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1. LUBRICATION SYSTEM 5 1 Lubrication System Table of Contents Exploded ME a E O aida iia 5 2 Engine Oil Flo WC ico A A A See ace ir 5 4 Engine Qil Flo Whats toda iii 5 5 SPecic a ON Sii a A A api 5 6 Engine Oil Oil Filter and Oil Cooler ocoocccccccccccncnonnnnnnnnonnnonnnonnnonnnonnnonnnnnnonnnonnnnnnncnnnnss 5 7 Oil Level InSpectioN ccoccccnccnnnonononnnonononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnneninnss 5 7 TS ING keanan A atten Cara utara tic der Uae Ae uated acral aa AIAS ERA 5 8 Oil Filter Removal aiii 5 9 OI Filter Installation iio a ind ioicciaa 5 9 Oil Cooler Removal FH721V veia pri dada 5 9 Oil Cooler Installation FEAI2 Vicos eee eda eei 5 9 Pressurized Lubrication System iia lt tecacueememesnentts 5 10 Oil Pressure Measurement ccccccceccceccceeeeeceeeceeeceeeeceaeceaeceaecaaecaaeaeaeeeeceaeseaeeeaeeeaeees 5 10 Oil Pressure Switch Inspection cccccccccnccnnncnnnnnncnnnnnnnnnnnonnnnnnnnnnnonnnnnnnnnnnnnnnnnnnninnninnss 5 10 Oil Pump Relief ValVe coi DAD eed CEE 5 11 Oil Pump Relief Valve Removal ccccccccccccoconccnnnnnncnocononencnnnnnonononencncnnonnnnnnononincnneneninons 5 11 Oil Pump Relief Valve Installation oooonccnncnncccccononcnenonononononencncnnonnnnnnononincnnnnnnnns 5 11 Oil Pump Relief Valve InspectiON ococcccccccccccnnncnnnnnnnnnnnnonnnnnnnnnnnnnonnnnnoninnninnninnnnnnnnos 5 11 Ol A E
2. Valve Seat Cutter 30 430 57001 1120 1 14 GENERAL INFORMATION Special Tools Oil Filter Wrench Kawasaki Bond Silicone Sealant 57001 1249 56019 120 Hand Tester 57001 1394 FUEL SYSTEM 2 1 Fuel System Table of Contents Exploded VIEW 2 2 Carburetor Cleaning 2 24 Specifications oooooncondnnnnnninnnicncccos 2 10 Carburetor Inspection 2 25 Governor Link Mechanism 2 11 Fuel Shut Off Solenoid Valve Test Control Panel Assembly Removal 2 11 Electric Starter Model 2 26 Control Panel Assembly Intake Manifold oooooooocococococccnccnncooo 2 27 Installation 0 eeseeeseeereeeeee 2 11 Intake Manifold Removal 2 27 Governor Arm Removal 2 11 Intake Manifold Installation 2 27 Governor Arm Installation 2 12 Intake Manifold Inspection 2 28 Governor Assembly Removal 2 12 Fuel Pump Fuel Filter 2 29 Governor Assembly Installation 2 13 Fuel Pump Inspection 2 29 Governor Assembly Inspection 2 13 Fuel Filter Inspection 2 29 Governor Shaft Removal 2 13 Air ClOAnel cceeeeesseeseeeeneeeeeeee 2 30 Governor Shaft Installation 2 13 Element Removal FH451V Carburetor cccceceeeceeeeeeeeeeeeeeeeeeees 2 14 500V 531
3. Oil Screen Removal e Remove the crankcase cover see Camshaft Crankcase chapter e Unscrew the mounting bolts A and remove the oil pump parts assembly e Remove the oil screen B e Before FH500 A50136 FH531 A07510 model as shown in the figure Oil Screen Installation e Clean the oil screen thoroughly whenever it is removed for any reason e Insert the oil screen A in position and install the oil pump parts assembly see Oil Pump Relief Valve Installation e Before FH500 A50136 FH531 A07510 model as shown in the figure LUBRICATION SYSTEM 5 15 Oil Screen Cleaning and Inspection e Clean the oil screen with high flash point solvent and re move any particles stuck to it A WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes and broken wire lf the screen is damaged replace it CAMSHAFT CRANKSHAFT 6 1 Camshaft Crankshaft Exploded View Specifications Crankcase 00 Table of Contents Crankcase Cover Removal cccccececececececececececeecesecaeeeaeeeaeeaueeaaeeaeeaeeaeeneeeneeeeeesseeeneees
4. KHO2006BWS ELECTRICAL SYSTEM 7 3 Exploded View FH451V FH500V FH531V T1 3 9 N m 0 40 kgf m 35 in Ib T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in lb T4 22 N m 2 2 kgfm 16 ft lb T5 56 N m 5 7 kgf m 41 ft lb FH541V FH580V T1 T2 T3 T4 T5 3 9 N m 0 40 kgfm 35 in Ib 5 9 N m 0 60 kgfm 52 in Ib 7 8 N m 0 80 kgfm 69 in Ib 22 N m 2 2 kgf m 16 feb 56 N m 5 7 kgfm 41 ft lb FH601V FH641V FH680V FH721V T1 T2 T3 T4 T5 OaRWNDN 3 9 N m 0 40 kgfm 35 in lb 5 9 N m 0 60 kgf m 52 in lb 7 8 N m 0 80 kgf m 69 in Ib 22 N m 2 2 kgfm 16 ft lb 56 N m 5 7 kgf m 41 ft lb Flywheel Recoil Starter Model Flywheel Electric Starter Model Charging Coil Voltage Regulator Stud Before 2002 4 Product Model Stud On and after 2002 5 Product Model 7 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 7 5 Exploded View FH451V FH500V FH531V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in lb T4 17 N m 1 7 kgfm 12 ftlb FH541V FH580V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in lb T4 17 N m 1 7 kgfm 12 ftlb FH601V FH641V FH680V FH721V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 7 8 N m 0 80 kgf m 69 in lb T
5. Cooling Fan Inspection e Visually inspect the blades A in the cooling fan B xf they are any cracks warps or damaged replace the cooling fan If any mud or dust have stuck to the cooling fan clean it e Cooling fan is cleaned by washing in detergent and water CAUTION Do not clean the cooling fan in oil solvent It may be damage by oil solvent Screen Clearance Adjustment e Check clearance between screen A and fan housing B If clearance is less than 1 mm 0 04 in add proper num ber of spacer C between screen and bracket comp D to adjust clearance G 1 3 mm 0 04 0 12 in F Screws G Clearance 1 3 mm 0 04 0 12 in ENGINE TOP END 4 1 Engine Top End Table of Contents Exploded Mi Wii ica desde ica 4 2 Specifications ii A A A A aiii 4 6 Cylinder Hed ito ld delia 4 9 Compression Measurement occocccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnneninininnss 4 9 Cylinder Head Assembly Removal oooooococinnnoninnnncccnnncconnnnnnnnccncnnnnnnnnnnncnrn rre 4 10 Cylinder Head Assembly Installation oonnonmonnnncnnnnnnnnnnncorrcrnnnnnnnnnn nn 4 10 Push Rod Removal EEEE A A 4 11 Push Rod Installation oaks a E olien hpeie tei bwin nents 4 11 PUSH ROG INSPSCUOMN er ciets ac avcay A ocods secu e a ra e EEE doo aaa 4 12 Valve Mechanism Removall Installation ooooooocccccccnccnnncnnnnnnnnonnnnnnnnnnnnnnnnnno
6. Clean Correct Replace Clean or replace Bore or replace Replace Tighten Tighten Replace Replace Adjust Change Clean Adjust See engine loss power Replace 8 6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1 Disconnect spark plug caps from the spark plugs 2 Turn engine switch to start position and check condi tion A WARNING test CAUTION Engine may be cranked in this test Do not touch any rotating parts of engine and equipment during If starter does not stop by engine switch OFF dis connect negative lead from battery as soon as possible STARTER DOES NOT ROTATE Y Is click sound from solenoid switch Is battery normal and well charged STARTER ROTATES BUT SLOW NO Faulty battery Faulty leads or connection Melted fuse Faulty engine switch Faulty solenoid switch HF Charge or replace Repair or replace H Replace Repair or replace Replace YES Weak battery Faulty leads or connection Solenoid to motor g Faulty solenoid switch Main terminal in solenoid Faulty starter motor Charge or replace H Repair or replace Replace H Repair or replace NO Weak battery H Charge or replace STARTER ROTATES BUT CAN NOT CRANK ENGINE gt Faulty leads or connection Solenoid to motor Faulty solenoid s
7. e Measure connection rod twist OWith the big end arbor still on the V blocks hold the con nection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist lf connection rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit 0 15 100 mm 0 006 3 94 in Connecting Rod Big End Crankpin Width Wear e Measure the connecting rod big end width A with a mi crometer or dial caliper If the measurement is less than the service limit replace the connecting rod Connecting Rod Big End Width Model Service Limit FH451V 500V 531V 18 80 mm 0 74 in FH541V FH580V 18 80 mm 0 74 in FH601V 641V 680V 721V 19 90 mm 0 783 in e Measure the crankpin width A with a dial caliper x lf the crankpin width is more than the service limit replace the crankshaft Crankpin Width Model Service Limit FH451V 500V 531V 39 50 mm 1 56 in FH541V FH580V 39 50 mm 1 56 in FH601V 641V 680V 721V 43 1 mm 1 697 in CAMSHAFT CRANKSHAFT 6 15 Crankshaft Connecting Rod Connecting Rod Big End Bearing Crankpin Wear e Apply a light film of oil on the thread of the cap bolts e Install the cap bolts and tighten the bolts to the spe
8. Inner and Outer Rotor Clearance Service Limit 0 2 mm 0 008 in 5 12 LUBRICATION SYSTEM Oil Pump Relief Valve e Before FH500 A50136 FH531 A07510 model as shown in the figure e Measure the outside diameter A of the outer rotor with a micrometer at several points If the rotor diameter is less than the service limit replace both the inner and outer rotor Outer Rotor Outside Diameter Service Limit 40 470 mm 1 5933 in e Measure the thickness B of the outer rotor with a mi crometer at several points x If the rotor thickness is less than the service limit replace both the inner and outer rotor Outer Rotor Thickness Service Limit 9 830 mm 0 3870 in e Measure the inside diameter A of the pump housing with a inside micrometer at several points x If the inside diameter is more than the service limit re place the crankcase cover Pump Housing Inside Diameter Service Limit 40 801 mm 1 6063 in e Measure the depth B of the pump housing with a depth micrometer at several points If any of measurement is more than the service limit re place the crankcase cover Pump Housing Depth Service Limit 10 230 mm 0 4028 in e Before FH500 A50136 FH531 A07510 model as shown in the figure LUBRICATION SYSTEM 5 13 Oil Pump Relief Valve e Measure the outside A diameter of the pump shaft with a micrometer at several points lf the diameter is less than the s
9. Specifications Item Service Limit FH451V FH500V FH531V FH541V FH580V Cylinder Head Cylinder compression MIN Cylinder head warp Valves Valve head thickness Valve stem runout Valve stem diameter Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Valve seating surface angle Intake Exhaust Valve seating surface width Intake Exhaust Valve clearance Valve guide inside diameter Intake Exhaust Valve spring free length Intake Exhaust Rocker arm push rod runout Intake Exhaust Cylinder Piston Piston diameter Piston ring groove Top clearance Second Piston ring thickness Top Second Piston ring end gap Top Oil Piston pin outside diameter Piston pin hole inside diameter 390 kPa 57 psi MIN 0 05 mm 0 002 in 1 0 35 mm 0 014 in 0 05 mm 0 002 in 5 95 mm 0 0234 in 5 93 mm 0 0233 in Standard 0 10 0 15 mm 0 004 0 006 in Standard 45 Standard 0 6 0 9 mm 0 024 0 035 in ee 6 08 mm 0 239 in t t 31 0 mm 1 22 in 0 5 mm 0 02 in 67 79 mm 2 669 in 0 15 mm 0 006 in 0 12 mm 0 005 in 1 40 mm 0 055 in 0 70 mm 0 028 in 0 78 mm 0 031 in 1 05 mm 0 041 in 15 96 mm 0 628 in 16 08 mm 0 633 in 73 79 mm 2 905 in a NN nN We HP de ele ade ae ky wale lca Connecting rod small end inside diameter Cylinder inside diameter Second Standard Cylinder 0 50 mm Oversize Cylinder in
10. e Check that no foreign material is obstructing the air pas sage COOLING SYSTEM 3 1 Cooling System Table of Contents EXploded View assis Activate E A E ET 3 2 Cooling FM id rata Malte at lb alot e Gee tien e 3 4 Cooling Fan Remolino ii 3 4 Cooling Fan nal A A A A A 3 4 Cooling Fan Inspection secreto ciar uterinas dieta 3 4 Screen Clearance AdjUSIMeNMt oooconiniocinnnnnnnnnnnanannnnrcncnrnn cane 3 4 3 2 COOLING SYSTEM Exploded View COOLING SYSTEM 3 3 Exploded View FH451V FH500V FH531V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 17 N m 1 7 kgf m 12 0 ft lb T4 56 N m 5 7 kgfm 41 ftlb T5 7 8 N m 0 8 kgf m 69 in Ib FH541V FH580V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 17 N m 1 7 kgfm 12 0 ft lb T4 56 N m 5 7 kgfm 41 ft lb T5 7 8 N m 0 8 kgf m 69 in lb FH601V FH641V FH680V FH721V T1 3 9 N m 0 40 kgf m 35 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 17 N m 1 7 kgfm 12 0 ft lb T4 56 N m 5 7 kgfm 41 ftlb T5 7 8 N m 0 8 kgf m 69 in Ib 1 Stud Before 2002 4 Product Model 2 Stud On and after 2002 5 Product Model A Recoil Starter Model B Electric Starter Model 3 4 COOLING SYSTEM Cooling Fan Cooling Fan Removal e Refer to Flywheel Removal in Electrical System chapter Cooling Fan Installation e Refer to Flywheel Installation in Electrical System chap ter
11. m lt FH451V FH500V FH531V FH541V FH580V FH601V Kawasaki FH641V FH680V FH721V a N o gt 4 stroke air cooled v twin gasoline engine Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Fuel System Cooling System Engine Top End Lubrication System Camshaft Crankshaft Electrical System Troubleshooting FH451V FH500V FH531V FH541V FH580V FH601V Kawasaki FH641V FH680V FH721V 4 stroke air cooled v twin gasoline engine Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring
12. on the carburetor e Turn out the drain screw a few turns to drain the carburetor and check to see if water or dirt has accumulated in the carburetor e For FH541V FH580V model remove the float bowl to drain the carburetor and check to see if water on dirt has accumulated in the carburetor e Tighten the drain screw Torque FH451V 500V 531V Drain Screw 1 3 N m 0 13 kgf m 11 in Ib FH601V 641V 680V 721V Drain Screw 2 0 N m 0 2 kgf m 18 in Ib e For FH541V FH580V model tighten the solenoid valve or float bowl mounting screw Torque Solenoid Valve 4 5 N m 0 46 kgf m 40 in Ib Float Bowl Mounting Screw 4 5 N m 0 46 kgf m 40 in Ib elf any water or dirt is found clean the carburetor see Carburetor Cleaning and fuel tank and check the fuel filter Carburetor Removal Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Air Cleaner and Related Parts see Cleaner Body e Turn the fuel shut off valve to the OFF position e Drain the carburetor e Disconnect the fuel tube at the fuel inlet joint A of the carburetor e For Electric Stater model disconnect the solenoid valve lead terminal and remove the earth terminal e Unhook the throttle link spring B at the throttle shaft
13. Center Spring D Washer E Pawls F Return Springs G A WARNING When removing the reel A be careful that the re coil spring B under the reel does not fly loose and cause injury The spring is under great pressure NOTE OThere should be no spring tension on the reel when removing it If tension is felt push the reel back into place and gently wiggle it until the reel can be easily removed e Slowly lift the reel straight up out of the case C A WARNING If the recoil spring cassette is sticking with the reel be careful that the cassette does not drop Be careful that the recoil spring does not fly loose from the cassette and cause injury The spring is under great pressure e Slowly lift the recoil spring cassette straight up out of the case or reel 7 26 ELECTRICAL SYSTEM Starter System x lf the recoil spring A must be removed from the cassette B hold the cassette with the opening side facing down ward in a suitable container and tap the cassette to re move the recoil spring Recoil Starter Assembly Wear gloves during the recoil spring installation to avoid injury The recoil spring must be assembled with great pressure e Lightly grease the recoil spring e Set the recoil spring into the spring cassette e Wind the rope clockwise A on the reel and hold the rope end B with tape e Install the spring cassette C on the reel so that the tongue
14. OThe depth is 0 1 mm 0 0 04 in D e When installing the governor shaft and plate in the crankcase cover see Fuel System chapter KG04013BS1 6 6 CAMSHAFT CRANKSHAFT Crankcase e Check to see that the crankcase dowel pins A are in place on the crankcase e Install the gasket on the crankcase e Install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown Torque Crankcase Cover Bolts 25 N m 2 6 kgf m 19 0 ft lb ODo not turn one screw down completely before the others as it may cause the crankcase cover to warp e For FH601V 641V 680V 721V model tightening se quence as shown Torque Crankcase Cover Bolts 25 N m 2 6 kgf m 19 0 ft Ib Inspection e Measure the inside diameter A of the PTO shaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit PTO Shaft Bearing Inside Diameter Model FH451V 500V 531V FH541V 580V FH601V 641V 680V 721V e Measure the inside diameter A of the crankshaft journal bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase if the inside diameter is more than the service limit Service Limit 35 15 mm 1 384 in 35 15 mm 1 384 in 40 15 mm 1 581 in Crankshaft Journal Bearing Inside Di
15. Pilot Jet Solenoid Valve Out Vent Tube Before 2003 5 Product model NOOR WD T1 0 7 N m 0 07 kgf m 6 in Ib T2 1 0 N m 0 10 kgf m 9 in Ib T3 1 3 N m 0 13 kgfm 11 in lb T4 1 7 N m 0 17 kgf m 15 in lb T5 2 0 N m 0 20 kgf m 17 in lb T6 3 4 N m 0 35 kgf m 30 in Ib T7 5 9 N m 0 6 kgf m 52 in lb T8 6 9 N m 0 70 kgf m 61 in Ib T9 8 8 N m 0 90 kgf m 78 in lb 2 4 FUEL SYSTEM Exploded View FH541V FH580V FUEL SYSTEM 2 5 Exploded View FH541V FH580V 1 Pilot Screw 2 Main Jet 3 Solenoid Valve T1 0 7 N m 0 07 kgf m 6 in lb T2 2 3 N m 0 23 kgf m 20 in lb T3 4 5 N m 0 46 kgf m 40 in lb T4 3 4 N m 0 35 kgf m 30 in lb T5 5 9 N m 0 6 kgf m 52 in lb L Apply non permanent locking agent 2 6 FUEL SYSTEM Exploded View FH601V FH641V FH680V FH721V Kc02011BW5 FUEL SYSTEM 2 7 Exploded View FH601V FH641V FH680V FH721V NOOR WD Pilot Screw Pilot Air Jet Main Air Jet Main Jet Pilot Jet Solenoid Valve Out Vent Tube Before 2003 5 Product model 1 0 N m 0 10 kgf m 9 in Ib 3 9 N m 0 40 kgfm 35 in Ib 2 0 N m 0 20 kgfm 18 in lb 19 N m 1 9 kgf m 14 ftlb 20 N m 2 0 kgfm 15 ft lb 5 9 N m 0 60 kgf m 52 in lb 2 8 FUEL SYSTEM Exploded View SS y SS Si ut Sy SS ed ee ed L AE NS a ee l A A eS e cel KCO2012BW5 FUEL SYSTEM
16. e Remove Ignition Coils see Ignition Coil Removal Stud Bolts A e Hold the flywheel with a suitable tool remove the flywheel bolt and washer e For Electric Starter model note the following procedure ORemove Nuts A and Guard B Bolt C and Screen D Spacer E OLoosen the fan housing bolts A and remove the fan housing B ELECTRICAL SYSTEM 7 13 Charging System ORemove Ignition Coil see Ignition Coil Removal Stud Bolts A OHold the flywheel with a suitable tool remove the flywheel bolt and washer e Using a suitable flywheel puller A remove the flywheel B CAUTION Always use flywheel puller e Remove Woodruff Key A Stator Coil Lead Connector B Stator Coil Screw C Stator Coil D Flywheel Stator Coil Installation e Install the stator coil and tighten the screws Torque Stator Coil Screws 3 4 N m 0 35 kgf m 30 in Ib e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth A Crankshaft Tapered Portion B Flywheel Tapered Portion e Fit the Woodruff key C securely in the slot in the crank shaft before installing the flywheel 7 14 ELECTRICAL SYSTEM Charging System e Install the fan A so that two positioning bosses B fit around flywheel ignition magnet C e Install the plate D so that the notch E inserts into the slot in the flywheel e Install the scree
17. see Camshaft Crankshaft chapter e Unscrew the mounting bolts and remove the oil pump parts assembly pump gear pump cover plate pump shaft pins and rotors e Take off the relief valve spring and ball e Disassemble the pump parts assembly A Pin B Pump Gear C Mounting Bolts D Outer Rotor E Inner Rotor F Pump Shaft G Relief Valve Ball H Spring I Pump Cover Plate J 6 mm DIA Hole Oil Pump Relief Valve Installation e Fill the rotor housing with engine oil for initial lubrication e Install the relief valve ball and spring in position then in stall the pump parts assembly in the crankcase cover NOTE OWhen Installing the pump parts assembly align the 6 mm DIA hole A on the cover plate with center of the relief valve e Install the mounting bolts and tighten them Torque Oil Pump Cover Plate Mounting Bolts 5 9 Nm 0 6 kgf m 52 in Ib e Before FH500 A50316 FH531 A07510 model as shown in the figure Oil Pump Relief Valve Inspection e Remove the oil pump see Oil Pump Relief Valve Re moval e Visually inspect the pump gear outer and inner rotor and cover plate x If there is any damage or uneven wear replace them OCheck the clearance A between the inner and outer rotor with a feeler gauge Measure the clearance between the high point of the inner rotor and the high point of the outer rotor If the measurement exceed the service limit replace the rotors as a set
18. spark by cranking engine while having the plug touched against engine block Keep the plug as far possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap away as AWARNING HE WEAK gt STRONG Faulty plug insulation Fouled electrodes Faulty ignition coil lncorrect air gap H Replace Clean H Replace Correct Y Is unusual smoke emitted out of YES gt Overrich fuel in pilot system H Turn in pilot screw by muffler a minor extent NO Directly and gradually open YES gt Plugged in carburetor interior H Disassemble and throttle valve by hand Does the clean revolution drop or does engine NO stall at a certain position Is air sucked through carburetor YES gt Loose flange nuts Retighten or intake manifold flanges Damaged gasket Replace NO Are valve clearances of normal NO gt Compression leakage Adjust valve clearance values Wrong valve timing H Correct alignment of YES timing gear marks Is alignment of timing gear marks NO gt OLargely deviated valve timing Correct alignment of correct timing gear marks TROUBLESHOOTING 8 5 Engine Troubleshooting Guide Fuel consumption is excessive Is compression sufficient High fuel le
19. strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAU TION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing sesion dd did 1 2 Model Identifica coi a ia oca 1 4 General SpecificatiONS oooococnnnnnnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnninnninnn 1 6 Periodic Maintenance Chart c cceccceccceecceeeeeeeeeee eee e eee ae cae cee cngeeaeeseeeceeeeeeeeeneeeseeeseeeseeeees 1 7 Torque ANG HOCKING Age incio Ica allioli uta cade 1 9 Special TOD Da a A recs eh A A Gen
20. 2 9 Exploded View FH451V FH500V FH531V T1 5 9 N m 0 60 kgfm 52 in Ib T2 2 0 N m 0 20 kgf m 17 in Ib T3 7 8 N m 0 80 kgfm 69 in Ib FH541V FH580V T1 5 9 N m 0 60 kgf m 52 in Ib T2 2 0 N m 0 20 kgf m 17 in Ib T3 7 8 N m 0 80 kgf m 69 in Ib FH601V FH641V FH680V FH721V T1 5 9 N m 0 60 kgfm 52 in lb T2 2 0 N m 0 20 kgf m 17 in lb T3 7 8 N m 0 80 kgf m 69 in Ib O Apply engine oil A Separate Choke Type B Associate Choke Type 2 10 FUEL SYSTEM Specifications Standard Item FH451V FH531V FH541V FH580V FH601V FH641V FH500V FH680V FH721V Carburetor Specifications Make type MIKUNI B24T1 Walbro LMF Nikki 621266 Throttle bore diameter 24 mm 26 mm 1 02 in 0 94 in Venturi diameter 16 mm 18 mm 16 mm 18mm 21 mm 0 83 in 0 63 in 0 71 in 0 63 in 0 71 in Main Jet MJ 125 116 3 100 105 L 136 R 140 Pilot jet PJ 48 8 43 8 48 50 L 46 R 44 Main air jet MAJ p1 7 p1 4 150 110 p1 7 Pilot air jet PAJ 61 2 60 8 170 140 91 1 Pilot air screw turns 2 1 4 1 3 8 2 1 2 1 7 8 L 2 1 4 R 1 1 4 out PS Idle mixture screw turns out Float level Idle Speed 1 Low idle speed High idle speed Air Cleaner Type Pre cleaner Second stage cleaner Fuel Fuel requirement Float parallel to carburetor body 1550 r min rpm 3600 r min rpm Dual stage filtration system Foam element Paper el
21. 3 4W Solenoid Switch OFF OFF Jo START 7 8 ELECTRICAL SYSTEM Wiring Diagram FH451V FH500V FH531V Recoil Starter with Charging Coil Model Note Portion surrounded byzy shows KHI procurement parts Spark Plugs QQ a El Gn Coil Os 6A SEAS To Electric Clutch 12VDC Engine Stop Switch ELECTRICAL SYSTEM 7 9 Wiring Diagram FH451V FH500V FH531V Recoil Starter Model Note Portion surrounded by zz shows KHI procurement parts Flywheel Engine Stop Switch 7 10 ELECTRICAL SYSTEM Wiring Diagram FH601V FH641V FH680V FH721V Electric Starter Model Note Portion surrounded by zzz shows KHI procurement parts D Carburetor Spark Plugs Regulator CoN Ww I Oil Pressure Switch MA e aan j YA is A t Oil Lamp bb oc 3 4W do Fuse 20A E a Solenoid Switch fal b cd OF Joe 7 RUN i o START oto ELECTRICAL SYSTEM 7 11 Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery lead connections This will burn out the diodes in the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a
22. Air Cleaner Carburetor 5 9 0 6 52 in lb Mounting Intake Manifold Mounting Bolts 5 9 0 6 52 in lb Cleaner Body Mounting Screws 3 4 0 35 30 in lb Control Panel Mounting Bolts 5 9 0 6 52 in lb Cooling System Engine shoroud Bolt M8 15 1 5 11 Engine shoroud Bolts M6 5 9 0 6 52 in lb Plug Bolt Engine shroud 5 9 0 6 52 in lb Plug Screw Engine shroud 3 4 0 35 30 in lb Engine Top End Cylinder Head Bolts 25 2 6 19 0 S Valve Clearance Lock Screws 6 9 0 7 61 in lb Connecting Rod Big End Cap Bolts 5 9 0 6 52 in lb O FH541V FH580V 9 8 1 0 87 in lb O Rocker Arm Bolts 28 2 8 20 1 10 GENERAL INFORMATION Torque and Locking Agent FH451V FH500V FH531V Fastener eee gt Remarks Torque N m kgf m ft Ib Rocker Cover Mounting Bolts 5 9 0 6 52 in lb Exhaust Pipe Flange Nuts 15 1 5 11 Spark Plugs 22 2 2 16 Lubrication System Engine Drain Plugs Plastic 6 9 0 7 61 in lb Engine Drain Plug Metal 20 2 0 14 5 Engine Drain Plug Joint Plastic 17 1 7 12 0 Engine Drain Plug Joint Metal 39 4 0 29 Oil Pressure Switch 9 8 1 0 87 in lb SS Oil Passage Plug 3 9 0 40 35 in lb Oil Pump Cover Plate Mounting Bolts 5 9 0 6 52 in lb Oil Filter in the text Camshaft Crankshaft Crankcase Cover Bolts 25 2 6 19 0 S Breather Chamber Cover Bolts 5 9 0 6 52 in lb Electrical System Stator Coil Screws 3 4 0 35 30 in lb Flywheel Bolt 56 5 7 41 Fan Housing Bolts 5 9 0 6 52 in lb Screen Bolts 59 0 6 52 in lb Regulator Screws
23. Bearing Crankpin Wear ooocccccccoconoccccccccnonanonnncncnnnnnananannn nono Grankshatt RUNOU dude E ia Crankshaft Main Joumal Wear oooooniioooncccconnnncnnnnnancccnnnnnnnnnnnn cnc cren Crankpin Resizing 6 2 6 4 6 5 6 5 6 9 6 9 6 10 6 10 6 10 6 11 6 11 6 11 6 11 6 13 6 13 6 13 6 13 6 13 6 13 6 14 6 14 6 15 6 15 6 16 6 16 6 2 CAMSHAFT CRANKSHAFT Exploded View ERA a sm ITA VS a ae al H ACO i CAMSHAFT CRANKSHAFT 6 3 Exploded View FH451V FH500V FH531V T1 5 9 N m 0 6 kgf m 52 in Ib T2 25 N m 2 6 kgf m 19 0 ft lb T3 See Engine Top End chapter FH541V FH580 T1 5 9 N m 0 6 kgf m 52 in Ib T2 25 N m 2 6 kgf m 19 0 ft lb T3 See Engine Top End chapter FH601V FH641V FH680V FH721V T1 5 9 N m 0 6 kgf m 52 in Ib T2 25 N m 2 6 kgf m 19 0 ft lb T3 See Engine Top End chapter O Apply engine oil G Apply grease SS Apply silicone sealant S Follow the specific tightening sequence A FH451V FH500V FH531V FH541V FH580V Model B FH601V FH641V FH680V FH721V Model 1 Screw 2 Plate 3 Breather Valve 6 4 CAMSHAFT CRANKSHAFT Specifications Service Limit Item FH451V 500V FH541V FH601V 641V 531V 580V 680V 721V Camshaft Tappet Cam lobe height Intake 29 131 mm 29 621 mm 1 1469 in 1 166 in Exhaust 29 131 mm 29 621 mm 1 1469 in 1 166 in Ca
24. Crankcase Cover Installation a a e a e e aa a aaa a A a a rnae Treaa ia iaaa Inspection Cleaning Breather Breather Element Removal FH451V 500V 531V 541V 580V coocccccccncccncccncconcconcnonos Breather Element Installation FH451V 500V 531V 541V 580V ooo eee eeecee seen eeeees Breather Valve Inspection FH601V 641V 680V 721V ooconccccncnnccccnononononennnonononeneninnns Camshaft Tappet Camshaft Tappet Removal occoccccnnccnnccnnnnnnnnnnnnnnnnnonnnnnononnnnnnnonnnonnnnnnnnnnnnnnnnnnnnnnnnnnnss Camshaft Tappet InstallatiOn ooooonononnnonnncconcnnnonononnnonnnnnnnnnnnonnnnnnnnnnnnonnnnnnnnnnnnnnos Camshaft Disassembly esoo bead lso ded didas troba eae Camshal ANS SOM OM aaa aaae aer aaaea tea daaa dan AAAA p AA AARTE AETA ped aaah Saab ackiee Camshaft Inspection oaren ien eat Camshaft Bearing Journal Wear oonncoccnnnnininannnnnonnnnccnnnnnnnnnnenrennnnnn nn Crankshaft Connecting Rodnina a e e a e a a a a Connecting Rod Removal airiran na lic Connecting Rod Installation ssessssessssrrrseeecceeeeesssssssrrrerrrrnnnarutrntrrnnnusutrnnunauaasteceeeeeenese Crankshaft Removal u caba a Crankshaft Installation seein aaaea ae a aa E A E a a a a a aE Cleaning INSpEction vn suindc lidia Connecting Rod Bend TWiSt c ir a o nent Connecting Rod Big End Crankpin Width Wear oooooccccnnncccococoncccccncccnanananrncncnnnnnanannnnnnnos Connecting Rod Big End
25. FH680V FH721V 0 15 mm 0 006 in 0 18 mm 0 007 in eal ae 0 005in lt 0 16 mm 0 006 in NOTE OThe oil ring is a three piece assembled ring Difficult to measure the ring groove clearance and thickness visually inspect only 4 24 ENGINE TOP END Cylinder Piston e Measure the piston ring thickness A OUse a micrometer to measure at several points around the rings If any of the measurement are less than the service limit replace the entire set of rings Piston Ring Thickness Service Limit Top Second 1 40 mm 0 055 in NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Remove the piston rings e Push each ring one at a time in the cylinder bore to a point close to the bottom of the cylinder bore OUse the piston to push it in to be sure it is square e Measure the gap A between the ends of the ring B with a thickness gauge xlf the end gap of any ring is greater than the service limit replace the entire set of rings Piston Ring End Gap Service Limit FH451V FH500V FH541V FH601V FH641V FH531V FH580V_ FH680V FH721V 0 70 mm 0 028 in 0 65 mm 0 026 in 0 78 mm 0 031 in Oil 1 05 mm 0 041 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin e Measure the d
26. Inspection OVisually check all governor parts for wear and damage lf any parts are worm or damaged replace them Governor Shaft Removal e Split the crankcase see Camshaft Crankcase chapter e Unscrew the governor shaft plate screws A and pull out the governor shaft B outside NOTE Olt is not necessary to remove the governor shaft unless it is being replaced e Replace the oil seal only if the lip shows signs of leakage or it has been damaged e The oil seal A must be assembled with seal lip towards inside of the engine e Press in the oil seal O 1 0 mm 0 04 in B flush or below the crankcase cover surface C Governor Shaft Installation e Apply engine oil to the governor shaft e Insert the governor shaft into the crankcase e Install the governor shaft plate A to the shaft B as shown Torque Governor Shaft Plate Screws 2 0 N m 0 20 kgf m 17 in Ib e Check that the governor shaft moves freely in its operating range NOTE Olf the oil seal is removed oil seal is put on after shaft is installed KCO4013BS1 2 14 FUEL SYSTEM Carburetor Fuel and Air Flow The main system of the carburetor consists of the main jet A valve seat B main nozzle C and the main air pas sage D main air jet E The main system meters fuel to the engine during moderate to heavy load conditions Fuel flows through the main jet and into the main nozzle where it is jo
27. Main Journal Wear e Measure both main journals at several points around the journal circumference xf the journal diameter is less than the service limit re place the crankshaft with a new one PTO Side Crankshaft Journal Diameter A Model Service Limit FH451V 500V 531V 34 90 mm 1 374 in FH541V FH580V 34 90 mm 1 374 in FH601V 641V 680V 721V 39 896 mm 1 571 in Flywheel Side Crankshaft Journal Diameter B Model Service Limit FH451V 500V 531V 34 93 mm 1 375 in FH541V FH580V 34 93 mm 1 375 in FH601V 641V 680V 721V 39 896 mm 1 571 in Crankpin Resizing Crankpin can be resized to accept 34 5 mm 1 3583 in dia under size connecting rod The crankpin should be re ground if the crankpin is so much undersize and so much scored that a lapping operation will prove unsatisfactory Reground can be done by a reliable repair shop e Before sending the crankshaft inspect the crankpin for cracks If any cracks no matter how small are found the crank shaft must be rejected e The final finishing dimensions should be shown in the ta ble Finishing Dimensional Specifications FH451V FH500V FH531V 34 457 34 470 mm 1 356 1 357 in R 2 0 2 4 mm R 0 0787 0 0945 in 39 50 mm MAX 1 555 in MAX 33 950 34 050 mm 1 337 1 340 in Finishing Dimensional Specifications FH541V FH580V 37 457 37 470 mm 1 4
28. Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder CAUTION Note a location of the arrow match mark A on the piston head in relation to K Mark B on the connect ing rod No 1 cyl K Mark on the connecting rod is face to face with No 2 cyl K Mark on the connecting rod Keep parts together as a set e Remove one of the piston pin snap rings A with needle nose pliers B e Remove the piston by pushing the piston pin A out the side from which the snap ring was removed ENGINE TOP END 4 21 Cylinder Piston e Remove the top and second rings with piston ring pliers Special Tool Piston Ring Pliers 57001 115 e If the special tool is not available carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the 3 piece oil ring with your thumbs in the same manner Piston Installation e Install the expander A in the piston oil ring groove so that the expander ends B touch together never overlap e Install the upper and lower steel rails There is no UP or Down to the rails They can be installed either way e Do not mix up the top and second rings e Install the second and top rings as shown The rings should turn freely in the grooves A Piston Head B Top Ring for FH451V 500V 531V 541V 580V C Second Ring for FH451V 500V 531V 541V 580V D Top
29. Speed Screw Solenoid Valve Type 5 Spring 24 Gasket 6 Seal 25 Solenoid Valve 7 Ring Electric Starter Model 8 Throttle Shaft 26 Drain Screw 9 Throttle Valve 27 Gasket 10 Screws 28 Pin 11 Pilot Jet 29 Snap Ring 12 Screw 30 Float Valve 13 Choke Valve 31 Main Air Jet 14 Choke Shaft 32 Air Jet 15 Spring 33 Washer 16 Coller 34 E Type Circlip 17 Main jet 35 Cap 18 Float 36 Earth Lead 19 Main Nozzle Electric Starter Model 20 Valve Seat KC05040B53 FUEL SYSTEM 2 21 Carburetor Carburetor Disassembly Assembly FH541V FH580V e Refer to the illustration shown for disassembly and as sembly e There are several passage plugs Ball plugs in the car buretor body Do not remove e Before disassembly mark the out side of choke valve and throttle valves for assembling them e Replace the pilot screw in accordance with the following procedure if necessary OCarefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later ORemove the limiter Be careful not to turn pilot screw at this point OTurn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage Record the number of turns needed to close the screw OTurn out the pilot screw to replace it with a new one Olnstall the new pilot screw until the screw is gently seated Then open the s
30. Stem Diameter e Measure the diameter of the valve stem A in two di rections at right angles at four different positions on the stem lf any single measurement is less than the service limit replace the valve Valve Stem Diameter Service Limit Intake 5 95 mm 0 234 in Exhaust 5 93 mm 0 233 in Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide B a three places down the length of the guide If the measurement is more than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Intake Exhaust 6 08 mm 0 239 in KEO5007BS1 ENGINE TOP END 4 19 Valves Valve Spring Inspection e Inspect the valve spring for pitting cracks rusting and burns Replace the spring if necessary e Measure the free length A of the spring lf the measurement is less than the service limit replace the spring Valve Spring Free Length Service Limit 31 0 mm 1 22 in 4 20 ENGINE TOP END Cylinder Piston Piston Removal e Split the crankcase see Camshaft Crankshaft chapter e Remove the camshaft see Camshaft Crankshaft chap ter e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod caps B NOTE ONote the position of the connecting rod caps for rein stalling the caps e
31. by fan Dimensions 425 mm x 359 mm x 425 mm x 359 mm 458 mm x 430 LxWxH 324 mm x 425 mm mm x 381 mm Electric starter model 16 7 in x 14 1 in x 16 7 in x 14 1 in 18 0 in x 16 9 in 12 8 in x 16 7 in x 15 0 in Recoil starter model 425 mm x 359 mm x 361 mm 16 7 in x 14 1 in x 14 2 in Dry weight Electric starter model 34 kg 75 Ibs 32 Kg 71 lbs 40 5 kg 89 3 Ibs 41 2 kg Recoil starter model 32 kg 71 lbs 90 8 Ibs Specifications are subject to change without notice GENERAL INFORMATION 1 7 Periodic Maintenance Chart To ensure satisfactory operation over an extended period of time any engine requires normal main tenance regular intervals The Periodic Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals The bullet mark e designates that the corresponding item should be performed at that interval Some adjustments require the use of special tools or other equipment An electronic tachometer will facilitate setting idle and running speeds FH451V FH500V FH531V FH541V FH580V OPERATION INTERVAL Dail First Every Every Every Every Every Y 8hr 25hr 50 hr 100 hr 200 hr 300 hr Check or clean air intake screen Check and add engine oil Check for fuel and oil leakage Check battery electrolyte level Clean air cleaner foam element 1 Clean air cleaner paper element 1 Clean dust and dirt from cylinder and cylinder
32. directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 10 Press A part installed using a press or driver such as a journal should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 11 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals 3 GENERAL INFORMATION 1 3 Before Servicing When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 13 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little oil preferably high temperature grease on the lips to re
33. e Check the O ring C in groove of the oil cooler for dam age Replace the O ring with a new one if necessary Oil Cooler Installation FH721V e Install the oil cooler with the mounting joint and tighten it Torque Oil Cooler Mounting Joint 44 N m 4 5 kgf m 33 ft Ib e Install the oil filter see Oil Filter Installation FH721V578S1 5 10 LUBRICATION SYSTEM Pressurized Lubrication System The engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase The oil is pumped to a replaceable oil filter cartridge through the engine s oil passages to lubricate internal components and return to the crankcase A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excess oil to the crankcase see Oil Flow Chart Oil Pressure Measurement e Remove the oil pressure switch or oil passage plug from the crankcase e Install an appropriately sized oil pressure gauge adapter A and oil pressure gauge B e Run the engine and allow warm up completely e Run the engine at fast idle speed and read the oil pressure gauge e Stop the engine e Remove the oil pressure gauge and adapter e Apply silicone sealant to the threads of the pressure switch and tighten it or tighten the plug Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure S
34. e Coat the seat with machinist s dye e Fit a 45 cutter A to the holder and slide it into the valve guide OResurface the valve seat with a 45 cutter removing only enough material to produce a smooth and concentric seat CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced Do not turn the cutter counterclockwise or drop it against the seat or it will be dulled e Use a 32 seat cutter A to narrow the seat width to the STD width OTurn the seat cutter one turn at a time while pressing down very lightly Check the seat width after each turn CAUTION The 32 cutter removes material very quickly Check the seat width frequently to prevent over grinding NOTE OKeep the seat width as closely as possible to the STD width e Make a light pass with the 45 cutter to remove any pos sible burrs at the edge of the seat e After resurfacing the seat inspect for even valve seating OApply a machinist s dye to the valve face insert the valve and snap it closed against the seat several times The valve surface should show good contact all the way around Be sure the valve seat is centered on the valve face The position of the valve in the seat is evident after lapping the valve x lf the seat
35. engine oil to the journal and bearing e Carefully insert the crankshaft flywheel end into the main bearing and oil seal in the crankcase Cleaning Inspection e After removing clean the crankshaft and connecting rods with a high flash point solvent and dry them with com pressed air e Inspect the teeth of the crankshaft gear for pitting fatigue cracks burrs and evidence of improper tooth contact Replace the gear if necessary e Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear scratches evidence of im proper contact or other damages Replace them if necessary 6 14 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Bend Twist e Measure connecting rod bend OSelect an arbor of the same diameter as the connecting rod big end and insert the arbor through the connecting rod big end OSelect an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor through the connecting rod small end OOn a surface plate set the big end arbor on V blocks OWith the connecting rod held vertically use a height gauge to measure the difference in the height of the small end arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit 0 15 100 mm 0 006 3 94 in
36. hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the engine switch is on or while the engine is running OBecause of the large amount of current never keep the engine switch turned to the start position when the starter motor will not turn over or the current may burn out the starter motor windings OTake care not to short the leads that the directly connected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was brought on by some other item or items they too must be repaired or replaced or the replacement part will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OElectrical Connectors Female Connectors A Male Connectors B GP07000281 GPO070003S1 7 12 ELECTRICAL SYSTEM Charging System Flywheel Stator Coil Removal e Remove Recoil Starter see Recoil Starter Removal e Loosen the fan housing bolts A and remove the fan housing B
37. has been found to be the cause of malfunctioning Engine hard to start Remove spark plug and check spark by cranking engine while having the plug touched against engine block AWARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap r NO gt Are spark produced when spark plug is replaced YES4 YES gt Faulty spark plug Replace Faulty ignition coil Replace m Is compression sufficient aire Check carburetor NO gt lncorrect air gap Faulty flywheel Correct Replace No fuel in the tank Entry of dust or air into fuel pipe or filter Plugged air hole in tank cap and fuel pump Plugged fuel line Add E Clean Clean Clean Excessive use of choke Plugged air cleaner eToo high fuel level in float bowl crankshaft without loading Clean H Adjust NO y Are sparks produced m YES gt when ignition coil is replaced NO gt Make starting attempts NO gt a number of times and then remove spark plug and observe electrodes Are they wet YES gt o Check for fuel line Check for plugged air passage Check float level Check carb setting plugged Worn piston pi
38. have the proper equipment and mechanical proficiency GENERAL INFORMATION 1 9 Torque and Locking Agent The following tables lists the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads M Apply a molybdenum disulfide lubricant grease or oil to the threads seated surface or washer O Apply oil to the threads seated surface or washer S Tighten the fasteners following the specified sequence SS Apply silicone sealant FH451V FH500V FH531V FH541V FH580V FH451V FH500V FH531V Fastener PUSA U SD Remarks Torque Fuel System Carburetor FH451V FH500V FH531V Choke Valve Screw 0 7 0 07 6 in Ib Throttle Valve Screws 1 0 0 1 9 in lb Pilot Jet 1 7 0 17 15 in lb Main Jet 0 7 0 07 6 in lb Main Air Jet 0 7 0 07 6 in lb Main Nozzle 2 0 0 2 17 in lb Pilot Air Jet 0 7 0 07 6 in lb Drain Screw 1 3 0 13 11 in lb Earth Lead Screw Carburetor Side 3 4 0 35 30 in lb Fuel Shut Off Solenoid Valve 6 9 0 7 61 in lb Float Bowl Mounting Bolt 8 8 0 9 78 in lb Carburetor FH541V FH580V Throttle Valve Screws 0 7 0 07 6 in lb L Main Jet 2 3 0 23 20 in lb Fuel Shaft off Solenoid Valve 4 5 0 46 40 in lb Float Chamber Mounting Screw 4 5 0 46 40 in lb Governor Arm Clamp Nut 7 8 0 8 69 in lb Governor Shaft Plate Screws 2 0 0 2 18 in lb Holder Plate Nuts
39. into the cylinder Special Tool Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 57001 1097 e Insert the piston and connecting rod so that the arrow match mark A on the top of the piston is facing the fly wheel side B CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state so they must be replaced together as a set e Apply engine oil to the inner surface A of the connecting rod big end B and caps C e Install the connecting rod big end caps on their original position on each connecting rod big ends e Apply a small amount of engine oil to the thread D and seating surface E of the cap bolts e Tighten the cap bolts Torque FH451V 500V 531V Connecting Rod Big End Cap Bolts 5 9 N m 0 60 kgf m 52 in Ib FH541V FH580V Connecting Rod Big End Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib FH601V 641V 680V 721V Connecting Rod Big End Cap Bolts 21 N m 2 1 kgf m 15 ft lb e Install e Camshaft see Camshaft Crankshaft chapter e Crankcase Cover see Camshaft Crankshaft chapter ENGINE TOP END 4 23 Cylinder Piston Piston Cylinder Seizure e In case of seizure remove the piston e Visually inspect the cylinder and piston damage xf there is only light damage smooth the position with 400 emery cloth Remove the small aluminum deposits from the cylinder with 400 emery cloth or light h
40. lever C top end with a long nose plier e Unhook the throttle D and choke link rods E at the top ends of their arms while pull off the carburetor FUEL SYSTEM 2 19 Carburetor e For FH541V FH580V model as shown in the figure e For FH601V 641V 680V 721V model note the following OUnhook the throttle link spring B at the link clip F with a long nose plier OUnhook the link clip F and remove the throttle D and choke link rods E at the ends of their arms while pull off the carburetor Carburetor Installation e Clean the mating surfaces of the carburetor and intake manifold and fit the new gaskets e Take care not to bend the throttle and choke link rods during installation Make sure the link spring around the throttle link rod is inplace and that it pulls the governor arm and carburetor throttle shaft lever toward each other e Be sure the fuel tube clip ends A face horizontal direc tion Improper installation of the fuel intake hose clamp can result in gasoline leakage and potential fire haz ard Be sure the clip ends of the hose clamp face in a horizontal direction In a vertical position see il lustration the clip ends A can come into contact with the intake pipe and become loose e Adjust Carburetor Pilot Screw Idle Speed 2 20 FUEL SYSTEM Carburetor Carburetor Disassembly Assembly FH451V 500V 531V e Refer to the illustration sh
41. pin or bolt e Check the idle speed and readjust the idle speed if nec essary CAUTION Be sure to make the idle and high idle speeds re spectively correspond to those of the equipment High Altitude Operation At high altitude the standard carburetor air fuel mixture will be excessively rich Performance will decrease and fuel consumption will increase High altitude performance can be improved by installing a smaller diameter main jet in the carburetor and correct idle speed NOTE OThe main jet high altitude kits are available if the equip ment is to be used in the high altitudes The main jet numbers are stamped on ends of the main jets High Altitude Main Jet Main Jet No FH601V Altitude LS Fhs31v FH541v FHssov Potty FH500V FH680Y FH721V 0 1000m 4125 116 3 100 105 E R 9300004 136 4140 1 000 2 000 m 3 L R 122 5 113 8 98 100 000 6 000 133 139 ft 2 000 m 6 L R 000 ft and 120 111 3 96 98 130 134 higher FUEL SYSTEM 2 17 Carburetor Main Jet Replacement e Place the engine equipment on a level surface e Close the fuel shut off valve in the equipment e Drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber e Remove the carburetor see Carburetor Removal e Unscrew the float chamber bolt A and take off the float bowl B e For Electric Start
42. take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In preparing this manual we divided the prod uct into its major systems These systems be came the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a sin gle chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for exam ple go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug sec tion Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not
43. the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder A in position op erate the cutter B with one hand C Do not apply too much force to the diamond portion NOTE OPrior to grinding apply oil to the cutter and during the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash the cutter with washing oil and apply a thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following 1 Cutter number selected from 1 to 12 32 Cutter angle A 37 5 Cutter diameter of cutter B KS8B Manufactured lot number Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters 45 32 and lap the valves e Check the seats for good contact all the way around with machinist s dye e Measure the seat width A If it is more than the STD width the seating surface should be refaced e If the valve seating pattern is not correct repair the seat SE KEO5O016BS1 KEO5002BS1 ENGINE TOP END 4 17 Valves
44. too tight Loosen the hone until it can be turned by hand e Be sure that the cylinder and hone are centered and aligned with the drive shaft and drill spindle e Pour honing oil inside of the cylinder during the honing operation start the drill press Move the hone up and down in the cylinder approximately 20 cycles per minute e Check the diameter of the cylinder bore regularly during honing using an inside micrometer ENGINE TOP END 4 27 Cylinder Piston CAUTION Stop the drill press before measuring and remove the hone from the cylinder NOTE OThe finish should not be smooth but have a 40 to 60 degree crosshatch pattern e Hone the cylinder until it is about 0 007 to 0 009 mm 0 0003 to 0 0004 in large to allow for shrinkage when the cylinder cools NOTE ODo not use gasoline kerosene or commercial solvent to clean the cylinder bore These fluids only wash all the oil from the cylinder wall They do not remove the metal particles produced during honing e Clean the cylinder thoroughly Using soap warm water and clean rags clean the cylinder wall A clean white rag should not show soil from the cylinder wall e Dry the cylinder and coat with engine oil CAUTION The cylinder must be thoroughly cleaned after hon ing to eliminate all grit 4 28 ENGINE TOP END Muffler Exhaust Pipe Installation Muffler Exhaust Pipe Removal e Loosen the clamp nut A e Remove the bolt B on
45. 3 4 0 35 30 in lb Ignition Coil Bolts Studs 7 8 0 8 69 in lb Ignition Coil Bolts Bolts 5 9 0 6 52 in lb Starter Motor Mounting Bolts 15 1 5 11 Recoil Starter Mounting Nuts 5 9 0 6 52 in lb Recoil Starter Retainer Screw 7 8 0 8 69 in lb Spark Plugs 22 2 2 16 The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads dia Torque 17 in lb 30 in lb 52 in lb 11 GENERAL INFORMATION 1 11 Torque and Locking Agent The following tables lists the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads M Apply a molybdenum disulfide lubricant grease or oil to the threads seated surface or washer O Apply oil to the threads seated surface or washer S Tighten the fasteners following the specified sequence SS Apply silicone sealant FH601V FH641V FH680V FH721V FH601V FH641V FH680V FH721V Fasteners Torque Remarks kgf m Fuel System Choke Valve Screw 1 0 0 10 8 9 in lb L Throttle Valve Screws 1 0 0 10 8 9 in lb E Pilot Jet Main Jet Main Jet Plug 19 1 9 14 Mai
46. 4 17 N m 1 7 kgfm 12 ft lb Recoil Starter Model Electric Starter Model Apply grease Apply engine oil OQUP 7 6 ELECTRICAL SYSTEM Specifications Standard Item FH451V 500V 531V FH601V 641V Service Limit 541V 580V 680V 721V Charging System Regulated output voltage 14 1 VDC 15 V DC Alternator stator coil resistance in the text Unregulated stator output 28 4 V AC 3000 rpm 26V AC 3000 rpm Regulator resistance in the text Ignition System Ignition coil Primary winding resistance in the text Secondary winding resistance 8 to 11 kQ Spark Plug CHAMPION RCJ8Y NGK BPR4ES Plug gap 0 75 mm 0 030 in 0 75 mm 0 030 in Electric starter System starter motor Carbon brush length with spring boss Commutator groove depth approx Commutator diameter Commutator runout 12 7 mm 0 500 in 2 0 mm 0 078 in 31 7 mm 1 250 in 6 4 mm 0 250 in 0 9 mm 0 035 in 31 1 mm 1 225 in 0 4 mm 0 016 in Special Tool Hand Tester 57001 1394 ELECTRICAL SYSTEM 7 7 Wiring Diagram FH451V FH500V FH531V FH541V FH580V Electric Starter Model Note Portion surrounded by zzz shows KHI procurement parts LB Carburetor Spark Plugs Paed a ill A Starter Flywheel s Ss A Voltage Charging j Coil fy Regulator Opti ption W Oil Pressure Switch 2 MW e a Oil Lamp
47. 5 14 Ol Screen RemoOV ali AA A A a id 5 14 OilScreen Installation ooo dida iba adas 5 14 Cleaning and NS pectin restos lid tado dedo 5 15 5 2 LUBRICATION SYSTEM Exploded View E 350 gt A 95 mi E SO Nae OO 8 taf ADES LUBRICATION SYSTEM 5 3 Exploded View FH451V FH500V FH531V T1 T2 T3 T4 T5 T6 T7 T8 3 9 N m 0 40 kgf m 35 in lb 6 9 N m 0 7 kgf m 61 in lb Plastic 9 8 N m 1 0 kgf m 87 in lb 20 Nm 2 0 kgf m 14 5 ft lb Metal 39 Nm 4 0 kgf m 29 ft lb Metal 17 Nm 1 7 kgf m 12 0 ft lb Plastic See the text 5 9 N m 0 6 kgf m 52 in Ib FH541V FH580V T1 T2 T3 T4 T5 T6 T7 T8 3 9 N m 0 40 kgf m 35 in Ib 6 9 N m 0 7 kgf m 61 in Ib Plastic 9 8 N m 1 0 kgf m 87 in Ib 20 N m 2 0 kgf m 14 5 ft lb Metal 39 N m 4 0 kgf m 29 ft lb Metal 17 N m 1 7 kgf m 12 0 ft lb Plastic See the text 5 9 N m 0 6 kgf m 52 in Ib FH601V FH641V FH680V FH721V T1 T2 n no 3 9 N m 0 40 kgf m 35 in Ib 6 9 N m 0 7 kgf m 61 in Ib Plastic 9 8 N m 1 0 kgf m 87 in lb 20 N m 2 0 kgf m 14 5 ft lb Metal 39 Nm 4 0 kgf m 29 ft lb Metal 17 N m 1 7 kgf m 12 0 ft lb Plastic See the text 5 9 N m 0 6 kgf m 52 in Ib 44 N m 4 5 kgfm 33 ft lb FH721V Before FH500 A50316 FH531 A07510 Model FH451V FH500V FH531v FH451V FH580V Model
48. 57001 1249 Sealant Kawasaki Bond Silicone Sealant 56019 120 LUBRICATION SYSTEM 5 7 Engine Oil Oil Filter and Oil Cooler CAUTION Engine operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure and accident Before starting the engine for the first time add oil The engine is shipped dry Preoil the engine to force all air from the internal oil passages and the oil filter e Fill fresh engine oil to the specified level see Oil Level Inspection e Run the engine at slow speed 2 minutes e Stop the engine and check the oil level Oil Level Inspection e Place the engine on a level surface e Remove the oil filler cap A and wipe its dipstick B with a clean cloth e Insert the dipstick into tube C without screwing it in then check the oil Level e The oil level should be the operating range D grid area on the dipstick xf the oil level is ADD range E add enough engine oil to bring oil level to the operating range CAUTION Do not add more oil above the operating range Ex cess oil will cause a smoking condition OUse the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil comp
49. 747 1 4752 in R 2 0 2 4 mm R 0 0787 0 0945 in 33 950 34 050 mm 1 337 1 340 in Finishing Dimensional Specifications FH601V FH641V FH680V FH721V 37 457 37 470 mm 1 4747 1 4752 in R 2 0 2 4 mm R 0 0787 0 0945 in 43 0 mm MAX 1 693 in MAX 37 95 38 05 mm 1 4941 1 4980 in e The crankpin surface should be concentric and parallel to each other within 0 006 mm 0 0002 in full indicator reading e Finish the crankpin surface with a super finishing stone ELECTRICAL SYSTEM 7 1 Electrical System Table of Contents Exploded MI o A E A Aasduoncet T A 7 2 SPECITICATIONS enea a cous Caan N aa e a aa 7 6 Wiring Diagram FH451V FH500V FH531V FH541V FH580V eeen 7 7 Wiring Diagram FH451V FH500V FHSS Vivitar 7 8 Wiring Diagram FH601V FH641V FH680V FH721V 0 cece center eter rete eenaaaaeeeeeeeeeeee 7 10 Precaution Sii A dias 7 11 CHATO SS Mo a a bicis 7 12 Flywheel Stator Coil RemoVal ooocooccconiciciconoccconcnoncnoncnonno nono nono nono nnnn nn nn nn nnnn cnn nnnn narran nnnnnnns 7 12 Flywheel Stator Coil InstallatiOD ooooonooonnonininnococococcoocconcconnnonnnonrn nro nr nono non rnnrnnnr ran nnnrnnns 7 13 Charging System Operational Inspection ooonicononcccnnncccnnnnonanncnnnononanananrncnnnnnnnn nana nnnnnos 7 15 Stator Coil RESiStanCe iii iaa 7 16 Unregulated Stator QUIPU EL uri id rta 7 16 Regul tor Removal tota e aie e ced
50. FH601V FH641V FH680V FH721V Model Apply engine oil Apply silicone sealant 5 4 LUBRICATION SYSTEM Engine Oil Flow Chart FH451V FH500V FH531V FH601V FH641V FH680V FH721V LUBRICATION SYSTEM 5 5 Engine Oil Flow Chart FH541V FH580V FH601V FH641V FH680V FH721V On and after 2003 5 product model a KFO4001BWS 5 6 LUBRICATION SYSTEM Specifications Standard Item Engine Oil Grade Viscosity Capacity When filter is not removed When filter is removed Level Oil Pressure Oil Pressure Switch Detect pressure Screw Oil Filter By pass Valve Opening Pressure SF SG SH or SJ class SAE40 SAE30 SAE10W 30 SAE10W 40 or SAESW 20 1 5 L 1 6 US qt 1 7 L 1 8 US qt except FH721V 1 8 L 1 9 Us qt FH721V Operating range grid area on dipstick 241 to 310 kPa 35 to 45 psi 98 kPa 14 2 psi PT 1 8 pipe thread 78 5 117 5 kPa 11 4 17 1 psi Item Service Limit Oil Pump Inner and outer rotor clearance Outer rotor outside diameter Outer rotor thickness Pump housing inside diameter Pump housing depth Pump shaft outside diameter Pump shaft bearing inside diameter Relief valve spring free length 0 2 mm 0 008 in 40 470 mm 1 5933 in 9 830 mm 0 3870 in 40 801 mm 1 6063 in 10 230 mm 0 4028 in 10 923 mm 0 4300 in 11 072 mm 0 4359 in 19 50 mm 0 77 in e rr Special Tool Oil Filter Wrench
51. FH721V 1 8 L 1 9 US qt FH721V e Check the O ring A on the oil filler cap for damage Re place the O ring with a new one if it is damaged When checking oil level do not turn oil filler cap on threads NOTE OSome increase in oil consumption may be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level frequently lt Ambient Temperature _ gt 20 C i fel 10 C To se 40 C AF 14 F 32 F e 68 F pl 104 F KFO5004BS1 LUBRICATION SYSTEM 5 9 Engine Oil Oil Filter and Oil Cooler Oil Filter Removal e Using a strap wrench or oil filter wrench A remove the oil filter B Special Tool Oil Filter Wrench 57001 1249 OWhen unscrewing the oil filter place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine Turn the filter counter clockwise to remove it Oil Filter Installation e Apply light film of engine oil to the seal A Install new filter OTurn the filter until the seal contacts mounting surface B of the engine Then turn the filter BY HAND S 3 4 turn more e Run the engine at slow idle speed 2 minutes Check for leaks around the engine e Stop the engine Check the oil level see Oil Level Inspec tion Oil Cooler Removal FH721V e Remove the oil filter see Oil Filter Removal e Unscrew the mounting joint A and remove the oil cooler B
52. Head Cylinder Head Assembly Removal e Remove Air Cleaner and Carburetor see Fuel System chapter Muffler see Muffler Exhaust Pipe Removal Intake Manifold see Fuel System chapter Spark Plug e Unscrew the rocker cover mounting bolts A and remove the cover B and gasket e When removing the 1 2 cylinder head set each piston at top dead center T D C A of compression stroke e Loosen the cylinder head bolts 1 4 turn in the sequence shown CAUTION If the above procedure is not followed the cylinder head may be warped during removal e Repeat the sequence until all bolts are removed and lift off the cylinder head assembly NOTE OMark the push rods so they can be installed in their orig inal position during assembly Cylinder Head Assembly Installation e Clean the mating surfaces of the cylinder heads and cylin der e Install the push rods in their original positions on each cylinder see Push Rod Installation e Install the knock pins e Set each piston at T D C A of compression stroke e Put a new gaskets and the cylinder head assemblies on each cylinder then let the cylinder heads with push rods aligned under the rocker arms NOTE OAs the head gaskets are coated with sealing agents be careful not to damage the surfaces KE04013BS1 KE04013BS1 ENGINE TOP END 4 11 Cylinder Head e Tighten the cylinder head bolts following the tightening sequenc
53. Ring for FH601V 641V 680V 721V E Second Ring for FH601V 641V 680V 721V e Align the piston and rings with the piston ring end gap as shown A Arrow Match Marks B Top ring End Gap Upper Steel Rail End Gap C 30 45 D Second Ring End Gap Lower Steel Rail End Gap e Apply engine oil to the piston pins Assemble the pistons onto the connecting rods as follow No 1 cyl Piston align the arrow match mark on the piston head with opposite the raised letters K Mark on the con necting rod No 2 cyl piston align the arrow match mark on the piston head with K Mark on the connecting rod A No 1 Cyl Piston B No 2 Cyl Piston C Arrow Match Marks D K Mark E Opposite K Mark GE160606S1 GE16013081 4 22 ENGINE TOP END Cylinder Piston e When installing a piston pin snap ring compress it only enough to install it and no more Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the notch B in the edge of the piston pin hole CAUTION Do not reuse the snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Apply engine oil to the piston skirt and the cylinder bore x Using the piston ring compressor grip A and the belt B lightly tap the top of the piston with a plastic mallet C to insert the piston and connecting rod
54. V 541V 580V 2 30 Fuel and Air FlOW ooooonnccccncooo 2 14 Element Removal FH601V Fuel Shut Off Solenoid Valve 641V 680V 721V ee 2 30 Electric Starter Model 2 15 Element Installation 2 30 Low Idle Speed Adjustment 2 15 Element Cleaning and Inspection High Idle Speed Adjustment 2 15 FH451V 500V 531V 541V High Altitude Operation 2 16 A O 2 30 Main Jet Replacement 2 17 Element Cleaning and Inspection Fuel system Cleanliness FH601V 641V 680V 721V 2 31 A ardeanteeccpsebleanes 2 18 Cleaner Body Removal FH451V Carburetor Removal 2 18 500V 531V 541V 580V 2 31 Carburetor Installation 2 19 Cleaner Body Removal FH601V Carburetor FH641V FH680V FH721V 2 31 Disassembly Assembly Cleaner Body Installation FH451V 500V 531V 2 20 FH451V 500V 531V 541V Carburetor OO it ated ets 2 32 Disassembly Assembly FH541V Cleaner Body Installation A dgcestaee csvanrian 2 21 FH601V 641V 680V 721V 2 32 Carburetor Housing Case and Body Disassembly Assembly FH601V INSpectiON oooocococcccconcconcnoncnnncnoo 2 32 641V 680V 721V neeese 2 22 2 2 FUEL SYSTEM Exploded View FH451V FH500V FH531V FUEL SYSTEM 2 3 Exploded View FH451V FH500V FH531V Pilot Screw Pilot Air Jet Main Air Jet Main Jet
55. air cleaner body e Be sure the paper element is in place in the air cleaner body e Be sure the foam element is in place on the paper ele ment body Element Cleaning and Inspection FH451V 500V 531V 541V 580V NOTE Oln dusty areas the elements should be cleaned more frequently than the recommended intervals A WARNING Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element e Remove the foam element and the paper element e Clean the foam element A in a bath of detergent and water and let the element air dry thoroughly before install it FUEL SYSTEM 2 31 Air Cleaner e Clean the paper element A by tapping it gently on a flat surface to remove dust If the element is very dirty re place it with a new one CAUTION Do not use compressed air to clean the paper ele ment Do not oil the paper or foam element Element Cleaning and Inspection FH601V 641V 680V 721V e See Element Cleaning and Inspection FH451V 500V 531V Foam Element A Paper Element B Cleaner Body Removal FH451V 500V 531V 541V 580V e Remove the elements see Element Removal e Remove the cleaner body mounting screws A holder plate nuts B and holder plate C e Pull the breather tube A off the pipe at the back of the body and remove the cleaner body B Cleaner Body Removal FH601V FH641V FH680V FH721V e Remove the
56. alve for excessive wear or damage The tip should be smooth without any grooves scratches or tears The rod atthe other end of the needle should move smoothly when push in and released x lf either the needle or the seat is worn or damaged re place the float assembly and carburetor body as a set Good Bad 2 26 FUEL SYSTEM Carburetor e Inspect the tapered portion A of the pilot screw B for wear or damage x lf the pilot screw is worn or damaged on the taper portion replace it e Check the spring for weakened condition replace it if necessary e For FH601V 641V 680V 721V model as shown in the figure Fuel Shut Off Solenoid Valve Test Electric Starter Model e Unscrew the fuel shut off valve and remove the valve e Connect a 12 VDC source to the solenoid as shown x lf the actuate solenoid plunger Needle Valve does not pop in when the Test Voltage is applied replace it NOTE Olf may be necessary to push the plunger slightly for the plunger to withdraw FUEL SYSTEM 2 27 Intake Manifold Intake Manifold Removal e Remove Air Cleaner see Cleaner Body Removal Engine Upper Cover e Cut off the band A and harness and or wire lead are released from intake manifold e Unscrew the manifold mounting bolts B e Then lifting up the intake manifold middle A pull out the intake manifold from the carburetor B as shown Intake Manifold Installation e Replace the intake manif
57. alve seating surface A between the valve B and valve seat C e Rocker Arm Installation OSoak the valve clearance adjusting nuts and rocker arm in the engine oil Olnstall the rocker arm ENGINE TOP END 4 13 Cylinder Head Cleaning and Inspection e Scrape the carbon deposits from the head and exhaust port with a suitable tool A e To avoid gouging use scrapers that are made of a mate rial that will not cause damage e Clean the head in a bath of high flash point solvent and dry it with compressed air A WARNING Clean the cylinder head in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head A fire or explosion could result e Lay a straightedge A across the mating surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and head lf warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm 0 002 in e Check the cylinder head for cracks or other damage e Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 kerosene and 75 light engine oil e Wipe the area dry and
58. amber and internal parts e Intake pipe and tube Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts as to his ability to do the work all ad justments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation To get the longest life out of your engine e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki en gine parts Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t
59. ameter Model Service Limit FH451V 500V 531V 35 15 mm 1 384 in FH541V FH580V 35 15 mm 1 384 in FH601V 641V 680V 721V 40 15 mm 1 581 in CAMSHAFT CRANKSHAFT 6 7 Crankcase Cleaning e Remove Camshaft and Tappets see Camshaft Tappet Removal Crankshaft see Crankshaft Removal e Clean up the crankcase and cover with a high flash point solvent and blow out any foreign particles that may be in the pockets inside of the crankcase with compressed air A WARNING Clean the crankcase and cover in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents 6 8 CAMSHAFT CRANKSHAFT Breather The function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings oil seals or gaskets A sealed type crankcase emis sion control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase and the camshaft Then it is drawn into the clean side of the air cleaner through the cylinder head and the hose and mixed with the clean air flow and subsequently coming into the combustion chamber through the carburetor and the intake manifold Oil is primarily separated from the gases while passing through the inside of the r
60. an obligation to make such changes to products manufactured previously All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 1999 Kawasaki Heavy Industries Ltd Fifth Edition 1 Apr 30 2003 K LIST OF ABBREVIATIONS ampere s pound s ABDC after bottom dead center meter s AC alternating current minute s ATDC after top dead center newton s BBDC before bottom dead center pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems EM in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to
61. asure the inside diameter A of the camshaft bearing on the crankcase at several points This bearing is not replaceable Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Service Limit 16 136 mm 0 6352 in e Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points This bearing is not replaceable Replace the crankcase cover if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 16 136 mm 0 6352 in CAMSHAFT CRANKSHAFT 6 13 Crankshaft Connecting Rod Connecting Rod Removal e Remove Piston see Engine Top End Chapter Connecting Rod Installation e Install Piston see Engine Top End chapter Crankshaft Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Flywheel see Electrical System chapter Camshaft see Camshaft Tappet Removal Connecting Rod and Piston Assembly see Engine Top End chapter e Pull the crankshaft A out of the crankcase Tap gently with a wooden or plastic mallet if necessary to loosen the crankshaft Crankshaft Installation e Clean up the crankshaft and crankcase thoroughly espe cially at the bearing contact surfaces e Pack some amount of high temperature grease into the oil seal on the crankcase e Apply
62. ator runout If runout is more than the service limit turn down the commutator or replace the armature with a new one Commutator Runout Service Limit 0 4 mm 0 016 in e Measure the armature winding resistance OSet the hand tester to the R x 1 Q range and measure the resistance between each segment A and all the others xf the resistance it too high or even infinite the armature winding has an open circuit Replace the starter motor Armature Winding Resistance Close to 0 Q e Set the hand tester to the R x 1 kQ range and measure the resistance between the commutator and the armature shaft B xf the resistance is less than infinite the armature is shorted Replace the starter motor Commutator to Shaft Resistance GP110607S1 GP110608S1 7 24 ELECTRICAL SYSTEM Starter System e Test the armature winding for shorts OPlace the armature on a growler A OHold a thin metal strip e g hack saw blade on top of the armature OTurn on the growler and rotate the armature one complete turn lf the metal strip vibrates the windings are internally shorted to each other and the starter motor must be replaced Yoke Assembly Inspection e Set the hand tester to the R x 1 kQ range and measure the resistance between the positive brush es A and brush plate B x lf the resistance is less than infinite the positive brush is shorted to ground Replace the b
63. cified torque see Piston Installation in Engine Top End chap ter e Measure the inside diameter A of big end at several points with a telescoping gauge or inside micrometer xf the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Big End Inside Diameter Model Service Limit FH451V 500V 531V 35 055 mm 1 380 in FH541V FH580V 38 055 mm 1 498 in FH601V 641V 680V 721V 38 055 mm 1 498 in e Measure the crankpin outside diameter A OUse a micrometer to measure several points around the crankpin circumference x lf the crankpin diameter is less than the service limit re place the crankshaft with a new one Crankpin Outside Diameter Model Service Limit FH451V 500V 531V 34 94 mm 1 3756 in FH541V FH580V 37 94 mm 1 494 in FH601V 641V 680V 721V 37 94 mm 1 494 in Crankshaft Runout e Measure the crankshaft runout OSet the crankshaft in a flywheel alignment jig or on V blocks gauge OSet a dial gauge against both bearing journals OTurn the crankshaft slowly to measure the runout The dif ference between the highest and lowest dial gauge read ings TIR is the amount of runout lf the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Service Limit 0 05 mm 0 002 in TIR 6 16 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Crankshaft
64. crew the same number of turns as recorded prior to removal OAlign the limiter with the mark on the carburetor body to install taking care not to turn the pilot screw e Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side e Drive the float pin into the carburetor body from the choke valve side e Assemble carburetor parts with recommended tightening torque see Exploded View 1 Limiter 2 Pilot Screw 3 Spring 4 Spacer 5 Low Idle Speed Screw 6 Spring 7 Screws 8 Throttle Valve 9 Throttle Shaft 10 Dust Seal 11 Choke Valve 12 Choke Shaft 13 Dust Seal 14 Solenoid Valve Electric Starter Model 15 Gasket 16 Float Bowl 17 Gasket 18 Float Pin 19 Float 20 Main Jet 21 Main Nozzle 22 Float Valve 23 Gasket 24 Screw Other than Solenoid Valve Type KC05041B53 2 22 FUEL SYSTEM Carburetor Carburetor Disassembly Assembly FH601V 641V 680V 721V e Refer to the illustration shown for disassembly and as sembly e There are several passage plugs Ball plugs in the car buretor body Do not remove e Before disassembly mark the out side of choke valve and throttle valves for assembling them 1 Plug Pilot Screw 15 Float 2 Pilot Screw 16 Gasket 3 Low Idle Speed Screw 17 Float Bowl 4 Spring 18 Screw 5 Seal 19 Clamp 6 Collar 20 Plug Main Jet 7 Throttle Valve 21 Gasket 8 Screws 22 Mai
65. does not make proper contact lap the valve into seat with a vacuum cap tool e Coat the face of valve sparingly with a fine lapping com pound e Use the vacuum cup tool A to grip top of the valve B Rotate the valve in a circular motion to lap the valve to the seat e Lift the valve slightly from the seat every 8 to 10 strokes continue lapping operation until a uniform ring appears around entire surface of the valve face 4 18 ENGINE TOP END Valves e When lapping is completed wash all parts in solvent to remove lapping compound Dry the parts thoroughly e Note the position of the lapping mark on the valve face The lapping mark should appear on or near the center of the valve face e When the engine is assembled be sure to adjust the valve clearances see Valve Clearance Adjustment Valve Head Thickness e Remove the valve see Valve Mechanism Removal Instal lation e Measure the thickness of the valve head lf the valve head thickness valve margin A is less than the service limit replace the valve Valve Head Thickness Service Limit IN EX 0 35 mm 0 014 in Valve Stem Runout e Support the valve in V blocks at each end of the stem e Position a dial gauge perpendicular to the stem e Turn the valve and read the variation on the dial gauge If the stem runout is greater than service limit replace the valve Valve Stem Runout Service Limit IN EX 0 05 mm 0 002 in Valve
66. duce rubber to metal friction 14 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 15 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them 16 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS2 in the assembly of certain engine parts Always check manufacturer recommendations before using such special lubricants 17 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser am
67. e Torque Cylinder Head Bolts 25 N m 2 6 kgf m 19 0 ft lb CAUTION A torque wrench must be used to assure proper torque Improper tightening of the head bolts can result in warping of the cylinder head e Check and adjust the valve clearance e Install the gasket and rocker cover Torque Rocker Cover Mounting Bolts 5 9 N m 0 6 kgf m 52 in Ib e Install the other removed parts Push Rod Removal e Set each piston at T D C of compression stroke e Remove the rocker covers see Cylinder Head Assembly Removal e Loosen the valve clearance adjusting nuts A e Move the rocker arms B to clear the push rod upper ends e Pull out the push rods NOTE OMark the push rods so they can be installed in their orig inal position during assembly Push Rod Installation e Set each piston at T D C of compression stroke e Install the push rods A in their original positions on each cylinder OTo Install the push rod in a correct position on the tappet B insert the push rod so end of the push rod is sliding down C along inside wall D of the crankcase and posi tion the push rod end on to the tappet e Check that both intake and exhaust push rods on each cylinder are at lowest position on the cam lobes E if not turn the flywheel clockwise one turn 360 and reset each piston at T D C of compression stroke e Be sure the end of the push rods are correctly seated on the tappets e Tighten the valve cleara
68. e 7 16 Regulator Instala ii a ic 7 16 Regulator Resist iii A A en eae is ites 7 17 E RS 7 18 Ignition Coil REMOVAL avion a dale 7 19 e O ve aaa Aea AEN ARREK a DAES hEN aE 7 19 Ignition Coil Inspection ds 7 20 Spark Plug Cleaning and Inspection corta eee a 7 20 Spark Plug Gap Inspection ooccccccccnccnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnonnnnnnnnnnnnnnnnnnennneninnss 7 20 SPATE OY SIGM rrr lns tuted unde al aleactaiaterheal head datatel sh E laias cata ctniahashie A 7 21 Starter Motor Removal cooccoccccnncnnnonnnonononnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnonnnenineninnss 7 21 Starter Motor InstallatioN coocoooconocononononnnonnnononononononononnononnnnnnnnncnnncnnnonenennnnnss 7 21 Starter Motor DisassemDiVa io rt Ii o 7 21 Starter Motor ASSembIY siirre a did E E 7 22 Starter Motor Brush Inspection ccccccccccccnnnnnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnononnnonineninnss 7 22 BrUSH Spring INSPECION a dei 7 22 Armature Inspection iii 7 22 Yoke Assembly Inspection sico ir id 7 24 PINION Clutch INSPECTION s mesere arara aaa dae ad add AAA AA ei 7 24 Recoil Starter Removal oocoocicocicicococccconcnonononnnonnno ono nn nnn nana 7 24 Recoil Starter Installation sece a a a Gare a e ner nens 7 24 Recoil Starter Disassembly xis iasedissicaceshalandgvinded Satta ie 7 25 Recoil Starter Assia cai acu oder cuidate ie ERY 7 26 7 2 ELECTRICAL SYSTEM Exploded View
69. ecommended tighten ing torque see Exploded View 2 24 FUEL SYSTEM Carburetor Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area and take care that there is no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetors CAUTION Do not use compressed air on an assembled carbu retor or the floats may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu retor with a cleaning solution This will prevent to damage or deterioration of the parts The carburetor body has plastic parts that can not be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor e Immerse all the carburetor metal parts in a carburetor cleaning solution and clean them e Rinse the parts in water and dry them with compressed air e Do not use rags or paper to dry parts Lint may plug the holes or passages e Blow air through the holes and fuel passages with the compressed air All holes must be open e Assemb
70. ed Lap the valves to the seats after refacing e Coat the valve seat with machinist s dye e Push the valve into the guide e Rotate the valve against the seat with a lapping tool e Pull the valve out and check the seating pattern on the valve head It must be the correct width A and even all the way around NOTE Good Too Wide OThe valve stem and guide must be in good condition or this check will not be valid xf the valve seating pattern is not correct repair the seat Valve Seating Surface Width STD Too Narrow Uneven FH451V FH500V FH531V FH541V FH580V Inlet Exhaust 0 6 0 9 mm 0 024 0 035 in FH601V FH641V FH680V FH721V Inlet 0 8 1 4 mm 0 03 0 05 in Exhaust 1 1 1 6 mm 0 04 0 06 in Q Valve Seat Repair e Follow the manufacture s instructions for use of valve seat cutters Special Tools Intake Valve Seat Cutter 45 35 0 57001 1116 Outside Cutter 32 633 0 57001 1199 Exhaust Valve Seat Cutter 45 630 0 57001 1187 Outside Cutter 32 630 0 57001 1120 Valve Seat Cutter Holder d6 0 57001 1360 Valve Seat Cutter Holder Bar 57001 1128 If the manufacture s instructions are not available use the following procedure 4 16 ENGINE TOP END Valves Seat Cutter Operating Cares 1 This valve seat cutter is designed only for valve seat repair Therefore the cutter must not be used for other purposes 2 Do not drop or hit the valve seat cutter or
71. element see Element Removal e Remove the clamp A and take off the breather tube B e Loosen nuts C and remove the solenoid valve wire D e Unscrew the bolts E and remove the intake pipe F 2 32 FUEL SYSTEM Air Cleaner Cleaner Body Installation FH451V 500V 531V 541V 580V e Connect the breather tube from the crankcase to the pipe at the back of the cleaner body e Tighten the holder plate nuts and cleaner body mounting screws Torque Holder Plate Nuts 5 9 N m 0 6 kgf m 52 in Ib Cleaner Body Mounting Screws 3 4 N m 0 35 kgf m 30 in Ib Cleaner Body Installation FH601V 641V 680V 721V e Replace the intake pipe gasket with new ones e Clean the mating surfaces of the carburetor and intake pipe e Install the intake pipe and solenoid valve wire e Tighten the mounting bolts and nuts Torque Intake Pipe Mounting Bolts and Nuts 5 9 N m 0 6 kgf m 52 in Ib e Install the sleeve on the intake pipe e Press in the sleeve A to the intake pipe B fixing the groove C to the projection D as following e Connect the breather tube to the pipe at the intake pipe and clip it with a clamp Housing Case and Body Inspection e Clean the housing with detergent and water and dry thor oughly e Check the housing for deformation or other damage The housing must seal well and permit only filtered air to reach the carburetor If the housing is damaged it must be replaced
72. ement Unleaded regular grade gasoline Fuel Pump Type Governor Type Pulse diaphragm pump Flyweight all speed governor 1 Idle speeds may vary depending on each equipment Refer to the equipment specification FUEL SYSTEM 2 11 Governor Link Mechanism Control Panel Assembly Removal e Remove Air Cleaner see Cleaner Body Removal Air Cleaner Mount Bracket Bolts A Air Cleaner Mount Bracket B Earth Lead Starter Model Control Panel Mounting Bolts C e Remove the control panel assembly A while unhooking the governor spring B end loop at the panel bracket e Clear the choke link rod lower end C from the choke lever Control Panel Assembly Installation e Before installing the control panel assembly check to see that the choke lever A and engine speed control lever B move smoothly in all directions lf any part is worn or damaged replace the control panel assembly e After installation adjust the low idle speeds and high idle speeds to the specifications see Low Idle Speed and High Idle Speed adjustment e For separate choke type as shown in the figure Governor Arm Removal e Remove Control Panel Assembly e Loosen the clamp nut A and take off the governor arm B e Unhooking the throttle link rod spring C end loop and clear the throttle link rod lower end D 2 12 FUEL SYSTEM Governor Link Mechanism e For FH541V FH580V model as shown i
73. emove the ignition coils see Ignition Coil Removal e Measure the winding resistance as follows OSet the hand tester to the R x 1 KQ range Special Tool Hand Tester 57001 1394 OMake the measurements shown in the table Ignition Coil Winding Resistance Iiz 2 1eka fo DN CAUTION Use only Tester 57001 1394 with new battery at room temperature for this test A tester other than the Kawasaki Hand Tester should show different readings If a megger or a meter with a large capacity battery is used the ignition coil will be damaged x lf the tester does not read as specified replace the coil Spark Plug Cleaning and Inspection e Carefully pull the plug cap from the spark plug and re move the spark plug lf the plug is oily or has carbon built up on it clean the _ RRELL ELL KS Wl SERRER E plug using a high flash point solvent and a wire brush or _ E other suitable tool EN xf the spark plug electrodes are corroded or damaged NA SS LZZ NO ES or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent A Insulator B Center Electrode C Plug Gap D Side Electrode GP10012381 Spark Plug Gap Inspection e Measure the gap with a wire type thickness gauge lf the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap M
74. ening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s
75. ent hole and filter are plugged or clogged remove the foreign matter from them Fuel Flow Test A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Disconnect the fuel pump outlet nozzle from the tube e Connect a suitable hose A to the outlet nozzle e Run the lower end of the hose into a container e Start the engine Check the fuel flow lf fuel flow is none or little replace the fuel pump x Check for clogged or damaged tubes and fuel filter Re place the faulty parts Fuel Filter Inspection e Visually inspect the fuel filter A x If the filter is clear with no signs of dirt or other contami nation it is OK and need not be replaced lf the filter is dark or looks dirty replace with a new one Also check the rest of the fuel system for contamination 2 30 FUEL SYSTEM Air Cleaner Element Removal FH451V 500V 531V 541V 580V e Pull the hooks A to outside and remove the air cleaner cover B e Remove Wing Bolt A Foam Element B Paper Element C Element Removal FH601V 641V 680V 721V e Remove Air Cleaner Case Nut Air Cleaner Case Wing Nut A Foam Element B Paper Element C Element Installation e Install the element correctly on the
76. er across the battery terminals The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must stay within the specified range x lf the output voltage is much higher than the specification the regulator is defective or the regulator leads are loose or open lf the output voltage dose not rise as the engine speed increase the regulator is defective or the alternator output is insufficient for the loads Regulated Output Voltage Battery Voltage to 15 VDC KHO7O10BS2 C 7 16 ELECTRICAL SYSTEM Charging System Stator Coil Resistance e Disconnect the connector A e Measure the stator coil resistance Electric starter Model OConnect an ohmmeter between stator pins B Stator Coil Resistance Electric starter Model 0 01 to 0 1 O Recoil starter Model with Electric Clutch OConnect an ohmmeter between stator pin and en gine body Stator Coil Resistance Recoil starter Model with Electric Clutch 4 4 to 150 If the meter does not read as specified replace the stator coil lf the coil has normal resistance but the voltage inspec tion showed the alternator to be defective the flywheel magnets have probably weakened and the flywheel must be replaced e Check for continuity between each stator pin and ground There should be no continuity infinite ohm x lf the stator coil fails any of these t
77. er model unscrew the solenoid valve and take off the valve and gasket e Using a proper blade screw driver carefully replace the main jet A with a new one for altitude expected e Tighten the main jet to the specification see Carburetor Disassembly Assembly Notes e Install the float chamber gasket and float bowl bolt e For Electric Stater model install the float chamber gasket and solenoid valve e For FH601V 641V 680V 721V model note the following ORemove the carburetor see Carburetor Removal OUnscrew the main jet plugs C and take off the main jet plugs and gaskets OMake sure that L L or R R mark on the float bowl is shown the main jet position OUsing a proper blade screw driver carefully replace the main jet D with a new one for altitude expected OTighten the main jet to the specification see Carburetor Disassembly Assembly Olnstall the gasket and the main jet plug Torque Main Jet Plug 19 N m 1 9 kgf m 14 ft lb 2 18 FUEL SYSTEM Carburetor Fuel system Cleanliness Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the air cleaner see Cleaner Body Removal e Place a suitable container A under the drain screw B
78. ervice limit replace the pump shaft Pump Shaft Outside Diameter Service Limit 10 923 mm 0 4300 in e Measurer the inside diameter A of the pump shaft bear ing in the crankcase cover with a inside micrometer at several points If the inside diameter is more than the service limit replace the crankcase cover Pump Shaft Bearing Inside Diameter Service Limit 11 072 mm 0 4359 in e Before FH500 A50136 FH531 A07510 model as shown in the figure e Visually inspect the relief valve spring steel ball and valve seat in the crankcase cover lf any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air A WARNING Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents x lf cleaning does not solve the problem replace the relief valve parts If necessary put the ball in position and lightly tap the ball with a suitable tools to form a perfect seat e Measure free length A of the spring with a vernier caliper x lf the free length of the spring is less than the service limit replace the spring Relief Valve Spring Free Length Service Limit 19 50 mm 0 77 in 5 14 LUBRICATION SYSTEM Oil Screen
79. ests replace the coil with a new one Unregulated Stator Output e Disconnect the connector A e Connect AC voltmeter to the stator pins B e Start the engine Run the engine at the 3 000 rpm speed e Voltage reading should be minimum 26 VAC 3 000 rpm xf the AC voltage reading is less than the specification replace the stator Unregulated Stator Output MIN 26 VAC 3 000 rpm Regulator Removal e Remove Stator Coil Lead Connector A Regulator Screws B Regulator C Regulator Installation e Install the regulator and tighten the screws Torque Regulator Screws 3 4 N m 0 35 kgf m 30 in Ib ELECTRICAL SYSTEM 7 17 Charging System Regulator Resistance i e Set the KAWASAKI Hand Tester selector switch to the R A x 100 Q position e Connect the test leads to the points shown on the chart J and read the resistance O O OThere are two 2 types of Regulator on FH engines as i Fi follows l l lo lo ha with out Charging Monitor Type 3 Blades A la D B NOTE OResistance value may vary with individual meters With Charging Monitor type 5 Blades L r A a y P GI o Oo O D B x lf the resistance is not as specified replace the regulator 7 18 ELECTRICAL SYSTEM Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main tenance except for the spark p
80. ew NOTE OThe mounting screw is a self tapping one Be aware that misthreading or overtightening screw will strip the female threads and ruin the hole 6 10 CAMSHAFT CRANKSHAFT Camshaft Tappet Camshaft Tappet Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Muffler see Engine Top End chapter Throttle Control Panel see Fuel System chapter Carburetor see Fuel System chapter Intake Manifold see Fuel System chapter Crankcase Cover see Crankcase Cover Removal Rocker Covers A e Position the piston TDC at the end of the compression stroke e Push down A the spring side of the rocker arm B and move it to clear the push rod C e Remove the push rods and mark them so they can be installed in their original positions during assembly e Turn the crankcase up side down so that the tappets will fall away from the cam lobes e Pull the camshaft A out of the crankcase e Remove the tappets A and mark them so they can be installed in their original positions during assembly Camshaft Tappet Installation e Apply engine oil to the following Tappet Journal Camshaft Journal Cam Lobe Surface Camshaft Gear e Align the punch marks A on the crankshaft gear and camshaft gear e Install the shim B on the camshaft CAMSHAFT CRANKSHAFT 6 11 Camshaft Tappet Camshaft Disassembly e Remove the governor assembly
81. ffler O Carbon deposit in exhaust hole Clean NO and muffler Carb not properly adjusted Adjust Too much oil in crankcase H Adjust level Worn piston piston rings Replace O Worn cylinder bore Bore or replace ls compression sufficient NO gt O See Engine Starts Hard Engine runs erratically gt O Spark plug fouled pitted or Replace or adjust gapped incorrectly Problem in the fuel ________LLLL_L____ Entry of dust or water into fuel Clean system lack of fuel pipe or fuel filter Air or vapour lock in fuel line Clean Plugged air vent of fuel tank Clean cap Plugged air fuel passes in carb Clean O Too little opening of carb pilot Correct screw Carb not properly adjusted Adjust Carb flange leaking at gasket Tighten or replace Worn carb body and throttle shaft Replace 8 4 TROUBLESHOOTING Engine Troubleshooting Guide Problem in the governor system Engine malfunctions at high speed lncorrect adjustment Faulty governor spring Governor ass y malfunctioning governor linkage Correct Replace Check Is revolution fluctuation of relatively large period produced when a load is applied YES Plugged air hole in tank cap Entry of dust and air into fuel filter or fuel pipe Clean Clean Engine malfunctions at low speed Remove spark plug and check
82. from the air cleaner No 2 Cylinder is the right hand cylinder viewed from the air cleaner GENERAL INFORMATION 1 5 Model Identification Electric starter Model FH580V 1 6 GENERAL INFORMATION General Specifications FH451V FH500V FH601V FH641V Items FH531V FH541V FH580V FH680V FH721V Type of engine Forced air cooled vertical shaft OHV 4 stroke gasoline engine Cylinder layout 90 V Twin Bore x Stroke 68 mm x 68 mm 74 mm x 68 mm 75 2 mm x 76 mm 2 68 in x 2 68 in 2 91 in x 2 68 in 2 96 in x 2 99 in Piston displacement 494 mL 30 1 cu in 585 mL 675 mL 41 19 cu in 35 6 cu in Direction of rotation Counterclockwise facing the PTO shaft Compression release Automatic compression release Low idle speed 1550 rpm Ignition system Transistorized fly wheel magneto RFI Per Canada and U S A requirements starting system Electric starter and or recoil starter 12 V 13 amps with regulator Spark plug CHAMPION RCJ8Y NGK BPR4ES Carburetor Float type fixed main jet de type lixedimaln jot IWD arrel Fuel pump Diaphragm type pulse pump Air cleaner Dual stage element dry type Flyweight all speed governor Lubrication system Pressure feed by positive displacement pump Oil filter Cartridge type full flow filter Oil pressure switch ON OFF switch Option Oil capacity when 19L a is completely 1 8 L 1 9 US qt 2 0 US at Cooling system Forced air cooling
83. head fins 1 Tighten nut and screws Change engine oil Clean and re gap spark plugs Change air cleaner paper element 1 Check and adjust valve clearance Clean and lap valve seating surface Clean combustion chamber 1 Service more frequently under dusty conditions A These items must be performed with the proper tools See your authorized Kawasaki Engine Dealer for service unless you have the proper equipment and mechanical proficiency 1 8 GENERAL INFORMATION Periodic Maintenance Chart FH601V FH641V FH680V FH721V OPERATION INTERVAL Every Every Every Every Every 200 hr 300 hr Check or clean air intake screen Check and add engine oil Check for fuel and oil leakage Check for loose or lost nut and screw Check battery electrolyte level Clean air cleaner foam element 1 Clean air cleaner paper element 1 Clean dust and dirt from cylinder and cylinder head fins 1 Tighten nut and screws Change engine oil Clean and re gap spark plugs Check and clean oil cooler fins FH721V model Change Oil filter Change air cleaner paper element 1 Check and adjust valve clearance Clean and lap valve seating surface Clean combustion chamber 1 Service more frequently under dusty conditions These items must be performed with the proper tools See your authorized Kawasaki Engine Dealer for service unless you
84. hes several thousand volts the spark plug SP gap is ionized and ignition occurs The placement of the trigger sensor internal to the ignition insures constant timing over speed and temperature and prevents counterclockwise operation The diode D1 in the ignition shut off circuit blocks inadvertent application of battery voltage pro tecting the internal components of the ignition With the stop switch SW in the closed position primary voltage is routed to ground preventing ignition operation ELECTRICAL SYSTEM 7 19 Ignition System Ignition Coil Removal e Remove Fan Housing see Flywheel Stator Coil Removal Spark Plug Cap A Stop Switch Lead Connector B Bolts C Ignition Coil D Ignition Coil Installation e Install ignition coil on crankcase so that the stop switch lead connector B face the screen and tighten bolt 1 first then tighten bolt 2 While tightening bolts adjust the air gap A between the three legs of ignition coil and the two pole plates of magnet to the specified gap value as shown Ignition Coil Air Gap Standard 0 2 0 4 mm 0 008 0 016 in Torque Ignition Coil Bolts Stud Bolt 7 8 N m 0 80 kgf m 69 in Ib Ignition Coil Bolts Flanged Bolt 5 9 N m 0 6 kgf m 52 in Ib NOTE OAbove procedure must be used to insure proper coil air gap is not too large KHO7O03BS1 KHO7O04BS1 7 20 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection e R
85. iameter of the piston pin with a micrometer at several points lf the outside diameter is less than service limit replace the piston pin Piston Pin Outside Diameter Service Limit 15 96 mm 0 628 in e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge x If the inside diameter is more than the service limit re place the piston Piston Pin Hole Inside Diameter Service Limit 16 08 mm 0 633 in ENGINE TOP END 4 25 Cylinder Piston e Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge lf the inside diameter is more than the service limit re place the connecting rod Connecting Rod Small End Inside Diameter Service Limit 16 05 mm 0 632 in Piston Diameter e Measure the outside diameter A of the piston 12 5 mm 0 9 in B up from the bottom of the piston at a right angle to the direction of the piston pin hole lf the measurement is less than the service limit replace the piston Piston Diameter Model FH451V FH500V FH531V Service Limit 67 79 mm 2 669 in KEO6015BS1 FH541V FH580V FH601V FH641V FH680V FH721V 73 79 mm 2 905 in 74 99 mm 2 952 in Cylinder Inside Diameter e Clean and measure the cylinder inside diameter OUse a cylinder gauge to measure front to back and side to side a
86. ie A ai 1 13 1 2 GENERAL INFORMATION Before Servicing Before starting to service the engine carefully read the applicable section to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been in cluded wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the engine Any dirt entering the engine carburetor or other parts will work as an abrasive and shorten the life of engine For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the equipment This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a staggered sequence This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of a turn and then remove them Where there is a tight
87. immediately apply a coating of zinc oxide dissolved in wood alcohol If a cracks is present the coating will become discolored at the defective area e f a cracks is present in the cylinder head replace it e Inspect the mating surface for burrs and nicks e Clean and inspect the rocker arm where it touches the push rod and valve stem lf the contact points A are worn or damaged replace the rocker arm 4 14 ENGINE TOP END Valves Valve Clearance Inspection NOTE OValve clearance must be checked when the engine is cold at room temperature e Remove the rocker cover see Cylinder Head Removal e Place the piston at top dead center TDC of the compres sion stroke turning the crankshaft clockwise facing the fly wheel No 1 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown OCheck the intake and exhaust valves are closed com pletely if not turn the flywheel one turn 360 clockwise and face the left projection with the right leg again No 2 Cylinder OThe left projection A on the flywheel is faced with the right leg B on the 2 ignition coil C as shown Follow No 1 Cylinder alignment e Then check the valve clearance OUsing a thickness gauge A measure the valve clearance between the rocker arm B and the valve stem end x If the valve clearance is incorrect adjust it Valve Clearance when cold In
88. ined by air from the main air passage main air jet The resulting mixture flows out the end of the main nozzle into the carburetor bore where it is atomized by the high speed air flow and carried into the engine The pilot system includes the pilot jet F pilot screw G Idle mixture screw pilot air jet H pilot outlet I and the bypass holes J The pilot system meters the fuel air mix ture while the engine is idling and running under a light load Under these conditions there is very little air flow through the carburetor bore so little that it is not enough to draw fuel through the main system of the carburetor and atom ize it Instead the fuel is drawn through the pilot system since the nearly closed throttle valve K causes high speed air flow past the pilot outlet and bypass holes even at low engine speed Fuel flow in the pilot system is metered by the pilot jet Air for better atomization is admitted via the pilot air jet in the mouth of the carburetor The fuel air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet While the throt tle valve is almost closed it covers the small bypass holes Opening into the bore from the pilot system As the throttle valve begins to open it uncovers the bypass holes allow ing more fuel air mixture to flow The extra flow is needed because the engine starts to run faster as the throttle is opened The pilot sc
89. le the carburetor FUEL SYSTEM 2 25 Carburetor Carburetor Inspection A WARNING Gasoline is extremely flammable and can be explo sive under certain Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Inspect the carburetor body for damage Flange sealing surfaces should be smooth and free of burns and nicks Replace the gasket if necessary e Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly x If the valves do not move smoothly replace the carburetor body and or throttle shaft and choke shaft assembly e Check the gasket on the carburetor body lf the gasket is not in good condition replace it e Check the other parts of the carburetor for wear or dam age Replace the part if necessary e Clean and check the float level as follows CAUTION Do not push down on the float during float level checking e With the float A assembly installed onto the carburetor body B hold the carburetor upside down at eye level Gently support the float with a finger and bring it down slowly so that the float arm tab C just touches the float valve D The float lower surface E should be parallel with the carburetor body mating surfaces F lf the float position is not correct replace the float with a new one e Inspect the float v
90. letely xf the oil level is FULL range F drain the excess oil by loosening the drain plug e On and after 2002 2 product model as shown in the figure KFO5003BS1 5 8 LUBRICATION SYSTEM Engine Oil Oil Filter and Oil Cooler Oil Change e Change the oil after first 8 hours of operation Thereafter change oil every 100 hours e start and warm up the engine so the oil will drain easily Stop the engine e Place the engine on a level surface e Place a suitable container under the engine e Remove the drain plug A and drain the oil A WARNING Be careful of hot oil when drained It may be hot enough to burn you severely e Check the O ring B at the drain plug for damage Re place the O ring with a new one if it is damaged xf the oil drain plug joint is removed tighten it Torque Oil Drain Plug Joint Plastic 17 N m 1 7 kgf m 12 0 ft lb Oil Drain Plug Joint Metal 39 N m 4 0 kgf m 29 ft lb e Install the drain plug with the O ring and tighten it Torque Oil Drain Plug Plastic 6 9 N m 0 7 kgf m 61 in Ib Oil Drain Plug Metal 20 N m 2 0 kgf m 14 5 ft lb e Remove the oil filler cap and pour in the specified type and amount of oil Engine Oil Grade SF SG SH or SJ Class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When filter is not removed 1 5 L 1 6 US qt When filter is removed 1 7 L 1 8 US qt except
91. limit replace them Brush Length Service Limit 6 4 mm 0 25 in Brush Spring Inspection e Inspect the brush springs for pitting cracks rusting and burrs Replace the spring if necessary e Inspect the springs for weakened conditions and distor tion Replace the springs if necessary lf the brush springs are able to press the brushes firmly into place they may be considered serviceable If they cannot replace them Armature Inspection e Inspect the surface of the commutator A x lf it is scratched or dirty polish it with a piece of very fine emery cloth B and clean out the grooves GP110610S1 ELECTRICAL SYSTEM 7 23 Starter System e Measure the depth of the grooves between the commu tator segments lf the grooves are shallower than the specified limit re place the armature with a new one If the grooves are only dirty clean them carefully Commutator Groove Depth Limit Less than 0 9 mm 0 035 in A Bad B Segment C Good D 0 9 mm 0 035 in limit E Mica e Measure the diameter A of the commutator B at several points lf the diameter is less than the service limit replace the armature with a new one Commutator Outside Diameter Service Limit 31 1 mm 1 225 in e Support the armature in an alignment jig at each end of the shaft as shown Position a dial indicator perpendicular to the commutator e Rotate the armature slowly and read the commut
92. llation cccccecceceee cee e cece cece eeeeeeeeenee sees eeeeeeeeseeseeeseeeseeeeeeeeeeees 4 28 Muffler Exhaust Pipe Removal oooooccccccccccciccciccciconococininononocnnnnnnnnnn nr rn rr rn rr 4 28 Muffler Exhaust Pipe Installation ccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 4 28 INSPECUON Sees NA Moraes a se ces 4 28 4 2 ENGINE TOP END Exploded View ENGINE TOP END 4 3 Exploded View FH451V FH500V FH531V T1 5 9 N m 0 60 kgf m 52 in lb T2 5 9 N m 0 60 kgf m 52 in lb T3 25 N m 2 6 kgf m 19 5 ftlb T4 28 N m 2 8 kgf m 20 ft lb T5 22 N m 2 2 kgfm 16 ft lb FH541V FH580V T1 9 8 N m 1 0 kgf m 87 in Ib T2 5 9 N m 0 60 kgf m 52 in lb T3 25 N m 2 6 kgf m 19 5 ft lb T4 28 N m 2 8 kgf m 20 ft lb T5 22 N m 2 2 kgfm 16 ft lb FH601V FH641V FH680V FH721V T1 21 N m 2 1 kgfm 15 ftlb T2 5 9 N m 0 60 kgf m 52 in lb T3 25 N m 2 6 kgf m 19 5 ftlb T4 28 N m 2 8 kgf m 20 ft lb T5 22 N m 2 25 kgf m 16 ft lb O Apply engine oil G Apply grease S Follow the specific tightening sequence 4 4 ENGINE TOP END Exploded View ENGINE TOP END 4 5 Exploded View FH451V FH500V FH531V T2 15 N m 1 5 kgf m 11 0 ft lb FH541V FH580V T2 15 N m 1 5 kgfm 11 0 ft lb FH601V FH641V FH680V FH721V T2 15 N m 1 5 kgfm 11 0 ft lb 4 6 ENGINE TOP END
93. lts A and remove the crankcase cover B from the crankcase OThere are two knock pins on the crankcase mating sur face A wooden or plastic mallet may be used to gently tap loose the crankcase cover Crankcase Cover Installation e Chip off the old gasket from the mating surfaces of the crankcase and cover e Using compressed air blow out the oil passage in the crankcase cover e With a high flash point solvent clean off the mating sur faces of the crankcase and cover and wipe dry A WARNING Clean the crankcase and cover in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or explosion could result e Be sure to replace any oil seal removed with a new one Olnstall the oil seal so that the marks A face out OPack some amount of a high temperature grease B into the space between the seal lip C and dust lip D OPress in the new oil seal using a press or suitable tools until it is flush or below the flange surface E ODo not damage the seal lips F PTO Side 1 2 mm 0 04 0 08 in Flywheel Side 0 1 mm 0 0 04 in e When replacing the oil seal A of the governor shaft note the following Olnstall the oil seal into the crankcase cover B after the governor shaft is inserted in the cover and so that the marks C face out
94. lugs The system consists of the following Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch Co Core Lamination D1 Diode L1 Primary Coil L2 Secondary Coil Q1 Transistor B Base C Collector E Emitter R1 Control Resistor TS1 Trigger Sensor SP Spark Plug M SW Stop Switch Flywheel E Magnet F a SR M CW Rotation N North Pole S South Pole Ignition Theory of Operation Mounted to the periphery of a flywheel are a pair of magnetic poles south leading in clockwise rotation generated by a permanent magnet By rotating the flywheel magnetic poles clockwise past the ignition module on a laminated core group a voltage is generated in the primary winding L1 This generates a small bias current to flow through the control resistor R1 to the base of Q1 This base drive causes the transistor to conduct turns on completing the primary circuit Current flows from the high side of the primary winding through the transistor collector to emitter to ground The trigger sensor TS1 senses the optimum time peak current to remove the base drive from the transistor Q1 This abrupt turning off of the transistor causes an interruption in current flow which allows its associated flux collapse and several hundred volts is induced through the primary winding L1 inducing a very large voltage in the secondary winding L2 When the secondary voltage reac
95. mshaft journal diameter PTO side 15 985 mm 0 6293 in Flywheel side 15 985 mm 0 6293 in Camshaft bearing inside diameter Crankcase 16 136 mm E 0 6352 in Crankcase cover 16 136 mm 0 6352 in Crankshaft Connecting Rod Connecting rod bend 0 15 100 mm E E 0 006 3 94 in Connecting rod twist 0 15 100 mm 0 006 3 94 in Connecting rod big end width 18 80 mm 19 90 mm 0 74 in 0 783 in Crankpin width 39 50 mm 43 1 mm 1 56 in 1 697 in Connecting rod big end inside diameter 35 055 mm 38 055 mm 1 3801 in 1 498 in Crankpin Outside diameter 34 94 mm 37 94 mm Crankshaft runout 0 05 mm 1 494 in 0 002 in TIR Crankshaft journal diameter PTO side 34 90 mm 39 896 mm 1 374 in 1 571 in Flywheel side 34 93 mm 39 896 mm 1 375 in 1 571 in Crankcase PTO shaft bearing inside diameter 35 15 mm 40 15 mm Crankcase Cover 1 384 in 1 581 in Crankshaft journal bearing inside diameter 35 15 mm 40 15 mm Crankcase 1 384 in 1 581 in Sealant Kawasaki Bond Silicone Sealant 56019 120 CAMSHAFT CRANKSHAFT 6 5 Crankcase Crankcase Cover Removal e Set the engine on a clean surface while parts are being removed e Drain the oil see Lubrication System chapter e Remove Exhaust Pipe and Muffler see Engine Top End chapter Control Panel see Fuel System chapter Governor Arm see Fuel System chapter e Unscrew the mounting bo
96. n A so that the projections B fit into the recess C of the fan e Install the pulley A so that the tabs of the plate fit into holes B in the pulley e Put the washer C as shown e Tighten the flywheel bolt D Torque Flywheel Bolt 56 N m 5 7 kgf m 41 ft lb e Install the fan housing and tighten the bolts Torque Fan Housing Bolts 5 9 N m 0 6 kgf m 52 in Ib e Install Recoil Starter see Recoil Starter Installation e For Electric Starter model note the following procedure Olnstall the bracket A so that the notch B inserts into the slot in the flywheel OPut the washer C OTighten the flywheel bolt D Torque Flywheel Bolt 56 N m 5 7 kgf m 41 ft lb Olnstall the fan housing and tighten the bolts Torque Fan Housing Bolts 5 9 N m 0 6 kgf m 52 in Ib ELECTRICAL SYSTEM 7 15 Charging System Olnstall Spacer A Screen B OPosition three sets C of screen notches around the fan blades OTighten the screen bolts D Torque Screen Bolts 5 9 N m 0 6 kgf m 52 in Ib Charging System Operational Inspection e Check battery condition NOTE OAlways check battery condition before condemning other parts of the charging system The battery must be fully charged in order to conduct accurate charging system tests e Warm up the engine to bring the components up to their normal operating temperatures e Measure regulated output voltage at various engine speeds OConnect a voltmet
97. n Jet L 9 Throttle Shaft 23 Main Jet R 10 Choke Valve 24 Slow Jet 11 Choke Shaft 25 Drain Screw 12 Seal 26 Spring 13 Float Valve 27 Gasket 14 Pin 28 Solenoid Valve FUEL SYSTEM 2 23 Carburetor e Replace the pilot screw A in accordance with the follow ing procedure if necessary ORemove the pilot screw plug B material Stainless steel as follows Punch a hole in the plug and pry it out with an awl or other suitable tool OTurn in the pilot screw and count the number of turns until it seats fully but not tightly and then remove the screw This is to set the screw to its original position when as sembling OTurn in the new pilot screw A fully but not tightly and then back it out the same number of turns counted during disassembly Olnstall a new pilot screw plug B in the pilot screw hole by pressing with the rod C and apply a small amount of a bonding agent D to the circumference of the plug to fix the plug e Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side and apply a small amount of a bonding agent to the valve screw threads CAUTION Do not apply too much bonding agent to the valve screws itself may be fixed e Drive the float pin so that it s big diameter side faces the throttle shaft lever side e The fuel inlet valve seat is pressed into the carburetor body and is not replacable e Assemble carburetor parts which r
98. n Nozzle Main Air Jet Pilot Air Jet Drain Screw Carburetor 2 0 0 2 18 in lb Earth lead screw Carburetor Side Fuel Shut Off Solenoid Valve Carburetor 20 2 0 15 Float Bowl Mounting Screw Carburetor 3 9 0 4 35 in lb Governor Arm Clamp Nut 7 8 0 8 69 in lb Governor Shaft Plate Screws 2 0 0 2 18 in lb Intake Pipe Mounting Bolts and Nuts 5 9 0 6 52 in lb Intake Manifold Mounting Bolts 5 9 0 6 52 in lb Cleaner Body Mounting Screws Control Panel Mounting Bolts 5 9 0 6 52 in lb Cooling System Engine shroud Bolt M8 15 1 5 11 Engine shroud Bolts M6 5 9 0 6 52 in lb Plug Bolt Engine shroud Plug Screw Engine shroud 3 4 0 35 30 in lb Engine Top End Cylinder Head Bolts 25 2 6 19 S Valve Clearance Lock Screws 6 9 0 7 61 in lb Connecting Rod Big End Cap Bolts 21 2 1 15 O Rocker Arm Bolts 28 2 8 20 Rocker Cover Mounting Bolts 5 9 0 6 52 in lb Exhaust Pipe Flange Nuts 15 1 5 11 Spark Plugs 22 2 2 16 Lubrication System Engine Drain Plugs Plastic 6 9 0 7 61 in lb Engine Drain Plug Metal 20 2 0 14 5 Engine Drain Plug Joint Plastic 17 1 7 12 Engine Drain Plug Joint Metal 39 4 0 29 1 12 GENERAL INFORMATION Torque and Locking Agent FH601V FH641V FH680V FH721V Fasteners Torque Remarks N m kgf m ft Ib Oil Pressure Switch 9 8 1 0 87 in lb SS Oil Passage Plug 3 9 0 40 35 in lb Oil Pump Cover Plate Mounting Bolts 5 9 0 6 52 in lb Oil Filter in the text Oil Cooler Mounting Joi
99. n the figure fl Governor Arm Installation e Install the governor arm A onto the governor shaft B temporarily e Be sure the link spring C around the throttle link rod D is inplace and that it pulls the governor arm and throttle lever E each other e Loosen the clamp nut F on the governor arm enough to move the governor shaft e Turn the top end of the governor arm counterclockwise to fully open the carburetor G throttle valve and hold it there e Turn the governor shaft counterclockwise fully turn the shaft to end of its travel e Tighten the clamp nut Torque Governor Arm Clamp Nut 7 8 N m 0 80 kgf m 69 in Ib e Be sure the governor shaft extend from the governor arm is approximately 7 mm 0 3 in H as shown e Install the control panel assembly and connect the gov ernor arm with the governor spring Governor Assembly Removal e Remove the crankcase cover see Camshaft Crankshaft chapter e Remove the push rod see Engine Top End chapter e Upside down the engine e Remove the camshaft A e Remove Washer A Snap Ring B Sleeve C Governor Plate D Snap Ring B Steel balls E Ball Guide F Ball Plate G FUEL SYSTEM 2 13 Governor Link Mechanism Governor Assembly Installation e Fit the snap rings A into the grooves securely e Spin the governor plate by hand and check that the steel balls and governor plate operate freely Governor Assembly
100. nce adjusting nuts e Check and adjust the valve clearance 1 CYLINDER 2 CYLINDER 4 12 ENGINE TOP END Cylinder Head Push Rod Inspection e Place the push rod in V blocks that are as far apart as pos sible and set a dial gauge on the rod at a point halfway between the blocks Turn the rod to measure the runout The difference between highest and the lowest dial read ings is the amount of runout If the runout exceeds the service limit replace the rod Rocker Arm Push Rod Runout Service Limit 0 5 mm 0 02 in Valve Mechanism Removal Installation e Remove the cylinder head assembly see Cylinder Head Assembly Removal NOTE OWhen removing the valve mechanism parts note their position so that they may be reinstalled in their original position during assembly e Remove Valve Clearance Adjusting Nuts A Rocker Arms B e Support the valve head in the combustion chamber with a suitable block e To remove the collets A push down the valve retainer B with thumbs and remove the Collets e Remove the spring C and valve D e Remove the stem seals A NOTE Olt is not necessary to remove the stem seal unless it is being replaced OValve guide B is not replaceable do no remove it e Valve Installation OApply engine oil to the valve stem to avoid damaging the stem seal OCheck to see that the valve moves smoothly up and down in the guide OCheck the v
101. noncnnnons 4 12 Cleaning ANG INSPOCHON std tt 4 13 Va VS at AA A A aaa 4 14 Valve Clearance Inspection coocccccconcconccnnnnoncnnnnnnnnnnnnnnnnnnnnnnonnnonnnnnnnnononnnnnnnonnnnnnnnss 4 14 Valve Clearance AdjUStment c ccccecccceeeeeeeneeeeeeeceeeeeeenseeeaceceeseeeeesenesseeeneeeeseetenseenenee 4 14 Valve Seat Inspection miii dlls 4 15 Valve Seat Repair issis ei ieia dad Ed lod ad 4 15 Valve Head Thickness ooooooccconccnccnnccnncnnnnnonnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneninnninoss 4 18 Valve Stem RUNOUt sissie epen e eaei enere aapa nono nnnnnnnonnnonnnonnnonnnnnnnnnnnnnnnnnennnonos 4 18 Valve Stem Diameteren ienas ia 4 18 Valve Guide Inside Diameter ooooccccccccncconcconnnonononnnnnnnnononnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnos 4 18 Valve Spring Inspection Arca n a a e e a a a o 4 19 Cylinder A EIo a EEE ad T E E E E T EN 4 20 Piston REMOVALS oes reren a e aea E a a a e tT ae a a EEA 4 20 Piston RAIS II ATION EEEE E E A oAEin dio Ron daban radiaci n 4 21 Piston Cylinder SelzUrO suis add 4 23 O O E EASI SaS 4 23 Piston Ring and Ring Groove Wear coincidir aio 4 23 PRISTON Ring End Gap ile ria ias 4 24 Piston Pin Piston Pin Hole and Connecting Rod Wear c cccceeeeeeeeeeeeeeeeeeeeeeeeees 4 24 PISTON Dia Meter iii asedio 4 25 Cylinder Inside Dial cli 4 25 Cylinder Boring and HONING iesise eiee sue iecdenasebent eeiid ae ekte een vita 4 26 Muffler Exhaust Pipe Insta
102. nt FH721V 44 4 5 33 Camshaft Crankshaft Crankcase Cover Bolts 25 2 6 19 0 S Breather Chamber Cover Bolts 5 9 0 6 52 in lb Electrical System Stator Coil Screws 3 4 0 35 30 in lb Flywheel Bolt 56 5 7 41 Fan Housing Bolts 5 9 0 6 52 in lb Screen Bolts 5 9 0 6 52 in lb Regulator Screws 3 4 0 35 30 in lb Ignition Coil Bolts Studs 7 8 0 8 69 in lb Ignition Coil Bolts Bolts 5 9 0 6 52 in lb Starter Motor Mounting Bolts 15 1 5 11 Recoil Starter Mounting Nuts Recoil Starter Retainer Screw Spark Plugs 22 2 2 16 The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners Threads dia Torque 17 in lb 30 in lb 52 in lb 11 GENERAL INFORMATION 1 13 Special Tools Compression Gauge 57001 221 Valve Seat Cutter Holder 6 57001 1360 Piston Ring Pliers 57001 115 Valve Seat Cutter 45 435 57001 1116 Bz Do Piston Ring Compressor Grip 57001 1095 Valve Seat Cutter 32 433 57001 1199 Piston Ring Compressor Belt 67 679 57001 1097 Valve Seat Cutter Holder Bar 57001 1128 Compression Gauge Adapter M14 x 1 25 57001 1159
103. ocker chamber from the crankcase and secondly separated from the gases in the breather chamber and then returned back to the crankcase cover Fresh Air Blow by Gas Oil CAMSHAFT CRANKSHAFT 6 9 Breather Breather Element Removal FH451V 500V 531V 541V 580V e Remove the bolts A and breather chamber cover B e Remove the element A e Check to see that the plate B is in place under the ele ment A Breather Element Installation FH451V 500V 531V 541V 580V e Apply sealant A to the mating surface of the crankcase Sealant Kawasaki Bond Silicone Sealant 56019 120 e Install a new gasket and the breather chamber cover and tighten the bolts Torque Breather Chamber Cover Bolts 5 9 N m 0 6 kgf m 52 in lb PPT lela 4 Pe Breather Valve Inspection FH601V 641V 680V 721V e Unscrew the mounting screw A and remove the plate B and the breather valve C e Inspect the breather valve C for breakage hair crack or distortion replace it if necessary e Inspect the plate B for damage or rough contact surface replace it if necessary e Inspect the valve seating surface The surface should be free of nicks or burrs e Be sure the drain hole on the breather chamber does not accumulate with slugs before installing the breather valve e Align center of the valve seat with center of the breather valve and the plate then tighten the mounting scr
104. odel Plug Gap Standard FH451V 500V 531V 541V 580V 0 75 mm 0 030 in FH601V 641V 680V 721V 0 75 mm 0 030 in ELECTRICAL SYSTEM 7 21 Starter System Starter Motor Removal e Remove the mounting bolts A and pull the starter motor B from the engine Starter Motor Installation e Clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts Torque starter Motor Mounting Bolts 15 N m 1 5 kgf m 11 0 ft lb Starter Motor Disassembly e Remove Through Bolts and Nuts A Brush Plate B York C Cap D e While the collar A is pushing remove the snap ring B e Remove Spring A Pinion Assembly B Washer C Bracket D Armature E 7 22 ELECTRICAL SYSTEM Starter System Starter Motor Assembly e Assembly is the reverse of disassembly e Apply a small amount of grease A to the armature shaft e Do not reuse the snap ring B Replace it with a new one e Check the cap and replace it with a new one if damaged e Fit the projection A on the bracket into the notch B in the yoke e Press the springs and holding the brush leads with suit able clips e Put the washer C among the brushes e Fit the projection D on the brush plate into the notch E in the yoke Starter Motor Brush Inspection e Measure the overall length of each brush A lf the brushes are shorter than the service
105. old gasket with new ones e Clean the mating surfaces of the cylinders and intake manifolds and fit a new gaskets A direction as shown B Distance FH451V 500V 531V 6 mm 0 24 in B Distance FH541V 580V 0 mm 0 in B Distance FH601V 641V 680V 721V 12 mm 0 47 in e Clean the mating surfaces of the carburetor and intake manifold and install the new gaskets A and insulator B sequence as shown e Install the intake manifold e Tighten the mounting bolts Torque Intake Manifold Mounting Bolts 5 9 N m 0 6 kgf m 52 in Ib e Install and tighten the band A around the manifold B and wire lead C and or harness D OPosition the wire and or harness on top of the manifold as shown e Cut excess the band off e Install the other removed parts 2 28 FUEL SYSTEM Intake Manifold Intake Manifold Inspection e Inspect the intake manifold for cracks or porous casting e Cracks not visible to the eye may be detected by using a metal crack detection system Visual color check com monly found at automotive parts store lf a crack is present in the intake manifold replace it e Inspect the gasket surfaces for burns and nicks FUEL SYSTEM 2 29 Fuel Pump Fuel Filter The fuel pump cannot be disassembled if any damage for the pump is noticed replace it with a new one Fuel Pump Inspection e Check the vent hole A and filter B for plugging or clog ging lf v
106. oning If the damage is severe the both cylinders must be bored oversize and oversized pistons installed Piston Cleaning e Remove the piston and piston rings see Piston Re moval CAUTION Never clean the piston head with the engine assem bled Carbon particles will fall between the piston and cylinder and damage the crankshaft bearings e Scrape the carbon off A the piston head e Use the scraping tools carefully Do not gouge the piston head To avoid gouging use scrapers that are made of a material that will not cause damage e Clean the piston ring grooves A with a broken piston ring or other suitable tools CAUTION Be careful not to widen the ring grooves Damaged ring grooves will require piston replacement Piston Ring and Ring Groove Wear e Clean the piston see Piston Cleaning e Visually inspect the piston rings and ring grooves x lf the piston rings are worn unevenly or damaged replace them If the ring grooves are worn unevenly or damaged re place both the piston and piston rings e Check ring grooves for wear by inserting a new ring in the proper groove at several points around the piston e Measure the clearance between the top and second rings and their grooves using a thickness gauge A lf the piston ring groove clearance is greater than the specified value replace the piston Piston Ring Groove Clearance FH451V FH500V FH541V FH601V FH641V FH531V FH580V
107. ore first the inside diameters should be shown in the table Final Boring Inside Diameter Fine Boring Inside Diameter Oversize FH451V 500V FH541V FH601V 641V 531V FH580V 680V 721V 68 46 68 48 74 46 74 48 75 65 75 68 mm mm mm 0 50 mm 2 695 2 696 2 931 2 932 2 978 2 979 in in in Final Inside Diameter Final Inside Diameter Oversize FH451V 500V FH541V FH601V 641V 531V FH580V 680V 721V 68 48 68 50 74 48 74 50 75 68 75 70 mm mm mm 0 50 mm 2 696 2 697 2 932 2 933 2 979 2 980 in in in Change to a honing stone for finishing the final inside di ameter should be as shown in the table Be sure the correct stone is used and the stone is not worn e Clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket e Anchor the cylinder block on the drill press table before honing e Align the center of the cylinder bore to the press center Set the press to operate from 200 to 250 rpm e Connect the drive shaft to the hone and set the stop on the drill press so the hone can only extend 20 to 25 mm 3 4 to 1 0 in above the top or below the bottom of the cylinder liner e Rotate the adjusting nut knob on the hone until the stones contact snugly against the cylinder wall at the narrowest point Do not Force e Turn the stone by hand If you cannot turn it the stone is
108. ount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Red Wire Strands Yellow Red Y hu Yellow Red 6B020601w1 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed There replacement parts will be damaged or lose their original function once removed 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or dete riorated performance replace the damaged parts 1 4 GENERAL INFORMATION Model Identification Electric starter Model FH500V Recoil starter Model FH500V Cylinder Number Designation No 1 Cylinder is the left hand cylinder viewed
109. own for disassembly and as sembly e There are several passage plugs Ball plugs in the car buretor body Do not remove e Before disassembly mark the out side of choke valve and throttle valves for assembling them e Replace the pilot screw in accordance with the following procedure if necessary OCarefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later ORemove the limiter Be careful not to turn pilot screw at this point OTurn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage Record the number of turns needed to closed the screw OTurn out the pilot screw to replace it with anew one Olnstall the new pilot screw until the screw is gently seated Then open the screw the same number of turns as recorded prior to removal OAlign the limiter with the mark on the carburetor body to install taking care not to turn the pilot screw e Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side e Drive the float pin so that it s big diameter side faces the engine flange side e The fuel inlet valve seat is pressed into the carburetor body and is not replaceable e Assemble carburetor parts which recommended tighten ing torque see Exploded View 1 Limiter 21 Float Bowl 2 Pilot Screw 22 Gasket 3 Spring 23 Bolt Other than 4 Low Idle
110. rew controls the amount of fuel air mixture allowed through the pilot outlet but does not me ter the bypass holes A moderate amount of air comes in around the throttle valve at an idle so adjusting the pilot screw changes the fuel air ratio Turning the pilot screw Idle mixture screw out Counterclockwise enrichens the mixture turning it in clockwise leans the mixture Main Fuel Flow gt Pilot Fuel Flow gt Main System Fuel and Air Supply Air Cleaner Fuel Main Engin Tank Jet haa Float Main Air Carburetor Chamber Passage Main Jet Pilot System Fuel and Air Suppiy Fuei Tank Float Chamber Main Jet FUEL SYSTEM 2 15 Carburetor Fuel Shut Off Solenoid Valve Electric Starter Model To avoid after firing when stopping the engine a solenoid actuated fuel shut off solenoid valve A is installed in the carburetor bowl The valve shuts off the fuel supply to the valve seat B simultaneously when the switch key turned to the OFF position The valve opens automatically when the switch key is turned to the Run position Low Idle Speed Adjustment e Disconnect all possible external loads from the engine e Start the engine and warm it up thoroughly A WARNING Always keep your hands clear of the moving parts e Move the throttle lever on dash to the idle position and hold the throttle lever on the carburetor in clo
111. rush plate assembly Positive Brush to Ground Resistance 2 e Set the hand tester to the R x 1 Q range and measure the resistance between the negative brush es A and brush plate B x lf the meter does not read close to 0 Q the brush plate is faulty Replace the brush plate assembly Negative Brush to Ground Resistance Close to 0 Q Pinion Clutch Inspection e Turn the pinion gear by hand The pinion gear should turn clockwise freely xlIf the pinion clutch does not operate as it should or if it makes noise replace the pinion clutch Recoil Starter Removal e Remove Recoil Starter Mounting Nuts A Recoil Starter B Recoil Starter Installation e Install the recoil starter and tighten the mounting nuts Torque Recoil Starter Mounting Nuts 5 9 N m 0 6 kgf m 52 in Ib ELECTRICAL SYSTEM 7 25 Starter System Recoil Starter Disassembly a e Remove the recoil starter see Recoil Starter Removal e Pull the handle A out 30 cm 1 ft and clamp the rope B with the clip C so it can not wind back onto the reel D e Pry the knot E out of the handle and untie it e Remove the handle from the rope A WARNING Wear gloves to avoid injury for the remaining steps e While carefully holding the reel A and case B remove the clip e Unwind the spring tension slowly NOTE ODo not wedge the rope between the reel and case e Remove Screw A Washer B Retainer C
112. s D on the cassette fit in the openings in the reel e Lightly grease the shaft A e Put the reel into the case with the round peg B aligned with the spring inner tongue C e Turn the reel clockwise until you feel the hang hook on the catch e Install Return Springs A and Pawls B Washer C and Center Spring D e Lightly grease the center spring ELECTRICAL SYSTEM 7 27 Starter System e Install Retainer A Washer B Screw C Torque Recoil Starter Retainer Screw 7 8 N m 0 80 kgf m 69 in Ib e Turn the reel two turns counterclockwise to preload the recoil spring e While holding the reel to keep it from unwinding feed the end of the rope through the hole in the case e Clip the rope as shown to hold it e Install the handle A and secure it with a knot B e Remove the clip C to release the rope TROUBLESHOOTING 8 1 Troubleshooting Table of Contents Engine Troubleshooting Guide iii 8 2 Starter Motor Troubleshooting Guide sec iciesccodoinconcioier iii 8 6 8 2 TROUBLESHOOTING Engine Troubleshooting Guide If the engine malfunctions check if the way the engine is used is correct If engine malfunctions even if engine is used correctly systematically carry out troubleshooting starting with simple points This chart describes typical troubleshooting procedures Do not unnecessarily disassemble carburetor magneto or engine unless it
113. sed position turn the governor arm clockwise all the way and adjust the low idle speed screw A until the engine idles at spec ified speed e For FH601V 641V 680V 721V model adjust the low idle speed screw C with Phillips Screwdriver D until the en gine idles at specified speed Low Idle Speed Carburetor idle rpm 1450 rpm e Release the throttle lever and adjust the low idle speed set screw A on the control plate to obtain the specified governed low idle speed Low Idle Speed Governed idle rpm 1550 rpm High Idle Speed Adjustment NOTE OHigh idle speed adjustment should be made after the low idle speed adjustment is performed CAUTION Do not adjust high idle speed with the air cleaner removed e start and warm up the engine thoroughly KC05043BS1 2 16 FUEL SYSTEM Carburetor A WARNING Always keep your hands clear of the moving parts e Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia pin or bolt A e Loosen two M6 control panel mounting bolts B enough to move the control panel assembly e Carefully move the control panel assembly right side C up or down to obtain the specified high idle speed High Idle Speed 3600 rpm e Tighten the M6 Mounting bolts Torque Control Panel Mounting Bolts 5 9 N m 0 60 kgf m 52 in Ib e Remove the 6 mm dia
114. see Fuel System chap ter e Remove Spring A ODo not remove the ACR automatic compression release weight B Camshaft Assembly e Install the governor assembly see Fuel System chapter e After assembling the camshaft check the following items OThe governor plate A must move freely OWhile shaking the camshaft ACR weight B swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or an evidence of improper tooth contact k Replace the shaft if necessary e Check the top of the cam lobes B for wear burrs or un even contact Replace the shaft if necessary Camshaft Bearing Journal Wear e Measure the height of each cam lobe If the cam height is less than the service limit for either lobe replace the camshaft Cam Lobe Height Model Service Limit FH451V 500V 531V IN 29 131 mm 1 1469 in EX 29 131 mm 1 1469 in FH541V FH580V IN 29 131 mm 1 1469 in EX 29 131 mm 1 1469 in FH601V 641V 680V 721V IN 29 621 mm 1 166 in EX 29 621 mm 1 166 in 6 12 CAMSHAFT CRANKSHAFT Camshaft Tappet e Measure both camshaft journals at several points around the journal circumference xf the journal diameter is less than the service limit re place the camshaft PTO Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in Flywheel Side Camshaft Journal Diameter Service Limit 15 985 mm 0 6293 in e Me
115. side diameter out round 16 05 mm 0 632 in 68 10 mm 2 681 in 68 60 mm 2 701 in 0 056 mm 0 0022 in 74 10 mm 2 917 in 74 60 mm 2 937 in lt lt ENGINE TOP END 4 7 Specifications Item Service Limit Cylinder Head Cylinder compression MIN 390 kPa 57 psi MIN Cylinder head warp 0 05 mm 0 002 in Valves Valve head thickness Intake Exhaust 0 35 mm 0 014 in Valve stem runout Intake Exhaust 0 05 mm 0 002 in Valve stem diameter Intake 5 95 mm 0 0234 in Exhaust 5 93 mm 0 0233 in Valve clearance Standard Intake Exhaust 0 10 0 15 mm 0 004 0 006 in Valve seating surface angle Standard Intake Exhaust 45 Valve seating surface width Standard Intake 0 8 1 4 mm 0 03 0 06 in Exhaust 1 1 1 6 mm 0 04 0 06 in Valve guide inside diameter Intake Exhaust 6 08 mm 0 239 in Valve spring free length Intake Exhaust 31 0 mm 1 22 in Rocker arm push rod runout Intake Exhaust 0 5 mm 0 02 in Cylinder Piston Piston diameter 74 99 mm 2 952 in Piston ring groove clearance Top 0 18 mm 0 007 in Second 0 16 mm 0 006 in Piston ring thickness Top Second 1 40 mm 0 055 in Piston ring end gap Top 0 65 mm 0 026 in Second 0 78 mm 0 0371 in Oil 1 05 mm 0 041 in Piston pin outside diameter 15 96 mm 0 628 in Piston pin hole inside diameter 16 08 mm 0 633 in Connecting rod small end inside diameter 16 05 mm 0 632 in Cylinder inside diameter S
116. ston rings Stuck piston rings Worn cyl bore lnsufficient cyl head tightening Faulty contact valve seat Plunge up by valve Warped cyl head Broken valve spring Stuck valve of Burned head gasket Replace H Clean or replace Bore or replace Retighten Lap Adjust valve clearance Replace Clean or replace H Replace H Remove the plug and turn the TROUBLESHOOTING 8 3 Engine Troubleshooting Guide Engine loss power Is engine overheated YES gt O Crankcase low on oil Adjust level or add Too much oil in crankcase Adjust level NO O Excessive engine load Decrease load Carb not properly adjusted Adjust Carbon deposit in combustion Clean chamber O Clogging of cooling system E Clean Damaged cooling fan Replase ls the ignition spark NO gt Wrong spark plug T Replace normal Faulty ignition coil Replace YES Incorrect air gap Adjust gap Y ls lubricationg condition NO gt O Too much or too little oil in Correct normal crankcase YES O Excessively contaminated lub Change ricating oil O Defective oil filter Replace O Faulty relief valve Replace Faulty oil pump Replace Clogging oil system Clean ls unusual smoke emitted YES gt O Plugged air cleaner Clean out of mu
117. t the points shown figure lf any of the cylinder inside diameter measurements is greater than the service limit the cylinder must be bored to the next oversize and then honed see Cylinder Boring and Honing Cylinder Inside Diameter Model Item Standard Serv Ice Limit FH451V Standard 67 98 68 00 mm 68 10 mm FH500V Cylinder 2 676 2 677 in 2 681 in FH531V 0 5 mm Oversize 68 48 68 50 mm 68 60 mm Cylinder 2 696 2 697 in 2 701 in Standard 73 98 74 00 mm 74 10 mm FH541V Cylinder 2 912 2 913 in 2 917 in FH580V 0 5 mm Oversize 74 48 74 50 mm 74 60 mm Cylinder 2 932 2 933 in 2 937 in FH601V Standard 75 18 75 20 mm 75 28 mm FH641V Cylinder 2 964 in FH680V 0 5 mm Oversize 75 68 75 70 mm 75 78 mm FH721V Cylinder 2 979 2 980 in 2 983 in Cylinder Inside Diameter Out Round Standard 0 01 mm 0 004 in Service Limit 0 056 mm 0 0022 in 4 26 ENGINE TOP END Cylinder Piston Cylinder Boring and Honing Always resize to exactly 0 5 mm 0 02 in over the stan dard bore size If this is done accurately the stock oversize rings and pis ton will fit perfectly and proper clearance will be maintained Resizing the cylinder bore can be done by reliable repair shop or by using a drill press and honing tool Use the stone recommended by the hone manufactures to produce correct cylinder wall finish Machine b
118. take Exhaust 0 10 0 15 mm 0 004 0 006 in Valve Clearance Adjustment e Since valve repairs change the valve clearance adjust the valve clearance to the specification e Assemble the cylinder head and install the cylinder head assembly on the block see Cylinder Head Installation e Turn the crankshaft proper direction until the piston is at TDC of the compression stroke described above e Loosen the lock screws A and valve clearance adjusting nuts B Insert a 0 10 mm 0 04 in thiclntrakness gauge C be tween the rocker arm and valve stem and tighten the adjusting nut until the thickness gauge begin to bind be tween the rocker arm and valve stem end Use a sweep ing motion with the thickness gauge while making this ad justment Valve Clearance when cold Intake Exhaust 0 10 0 15 mm 0 004 0 006 in e Holding the adjusting Nut with a spanner tighten the lock screw to the specified torque Torque Valve Clearance Lock screws 6 9 N m 0 70 kgf m 61 in Ib e Do not overtighten e Remeasure any clearance that was adjusted Readjust if necessary KEO5014BS1 KEO5015BS1 ENGINE TOP END 4 15 Valves Valve Seat Inspection e Remove the valve see Valve Mechanism Removal In stallation e Inspect the valve seats for damage If the seats are warped or distorted beyond recondition ing replace the cylinder head e Pitted or worn valve seats can be refac
119. tandard Cylinder 75 28 mm 2 964 in 0 50 mm Oversize 75 78 mm 2 983 in Cylinder inside diameter out round 0 056 mm 0 0022 in 4 8 ENGINE TOP END Specifications Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M14 x 1 25 57001 1159 Piston Ring Pliers 57001 115 Piston Ring Compression Grip 57001 1095 Piston Ring Compression Belt 667 679 57001 1097 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter Holder 6 57001 1360 Valve Seat Cutter 45 635 0 57001 1116 Valve Seat Cutter 32 633 0 57001 1199 Valve Seat Cutter 45 430 0 57001 1187 Valve Seat Cutter 32 430 0 57001 1120 ENGINE TOP END 4 9 Cylinder Head Compression Measurement e Before measuring compression do the following OBe sure the battery is fully charged OThoroughly warm up the engine so that engine oil be tween the piston and cylinder wall will help seal compres sion as it does during normal running OStop the engine e Disconnect the spark plug caps of each cylinder and re move the spark plugs e Attach the compression gauge assembly firmly into one plug hole Special Tool Compression Gauge 57001 221 A Compression Gauge Adapter 57001 1159 B e Ground the spark plugs to the engine To avoid fire do not ground the spark plugs in prox imity to the plug holes Keep the plugs as far away as possible from the plug holes e With the throttle fully open
120. the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal law and California State law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the engine after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Do not tamper with the original emission related part e Carburetor and internal parts e Spark plugs e Magneto or electronic ignition system e Fuel filter element e Air cleaner elements e Crankcase e Cylinder heads e Breather ch
121. the muffler bracket and take off the muffler e Unscrew the exhaust pipe flange nuts A and remove the exhaust pipe B with pipe cover C Use a penetrating oil if necessary to break threads loose e Remove the gaskets e Unscrew the hook nut D separate the exhaust pipe and pipe cover e Do not use unnecessary force on the exhaust pipes when removing the muffler assembly or they could become damaged or destroyed Muffler Exhaust Pipe Installation e Clean the exhaust pipe flanges to the exhaust port gasket surfaces and install a new gaskets each time the muffler installed e Install the gasket e To prevent mis threading finger tight the flange nuts first Next tighten the hook nut e Tighten the nuts Torque Exhaust Pipe Flange Nuts 15 N m 1 5 kgf m 11 ft lb e Install the muffler e After installation thoroughly warm up the engine wait un til the engine cools down and retighten the bolts and nuts Inspection e Inspect the exhaust pipe or muffler for dents cracks rust and holes lf the exhaust pipe or muffler is damaged it should be replaced for best performance and least noise e Check the muffler for distortion and or loose internal com ponents Loss of power could develop if the muffler loose the internal components restricting the exhaust flow e Check for breaks in the seams and check weld at the junction of the exhaust pipes and muffler e Tap the muffler with a plastic hammer to decarbonize
122. turn engine over sharply with the recoil starter several times until the compression gauge stops rising the compression is the highest read ing obtainable Recoil Model Cylinder Compression MIN 390 kPa 57 psi e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising Electric starter Model Cylinder Compression MIN 390 kPa 57 psi e Repeat the measurement to the other cylinder If the compression is higher than the specified value the piston rings cylinder and valves are probably in good con dition If the compression is too high check the following 1 Carbon build up on the piston crown and cylinder head clean off any carbon on the piston crown and cylinder head 2 Cylinder head gasket use only the proper gasket The use of a gasket of incorrect thickness will change the compression 3 Valve guides and piston rings rapid carbon accumula tion in the combustion chamber may be caused by worn valve guides and or worn piston oil rings This may be indicated by white exhaust smoke x If cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket and check and check the cylinder head warp Condition of the valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove 0 a0N 4 10 ENGINE TOP END Cylinder
123. vel in carb float chamber including overflow High idling R P M Choke partially closed Excessively backed off carbu retor pilot screw Worn piston piston rings Stuck piston Worn cylinder bore lnsufficient cyl head tightness Faulty valve seat contact Plunge up of valve Wrong valve timing Broken valve spring Stuck valve Oil consumption is excessive Is compression sufficient Engine backfires gt Engine knocks gt Plugged oil ring groove High oil level Worn valve stems and valve guide 0il leakage along governor shaft Oil leakage from oil seal Oil leakage from mounting surface 0il leakage from drain plug Clogged breather valve Drain back hole in breather chamber plugged lncorrect oil viscosity Worn piston rings Stuck piston rings Worn cylinder bore Broken piston ring Loose carb or intake manifold Loose cyl head or leaking head gasket Burned or sticking intake valve Faulty ignition coil Carb not properly adjusted Stale fuel Excessive carbon deposit in engine Excessive engine load Engine overheating Faulty ignition coil Adjust Adjust Open choke Adjust Replace Clean or replace Bore or replace Retighten Lap Adjust valve clearance Adjust Replace Clean or replace Clean Adjust Replace Replace Replace Replace gasket Retighten or replace gasket Clean
124. witch Main terminal in solenoid Faulty starter motor Faulty engine Does pinion mesh with ring gear Repair or replace Replace Repair or replace Repair or replace NO gt Worn pinion or ring gear Replace lncorrect starter alignment Correct Y STARTER DOES NOT STOP IN ENGINE SWITCH OFF Faulty pinion clutch Replace Repair or replace Faulty engine Can stop starter by engine switch OFF Y NO O Faulty engine switch Faulty solenoid switch Repair or replace Replace Y Faulty pinion or ring gear O incorrect starter alignment Faulty pinion return mechanism H Repair or replace E Correct Repair or replace H Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 2045 05 Printed in Japan
125. witch 9 8 N m 1 0 kgf m 87 in Ib Oil Passage Plug 3 9 N m 0 40 kgf m 35 in Ib x lf the oil pressure is below the specification inspect the oil pump and relief valve lf the oil pump and relief valve are not at fault inspect the rest of the lubrication system Oil Pressure 241 to 310 kPa 35 to 45 psi Oil Pressure Switch PT 1 8 Taper Pipe Threads Oil Pressure Switch Inspection When the oil pressure falls below 98 kPa 14 2 psi the oil pressure switch activates the oil warning lamp to alert the operator or lubricating problem e To check the oil warning system insert the switch key into the OFF position of the engine switch then turn it to the RUN position The warning light must be illuminated e When the engine is running be sure the warning light is OFF x If the warning light comes on stop the engine immediately and check the oil level e When starting the engine note the warning light on dash carefully lf the warning light is on in the started engine in spite of adequate oil level check the lead from the pressure switch to the warning light for short circuit and or check the pressure switch and replace damaged part xf the light is not on at the moment of the engine switch operation check all leads of the warning light circuit or bulb and replace damaged parts LUBRICATION SYSTEM 5 11 Oil Pump Relief Valve Oil Pump Relief Valve Removal e Remove the crankcase cover

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