Suzuki: Engine K6A-YH6. Service manual - part 1

 

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Suzuki: Engine K6A-YH6. Service manual - part 1

 

 

i

Foreword

General 

This manual provides detailed information and 
procedures to safely repair and maintain the following:

Suzuki K6A-YH6 gasoline engine

This manual is intended to introduce and guide the user 
through the latest factory-approved troubleshooting and 
repair techniques and practices. 

Before you attempt to troubleshoot or make repairs, you 
must be familiar with the operation of this engine. Refer to 
the operator’s manual and parts manual for specific 
information on these topics.

THE INFORMATION CONTAINED IN THIS MANUAL IS 
BASED ON ENGINES MANUFACTURED UP TO THE 
TIME OF PUBLICATION. JACOBSEN RESERVES THE 
RIGHT TO CHANGE ANY OF THIS INFORMATION 
WITHOUT NOTICE.

CALIFORNIA
Proposition 65 Warning

!

WARNING

Trademark Acknowledgement

Jacobsen acknowledges the following trademarks for 
company names or products mentioned within this 
publication:

Jacobsen® is a registered trademark of Textron Inc.

Suzuki® is a registered trademark of the 
American Suzuki Motors Corporation

ThreeBond™ is a trademark of the ThreeBond Co., Ltd.

 

Plastigage® is a registered trademark of AE Clevite Inc.

Certain vehicle components contain or emit 
chemicals known to the State of California to 
cause cancer and birth defects or other 
reproductive harm.

ii

FOREWORD

How to Use This Manual 

This manual is designed to provide multiple ways to 
locate and access repair information. 

Read each section in entirety before beginning a 
procedure. Proper understanding of machine operation 
and components is the key to successful diagnostics and 
repair. 

Make use of special information features with in this 
manual in order to be better prepared to perform repairs. 
Always follow manual procedures and safety guidelines. 
Never take shortcuts. 

Table of Contents 

Major machine components or topics of interest are 
separated into specific chapters. Each manual lists these 
chapters in a main Table of Contents.  

Chapter Table of Contents

Each chapter begins with a detailed Table of Contents 
related to the specific machine component or system.

Use the Chapter Table of Contents to find specific 
component or procedural information. 

Index

An alphabetical Index is located at the back of the 
manual.  

Use the Index to find specific components and related 
procedures. 

Required Tools and Materials

Some procedures will require the use of specific tools 
and/or materials. These tools and/or materials will be 
listed for reference, prior to beginning a procedure. 

Specifications

Specifications are listed at the point of use with in the 
procedure.  

Quick Reference Specifications

A list of all machine specifications can be found in 
Chapter 2 Specifications and General Information. This is 
a list of all specifications from each chapter, combined 
and listed in one place for easy reference. 

Warnings and Cautions

Warning and Caution indicators are located throughout 
the manual at specific points of interest. These notices 
are given to prevent personal injury, death and/or 
equipment damage. Always heed these notices, and 
practice common sense when performing any 
maintenance or repair procedure. 

Notes

Special notes are given in order to draw attention to 
detailed instructions. These notes are intended to give 
further important information regarding the machine 
and/or a step in a procedure. 

Troubleshooting

Troubleshooting charts are provided in chapter 6 to aid in 
the diagnostic process. Use these suggestions to aid in 
identifying a potential mechanical or machine adjustment 
problem. 

Copyright 2008 Textron Inc. 
“All rights reserved, including the right to reproduce this material or portions thereof in any form.”

1-2

SAFETY

1

Introduction

Safety is the most important element of any repair 
procedure. Knowledge of the procedure to be performed 
and safe work habits are essential to preventing death, 
personal injury, or property damage. Use the following 
statements as a common-sense guide to proper work 
and tool-use habits. 

Prepare for the Job

Preparation is essential to complete a procedure in a 
safe and efficient manner.

• Wear proper clothing. Loose or baggy clothing could 

become tangled in moving parts.

• Use eye/face protection. Always use proper eye/face 

protection to protect your eyes from flying debris or 
chemical splatters. 

• Wear protective footwear. Wear safety shoes 

(steel-toe) to protect your feet from falling objects.

• Use gloves when handling parts. Parts may have 

sharp edges or may be hot. 

• Remove jewelry prior to servicing electrical systems. 

• Prepare proper tools and equipment. Always use the 

correct tool for the job. Improper or homemade tools 
can cause injury or machine damage. 

• Prepare needed parts and materials. Gather the 

needed parts and materials before beginning the 
procedure.

• Allow machine to cool. Many components can get hot 

during operation. Be sure to allow enough time for 
components to cool before beginning service.

• Prepare proper work-space lighting. A well-lit work 

area can make the job easier.

• Follow procedures and safety warnings. Service 

procedures are written to be as safe and efficient as 
possible. Never take shortcuts.

• Be prepared for emergencies. Accidents can happen, 

even under the best conditions. Fire extinguishers 
and first aid kits should be well maintained and easily 
accessible. 

Safety Notices

Throughout this manual, the following key safety words 
will be used to alert the reader of potential hazards. 
Become familiar with these words and their meaning. 
Take all precautions to avoid the hazards described.

!

DANGER

!

WARNING

!

CAUTION

NOTICE

Keep Work Area Clean

A clean, organized, well lit work area is important to 
promote safe working conditions.

• Keep floor clean of debris and clear of parts and 

tools.

• Clean up any spilled fuel, oil, and/or chemicals 

immediately.

• Store all air hoses and electrical cords properly when 

not in use.

This safety alert symbol is used to 
alert you to potential hazards.

Indicates an imminently hazardous situation 
which, if not avoided, WILL result in death or 
serious injury.

Indicates a potentially hazardous situation which, 
if not avoided, COULD result in death or serious 
injury.

Indicates a potentially hazardous situation which, 
if not avoided, MAY result in minor or moderate 
injury and property damage. It may also be used 
to alert against unsafe practices.

Indicates a potentially hazardous situation which, 
if not avoided, MAY result in property damage. It 
may also be used to alert against unsafe 
practices.

!

SAFETY

1-3

1

Keep Work Area Well Ventilated

!

WARNING

Certain test and adjustment procedures require the 
engine to be running. Be sure work area is well 
ventilated; never run the engine in an enclosed area.

Use Proper Eye and Face 
Protection

!

WARNING

Always wear eye protection while in a shop environment. 

• Safety Glasses: Safety glasses offer a minimum level 

of protection from flying debris.

• Face Shields: Face shields are often used along with 

safety glasses to offer a higher level of protection 
when sparks and flying debris are present.

• Vented Goggles: Goggles offer side protection not 

offered by safety glasses alone.

• Unvented Goggles: Unvented goggles offer 

protection from chemical splashes and vapors. 

Use Lifting Equipment Safely

!

WARNING

• Always use a lifting device with a lifting capacity 

greater than the weight of the item being lifted.

• Secure the load to the lifting device using cables, 

chains, or slings rated to handle the load being lifted. 
Fasteners being used to connect lifting devices must 
be strong enough to handle the load. Also be sure 
the mounting point of load is strong enough to handle 
the load. 

• When using a lifting device, always connect the load 

so it is balanced. 

• Always use a lifting device on a hard, level surface.

• Lower the lifting device to the lowest point before 

moving. Move the load slowly. 

• Always support the load as soon as possible; never 

leave a load suspended in mid-air.

Use Compressed Air and Air 
Tools Safely

!

WARNING

• Compressed air is a useful tool when used in a safe 

manner.

• Always use eye and ear protection while using 

compressed air and air tools.

• When using air tools, do not exceed the air pressure 

rating for the tool.

• When using an impact wrench, always use approved 

impact sockets. Never use standard sockets on an 
impact wrench.

• Disconnect the air supply before changing air tool 

attachments. 

• Never point air nozzles or air tools at another person.

• Always maintain air tools properly.

Never operate the engine without proper 
ventilation; exhaust fumes can be fatal if inhaled.

Always use approved personal protection 
equipment. Avoid workplace hazards by wearing 
properly maintained, approved eye and face 
protection. Failure to use appropriate protection 
equipment may result in death or serious injury.

Always check the lifting capacity and condition of 
hoists, slings, cables, or chains before use. 
Using underrated or worn lifting components can 
result in death or serious injury. 

Always wear approved eye and ear protection 
while using compressed air. Misuse of 
compressed air could result in death or serious 
injury. 

• When using air nozzles, air pressure should 

not exceed 30 psi (206.8 kPa).

• Never direct air nozzles or tools at a person.

• Never point air nozzles directly at skin.

 

 

 

 

 

 

 

 

 

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