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1. Commutator to Shaft Resistance ai 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 KHO9015B S www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 21 Electric Starter System Yoke Assembly Inspection e Set the multimeter selector switch to the R x 1 KQ position and measure the resistance between the positive brushes and stator motor yoke x If the resistance is less than infinite the positive brush is shorted to ground Replace the yoke assembly Positive Brush to Ground Resistance 2 e Set the multimeter selector switch to the R x 1 Q posi tion and measure the resistance between the negative brushes and starter motor yoke x If the meter dose not read close to 0 Q the yoke assembly is faulty Replace it Negative Brush to Ground Resistance Close to 0 Q Pinion Clutch Inspection e Remove the pinion clutch e Turn the pinion gear by hand The pinion gear should turn clockwise freely but should not turn clockwise Alf the pinion clutch dose not operate as it should or if it makes noise replace the pinion clutch www mymowerparts com For Kawasaki
2. Piston Cleaning e Remove the piston and piston rings see Piston Removal in this chapter 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 KE06037BS1 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 16 ENGINE TOP END Cylinder Piston 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 KE06038BS1 Piston Ring and Ring Groove Wear e Clean the piston see Piston Cleaning in this chapter e Visually inspect the piston rings and ring grooves x If the piston rings are worn unevenly or damaged replace them x lf the ring grooves are worn unevenly or damaged re place both the piston and piston rings e Measure the clearance between the top and second rings and their grooves using a thickness gauge A x lf the piston ring groove clearance is greater than the specified value replace the piston KE06039BS1 Piston Ring Groove Clearance Service Limit Top 0 18 mm 0 00709 i
3. www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 14 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Removal e Refer to the Piston Removal in the Engine Top End chap ter Connecting Rod Installation e Refer to the Piston Installation in the Engine Top End chapter Crankshaft Removal e Drain the oil see Oil Change in the Periodic Maintenance chapter e Remove Flywheel see Flywheel Removal in the Electrical Sys tem chapter Camshaft see Camshaft Tappet Removal in this chap ter Balancer shaft see Balancer shaft Removal in this chap ter Connecting Rod Cap see Piston Removal in the 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 Check that the pivot arm for the governor is installed see Governor Arm Installation in the Fuel System chapter e Clean up the crankshaft and crankcase thoroughly espe cially at the bearing contact surfaces e Pack some amount of high temperature grease to 60 volume between the lips of the oil seal on the crankcase Press in the new oil seal 0 1 mm 0 0 04 in below the crankcase surface e Apply engine oil to the PTO side journal crank pin and bearing e Insert the crankshaft into the crankcase Cleaning Inspection e After removing clean the crankshaft and connecting rods with a high
4. 45 32 and lap the valves e Check the seats for good contact all the way around with A machinist s dye e Measure the seat width A If it is more than the STD width the seating surface should be refaced x If the valve seating pattern is not correct repair the seat KEO5002BS1 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures 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 close as possible to the STD width e Make a light pa
5. as it may cause the crankcase cover to warp Inspection e Measure the inside diameter A of the crankshaft journal bearing on the crankcase at several points Replace the crankcase if the inside diameter is more than the service limit Crankshaft Bearing Inside Diameter Service Limit 35 055 mm 1 380 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 8 CAMSHAFT CRANKSHAFT Crankcase Cleaning e Remove Camshaft and Tappets see Camshaft Tappet Removal in this chapter Crankshaft see Crankshaft Removal in this chapter Balancer Shaft Balancer Shaft Removal in this chapter 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 washing www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 9 Breather The function of the breather is to create a negative pressure 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 emission control system is used to prevent blow by gases from
6. e Too much or too little oil in Correct crankcase eExcessively contaminated Change lubricating oil e Defective oil filter Replace e Faulty relief valve Replace e Faulty oil pump Replace e Clogging oil system Clean e Plugged air cleaner Clean e Carbon deposit in exhaust Clean hole and muffler e Carb not properly adjusted Adjust e Too much oil in crankcase Adjust level e Worn piston piston rings Replace e Worn cylinder bore Replace e See Engine hard to start Correct alignment NO eLargely deviated valve timing of timing gear marks e Spark plug fouled pitted or gapped incorrectly Problem in the fuel system e Entry of dust or water into fuel Clean lack of fuel hose or fuel filter e Air or vapor lock in fuel line Clean e Plugged air vent of fuel tank Clean cap e Plugged air fuel passes in Clean carb e Carb not properly adjusted Adjust e Carb flange leaking at gasket Tighten or replace e Worn carb body and throttle Replace shaft Is unusual smoke emitted out of muffler Is compression sufficient Is alignment of timing gear marks correct Engine runs erratically Replace or adjust KI02020B F www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 4 TROUBLESHOOTING Engine Troubleshooting Guide Problem in the governor system Engine malfunctions at high speed Is revolution fluctuation of relatively large period produced whe
7. crometer at several points x lf the outside diameter is less than service limit replace the piston pin Piston Pin Outside Diameter Service Limit 18 96 mm 0 746 in e Measure the inside diameter A of the piston pin hole at several points on both side Use a dial bore gauge Y lf the inside diameter is more than the service limit re place the piston Piston Pin Hole Inside Diameter Service Limit 19 08 mm 0 751 in e Measure the inside diameter A of the small end of the connecting rod at several points Use a dial bore gauge Y lf the inside diameter is more than the service limit re place the connecting rod Connecting Rod Small End Inside Diameter Service Limit 19 06 mm 0 750 in KE06042BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 18 ENGINE TOP END Cylinder Piston Piston Diameter e Measure the outside diameter A of the piston 10 mm 0 39 in up B from the bottom of the piston at a right angle to the direction of the piston pin hole x If the measurement is less than the service limit replace the piston Piston Diameter Service Limit 81 77 mm 3 217 in KEO6043BS1 Cylinder Inside Diameter e Clean and measure the cylinder inside diameter OUse a dial bore gauge to measure front to back and side to side at the points as shown in the figure x lf any
8. Align center of the valve seat with center of the reed valve and back plate then tighten the breather valve screw www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 11 Camshaft Tappet Camshaft Tappet Removal e Drain the oil see Oil Change in the Periodic Maintenance chapter e Remove Crankcase Cover see Crankcase Cover Removal in this chapter Rocker Cover A e Position the piston TDC at the end of the compression stroke e Remove the lock screws A and the valve clearance ad justing nuts B which are installed on the rocker arms C and pull the rocker arms off the push rods D e Remove the push rods and mark them so they can be installed in their original positions during assembly 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 Install the tappets in their original positions e Align the punch marks A on the crankshaft gear and on the camshaft gear www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 12 CAMSHAFT CRANKSHAFT Camshaft Tappet e Install the crankcase cover see Crankcase Cover Instal lation in this chapter e Install the push rods see Push
9. Cover B e Slip the actuating arm C from the pinion gear e Pull the armature A from the yoke B www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 17 Electric Starter System e Separate the front stopper A and rear stopper B each other and remove the front stopper to left side C as shown in the figure e Push the rear stopper to right side D and remove the snap ring E as shown in the figure e Pull the rear stopper and pinion gear F from the armature shaft e Gently pull the end cover A from the yoke and remove the insulator B e Using a needle nose pliers remove the brush springs A from the brush holder B e Separate the brushes C from the holder and remove the holder from the yoke D Starter Motor Assembly Notes e Apply a small amount of grease to the armature shaft A as shown e Do not reuse the snap ring B Replace it with a new one www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 18 ELECTRICAL SYSTEM Electric Starter System e Inspect the rubber insert A and or boot B for visible damage x lf they are damaged replace them e Fit the notch A in the lead grommet onto the projec tion B on the end cover C e Grease the pinion gear fork fingers e Set the pinion gear fork so that the fingers fit into the groove in the gear e Fit the notch A in
10. Disconnect the spark plug cap of the cylinder and remove the spark plug keeping the engine throttle and the choke valve fully open e Attach the compression gauge assembly firmly into the plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 A Compression Gauge Adapter M14 x 1 25 57001 1159 B e Ground the spark plug to the engine To avoid fire do not ground the spark plug in prox imity to the plug hole Keep the plug as far away as possible from the plug hole e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising Cylinder Compression MIN 294 kPa 43 psi x If the compression is higher than the specified value the piston rings cylinder and valves are probably in good con dition x 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 4 Malfunction of ACR Automatic Compression Release with the camshaft x If cylinder compression is lower than the MIN check the following 1 Gas lea
11. Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 9 1 Troubleshooting Table of Contents Engine Troubleshooting Guide ia Ri eee 9 2 starter Motor Troubleshooting Guide curando ss i n 9 6 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 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 has been found to be the cause of the malfunction Engine hard to start Remove spark plug and Are sparks produced when check spark by cranking spark plug is replaced e Faulty spark plug Replace engine while having the plug touched against engine block A WARNING Keep the plug as far Are sparks produced when e Faulty ignition coil Replace away as possible from ignition coil is replaced the plug hole e Incorrect air gap Correct To avoid an electric e Faulty flywheel Replace shock do not hold the plug itself Make sure to hold the plug cap e No fuel in the tank Add e Entry of dust or air into fuel Clean hose or filter ePlugged air hole in tank
12. EEEE 6 12 Oil Screen Installation ici da a a 6 12 Cleaning and Inspection dr 6 12 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 2 LUBRICATION SYSTEM Exploded View KF02006BW5 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 3 Exploded View Torque No Fastener Nem kgfm ftlb Remarks 1 Oil Filter Joint 6 9 0 70 61 in lb 2 Oil Filter 9 8 1 0 87 in lb O 3 Oil Drain Plugs 6 9 0 70 61 mb 4 Crankcase Cover Plug 6 9 0 70 61 mb 5 Crankcase Cover Bolts 21 6 2 2 S 6 Cylinder Head Bolts ene on e oi Pressure Sat os mo Cn ss G Apply grease L Apply a non permanent locking agent to the threads O Apply engine oil R Replacement Parts S Tighten the fasteners following the specified sequence SS Apply silicone sealant www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 4 LUBRICATION SYSTEM Engine Oil Flow Chart Oil Flow by Pressure lt Oil Mist qu www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 5 Specifications Item Standard Engine Oil Type SF SG SH or SJ class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAESW 20 Capacity 1 1 L 1 16 US qt When filter is not removed 1 3 L 1 37 US qt When filter is removed Level O
13. Is compression sufficient Make starting attempts a cap and fuel pump number of times and then remove spark plug and observe electrodes Are they wet e Plugged fuel line e Excessive use of choke Remove the plug and turn the crankshaft without loading e Plugged air cleaner Clean e Too high fuel level in float Agjust bowl e Worn piston piston rings Replace e Stuck piston rings Clean or replace eWorn cyl bore Replace e Insufficient cyl head Retighten tightening Check carburetor Check for plugged fuel Faulty contact of valve Lap line seat Check for plugged air e Plunge up by valve Adjust valve clearance passage e Warped cyl head Replace Check float level e Broken valve spring Replace Check carb setting e Stuck valve Clean or replace e Burned head gasket Replace KI02019B_F www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 9 3 Engine Troubleshooting Guide Engine power loss Is engine overheated YES e Crankcase low on oil Adjust level or add NO e Too much oil in crankcase Adjust level e Excessive engine load Decrease load eCarb not properly adjusted Adjust e Carbon deposit in combustion Clean chamber e Damaged cooling fan Replace e Wrong spark plug Replace e Faulty ignition coil Replace eIncorrect air gap Adjust gap Is the ignition spark normal Is lubricating condition normal
14. Parts Call 606 678 9623 or 606 561 4983 COOLING SYSTEM 4 3 Exploded View Torque No Fastener Nem kgf m ftlb Remarks 1 Fan Housing Bolts 5 9 0 60 52 mb 2 Flywheel Bolt 56 5 7 41 3 Fan Housing 4 Fan www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 4 COOLING SYSTEM Cooling Fan Cooling Fan Removal e Refer to the Flywheel Removal in the Electrical System chapter Cooling Fan Installation e Refer to the Flywheel Installation in the Electrical System chapter Cooling Fan Inspection e Visually inspect the blades A in the cooling fan B x If they are any cracks warps or damage replace the cool ing 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 solvents It may be damaged by solvents www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded Vi Wir A A Dia Ae a hens eae ana 5 2 SPECITICATIONS EE 5 4 Special Taldea 5 5 Cylinder Hedd EE 5 6 Compression Measurement 5 6 Cylinder Head Assembly Removal c ccccccccseccceceeeeeeeeseeeceeeeeeeeneeneesenseeeeeeseeeeseeeneneeee 5 7 Cylinder Head Assembly Installation ooonnnnnnnnnnncccnnnnnnnanccconccncncnnnannrnrrn co nnnnnnonanannnnnnnos 5 7 Push R
15. Parts Call 606 678 9623 or 606 561 4983 TROUBLESHOOTING 9 5 Engine Troubleshooting Guide Fuel consumption is excessive Is compression sufficient YES e High fuel level in carb float Adjust NO chamber including overflow e High idling R P M Adjust e Choke partially closed Open choke e Worn piston piston rings Replace e Stuck piston Clean or replace e Worn cylinder bore Replace e Insufficient cyl head tightness Retighten e Faulty valve seat contact Lap e Plunge up of valve Adjust valve clearance Wrong valve timing Adjust e Broken valve spring Replace e Stuck valve Clean or replace Oil consumption is excessive Is compression sufficient YES e Plugged oil ring groove Clean NO e High oil level Adjust e Worn valve stems and valve Replace guide e Oil leakage along governor Replace shaft e Oil leakage from oil seal Replace e Oil leakage from mounting Replace gasket surface e Oil leakage from drain plug Retighten or replace gasket e Clogged breather valve Clean eDrain back hole in breather Clean chamber plugged e Incorrect oil viscosity Correct e Worn piston rings Replace e Stuck piston rings Clean or replace e Worn cylinder bore Replace e Broken piston ring Replace Engine backfires e Loose carb Tighten e Loose cyl head or leaking head Tighten gasket e Burned or sticking intake valve Replace e Faulty ignition coil Replace e Carb not properly adjusted Adjust Engine knocks e Stale fuel Ch
16. Rod Installation in the Engine Top End chapter e Mount the rocker arms on the push rods and install the valve clearance adjusting nuts and the lock screws Torque Valve Clearance Lock Screws 6 9 N m 0 70 kgf m 61 in Ib e Adjust the valve clearance see Valve Clearance Adjust ment in the Periodic Maintenance chapter e Install the rocker cover Camshaft Disassembly e Remove the governor assembly see Governor Assembly Removal Inspection in the Fuel System chapter e Remove Spring A e Do not remove the ACR Automatic Compression Re lease weight B KGO5010BS1 Camshaft Assembly e Install the governor assembly see Governor Assembly Installation in the Fuel System chapter e After assembling the camshaft check the following items OWhile shaking the camshaft ACR weight A swings smoothly Camshaft Inspection e Check the camshaft gear A for pitting fatigue cracks burrs or an evidence of improper tooth contact 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 e Inspect the camshaft to make sure that its Automatic Compression Release ACR function operates smoothly and does not have any damage or abnormal wear lf ACR parts are worn replace the camshaft When the weight A is closed if the top of the shaft B is lower than the base C replace the camshaft with a new one When wei
17. e Install the balancer shaft A to the balancer shaft bearing on the crankcase e Install the crankcase cover see Crankcase Cover Instal lation in this chapter e Align the punch marks A on the crankshaft gear and on the balancer shaft gear Balancer Shaft Bearing Journal Wear e Measure both balancer shaft journals diameter A at sev eral points around the journal circumference Alf journal diameter is less than the service limit replace the balancer shaft with a new one Balancer Shaft Journal Diameter Service Limit 31 935 mm 1 258 in e Measure the inside diameter A of the balancer shaft bearing on the crankcase at several points x lf inside diameter is more than the service limit replace the crankcase with a new one Balancer Shaft Bearing Inside Diameter Crankcase Service Limit 32 06 mm 1 262 in e Measure the inside diameter A of the balancer shaft bearing on the crankcase cover at several points x lf inside diameter is more than the service limit replace the crankcase cover with a new one Balancer Shaft Bearing Inside Diameter Crankcase cover Service Limit 32 06 mm 1 262 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 1 Electrical System Table of Contents EXPO WA 8 2 eet le TEE 8 4 leet Mt 8 5 MV UPI AQUA A O 8 6 l
18. e Install the pump parts assembly and circlip in the crankcase cover e Reinstall pump cover the same side down Olnstall the circlip A with the tapered side out B as shown in figure CAUTION Do not damage camshaft bore with the circlip Oil Pump Inspection e Remove the oil pump see Oil Pump Removal in this chapter e Visually inspect the pump gear outer and inner rotor and cover plate Alf 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 x If the measurement exceed the service limit replace the rotors as a set Inner and Outer Rotor Clearance Service Limit 0 20 mm 0 00787 in e Measure the outside diameter A of the outer rotor with a micrometer at several points x 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 KFO7001BS1 Outer Rotor Thickness Service Limit 9 94 mm 0 391 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 10 LUBRICATIO
19. 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 in this chapter lt Ambient Temperature _ gt 20 C T E 10 C SES se 40 C at 30 S a E e 4 F 14 F 32 F BEE 68 F Ei 104 F www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Gap Inspection WN e Remove the spark plug see Spark Plug Removal in the f SG Electrical System chapter UW x If the plug is oily or has carbon build up on it clean the I plug using a high flash point solvent and a wire brush or AZ other suitable tool EN x lf the spark plug electrodes are corroded or damaged A or if the insulator is cracked replace the plug Use the SA standard spark plug or its equivalent E ea Insulator A Center Electrode B Plug Gap C Side Electrode D e Measure the gap with a wire type thickness gauge x lf the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 1 Fuel System Table of Contents EXPO WA eet le TEE Governor Link Mechansm ce
20. flash point washing 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 15 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 long and insert the arbor through the connecting rod small end OOn a surface plate set the big end arbor on V blocks A OWith the connecting rod held vertically use a height ME gauge B to measure the difference in the height of the small end arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend Alf connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit 0 2 100 mm 0 008 3 94 in e Measure connecting rod twist OWith the big end arbor still on the V blocks A hold the connecting rod horizontally and measure the amoun
21. manufacturer s instructions are not available use the following procedure 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 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following 45 Cutter angle A p24 5 Cutter diameter of cutter B KEO5005BS1 Operating Procedures e Clean the seat area carefully e Recondition the valve seats with the valve seat cutters
22. 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 B of Tran sistor 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 C to emitter E to ground The trigger sensor TS1 senses the optimum time peak current to remove the base drive from the transistor 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 reaches 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 p
23. of the cylinder bore measurements is greater than the service limit replace the cylinder 10 mm 0 39 in A 35 mm 1 38 in B Cylinder Inside Diameter Standard 81 980 82 000 mm 3 2276 3 2283 in Service Limit 82 10 mm 3 232 in KE06044BS1 Cylinder Bore Out Round Service Limit 0 056 mm 0 0022 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 1 Lubrication System Table of Contents Exploded MI A dida 6 2 Erigine Oil Flow CaM cti A a A a 6 4 ellene le 6 5 Special Tools and Sealant me rnei a a e e a a ia 6 6 E gine Oil A a anae eaaa de as aee adana diaaa Anha AAE hi aAa ia Sah aaa danai aiioe sataa 6 7 Oil Level Inspechon ie irar a a aaae aaa aa aa Eae E Aa E a T E EAE Eaa i 6 7 MOTUS ee 6 7 Oil Filter Replacement 6 7 Pressurized L bricati n System EE 6 8 Oil Pressure Measurement oocccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneninenss 6 8 Kl Pump Relief Val ut deed EE ed Da 6 9 Oil Pump Removal E E EE cccecatesecastedesaenesssadeaaguetencadeled E T 6 9 Qil Pump Installation a TA At Belen diet 6 9 SA Aeiaaeeia ors eile a bee se e AAE TTA E ATAT 6 9 Relief Valve REMOVAL ss meriter A A 6 10 Relief Valve Installation cccccecceeeceeec eee eene eee tence eeeeeeeeeeeeeeeeeeeeegeeegeeeegeeeeeeeeeeneeeeeeeeeeeeees 6 10 Relief Valve Inspection 6 11 ON SCO E 6 12 Oil Screen HRemova EEEE
24. the gover nor shaft B is inserted in the crankcase and so that the marks C face out e Press in the new oil seal using a press or suitable tools until it is flush with crankcase surface D e Hold the governor shaft with the snap pin e Check that the governor shaft moves smoothly in its op erating range KC04030BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 8 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 passage 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 joined 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 erg A ET E i dll 77 HSY ECH R A He i yen Al rf y lt AIR YA FUEL mm MIXTURE KC05067BW4 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 9 Carburetor Dummy Page www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 10 FUEL SYSTEM Carburetor The slow system includes the slow jet pilot
25. the yoke onto the projection B on the pinion gear fork e Engage the hook on the starter solenoid with the hook A on the pinion gear fork B www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 19 Electric Starter System Starter Motor Brush Inspection e Measure the overall length of each brush A Alf the brushes are shorter than the service limit replace them Carbon Brush Length Standard 10 mm 0 394 in Service Limit 6 0 mm 0 236 in Brush Spring Inspection e Inspection 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 Alf 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 6P11061081 e Measure the depth of the grooves between the commu tator segments Alf the grooves are shallower than the specified limit un dercut the insulating material to the standard depth 0 5 to 0 8 mm 0 012 to 0 031 in using a thin file Alf the grooves are only dirty clean them carefully Commutator Groove Depth Standard 0 5 0 8 mm 0 02 0
26. 031 in Service Limit 0 2 mm 0 008 in KH09013BS1 Bad A Segment B Good C 0 2 mm 0 008 in limit D Mica E www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 20 ELECTRICAL SYSTEM Electric Starter System e Measure the commutator B outside diameter A at sev eral points x If the diameter is less than the service limit replace the armature with a new one Commutator Outside Diameter Standard 28 mm 1 102 in Service Limit 27 mm 1 063 in GP110607S1 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 commutator runout x If runout is more than the service limit replace the ar mature with a new one Commutator Runout Service Limit 0 4 mm 0 016 in KHO9014BS1 e Measure the armature winding resistance OSet the multimeter selector switch to the R x 1 Q position and check the resistance between each segment and all the others x lf the resistance is 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 multimeter selector switch to the R x 1 KQ position and measure the resistance between the commutator and the armature shaft x lf the resistance is less than infinite the armature is shorted
27. 06 561 4983 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 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 purc
28. 15 ft lb Starter Solenoid and Circuit Test NOTE OBefore this test be sure the battery is fully charged e Disconnect the starter motor lead A from the solenoid terminal as shown and keep the lead away from the sole noid terminal e Measure the continuity of the solenoid when activated OSet the hand tester selector switch to the R x 1 Q position and connect the leads across the large terminals A as shown OTurn the engine switch to the START II position and read the tester x lf the solenoid does not click or if the tester reads more than 0 Q the solenoid is faulty Replace it x lf the solenoid makes a single clicking sound the tester reads 0 Q and the rest of the starter circuit is good x If solenoid clicks once but the tester does not read 0 Q the solenoid is faulty Replace it x If the solenoid does not click at all proceed with the fol lowing e Disconnect the switch lead A shown www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 15 Electric Starter System e Set the hand tester to the R x 1 Q position and connect the leads as shown Switch Terminal A To Ground B x If the tester does not read close to 0 Q the solenoid is faulty Replace it x If the tester reads close to 0 Q the solenoid may be good e Check the voltage to the solenoid from the engine switch e Set the hand tester selector switch to the 25V DC positi
29. 4 3 15 3 16 3 18 3 18 3 18 For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 2 FUEL SYSTEM Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Inlet Pipe Nuts 5 9 0 60 52 mb 2 Control Panel Bolts 6 9 0 70 61 in lb 3 Governor Arm Clamp Nut 5 9 0 60 52 in lb 4 Choke Valve Screws 0 9 0 09 7 8 in lb L 5 Throttle Valve Screws 0 9 0 09 7 8 in lb L 6 Pilot Jet Slow Jet 0 7 0 07 6 1 in lb 7 Main Jet 2 0 20 17 in lb 8 Drain Screw 2 0 20 17 in lb 9 Float Chamber Mounting Bolt 9 8 1 0 87 in lb 10 High Idle Speed Screw ch Low Idle Speed Screw Governor Arm Governor Shaft Governor Assembly Apply a non permanent locking agent to the threads Apply engine oil Replacement Parts a E VOF ROON www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 4 FUEL SYSTEM Specifications Item Standard Caburetors Specifications Make Type Throttle Bore Diameter Venturi Diameter Main Jet MJ Pilot Jet PJ Pilot Screw Turns Out PS Idle Mixture Screw Turns Out Float Level Idle Speed 1 Low Idle Speed High Idle Speed Air Cleaner Type Cleaner Fuel Fuel Requirement NIKKI 6C1026 511 26 mm 1 02 in 20 mm 0 79 in 110 50 2 3 4 43
30. 561 4983 PERIODIC MAINTENANCE 2 5 Specifications Item Standard Fuel System Idle Speed 1 Low Idle Speed High Idle Speed Air Cleaner Type Cleaner Engine Top End Valve Clearance Inlet Exhaust Valve Seating Surface Angle 1 125 75 r min rpm 3 750 50 r min rpm 0 10 0 15 mm 0 0039 0 0059 in Inlet Exhaust 45 Valve Seating Surface Width Inlet 1 1 1 7 mm 0 043 0 070 in Exhaust 1 0 1 5 mm 0 039 0 059 in Lubrication System Engine Oil Type SF SG SH or SJ class Viscosity SAE 40 SAE 30 SAE 10W 30 SAE 10W 40 or SAE 5W 20 Capacity 1 1 L 1 16 US qt When filter is not removed 1 3 L 1 37 US qt When filter is removed Level Operating range grid area on dipstick Electrical System Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in 1 Idle speeds may vary depending on each equipment Refer to the equipment specification www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 6 PERIODIC MAINTENANCE Special Tools Valve Seat Cutter 45 632 Valve Seat Cutter Holder 7 57001 1115 57001 1126 Valve Seat Cutter 45 635 Valve Seat Cutter Holder Bar 57001 1116 57001 1128 ST571116ST ST571128ST Valve Seat Cutter 32 635 Oil Filter Wrench 57001 1121 57001 1249 ST5711218T T5712498T Valve Seat Cutter 32 638 5 57001 1122 8757112297 www mymowerparts co
31. 7 Low Idle Speed AdjustMent ccooniioio in aii 2 7 High Idle Speed E ME dn LEE 2 7 Fuel system Cleanliness INSpection ccccceeceeeeeeetececeeeeeeeeeeseceenececseeessseecneeeeseeeenees 2 8 Engine TOD ENO DEET 2 9 Cylinder Head Cleaning and Inspechon nc nn nnnnnnanannnnnnno 2 9 Valve Clearance Inspection ooooccooncnccinicnocococccccccn cnn 2 9 Valve Clearance AUS EE 2 10 VENCE 2 10 Valve Stat REpalE cidcid idad E EES 2 11 L brication System EE 2 14 Oil Level EE 2 14 OEO PYE iale e E das 2 15 Oil Fille Replacement ege geg e e a ae a a a aS 2 15 Electrical System a Sot a 2 16 Spark Plug Cleaning and Gap Inspection 2 16 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 2 PERIODIC MAINTENANCE 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 OPERATION INTERVAL Every Every Every Every Every 100 hr 200 hr 300 hr Check or clean air inlet screen Check and add engine oil Check for fuel and oil leakage e
32. 7 11 Camshaft Tappet Removal oooococcccnncccnncnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininins 7 11 Camshaft Tappet Installaton a a aaa aa aa A aa A A at iS 7 11 Camshaft Disassembly iio i 7 12 Camshaft Eegenen ege egen eege Eed eege 7 12 Camshaft Inspection oooccccccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnonnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnss 7 12 Camshaft Bearing Journal Ver cionado aia te ceewesdaddnedbe 7 13 Crankshaft Connecting Rod 7 14 Connecting Rod Removal rniii ia iris ines 7 14 Connecting Ree e REENERT 7 14 Crankshaft Removal iii E a 7 14 Crankshaft Installation EE 7 14 Cleaning Inspection mii ios 7 14 Connecting ROG Bend TWiSt nal a TOO 7 15 Connecting Rod Big End Crankpin Width Wear oocccconncoconccccccccnncnonancnononnnnnnnnnana conc 7 15 Connecting Rod Big End Bearing Crankpin Wear oooccconnnononccccnnccnnnconnoncnoncnnnnnnnannannnnno 7 16 Crankshatt RUE geess eege REENEN ege 7 16 Crankshaft Main Journal Wear ssssesssesseeeeseneeeeesereerrrrrrrtrrtttrrttrrtrrrttttttrttttttttrttrtttrtrtrtttnnt 7 16 Balan Sat EEN 7 17 Balancer Shaft Removal nerie e a a a E E R aa e a EE 7 17 Balancer Shaft Installation ooononnccnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnninnniss 7 17 Balancer Shaft Bearing Journal Weat c c ccceeeeeeeeeeeeeecceeeeeeseesecceeeeneeeeeeeenteneeneeeees 7 17 www mymowerparts com For Kawasaki D
33. 8 Float parallel to carburetor body 1 125 75 r min rpm 3 750 50 r min rpm Unleaded regular grade gasoline Fuel Pump Type Pulse diaphragm pump Governor Type Flyweight all speed governor 1 Idle speeds may vary depending on each mounting equipment Refer to the mounting equipment specification www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 5 Governor Link Mechanism Control Panel Assembly Removal e Remove the control panel mounting bolts A e Remove the control panel assembly A while unhooking the governor spring B end loop at the engine speed con trol lever C Control Panel Assembly Installation e Before installing the control panel assembly check to see that the engine speed control lever A move smoothly in all directions Alf any part is worn or damaged replace the control panel assembly e Hook the governor spring end loop e Install the control panel assembly with the mounting bolts A e After installation adjust the low idle speed and high idle speed to the specifications see Low High Idle Speed Ad justment in the Periodic Maintenance chapter Governor Arm Removal e Remove the control panel assembly see Control Panel Assembly Removal in this chapter e Loosen the clamp nut A and take off the governor arm B e Unhook the throttle link rod spring C end loop and clear the throttle link rod lower e
34. AL INFORMATION 1 5 General Specifications Item FJ400D Type of Engine Air cooled 4 stroke OHV single cylinder gasoline engine Bore x Stroke 82 mm x 76 mm 3 23 in x 2 99 in Piston Displacement 401 mL 24 5 cu in Direction of Rotation Counterclockwise facing the PTO shaft Compression Release Automatic compression release Low Idle Speed 1 175 r min rpm High Idle Speed 4 000 r min rpm gnition System Transistorized fly wheel magneto All speed mechanical fly weights Lubrication System Pressure feed by positive displacement pump Oil Filter Cartridge type full flow filter Oil Pressure Switch On Off switch Oil Capacity when engine 1 3 L 1 37 US qt is completely dry Cooling System Forced air cooling by fan Dimensions Lx W x H 407 mm x 472 mm x 319 mm 16 0 in x 18 6 in x 12 6 in Dry Weight 31 5 kg 69 5 Ib Specifications subject to change without notice www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 2 Torque anid LOCkinG AOL ao Gis ana lona ten niaaa a Ean TE aio dn aided 2 3 eene te TEE 2 5 Special OD EE 2 6 Periodic Maintenance Procedures cccccccceceeeeeeeeeeeeeeeeeeceeeceeeeeeeeeeeeeeeceeeeeeeeeeeeeneeeeeeeneeens 2 7 F el SS LSU liste A 2
35. Check for loose or lost nuts and screws Clean dust and dirt from cylinder and cylinder head fins 1 Tighten nuts and screws Change engine oil Change oil filter Clean and re gap spark plugs 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 have the proper equipment and mechanical proficiency www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 3 Torque and Locking Agent The following tables list 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 O Apply engine oil S Tighten the fasteners following the specified sequence SS Apply silicone sealant Torque Fastener Nan kgfm Pe Remarks Fuel System Inlet Pipe Nuts 5 9 0 60 52 in lb Control Panel Bolts 6 9 0 70 61 in lb Governor Arm Clamp Nut 5 9 0 60 52 in lb Choke Valve Screws 0 9 0 09 7 8 in lb L Throttle Valve Screws 0 9 0 09 7 8 mb L Pilot Jet Slow Jet 0 7 0 07 6 1 in Ib Main Jet 2 0 20 17 in lb Drain Screw 2 0 20 17 in lb Float Chamber Mounting Bolt A 1 0 87 in
36. D 5 3 Exploded View No Fastener Torgu Remarks N m kgf m ft Ib 1 Spark Plug 22 2 2 16 2 Cylinder Head Bolts 37 3 8 27 S 3 Connecting Rod Big End Cap Bolts 5 9 0 60 52 mb O 4 Valve Clearance Lock Screws 6 9 0 70 61 mb 5 Rocker Arm Bolts 28 2 9 21 VNILOZO Apply grease Apply molybdenum disulfide grease Apply engine oil Replacement Parts Tighten the fasteners following the specified sequence www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 4 ENGINE TOP END Specifications Item Service Limit Cylinder Head Cylinder Compression MIN 294 kPa 43 psi MIN Cylinder Head Warp 0 03 mm 0 001 in Valves Valve Head Thickness Inlet Exhaust 0 4 mm 0 016 in Valve Stem Runout Inlet Exhaust TIR 0 05 mm 0 002 in Valve Stem Diameter Inlet 6 95 mm 0 274 in Exhaust 6 93 mm 0 273 in Valve Guide Inside Diameter Inlet Exhaust 7 08 mm 0 279 in Valve Spring Free Length Inlet Exhaust 32 6 mm 1 28 in Rocker Arm Push Rod Runout Inlet Exhaust TIR 0 5 mm 0 02 in Cylinder Piston Piston Diameter 81 77 mm 3 217 in Piston Ring Groove Clearance Top 0 18 mm 0 00709 in Second 0 18 mm 0 00709 in Piston Ring Thickness Top Second 1 40 mm 0 0551 in Piston Ring End Gap Top 0 7 mm 0 028 in Second 0 8 mm 0 031 in Oil 1 0 mm 0 039 in Piston Pin Outside Diameter 18 96
37. For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 XK Kawasaki FJ400D 4 stroke air cooled gasoline engine Service Manual www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft Crankshaft Electrical System Troubleshooting 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FJ400D Kawasaki 4 stroke air cooled 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 Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liabili
38. M 8 3 Exploded View No Fastener Torgus Remarks N m kgf m ft Ib 1 Flywheel Bolt 56 5 7 41 2 Stator Coil Screws 3 4 0 35 30 mb 3 Ignition Coil Bolts 5 9 0 60 52 mb 4 Spark Plug 22 2 2 16 5 Starter Motor Mounting Bolts 20 2 0 15 G Apply grease M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Charging System Alternator Stator Coil Resistance Unregulated Stator Output 0 01 0 1 0 28 4 V AC 3 000 rpm 26 V AC 3 000 rpm Ignition System Ignition Coil Coil Air Gap Primary Winding Resistance Secondary Winding Resistance Spark Plug Plug Gap Electric Stater System Starter Motor Carbon Brush Length Commutator Groove Depth Commutator Outside Diameter Commutator Runout 0 2 0 4 mm 0 0079 0 0157 in in the text 8 11 kO NGK BPR5ES 0 7 0 8 mm 0 028 0 031 in 10 mm 0 394 in 0 5 0 8 mm 0 02 0 031 in 28 mm 1 102 in 6 0 mm 0 236 in 0 2 mm 0 008 in 27 mm 1 063 in 0 4 mm 0 016 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 5 Special Tool Hand Tester 57001 1394 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 6 ELECT
39. N SYSTEM Oil Pump Relief Valve e Measure the inside diameter A of the pump housing with an inside micrometer at several points x lf 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 x If any of measurement is more than the service limit re place the crankcase cover Pump Housing Depth Service Limit 10 160 mm 0 4000 in e Measure the outside A diameter of the pump shaft with a micrometer at several points x If the diameter is less than the service limit replace the pump shaft Pump Shaft Outside Diameter Service Limit 12 645 mm 0 4978 in e Measurer the inside diameter A of the pump shaft bear ing in the crankcase cover with a inside micrometer at several points x If the inside diameter is more than the service limit replace the crankcase cover Pump Shaft Bearing Inside Diameter Service Limit 12 811 mm 0 5044 in Relief Valve Removal e Remove Camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter Relief Valve Cover Bolt A Relief Valve Installation e Install the relief valve ball and spring in position and tighten the relief valve cover bolt www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 11 Oil Pum
40. RICAL SYSTEM Wiring Diagram www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 7 Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them 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 KHO6000BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 8 ELECTRICAL SYSTEM Charging Ignition System Flywheel Stator Coil Removal e Remove Control Panel Assembly see Control Panel Assembly Removal in the Fuel System chapter Carburetor see Carburetor Removal in the Fuel System chapter e Loosen the fan hous
41. ange e Excessive carbon deposit in Clean engine e Excessive engine load Adjust e Engine overheating See engine loss power e Faulty ignition coil Replace K102022B F www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 9 6 TROUBLESHOOTING Starter Motor Troubleshooting Guide 1 Disconnect spark plug cap and ground the cap terminal 2 Turn engine switch to START position and check condition A WARNING Engine may be cranked in this test Do not touch any rotating parts of engine and equip ment during test CAUTION If starter does not stop by engine switch OFF disconnect negative lead from battery as soon as possible Starter does not rotate Is click sound from solenoid switch Starter rotates but slow Is battery normal and well charged Starter rotates but can not crank engine Does pinion mesh with ring gear Starter does not stop in engine switch OFF Can stop starter by engine switch OFF www mymowerparts com e Faulty battery e Faulty leads or connection e Melted fuse e Faulty engine switch e Faulty solenoid switch e Weak battery e Faulty leads or connection Solenoid to motor e Faulty solenoid switch Main terminal in solenoid e Faulty starter motor e Weak battery e Faulty leads or connection Solenoid to motor e Faulty solenoid switch Main terminal in solenoid e Faulty starter
42. ap rings as removal weakens and deforms them They could fall out and score the cylinder wall www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 15 Cylinder Piston e Apply engine oil to the piston skirt and the cylinder bore e 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 into the cylinder Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 80 91 57001 1320 e Facing the arrow mark D on the top of the piston toward the flywheel side E 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 cap C e Install the connecting rod big end cap in their original posi tion on the connecting rod big end by matching the marks D KE06036BS1 e Apply a small amount of engine oil to the thread and seat ing surface of the cap bolts E e Tighten the cap bolts Torque Connecting Rod Big End Cap Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install Camshaft see Camshaft Tappet Installation in the Camshaft Crankshaft chapter Crankcase Cover see Crankcase Cover Installation in the Camshaft Crankshaft chapter
43. ce cece nr Control Panel Assembly Removal iooiocccina ic ic Control Panel Assembly Installation oooonnnnnnnonccnnnnnnncccnncnncanncnncccnnnnnanrr rn cnnnnnnnnnnnnnnnno Governor Arm Remo Governor Arm Installation ooooooncccncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos Governor Assembly Hemovallnspechon cnn Governor Assembly Installation WEE Governor Shaft Removal o ooocccccnccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininins Governor Shaft Installation oooccocccnnnnnnnnonnnonononnnononononnnnnononononnnnnnnnnninnnnnnnnnnnnss CARDUGCTOR ta tuennianentaasctereceacomeasetezaaaetaGeasetud A otas DEE Fuel And Rule De EE Low Idle Speed Adjustment ve e ekedetkeggiR EES Ed EAEEEEE id li tada de en elle ITER En LEE Aigh Altitude Operation EE Main Jet Renlacement e r tiai AEEA EA EEE e AREARE EEA EE AEE EERE AA EEN Fuel system Cleanliness Inspection deE Add dee Carburetor Remova t rtttEttEEEtEEE EEEE EEE EEE EEEE EEnEnE Carburetor Installation rin in las Carburetor Disassembly Assembly oooococccononinnncconocconccconnnn cancer Carburetor GIS ale e GE Carburetor Inspection essees e a a aaa ea a aiar aE Taa A t ea E STEA E drapa Taai S NGE Oe EE Ee EE eg eegene EE eeh ee EE Fuel Pump inspection tarin E he ee EN www mymowerparts com 3 5 3 5 3 5 3 6 3 7 3 7 3 7 3 8 3 8 3 12 3 12 3 12 3 12 3 13 3 13 3 13 3 1
44. ctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not 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 A 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing DEE 1 2 Model JdentttEet rt et SEENEN EE ege a E a Cie 1 4 General Specifications ssiri aran ee eaa Ee a rae E AEE EEE ea E ETIE E EEEE i 1 5 www mymo
45. ding down along inside wall C of the crankcase and position the push rod end onto the tappet e Check that both inlet and exhaust push rods on the cylin der are at lowest position on the cam lobes D if not turn the flywheel clockwise one turn 360 and reset the cylin der at TDC of power stroke in e Be sure the both ends of the push rods are correctly seated on the tappets and rocker arms e Tighten the lock screws and the valve clearance adjust ing nuts see Valve Clearance Adjustment in the Periodic Maintenance chapter e Check and adjust the valve clearance see Valve Clear ance Adjustment in the Periodic Maintenance chapter KEO4017BS2 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 9 Cylinder Head Push Rod Inspection e Place the rocker arm push rod in V blocks that are as far apart as possible and set a dial gauge A 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 readings is the amount of runout x If the runout exceeds the service limit replace the rod Rocker Arm Push Rod Runout Service Limit TIR 0 5 mm 0 02 in Valve Mechanism Removal Installation e Remove the cylinder head assembly see Cylinder Head Assembly Removal in this chapter NOTE OWhen removing the valve mechanism parts note their position so that they may be rein
46. e stem x If any single measurement is less than the service limit replace the valve Valve Stem Diameter Service Limit Inlet 6 95 mm 0 274 in Exhaust 6 93 mm 0 273 in KEO5008BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 12 ENGINE TOP END Valves Valve Guide Inside Diameter e Use a small bore gauge or a micrometer to measure the inside diameter A of the valve guide B at three places down the length of the guide x If the measurement is more than the service limit replace the cylinder head with a new one Valve Guide Inside Diameter Service Limit Inlet Exhaust 7 08 mm 0 279 in KEO5020B81 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 x If the measurement is less than the service limit replace the spring Valve Spring Free Length Service Limit 32 6 mm 1 28 in GFO60603S1 Automatic Compression Release ACR Inspection ACR is the equipment which allows some of the compres sion pressure to escape making it easy to turn over the crankshaft during starting e Remove Rocker Cover see Cylinder Head Assembly Removal in this chapter Spark Plug see Spark Plug Removal in the Electrical System chapter e Confirm that the valve clearance is the specified value see Valve Clearanc
47. e A eases ch OO 8 7 Charging Ignition SySteM aii die 8 8 Flywheel Stator Coil Removal nin 8 8 Flywheel Stator Coil Installation cccecceee cee ee cece cece eee e ects eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 8 9 Stator Re UE ln 8 10 Unregulated Stator Output cocido A AAA cias 8 10 Ignition Gol Removal E aii 8 12 Ignition Col Installation ie EE 8 12 ignition Coil INSPOCUOM ici AA AAA A E 8 12 Spark Pl Re EE 8 12 Spark Pl gInstallatio mnanaa A Ia 8 13 Spark Plug Cleaning and Gap Inspection 8 13 Ele tric Starter Syst Meas Lesire init A eeu ta ed a ines aden 8 14 Starter Motor REMOVAL s ates a AN ins 8 14 Starter Motor Installation snnseneenneeeeseeneseeesrrrrrrrrrrrrrrrrrrrrrrrrrrrtrrrttrrrrrtttrrttertttttrttttttttnnt 8 14 Starter Solenoid and Circuit Test 8 14 Starter Motor EE 8 15 ee 8 16 Starter Motor Assembly Notes 2 c ccc cccetecseeseceteceeeeeeeeneseenueceeeeeenbesseueeceteeseteesereeeeecnes 8 17 Starter Motor Brush Inspection coccccccnccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninininss 8 19 Brush Spring Inspection 8 19 Armat re Lee xiii A A AAA 8 19 Yoke Assembly Inspection E 8 21 Pinion Clutch INS pecto niis ads 8 21 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 2 ELECTRICAL SYSTEM Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTE
48. e Adjustment in the Periodic Main tenance chapter e Observe the movement of the exhaust valve A and rocker arm B by turning slowly the crankshaft clockwise x lf the exhaust valve is not pushed up to open by the rockerarm just after the inlet valve closed ACR with the camshaft is out of order see Camshaft Inspection in the Camshaft Crankshaft chapter Exhaust Valve Lift by ACR Standard 1 1 mm 0 043 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 13 Cylinder Piston Piston Removal e Remove Crankcase Cover see Crankcase Cover Removal in the Camshaft Crankshaft chapter Camshaft see Camshaft Tappet Removal in the Camshaft Crankshaft chapter Balancer Shaft see Balancer Shaft Removal in the Camshaft Crankshaft chapter e Turn the crankshaft to expose the connecting rod cap bolts A e Remove the bolts and take off the connecting rod cap B NOTE ONote the position of the connecting rod cap for rein Stalling the cap e Push the connecting rod end into the cylinder and pull the piston and connecting rod out of the cylinder e Remove one of the piston pin snap rings A with needle nose pliers e Remove the piston by pushing the piston pin A out the side from which the snap ring was removed e 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
49. e carburetor body e Assemble carburetor parts with recommended tightening torque see Exploded View 1 Screw 2 Throttle Valve 3 Throttle Shaft 4 Dust Seal 5 Choke Valve 6 Choke Shaft 7 Spring 8 Snap Ring 9 Pilot Jet Plug 10 Pilot Jet 11 Low Idle Speed Screw 12 Main Jet 13 Pilot Screw Plug 14 Pilot Screw 15 Float Valve 16 Float 17 Float Pin 18 Gasket 19 Float Chamber Assy 20 Float Chamber Bolt KC05069B53 o www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 15 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 electrical appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point washing 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 washing This will prevent to damage or deterioration of the parts The carburetor body has plastic parts that cannot be removed Do not use a strong carburetor wash ing which could attack these parts instead use a mild high flash point washing safe for plastic parts Do not use wire or any other hard ins
50. e oil screen A into slots B in the pipe C and install the pipe on the crankcase cover with the mounting bolts and spacers 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 x lf the screen is damaged replace it www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 1 Camshaft Crankshaft Table of Contents Exploded Mi Wisin dd 7 2 elen e le EE 7 4 Special TOO s iii a A A A A a 7 5 Cra e a 7 6 Crankcase Cover Remova 7 6 Crankcase Cover Installation nnnnnneeneennnenneseererrrtrrrtrrrrtrrttrrtrrrtrrrrrrrttrrttrrtrrrtrrrrrrrrennt 7 6 nee Lan ME 1 7 RE e e EE 7 8 E ue O 7 9 Breather Valve Removal sssssssssnrrrnnrtnntnnnttnntnnntnnAnnnEEnAAEEEEEAEEEEEEEEEEEEEAEEEAE EEEn EEE En EEEE 7 10 Breather Valve Installaton 7 10 Breather Valve Inspection oococcccncccnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnninnnnnnninnnnss 7 10 Gamshaft Tapetes
51. eal Blue 9 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 10 Ball Bearing Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver to the end of the race that contacts the press fit portion and press it evenly over the base component 11 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENERAL INFORMATION 1 3 Before Servicing 12 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 reduce rubber to metal friction 13 Circlip Retaining Ring and Cotter Pin When installing circlips and retaini
52. emitting in the air The blow by gases are drawn into the clean side of the air cleaner through the crankcase and the cylinder head and mixed with the clean air flow and subsequently comes into the combustion chamber through the carburetor Oil is primarily separated from the gases while passing through the inside of the rocker chamber from the crankcase and secondly separated from the gases in the breather chamber and then brought back to the crankcase KG080098W4 C www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 10 CAMSHAFT CRANKSHAFT Breather Breather Valve Removal e Remove the cylinder head assembly see Cylinder Head Assembly Removal in the Engine Top End chapter e Unscrew the breather valve screw A Breather Valve Installation e Install the reed valve A and back plate B Then tighten the breather valve screw C Torque Breather Valve Screw 3 4 N m 0 35 kgf m 30 in Ib e Install the cylinder head assembly see Cylinder Head As sembly Installation in the Engine Top End chapter Breather Valve Inspection e Remove the breather valve see Breather Valve Removal in this chapter e Inspect the reed valve for breakage hair cracks or distor tion replace it if necessary e Inspect the back plate for damage or rough contact sur face replace it if necessary e Inspect the valve seating surface The surface should be free of nicks or burrs e
53. essed air 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 Straight edge 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 Alf 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 03 mm 0 001 in e Check the cylinder head for cracks or other damage e Cracks not visible to the eye may be detached by using a metal crack detection system Visual color check com monly found at automotive parts tore e If a crack is present in the cylinder head replace it e Inspect the mating surface for burrs and nicks 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 Assembly Removal in the Engine Top End chapter e Place the piston at top dead center TDC of the compres sion stroke turning the crankshaft rotational direction www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 10 PERIODIC MAINTENANCE Periodic Mainte
54. etor 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 17 Carburetor 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 x If the float position is not correct replace the float with a new one KCO5070BS1 e Inspect the float valve for excessive wear or damage The tip should be smooth without any grooves scratches or tears The rod at the other end of the needle should move smoothly when push in and released Good A Not Good B x lf either the needle or the seat is worn or damaged re place the float assembly and carburetor body as a set a KCO5011BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 18 FUEL SYSTEM Fuel Pump Fuel Filter The diaphragm in the fuel pump operates by the pulse generated in the crankcase and the fuel pump supplies fuel to the carburetor The fuel pump disassembly is not recommended if any damage for the pump is
55. 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 thread of the oil pressure switch Sealant Kawasaki Bond Silicone Sealant 56019 120 e Tighten the oil pressure switch ORemove excessive sealant after assembling x lf the oil pressure is below the specification inspect the oil pump and relief valve see Oil Pump Inspection and Relief Valve Inspection in this chapter x If the oil pump and relief valve are not at fault inspect the rest of the lubrication system Oil Pressure Low Idle Speed 196 343 kPa 2 0 3 5 kgf cm 28 50 psi High Idle Speed 343 490 kPa 3 5 5 0 kgf cm 50 71 psi Measurement Condition Engine Oil 10W 30 Engine Oil Temperature Low Idle Speed approx 50 C High Idle Speed approx 70 C Oil Pressure Switch Detect Pressure 69 124 kPa 0 7 1 3 kgf cm 10 18 psi Screw PT 1 8 pipe thread www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 9 Oil Pump Relief Valve Oil Pump Removal e Remove the crankcase cover see Crankcase Cover Re moval in the Camshaft Crankshaft chapter e Remove the circlip A and oil pump parts assembly pump cover plate inner rotor and outer rotor CAUTION Do not damage camshaft bore with the circlip Oil Pump Installation e Fill the rotor housing with engine oil for initial lubrication
56. ght is pulled entirely outward with your finger if the top of the shaft is higher than the cam base replace the camshaft with a new one KG05015BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 13 Camshaft Tappet Camshaft Bearing Journal Wear e Measure the height of each cam lobe A Alf the cam height is less than the service limit for either lobe replace the camshaft Cam Lobe Height Service Limit Inlet 29 86 mm 1 176 in Exhaust 29 86 mm 1 176 in KG05014BS1 e Measure both camshaft journals at several points around the journal circumference Alf the journal diameter is less than the service limit re place the camshaft PTO Side Camshaft Journal Diameter Service Limit 49 93 mm 1 966 in Flywheel Side Camshaft Journal Diameter Service Limit 19 97 mm 0 786 in KG05013BS1 e Measure the inside diameter A of the camshaft bearing on the crankcase at several points Replace the crankcase if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Service Limit 20 07 mm 0 790 in e Measure the inside diameter A of the camshaft bearing on the crankcase cover at several points Replace the crankcase cover if the inside diameter is more than the service limit Camshaft Bearing Inside Diameter Crankcase Cover Service Limit 50 09 mm 1 972 in
57. gine Top End chapter e Inspect the valve seats for damage lf the seats are warped or distorted beyond recondition ing replace the cylinder head e Pitted or worn valve seats can be refaced 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 Lapper 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 KEO5004BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures NOTE OThe valve stem and guide must be in good condition or this check will not be valid A Good A Too Wide B Too Narrow C Uneven D x If the valve seating pattern is not correct repair the seat Valve Seating Surface Width STD Inlet 1 1 1 7 mm 0 043 0 070 in Exhaust 1 0 1 5 mm 0 039 0 059 in KEO5003BS1 Valve Seat Repair e Follow the manufacturer s instructions for use of valve seat cutters Special Tools Valve Seat Cutter Holder 67 57001 1126 Valve Seat Cutter Holder Bar 57001 1128 Inlet Valve Valve Seat Cutter 45 p35 57001 1116 Valve Seat Cutter 32 638 5 57001 1122 Exhaust Valve Valve Seat Cutter 45 p32 57001 1115 Valve Seat Cutter 32 635 57001 1121 x If the
58. gine 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 Oil Level Inspection e Refer to the Oil Level Inspection in the Periodic Mainte nance chapter Oil Change e Refer to the Oil Change in the Periodic Maintenance chapter Oil Filter Replacement e Refer to the Oil Filter Replacement in the Periodic Main tenance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 8 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 filter and crankshaft bearing on the crankcase 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 from the crankcase e Install the oil pressure gauge adapter A and oil pressure gauge B Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Oil Pressure Gauge Adapter PT 1 8 57001 1033 e Run the engine and allow warm up completely e Run the engine at
59. good quality reliable torque wrench 4 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 5 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 6 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 7 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 8 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s 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 S
60. h rods under the rocker arms e Install the push rods in their original positions on the cylin der see Push Rod Installation in this chapter e Set the cylinder at TDC of power stroke in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 8 ENGINE TOP END Cylinder Head e Tighten the cylinder head bolts following the tightening sequence as shown in the figure Torque Cylinder Head Bolts 37 N m 3 8 kgf m 27 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 see Valve Clear ance Adjustment in the Periodic Maintenance chapter e Install the new gasket and rocker cover Push Rod Removal e Set the cylinder at TDC of power stroke e Remove the rocker cover see Cylinder Head Assembly Removal in this chapter e Loosen the lock screws A and the valve clearance ad justing nuts B e Move the rocker arms C to clear the push rod upper ends e Pull out the push rods y NOTE OMark the push rods so they can be installed in their orig inal position during assembly Push Rod Installation e Set the cylinder at TDC of power stroke e Install the push rods A in their original positions on each cylinder OTo Install the push rod in the correct position on the tappet B insert the push rod so end of the push rod is sli
61. haser 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 plug e Magneto or electronic ignition system e Fuel filter element e Air cleaner element e Crankcase e Cylinder head e Breather chamber and internal parts e Inlet pipe and tube www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 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
62. he flywheel recess B e Insert the projection A ofthe plate to the hole B between the crankshaft and the flywheel e Install the washer and tighten the flywheel bolt Torque Flywheel Bolt 56 N m 5 7 kgf m 41 ft lb OSee the following instruction for installing the washer www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 10 ELECTRICAL SYSTEM Charging Ignition System Olnstall the washer A with its convex surface upward as shown in the figure Flywheel Bolt B e Install the ignition coil see Ignition Coil Installation in this chapter e Install the fan housing and tighten the bolts Torque Fan Housing Bolts 5 9 N m 0 60 kgf m 52 in Ib e Install the control panel on the fan housing with the mount ing bolts see Control Panel Assembly Installation in the Fuel System chapter Stator Coil Resistance e Disconnect the stator coil connector e Measure the stator coil resistance OConnect an ohmmeter between stator pins Stator Coil Resistance Standard 0 01 0 1 Q x If the meter does not read as specified replace the alter nator stator x If the coil has normal resistance but the voltage inspect showed the alternator to be defective the rotor magnets have probably weakened and the rotor must be replaced To Stator A Stator Coil Connector B Ohm Meter C e Check for continuity between each stator pin and ground There should be no continuit
63. ing bolts A and remove the fan housing B e Remove the ignition coil A see Ignition Coil Removal in this chapter e Hold the flywheel with a suitable tool A e Remove the flywheel bolt washer and plate then remove the fan B e Using a suitable flywheel puller remove the flywheel NOTE Olf a flywheel puller is not available screw the flywheel bolt A and tap sharply and squarely on the bolt end to break the flywheel loose Flywheel will loosen CAUTION Do not attempt to strike the flywheel itself Striking the flywheel can cause the magnets to lose their magnetism www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 9 Charging Ignition System e Remove Woodruff Key A Stator Coil Screws B 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 Crankshaft Tapered Portion A Flywheel Tapered Portion B OTreat deoiling the tapered portion of the flywheel and crankshaft e Fit the woodruff key C securely in the slot in the crank shaft before installing the flywheel e Install the flywheel onto the crankshaft taper so that the woodruff key fits in the key way in the hub of the flywheel e Insert the projections A of the fan to t
64. iscount Parts Call 606 678 9623 or 606 561 4983 7 2 CAMSHAFT CRANKSHAFT Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 3 Exploded View No Fastener Torque Remarks i N m kgf m ft Ib 1 Valve Clearance Lock Screws 6 9 0 70 61 in lb 2 Rocker Arm Bolts 28 2 9 21 3 Crankcase Cover Bolts 21 6 2 2 16 S 4 Connecting Rod Big End Cap Bolts 5 9 0 60 52 mb O 5 Breather Valve Screw 3 4 0 35 30 in lb G Apply grease M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts S Tighten the fasteners following the specified sequence www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 4 CAMSHAFT CRANKSHAFT Specifications Item Service Limit Camshaft Tappet Cam Lobe Height Inlet 29 86 mm 1 176 in Exhaust 29 86 mm 1 176 in Camshaft Journal Diameter PTO Side 49 93 mm 1 966 in Flywheel Side 19 97 mm 0 786 in Camshaft Bearing Inside Diameter Crankcase 20 07 mm 0 790 in Crankcase Cover Crankshaft Connecting Rod Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Width Crankpin Width Connecting Rod Big End Inside Diameter Crankpin Outside Diameter Crankshaft Runout Crankshaft Journal Diameter Flywheel Side Crankcase Crankshaft Bearing Inside Diameter Crankcase Balancer Shaft Balancer Shaft Journal Diamete
65. jet F idle screw G idle mixture screw slow air breed jet H idle port I and the slow port J The slow system meters the fuel air mixture 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 atomize it Instead the fuel is drawn through the slow system since the nearly closed throttle valve K causes high speed air flow past the idle port and slow port even at low engine speed Fuel flow in the slow system is metered by the slow jet pilot jet Air for better atomization is admitted via the air bleed 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 slow port and idle port While the throttle valve is almost closed it covers the small slow port opening into the bore from the slow system As the throttle valve begins to open it uncovers the slow port allowing more fuel air mixture to flow The extra flow is needed because the engine starts to run faster as the throttle is opened The slow screw controls the amount of fuel air mixture allowed through the idle port but does not meter the slow port A moderate amount of air comes in around the throttle valve at an idle so adjusting the idle screw changes the fuel air ratio Turning the idle screw idle mixture screw out c
66. kage around the cylinder head replace the damaged gasket and check the cylinder head warp Condition of the valve seating Valve clearance Piston cylinder wear piston seizure Piston ring piston ring groove See lS www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 7 Cylinder Head Cylinder Head Assembly Removal e Remove Cover Bolts A and Cover B Oil Gauge C Carburetor see Carburetor Removal in the Fuel System chapter Spark Plug see Spark Plug Removal in the Electrical System chapter Fan Housing see Flywheel Removal in the Electrical System chapter e Unscrew the rocker cover mounting bolts A and remove the cover B and gasket e When removing the cylinder head set the cylinder at TDC of power stroke in e Remove the push rods see Push Rod Removal in this chapter 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 head and cylin der e Install the knock pins e Put new gasket and the cylinder head assembly on the cylinder then align the pus
67. lb Cooling System Fan Housing Bolts 52 in lb Flywheel Bolt 41 Engine Top End Spark Plug 16 Cylinder Head Bolts 27 S Connecting Rod Big End Cap Bolts 52 in lb O Valve Clearance Lock Screws 61 in lb Rocker Arm Bolts 21 Lubrication System Oil Filter Joint 61 in lb Oil Filter 87 in lb O Oil Drain Plugs 61 in lb Crankcase Cover Plug 61 in lb Crankcase Cover Bolts 16 S Cylinder Head Bolts 27 S Oil Line Plugs 35 in lb L Oil Pressure Switch 87 in lb SS Camshaft Crankshaft Valve Clearance Lock Screws 61 in lb Rocker Arm Bolts 21 Crankcase Cover Bolts 16 S Connecting Rod Big End Cap Bolts 52 in lb O Breather Valve Screw 30 in lb Electrical System Flywheel Bolt 56 5 7 41 Stator Coil Screws 3 4 0 35 30 in lb www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Remarks Fastener Ignition Coil Bolts Spark Plug Starter Motor Mounting Bolts 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 mm Torque ft lb A 2 0 0 20 17 in lb S 3 4 0 35 30 in Ib 6 5 9 0 60 52 in lb 9 15 1 5 11 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606
68. lor 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 Yellow Red 6B020601w1 16 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 17 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 18 Service Data Service Data 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 deteri orated performance replace the damaged parts www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 1 4 GENERAL INFORMATION Model Identification www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 GENER
69. m For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 7 Periodic Maintenance Procedures Fuel System NOTE OHigh and low idle speeds may very depending on the equipment on which the engine is used Refer to the equipment specification Low Idle Speed Adjustment e Disconnect all 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 closed 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 Idle Speed Carburetor Idle rpm 950 50 rpm r min e Release the throttle lever and adjust the low idle speed set screw A on the control panel to obtain the specified governed low idle speed Low Idle Speed Governed Idle rpm 1 125 75 rpm r min High Idle Speed Adjustment NOTE OHigh idle speed adjustment should be made after the 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 8 PERIODIC MAINTENANCE Periodic Maintenance Procedures A WARNING Always keep your hands clear of the moving parts e Move the
70. mm 0 746 in Piston Pin Hole Inside Diameter 19 08 mm 0 751 in Connecting Rod Small End Inside Diameter 19 06 mm 0 750 in Cylinder Inside Diameter 82 10 mm 3 232 in Cylinder Bore Out Round 0 056 mm 0 0022 in Standard Valve clearance Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 in Valve seating surface angle Inlet Exhaust 45 Valve seating surface width Inlet 1 1 1 7 mm 0 043 0 070 in Exhaust 1 0 1 5 mm 0 039 0 059 in Valves guide inside diameter Inlet Exhaust 7 000 7 015 mm 0 2756 0 2762 in Exhaust Valve Lift by ACR 1 1 mm 0 043 in Cylinder inside diameter 81 980 82 000 mm 3 2276 3 2283 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 5 Special Tools Compression Gauge 20 kgf cm Compression Gauge Adapter M14 x 1 25 57001 221 57001 1159 T5702218T ST5711598T Piston Ring Compressor Grip Piston Ring Compressor Belt 80 91 57001 1095 57001 1320 ST5710958T 8757132097 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 6 ENGINE TOP END 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
71. motor e Faulty engine eWorn pinion or ring gear eIncorrect starter alignment e Faulty clutch e Faulty engine e Faulty engine switch eFaulty solenoid switch e Faulty pinion or ring gear e Incorrect starter alignment e Faulty pinion return mechanism Charge or replace Repair or replace Replace Repair or replace Replace Charge or replace Repair or replace Replace Repair or replace Charge or replace Repair or replace Replace Repair or replace Repair or replace Replace Correct Replace Repair or replace Repair or replace Replace Repair or replace Correct Repair or replace KI03004B_F For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 NX Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 2066 01 Printed in Japan www mymowerparts com
72. n Second 0 18 mm 0 00709 in NOTE OThe oil ring is a three piece assembled ring It is difficult to measure the ring groove clearance and thickness visually inspect only e Measure the piston ring thickness A OUse a micrometer to measure at several points around the rings x If any of the measurement are less than the service limit replace the entire set of rings Piston Ring Thickness Service Limit 1 40 mm 0 0551 in Top Second KE06010BS1 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 17 Cylinder 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 x If the end gap of any ring is greater than the service limit replace the entire set of rings KE06040BS1 Piston Ring End Gap Service Limit Top 0 7 mm 0 028 in Second 0 8 mm 0 031 in Oil 1 0 mm 0 039 in Piston Pin Piston Pin Hole and Connecting Rod Wear e Remove the piston pin e Measure the outside diameter of the piston pin with a mi
73. n a load is applied Engine malfunctions at low speed Remove spark plug and check spark by e Incorrect governor linkage adjustment Faulty governor spring e Governor assy malfunctioning e Plugged air hole in tank cap e Entry of dust and air into fuel filter or fuel pipe e Faulty plug insulation e Fouled electrodes e Faulty ignition coil e Incorrect air gap 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 Is unusual smoke emitted out of muffler Directly and gradually open throttle valve by hand Does the revolution drop or does engine stall at a certain position Is air sucked through carburetor e YES e Loose flange nuts flange NO e Damaged gasket m Are valve clearances of normal values YES e Compression leakage NO e Wrong valve timing Is alignment of timing gear marks NO eLargely deviated valve timing correct YES e Plugged in carburetor interior NO Correct Replace Check Replace Clean Replace Correct YES e Overrich fuel in pilot system Turn in pilot screw by a minor extent Disassemble and clean Retighten Replace Adjust valve clearance Correct alignment of timing gear marks Correct alignment of timing gear marks K102021B F www mymowerparts com For Kawasaki Discount
74. nance Procedures 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 Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 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 Assembly In stallation in the Engine Top End chapter e Turn the crankshaft to the proper direction until the piston is at TDC of the compression stroke described above e Loosen the lock screw A and valve clearance adjusting nuts B e Insert a thickness gauge C between the rocker arm and valve stem and tighten the adjusting nut until the thick ness gauge begins to bind between the rocker arm and valve stem end Use a sweeping motion with the thick ness gauge while making this adjustment Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 0039 0 0059 in e Holding the adjusting nut with a wrench tighten the lock screw to the specified torque Torque Valve Clearance Lock screw 6 9 N m 0 70 kgf m 61 in Ib CAUTION e Remeasure any clearance that was adjusted Readjust if necessary Valve Seat Inspection e Remove the valve see Valve Mechanism Removal Instal lation in the En
75. nd D www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 6 FUEL SYSTEM Governor Link Mechanism 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 in place and that it pulls the governor arm and throttle lever E toward 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 G to fully open the carburetor 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 OThere should be no gap between the governor arm and the snap pin on the governor shaft Torque Governor Arm Clamp Nut 5 9 N m 0 60 kgf m 52 in Ib e Install the control panel assembly and connect the gov ernor arm with the governor spring KCO4020BS2 C Governor Assembly Removal Inspection e Remove the crankcase cover see Crankcase Cover Re moval in the Camshaft Crankshaft chapter e Visually check the governor assembly as built in the crankcase cover for damage or wear CAUTION Do not remove the governor gear assembly unless the parts are to be replaced The parts cannot be reused once they are removed e When removing the governor assembly A for replacing use two screw drivers B of an approp
76. nd 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 enough to burn you severely It may be hot e Replace the O ring B with a new one e Install the drain plug with the O ring and tighten it Torque Oil Drain Plugs 6 9 N m 0 70 kgf m 61 in Ib e Remove the oil filler cap and pour in the specified type and amount of oil Engine Oil Type SF SG SH or SJ Class Viscosity SAE 40 SAE 30 SAE 10W 30 SAE 10W 40 or SAE 5W 20 Capacity 1 1 L 1 16 US qt When filter is not removed 1 3 L 1 37 US qt When filter is removed Oil Filter Replacement e Drain the engine oil see Oil Change in this chapter 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 e Apply engine oil to the seal A e Install new filter OTurn the filter until the seal contacts mounting surface B of the engine Then turn the filter 2 3 to 3 4 rotations by HAND S to install it e Pour in the specified type and amount of oil see Oil Change in this chapter e Run the
77. ng rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while running leading to a problem 14 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 15 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 amount of a second color so a two co
78. noticed replace it with a new one Fuel Pump Inlet A Pulse B Outlet C Fuel Pump Inspection e Check the vent hole A and filter B for plugging or clog ging x If vent hole and filter are plugged or clogged remove the foreign matter from them Fuel Flow Test Before this test be sure the battery is fully charged 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 to the outlet nozzle e Run the lower end of the hose into a container e Start the engine Check the fuel flow x If 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 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 COOLING SYSTEM 4 1 Cooling System Table of Contents Exploded EE 4 2 CODINA ici 4 4 AR Cooling Fan e EE 4 4 Cooling Fear E LL A cove ed rd ca eee A a A 4 4 Cooling age ee EE 4 4 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 4 2 COOLING SYSTEM Exploded View Za AN www mymowerparts com For Kawasaki Discount
79. nside Diameter Service Limit 43 08 mm 1 696 in e Measure the crankpin outside diameter A OUse a micrometer to measure several points around the crankpin circumference x If the crankpin diameter is less than the service limit re place the crankshaft with a new one Crankpin Outside Diameter Service Limit 42 95 mm 1 691 in Crankshaft Runout e Measure the crankshaft runout OSet the crankshaft in a flywheel alignment jig A or on V blocks gauge OSet a dial gauge B 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 A x If the measurement exceeds the service limit replace the crankshaft SE Crankshaft Runout Service Limit TIR 0 05 mm 0 002 in Crankshaft Main Journal Wear e Measure both main journals at several points around the journal circumference x If the journal diameter is less than the service limit re place the crankshaft with a new one Flywheel Side Crankshaft Journal Diameter A Service Limit 34 978 mm 1 377 in KG06021BS1 o www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 17 Balancer Shaft Balancer Shaft Removal e Remove Crankcase Cover see Crankcase Cover Removal in this chapter Balancer Shaft A Balancer Shaft Installation
80. nt solvent clean off the mating sur faces of the crankcase and the cover and wipe dry 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 Clean the bearing housing e Apply oil to a new ball bearing A e Using the bearing driver set B install the new ball bear ing until it stops at the bottom of its housing KG04008BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 7 Crankcase e Be sure to replace any oil seal removed with a new seal Olnstall the oil seal so that the marks A face out OPack high temperature grease B to 60 volume into the space between the seal lip C and dust lip D Press in the new oil seal 4 4 5 mm 0 16 0 18 in E below the crankcase cover surface F using a press or suitable tools Do not damage the seal lip 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 21 6 N m 2 2 kgf m 16 ft lb ODo not turn one bolt down completely before the others
81. od Re MOV poo A a a eg eer 5 8 Push Rod Installation A Ai RARO 5 8 PUSH Rod Inspeccion ele Pond IAE ed LIA iia 5 9 Valve Mechanism Removal Installation oooooooocococococococococococononaonnnnonnnrnnno nooo nnrrnnrnrnnns 5 9 Cleaning ANG AnS PO e EE 5 10 Rocker Arm Inspechon roca n cnn r rre 5 10 VE 5 11 Valve Clearance Inspection cccccccececeeeeeeeeeeeeeeete cee cee cee cedeeeeeeeeeeeeeeeeeeeeeseeeeeseeseeesees 5 11 Valve Clearance Adjustment oococcccncccncnnonos cacon e 5 11 Valve Seat INSPSCHON Aia 5 11 Valve Seat Repair ceee enra e eE AEE RAEE KE EaR da id A aa 5 11 Valve Head WR le NEE 5 11 Valve Stem RUmout AEEA TEETE TTE T TEET 5 11 Valve Stem Diameteriis scien A aa a a a ea iR 5 11 Valve Guide Inside Diameter 5 12 Valve Spring INSpectiON ENNEN 5 12 Automatic Compression Release ACR Inspection oooocccccccinccononccoccncnnncnnnanannnoncncncnnnnnos 5 12 Cylinders Pista A A A a a a Se 5 13 Piston Gun EC WE 5 13 Piston Installation ia 5 14 Pisto CIS IN EE 5 15 Piston Ring and Ring Groove Wear cocccconnnnionscccnecannanans amero nde 5 16 di A Nal Aa aeaa Geaa 5 17 Piston Pin Piston Pin Hole and Connecting Rod Wear 5 17 PIStOn BIEN 5 18 Cylinder inside Dia mete geegent 5 18 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 2 ENGINE TOP END Exploded View www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP EN
82. on and connect it as shown Switch Lead Connector A To Ground B e Turn the engine switch to the START II position and read the tester x lf the tester reads battery voltage the circuit is good Alf the tester reads much less than battery voltage or no voltage at all either the wiring or the engine switch is bad Check the engine switch or the wiring for damaged or broken wires and replace as required Starter Motor Test NOTE OAlways inspect the Starter Solenoid and Circuit Test section before starting following procedures e Remove the starter motor e Hold the starter motor with a vice CAUTION Be careful not to deform the starter motor body when holding it with a vice e Connect the first jumper cable to the battery terminal and the other end of the cable to the starter motor terminal on the solenoid as shown e Connect the second jumper cable to the battery termi nal e Turn on the switch intermittently for one second intervals e The pinion should rotate freely x If the pinion does not rotate freely replace the starter mo tor www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 16 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly e Remove the lead A from the starter motor to the sole noid e Unscrew the mounting nuts A and remove the solenoid assembly B e Remove Through Bolts A Pinion Gear
83. orn or damaged replace the rocker arm KE04003BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ENGINE TOP END 5 11 Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Seat Inspection e Refer to the Valve Seat Inspection in the Periodic Mainte nance chapter Valve Seat Repair e Refer to the Valve Seat Repair in the Periodic Mainte nance chapter Valve Head Thickness e Remove the valve see Valve Mechanism Removal Instal lation in this chapter e Measure the thickness of the valve head Alf the valve head thickness valve margin A is less than the service limit replace the valve Valve Head Thickness Service Limit Inlet Exhaust 0 4 mm 0 016 in KE05007BS1 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 x If the stem runout is greater than service limit replace the valve T A im Valve Stem Runout Service Limit Inlet Exhaust TIR 0 05 mm 0 002 in amp E03010781 Valve Stem Diameter e Measure the diameter of the valve stem A in two di rections at right angles at four different positions on th
84. ounterclockwise enrichens the mixture turning it in clockwise leans the mixture www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 11 Carburetor www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 12 FUEL SYSTEM Carburetor Low Idle Speed Adjustment e Refer to the Low Idle Speed Adjustment in the Periodic Maintenance chapter High Idle Speed Adjustment e Refer to the High Idle Speed Adjustment in the Periodic Maintenance chapter 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 Altitude Main Jet No 0 1 000 m 0 3 000 ft 110 1 000 2 000 m 3 000 6 000 ft 108 2 000 m 6 000 ft and higher 106 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 A at the bottom of the float chamber see Fuel S
85. p Relief Valve Relief Valve Inspection e Visually inspect the relief valve spring steel ball and valve seat in the crankcase Alf 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 Alf cleaning does not solve the problem replace the relief valve parts Alf 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 If the free length of the spring is less than the service limit replace the spring Relief Valve Spring Free Length Service Limit 15 70 mm 0 618 in ve P www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 12 LUBRICATION SYSTEM Oil Screen Oil Screen Removal e Remove the crankcase cover see Crankcase Cover Re moval in the Camshaft Crankcase chapter e Unscrew the mounting bolts A and remove the pipe B e Push C the oil screen with thumbs and remove it Oil Screen Installation e Clean the oil screen thoroughly whenever it is removed for any reason e Insert th
86. perating range grid area on dipstick Oil Pressure Low Idle Speed approx 50 C 196 343 kPa 2 0 3 5 kgf cm 28 50 psi High Idle Speed approx 70 C 343 490 kPa 3 5 5 0 kgf cm 50 71 psi Oil Pressure Switch Detect Pressure 69 124 kPa 0 7 1 3 kgf cm 10 18 psi Screw PT 1 8 pipe thread Oil Filter By pass Valve Opening Pressure 79 3 113 8 kPa 0 81 1 16 kgf cm 11 5 16 5 psi Oil Pump Inner and Outer Rotor Clearance 0 20 mm 0 00787 in Outer Rotor Outside Diameter 40 470 mm 1 5933 in Outer Rotor Thickness 9 94 mm 0 391 in Pump Housing Inside Diameter 40 801 mm 1 6063 in Pump Housing Depth 10 160 mm 0 4000 in Pump Shaft Outside Diameter 12 645 mm 0 4978 in Pump Shaft Bearing Inside Diameter 12 811 mm 0 5044 in Relief Valve Spring Free Length 15 70 mm 0 618 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 6 6 LUBRICATION SYSTEM Special Tools and Sealant Kawasaki Bond Silicone Sealant 56019 120 Oil Pressure Gauge 5 kgf cm 57001 125 ST5701258T ST5601208T Oil Pressure Gauge Adapter PT 1 8 57001 1033 ST5710338T www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LUBRICATION SYSTEM 6 7 Engine Oil and Oil Filter CAUTION Engine operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in en
87. piece oil ring with your thumbs in the same manner GE160606S1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 14 ENGINE TOP END Cylinder Piston 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 KEO6045BS1 e Do not mix up the top and second rings e Install the second ring so that the notched edge A faces down e Install the top ring e The rings should turn freely in the grooves Piston Head B Top Ring C Second Ring D KEO6033BS1 e Align the piston and rings with the piston ring end gap as shown Arrow Match Marks A Top ring End Gap Upper Steel Rail End Gap B About 45 C Second Ring End Gap Lower Steel Rail End Gap D e Apply engine oil to the piston pins e Assemble the piston onto the connecting rod so that the arrow mark A on the top of the piston can be aligned with MADE IN USA B on the connecting rod KEO6O035BS1 e 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 OWhen installing a piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse the sn
88. r Balancer Shaft Bearing Inside Diameter Crankcase Cover Crankcase 50 09 mm 1 972 in 0 2 100 mm 0 008 3 94 in 0 2 100 mm 0 008 3 94 in 27 0 mm 1 063 in 28 4 mm 1 112 in 43 08 mm 1 696 in 42 95 mm 1 691 in TIR 0 05 mm 0 002 in 34 978 mm 1 377 in 35 055 mm 1 380 in 31 935 mm 1 258 in 32 06 mm 1 262 in 32 06 mm 1 262 in www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 CAMSHAFT CRANKSHAFT 7 5 Special Tool Bearing Driver Set 57001 1129 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 6 CAMSHAFT CRANKSHAFT Crankcase Crankcase Cover Removal e Drain the oil see Oil Change in the Periodic Maintenance chapter e Unscrew the mounting bolts A and remove the crankcase cover B from the crankcase OThere are two dowel pins on the crankcase mating sur face To loosen the crankcase cover gently tap it with wooden or plastic mallet CAUTION Do not remove the ball bearing or the oil seal unless it is necessary If removed replace it with a new one e Remove the oil seal with a screw driver e Using the bearing driver set B push out the ball bearing A Special Tool Bearing Driver Set 57001 1129 KG04007BS1 Crankcase Cover Installation e Scrape off the old gasket from the mating surfaces of the crankcase and the cover e With a high flash poi
89. reventing ignition operation www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 12 ELECTRICAL SYSTEM Charging Ignition System Ignition Coil Removal e Remove Control Panel Assembly see Control Panel Assembly Removal in the Fuel System chapter Carburetor see Carburetor Removal in the Fuel System chapter Fan Housing see Flywheel Stator Coil Removal in this chapter Spark Plug Cap Bolts A Ignition Coil B Ignition Coil Installation e Install ignition coil A on the crankcase Tighten bolt 1 first then tighten bolt 2 While tightening bolts adjust the air gap B between the leg of ignition coil and the magnet to the specified gap value as shown Torque Ignition Coil Bolts 5 9 N m 0 60 kgf m 52 in Ib Ignition Coil Air Gap Standard 0 2 0 4 mm 0 0079 0 0157 in NOTE OAbove procedure must be used to insure proper coil air gap is not too large KHO8O13BS1 Ignition Coil Inspection e Remove the ignition coil see Ignition Coil Removal in this chapter 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 A B C A 2 18 kQ 2 18 kQ B 00 a a C 2 18 kQ 10 30 kO CAUTION Use only Tester 57001 1394 with new battery at room temperature for this test A te
90. riate size CAUTION Protect the gasket mount surface of the crankcase cover when removing the governor assembly with the screw drivers www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 7 Governor Link Mechanism Governor Assembly Installation e Install the sleeve A on the governor assembly B CAUTION First install the sleeve The sleeve cannot be installed after the governor gear assembly has been installed e To install first place the thrust washer C on the boss of the shaft D Then install the governor assembly with the sleeve attached on the shaft so that step E is fitted securely in groove F e After installing the assembly turn the governor by hand to make sure that the governor weights G and the sleeve move smoothly Governor Shaft Removal e Remove Crankcase cover see Crankcase Cover Removal in the Camshaft Crankcase chapter Crankshaft see Crankshaft Removal in the Camshaft Crankcase chapter Governor arm see Governor Arm Removal in this chap ter Snap Pin A Governor Shaft B Oil Seal C Washer D e Be sure to replace any oil seal removed with a new seal KC04022BS1 Governor Shaft Installation e Apply engine oil to the governor shaft e Install the washer A to the governor shaft B and insert it from the crankcase inside e Install the oil seal A into the crankcase after
91. s Inspection in the Periodic Maintenance chapter e Disconnect the fuel tube equipment part at the fuel inlet joint A of the carburetor e Unhook the throttle link spring B at the throttle shaft lever C top end with a long nose pliers e Unhook the throttle link rod D from the throttle shaft lever e Remove the carburetor the gasket and the insulator e Check the insulator for damage x lf the insulator is not in good condition replace it with a new one Carburetor Installation e Clean the mating surfaces of the carburetor and inlet pipe and fit the new gaskets e Take care not to bend the throttle link rod during instal lation Make sure that the link spring around the throttle link rod is in place and that it pulls the governor arm and carburetor throttle shaft lever toward each other e Adjust the idle speed see Low High Idle Speed Adjust ment in the Periodic Maintenance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 14 FUEL SYSTEM Carburetor Carburetor Disassembly Assembly 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 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 th
92. 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 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 this manual the product is divided into its major systems and these systems make up the manual s chapters 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 Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition coil section 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 corre
93. ss 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 If the seat does not make proper contact lap the valve into seat with a lapper e Coat the face of valve sparingly with a fine lapping com pound e Use the lapper 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 KEO5006BS1 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 in this chap ter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lubrication System Oil Le
94. stalled in their original position during assembly e Remove Lock Screws A Valve Clearance Adjusting Nuts B Rocker Arms C 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 valve retainer 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 Apply engine oil to the valve stem and install the valve e Check to see that the valve moves smoothly up and down in the guide e Install the spring and the valve retainer e Install the valve retainer while push down the valve re tainer with the thumbs e Soak the valve clearance adjusting nuts and rocker arm in the engine oil e Install the rocker arm by using the valve clearance adjust ing nuts and lock screws e Adjust the valve clearance see Valve Clearance Adjust ment in the Periodic Maintenance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 5 10 ENGINE TOP END Cylinder Head Cleaning and Inspection e Refer to the Cylinder Head Cleaning and Inspection in the Periodic Maintenance chapter Rocker Arm Inspection e Clean and inspect the rocker arm where it touches the A push rod and valve stem x If the contact points A are w
95. ster other than the Kawasaki Hand Tester may show different read ings If a meter with a large capacity battery is used the ignition coil will be damaged x If the tester does not read as specified replace the coil Spark Plug Removal e Carefully pull the plug cap from the spark plug e Remove the spark plugs using a suitable plug wrench www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 13 Charging Ignition System Spark Plug Installation e Screw the spark plug gently into the plug hole with the plug installed in the plug wrench e Tighten the plugs Torque Spark Plug 22 N m 2 2 kgf m 16 ft lb e Fit the plug cap securely e Pull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap Spark Plug Cleaning and Gap Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 8 14 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal e Disconnect the wires shown A e Remove the mounting bolts B and pull the starter motor from the engine with the switch lead C attached 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 20 N m 2 0 kg m
96. t that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor to deter mine the amount of connecting rod twist by using a height gauge B Alf connecting rod twist exceeds the service limit the con necting rod must be replaced KG06017BS1 Connecting Rod Twist Service Limit 0 2 100 mm 0 008 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 Alf the measurement is less than the service limit replace the connecting rod Connecting Rod Big End Width Service Limit 27 0 mm 1 063 in e Measure the crankpin width A with a dial caliper O x If the crankpin width is more than the service limit replace the crankshaft Crankpin Width Service Limit 28 4 mm 1 112 in KG06018BS1 www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 7 16 CAMSHAFT CRANKSHAFT Crankshaft Connecting Rod Connecting Rod Big End Bearing Crankpin Wear e Apply a thin film of oil on the thread of the cap bolts e Install the cap bolts and tighten the bolts to the speci fied torque see Piston Installation in the Engine Top End chapter e Measure the inside diameter A of big end with a inside micrometer x lf the inside diameter is more than the service limit re place the connecting rod with a new one Connecting Rod Big End I
97. throttle lever at a dash to the high idle position and adjust the high idle speed set screw A to obtain the specified high idle speed High Idle Speed Governed Idle rpm 3 750 50 rpm r min e Check the idle speed and readjust the idle speed if nec essary Fuel system Cleanliness Inspection Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the engine 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 Place a suitable container A under the carburetor drain screw B e Loosen the drain screw to drain the carburetor and check to see if water or dirt has accumulated in the carburetor e Tighten the drain screw elf any water or dirt is found clean the carburetor see Carburetor Cleaning in the Fuel System chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 9 Periodic Maintenance Procedures Engine Top End Cylinder Head Cleaning and Inspection e Remove the valves see Valve Mechanism Removal In stallation in the Engine Top End chapter e Scrape the carbon deposits from the head and exhaust port with a suitable tool A OTo 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 compr
98. trument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor see Caburetor Disassem bly Assembly in this chapter 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 Assemble the carburetor see Carburetor Disassem bly Assembly in this chapter www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 3 16 FUEL SYSTEM Carburetor Carburetor Inspection A WARNING Gasoline is extremely flammable and can be explo sive under certain Turn the engine 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 burrs and nicks 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 x lf the gasket is not in good condition replace it e Check the other parts of the carbur
99. ty 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 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 2004 Kawasaki Heavy Industries Ltd First Edition 1 Nov 1 2004 K www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 LIST OF ABBREVIATIONS ABDC AC ATDC BBDC BDC BTDC ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s Ib m min N Pa PS psi r rpm TDC TIR o pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 6
100. vel 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 gauge hole C without screwing it in then check the oil Level CAUTION Always insert the dipstick into the gauge hole so that the taper part A of the oil filler cap is facing the starter side B e The oil level should be in the range of H mark and L mark A grid area on the dipstick x If the oil level is L range B or below add enough engine oil to bring oil level to the range of H mark and L mark CAUTION Do not add more oil above the range of H mark and L mark Excess oil will cause a smoking con dition 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 completely x If the oil level is H range C or above drain the excess oil by loosening the drain plug www mymowerparts com KMOSOOOBS1 For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Oil Change e Change the oil after first 8 hours of operation Thereafter change oil every 100 hours e Start a
101. werparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 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 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 tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 3 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
102. y infinite ohm x lf the stator coil fails any of these tests replace the coil with a new one To Stator A Stator Coil Connector B Unregulated Stator Output e Disconnect the stator coil connector e Connect AC voltmeter to the stator pins e Start the engine Run the engine at the 3 000 rpm speed e Voltage reading should be minimum 26 VAC 3 000 rpm x lf the AC voltage reading is less than the specification replace the stator Unregulated Stator Output Standard 28 4 V AC 3 000 rpm Service Limit 26 V AC 3 000 rpm To Stator A Stator Coil Connector B AC Voltmeter C www mymowerparts com KHO7008BS1 KHO7025BS1 KHO7026BS1 KHO7027BS1 For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 ELECTRICAL SYSTEM 8 11 Charging Ignition System This engine ignition is controlled by a solid state ignition assembly and requires no periodic main tenance except for the spark plug The system consists of the following Inductive Ignition Assembly Permanent Magnet Flywheel Spark Plug Stop Switch D1 SW KHO7035BW2 B Base M Magnet C Collector N North Pole Co Core Lamination R1 Control Resistor D1 Diode S South Pole E Emitter SP Spark Plug F Flywheel SW Stop Switch L1 Primary Coil TS1 Trigger Sensor L2 Secondary Coil Q1 Transistor Ignition Theory of Operation Mounted to the periphery
103. ystem Cleanliness Inspection in the Periodic Maintenance chapter e Remove the carburetor see Carburetor Removal in this chapter e Unscrew the float chamber mounting bolt B and take off the float chamber C and gasket e Using a properly sized blade screw driver carefully re place the main jet A with a new one for altitude expected www mymowerparts com For Kawasaki Discount Parts Call 606 678 9623 or 606 561 4983 FUEL SYSTEM 3 13 Carburetor e Replace the float chamber gasket with a new one e Install the float chamber and gasket e Tighten float chamber mounting bolt A as shown the fig ure Drain Screw B Fuel Inlet Joint C Torque Float Chamber Mounting Bolt 9 8 N m 1 0 kgf m 87 in lb KCO5059BS1 Fuel system Cleanliness Inspection e Refer to the Fuel System Cleanliness Inspection in the Periodic Maintenance chapter Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the engine 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 breather hose A e Remove the inlet pipe B e Turn the fuel shut off valve to the OFF position in the equipment e Drain the carburetor completely by unscrewing the drain screw at the bottom of the float chamber see Fuel Sys tem Cleanlines

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