piston pin tool into the piston pin hole and
Fasten the tools ®and Sto the flywheel with lightly tap the other end of the tool with a hammer.
the bolts ~ and remove the magneto nut Hold the piston with your hand to prevent damage
(right-hand screw) with the socket wrench of to the connecting rod. (When inserting the piston
the correct size 24. pin again, take the same care as removing.)
Piston pin
Next, screw tool O into tool 8 and tighten 0
with the socket wrench of the correct size 24. Piston pin tool
The flywheel can be removed. Be sure to

use· bolts (D). /;\
c--:.'~/·
2?
@;©
~i 3. Piston slider
This tool is to be used for inserting the piston into
the cylinder. After inserting the piston into the
tapered end of the piston slider, set the piston
slider together with the piston tightly on the top of
the cylinder and insert the piston into the cylinder
by pushing the piston crown 'with fingers.
@When reassembiing
Before replacing the flywheel make sure that Note:
the magneto key has properly been set. After Don't stop inserting the piston into the cylinder
setting the washer and nut on the crank shaft, until all the piston rings enter the cylinder.
fasten tools@and e>to the flywheel and tighten
the nut.
Piston slider
Tightening torque: 70-90 N-m (7.0-9.0 kg-m)
(51-65 lb-ft)
. Top of cylinder
11
SERVICE STANDARDS/REPAIR LIMITS/MAINTENANCE
Part Name Check/ln~ct Standard Value/Maintenance R~airlimit
Cylinder Head 1. Carbon deposit on the combustion 1. Remove carbon deposit and clean.
chamber
2. Scratch depth and distortion of the 2. Scratch depth or distortion is 0.1 mm (0.004in) 2. Repair (set #240·#400 sandpaper
mounting surface. or more. the surface plate and polish the
surface for repair. Use #600 sandpaper
for finishing).
3. Corrosion in the mated surface. 3. Repair or replace depending on the situation.
4. Clogged cooling water passage. 4. Clean and remove foreign matters.
Cylinder 1. Deposit in the water jacket. 1. Clean and remove foreign matters.
2. Wear of the inside cylinder 2. 59.00mm (2.322Bin) 2. 59.06mm (2.3252in) or more
diameter. Measure the bore with (If wear is exceeding the repair limit,
a cylinder gauge replace or bore the cylinder and finish
by honing. Over-sized piston is 0.5mm.
refer to item 4).
3. Seizure 3. Replace or use an over-sized piston
after boring the cylinder.
4. Scratch and wearing down in the 4. When the liner cannot be repaired by means 4. Bore and hone&o 059.5K0.01mm
cylinder liner. of #400-#600 sandpaper because it is (02.3425 ± 0.0 04in).Use oversize
extremely scratched or scored, or the piston and rings.
difference between the max~mum wear and
minimum wear is 0.06mm (0.0024in) or more.
5. Mating surfaces of the cylinder and 5. When the depth of scratch or distQrtion 5. Use #400 sandpaper on the surface
cylinder head. in/of the mating surface is 0.1 mm (0.004in) plate and polish the surface. Use #600
or more. sandpaper for finishing.
Piston 1. Outside Diameter 1. Diameter: 58.960mm (2.3213in) 1. Outer Diameter: 58.90mm (2.3189in)
or more.
a) Measure the diameter at a point
7mm above the lower end of the
piston skirt.
b) Piston Clearance b) Piston clearance: 0.020-0.055mm b.) Piston Clearance: 0.15mm
(O.OOOB-0.0022in) (0.0059in) or more
2. Carbon deposit on the piston crown 2. Remove carbon residuum and clean.
and in the piston ring groove.
3. Scratch on the sliding surface. 3. Repair with #400·#600 sandpaper depending
on the situation.
4. Measurement of clearance between 4. Top: 0.04-0.0Bmm (0.0016-0.0031in) 4. Top: 0.10mm (0.004in) or more
the piston ring and ring groove. 2nd: 0.03·0.07mm (0.0012·0.002Bin) 2nd: 0.09mm (0.0035in) or more
Oil: 0.01-0.1Bmm (0.0004 - 0.0071in) Oil: 0.21mm (0.0083in) or more
NOTE: To be replaced with a new oil ring, when
replacing with new top and/or second rings.
Sandpaper means water proof paper.
5. Measurement of diameter of the 5. Clearance between pin and hole 5. 0.04mm (0.0016in) or more
piston pin hole. Loose: 0.002-0.012mm (0.00008·0.00005in)
Piston Ring 1. End Gap 1. Replace with new piston ring if wear of the
NOTE: Measurement of the end gap: cylinder liner is within the repair limit.
when no ring gauge is available,
measure the lower part of the
cylinder bore.
a) Top a) Top: 0.15·0.35mm (0.006·0.014in) a) Top: 0.5mm (0.020in) or more
b) Second b) Second: 0.30·0.50mm (0.012·0.020in) b) Second: 07mm (0.028in) or more
c) Oil c) Oil: 0.20-0.7mm (0.008-0.02Bin) c) Oil Ring: to be replaced with a new
oil ring, when replacing with new top
and/or second rings. Sandpaper
means water proof paper.
Piston Pin 1. Outer diameter 1. 16.00mm (0.6299in) 1. 15.97mm (0.629in) or less.
Crankshaft 1.Deflection of the crankshaft. 1. Less than 0.05mm (0.002in)-both ends. 1. 0.05mm (0.002in) or more.
Both the main bearings of the
crankshaft should be supported
with V-blocks.
2. Outer diameter of the crankpin. 2. 29.98mm (1.1803in) it 29.95mm (1.179in) or less.
3. Outer diameter of the bearing. : 3. 31 ;99mm,(1.2594in)- 3. 31.97mm (1.259in) or less.
4. Oil clearance of the bearing. 4. 0.012 • 0.044mm (0.0005 • 0.0017ln) 4. 0.06mm (0.002in) or more.
5. Side clearance of the crankshaft. 5. 0.1 • 0.2mm (0.004 - 0.008in) 5. 0.6mm (0.024in) or more.
12
Part Name Check/l~ct Standard Value/Maintenance Rl!P_air Limit
Connecting Rod 1. Inner diameter of the small end. 1. 16.01mm (0.630in) 1. 16.04mm (0.631in) or more.
2. Oil clearance of the big end. 2. 0.015 - 0.041mm (0.0006- 0.0016in) 2. 0.060mm (0.002in) or more.
3. Side clearance of the big end. 3. 0.1 - 0.25mm (0.004 - 0.01 in) 3. 0.6mm (0.024in) or more.
Magneto • lnition timing BTDC 5° - 5° (electric ignition advance)
• Spark performance 10mm (0.4in) or more/500 rpm
(measured by genuine spark tester.
•Spark plug NGK DCPR6E
•Spark gap 0.8 - 0.9mm (0.032 - 0.035in) 1.2mm 9 0.0047in) or more
• Alternator output 12V, 130W (5000 rpm)
•Resistance of coifs
Between white wire and yellow wire 0.27- 0.41n
Between red-white wire and
black wire 148 - 22211
Between black-red wire and blue wire 12.5 -18.8!l
Between yellow-red wire and
yellow -red wire 1.40 - 2.100
• ESG for high speed Restricting at 6250 rpm
• ESG for low speed Reducing at 2000rpm
Ignition Coil • Resistance of primary coll
between black wire and orange wire 0.26-0.35.n
• Resistance of secondary coil
between high tension cord and core 6800 - 10200.n
Battery Output 12V - 70AHto 12V • 100AH
12V0.6KW
Clutch Over-running clutch
1) Brush length 1) 12.5mm (0.49in) 1) 9.5mm (0.37in) or less
2) Commutator under-cut 2) 0.5-0.8mm (0.02-0.03in) 2) 0.2mm (0.008in) or less
3) Commutator diameter 3) 30mm (1.18in) 3) 29 mm (1.14in) or less
Fuse Capacity 120A
Thermostat Operation of thermostat e Start to open: 60°C ± 1.5°C If the valve opens at room temperature,
(140 ± 3°F) replace the thermostat.
• Temperature at which valve opens While immersing the thermostat in water,
full: 75°C (167°F) raise the water temperature and check the
temperature at which the valve opens.
Pump Impeller Worn-out, crack Replace
Pump Case Liner Worn-out Replace
Guide Plate Worn-out Replace
Intake Valve 1) Valve Clearance IN: 0.13 - 0.17mm (0.005 - 0.007in)
Exhaust Valve EX: 0.18 - 0.22mm (0.007 • 0.008in)
2) Outer diameter of valve stem IN: 0.13 - 0.17mm (0.005 - 0.007in) 5.46mm (0.215in) or less
EX: 0.18 - 0.22mm (0.007 - 0.008in) 5.44mm (0.214in) or less
3) Inner diameter of valve guide IN: 0.13 - 0.17mm (0.005 - 0.007in) 5.55mm (0.218in) or more
EX: 0.18 - 0.22mm (0.007 - 0.008in) 5.57mm (0.219in) or more
4) Clearance to valve stem IN: 0.13 • 0.17mm (0.005 - 0.007in) 0.07mm (0.0028in) or more
EX: 0.18 - 0.22mm (0.007 - 0.008in) 0.10mm (0.004in) or more
5) Contact width of valve seat IN: 0.13- 0.17mm (0.005 • 0.007in) 2.0mm (0.079in) or more
EX: 0.18 - 0.22mr,n (0.007 - 0.008in) 2.0mm (0.079in) or more
Valve Spring Free length 35mm (1.38in) 33.5mm (1.319in) or less
Camshaft 1) Height of cam (both IN and EX) 1) 23.90mm (0.94in) 1) 23.75mm (0.935in) or less
2) Outer diameter of bearing 2) Pulley side: 17.98mm (0.0708in) 2) 17.95mm (0.707in) or less
Oil pump side:: 15.97mm(0.629in) 15.95mm (0.628in) or less
3) Clearance of holder (bearing) 3) 0.02 - 0.05mm (0.0008 - 0.0020in) 3) 0.09mm (0.0035in) or more
Rocker Arm 1) Inner diameter 1) 13.01mm (0.512in) 1) 13.05mm (0.514in) or less
and Shaft 2) Outer diameter 2) 12.99mm (0.511in) 2) 12.94mm (0.509in) or less
3) Shaft Clearance 3) 0.006 - 0.035mm (0.00024 -0.00138in) 3) 0.6 mm (0.0024in) or less
Timing Belt Tension and appearance Wear, crack or lengthen-replace
13
Part Name- - Check/Inspect Standard Value/Maintenance Repair Limit
Engine Bio ck With de-compressor 0.4 ± 0.1 MPa (5 ± 1 kg/cm'. 71 psi) Pay heed to pressure leak in compression
from the rotation, sliding and sealing parts.
Without de-compressor 0.93 ± 0.1 MPa (9.5±1 kg/cm', 135 psi)
(rocker arm in EX side is removed)
Carbureto r • Setting mark 3H8A
• ThrottleNenturi bore 23/11.5mm
• Main jet (MJ) #68
• Main air jet (MAJ) #135
• Inner diameter of main nozzle 2.2mm
• Slow jet (SJ) #42
• Slow air jet (SAJ) #115
• Opening angle of throttle (at W.0.T.) 80°
• Pilot screw (PS) - Blind 1-3/4
• Fuel level (from flange surface 14mm (0.55in)
to float bottom
• Resistance of PTC* heater for 20fl
auto-bystarter at 20° C (68° F)
(*PTC: positive temperature coefficient
thermistor)
• Idle speed (clutch in) 900 rpm
Oil Pump 1) Inner diameter of pump body 1) 29.04mm (1.143in) or more
2) Clearance between outer rotor 2) 0.36mm (0.014in) or more
and body
3) Height of outer rotor 3) 14.96mm (0.589in) or less
4) Clearance between rotor and 4) 0.11 mm (0.0043in) or more
body side (incl. wear of the pump cover)
5) Clearance between outer rotor 5) 0.16mm (0.006in) or more
and inner rotor
14
190
ENGINE DISASSEMBLY
Bolts, nuts, and washers are indicated by the symbols below.
.,, as~ .,, 40Hol&.;
I
·I/> 32... if, 35Hole ·
H820 - Hexagon headed bolt Diameter 8 mm Length 20 mm
NS - Normal hexagon nut Diameter 8 mm -t/> 15- t/> 20Hole'
LS - Hexagon lock nut Diameter 8 mm
W6 - Plain washer Diameter 6 mm
SW6 - Spring washer Diameter 6 mm Thickness : 30 or more
Screw 620 - Pan headed screw Diameter 6 mm Length 20 mm Unit : mm Setting board for power unit
Removing Parts Alternator

Oil strainer <D Remove the alternator fitting screw
<D Cut the hose band and then remove the oil and then remove the alternator.
strainer with the hose from the nipple.
Pulser coil
<D Remove the pulser coil fittlng screw
and then remove the pulser coil.
Startor motor and starter solenoid

<D Remove the starter motor fitting bolt
and then remove the starter motor.
@ Pull the starter solenoid from the electric
bracket.
Ignition coil Rectifier
<D Remove the plug cap from the spark plug. <D Remove the rectifier fitting bolt
® Remove the ignition coil fitting bolt

and then remove ignition coil.
C. D. Unit
<D Remove the C.D. unit fitting bolt
then remove the C.D. unit.
· Magneto flywheel cup

<D Remove the flywheel cup with a special tool
according to the instructions of "How to Use
Special Tools': . Carburetor
Q) Remove the carburetor fitting bolt
and then remo'{e the carburetor together with
the air silencer, insulator and gaskets.
'Fuel pump
Q) Remove the fuel pump fitting bolt
then remove the fuel pump.
15
ENGINE DISASSEMBLY
POWER UNIT Cylinder head, valves and relating parts
NO Part name Check point, etc.

Note: Must be replaced by new parts whenever they are once
Gasket & 0-ring
removed for'disassembling.
e Carbon deposit in combustion chamber
1 Cylinder head •Surface width-and roughness between valve seat anct valve
e Scratch or distortion
esurface width and roughness between valve seat and

Intake valve
2 intake/exhaust valve
Exhaust valve
ecarbon deposit
Valve stem seal - IN Black color: Wear of contact surface with valve stem
3
Valve stem seal - EX Green color: Wear of contact surface with valve stem
4 Valve spring eweekness
ewear of three contact points: contact surface with cam,
5 Rocker arm
rocker arm shaft and rocker arm washer.
6 Rocker arm shaft e Wear of contact surface with rocker arm
Cover, Cylinder head
3. Valve stem seal-EX

(Green color)
6. Rocker arm shaft-EX

VIEW FROM UNDER BASE FRAME
Engines.& Generators
16
ENGINE DISASSEMBLY
POWER UNIT Crank shaft, pistons, cylinder/crank case and related parts
NO. Part name Check point, etc.

e Oil clearance at main bearings
e Oil clearance at big end of connecting rod
Note: Align the tab of the metal bearing with the notch in the
1 Crankshaft
cylinder/crank case
Note: There are two type of metal bearings
(Thickness code: Black color and Brown color)
Note: Pay attention to the connecting rod orientation for
2 Connecting rod reassembling
("UP" mark must face the magneto side)
Note: Mate the markings of the cap and connectin~ rod with
3 Connecting rod cap
each other ("UP" mark must face the magnetq side)
Note: Tighten the bolts in 'careful manner; 11
4 Connecting rod bolt Gradually tighten the two bolts alternately seV;eral times
so thatthey are evenly tightened.
Note: Pay attention to the piston direction
5 Piston
("UP" mark faces the magneto side)
Note: Don't use the clip that is once removed.
6 Piston pin clip
Be sure to use a new part for reassembling.
Oil pressure sw,...,
IQllIDJ Loctite "518"

~1
~
~ 4-stroke Engine Oil
5. Piston
a,._ 6. Piston pin, Clip
2. Connecting rod
3. Connecting rod cap
4~ Connecting rod bolt
H850·4
111-13 N - ml
H630-6 Oil strainer
123-25 N- ml w WESTERBEKE
IB-10 N - ml Engines & Generators
17
ENGINE DISASSEMBLY
BEARINGS
ENGINE DRIVE, PULLEY
SHEAVE ARRANGEMENT
VIEW FROM UNDER BASE FRAME
18
ENGINE DISASSEMBLY
POWER UNIT Cam shaft, oil pump and related parts
NO. Part name Check point,' etc.
1 Cam shaft
e Smooth movement of decompressor weight
Note: This part is very weak_againstimpact.
2 Timing belt Note: Be sure to keep clean free from oil and grease
Note: Be sure to keep clean free from oil and grease

3 Drive pulley Note: Pay attention of direction
Note: Be sure to keep clean free from oil and grease

4 Driven pulley Note: Pay attention of direction
5 Oil pump
Ii:@!> 4-stroke Engine 011
HEAT EXCHANGER 2. Timing belt

ASSEMBLY
26mmNut ~ 4. Driven pulley
134-36 N - m I~
Lock washer ~
Plate~
Mar~
3. Driven pulley ~
Plate_.
Decompressor
HEAT EXCHANGER (FRESH WATER COOLED MODELS) I weight ---~R.!1-
The heat exchanger should be removed, inspected, and
cleaned. Install a new zinc and fresh hoses with riew clamps
at reassembly. If suspect, a local automotive radiator shop
should be able to clean and pressure test the heat exchanger. Pin
The water injected exhaust elbow should be removed and

inspected for defects and corrosion. Also inspect the siphon
break hose and its connections.
0-ring -d::'.)-~
Flush out the coolant recovery tank and its connecting hose. ©
Loosen the raw water pump, remove the drive belt and then
~ ~
remove the raw water pump.
Remove the engines coolant pump. For servicing, refer to 5. Oil pump
COOLANT PUMP.
Remove the thermostat assembly and clean the interior
chambers. Inspect the seals in the pressure cap when
reassembling. Replace the thermostat and gasket.
19
INSPECTION AND MEASUREMENTS
POWER UNIT
Measurement with vernier calipers · e Piston clearance (Clearance between piston
and cylinder)
e Valve seat width Standard value Out of the limit to use
0.020 - 0.055 mm If 0.15 mm (0.0059 in) or
Standard value Out of the limit to use
0.0008 - 0.0022 in more, it needs replacement.
If 2.0 mm (0.079 in) or
1.0 mm
more, it needs replacement • Outer diameter of piston pin
0.0393 in
or repair.
16.00mm If 15.97·mm (0.629 in) or
0.6299 in less, it needs replacement.
e Outer diameter of crank pin

Standard value Out of the limit to u~e
e Valve spring free length·
29.98mm If 29.95 mm (1.179 in) or
Standard value Out of the limit to use 1.1803 in - less, it needs replacement.
35mm · If 33.5 mm (1.319 in) or
1.38 in less, it needs replacement.
Measurement with micrometer e Outer diameter of crank shaft in metal bearing

e Outer diameter of piston skirt Standard value Out of the limit to use
31.99 mm If 31.97 mm. (1.259 in) or
Standard value Out of the limit to use 1.2594 in less, it needs replacement.
58.960 mm If 58.90 mm (2.3189 in) or
2.3213 in less, it needs replacement,
20
e Cam shaft e Outer diameter of rocker arm shaft
Standard Out of the limit Standard value Out of the limit to use
value to use
12.99 mm If 12.94 mm (0.509 in) or
Outer dia. in 17.98.mm If 17.95 mm (0.707 0.511 in less, it needs replacement.
bearing in) or less, it needs
(Upper) 0.708 in replacement.
Outer dia~ ih 15.97mm If 15.95 mm (0.628
bearing in) or less, it needs
(Lower) 0.629in replacement.
23.90mm If 23.75 mm (0.935

Cam height
in) or less, it needs Measurement with cylinder gauge
IN&EX o.94in replacement.
e Inner diameter of cylinder
Standard value Out of fhe limit to use

, 59.00mm If 59.06 mm (2.3252 in) or
2.3228 in more, it needs replacement.
e Valve stem
Standard Out of the limit
value to use
5.48 mm If 5.46 mm (0.215

IN in) or less, it needs
0.216 in replacement.
5.46mm If 5.44 mm (0.214

EX in) or IEtsS, it needs
e Diameter of piston pin hole

16.002 mm Depends on clearance
0.630 in between pin and hole.
e Clearance between valve guide and valve stem
Out of the limit
Standard value
to use
If 0.07 mm (0.0028
IN 0.008 - 0.04 mm in) or more, it needs
0.003 - 0.0016 in replacement.
If 0.10 mm (0.004
EX 0.025 - 0.057 mm in) or more, it needs
0.001 O - 0.0022 in replacement. e Clearance between piston pin and piston pin
hole
0.002 - 0.012 mm If 0.04 mm (0.0016 in) or
0.00008 - o:ooos in more, it needs replacement.
21
e Oil clearance at big end of connecting. rod
m
0.015 - 0;041 mm If 0.060 mm (0.002 in) or
·• Oil clearance between cam shaft and holder
Standard value · Out of the limit to use

0.02 - 0.05 mm 0.09 mm (0.0035 in)
Upper
0.0008 - 0.0020 in or rqore
• Inner diameter of small end of connecting rod 0.02 - 0.05 mm 0.09 mm (0.0035 in)
Loi,ver
0.0008 - 0.0020 in or more
If the oil clearance is out of the limit, replace
16.01 mm If 16.04 mm (0.631 in) or cylinder head and/or cam shaft and/or oil pump.
0.630in more, it needs replacement.
• Inner diameter of rocker arm

13.01 mm If 13.05 mm (0.514 in) or
0.512 in more, it needs replacement.
e Inner diameter of valve guide

• Oil clearance between rocker arm and shaft
5.51 mm If 5.55 mm (0.218 in)
If 0.06 mm (0.0024 in) or IN or more, it needs
0.006 mm - 0.035 mm
more, it needs 0.217 in replacement.
0.00024 - 0.00138 in
replacement.
5.51 mm If 5.57 mm (0.219 in)
EX or more, it needs
• Inner diameter (bearing) of cam shaft holder
Standard value EX
Upper 18.01-18.025 mm
(Cylinder head) 0.709 - 0.710 in
Lower
(Oil pump) IN
Engines_ & Generators

22 .
Measurement with thickness gauge • Side clearance at big end of connecting rod
• Clearance between piston ring and ring groove Standard value Out of the limit to use
Out of the limit to use 0.1 - 0.25 mm If 0.6 mm (0.024 in) or more,
Standard value
0.004 - 0.01 in it needs replacement.
0.04 - 0.08 mm If 0.1 o mm (O.Q04 in} or
Top 0.0016 - 0.0031 in more, it needs replacement.
0.03 - 0.07 mm If 0.09 mm (0.0035 in} or
Second
0.01 - 0.18 mm If 0.21 mm (0.0083 in) or
Oil 0.0004 - 0.0071 in more, it needs replacement.
• Side clearance of crankshaft

0.1 - 0.3 mm
0.6 mm (0.024 in) more
0.004 - 0.012 in
If the side clearance is out of the limit, measure
length of the crankcase (cylinder side) and the
• Piston ring end gap crankshaft and replace crankshaft and/or
Standard value Out of the limit to use cylinder-crankcase ass'y.
0.15 - 0:35 mm If 0.5 mm (0.020 in) or

Top
r--
0.30 - 0.50 mm If 0.7 mm (0.028 in} or
Second
0.20 - 0.70 mm
Oil
0.008 - 0.028 in
Standard value
Note: 126.8 - 126.9 mm
Crankshaft length
• Set the piston ring by pressing it in the piston 4.992 - 4.996 in
crown side.
·To be replaced with a new oil ring when replacing 127.0 - 127.1 mm
Crankcase length
with new top and/or second rings. 5.000 - 5.004 in
23
5) Measurement with Plastigage®
e Oil clearance between crankshaft and metal
bearing
1) Wipe oil out of:
• Crankshaft bearing journals
•Metal bearings (both sides)
• Bearing· portions of cylinder and crankcase
2) Install metal bearings into the cylinder and

crankcase.
Note:
Align the tab of the bearing with the notch @ in
the cylinder and crankcase.
0.012 - 0.044 mm
0.06 mm (0.002 in) or less
o.ooos - 0.0011 in ~
If the oil clearance is out of the limit, measure

inside diameter of the cylinder/crankcase bearing
holders and the crankshaft bearing journals.
There are within the standard value, replace
metal bearings.
e Cylinder/Crankcase bearing holder inside
diameter code
The codes (2 sort) are stamped on the upper
side of the crankcase.
3) Install the crankshaft to cylinder.
4) Place a piepe· of the plastigage on the 1.0. code Standard value Appling metal bearing
crankshaft main bearing journal. 35.000 - 35.008 mm
5) Assenble the crankcase. A,X Brown color paint
1.3780 - 1.3783·1n
Tighten· the crankcase bolts to the specified
torque in the i_11dicated order. 35.008 - 35.016 mm
B,Y Black color paint
Torque: : 23-25 N - m (2.3-2.5 kg - m) 1.3783 ::.... 1 .3786 in
(17-18 lb - ft)
: :8-1 O N - m (0.8-1.0 kg - m) Remark: 1.0. code A and B - For upper bearing
. (5.8-7.2 lb - ft) holder
1.0. code X and X - For lower bearing
INote:
Do not crank up the crankshaft. I
holder
6) Disassemble the crankcase.

7) Measure the compressed plastigage width at
its widest point.,
24
e Metel bearing thickness code Standard value Out of the limit to use
The codes are painted on the side of the bearing. 0.015- 0.041 m.m If 0.06 mm (0.002 in) or
0.0006 - 0.0016 in less, it needs replacement
e Repair of valve seat

1) Plane the valve seat face with the 45 ° valve
seat cutter.
2) Depending on the situation (the contact
Color code Thickness
position of the seat is too high or too low), use
1.488 - 1.494 mm the 30 ° cutter or 60 ° cutter and then repair the
Brown
0.0586 - 0.0588 in
surface area with the 45 ° cutter.
1.494- - 1.500 mm
Black
0.0588 - 0.0590 in
e Oil clearance at big end of connecting rod

1) Wipe oil out of the crank pin and big end
bearing of connecting rod.
2) Set the Plastigage to the crank pin and fit it to
the connecting rod. Tighten the bolt with the
specified torque.
Plastigage
3) Apply Prussian Blue compound (or equivalent)

mm
evenly on the seat face. While turning the valve
with the valve lapper, check face, wiclth
between the valve and valve seat. If necessary,
repair.the face width with the V?lve seat cutter.
Tightening torque: 11-13 N-m (1.1-1.3 kg-m) ,

(8.0-9.4 lb - ft)
Note:
Do not tum the connecting rod.
3) Remove the connecting rod and check the

Plastigage reading.
25
Face width
Standard value Limit that needs repair

1.0mm 2.0 mm or more
IN Notes:
0.04in 0.08in
1.0mm 2.0 rilm or more • When using lapping compound of a different
EX 0.04in 0.08in . grade, completely wipe oU! the previously used
compound beforehand.
: 4) After repair of the valve seat, lap the valve for e After lapping is complete, wash ~he valve and
good fitting. valve seat·atter completely wiping the
Apply lapping compound thinly on the seat 11nd compound out of them.
lap the valve while turning and tapping it with.
the valve lapper. ·
Remarks: Since the lapping compound is supplied
in a set of three grades (coarse,
medium and fine). lap the valve with all
of them in order from coarse, medium
and fine.
26
ASSEMBLY
POWER UNIT
Reassembling Engine
e Camshaft
Reassemble the engine in the reverse order of • Carefully press the oil pump pin so that it does
disassembling with careful attention to the not come out of the cam shaft.
following points. • When reassembling the cam shaft to the cylinder
(1) Cylinder head and related parts head, apply the engine oil for the 4-stroke cycle
e Valve stem seal engine to the cam and bearing beforehand and
•There are two kinds of valve stem seals, namely, then insert the cam shaft into the cylinder head
the valve stem seal for the intake valve is from the oil pump side while twisting it with care
identified by the black color while the other for not to turn over the oil seal lip:
the exhaust valve is identified by the green color.
e Rocker arm
• On installing the valve stem seal to the cylinder
•Temporarily set the tappet adjusting screw and
head, apply the engine oil for the 4-stroke cycle
tappet adjusting nut to the rocker arm.
engine to the insertion point. For setting the
Note:
valve stem seal, press it into the valve guide with
Set the tappet adjusting nut with the chamfered ·
fingers. side down.
e Intake valve, Exhaust valve • Apply the engine oil for the 4-stroke cycle engine
• The intake valve and exhaust valve are different to the rocker arm shaft.
from each other, namely the intake valve is • Set the rocker arm shaft from the side of the oil
identified by the "IN" mark while the exhaust pump of the cylinder head. Pay heed to
valve is identified by the "EX" mark. orientation of the rocker arm shaft so that the
• Apply the engine oil for the 4-stroke cycle engine tapped hole side is positioned in the oil pump
to the valve stem. Then, insert the valve into the side.
•Set the rocker arm shaft spring, washer, rocker
valve guide while twisting it.
arm, rocker arm shaft collar to the rocker arm
• After setting the cotter on-to the valve stem, tap
shaft from the bottom side in this order.
the valve shaft end with a small plastic hammer
several times for stabilizing the cotter in setting. • When setting the above-mentioned parts, apply
• After reassembling the valves, apply the engine the engine oil to every part.
Bolt M6-19
oil for the 4-stroke cycle engine to the upper side Washer 6.5-19-3.2 Washer 14.2-25-2.5
of the retainer and its periphery.

Washer 13.2·21.8-2.0
Washer
Rocker arm shaft collar
Washer Rocker arm shalt spring
t Rocker arm shaft setting direction

27
ASSEMBLY
e Oil pump e Plunger
• Pour the engine oil of approximately 2.0 ml into • When setting the plunger stopper into the
the oil pump through the inlet a'nd outlet ports. plunger case, pay attention to the orientation of
• Apply the engine oil for the 4-stroke cycle engine the plunger stopper so that it is set as shown.
to the 0-rings (1.5-10.70, 1.5-8.50, 1.5-15,50)
and the 0-ring at the boss before setting them in • When assembling the plunger assembly to the
the oil pump. cylinder, fasten it together with the cover.
• When assembling the oil pump to the cylinder

head, carefully set it so that the cam shaft pin
(12-15 lb - ft)
and the notch on the oil pump shaft meet each
other. Plunger case
Cover
• Fasten the oil pump with the three M6 bolts with
the tightening torque and in the tightening order
specified below.
Tightening order: CD. ® and @
e Piston ring
Tightening torque: 5-6 N - m (0.5-0.6 kg - m) Fitting oil rings to piston
1. Set the spacer expander in the oil ring groove,
and check to see if both the ends of it correctly
link with each other as shown in CD.
-Cam shaft
Pin
1
Oil ri~~liiS
CORRECT
on rour J
--Oil pump INCORRECT
Oil flNJ
28
ASSEMBLY
2. While holding down the slit of the spacer Check of correct setting of each piston ring
expander with a thumb, set the upper rail as its 1. Check to see if the slit of each piston ring is not
slit is deviated from the slit of the spacer set in the piston thrust direction or piston pin
expander at an angle of 90° in the direction.
counterclockwise direction. ® 2. After the assembling work is complete, make sure
3. In the same manner as the preceding step, set that each piston ring is set as shown once again.
the lower rail as its slit is deviated from the slit of
the spacer expander at an angle of 90° in the e Piston and Connecting rod
clockwise direction. @ • Assemble the connecting rod and connecting
Top ring ~ Chrome

rod cap to each other as they were put together
~plating before removing. (Before removing the
Second ring ~
\if..fil1\ Tapered
connecting rod cap, be sure to leave a markin.g
at a mated point between the connecting rod
and connecting rod cap as a reference for
reassembling.)
.__ _ _ _ _ _ _ _ ___, •The upper sides of. the. connecting rod cap,
Fitting compression rings to piston connecting rod and piston are identified by the
Fit the compression rings onto the piston in the "UP" mark.
correct order to start with the lower ring. Set each • For inserting the piston and connecting rod
compression ring. with the side marked with the assembly intq the cylinder, use the piston slider.
brand and size up. Apply the engine oil for the 4-stroke cycle engine
to the cylinder liner, piston rings before inserting
the assembled piston.
Oversize mark
29
ASSEMBLY
e Cylinder and Crank case 5 6
• When fitting the metal bearing to the cylinder
and crank case, set the tab in the notch.
1 2
• Apply the engine oil for the 4-stroke cycle engine
to the metal bearing.
• Degrease the mating surface between the
cylinder and crank case.
4 3
•Apply the Locktight #518 to either of the cylinder
and crank case with careful attention to the
Tightening torque:
applying part and width so as to avoid overflow.
MB bolt: 28-30 N - m (2.8-3.0 kg' - m)
Apply Locktight #518 to the black part.
Applying width: 1 mm (20-22·1b - ft)
M6 bolt: 8-10 N - m (0.8-1.0 kg - m)
(5.8-7.2 lb - ft)
• Cylinder head cover

CarefUHy avoid
overflow. • Fit the gasket to the cylinder head cover and
apply the Three Bond #12078 to the shaded
part shown.
Matingmark#2
Apply the sealant to the shaded part.

Shaded part (Part shown by slanted lines)
e Fitting cylinder head to cylinder
•Before fitting the cylinder head to the cylinder, Tightening torque: 8-10 N-m (0.8-1.0 kg-m)
set the piston at the top dead center. (5.8-7.2 lb - ft)
• When fastening the cylinder head, carefully

tighten the bolts with the specified tightening
torque and in the correct order.
30
ASSEMBLY
e Fuel pump e Oil filter
• Make sure that the marks "2" and ~o" on the • Apply the engine oil for the 4-stroke cycle engine
driven pulley and the mark " \J " on the cylinder to the rubber seal of the oil filter.
head are aligned in a straight line.
• Apply the engine oil for the 4-stroke cycle engine
to the top of the plunger and 0-ring of the fuel
pump.
Crank shaft holder FILTER WRENCH
Oil FILTER
Tightening torque: 18 N - m (1.8 kg - m)

(13 lb - ft)
Tightening torque: 5-6 N - m (0.5-0.6 kg - m)

• Water Injected Exhaust
(3.6-4.3 lb - ft) Elbow
SIPHON BREAK
e Drive pulley
• For tightening the nut to. fasten the drive pulley,
use the crank shaft holder.

(25-26 lb - ft)
lock washer
(Bend it by a part.)
Crank shaft •Oil Pan
Coat the new gasket with
three bond #12078 on both sides
and mount the oil pan. Tighten
the cap screws gradually in
opposing order.
Torque at 28 - 30 Nm (20 - 22 lb-ft)
• After tightening the nut, bencf up the lock washer

by a part.
31
LUBRICATION SYSTEM
OIL PUMP
Using a micrometor, cylinder gauge, depth gauge and feeler gauge, measure the following oil pump clearances.
Replace if worn or out of specification.
CD Inner diameter of pump body 29.04 mm (1.143 in) or more
@ Clearance between outer rotor and body 0.36 mm (0.014 in) or more
@ Heigth of outer rotor 14.96 mm (0.589 in) or less
© Clearance between rotor and body side 0.11 mm (0.0043 in) or more (incl. wear of the pump
cover)
® Clearance between outer rotor and inner rotor 0.16 mm (0.006 in) or more
0-Ring ---6--~
@>
®@! ©
I
Pump body @
OIL INSPECTION
~
Always observe the old oil as it is removed. A yellow/gray
emulsion indicates the presence of water in the oil. Although
Outerroror this condition is rare, it does require prompt attention to
prevent serious damage. Call a competent mechanic if water
is present in the oil. Water present in the oil can be the result
~
of a fault in the exhaust system attached to the engine and/or
a siphoning through the water cooling circuit into the
Inner rotor
Shatt4
exhaust, filling it up into the engine. Use an oil test kit and
I send a sample of the engine oil to a qualified oil test lab for
analysis.
WIPE THIS SURFACE

CLEAN BEFORE OIL FILTER ASSEMBLY
Pin ~ INSTALLING FILTER
Gasket~ .OIL PRESSURE SWITCH
Oil pump cover ---A .OIL FILTER

'WRENCH
~
OIL FILTER
l--H635-3
32
FUEL SYSTEM
FUEL PUMP
OISASSEMBLY
Before disassembly, make a aligning line on the out
side of fuel pump for correctly reassembling. Valve body
CD Remove screw, and take off: Inspection:
• Outer plate 9/Wear and damage
•Gasket
•Valve body
®Turn the piston clockwise or counter clockwise

until you look the pin from the cutaway of the
pump body.
® Pull the pin, and remove from the pump body:

•Piston
•Spring
•Diaphragm
•Spring
Pump body Diaphragm

Inspection:
•Crack and damage
ENGINE REASSEMBLY
FUEL LUBRICATE WITH Reassembly is reverse order of disassembly
FILTER· CLEAN FUEL ANO
' PRESS THE FILTER
ON OVER THE. 0-RING Note:
After connecting the diaphragm rod to the piston
with pin, align the diaphragm holes (6) to the
pump body holes so that the pin wilt not come out
through pump body cutaway.
33
STARTER MOTOR
eSNAPRING
PINION
ASSEMBLY
STARTER
MOTOR
STARTER
MOTOR
'(+)POSITIVE FROM ,
BATTERY
DISASSEMBLY
Remove the snap ring from the end of the shaft and the
pinion assembly can be disassembled from the front of the
housing.
Remove the long bolts from the motor base and disconnect
-the wiring connection hardware. This will separate the base
from the housmg allowing access to the brush holder
assembly.
NOTE: This exploded view is to enable the customer to inspect

clean and possiblty repair this starter motor, but parts are no longer
available for this model motor.
34
CARBURETOR
DC REGULATOR
DESCRIPTION
The carburetor is a single barrel, side-draft type with a
cleanable metal screen air intake filter/spark arrester.
The choke is operated by a 12 VDC solenoid. The choke Fuel Overflow Chamber
solenoid is activated when the start switch is depressed and is Excess fuel drains into the fuel overflow chamber but is
controlled by the I.C.M. drawn out again at start-up. This chamber should be kept free
of contaminates. Cleaning every 250 operating hours should
Air Screen/Flame Arrester be sufficient unless there is a fuel problem.
The air screen can easily be removed. Clean after the first 50
hours of operation and every 100 hours from then on. Clean Idler Mixture Jet
the air screen in a water soluble cleaner such as GUNK. Adjustment is performed with the generator operating.Screw
the jet slowly in until it seats, then back it out 2 to 3 turns.
Maximum adjustment is 5 turns.
NOTE: An idle mixture jet adjusted too far off its seat can
induce a sooty exhaust discharge at engine start-up and
IDLER Ml shut-down.
De-Richening Valve
The de-richening valve closes off a fuel port that is supplying
additional fuel on a cold start after start up. This is a thermal
electric device that slowly moves a needle outward when
DC power is applied after start up to close this fuel port.
To check this valve, remove from the carburetor (cold) and
apply DC voltage across its electrical connections. The
devise should get hot and the needle will slowly move·
outward. the devise will remain hot during engine operation
FUEL OVE FL
CHAMBER
Carburetor Bowl. Drain
A bowl drain slotted plug is located on the lower right comer
of the carburetor bowl. This is located just inboard of the
actuators ball joint/clevis.,
CARBURETOR WITH SPEED ACTUATOR
35
RAW WATER PUMP IMPELLER
INSPECTION: CHECK AT THE BASE OF
EACH BLADE BY BENDING VIGOROUSLY.
DESCRIPTION REPLACE THE IMPELLER IF THERE
~ .AREANYCRACKS.
Coolant (fresh water) cooled generators have dual water
pumps while the raw water cooled models use a single water \________/ °' COVER
pump. The pumps are essentially the same. The upper pump
a
mounts to the top of the lower pump and has a tang on the
shaft that fits into the shaft of the lower pump. Both pumps
are driven simultaneously by the engines drive belt.
INSPECT THE 0-RING
The following instructions apply to either pump. AND IMPELLER. REPLACE
IF ANY SIGNS OF WEAR
OR TEARING
PUMP OVERHAUL
Disassembly
The pump, when removed from the engine will have the hose
attachment nipple threaded into the inlet and outlet ports of IMRELLER PIN
FITS INTO SHAFT
the pump along with a drive pulley attached to the shaft of
the pump. Remove these attachments noting their positions
before starting the pump disassembly. SHAFT
1. Remove the four cover plate screws, cover plate, and

sealing 0-ring. $
Dual Pumps CIRCLIP
B
Remove the cover screws and the cover will separate the
upper pump (raw water)from the fresh water (coolant) pump
SLINGER
as shown in the Blustration. 0-RING
Remove the wear plate to expose the impeller. Notice the INNER
direction the impeller blades are working in so as to install BEARING
the replacement impeller with blades working in the same
direction. SPACER
2. Remove the impeller using a pair of pliers, grasping the
hub and pulling it out of the pump with a twisting motion. OUTER
BEARING
3. · Remove the screw and sealing washer that hold the cam
in place. Remove the cam and inner wear plate behind it. 0
CIRCLIP
4. Remove the brass cirdip A and brass plate found behind c
the wear plate.
DUST
5. Remove the dust pfa,te and circlip B. PLATE
6. Support the pump body on an arbor press and with a drift,
carefully press the shaft and bearing assembly out of the LIGHTLY GREASE THE PUMP
CHAMBER WITH GLYCERIN
pump body out the pulley end.
7. Remove the slinger 0-ring from the shaft.
8. Support the outer bearing and push the shaft out of the
bearing.
9. Remove the spacer and circlip C.
to.Support the inner bearing and push the shaft out of the
bearing.
11.Remove the two piece ceramic shaft water seal. PULLEY
Inspection
Inspect all pa.its and replace those showing wear and
corrosion.
36
.RAW WATER PUMP
Reassembly
Wipe the inside surface of the pump dry. Apply a film of ·
glycerin supplied in the impeller kit to the inside pump
surfaces and to the exposed area of the shaft lip seal.
1. Install a new shaft seal in the pump body. Apply some
glycerin to the lip of the seal.
2. Install the circlip shaft. Support the outer bearing and UPPER.
push the shaft into the bearing until the bearing contacts PUMP SHAFT
the circlip.
3. Install the spacer against the circlip. Support the inner
bearing and push the shaft into the bearing until it
contacts the spacer.
4. Warming the pump body should aid in installing the shaft SCREWS
and bearing assembly. Support the pump body on an arbor @ FASTENS THE ·
press. With a twisting motion, install the shaft and bearing ~ UPPERPUMP
assembly into the pump until the inner bearing seats and BODY TO THE
the outer bearing should just clear the boss for circlip B. THE TANG 01' THE END LOWER PUMP
Rotate the shaft. It should tum freely. OF THE UPPER SHAFT
FITS INTO THE SLOT IN
5. Install circlip B and push the shaft assembly until the THE LOWER SHAFT.
outer bearing just contacts circlip B and install the dust
plate. Rotate the shaft. It should tum freely.
6. Put some glycerin on the outer surface of the ceramic seal
seat and slide it over the shaft white ceramic facing out
and seat it in the body of the pump. Place some glycerin
on the inner area and with a twisting motion slide it over THE O·RING!GASKET
. ONLY NEE/JS TO BE
the shaft until the ceramic of the spring seal touches the REPLACES IF IT SHOWS
white ceramic face. SIGNS OF AGING.
7. Install the brass plate and circlip A.
8. Install the wear plate, locking it in position on the dowel
pin. DUAL PUMPS
ASSEMBLY
Dual Pumps
The wear plate is assembled above the impeller.
9. Install the cam and place some gasket cement on the
threads of the screw that secures it in place.
10.Place some glycerin on the inner surface of the pump, the
inner surface of the cover and the cover sealing 0-ring
and with a twisting motion install the impeller on the shaft
of the pump. Install the covers 0-ring and cover and
secure the cover with the four cover screws.
PULLEY
NOTE: Install the new impellers with a rotating motion so the
blades are working in the same direction of those of the
removed impeller.
DuaJ.Pumps
Assemble the upper pump to the lower pump as illustrated
making sure the mounting screws are tight.

37
ENGINE TUNING
TEST RUN AND INSPECTION AFTER COMPLETE ASSEMBLY
After reassembly, the engine must be tuned. This will ensure • Check that the engine oil is continuously circulating from
that the engine operates at its maximum efficiency. the oil pump to the valve rockers through the cylinder
•Mount the engine on a test bench. head.
• Connect the electrical wiring. refer to the WIRING If there is no oil circulation or if the oil circulation is
DIAGRAM. sluggish, stop the engine and make the appropriate repairs
and adjustments.
e Connect the air intake line to the air cleaner. • Re-install the cylinder head cover.
• Connect the exhaust.
• Check the engine for oil, fuel, coolant, and air intake
• Fill the engine cooling system with coolant and the engine leakage.
oil sump with lube oil.
• Check for abnormal noise and odor.
• Connect the fuel lines.
• Check for abnormal electrical charging.
• Crank the engine with the starter (non-ignition operation)
for about twenty seconds. This will pre-lubricate the • Check the engine fastening parts for looseness.
engine internal components. • Check the operation of the start/stop switch and LED
• Start the engine and allow it to run five minutes. panel lights.
• Remove the cylinder head cover while the engine is • Adjust the engine speed to the specified value for
running. generator operation.
• Stop the engine to complete the tuning procedure.
• Additional tightening after test run. Check the tightening
condition of respective bolts and nuts after test run, and
additionally tighten them with the specified tightening
torques.
38
ENGINE ADJUSTMENTS
ENGINE COMPRESSION TEST WATER PUMP BELT
To check the engine's compressimi pressure, wann up the
engine, then shut it down.
1. Remove both spark plug caps and both spark plugs.
2. Install a compression adapter and gauge in a spark
plug hole.
3. Close the thru hull valve (seacock).
4. Crank the engine several times quickly so that the gauge ·same.
pointer reaches it's maximum.
STANDARD COMPRESSION PRESSURE AT 500 RPM:
71 psi, (5 .1 kgf/CM ) ,(0.50 MPa) with decompressor
186 psi, (13.8 kgf/cm ), (1.35 MPa) without decompressor
5. Test the compression pressure on the other cylinder.

If either cylinder is below the standard try adding a
small amount of engine oil through the spark plug hole
and repeat the test.
(a) If additional oil causes an increase of pressure,
the piston ring and/or cylinder may be worn
or damaged.
(b) If additional oil does not increase compression I
pressure suspect poor valve contact, valve seizure r
or valve wear. . ,,,
6. Reinstall the two plugs, connect the wires and open the· WATER PUMP BRACKET
"lr
thru hull valve Cseacock). li'1t'/~
~/ ==-=----·-----=~
I!
NOTE: The a.dju.s~;ient is the same for the FRESH WATER
COOLED MODEL dual pumps.
IGNITION TIMING
The magneto employs the electric ignition advance system 30
that advances ignition timing with an increase of engine BTDC 2s-1-~~-+~:::_.~~~
IGNITION TIMING
speed. While running the engine, check the ignition timing IN DEGREES 20
with a timing light.
There are nine (9) markings (TDC, ATDC 5° and BTDC 5°,
10°, 15°, 20°, 25°, 30°, 35) on the flywheel cup. 10
Check the timing while observing the position of the carved 5

marking on the starter case. 0 i..--.i....~1--.....1---i.-....t.-...1
0 3 4 5 6x103
FLYWHEEL
Engine speed rpm
-==
--CARVED MARKINGS
/w/WESTERBEKE
I Engines & Generators
39
ENGINE ADJUSTMENTS
ADJUSTING THE DRIVE BELT BELT ASSEMBLY VIEWED FROM BENEATH
The engine's drive belt is located under the engine. To

access the belt, for inspection and/or adjustment, remove
the cover as shown. Inspect the belt for wear along the edges
and for proper belt tension (belt should be tight).
TI1e belt tension ca11 be checked by meassuring the
spring length. 11/4in (31.79mm)
To set the spring tension at 1-1/4", release the jam nut and
use a rod such as an alien wrench to turn the adjustinff nut (as
shown) to tighten or loosen the spring tension, which in turn
adjusts the tension on the belt.
The lubricating system is a pressure feeding system using an

oil pump. The engine oil is drawn from the oil sump by the
oil pump, which drives the oil, under pressure, through the
oil filter and vmious lubricating parts in the engine. The oil
then returns to the oil sump to repeat the continuous cycle.
. IT IS NORMAL FOR SOME BELT When the oil pressure exceeds the specified pressure, the oil
DUST TO ACCUMULATE IN THE pushes open the relief valve in the oil pump and returns to
ENGINE PAN, SIMPLY WIPE CLEAN the oil sump, keeping the oil pressure within it's specified
COVER range.
TESTING OIL PRESSURE

To test the. oil pressure, remove the oil switch and install a
mechanical oil pressure gauge in it's place, it will be
necessary to connect the two switch wires together for the
engine to nm. After warming up the engine, with tlie engine
speed at 2200 rpm, read the oil pressure gauge.
OIL PRESSURE: between 30 and 40 psi al 2200 rpm
NOTE: A newly starter (cold) engine may have an oil
pressure up to 40 psi. A wanned engine can have an oil
pressure as low as 30 psi. Oil pressure will vary depending
on the load placed on the generator.
OIL PRESSURE SWITCH/SENSOR
BELT ASSEMBLY VIEWED FROM BELOW The generator is ntted with an oil pressure shutdown
switch. Should the engine's oil pressure drop below the safe
* IMPORTANT: REFER TO THE WESTERBEKE SERVICE

BULLETIN (LAST PAGE IN THIS MANUAL) FOR THE
minimum, the switch will shut the engine down to prevent
damage by intetrupting the DC voltage to the ignition coil.
NOTE: The specified minimum oil pressure is 5 psi. A gradual
ADDITION OF A SPACER ON THE 3.0BCG MODEL.
loss of oil pressure usually indicates worn bearings. For
additional infomiation on low oil pressure readings, see the
ENGINE TROUBLESHOOTING chart.
l "flllY'/WESTERBEKE
Enaines & Generators
40
ENGINE ADJUSTMENTS
SPARK PLUGS
The spark plugs should be cleaned and re-gapped after the
first 50 hour break-in period, then inspected every 250 hours
thereafter and replaced as needed.
A WARNING: Do not remove the spark plugs while

the engine is hot. Allow the engine to cool before
removing them.
SPARK PLUG GAP: 0.032- 0.035in. (0.8 • 0.9mm).

SPARK PLUG TORQUE: 11 -15 lb-ft (15- 26 Nm).
NOTE: Loctite Anti-Seize applied to the threaded portion of
the spark piugs will retard corrosion, making future removal THERMOSTAT [Raw Water Cooled Models}
of the ,\park plugs easier.
A thermostat controls the coolant temperature as the raw water
t continuously flows through the closed cooling circuit. When
the engine is first started, the closed thermostat prevents the
water from flowing (some water is by-passed around the
INSPECT FOR / thermostat to provide coolant circulation in the engine block).
WEAR & CARBON,,,.-
As the engine warms up, the thermostat gradually opens. The
thermostat is accessible and can be checked,, cleaned, or
replaced easily. Carry a spare thermostat and gasket.
If you suspect a faulty thermostat, place it in a pan of water
INSPECTING and bring to a boil. A working thermostat should open when
THE SPARK heated and close when cold.
PLUGS '--.__CHECK FOR
DETERIORATION
ANDDAMAGE
CHOKE SOLENOID
The choke solenoid is a 12 volt DC operated unit that
is an integral part of the carburetor. When the engine is cold,
extra fuel is supplied to the engine. The choke is controlled
by the ignition control module and requires no adjustments.
ZINC ANODE [Raw Water Cooled Models}

The zinc anode is located just below the thermostat cover
and next to the oil filter.The purpose of the zinc anode is to
sacrifice itself to electrolysis ai::tion taking place in the raw
water cooling circuit, thereby reducing the effects of
electrolysis on other components of the system. The
condition of the zinc anode should be checked monthly and
the anode cleaned or replaced as required. Spare anodes ZINC ANODE
should be carried on board.
ZINC ANODE
NOTE: Refer to the Cooling System THE GASKET IS SEALED TO AND GASKET
THE CASTING AND, UNLESS
pages.for Fresh Water Cooled Thermostat
DAMAGED, CAN BE LEFT IN
and Zinc Anode assemblies.
POSITION. ADD SEALANT TO
THE GASKET SURFACE WHEN
REASSEMBLING THE COVER.
41
.
ENGINE ADJUSTMENTS
INSPECTION/REPLACING OF THE TIMING BELT
If cracks, wear, lengthening or other damage is found,
replace the ti.ming belt.
LIMIT OF ELONGATION: MORE THAN 10mm (0.4 IN) DEFLECTION BY
PUSHING WITH YOUR FINGER
Replacement of the Timing Belt

1. Remove the parts in the following order:
a. Spark Plugs
b. Voltage Regulator FLYWHEEL

ASSEMBLY
c. Unplug MPU
d. Unplug Cam Sensor
e. Flywheel Housing
f. Flywheel assembly
g. Altemafor Bracket
2. Turn. the crankshaft and align "O" mark on: the drive
pulley and the "O,, inark: on the ·cylinder head.
3. · Remove the timing belt from the driven pulley side.
4. Install the timing belt froni the drive pulley side.
NOTE: After insttitllng the timing belt, when the aligning
"O" rnark on the drive puUey with "O" on the cylinder
block Please confirm that the "l & O" or "2 & 0" mark
on the driven pulley are aligned with the ''\!" mark on the
cylinder head. · ,'
NOTE: Always k2ep the timing belt away from (my oil and
grease.
ALTERNATOR
I
BRACKET
' TIMING BELT.
l...Y.IWESTERBEKE
(Engines & Generators
43
ELECTRONIC GOVERNOR
DESCRIPTION
The system is composed if three basic components.
1. Controller. The PC board that governs the system is
Iocat~d in the control panel. · · , CONTROLLER
2. Sensor. Mounted on the flywheel cover, the sensor mea- GOVERNOR
sures the speed of the engine (via the ring gear). PC BOARD
3. Actuator~ Electronically controls the carburetor throttle.
The sensor and actuator are wired thru the wiring hamess to. GAIN (P3)
the controller (PC board).
..CONTROL -STABILITY (P2)
.SENSOR .PANEL
(INTERIOR SPEED {P1)
, !!,•n (0~762mrn) VIEW)
'{!)r---. ACTUATOR
FEEDBACK (P4)
~.
INSTALLING THE SENSOR
THREAD THE SENSOR IN TO CONTACT Before starting the engine
THE FLAT ON THt RING GEAR TOOTH.
BACK OUT THE SENSOR ONE TURN B Remove all loads and turn off the AC circuit breaker
AND TIGHTEN THE JAM NUT TO SECURE. to insure that loads will not be subjected to voltage
variations while these adjustment are made.
• Decrease the speed pot to prevent overspeed at start up.
• Turn the other adjustment pots to the middle position.
Start. the engine, monitor speed. and adjust to the hehz rating
of the unit by adjusting the. SPEEO (Pl) as needed. Verify
tSPEED ACTUATOR that the AC voltage output is in the correct range.
Decreasing the gain (P3) dampens no load hunting. With the
· engine running at no load and proper speed, manually bump
the throttle lever to cause hunting. If necessary, decrease the
gain in small increments to eliminate hunting.
.After the engine's no load speed and gain are set correctly,
ADJUSTMENT PROCEDURE . the AC circuit breaker can be ~ed on and the ships load
Speed. This adjustment is used to raise or lower the · applied. In the event of speed variations with loads applied,
engine's speed. This generator engine is set to run at · the stability (P2) pot may need adjustment. This adjustment
2200RPM. also changes how the engine responds to generator load
Gain. Adjusts the overall set of the engine. If too low, the changes.
engine seems sluggish, to high causes the engine to hunt. If the range of adjustment of eithe:t: gall}. (P3) or stability (P2)
Stability. Adjusts the engine's response to generator load pots do not corr.ect engine hunting, the actuator feedback
changes. · (P4) pot can be increased. This adjustment dampens the sig-
nals to the throttle control actuator. Increasing this,. adjustment
Altemator.Feedback.·Adjusts the stability of the speed will decr:ease the amount of throttle ·control resolution.
signal to the throttle actuator. Because of this, it is recommended the adjustment be made
NOTE: These adjustments are extremely delicate and in very small increments. The gain and ru.bility pots may
require proper meters for measuring voltage and RPM'S. now need to be readjusted,
Most hunting problems occur because of mechanical prob-
lems with the linkage between the actuator and the carbure-
ADJUSTING THE CONTROLLER PODS tor. Insure that the linkage is free of any debris or corrosion
Following are the basic procedures for adjusting the speed .and that it moves freely. It is reco:rllo/ended that the linkage
(Pl). stability (P2), gain (P3), and actuator feedback (P4) be lubricated with a graphite lubricant. Do not use oil
pots.· because it tends to collect dirt and dust.
The adjusting pots (except speed) have physical internal NQTE: Adjustments to one parameter may affect others,
stops. Turn to the right (clockwise) to increase, turn to the such as speed. It may be necessary to readjust some pots
left (counter-clockwise) to decrease. throughout this process.
44
GENERATOR WIRING DIAGRAM
RESISTANCE VALUES IN OHMS IN BLACK ITALIC
MAG.PICK-UP
950-1000Cl
)
SKI tLOCD 148·222[} IGNITION SPARK
IGNITION
PULSER COIL MODULE COIL PLUGS
116 RED/ HT ~ fl II EO/ HT

ti& 8LU
'(__ 12.5 • 18.5 n

EXCITER COIL
T3 H
CARBURETOR Oil. PRESS
SOLENOIO 20/l SWITCH
OE-RICHENING VAL vi;
ti& RED/VIO jlWA~T~

BATTERY
1i voe
COIL
REI.AV EXHAUST
TEMPERAl\JRE
; ;; ; SWITCH
VOLTAGE
REOIJLATOR
II B GRN/REO
#8 Bl.K
RESISTANCE VALUES IN OHMS
MAGNETO COIL.....................1.4 • 2.1
EXCITER CDIL.. .....................12.5-18.8
PULSER C.DIL ......................148 • 222
EtfG IHE CONNECTOR
ALTERNATOR COIL.................. 0.27 • 0.41
CONTROL PC BOARD
IGNITION COIL ....................... 0.26 • 0.35 FUSE IOA
(Primary)
MAGNETIC i'ICK-UP............... 950-1000.
tl6 RED/ HT +
START SOLENOID...................4.7 HOUR
HIGH TENSION LEADS ..............6.8.00·10.000 METER
116 BLK
DE-RICH VALVE-~ .................. 20
ACTUATOR ...........................3.0 ·3.1
4116 ORG
.
NOTE: TESTER USED· FlUKE MULTIMETER UNIT CAN
REMOTE SHUTOOWk TERM I HAL
I: POSITIVE I+) "
TOLERANCE ± 20% RESTART 2: AUX. SHUTOOl'/M
UH IT CAM 3: EMERGENCY STOP
NOT RESTART 4: GROUND <• l .
JUMPER<SI MUST BE REMOVED
TERMINALS 1 & 2 ARE FOR

"FIREBOY" CONNECTION
OVERSPEED PC BOARD (PN lt045377)
PANELi REMOTE CONNECTOR STARTISTOP
CONTROL PC BOARD (PN # 045369) .TERMINALS 3 & 4 ARE FOR
CONTROL PC BOARD SWITCH
"EMERGENCY STOP SWITCH"
PART NUMBERS: REMOTE STOP/START PANEL lt048056 PANEL EXTENSION HARNESS 15FT lt048200, 30 FT lt048201
GREEN TO STARTER GROUND

RED ISOLATION POST 0
WHITE
N
220V·50HZ
0 0
AC OUTPUT CONNECTIONS 120V 611Hz CONNECTIONS FOR

0 0
230V50Hz
L N
LOAD
45
3.0 KW GENERATOR
. . . SPECIFICATIONS
ENGINE SPECIFICATIONS COOLING SYSTEM

Engine Type Two cylinder, four strq~I! gasoline engine. General Water cooled via raw water pump.
Bore & Stroke 2.32 x2.36 inches (59 x60 mm) Raw Water Pump Positiv,e displacement type, rubber impeller,
belt driven.
Total Displacement 20.01 Cubic Inches (.33 liter)
Raw Water Row 1.75 GPM'(before thermostat opens)
Bearings Two main bearings. (into water injected
Valve System Overhead cam-cross flow. exhauSt elbow) 2.0 GPM (thermostat open)
Compression Ratio 9:1 Operating Temperature 140°F (60°C)
Aring Order 1-2

AC GENERATOR (SINGLE PHASE)
Aspiration Naturally aspirated.
Type Permanent magnet generator (two pole)
Direction of Rotation Counterclockwise viewed from the back end. Brushless/capacitor (two pole)
Inclination 25° maximum angle of operation Speed 3600 RPM/ 60Hz.
Dry Weight. 165 lbs (75 Kg) 3000 RPM / 50 Hz.
Governor Bectronic 3.0Kw 3.0 KW - 60 Hz single phase, 120 volts

2 wire, 25 amp.
FUEL SYSTEM 3.0 KW - 50 Hz single phase, 230 volts
Fuel Pump Mechanical fuel pump. 2 wire, 13 amp.
Fuel Unleaded 89 Qctane or higher gasoline.
Ignition Timing BTDC 25° (not adjustable).
TUNE-UP SPECIFICATIONS
Spark Plug Gap 0.032 - 0.035in (0.8 - 0.9mm)
Ignition Con 12 volt.
Aame Arrester Spark Plug Torque - 11-15 lb-ft (15-20 Nm)
Metal screen type.
Bolt Torque See TORQUING THE CYLINDER HEAD.
Carburetor Single barrel side draft.
Fuel Consumption 0.4 GPH@ 2200 RPM/25 Amps
(Fun Load) AIR REQUIREMENTS
Ignition Timing 12-Volt flywheel magneto. Engine Combustion 13 CFM (0.287 cmm)
Generator Cooling 200 CFM (5.66 cmm)
ELECTRICAL SYSTEM
Start Motor 12-Volt Direct Drive-Remote Solenoid
Starting Battery 12-Volt, (-) negative ground
FRESH WATER COOLED MODELS
Battery Capacity 600-900 Cold Cranking Amps (CCA)
Cooling System Fresh water cooled block, thermostatically
Battery Charging . 11 Amp controDed thru a heat exchanger.
DC Amperage Draw 70 Amps DC Cranking Fresh Water (coolant) Positive displacement, rubber impeller belt
Pump driven
LUBRICATION SYSTEM Raw Water PulTlp Positive displacement, rubber impeller belt
Type 'Wet sump system trochoid type pump. driven
Oil Fnter Fuel flow, paper element, spin-on disposals. Raw Water Row 2.5-3.0 GPM
(into water injected 9.5-11.3 LPM
Oil Capacity 1.5 qts. (91.4 L) exhaust elbow)
Oil Grade API Service Calegol'Y SJ, SL, SM, SN or belier Operating Temperature 180°F (82°C)
SAE 10W-30 or 15W-40
Engines & Genera.tors

46 .
AC GENERATOR
MOTOR DATA
The power required to start an electric motor is considerably
more than is required to keep it running after it is started.
Some motors require much more current to start them than
others. Split-phase (AC) motors require more current to start,
under similar circumstances, than other types. They are com-
monly used on easy-starting loads, such as washing
machines, or where loads are applied after the motor is
started, such as small power tools. Because they require 5 to
7 times as much current to start as to run, their use should be
avoided, whenever possible, if the electric motor is to be dri-
ven by a small generator. Capacitor and repulsion-induction
motors require from 2 to 4 times as much current to start as
to run. The current required to start any motor varies with the
load connected to it. An electric motor connected to an air
compressor, for example, will require more current than a
motor to which no load is connected.
In general, the current required to start 115-Volt motors connected
to medium starting loads will be approximately as follows:
MOTOR SIZE AMPS FOR AMPS FOR
(HP) RUNNING J!STARTIN~L
(AMPERE~ AMPERES
1/6 3.2 6.4 to 22.4*
'
1/4 4.6 9.2 to 32.2*
1/3 5.2 10.4 to 72.8*
PERMANENT MAGNET GENERATOR 1/2 7.2 14.4 to 29.2*
Engine rpm at 2200 3/4 10.2 20 .4 to 4@._*
Generator turns at 3600 (60 Hz), 3000 (50Hz) 1 13 26 to 52
60Hz 120 volts/25 amps, 50 Hz 230 volts/13 amps
*NOTE: In the above table the maximum Amps for Starting is
more for some small motors than for larger ones. The reason
A WARNING: Do not attempt to make adjustments or for this is that the hardest starting types (split-phase) are not
made in larger sizes.
repairs to the generator. the generator is maintenance
free. It the generator tails (no ac output}, contact your Because the heavy surge of current needed for starting
WESTERBEKE dealer or distributor. motors is required for.only an instant, the generator will not
be damaged if it can bring the motor up to speed in a few
Required Operating Speed . seconds. If difficulty is experienced in starting motors, turn
off all other electrical loads and, if possible, reduce the load
Run the generator first with no load applied, then at half the on the electric motor. ·
generators capacity, and finally loaded to its full capacity as
indicted on the generators data plate. The output voltage
should be checked periodically to ensure proper operation of GENERATOR FAILURE
the generating plant and the appliances it supplies. To Should a failure occur in the permanent magnet generator,
monitor voltage and load, check it with a portable meter and contact your Westerbeke dealer of the Westerbeke factory.
ampprobe.
NOTE: It would be important to inspect the pulley and drive
Generator Maintenance belt under the generator base frame.
Maintaining reasonable cleanliness is important. Connections
of terminal boards and rectifiers may become corroded, and
insulation surfaces may start conducting if salts, dust, engine
exhaust, carbon, etc. are allowed to build up. Clogged venti-
lation openings may cause excessive heating and reduced life
of windings.
In addition to periodic cleaning, the generator should be
inspected for tightness of all connections, evidence of
overheated terminals and loose or damaged wires.
lwlWESTERBEKE
l Engines .&·Generators
47
.CAPACITOR
BCGBACKEND
COMPONENTS
(TOP VIEW)
THESE COMPONENTS
ARE LOCATED ON THE
ROTOR .
AC TERMINAL BLOCK ..
. GRCiOND~ . . .
~WINDING RESISTANCE (Measured at 20'C/68'f)

60 Hertz Models : Stator Winding 0.93 Ohm/winding. 50 Hertz Models : Stator Winding 1.35 Ohm/winding.
Rotor Wmding - 4.0 Ohm Rotor Winding• 4.0 Ohm
Excitor Winding - 2.0 Qhm Excitor Winding - 2.S Ohm
Capacitor Rating - 34 uF Capacitor Rating - 31.55 uF
BCG INTERNAL WIRING DIAGRAM

GREEN
ROTOR YELLOW
I
STATOR OR
I EXCITOR
I•N.WHITE WHITE
I .
THERMISTER .
'12ov·
1· . • ' ·11
~
I
RED RED
~~
ILBLA K
I .
,I
:1
I
BLACK
.·BLUE i
;I CAPACITOR
.11
BY-PASSING THE OVERSPEED BOARD

An unwanted shutdown or if the engine runs 10-15 seconds 4. Manually controlling #30 and #87, start the engine
and then shuts down can be caused by a faulty over-speed physically controlling the actuator/throttle keeping the
board. engine speed at a low comfortable range. If the engine
1. Refer to the Wiring Diagram in this manual. continues to run more than 15 seconds, a faulty overspeed
board exists.
2. Unplug the brown #6 wire that connects between pin #12
of the 15 pin plug connector and the ignition module. The NOTE: The above should only be performed as a test. The
wire plug connection is in the harness between the two generator with a by-passed overspeed board should not be
components. run under normal use. This can present a ~ard.
3. Without unplugging any connections on the coil relay,
place a jumper between connection #30 and #87.

48
BCG/BPMGDESCRIPTION. and· TROUBLESHOOTING
REFER ALSO TO THE SPECIFICATION PAGE
rROUBLESHOOTING CHART (BCG)

BRUSHLESS CAPACITOR CAUSE FAULT
No AC Output Voltage 1. Shorted Stator.
GENERATOR (BCG) 2. Open Stator.
Engine RPM at 2200 3. Shorted Rotor Diode.
generator turns at 4. Shorted Rotor Thermister.
3600 (60Hz) 3000 (SOHz) 5. Shorted Rotor Gapacitor.
60Hz 120 Volts/25 Amps 6. Open Rotor Diode.
SOHz 230 Volts/13 Amps Residual Voltage 1. Faulty Capacitor.
Line - Neutral at 2. Open Exciter Winding.
No Load 3. Shorted Exciter Winding.
Low AC Output 1. Faulty Rotor Diode.
NOTE: Refer to the following page for the BCG lnte1!'JU1l Voltage 60 -100 Volts 2. Faulty Rotor Winding.
3. Faulty Exaiter Capacitor.
Wiring Schematic and BCG Winding Resistances.
AC Voltage Drop with 1. Faulty Rotor Diode.
Inductive Load 2. Faulty Exciter Capacitor.
BLACK 3. Amperage Overload.
Refer to the following page for the BCG Internal Wiring
RED ISOLATION POST
DIAGRAMS ARE Schematic and the BCG Winding Resistances.
FOR BOTH MODELS WHITE AC
N CIRCUIT
120V/60Hz BREAKER
TROUBLESHOOTING CHART (BPMG)
BCG/BPMG AC OUTPUT
CONNECTIONS DIAGRAM CAUSE FAULT
jj
No AC Output Voltage 1. Shorted Stator Winding.
Open Stator Winding.
GREEN TO srARTERJiRDUND RED IS_OLATION POST
Low AC Output 1. Faulty Rotor.
Voltage 60 - 100 Volts
WHITE
AC~------. Voltage Drop 1. Generator Overload.
,-.::v-1---B-LA-CK....,..----. Under Load
ZZOV·50HZ
WINDING RESISTANCE (Measured at 20°C/68°F)

230V/50Hz PM (Permanent Magnet) stator winding resistance 0.4 ohm
hertz model resistance is measured between line and neutral.
50 hertz models is 0.8 ohm.
NOTE: The permanent magnet style generator can not be dis-
assembled. If an electrical fault should occur, the generator
must be replaced.
PERMANENT MAGNET IR NOTE: It would be important to inspect the pulley and drive
GENERATOR (BPMG) belt under the generator base frame.
Engine RPM at 2200
generator turns at
3600 (60Hzj 3000 (50Hz)
60Hz 120 Volts/25 Amps
50Hz 230 Volts/13 Amps

49
FLUSHING THE COOUNG,SYSTEM
RAW WATER COOLED
REMOVE THERMOSTAT
DON'T FORGET TO
REPLACE
REPLACE COVER
AND GASKET
THERMOSTAT
ASSEMBLY
'--~-""~-"-~-----'!.
RAW WATER PUMP -·---.

..... ~~'\\
'
EXTERNAL FRESH
WATER SUPPLY
Engine flushing should be performed a minimum of at least

twice per operating season. More often in those areas ~here
the unit is not subject to winter storeage. In those locations
A CAUTION:. Oil not connect an external fresh water
where the unit is used year round, flushing the unit every
supply directly to the engine's cooling system. This can
4 months is recommended. cause flooding of the engine resulting in internal
This procedure is best accomplished by disco~ecting the damage.
water intake hose from the vessels thru-hull fitting. Close the
intake valve before disconnecting the hose. Insert the hose
Run the unit for 10 minutes or longer to adequately flush the
end into a large container of fresh water.
cooling system.
Before starting the engine, remove the engine thermostat
the fresh water will flush out the engines water passages and
(replace the gasket and cover). This will ensure a full flow
exhaust lines. If the engine is being stored and there is a
of water thru the engine. Re-install the thermostat once
probability of freezing, flush the engine with fresh water and
flushing is complete.
then prior to shutting the unit down substitute the fresh water
NOTE: Prior to flushing the engine/ inspect the coolant by- supply with a concentrated antifreeze mixture and run this
pass hose and its attachment fittings to insure that there are through the engine to provide freeze and corrosion protection
no obstructions occurring in thefittings or the hose. · for both the engine and exhaust system.
Provide an external fresh water:s1,1pply for the bucket to When recommissioning, make certain the valves and
maintain the water level in the bucket while the unit is being seacocks are open so the engine will quickly receive fresh
operated during the flushing process. water.
50
ENGLISH TO METRIC CONVERSION CHART
Mult!Qly Temperature B_y_ To qet ~uivalent number of:
Dimree Fahrenli'eit.J'.'6- .fF-3fl + 1.8 Ofillree Celsius °CJ_
Multfil!y_ Acceleration B_y_ To_g_et ~uivalent number of:
FooVsecond1ft/sec:i.. 0.3048 Meter/second1mts:i..
lnch/second 2(1n./seci. 0.0254 Meter/second2 (mis:>_
Mult~Tor.g__ue By To_mlt ~ulvalent number of:
Pound-inch J!b·in_l 0.11298 Newton-meters JN ·mi
Pound-footJ!b·f!l 1.3558 Newton-meters JN-ml
Multiply Power ~ To get equivalent number of:
Hors®9WerJ_f:mL 0.746 Kilowatts J!<WJ_
Multm!Y_Pressure or Stress B_y_ To_g_et ~uivalent number of:
Inches of water J!n. H..!2. OJ_ 0.2491 K'rl<?Q_ascals J!<Paj_
Pounds/~uare in. J!b!in.:l_ 6.895 KiloPE!Scals J_kPaj~
Multililir_Ene!Jllf._ or Work ~ To _g_et ~uivalent number of:
British Thermal UnitJ.!3t!J1. 1055 Joules Jn_
Foot:12_oundJ_ft.Jbl 1.3558 Joules Jn_
3,600,000. or
ki.lowatt-hour {kW-hr)
~~·
Joules (J = one W/s)
Mutt~ L!g_ht ~ To ..9_et ~uivalent number of:
Foot candle Jf9.. 1.0764 Lumens/meter2Jlm/m~
Multipjy_ Fuel Performance lk. To_mlt ~ivalent number of:
Miles{g_al l_milefg_aJl 0.4251 Kilometers/liter j_km/Ll
Gallons/mileJgaVmilfil 2.3527 Liter/kilometer j_Ukl'I})_
Mult.!2!Y. Veloci!Y_ ~ To_get ~ivalent number of:
Miles/hour {mile/hli 1.6093 Kilometers/hourJ_krnlhrl..
Multm!Y_ Lel!filh B_y_ To_g_et ~ivalent number of:

lnchJjn_l 25.4 Millimeters l.mn:il.
FootJ_fl;}_ 0.3048 Meters .in:!l
Yard~ 0.9144 Meters _{!nJ.
Milej_mifel 1.609 Kilometers Jkm_l
Multm!Y. Area 6Y To__ru!t i:m_uivalent number of:
lncJ:Bjn.21_ 6452 Millimeters~m2l
lnch2{in. 2} 6.45 Centimeters:i_cml)_
Foot:!_ft:l_ . 0.0929 Meters_:Lnfl.
Yard~d::l. 0.8361 Meters:Lm2_l
Mult!J:>Iy_ Volume ~ To_get eauivalent number of:
lnch~n.~ 16387 Millimeters:£_mm~
lnch~n.~ 16.387 Centimeters~cm~
lnch~in. 3 } 0.0164 Litersj!J_
Quart jg!)_ 0.9464 Litersj!J_
·Gallon Jg_aJl. 3.785 Litersfil
Yard!lfuj~ 0.7646 Meters3 (rn~
Multiply Mass B_y_ To ..9_et ~uivalent number of:
PoundJ!Ql 0.4536 KilQQ!"ams J!sg}_
. - Jon..(!oll). ··--··-· 907.18 Ki].Qgrams J!sg}_
Tonj!oril. 0.907 Tonne..fil_
MultlPk Force lk. To_g_et e..9_uivalent number of:
Kil<mramJ!sgl 9.807 Newtons l_N_l
OunceJ.o~ 0.2780 Newtons lN)_
PoundJ!Ql_ 4.448 Newtons ..llill
~nglnes & Generators
51
STANDARD AND METRIC CONVERSION DATA
LENGTH-DISTANCE
Inches .(in} x 25.4 = Millimeters {mm} x .0394 = Inches
Feet (ft) x .305 = Meters (m) x 3.281 = Feet
Miles x 1.609 =Kilometers (km) x .0621 =Miles
DISTANCE EQUIVALENTS
1 Degree of Latitude= 60 Nm= 111.120 km
1 Minute of Latitude = 1 Nm = 1.852 km
VOLUME
Cubic Inches (in3) x 16.387 =Cubic Centimeters x .061 =in3
Imperial Pints (IMP pt) x .568 =Liters (L) x 1.76 =IMP pt
Imperial Quarts (IMP qt) ·x 1.137 = Liters (L) x.88 = IMP qt
Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal
lmp~rial Quarts (IMP qt) x 1.201 =US Quarts_ (US qt) x .833 =IMP qt
Imperial Gallons (IMP gal) x 1.201 =US Gallons (US gal) x .833 =IMP gal
Fluid Ounces x 29.573 = Milliliters x .034 = Ounces
US Pints (US pt) x .473 = Liters(L) x 2.113 =Pints
US Quarts (US qt) x .946 = Liters (L) x 1.057 = Quarts
US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons
MASS·WEIGHT
Ounces (oz) x 28.35 =Grams (g) x .035 =Ounces
Pounds (lb) x .454 =Kilograms (kg) x 2.205 =Pounds
PRESSURE
Pounds Per Sq In (psi) x 6.895 = Kil6pascals (kPa) x .145 =psi
Inches of Mercury (Hg) x .4912 =psi x 2.036 =Hg
Inches of Mercury {Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
Inches of Water {H20) x .07355 =Inches of Mercury x 13.783 = H20
Inches of Water (H20) x .03613 =psi x 27.684 = H20
Inches of Water (H20) x .248 = Kilopascals (kPa) x 4.026 = H20
TORQUE
Pounds-Force Inches (in-lb) x .113 =Newton Meters (Nm) x 8.85 =in-lb
Pounds-Force Feet (ft-lb) x t .356 = Newton Meters (Nm) x .738 =·ft-lb
VELOCITY
Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH
POWER
Horsepower (Hp) x .745 =Kilowatts (Kw) x 1.34 =MPH
FUEL CONSUMPTION
Miles Per Hour IMP (MPG) x .354 = Kilometers Pe~ Liter (Km/L)
Kilometers Per liter (Km/L) x 2.352 = IMP MPG
Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (Km/l}
Kilometers Per liter (Km/L) x 2.352 = US MPG
TEMPERATURE
Degree Fahrenheit ( F} = (°C X 1.8) + 32
0
Degree Celsius (°C) = (°F - 32) x .56
LIQUID WEIGHTS
Diesel Oil= 1 US gallon= 7.13 lbs
Fresh Water == 1 US g~llon = 8.33 lbs
Gasoline'= 1 US gallon= 6.1 lbs
Salt Water = 1 US gallon = 8.56 lbs
52
INDEX
AC Generator ............................. .47 Oil Pressure .............................. .40
Assembly .................................27 Oil Pump ...............................28,32
Assembly Procedures ........................6 Overspeed Switch ......................... .44
Camshaft ................................. 19 Overspeed Board - By-Passing ............... .49
Carburetor ................................ 35 Parts Identification ........................... 2
Choke Solenoid ........................... .41 Piston Rings ...............................28
Compression Test .......................... .39 Pump-Raw Water .......................... .36
Cylinder Head Cover ....................... .30 Raw Water Pump ........................... 36
Disassembly Procedures ......................6 Repair Limits .............................. 12
Drive Belt Adjustment ...................... .40 Required Tools ............................. 10
Drive Pulley ............................... 31 · Resistance Values ......................... .45
Electronic Governor ....................... .44 Safety Instructions ...................... .I,Il,Ill
Flushing the Cooling System .................50 Sealants and Lubricants Chart .................. 7
Engine Adjustments ........................ .39 Shutdown Switches .........................44
Engine Disassembly ........................ 15 Siphon-Break ............................. .IV
Engine Tuning .............................. 38 Spark Plugs .............................. .41
Exhaust Valve ............................. 27 Special Tools .............................. 11
Fuel Filter ............................... .33 Specifications ..............................46
Fuel Pump ................................ 33 Standard and Repair Limits .................. .12
Fuses ....................................44 Starter Motor .............................. 34
Gasket Information .......................... 6 Testing for Overhaul ........................ .3
Governor-Electric ......................... .43 Testing Oil Pressure ........................ .40
Heat Exchanger ............................ 19 Thermostat ................................41
Ignition Timing ............................39 Timing Belt Replacement/Adjustments ......... .43
Inspection and Measurement ..................20 Torque Specifications ........................9
Intake Valve ............................... 27 Troubleshooting Charts ..................... .49
Internal Wiring Diagram .................... .48 Valve Clearance ........................... .42
Lubrication .............................51,52 Valve Seat ........ ; .......................25
Metric Conversion Chart .................... .48 Water Pump Belt ........................... 39
Oil Clearance ..............................22 Winding Resistance ........................ .48
Oil Inspection ............................ .32 Wiring Diagram ........................... .45
Zinc Anode .............................. .41

53
SERVICE BULLETIN
DATE: _ _2_4_·A....p_r-_15_ _ BULLETIN NUMBER:
----
276
SUBJECT: Generator Drive Belt Performance
MODELS
AFFECTED: 3.5 SBCG and 3.0 BCG Gasoline Generators
DETAIL: Generator drive belt life performance improvements'include a belt tension adjustment
change, the addition of a spring spacer, and a n~ idler pulley. 3.5 SBCG generators
produced on or after manufacturing date code OD (April 2015) will have these changes.
Changes made are enhancements, modification to existing products in the field is not
covered under warranty.
Manufacturing of new products includes, for optimum belt break in, adjusting the belt to a
dimension of 1" in our assembly process as illustrated below. After the first hour of run time,
if necessary, it is adjusted again to 1" prior to releasing the unit for shipment.
Important Note: Maximum performance of the drive belt and prevention of potential failure
due to incorrect tension requires the belt be to adjusted to 1" at the recommended 50 hour
maintenance service.
Generator drive belts for regular maintenance replacement (part numbers remain the same)
will be sold as a kit with instructions that includes the required spring spacer. Replacing the
puttey is not required. Initial adjustment of the belt with the spacer installed is 1". After
running the unit for 1 hour, varying AC loads in the process, the belt must be adjusted again
to 1". After 50 hours run'time, or during the next scheduled service, inspection and
adjustment to 1" is required to ensure proper belt tension.
Add 1/8" Spacer Here
WESTERBEKE CORPORATION
Myles St;mdish Industrial Parl<, 150John Hancock Road, Taunton, MA 02780-7319 •Tel: 508.823.7677 •Fax: 508.884.9688
www.westerbeke.com
1249/5-2018

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~j'f'j,,1 "·!

WESTERBEKE CORPORATION• 150 JOHN HANCOCK ROAD

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,

A WARNING DECAL Is provided by

Parts Identification ... :.........................................2

Engines & Generators

ENGINE SERIAL NUMBER THERMOSTAT

RAW WATER PUMP

PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE

Engine does not 1. Voltage drop at starter solenoid

Engines & Generators

Blue Exhaust Smoke Discharge 1. Lube oil is diluted.

Note: MPU voltages to PC board:

Engines & Generators

Metal {Cylinder block, crank case)

Crank shaft (thrust place)

Crank shaft oil seal

Crank case cylinder mating surface

Valve (IN, EX)

Valve stem seal (IN, EX)

Valve spring seat

w Cam pulley bolt

Rocker arm shaft

Tappet adjust screw

Washer (rocker arm, t=0.5)'

Washer (rocker arm, t=2.5)

1342 137.lB 1741 1207B 516 G17 KS-64 5900

Oil filter bolt

Filter cap, 0-ring

Spark plug cap • Spark plug insertion part

• Friction plate, reel shaft part,

Starter seal rubber

Upper pump case

Ms x 1.25 Bolt 23-25 2.3-2.5 17-1S

Connecting Rod M7 x 1.0 Bolt 11-13 1.1-1.3 S.0-9.4

Tappet Lock Nut MS X0.75 Nut S-8 O.S-0.8 4.4-5.8

Flywheel Cup M1S x 1.5 Nut 70-90 7-9 51-65

Drive fTimlng) Pulley M2S x 1.0 Nut 34-3S· 3.4!1·3.6 25-26

Plunger Assembly M16 x 1.5 - 19-21 1.9-2.1 12-15

Oil Filter M20 x 1.5 - 18 1.S 13

Oil Pressure Switch PT1/S - 7-9 0.7-0.9

Cylinder Head Cover M6x1.0 Bolt 8-10 0.8-1.0 5.S-7.2

Inlet Manifold M6 x 1.0 Bolt S-10 0.8-1.0 5.8-7.2

Spark Plug M12 x 1.25 - 15-20 1.5-2.0 11-15

Engine Assembly MB x 1.25 Bolt 29-31 2.9-3.1 21-22 '

Engines & Generators

The flywheel can be removed. Be sure to

Engines & Generators

Engines & Generators

Removing Parts Alternator

Startor motor and starter solenoid

Ignition coil Rectifier

® Remove the ignition coil fitting bolt

· Magneto flywheel cup

Engines & Generators

POWER UNIT Cylinder head, valves and relating parts

NO Part name Check point, etc.

esurface width and roughness between valve seat and

Cover, Cylinder head