87121-ZV9-801 Honda MARK, RR. (20)

Installation Of 2W4387 Engine Arrangement In 910 Machines
Before installation of the 2W4387 Engine Arrangement, some changes must be made to the new engine and machine. See the information that follows. After engine installation is complete, adjust the fuel setting according to the dimension given in the FUEL SETTING INFORMATION. See the Service Manual for engine installation procedure.Oil Filler Tube
(1) Remove bolts (1), the washers, tube (2) and cap (3) from cover (4). (2) Use the former bolts (1) and washers to install 6N7401 Plate (5) and 6N7402 Gasket on cover (4). (3) Remove the 2P2772 Cover at location (A) on the side of the cylinder block. Use the bolts and washers from the 2P2772 Cover and a 4N933 Gasket to install 1W261 Tube Assembly (6) [in place of the 2P2772 cover] on cylinder block (7). Install 9L8439 Cap (8).Oil Level Gauge Group
(1) Remove the oil level gauge and guide from the cylinder block, and install 1W366 Oil Level Gauge Group (1). Governor Group
(1) Remove six bolts (1) and cover (2). (2) Remove snap rings (3) and plate (4). Hold governor shaft (5) in position while removing the cover and the plate. If the shaft is allowed to move out with the cover or plate, internal levers will come off of the shaft.(3) Remove spring (6) from the shaft assembly, and install a 8N3093 Spring in the same place. Do not remove shaft assembly as shown. The 8N3093 Spring has one blue stripe and former spring (6) has one pink stripe. (4) Assemble plate (4), snap rings (3), cover (2) and bolts (1) on the governor group.Governor Control Group
(1) Remove lever assembly (1) and rod (2). The rod ends, pins and cotter pins will be used again. (2) Fasten 5G4944 Lever (3) to the governor shaft with S1591 Bolt (4) and 9S8752 Nut (5). Use the former rod ends, pins and cotter pins to connect 1N9389 Rod (6) to lever (3) and intermediate lever (7).(3) Use the procedure shown in the Service Manual to adjust the linkage. Distance (A) should be 1120.0 1.5 mm (44.09" 0.06") instead of distance shown in Service Manual. Tighten nuts (8) to a torque of 5.0 0.5 N m (3.7 0.4 lb ft), and nuts (9) to a torque of 14.0 4.0 N m (10.4 3.0 lb ft).Fuel Filter Group
(1) Remove clips (1) and (2). Remove tube assembly (3) and elbow (4) from the fuel transfer pump on the replacement engine. Installation of new line is shown in Fuel Lines Group, Page 8.Fuel Tank Group
(1) Remove the fuel tank from the machine; see the Service Manual. (2) Fabricate boss (1) to the dimensions shown. Make 1/8" - 27 NPTF threads in one end. (3) Drill a 20.0 mm Ø (0.78" Ø) hole (A) through the bottom of the tank as shown. (4) Put boss (1) in hole (A) with the threaded end extending below the bottom of the full tank as shown. Make a 3.0 mm (0.12") fillet weld all around the boss.(5) Clean and install the fuel tank; see the Service Manual.Fuel Lines Group
(1) Remove fuel inlet hose (1) and tube assembly (2) from tube (A). (2) Install 307946 Elbow (3) and a 3J7354 Seal in the fuel transfer pump. Install 2V4869 Fitting (4) on elbow (3). Cut a 360.0 mm (14.17") length of 5P1465 Hose (5), and connect it to fitting (4) and tube assembly (A) with the former clamps.(3) Install 6D238 Valve Assembly (7) in the boss installed in the fuel tank (see Step 4, Page 7). Fasten 5G5681 Tube (8) to valve assembly (7). Use L2072 Clamp (9) to hold the other end of tube (8) in position. Install clamp (9) under bolt (10).(4) Install 307941 Elbow (11) and a 3J7354 Seal in the fuel return port of the fuel injection pump housing. Install 2V4869 Fitting (12) on elbow (11).(5) Cut a 520.0 mm (20.47") length of 5P1465 Hose (13), and connect it to fitting (12) and tube (8) with a 1P4278 Clamp (14). An optional step to the above procedure is to connect a 60.0 mm (2.36") length of 5P189 Tube to valve assembly (7). Cut a 2000.0 mm (78.75") length of 5P6442 Hose and connect it to 2V4869 Fitting (12) and to the 5P189 Tube with a 1P4278 Clamp. Tie the hose to the machine to prevent damage to the hose.Electrical System
(1) For all machines, connect the alternator wire of the harness to the alternator.(2) For machines 80U1-80U6734, remove the original voltage regulator. Put tape over the wire connection to the wiring harness so it will be out of the way. The alternator for this engine has a built in voltage regulator so the original voltage regulator is not needed for the electrical system.Flywheel Group (For Replacement of 7N9437, 1W163 or 2W7488 Engine Arrangements)
(1) Remove the flywheel from the new replacement engine.(2) Install a new 7W2290 Flywheel Assembly, and fasten it to the crankshaft with four T489 Bolts. See the Service Manual for the procedure and the bolt torque. If necessary, use of the former flywheel from the engine being replaced is acceptable.Installation Of Ether Starting Aid Group
The ether starting aid is no longer a required component of direct injection engine arrangements.(1) If the machine is equipped with an ether starting aid group, its reuse is optional. To reuse, install the parts on the replacement engine according to the Service Manual.Installation Of 2W4387 Engine Arrangements In D3, D3B, 931, 931B Machines
Before installation of the 2W4387 Engine Arrangement, some changes must be made to the new engine and machine; see the information that follows. Adjust the fuel setting according to the dimensions given in the Testing And Adjusting section of the Service Manual. Use the Service Manual for the engine installation procedure.